WO2021033193A1 - Red brick and process for preparation thereof - Google Patents
Red brick and process for preparation thereof Download PDFInfo
- Publication number
- WO2021033193A1 WO2021033193A1 PCT/IN2019/050858 IN2019050858W WO2021033193A1 WO 2021033193 A1 WO2021033193 A1 WO 2021033193A1 IN 2019050858 W IN2019050858 W IN 2019050858W WO 2021033193 A1 WO2021033193 A1 WO 2021033193A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- red
- brick
- mixture
- red brick
- bricks
- Prior art date
Links
- 239000011449 brick Substances 0.000 title claims abstract description 109
- 238000000034 method Methods 0.000 title claims description 12
- 238000002360 preparation method Methods 0.000 title description 8
- 239000000203 mixture Substances 0.000 claims abstract description 72
- 239000010882 bottom ash Substances 0.000 claims abstract description 28
- 239000004576 sand Substances 0.000 claims abstract description 26
- 239000010881 fly ash Substances 0.000 claims abstract description 24
- 239000011398 Portland cement Substances 0.000 claims abstract description 16
- 238000004519 manufacturing process Methods 0.000 claims abstract description 14
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 238000000465 moulding Methods 0.000 claims abstract description 7
- 238000005096 rolling process Methods 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 12
- 239000011499 joint compound Substances 0.000 description 24
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 23
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 11
- 235000011941 Tilia x europaea Nutrition 0.000 description 11
- 239000004571 lime Substances 0.000 description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 10
- 239000004927 clay Substances 0.000 description 10
- 239000003245 coal Substances 0.000 description 6
- 229910052602 gypsum Inorganic materials 0.000 description 6
- 239000010440 gypsum Substances 0.000 description 6
- 239000002699 waste material Substances 0.000 description 6
- 239000000047 product Substances 0.000 description 5
- 239000004568 cement Substances 0.000 description 4
- 239000000945 filler Substances 0.000 description 3
- 230000009257 reactivity Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000002956 ash Substances 0.000 description 2
- 229910001570 bauxite Inorganic materials 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000011453 chemically set brick Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000006253 efflorescence Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000011454 mudbrick Substances 0.000 description 2
- 206010037844 rash Diseases 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000006004 Quartz sand Substances 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000012717 electrostatic precipitator Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000003337 fertilizer Substances 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 239000002440 industrial waste Substances 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
Definitions
- the present disclosure relates to red bricks made up of waste material generated in power plant and alumina refinery.
- the present disclosure also related to a process of preparation of red bricks using the waste material generated in power plant and alumina refinery.
- Bricks are the most used building materials in construction industry. It is being used to construct walls, foundations and many other parts of buildings and other masonry structures. Bricks are laid in courses and other many patterns termed as bond, it may be laid with various kinds of mortar to hold the bricks together and make a durable structure. The structures may be load bearing or just partition walls.
- clay bricks There are many types of bricks available based on their use, size, forming methods, quality and material used for construction. Most common are clay bricks and chemically set bricks. Generally, clay bricks are baked in kiln after moulding and drying. Chemically set bricks are mixed with chemical or cement moulded and dried in open air and curing with watering or without watering. It gains strength with chemical reaction within it and therefore, there is no need of baking in kiln.
- Red mud is an industrial waste from an alumina-producing industry.
- the red mud is composed mainly of iron oxide, and hence is red in colour.
- the quantity of red mud produced per ton of alumina produced, is generally about 1-2.5 tons.
- the red mud is generally disposed of, posing environmental problems.
- Chinese Patent Application Number CN101468905 discloses red mud unburned brick which mainly consists of 5-30 parts of red mud, 20-30 parts of fly ash, 20-50 parts of quartz sand or gravel powder, 5-15 parts of lime, 2-8 portions of gypsum and 0-3 parts of cement.
- Chinese Patent Application Number CN1079452 discloses a red mud composite brick comprising red mud, fly ash, lime, gypsum and sand.
- Another Chinese Patent Application Number CN101215142 relates to Bayer red mud composite brick, prepared by mixing raw materials of 20-35 parts of Bayer red mud, 15-34 parts of fly ash, 5-15 parts of carbide slag, 30-40 parts of slag, 5-12 parts of cement and 0-5 parts of gypsum.
- Chinese Patent Application Number CN 101020603 discloses light red mud brick and its making process. The red brick in this publication is composed of 15-50 parts of red mud, 35-70 parts of fly ash, 8-12 parts of lime and 4-6 parts of silica sand.
- carbide lime mostly used and it is by product of gas making plants and does not meet consistency in quality. Purity of such lime varies from 40 to 70%. Due to such non-consistency of lime quality, brick quality also gets affected and varies in compressive strength. Therefore, there is a need for an alternative to compositions using lime.
- the primary object of the present disclosure is to provide a red brick comprising red mud; bottom ash; natural sand; fly ash; and Portland cement.
- Another objective of the present disclosure is to provide a red brick having compressive strength of not less than 75 kg/cm 2 .
- Yet another objective of the present disclosure is to provide a process for preparing a red brick.
- an objective of the present disclosure is to provide a red brick made up of waste material generated in power plant and alumina refinery.
- the present disclosure relates to a red brick comprising: 20-50 wt% of red mud; 10-20 wt% of bottom ash; 10-30 wt% of natural sand; 15-30 wt% of fly ash; and 4-15 wt% of Portland cement.
- the present disclosure also relates to a process for preparing a red brick comprising: mixing 20-50 wt% of red mud, 10-20 wt% of bottom ash, 10-30 wt% of natural sand to form a first mixture; adding 15-30 wt% of fly ash and 4-15 wt% of Portland cement to the first mixture to form a second mixture; rolling the second mixture in a pan mixer having roller and scraper to produce a final mixture; moulding the final mixture in a brick press to provide a pressed red brick; and stacking the pressed red brick in yards to form a red brick.
- the present disclosure provides a red brick comprising: 20-50 wt% of red mud; 10-20 wt% of bottom ash; 10-30 wt% of natural sand; 15-30 wt% of fly ash; and 4-15 wt% of Portland cement.
- the red brick of the present disclosure has compressive strength of not less than 75 kg/cm 2 .
- the red mud is a bi-product of Alumina refinery in aluminum manufacturing plant. It is generated in the process of extracting alumina from Bauxite ore. It is approx. 50 to 60 % of Bauxite used for alumina extraction. After drying and sieving the red mud (collected from pond), it is ready to use for red brick manufacturing.
- the fly ash used in the present application has a particle size in the range of 90 Micron to 600 Micron.
- the fly ash is very fine material generated in thermal power plant in process of burning coal in boilers to produce thermal energy.
- the total ash generation is normally 40% of coal fed in boilers.
- the fly ash generation is approx. 80% of total ash generation. Normally it is collected through electrostatic precipitators. Fly ash has a higher reactivity, and it acts as binding materials in reaction with cement.
- the fly ash is directly mixed in red brick manufacturing.
- the bottom ash has a particle size in the range of 0.15 mm to 4.75 mm.
- the bottom ash is also a bi-product of coal burning in boilers of thermal plant. It is coarser in nature. Bottom ash generation is approx. 20% of total as generation in thermal power plant. Bottom ash has a reactivity value of 5-7% which helps to increase the strength of the brick. Due to less reactivity, bottom ash also acts as filler material like natural sand. After getting desired particle size, it is ready to use in red brick manufacturing.
- the natural sand has a particle size in the range of 0.3 mm to 4.75 mm. Natural sand is found in river bed. The dried sand is cleaned to remove any foreign materials and it is ready to use in red brick manufacturing. Natural sand acts as a filler material.
- Bottom ash has lesser number of coarse particles in comparison to natural sand.
- a combination of sand and bottom ash meets the desired particle size distribution of the composition of the composition for better workability of mix during the manufacturing of red bricks.
- Portland cement is a standard product available in market. It is a binding material commonly used in building construction industries. It reacts with filler materials and develops strength. It is directly added in red brick manufacturing.
- the Portland cement contains gypsum. Gypsum is available as a bi-product of chemical and fertilizer industries. Gypsum also influences the setting process of brick and gaining early strength.
- the present disclosure also provides a process for preparing a red brick comprising: mixing 20-50 wt% of red mud, 10-20 wt% of bottom ash, 10-30 wt% of natural sand to form a first mixture, adding 15-30 wt% of fly ash and 4-15 wt% of Portland cement to the first mixture to form a second mixture, rolling the second mixture in a pan mixer having roller and scraper to produce a final mixture, moulding the final mixture in a brick press to provide a pressed red brick, and stacking the pressed red brick in yards to form a red brick.
- the rolling of second mixture in the pan mixer is carried out for 3 minutes, at 28-35 °C.
- the molding of final mixture is carried out for 30 Sec, at 28-35 °C.
- the stacking of pressed red brick is carried out for 3 days inside shed and 12 days in open yard, at atmospheric temperature and pressure. Further, the natural sand is dried and cleaned to remove foreign materials before mixing with red mud and bottom ash to obtain
- the developed red bricks are made using 70% waste material generated in power plant and alumina refinery. These bricks are not required to burn in kiln and no air pollution is caused due to burning of huge coal in normal lay bricks production.
- the parameters such as Compressive Strength, Size, Weight, Water Absorption and Efflorescence, of the red bricks of the present application are comparative to normal clay bricks which are commercially available.
- red bricks gain required strength in 15 days in open area and ready to use. As it is machine produced so there is no any dimensional variation, it is little higher in weight but very little water absorbent.
- the advantages of the present disclosure include utilization of waste generated in power plant and alumina refineries, up-cycling of waste to useful product, low costs as machine production is involved. As no precious earth/clay is being used, and no coal is burnt as it is a cold setting material, it also saves environment. There is no deformation in shape and size, and the red bricks are comparable to normal clay bricks in shape, size, appearance and strength.
- EXAMPLE 1 Preparation of Red Brick 13 wt% of Bottom ash in the particle size range of 0.15 mm to 4.75 mm, 20 wt% of natural sand in the particle size range of 0.3 mm to 4.75 mm and 31 wt% of red mud were mixed to form a first mixture. To this first mixture, 25 wt % of fly ash in the particle size range of 45 pm to 600 pm, and 11 wt % of Portland cement were added and mixed to form a second mixture. The second mixture thus formed was then rolled for 3 minutes in a pan mixer having roller and scraper at 30 °C to produce final mixture. This final mixture was moulded for 30 seconds in a brick press at 30 °C to provide a pressed red brick. The pressed red brick was stacked for 3 days inside shed and 12 days in open area in yards at atmospheric temperature and pressure to form a red brick.
- the red brick thus formed has a composition as set out in the table below -
- the red brick thus formed has a composition as set out in the table below -
- the red brick thus formed has a composition as set out in the table below -
- the red brick thus formed has a composition as set out in the table below -
- 15 wt% of Bottom ash in the particle size range of 0.15 mm to 4.75 mm, 15 wt% of natural sand in the particle size range of 0.3 mm to 4.75 mm and 45 wt% of red mud were mixed to form a first mixture.
- 17 wt % of fly ash in the particle size range of 45 pm to 600 pm, and 8 wt % of Portland cement were added and mixed to form a second mixture.
- the second mixture thus formed was then rolled for 3 minutes in a pan mixer having roller and scraper at 35 °C to produce final mixture.
- This final mixture was moulded for 30 seconds in a brick press at 35 °C to provide a pressed red brick.
- the pressed red brick was stacked for 3 days inside shed and 12 days in open area in yards at atmospheric temperature and pressure to form a red brick.
- the red brick thus formed has a composition as set out in the table below - Table 5.
- Composition of the Red Brick 5 EXAMPLE 6: Testing of compressive strength of red bricks
- red bricks of the present disclosure were tested for compressive strength in comparison with the commercially available clay bricks, such as MEERA, DLX, SAMAJ, TRISHOOL, KAMAL and JAMUNA. Comparison of the compressive strengths are shown in the table below -
- the red bricks of the present disclosure exhibit superior compressive strength than the red bricks with lime but without bottom ash.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Processing Of Solid Wastes (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BR112022003387A BR112022003387A2 (en) | 2019-08-22 | 2019-11-20 | Red brick and process for its preparation |
EP19942372.4A EP4017838A4 (en) | 2019-08-22 | 2019-11-20 | Red brick and process for preparation thereof |
CN201980100446.2A CN114787099A (en) | 2019-08-22 | 2019-11-20 | Red brick and method for preparing same |
AU2019462547A AU2019462547A1 (en) | 2019-08-22 | 2019-11-20 | Red brick and process for preparation thereof |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN201911033876 | 2019-08-22 | ||
IN201911033876 | 2019-08-22 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2021033193A1 true WO2021033193A1 (en) | 2021-02-25 |
Family
ID=74660639
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IN2019/050858 WO2021033193A1 (en) | 2019-08-22 | 2019-11-20 | Red brick and process for preparation thereof |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP4017838A4 (en) |
CN (1) | CN114787099A (en) |
AU (1) | AU2019462547A1 (en) |
BR (1) | BR112022003387A2 (en) |
WO (1) | WO2021033193A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113264715A (en) * | 2021-05-24 | 2021-08-17 | 燕山大学 | Heavy metal curing baking-free brick based on household garbage incineration fly ash and preparation method thereof |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101020603A (en) * | 2006-09-07 | 2007-08-22 | 贵阳白云耀筑新型建筑材料厂 | Light red mud brick and its making process |
CN101468905A (en) * | 2007-12-28 | 2009-07-01 | 刘贵堂 | Red mud unburned brick and preparation thereof |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101456703A (en) * | 2007-12-12 | 2009-06-17 | 孙建树 | Production process of red mud unburned brick |
CN101215142A (en) * | 2008-01-04 | 2008-07-09 | 华中科技大学 | Bayer process red mud composite brick and producing method thereof |
WO2018037422A1 (en) * | 2016-08-22 | 2018-03-01 | Hindalco Industries Limited | Ready-mix plaster material prepared using industrial wastes |
-
2019
- 2019-11-20 BR BR112022003387A patent/BR112022003387A2/en unknown
- 2019-11-20 EP EP19942372.4A patent/EP4017838A4/en active Pending
- 2019-11-20 WO PCT/IN2019/050858 patent/WO2021033193A1/en active Application Filing
- 2019-11-20 AU AU2019462547A patent/AU2019462547A1/en active Pending
- 2019-11-20 CN CN201980100446.2A patent/CN114787099A/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101020603A (en) * | 2006-09-07 | 2007-08-22 | 贵阳白云耀筑新型建筑材料厂 | Light red mud brick and its making process |
CN101468905A (en) * | 2007-12-28 | 2009-07-01 | 刘贵堂 | Red mud unburned brick and preparation thereof |
Non-Patent Citations (1)
Title |
---|
MANDAL, A. K.; SINHA, O. P.: "Effect of bottom ash fineness on properties of red mud geopolymer", JOURNAL OF SOLID WASTE TECHNOLOGY AND MANAGEMENT, vol. 43, no. 1, 1 May 2017 (2017-05-01), US , pages 26 - 35, XP009534829, ISSN: 1088-1697, DOI: 10.5276/JSWTM.2017.26 * |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113264715A (en) * | 2021-05-24 | 2021-08-17 | 燕山大学 | Heavy metal curing baking-free brick based on household garbage incineration fly ash and preparation method thereof |
CN113264715B (en) * | 2021-05-24 | 2022-07-29 | 燕山大学 | Heavy metal curing baking-free brick based on household garbage incineration fly ash and preparation method thereof |
Also Published As
Publication number | Publication date |
---|---|
EP4017838A1 (en) | 2022-06-29 |
EP4017838A4 (en) | 2023-10-11 |
AU2019462547A1 (en) | 2022-04-07 |
BR112022003387A2 (en) | 2022-05-17 |
CN114787099A (en) | 2022-07-22 |
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