JP4421477B2 - 注型品の製造方法 - Google Patents
注型品の製造方法 Download PDFInfo
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- JP4421477B2 JP4421477B2 JP2004530767A JP2004530767A JP4421477B2 JP 4421477 B2 JP4421477 B2 JP 4421477B2 JP 2004530767 A JP2004530767 A JP 2004530767A JP 2004530767 A JP2004530767 A JP 2004530767A JP 4421477 B2 JP4421477 B2 JP 4421477B2
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
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- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 8
- 238000005495 investment casting Methods 0.000 description 8
- 239000002245 particle Substances 0.000 description 8
- 239000010949 copper Substances 0.000 description 6
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- 229920000642 polymer Polymers 0.000 description 5
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 4
- 238000004512 die casting Methods 0.000 description 4
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
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- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
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- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910000677 High-carbon steel Inorganic materials 0.000 description 1
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- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910000954 Medium-carbon steel Inorganic materials 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- 241000218657 Picea Species 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
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- 229910002804 graphite Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
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- 229910000765 intermetallic Inorganic materials 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
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- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
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- 238000005507 spraying Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
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- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/16—Formation of a green body by embedding the binder within the powder bed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F3/26—Impregnating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
- C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/68—Cleaning or washing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Powder Metallurgy (AREA)
- Mold Materials And Core Materials (AREA)
- Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Jellies, Jams, And Syrups (AREA)
Description
本出願は、2002年8月20日申請の米国仮出願番号第60/404,642号に対して優先権を主張する。その全体がこの参照により本明細書に組み込まれる。
Tphは、フラスコアセンブリの予熱量で、これには多孔性粉末品が含まれる。
Tmpは、粉末物質の溶解温度。
Cppは、粉末物質の特定熱。
Hmpは、粉末物質の融合熱。
Tmmは、溶融金属の溶解温度。
Tohは、溶融金属の過熱温度。
Cpmは、溶融金属の特定熱。
近年、鋳造工場には新しい鋳造設計をより速いペースで紹介するという商業的圧力があった。このため、新しい設計が概念からプロタイプ段階を通って産業的製造に入るために利用できる時間が少なくなってきた。以下の机上の実験例は、本発明の実施形態の応用を説明するものである。
Claims (27)
- 注型品を製造するための方法であって、
a)80%未満の相対密度を有する多孔性粉末品を提供する工程と、
b)前記多孔性粉末品の周囲を鋳型成形用材料で囲むことにより当該多孔性粉末品の形状から成る注型品成形用キャビティを有する鋳型を成形する工程であって、これにより、前記鋳型の注型品成形用キャビティは前記多孔性粉末品と同一形状となり、前記多孔性粉末品は当該注型品成形用キャビティ全体に充填されるものである、前記成形する工程と、
c)前記鋳型へ溶融金属を注入する工程であって、前記注入された溶融金属により前記多孔性粉末品は破壊されて液体状態の残留物、または固体状態の残留物、または液体状態および固体状態の混合物からなる残留物となり、当該多孔性粉末品の残留物を含む溶融金属が前記注型品成形用キャビティ全体に充填されるものである、前記注入する工程と
d)前記多孔性粉末品の残留物を含む溶融金属を前記注型品成形用キャビティ内で凝固させて注型品を製造する工程であって、当該注型品は溶浸された多孔性粉末品ではないものである、前記製造する工程と
を有し、
前記工程c)の開始時点において、前記鋳型の温度は前記溶融金属の固相線温度よりも低いものである
方法。 - 請求項1記載の方法において、この方法は、さらに、
立体形状作成技術によって前記多孔性粉末品を作成する工程を有するものである方法。 - 請求項2記載の方法において、前記立体形状作成技術は、三次元印刷および選択的レーザー焼結法から成る群から選択されるものである方法。
- 請求項1記載の方法において、この方法は、さらに、
前記鋳型を加熱する工程を有するものである方法。 - 請求項4記載の方法において、この方法は、さらに、
前記鋳型を加熱する工程の後、前記鋳型を保存する工程を有するものである方法。 - 請求項1記載の方法において、この方法は、さらに、
前記工程c)の直前に、前記鋳型を加熱する工程を有するものである方法。 - 請求項4記載の方法において、前記鋳型を加熱する工程および前記工程c)のうち少なくとも1つは雰囲気制御下で行われるものである方法。
- 請求項7記載の方法において、前記雰囲気制御には、水素、窒素、およびアルゴンから成る群のうち少なくとも1つが使用されるものである方法。
- 請求項1記載の方法において、前記多孔性粉末品はポリマー粘結剤を有し、前記方法はさらに、前記工程c)の前に、前記ポリマー粘結剤から前記多孔性粉末品を非結合にする工程を有するものである方法。
- 請求項1記載の方法において、この方法は、さらに、
前記工程d)の間に前記多孔性粉末品の粉末と前記溶融金属とが結合して複合材料を形成するように、前記多孔性粉末品の粉末と前記溶融金属とを選択する工程を有するものである方法。 - 請求項1記載の方法において、この方法は、さらに、
前記工程c)の間に前記溶融金属が少なくとも部分的に前記多孔性粉末品の粉末を溶解するように、前記多孔性粉末品の粉末と前記溶融金属とを選択する工程を有するものである方法。 - 請求項1記載の方法において、前記多孔性粉末品は30%〜40%の範囲の相対密度を有するものである方法。
- 請求項1記載の方法において、この方法は、さらに、
前記多孔性粉末品を作成する工程は、前記多孔性粉末品が金属粉末、セラミック粉末、およびサーメット粉末から成る群のうちの少なくとも1つを含むように当該多孔性粉末品を作成する工程を有するものである方法。 - 注型品を製造するための方法であって、
a)80%未満の相対密度を有する多孔性粉末品を提供する工程と、
b)前記多孔性粉末品をコーティングして、当該多孔性粉末品上にセラミックシェルを作製する工程と、
c)前記コーティングされた多孔性粉末品の周囲を鋳型成形用材料で囲むことにより当該コーティングされた多孔性粉末品の形状から成る注型品成形用キャビティを有する鋳型を成形する工程であって、これにより、前記鋳型の注型品成形用キャビティは前記コーティングされた多孔性粉末品と同一形状となり、前記コーティングされた多孔性粉末品は当該注型品成形用キャビティ全体に充填されるものである、前記成形する工程と、
d)前記鋳型へ溶融金属を注入する工程であって、前記注入された溶融金属により前記多孔性粉末品は破壊されて液体状態の残留物、または固体状態の残留物、または液体状態および固体状態の混合物からなる残留物となり、当該多孔性粉末品の残留物を含む溶融金属が前記注型品成形用キャビティ全体に充填されるものである、前記注入する工程と、
e)前記多孔性粉末品の残留物を含む溶融金属を前記注型品成形用キャビティ内で凝固させて注型品を製造する工程であって、当該注型品は溶浸された多孔性粉末品ではないものである、前記製造する工程と
を有し、
前記工程d)の開始時点において、前記鋳型の温度は前記溶融金属の固相線温度よりも低いものである
方法。 - 請求項14記載の方法において、この方法は、さらに、
立体形状作成技術によって前記多孔性粉末品を作成する工程を有するものである方法。 - 請求項15記載の方法において、前記立体形状作成技術は、三次元印刷および選択的レーザー焼結法から成る群から選択されるものである方法。
- 請求項14記載の方法において、前記多孔性粉末品はポリマー粘結剤を有し、前記方法はさらに、前記工程d)の前に、前記ポリマー粘結剤から前記多孔性粉末品を非結合にする工程を有するものである方法。
- 請求項17記載の方法において、この方法は、さらに、
前記多孔性粉末品を非結合にする工程の後、前記多孔性粉末品を保存する工程を有するものである方法。 - 請求項14記載の方法において、この方法は、さらに、
前記鋳型を加熱する工程を有するものである方法。 - 請求項19記載の方法において、この方法は、さらに、
前記鋳型を加熱する工程の後、前記鋳型を保存する工程を有するものである方法。 - 請求項14記載の方法において、この方法は、さらに、
前記工程d)の直前に、前記鋳型を加熱する工程を有するものである方法。 - 請求項19記載の方法において、前記鋳型を加熱する工程および前記注入する工程のうち少なくとも1つは雰囲気制御下で行われるものである方法。
- 請求項22記載の方法において、前記雰囲気制御には、水素、窒素、およびアルゴンから成る群のうち少なくとも1つが使用されるものである方法。
- 請求項14記載の方法において、この方法は、さらに、
前記工程e)の後冷却された時点で、前記多孔性粉末品の粉末と前記溶融金属とが結合して複合材料を形成するように、前記多孔性粉末品の粉末と前記溶融金属とを選択する工程を有するものである方法。 - 請求項14記載の方法において、この方法は、さらに、
前記工程d)の間に前記溶融金属が少なくとも部分的に前記多孔性粉末品の粉末を溶解するように、前記多孔性粉末品の粉末と前記溶融金属とを選択する工程を有するものである方法。 - 請求項14記載の方法において、前記多孔性粉末品は30%〜40%の範囲の相対密度を有するものである方法。
- 請求項14記載の方法において、この方法は、さらに、
前記多孔性粉末品を作成する工程は、前記多孔性粉末品が金属粉末、セラミック粉末、およびサーメット粉末から成る群のうちの少なくとも1つを含むように当該多孔性粉末品を作成する工程を有するものである方法。
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2003
- 2003-02-25 KR KR1020057002911A patent/KR20050058404A/ko active IP Right Grant
- 2003-02-25 EP EP03716204A patent/EP1534451B1/en not_active Expired - Lifetime
- 2003-02-25 RU RU2005107702/02A patent/RU2311984C2/ru not_active IP Right Cessation
- 2003-02-25 US US10/416,148 patent/US7461684B2/en active Active
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- 2003-02-25 CA CA002496382A patent/CA2496382A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
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KR20050058404A (ko) | 2005-06-16 |
WO2004018132A1 (en) | 2004-03-04 |
JP2005536353A (ja) | 2005-12-02 |
ES2281635T3 (es) | 2007-10-01 |
EP1534451A1 (en) | 2005-06-01 |
RU2311984C2 (ru) | 2007-12-10 |
RU2005107702A (ru) | 2005-09-10 |
EP1534451B1 (en) | 2007-02-14 |
US20040140078A1 (en) | 2004-07-22 |
CA2496382A1 (en) | 2004-03-04 |
ATE353729T1 (de) | 2007-03-15 |
DE60311824D1 (de) | 2007-03-29 |
CN1684786A (zh) | 2005-10-19 |
US7461684B2 (en) | 2008-12-09 |
DE60311824T2 (de) | 2007-10-31 |
PT1534451E (pt) | 2007-05-31 |
AU2003219919A1 (en) | 2004-03-11 |
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