WO2014055082A1 - Roues de coulée composites - Google Patents
Roues de coulée composites Download PDFInfo
- Publication number
- WO2014055082A1 WO2014055082A1 PCT/US2012/058763 US2012058763W WO2014055082A1 WO 2014055082 A1 WO2014055082 A1 WO 2014055082A1 US 2012058763 W US2012058763 W US 2012058763W WO 2014055082 A1 WO2014055082 A1 WO 2014055082A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- rim
- composite
- spouts
- casting
- wheel
- Prior art date
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D5/00—Machines or plants for pig or like casting
- B22D5/04—Machines or plants for pig or like casting with endless casting conveyors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D39/00—Equipment for supplying molten metal in rations
Definitions
- Casting wheels formed of metal exist for pouring molten aluminum into ingot molds on a conveyor system.
- these metal casting wheels conduct heat from the molten aluminum. Because the metal casting wheels conduct heat from the molten aluminum, the casting process requires higher casting temperatures. The higher casting temperatures produce more impurities, which to remove the byproducts adds complexity to the casting process. For example, because of the higher temperatures demanded by the metal casting wheel, existing casting processes produce more dross (i.e., masses of solid impurities thrown off of molten metal). Typically, more dross is formed in the ingot molds, the troughs, and the furnace. Subsequently complicated and time consuming processes are added to the casting process to remove the dross.
- the removal of the dross causes a loss of aluminum. That is, typically a portion of the molten aluminum is removed along with the dross. Further, the higher temperatures required by the metal casting wheel cause a higher level of gassing of the molten aluminum. That is, the higher temperatures required by the metal casting wheel cause a higher level of affinity of the molten aluminum to pick up hydrogen from the air. Subsequently, complicated and time consuming processes are added to the casting process to remove the hydrogen picked up by the molten aluminum. In addition, iron contamination is typical due to the continual corrosion of the metallic wheel. [0003] Thus, there remains a need to develop new casting wheels formed of composite materials that don't demand higher casting temperatures and eliminate iron contamination.
- This disclosure relates to composite wheels for casting molten metal (e.g., molten aluminum).
- molten metal e.g., molten aluminum
- such composite wheels may be configured to insulate the molten metal in the composite wheels and thereby lower the casting temperature of the molten metal.
- the composite wheels may include a rim formed of a composite material (e.g., a ceramic), and a plurality of spouts removeably coupled to the rim.
- a composite material e.g., a ceramic
- the rim may be formed as a single unit of the composite material.
- the rim may be one contiguous unit formed of the composite material.
- the rim may be formed from a plurality of segments.
- the each segment may be formed of the composite material and configured to cooperate (e.g., interlock, link, fit together, etc.) to form the rim of the composite wheel.
- the plurality of spouts may be removeably coupled to the rim via an adhesive.
- FIG. 1 illustrates an example casting wheel comprising a rim formed of a composite material, and a plurality of spouts removeably coupled to the rim.
- FIG. 2 illustrates a detail section view of the illustrative casting wheel illustrated in FIG. 1 taken along line A— A.
- FIGS. 3 and 4 are flow diagrams illustrating example processes of installing the illustrative casting wheel illustrated in FIG. 1 in a casting facility.
- composite casting wheels as described in this application include a rim formed of a composite material, and a plurality of spouts removeably coupled to the rim to pour molten metal from the composite casting wheel to respective permanent molds arranged in a conveyor system.
- the composite materials may comprise a fibrous material (e.g., individual threads, a fabric, patches or segments of a fabric, chopped fibers, etc.) embedded in a ceramic matrix.
- the composite materials may comprise a fiberglass fabric embedded in a calcium silicate Ca 2 Si0 4 slurry as described in a white paper titled Development And Use Of A New Composite Material For Aluminium Contact Applications and edited by The Minerals, Metals, and Materials Society (TMS) in 2004, the contents of which are incorporated in its entirety herein.
- TMS The Minerals, Metals, and Materials Society
- U.S. Patent No. 5,154,955 titled Fiber-Reinforced Cement Composition describes other composite materials that may be used to form the composite casting wheels, the contents of which are incorporated in its entirety herein.
- the composite materials may comprise a ceramic void of fabric.
- the composite materials may comprise a fused silica.
- this application describes the rim formed of the fabric embedded in the ceramic, and the spouts formed of the fused silica.
- the rim and the spouts may be formed of any composite material suitable for being used to cast molten metal.
- the rim and/or the spouts may be formed of a fibrous material embedded in a ceramic matrix containing fused silica, silicon carbide, alumina, calcium silicate, bauxite, combinations of any of these, or other refractory materials.
- both the rim and the spouts may be formed of the same composite material.
- both the rim and the spouts may be formed of a composite material comprising a fabric embedded in the ceramic.
- metallic inserts may be embedded into the ceramic composite material.
- metallic inserts may be embedded into the ceramic composite wheel to provide for technical requirements (e.g., external attachments, fixings, fittings, wear surfaces, etc.).
- the composite casting wheels provide properties suitable for casting molten aluminum.
- the ceramic materials forming the composite casting wheels insulate the molten aluminum contained by the composite casting wheels.
- a temperature of the molten aluminum being received by the composite wheel can be reduced, as compared to a temperature of the molten aluminum being received by the existing casting wheels formed of metal. This is, because the composite casting wheels insulate the molten aluminum, the molten aluminum remains at a temperature suitable to be poured into respective ingot molds.
- the molten aluminum received by the metal casting wheel is at a higher or elevated temperature to make up a difference in heat loss by the metal casting wheel.
- a 60 degree C (140 degrees F) reduction in a casting temperature was observed.
- the lower casting temperatures allowed by the composite casting wheels reduces the amount of energy (i.e., combustion energy) required to cast the aluminum ingots.
- the reduced amount of energy consumption reducing C0 2 output and lowering energy costs.
- the lower casting temperatures allowed by the composite casting wheels reduces the amount of dross in the casting system.
- the lower casting temperatures allowed by the composite casting wheels reduces the amount of dross floating on the ingots, reduces the amount of dross in the launder, and reduces the amount of dross in the melting furnace.
- the lower casting temperatures allowed by the composite casting wheels reduce the amount of dross in the casting system, the casting process is simplified. For example, by reducing the dross floating on the ingots, this reduces the need to add a process in the casting process to remove the floating dross.
- this may eliminate the need to add a process in the casting process to have robots remove the floating dross.
- the composite casting wheel reduces the amount of dross being removed, this reduces an amount of lost aluminum in the casting process. For example, during the removal of the floating dross on the ingots some aluminum is also removed along with the floating dross. Thus, because there is less floating dross being removed from the ingots, there is less aluminum being removed from the ingots, reducing the amount of lost aluminum in the casting process.
- the lower casting temperatures allowed by the composite casting wheels as compared to the higher casting temperatures demanded by the existing metal casting wheels, less aluminum is lost to oxidation of the aluminum.
- the higher casting temperatures required by the metal casting wheels oxidizes about 3% of the aluminum being cast.
- the lower casting temperatures allowed by the composite casting wheels reduces the amount of aluminum being lost during the casting of the aluminum.
- the lower casting temperatures allowed by the composite casting wheels improves a usable life of refractories in the casting system.
- the lower casting temperatures allowed by the composite casting wheels reduces the temperatures exposed to the refractory materials in the launder, and in the melting furnace. Exposing the refractories in the launder and the melting furnace to lower casting temperatures extends the usable life of the refractories.
- the lower casting temperatures allowed by the composite casting wheels reduces the amount of gassing.
- the lower casting temperatures allowed by the composite casting wheels reduces an amount of hydrogen captured by the molten aluminum from the air.
- the ceramic materials forming the composite casting wheels chemically resist the molten aluminum contained by the composite casting wheels.
- the composite casting wheels produce a cleaner product free of iron contamination.
- the ceramic materials forming the composite casting wheels may not interact or react with the molten aluminum, leaving the molten aluminum free of any composite material forming the composite casting wheels.
- a casting wheel formed of metal e.g., cast iron or steel
- the metal interacts or reacts with the molten aluminum, leaving the molten aluminum contaminated with the metal forming the casting wheel.
- the rim may be formed as a single unit of the composite material.
- the rim may be formed as a single unit of composite material.
- the rim may be formed as a single unit of a fabric embedded in a ceramic.
- the rim may be formed as a plurality of segments of the composite material.
- the rim may be formed from two or more cooperating segments formed of the composite material, and configured to fit together to form the rim.
- the rim may have an inner surface opposite an outer surface. The inner surface may define a trough to receive the molten metal.
- the plurality of spouts may be removeably coupled to the rim, and interconnected with the trough to pour molten metal into respective molds fixed in a conveyor when the composite casting wheel is rotated above a conveyor.
- This section describes an exemplary casting wheels formed of a composite material.
- the composite casting wheels include a rim formed as a single unit of a composite material.
- the rim may be formed from a two or more segments formed a composite material.
- a plurality of spouts are removeably coupled to the composite rim.
- FIG. 1 illustrates an example casting wheel 102 comprising a rim 104 formed of a composite material, and a plurality of spouts 106 removeably coupled to the rim 104. While FIG. 1 illustrates the plurality of spouts 106 being removeably coupled to the rim 104, the plurality of spouts 106 may be formed integral with the rim 104. For example, the plurality of spouts 106 and the rim 104 may be formed as a single unit of the composite material, and fixed to the rim 104. Further, the plurality of spouts 106 may be permanently fixed to the rim via an adhesive.
- the rim 104 may have an inner surface 108 opposite an outer surface 1 10.
- the inner surface 108 of the rim 104 defining a trough 1 12 to receive molten metal (e.g., molten aluminum).
- molten metal e.g., molten aluminum
- the casting wheel 102 may be arranged above a conveyor 114 having respective permanent molds 1 16 moving in a linear direction 118 below the casting wheel 102, and a launder 120 may provide (e.g., spill, pour, dispense, feed, etc.) molten metal 122 into the trough 1 12 of the rim 104.
- the inner surface 108 may be substantially void of dimples, bumps, ridges, etc. to provide a smooth surface, and thus produce a laminar flow of the molten metal 122 in the trough 1 12.
- the inner surface 108 may include features to provide for uniformly dispense the molten metal 122 in the trough 112 into the ingots below.
- the inner surface 108 may include dimples, bumps, ridges, etc. to uniformly dispense the molten metal 122 in the trough 1 12 into the ingots below.
- the rim 104 may be formed as a single unit 124 of the composite material.
- the rim 104 may be formed as one contiguous unit of the composite material.
- the rim 104 may be formed from a plurality of segments 128(1) through 128(N).
- the plurality of segments 128(1) and 128(N) may be configured to cooperate together to form the rim 104.
- two or more segments 128(1) and 128(N) may include interlocking surfaces 130(A) and 130(B) that when mated together form the rim 104.
- An outer member 132 may be arranged around the two or more segments 128(1) and 128(N) to secure the two or more segments 128(1) and 128(N) together.
- an outer metal rim may be arranged around the segments 128(1) and 128(N), and retain the segments 128(1) through 128(N) around an inside diameter of the outer metal rim.
- the outer metal rim may be configured to have an inside surface arranged around the inside diameter of the outer metal rim for receiving the segments 128(1) through 128(N).
- the segments 128(1) through 128(N) arranged around the inside diameter of the outer metal rim forming a refractory liner of the outer metal rim.
- the segments 128(1) through 128(N) arranged around the inside diameter of the outer metal rim defining a casting wheel.
- the outer member 132 may be a band, a strap, a binder, etc., arranged around the segments 128(1) and 128(N) to retain the segments 128(1) through 128(N) together.
- any number of segments 128(1) through 128(N) may cooperate together to form the rim 104.
- 24 segments 128(1) through 128(24) may cooperate together to form the rim 104.
- each segment 128(1) through 128(24) may removeably receive one of the plurality of spouts 106.
- any number of spouts 106 may be removeably received by each of the plurality of segments 128(1) through 128(N).
- a plurality of multiple spouts, smaller than the spouts 106 may be removeably coupled to each of the plurality of segments 128(1) through 128(24).
- each of the plurality of segments 128(1) through 128(N) may be formed of the composite material.
- each of the plurality of segments 128(1) through 128(N) may be formed of a fabric embedded in a ceramic.
- FIG. 1 illustrates the plurality of spouts 106 may be arranged radially 134 in the outer surface 110 to pour the molten metal 122 into the respective molds 1 16.
- the plurality of spouts 106 may be arranged radially 134 in the outer surface 110 and have a degree of separation 136 substantially the same as a distance 138 between the respective molds 1 16.
- the plurality of spouts 106 may have a degree of separation 136 of at least about 15 degrees. For example, there may be about 15 degrees of separation between each center of each spout 106. While FIG. 1 illustrates a degree of separation of about 15 degrees, in other embodiments any degree of separation may be implemented.
- the plurality of spouts 106 may have any degree of separation depending on a conveyor 1 14 the casting wheel 102 is to interface with. That is, the plurality of spouts 106 may have a degree of separation 136 larger than 15 degrees if the distance 138 in the conveyor 114 is larger, or the plurality of spouts 106 may have a degree of separation 136 smaller than 15 degrees if the distance 138 in the conveyor 114 is smaller.
- the casting wheel 102 may be installed on an axle (not shown) via a plurality of apertures 140 arranged in a wall 142 of the casting wheel 102.
- the casting wheel 102 may be positioned (e.g., lifted) adjacent to the axle to be fastened via threaded fasteners (e.g., nuts and bolts) to the axle.
- threaded fasteners e.g., nuts and bolts
- the composite casting wheel weighs less than a casting wheel formed of metal (e.g., cast iron or steel).
- the casting wheel 102 formed of the composite material may weigh about 10 Kilograms (22 Pounds) as compared to a metal casting wheel weighing about 100 Kilograms (220 Pounds).
- the casting wheel 102 formed of the composite is much lighter and may be installed by a single installer without the use of a crane. Further, because the casting wheel 102 is much lighter than a metal casting wheel the time to install the casting wheel 102 reduced as compared to installing the heavier metal casting wheel.
- FIG. 1 also illustrates a section line A— A.
- the section line A— A is taken approximate to a center of the casting wheel 102.
- FIG. 2 illustrates a detail section view of the illustrative casting wheel 102 illustrated in FIG. 1 taken along the section line A— A.
- FIG. 2 illustrates that each of the plurality spouts 106 removeably coupled to the rim 104 may include a lip 202 opposite a base 204.
- An array of apertures 206 may be arranged around the rim 104. Each aperture 206 may extend through the inner surface 108 and the outer surface 110.
- the base 204 of each spout 106 may be removeably coupled to a respective aperture 206.
- the lip 202 may be interconnected to the trough 112 via an aperture 208 extending through the spout 106 from the lip 202 to the base 204. While the surface of the aperture 208 is illustrated as being substantially void of dimples, bumps, ridges, etc. to provide a smooth surface, the surface of the aperture 208 may include surface features (e.g., grooves, fms, rifling, etc.) to provide a laminar flow of the molten metal 122 through the spouts 106.
- FIG. 2 illustrates the lip 202 of the spout 106 may be arranged radially 134 and may project from the outer surface 1 10 to pour the molten metal 122 into the respective molds 116.
- each aperture 206 of the array of apertures 206 has a seat 212 arranged to receive the base 204 of each spout 106 of the plurality of spouts 106.
- An adhesive 214 may be disposed between the base 204 and the seat 212 to removeably couple the spout 106 to the aperture 206.
- the adhesive 214 may be a mastic adhesive applied to the seat 212 and/or the base 204 and configured to be resistant to molten aluminum.
- the adhesive 214 may be configured to fail (e.g., fracture, break, crack, crumble, etc.) upon impact of a sufficient force.
- the plurality of spouts 106 may be removed by applying an impact or blow to the lip 202 of a spout 106.
- the blow or impact having sufficient force to cause the adhesive 214 adhering the seat 212 of the rim 104 to the base 204 of the spout 106 to fail allowing the spout 106 to be removed.
- Detail view 210 illustrates the seats 212 may be arranged in the inner surface 108 of the rim 104. While the detail view 210 illustrates the base 204 of each spout 106 is substantially coplanar 216, the base 204 of each spout 106 may be below or above the inner surface 108 of the rim 104.
- Detail view 210 illustrates the base 204 of each spout 106 and the seat 212 of each aperture may have a substantially conical shape 218. Further, the lip 202 of each spout 106 may have a substantially conical shape 220. While detail view 210 illustrates the lip 202 having a substantially conical shape 220, the lip 202 may have a substantially circular shaped, rectangular shaped, pyramidal shaped (e.g., tetrahedron, pentagonal, hexagonal, or the like pyramid shapes).
- the shape of the spout 106 may be specific to a type of molten metal 122 being cast, a dispensing rate of molten metal 122, a speed of rotation of the casting wheel 102, a speed of the conveyor 114, the direction 118 of the conveyor 1 14 relative to the spouts 106 arranged on the casting wheel 102, combinations of any of these, or the like.
- the shape of the lip 202 of the spout 106 may be tailored to provide a laminar flow of molten metal 122 out of the spout 106 and into a respective permanent mold 116.
- the lip 202 of the spout 106 may have an inside diameter 222 smaller than an inside diameter 224 of the base 204.
- the inside diameter 222 and/or 224 may be smaller than an inside diameter of a spout formed of metal.
- the inside diameters 222 and/or 224 of the spout 106 may be smaller than an inside diameter of a metal spout to provide a slower filling rate of respective permanent molds 116 to produce a laminar flow of molten metal.
- the inside diameter 222 of the lip may be about 35 millimeters (1.3 inches), and the inside diameter 224 may be about 40 millimeters (1.6 inches).
- the inside diameters 222 and 224 may be any size based on the type of molten metal 122 being cast, a dispensing rate of molten metal 122, a speed of rotation of the casting wheel 102, a speed of the conveyor 114, the direction 1 18 of the conveyor 1 14 relative to the spouts 106 arranged on the casting wheel 102, combinations of any of these, or the like. Further, the length of the spout 106 may be tailored to provide a laminar flow of molten metal 122 out of the spout 106 and into a respective permanent mold 116.
- the plurality of spouts 106 removeably coupled to the rim 104 may be formed of the composite material.
- the plurality of spouts 106 may be formed of ceramic.
- the plurality of spouts 106 may be formed of a fused silica.
- the plurality of spouts 106 may be formed of a fiberglass fabric embedded in a calcium silicate Ca 2 Si0 4 slurry.
- the plurality of spouts 106 may be formed of any composite material suitable for being used to cast molten metal. Further, the plurality of spouts 106 may be formed of a metal.
- the spouts may be formed of a cast iron, a steel, etc., and fixed to the rim 104.
- the plurality of spouts 106 may be formed of a metal and at least partially encapsulated in a ceramic.
- an inner body formed of an iron, a cast iron, a steel, etc. may be encapsulated by a ceramic to form a spout 106.
- the plurality spouts 106 may be permanently fixed to the rim 104.
- the plurality of spouts 106 and the rim 104 may be formed as a single unit of a composite material.
- the spouts 106 and the rim 104 may be formed as a single unit of fiberglass fabric embedded in calcium silicate Ca 2 Si0 4 slurry.
- the plurality of spouts 106 may be formed of a ceramic (e.g., a fused silica) and fixed permanently to the rim 104, via a layer of the fiberglass fabric embedded in calcium silicate CaSi0 3 slurry.
- the composite material e.g., a fiberglass fabric embedded in a calcium silicate CaSi0 3 slurry
- the composite material may be applied to the spouts 106 and the rim 104 to fix the spouts 106 to the rim 104.
- the plurality of spouts 106 provides properties suitable for casting molten aluminum.
- the ceramic materials forming the plurality of spouts 106 insulate the molten aluminum being poured into the respective permanent molds 116.
- the molten aluminum does not freeze or solidify on the spouts 106 as the casting wheel 102 dispenses the molten aluminum.
- the ceramic materials forming the plurality of spouts 106 provide for a non-wetting surface.
- the ceramic materials forming the plurality of spouts 106 may keep the molten aluminum from maintaining intermolecular interaction with the surface of the spouts 106.
- the non-wetting surface of the plurality of spouts 106 may prevent the molten aluminum from sticking to the surface of the spouts 106 and building up on the spouts 106 as the casting wheel 102 dispenses the molten aluminum.
- the ceramic materials forming the plurality of spouts 106 provide for preventing the molten aluminum from freezing on the spouts 106 and/or wetting and sticking to the spouts 106, it is easier to remove the frozen and/or stuck aluminum from the plurality of spouts 106 than compared to removing frozen and/or stuck aluminum from spouts formed of metal.
- FIG. 3 illustrates an example process 300 of installing a casting wheel (e.g., casting wheel 102) at a casting facility.
- the casting wheel comprises a rim (e.g., rim 104) formed as a single unit (e.g., single unit 124) of a composite material (e.g., fabric embedded in ceramic).
- this process may be performed at a manufacturing facility, a plant, a foundry, a factory, or the like.
- Process 300 includes operation 302, which represents positioning (e.g., lifting) the casting wheel adjacent to an axle.
- a single user e.g., operator, technician, workman
- Process 300 may be completed at operation 304, which represents fastening the casting wheel to the axle.
- a user may insert one or more threaded fasteners (e.g., bolts) into an aperture (e.g., apertures 140) arranged in a wall (e.g., wall 142) of the casting wheel and into a mounting structure of the axle.
- Operation 304 may include tightening the one or more threaded fasteners (e.g., nuts) to secure the casting wheel to the axle.
- FIG. 4 illustrates an example process 400 of installing a casting wheel (e.g., casting wheel 102) at a casting facility.
- the casting wheel comprises a rim (e.g., rim 104) formed from a plurality of segments (e.g., segments 128(1) through 128(N)) formed of a composite material (e.g., fabric embedded in ceramic).
- this process may be performed at a manufacturing facility, a plant, a foundry, a factory, or the like.
- Process 400 includes operation 402, which represents positioning (e.g., lifting) at least one of the segments of the casting wheel adjacent to an axle.
- a single user e.g., operator, technician, workman
- Operation 402 may be followed by operation 404, which represents fastening the at least one segment to the axle.
- a user may insert one or more threaded fasteners (e.g., bolts) into an aperture (e.g., apertures 140) arranged in a wall (e.g., wall 142) of the segment and into a mounting structure of the axle.
- Operation 404 may include tightening the one or more threaded fasteners (e.g., nuts) to secure the segment to the axle.
- Process 400 may include operation 406, which represents positioning one or more additional segments of the casting wheel adjacent to the axle.
- Operation 406 may include interlocking the one or more additional segments together.
- a user may interlock interlocking surfaces (e.g., interlocking surfaces 130(A) and 130(B)) to form the rim.
- Operation 406 may include fastening the one or more additional segments to the axle.
- a user may insert one or more threaded fasteners (e.g., bolts) into apertures arranged in walls of the one or more additional segments and into a mounting structure of the axle.
- Process 400 may include operation 408, which represents tightening a band (e.g., outer member 132) around the interlocked segments of the rim.
- Process 400 may be completed at operation 410, which represents tightening the one or more threaded fasteners (e.g., nuts) to secure the casting wheel to the axle.
- a band e.g., outer member 132
- threaded fasteners e.g., nuts
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Abstract
L'invention concerne des roues de coulée composites. Une pluralité de goulottes sont accouplées de manière amovible à un rebord constitué d'un matériau composite. Le rebord peut être conçu sous forme d'une unité unique du matériau composite. Le rebord peut être formé à partir d'une pluralité de segments constitués du matériau composite. Le matériau composite isole le métal fondu contenu dans le rebord et fait baisser une température de coulée du métal fondu. Le matériau composite empêche également le métal fondu de geler et/ou de coller aux goulottes et au rebord.
Priority Applications (1)
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PCT/US2012/058763 WO2014055082A1 (fr) | 2012-10-04 | 2012-10-04 | Roues de coulée composites |
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PCT/US2012/058763 WO2014055082A1 (fr) | 2012-10-04 | 2012-10-04 | Roues de coulée composites |
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US9034244B2 (en) | 2002-07-12 | 2015-05-19 | Paul V. Cooper | Gas-transfer foot |
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