GB2478547A - Liquid cooled brake resistor with expansion guide to confine expansion of resistor in main plane - Google Patents

Liquid cooled brake resistor with expansion guide to confine expansion of resistor in main plane Download PDF

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Publication number
GB2478547A
GB2478547A GB201003867A GB201003867A GB2478547A GB 2478547 A GB2478547 A GB 2478547A GB 201003867 A GB201003867 A GB 201003867A GB 201003867 A GB201003867 A GB 201003867A GB 2478547 A GB2478547 A GB 2478547A
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Prior art keywords
resistor
liquid
block
cooled brake
insulating layer
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Application number
GB201003867A
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GB201003867D0 (en
GB2478547B (en
Inventor
Andrew Geoffrey Halstead
Andrew Keith
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Cressall Resistors Ltd
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Cressall Resistors Ltd
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Publication of GB201003867D0 publication Critical patent/GB201003867D0/en
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Application granted granted Critical
Publication of GB2478547B publication Critical patent/GB2478547B/en
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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01CRESISTORS
    • H01C1/00Details
    • H01C1/01Mounting; Supporting
    • H01C1/016Mounting; Supporting with compensation for resistor expansion or contraction
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01CRESISTORS
    • H01C1/00Details
    • H01C1/08Cooling, heating or ventilating arrangements
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01CRESISTORS
    • H01C1/00Details
    • H01C1/08Cooling, heating or ventilating arrangements
    • H01C1/082Cooling, heating or ventilating arrangements using forced fluid flow
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01CRESISTORS
    • H01C3/00Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
    • H01C3/10Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element having zig-zag or sinusoidal configuration
    • H01C3/12Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element having zig-zag or sinusoidal configuration lying in one plane

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Details Of Resistors (AREA)

Abstract

Liquid-cooled brake resistor (Fig 3) for use in electric vehicles, comprising a metallic block 3 having a inlet (4, fig 3), outlet (5, fig 3) and internal flow path (6, fig 2) to facilitate cooling of the resistor. The brake resistor has at least one flat resistor 7 located with its main plane parallel to the face of the block 3, and at least one thermally conductive, electrically insulating layer 9 placed between the block and the resistor. The resistor 7 comprises a retaining means which subjects the resistor to an uniform force against the face of the block, whilst an expansion guide partially or fully surrounds the resistor to confine expansion of the resistor in its main plane. The expansion guide is preferably manufactured from phlogophite mica paper and is preferably no thicker than the thickness of the resistor 7.

Description

LIQUID-COOLED BRAKE RESISTOR FOR USE IN
ELECTRIC VEHICLES
The present invention relates to liquid-cooled brake resistors for use in electric vehicles.
Electric vehicles, and in particular electric cars, must have at least two or three independent braking systems for safety and regulatory reasons. Modern cars generally have two mechanical brake systems comprising dual-circuit hydraulic brakes and a handbrake. Wherever possible, however, a regenerative type brake system is used rather than a mechanical system in order to store and re-use at least part of the braking energy. Storage of the recovered energy can be in the vehicle's batteries or in ancillary media such as flywheels or ultracapacitors.
A drawback of regenerative type brake systems, however, is that when the batteries or ultracapacitors are fully charged or when the flywheel is spinning at top speed, or alternatively if the power generated by braking exceeds the rate at which the storage medium can be recharged, the braking energy must be dissipated by other means, such as resistors. The use of liquid-cooled resistors is advantageous as they can make use of the liquid cooling circuit already present in many vehicles.
DE 3933956 discloses a water-cooled brake resistor for use in electric vehicles. A flat resistor is mounted between two liquid-cooled electrically insulating or electrically insulated blocks. The resistor is kept in place simply by the application of pressure between the two blocks. However, at the very high temperatures that the resistor is exposed to during the braking process, the resistor expands. In the event that the resistor expands beyond the area of the insulating blocks cooled by the cooling-liquid, or indeed even beyond the edge of the insulating blocks, the very hot resistor poses a safety hazard in itself and in that the energy is not effectively dissipated by the cooling liquid. Further, upon cooling the resistor contracts and the return rest position may have shifted from the initial position.
The technical task proposed by the present invention is therefore that of providing a water-cooled brake resistor for use in electric vehicles that overcomes the noted technical drawbacks of
the prior art.
\Vithin the scope of this technical task, one object of the invention is that of providing a liquid-cooled brake resistor for use in electric vehicles, having efficient heat dissipation from the resistor during braking of the vehicle.
Another object of the invention is that of providing a liquid-cooled brake resistor for use in electric vehicles that contracts to its correct position after braking of the vehicle.
A further object of the invention is that of providing a liquid-cooled brake resistor for use in electric vehicles that is compact and lightweight.
A last but not least object of the invention is that of providing a liquid-cooled brake resistor for use in electric vehicles that is safe and economical.
The technical task, as well as these and other objects, are achieved according to the present invention by a liquid-cooled brake resistor for use in electric vehicles according to claim 1.
The use of retaining means subjecting the at least one resistor to a uniform force against the face of the at least one block ensures effective heat transfer from the resistor to the block and prevents warping of the resistor, while allowing expansion of the resistor in its main plane, parallel to the face of the block. The use of expansion guide means at least partially surrounding the resistor ensures that the expansion of the resistor in its main plane is confined to a desired area. The expansion can thereby be controlled.
Other characteristics of the present invention are moreover defined in the subsequent claims. Further characteristics and advantages of the present invention will be more evident from the description of a preferred, but not exclusive, embodiment of the liquid-cooled brake resistor for use in electric vehicles according to the finding, illustrated in the attached non-limiting drawings, wherein: Figure 1 shows a partial perspective view of a first embodiment of the invention.
Figure 2 shows a different partial perspective view of the embodiment of Figure 1.
Figure 3 shows a coniplete perspective view of the embodiment of Figures 1 -2.
Figure 4 shows a partial perspective view of a second embodiment of the invention.
Figure 5 shows a complete perspective view of the embodiment of Figure 4.
Figures 6 -9 show perspective views of examples of flexible Phlogophite mica paper strips in accordance in accordance with the embodiments of Figures 1 -5.
Figures 10 -12 show different partial perspective views of a third embodiment of the invention.
Figure 13 shows a complete perspective view of the embodiment of Figures 10-12.
The reference numbers refer to equivalent features in each of the figures.
With reference to the above figures, the liquid-cooled brake resistor (generally indicated by 1), comprises at least one flat resistor (2), preferably of stainless steel and preferably of the laser-cut grid type, the plane of which is parallel to one face of at least one metallic block (3) as shown in Figure 1. The electrical connection terminals (7) of the resistor (2) protrude out over the edge of the block (3) and are preferably not rigidly fixed, being instead free to move with the expansion and contraction of the resistor. Optionally, the thickness of the block (3) is slightly relieved at the area around the connection terminals (7) in order to permit the presence of a sleeve of heat-shrink insulation around the terminals.
The at least one metallic block (3) is of any thermally conductive metal, preferably aluminium, and has on one side a liquid inlet (4) and a liquid outlet (5) disposed parallelly and as a function of the width of said block. The use of aluminium renders the design light-weight and cost-effective. The block further has an internal liquid flow path (6) between said inlet (4) and said outlet (5). Preferably, the flow path (6) covers the same size of area as the maximum area of the expanded resistor (2) in order to maximise energy dissipation. Preferably, the liquid flow path (6) is substantially perpendicular to the flow path of electricity in the resistor (2). Preferably, the liquid used for cooling is water and it is preferably introduced into the flow path (6) at a flow rate sufficiently high to sustain turbulent flow throughout the flow path.
Optionally, the liquid flow path (6) may be machined in the block (3) and the block may be closed by a closure plate (8), as in the embodiment shown in Figures 2 and 3.
At least one first thermally conductive, electrically insulating layer (9) is disposed between the at least one block (3) and the at least one resistor (2). The layer (9) preferably comprises plasma-sprayed alumina sprayed onto the block (3), or flexible Phlogophite mica paper. Both have the advantage of being able to withstand prospective resistor element temperatures of up to 500°C and above and that, at 800V operating voltage, 30kW continuous dissipation from the resistor (2) is achievable.
Optionally, a thermally conductive grease can be used between the at least one resistor (2) and the at least one insulating layer (9) and/or between the at least one insulating layer (9) and the at least one block (3) in order to improve the heat transfer from said resistor.
Retaining means are provided for subjecting the at least one resistor (2) to a uniform force against the face of the at least one block (3) parallel to the main plane of the resistor.
The retaining means preferably comprise an electrically insulated connection plate rigidly fastenable to the at least one block (3), preferably via nuts and bolts, the resistor (2) being disposed between the connection plate and the block (3). The connection plate may optionally be constructed of an electrically insulating, and preferably thermally conductive material.
Alternatively, as shown in the embodiment shown in Figure 5, the connection plate may be in the form of a rigid, electrically conductive panel (14), having an electrically insulating layer (15) disposed between it and the resistor (2).
The rigid fastening between the connection plate and the block (3) prevents the resistor (2) from expanding vertically, in other words in the direction perpendicular to the main plane of the flat resistor, while allowing expansion in the main plane.
The block (3) and the connection plate preferably comprise rounded edges in the area of protrusion of the end terminals (7) of the resistor (2), with the at least one insulating layer (9) extending to cover these edges in order to prevent electrical creepage between the resistor and the block or connection plate.
Preferably, the connection plate is in the form of a further metallic block (3) with a liquid flow path (6) as described above, having at least one thermally conductive, electrically insulating layer (9) disposed between said further block (3) and said resistor (2). This arrangement has the advantage of heat dissipation from the resistor (2) from two sides.
Expansion guide means at least partially surrounding the at least one resistor (2) are provided to confine the expansion of the resistor in its main plane. The expansion guide means are preferably configured so as to match the profile of the at least one resistor (2) in a first expanded configuration, while leaving an expansion space for said resistor in a second rest configuration.
Preferably, the expansion guide means are disposed in the main plane of the at least one resistor (2).
The expansion guide means preferably comprise at least one flexible Phlogophite mica paper strip (11) disposed between the at least one block (3) and the connection plate. Figures 1, 4 and 10 show the resistor (2) in the first expanded configuration wherein the expansion guide means are in contact with the resistor, preventing further expansion. Preferably, the thickness of this strip (11) is no more than that of the resistor (2) so that firm contact is maintained between the resistor and the insulating layer adjacent to the at least one block (3) for optimum thermal transfer.
Advantageously, the strip (11) comprises holes (10) for cooperating with the bolts fixing the connection plate to the block (3).
By using one or several strips (11) around the periphery of the resistor (2), it is possible to control the expansion and contraction of the resistor in all directions. Examples of such strips are shown in Figures 6 -9.
Advantageously, the resistor may exhibit protrusions (12) at the outer edge of each S-shaped bend, extending in the plane of the flat resistor. By providing a corresponding profile (13) of the strip (11), the nieshing action further helps to ensure that tl1e expansion is allowed only in a direction perpendicular to the flow of electricity through the resistor (2). Concertina-type expansion and the subsequent movement of the resistor to a contracted rest position different from the initial start position prior to expansion is hence avoided. The controlled expansion and contraction ensures that the resistor is always maintained in the area of the block (3) covered by the liquid flow path (6), thereby ensuring effective energy dissipation. Figures 8 and 9 show examples of such strips (11) having a profile suitable for meshing with such protrusions (12).
Moreover, the use of one or more strips (11) around the periphery of the resistor (2) prevents the resistor from expanding out beyond the edges of the block (3) and connection plate, thereby avoiding the potential health and safety hazard posed by an exposed hot resistor.
Advantageously, the expansion guide means may further comprise a granular electrically insulating material, at least disposed between at least two adjacent fins of the resistor (2). The granular insulating material may comprise large loose grains or other solid shapes having a characteristic diameter of 70% -90% of the thickness of the resistor (2). It is kept in place between the block and the retaining means by the remaining expansion guide means. The large granularity ensures that the material does not leak out of the resistor under vibration. The granular insulating material in the gap between at least two adjacent fins of the resistor, and preferably between each of the adjacent fins, prevents said adjacent fins from coming into contact with one another during heating and cooling.
In an alternative embodiment, shown in Figures 10 -13, the invention comprises a double arrangement, wherein it is possible to use two shorter resistors rather than one long resistor where space is a consideration. This arrangement is substantially as described above, but also comprises an additional resistor (2) disposed on the opposite side of the at least one block (3) from the first resistor (2), with a further thermally conductive, electrically insulating layer (9) disposed between the additional resistor (2) and the block (3). The two resistors (2) may be connected in series or in parallel to suit the required resistance. Preferably, the liquid inlet and outlet to the at least one block are disposed in a plane perpendicular to the sides of the block (3) facing the resistors (2) as this renders the flow path connection to further parallelly disposed blocks simpler.
In a variation of this alternative embodiment (not shown in the Figures), the two resistors (2) are instead simply separated by a layer of flexible Phlogophite mica paper.
The liquid-cooled brake resistor for use in electric vehicles thus conceived is susceptive to numerous modifications and variations, all falling within the scope of the inventive concept; furthermore, all details may be substituted by technically equivalent elements.
In practice, any material type or size may be used, according to the needs and the state of the art.

Claims (14)

  1. CLAIMSLiquid-cooled brake resistor for use in electric vehicles, comprising -at least one metallic block having a liquid inlet and a liquid outlet and an internal liquid flow path therebetween, -at least one flat resistor located with its main plane parallel to a face of said at least one block, aid -at least one thermally conductive, electrically insulating layer disposed between said at least one block and said at least one resistor, characterised in that of comprising -retaining means subjecting said at least one resistor to a uniform force against said face of said at least one block, and -expansion guide means at least partially surrounding said at least one resistor to confine expansion of said resistor in its main plane.
  2. 2. Liquid-cooled brake resistor as claimed in claim 1, characterised in that of said expansion guide means being configured so as to match the profile of the at least one resistor in a first expanded configuration, while leaving an expansion space for said resistor in a second rest configuration.
  3. 3. Liquid-cooled brake resistor as claimed in claim 1 or 2, characterised in that of said expansion guide means being disposed in said main plane of said at least one resistor.
  4. 4. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that the thickness of said expansion guide means is no more than that of said at least one resistor.
  5. 5. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said expansion guide means comprises a profile corresponding to protrusions extending from said at least one resistor in its plane.
  6. 6. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said expansion guide means con-iprise at least one flexible Phlogophite mica paper strip.
  7. 7. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said expansion guide means further comprise a granular insulating material at least disposed between at least two adjacent fins of said resistor.
  8. 8. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said retaining means comprise an electrically insulated connection plate rigidly fastenable to said at least one block, said at least one resistor being disposed between said connection plate and said block.
  9. 9. Liquid-cooled brake resistor as claimed in claim 8, characterised in that said electrically insulated connection plate comprises a further metallic block having at least one thermally conductive, electrically insulating layer disposed between said further block and said resistor.
  10. 10. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said at least one insulating layer comprises plasma-sprayed alumina.
  11. 11. Liquid-cooled brake resistor as claimed in any of claims 1 to 9, characterised in that said at least one insulating layer comprises flexible Phiogophite mica paper.
  12. 12. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that it comprises a thermally conductive grease between said resistor and said at least one insulating layer and/or between said at least one insulating layer and said at least one block.
  13. 13. Liquid-cooled brake resistor as claimed in any of claims 8 to 12, characterised in that said at least one metallic block and said connection plate comprise rounded edges in the area of protrusion of the end terminals of said resistor, said edges being covered by said at least one insulating layer.
  14. 14. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that of said at least one metallic block having said liquid inlet and said liquid outlet on one side and disposed parallelly and as a function of the width of said block.Amendments to the claims have been filed as follows:CLAIMS1. Liquid-cooled brake resistor for use in electric vehicles, comprising -at least one metallic block having a liquid inlet and a liquid outlet and an internal liquid flow path therebetween, -at least one flat resistor located with its main plane parallel to a face of said at least one block, and -at least one thermally conductive, electrically insulating layer disposed between said at least one block and said at least one resistor, -retaining means subjecting said at least one resistor to a uniform force against said face of said at least one block, characterised in that of comprising -expansion guide means at least partially surrounding said at least one resistor to confine expansion of said resistor *S***. . * * in its main plane, -said expansion guide means comprising at least one flexible Phiogophite mica paper strip. **S. * ** **2. Liquid-cooled brake resistor as claimed in claim 1, characterised in that of said expansion guide means being configured so as to match the profile of the at least one resistor in a first expanded configuration, while leaving an expansion space for said resistor in a second rest configuration.3. Liquid-cooled brake resistor as claimed in claim 1 or 2, characterised in that of said expansion guide means being disposed in said main plane of said at least one resistor.4. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that the thickness of said expansion guide means is no more than that of said at least one resistor.5. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said expansion guide means comprises a profile corresponding to protrusions extending from said at least one resistor in its plane.6. Liquid-cooled brake resistor as claimed in any preceding * * claim, charactensed in that said expansion guide means further comprise a granular insulating material at least disposed between at least two adjacent fins of said resistor. **S. * **.*7. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that said retaining means comprise an electrically insulated connection plate rigidly fastenable to said at least one block, said at least one resistor being disposed between said connection plate and said block.8. Liquid-cooled brake resistor as claimed in claim 7, characterised in that said electrically insulated connection plate comprises a further metallic block having at least one thermally conductive, electrically insulating layer disposed between said further block and said resistor.9. Liquid-cooled brake resistor as claimed in any preceding claim, charactensed in that said at least one insulating layer comprises plasma-sprayed alumina.10. Liquid-cooled brake resistor as claimed in any of claims 1 to 8, characterised in that said at least one insulating layer comprises flexible Phiogophite mica paper.S*.S... * S11. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that it comprises a thermally conductive grease between said resistor and said at least one insulating layer andlor between said at least one insulating layer and said at least *...one block.12. Liquid-cooled brake resistor as claimed in any of claims 7 to 11, characterised in that said at least one metallic block and said connection plate comprise rounded edges in the area of protrusion of the end terminals of said resistor, said edges being covered by said at least one insulating layer.13. Liquid-cooled brake resistor as claimed in any preceding claim, characterised in that of said at least one metallic block having said liquid inlet and said liquid outlet on one side and disposed parallelly and as a function of the width of said block.S..... * .* .SS*a * S *aS*I
GB201003867A 2010-03-09 2010-03-09 Liquid-cooled brake resistor for use in electric vehicles Active GB2478547B (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2592633A1 (en) 2011-11-14 2013-05-15 Cressall Resistors Limited Liquid-cooled resistor device
EP3016114A1 (en) * 2014-10-29 2016-05-04 REO Inductive Components AG Electrical resistor
CN105916349A (en) * 2016-04-27 2016-08-31 许继集团有限公司 Direct current power transmission converter valve and water cooling radiator
CN105915075A (en) * 2016-04-27 2016-08-31 许继集团有限公司 Direct current power transmission converter valve and water cooling apparatus
WO2022184628A1 (en) * 2021-03-03 2022-09-09 Heine Resistors Gmbh Liquid-cooled brake resistor in the form of a plate heat exchanger
EP4175008A4 (en) * 2021-04-30 2024-02-21 LG Energy Solution, Ltd. Battery pack and device including same

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109545486A (en) * 2019-01-09 2019-03-29 深圳市正阳兴电子科技有限公司 A kind of copped wave resistor and carrier arrangement
CN112086252A (en) * 2020-09-14 2020-12-15 广东意杰科技有限公司 High-voltage ultra-large-capacity water-cooled resistor

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4420739A (en) * 1980-09-15 1983-12-13 Peter Herren Liquid-cooled electrical assembly
GB2202382A (en) * 1987-03-16 1988-09-21 Bosch Gmbh Robert Hand-held machine tools
DE3933956A1 (en) * 1989-10-11 1991-04-25 Asea Brown Boveri Force-cooled power resistor e.g. for railway locomotive converter - is of flat metal sheet of high specific electrical resistance presenting large cooling area
DE4225723A1 (en) * 1992-08-04 1994-02-10 Abb Patent Gmbh Power resistance for liquid cooling
JP2001307902A (en) * 2000-04-19 2001-11-02 Mitsubishi Electric Corp Water-cooled resistor

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4420739A (en) * 1980-09-15 1983-12-13 Peter Herren Liquid-cooled electrical assembly
GB2202382A (en) * 1987-03-16 1988-09-21 Bosch Gmbh Robert Hand-held machine tools
DE3933956A1 (en) * 1989-10-11 1991-04-25 Asea Brown Boveri Force-cooled power resistor e.g. for railway locomotive converter - is of flat metal sheet of high specific electrical resistance presenting large cooling area
DE4225723A1 (en) * 1992-08-04 1994-02-10 Abb Patent Gmbh Power resistance for liquid cooling
JP2001307902A (en) * 2000-04-19 2001-11-02 Mitsubishi Electric Corp Water-cooled resistor

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2592633A1 (en) 2011-11-14 2013-05-15 Cressall Resistors Limited Liquid-cooled resistor device
EP3016114A1 (en) * 2014-10-29 2016-05-04 REO Inductive Components AG Electrical resistor
CN105916349A (en) * 2016-04-27 2016-08-31 许继集团有限公司 Direct current power transmission converter valve and water cooling radiator
CN105915075A (en) * 2016-04-27 2016-08-31 许继集团有限公司 Direct current power transmission converter valve and water cooling apparatus
WO2022184628A1 (en) * 2021-03-03 2022-09-09 Heine Resistors Gmbh Liquid-cooled brake resistor in the form of a plate heat exchanger
EP4175008A4 (en) * 2021-04-30 2024-02-21 LG Energy Solution, Ltd. Battery pack and device including same

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GB201003867D0 (en) 2010-04-21
GB2478547B (en) 2014-01-15

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