CN102112197B - 制造复合过滤介质的方法 - Google Patents
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Abstract
在示例性实施方案中,制备复合过滤介质的方法包括通过纺粘工艺形成包含多根合成纤维的非织造织物垫,并用压花压延辊压延该非织造织物垫,以便形成包括多个基本上平行的不连续粘结区域线条的粘结区域图案以将合成纤维粘结在一起形成非织造织物,所述非织造织物具有根据EN 1822(1998)测试规程测量的约35%至小于50%的过滤效率。所述方法也包括通过电吹制纺丝聚合物溶液施加纳米纤维层以在非织造织物垫的至少一侧上形成多根纳米纤维以形成复合过滤介质,所述复合过滤介质具有根据EN 1822(1998)测试规程测量的约70%的最小过滤效率。
Description
发明背景
本发明领域一般涉及复合非织造过滤介质,更具体地讲涉及纺粘的非织造过滤介质,其具有施用到至少一个表面上的基于纳米纤维的层。
某些已知的过滤介质复合构建体引入湿法成网造纸法来制备基底,并且引入电纺丝技术来将轻质纳米纤维涂层沉积在过滤介质基底的一侧或两侧上。所述介质基底通常具有100-120克/平方米(g/m2)的基重,并且所述纳米纤维层具有0.1g/m2或更小的基重。
已知轻质纳米纤维层易在高机械应力应用中受损,主要是因为所述纳米纤维层是由具有小于500纳米(nm),并且更典型为100nm直径的纤维形成的。就依靠极性吸引力电纺丝纤维而言,已知存在纳米纤维从过滤介质上脱落的“脱落”问题,因为纳米纤维和基础介质之间较弱的吸引键。并且,已知的电纺丝纳米纤维层在结构上是二维的或者在厚度上是单纤维层,并且当纳米纤维层断裂或破碎时,粉尘能够容易地穿过基本的介质基底。在纳米纤维层受损之后,粉尘允许穿过基础介质并且造成过滤器的操作压降升高。此外,已知的介质基底还具有机械应力限制,并且在高粉尘负荷下易于变形。
这些已知的过滤介质复合构建体,当被用于过滤电力生产气体涡轮机的入口空气时,能够在过滤器的使用寿命之内允许细尘颗粒穿过过滤器。这种已知的过滤介质类型通常将具有新的或清洁的操作电中性效率,当根据EN 1822(1998)测试规程在已知的操作流速下测试时,其在通常大于7.0mmH2O的压降和小于300的品质因子下,提供约55%的0.4μm颗粒的捕集。已知由于该低的初始效率,在24,000小时的使用寿命内,多达15至20磅的粉尘能够穿过已知的过滤介质。使涡轮叶片长期暴露在粉尘中能够造成严重的和灾难性的污垢和涡轮叶片的腐蚀。当前的清洁涡轮叶片的工序需要在定期的间隔时间处使涡轮机离线以将叶片水洗干净。涡轮机停机时间是昂贵的,因为涡轮机不工作并因此减少了电力生产。期望提供一种在相近的或减小的压降下比已知过滤介质效率更高的过滤介质以缩减或取消清洁涡轮叶片和/或更换受损叶片的涡轮机停机时间。
发明简述
在一个方面,提供了制备复合过滤介质的方法。所述方法包括通过纺粘工艺形成包含多根合成纤维的非织造织物垫,并用压花压延辊压延该非织造织物垫,以便形成包括多个基本上平行的不连续粘结区域线条的粘结区域图案以将合成纤维粘结在一起形成非织造织物,所述非织造织物具有根据EN 1822(1998)测试规程测量的约35%至小于50%的过滤效率。所述方法也包括通过电吹制纺丝聚合物溶液施加纳米纤维层以在非织造织物垫的至少一侧上形成多根纳米纤维以形成复合过滤介质,所述复合过滤介质具有根据EN 1822(1998)测试规程测量的约70%的最小过滤效率。
附图简述
图1是复合过滤介质的示例性实施方案的剖视图。
图2是图1中所示纤维的显微照片。
图3是图1中所示基本的介质基底的显微照片。
图4是图1中所示的粘结型基本的介质基底的顶视图。
图5是包括图1中所示过滤介质的滤筒的侧视图。
图6是包括图4中所示滤筒的过滤组合件的透视图。
图7是根据示例性实施方案在各种基重下0.3微米基本的介质基底的分级效率的柱状图。
图8是与具有和不具有纳米纤维层的比较性基本的介质基底相比,根据示例性实施方案具有和不具有纳米纤维层的0.3微米基本的介质基底的分级效率的柱状图。
图9是与具有和不具有纳米纤维层的比较性基本的介质基底相比,压降对根据示例性方面具有和不具有纳米纤维层的基本的介质基底的柱状图。
发明详述
以下详细描述了用于过滤组合件的复合过滤介质。在一个示例性实施方案中,所述复合过滤介质包括非织造合成织物的介质基底,所述非织造合成织物通过独特的纺粘工艺由两层纤维形成。将纳米纤维层沉积在所述介质基底的至少一侧上。当根据欧洲标准EN 1822(1998)测试规程测试时,所述复合材料介质提供约70%或更大的保留0.4μm颗粒捕集的初始过滤效率,其与已知的过滤介质相比在性能上有约15%的提升。此外,所述复合材料介质在比已知的过滤介质低大于30%的压降下提供70%的效率。所述方法包括通过纺粘工艺形成包含多根合成纤维的非织造织物垫,并用压花压延辊压延该非织造织物垫,以便形成包括多个基本上平行的不连续粘结区域线条的粘结区域图案以将合成纤维粘结在一起形成非织造织物,所述非织造织物具有根据EN 1822(1998)测试规程测量的约35%至小于50%的过滤效率。
所述复合过滤介质比已知的过滤介质更加耐用,并且提供更低的压降积累,因为在过滤和反向清洁操作期间,由施加在过滤介质上的力所造成的过滤介质的挠曲更少。所述复合过滤介质可具有大于约370,并且在优选的实施方案中,大于约440的品质因子(Qf)。此外,所述复合过滤介质可具有根据EN-1822(1998)测定的小于4.0mm水柱的阻力(或压降),同时所述基本的介质基底具有根据EN-1822(1998)测定的小于约2.5mm水柱的阻力此外,所述纳米纤维膜层具有比已知过滤介质更高的基重,其使得所述过滤介质在反向脉冲清洁下比已知过滤介质更有效地清洁。高基重的纳米纤维层提供耐用的三维表面过滤层,其具有大量曲折的路径,其允许高效且精细的颗粒捕集,而基本上不限制气流或者增加压降。
“品质因子(Qf)”是指由以下公式所定义的参数:
Qf=-25000·log(P/100)/Δp
其中“P”=颗粒穿透百分比,而“Δp”=以帕斯卡表示的穿过介质的压降。
“阻力”是指使用EN 1822(1998)中所述的测试方法所测得的阻力(压降)。
参见图片,图1过滤介质10的示例性实施方案的剖视图。过滤介质10包括具有第一侧面14和第二侧面16的基本的介质基底12。纳米纤维层20沉积在介质基底的第一侧面14上。在另一个实施方案中,纳米纤维层20沉积在第二侧面16上,而在另一个实施方案中,纳米纤维层20沉积在第一和第二侧面14和16的每一侧上。
介质基底12为使用纺粘工艺由合成纤维形成的非织造织物。非织造织物包括双重纤维横截面形状。合适的双重纤维层横截面可具有含圆形结构或三叶形结构的纤维形状。并且参见图2,在示例性实施方案中,双重纤维横截面30包括一层圆柱形的纤维32和一层三叶形的纤维33。纤维32和33通过喷嘴被熔纺成多股连续的纤维,其被均匀地沉积到无规的三维网上。然后将所述网加热并压花,其将所述网热粘结成图3中所示的强固的纺粘织物36。来自与压花图案的压延辊接触的热量软化或熔融热塑性纤维30,其在压花图案的压延辊的接触点处将非织造纤维粘结在一起。选择温度,使得纤维30软化或者熔化。在一个实施方案中,所述温度为约90℃至约240℃。通过纤维32和33的熔融和冷却后的再固化可产生期望的纤维连接。
圆形纤维32具有约18微米至约23微米的直径,而三叶形纤维33具有约22-30微米的点对点横截面距离。
参见图4,在基础介质12上的粘结图案40使基础介质12获得满意的耐久性,同时使得更多的纤维可用于过滤,因此增加了过滤效率。粘结图案40在沿整个基础介质12延伸的粘结区域上内包括多条平行的不连续线条42。粘结区域平行的不连续线条42是彼此错开的,使得不连续线条42上的非粘结区域44的位置与邻近的不连续线条42上的粘结区域46对齐。在示例性实施方案中,基础介质12的基重为约100g/m2至约330g/m2,在另一个实施方案中,约100g/m2至约220g/m2。
任何合适的合成纤维均可用于制备介质基底12的非织造织物。适用于圆形纤维32和三叶形纤维33的材料包括但不限于聚酯、聚酰胺、聚烯烃、热塑性聚氨酯、聚醚酰亚胺、聚苯醚、聚苯硫醚、聚砜、芳族聚酰胺、以及它们的混合物。
在示例性实施方案中,纳米纤维层20通过电吹制纺丝工艺形成,所述工艺包括:将聚合物溶液给料到纺丝喷嘴中,对纺丝喷嘴施加高电压,并且当向纺丝喷嘴的下端注入压缩空气时通过纺丝喷嘴排出聚合物溶液。所施加的高电压在约1kV至约300kV的范围内。形成纳米纤维的电吹制纺丝工艺和所使用的独特设备详细描述在美国专利申请公布号为2005/00677332的专利中。所述电吹制纺丝工艺提供耐用的纳米纤维三维过滤层,其比已知过滤介质上的已知纳米纤维过滤层更厚。在示例性实施方案中,纳米纤维层20的基重为约0.6g/m2至约20g/m2,在另一个实施方案中,约2g/m2至约20g/m2,在另一个实施方案中,约5g/m2至约10g/m2,在另一个实施方案中,约1.5g/m2至约2.5g/m2。纳米纤维层20中的纳米纤维具有约500nm或更小的平均直径。
在供选择的实施方案中,纳米纤维层20可通过静电纺纱、离心纺丝、或熔融喷制形成。传统的静电纺纱是详细描述在美国专利4,127,706中的技术。向溶液中的聚合物施加高电压以生成纳米纤维和非织造垫。然而,静电纺纱工艺中的总生产能力太低,无法生产较重基重的纤维网。离心纺丝是一种纤维形成工艺,其包括向具有旋转的圆锥形喷嘴的旋转喷射器提供纺丝溶液,所述纺丝溶液具有溶于至少一种溶剂中的至少一种聚合物。所述喷嘴具有凹形内表面和向前的表面排放边缘。所述纺丝溶液通过旋转喷射器沿凹形内表面移动,以便向喷嘴排放边缘向前的表面分配纺丝溶液。当溶剂在电场的存在下或无电场存在下蒸发以产生聚合物纤维时,单独的纤维流由纺丝溶液形成。成型流体可在喷嘴周围流动以引导纺丝溶液离开旋转喷射器。将纤维收集到收集器上以形成纳米纤维网。此外,熔融喷制详细描述在美国专利6,520,425中。
用于通过电吹制纺丝工艺形成纳米纤维的合适聚合物不限于热塑性聚合物,并且可包括热固性聚合物。合适的聚合物包括但不限于聚酰亚胺、聚酰胺(尼龙)、聚芳酰胺、聚苯并咪唑、聚醚酰亚胺、聚丙烯腈、聚对苯二甲酸乙二醇酯、聚丙烯、聚苯胺、聚环氧乙烷、聚萘二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、苯乙烯丁二烯橡胶、聚苯乙烯、聚氯乙烯、聚乙烯醇、聚偏1,1-二氯乙烯、聚乙烯基丁烯、聚缩醛、聚酰胺、聚酯、聚烯烃、纤维素醚和酯、聚亚烷基硫、聚亚芳基氧、聚砜、改性的聚砜聚合物、以及它们的混合物。还可使用属于一般类别的这些材料:聚氯乙烯、聚甲基丙烯酸甲酯(及其它丙烯酸类树脂)、聚苯乙烯、以及它们的共聚物(包括ABA型嵌段共聚物)、聚偏二氟乙烯、偏二氯乙烯、交联与非交联形式的多种水解度(87%至99.5%)的聚乙烯醇,以及它们的共聚物或衍生化合物。一类合适的聚酰胺缩聚物为尼龙材料,例如尼龙-6、尼龙-6,6、尼龙6,6-6,10等等。通过选择溶解所选聚合物的溶剂制备所述聚合物溶液。所述聚合物溶液能够与添加剂混合,例如增塑剂、紫外线稳定剂、交联剂、固化剂、反应引发剂等等。虽然溶解所述聚合物可以不需要任何具体的温度范围,但是可能需要加热以有助于溶解反应。
可能有利的是,向上述多种聚合物中加入增塑剂以降低纤维聚合物的Tg。合适的增塑剂将取决于所述聚合物,也取决于纳米纤维层具体的最终用途。例如,尼龙聚合物可用水或甚至用静电纺纱或电吹制纺丝工艺中残余的溶剂来增塑。可用于降低聚合物Tg的其它增塑剂包括但不限于脂族乙二醇类、芳族磺胺类、邻苯二甲酸酯类,所述邻苯二甲酸酯类包括但不限于邻苯二甲酸二丁酯、邻苯二甲酸二己酯、邻苯二甲酸二环己酯、邻苯二甲酸二辛酯、邻苯二甲酸二异癸酯、邻苯二甲酸双十一酯、邻苯二甲酸双十二酯、以及邻苯二甲酸二苯酯等。
图5是由过滤介质10形成的过滤元件50的侧视图。在示例性实施方案中,过滤介质10包括多个褶绉52。过滤元件50包括第一端盖54和相对的第二端盖56,过滤介质10延伸在端盖54和56之间。过滤元件50具有管状造型,其具有内部导管58(示于图6中)。过滤元件50是圆柱形的,但也可以是如图6中所示圆锥形的。过滤元件50还可包括内部和/或外部支承衬管以提供过滤元件50的结构完整性和/或用于过滤介质10的支撑。
图6是过滤组合件60的透视图,所述过滤组合件包括以首尾相连的关系成对安装在管板62上的多个过滤元件50。管板62将脏空气侧与过滤组合件60的干净空气侧分隔开。用脉冲空气用于清洁过滤元件50的清洁系统64包括多个安装在空气供应管68上的空气喷嘴66。使用直接进入过滤元件50的内部导管58中的压缩空气脉冲来清洁收集了污垢和粉尘的过滤元件50。
根据EN 1822(1998)测试方法,在平片材分级效率测试中,将具有各种基重的基础介质基底12测试样本的平片材与比较性的基础介质基底相比较。引导包含DEHS颗粒的空气以约5.3cm/s的流速通过每个试验样本。图7示出了比较测试和纺粘的基础介质12增强的过滤效率性能的图解表示。柱A表示基重为165g/m2的基础基底12,而柱B表示基重为230g/m2的比较性基础基底。柱C表示具有130g/m2基重的比较性基础介质基底。所述基础介质基底不包括纳米纤维层。以0.3微米的粒度以5.3cm/s测试时,基础介质基底12具有比比较性基础基底更高的效率。
根据EN 1822(1998)测试方法,在平片材分级效率测试中,将基础介质基底12和包括纳米纤维层20的基础介质基底12的平片材与具有和不具有纳米纤维层的比较性基础介质基底相比较。引导包含0.3微米DEHS颗粒的空气以约5.3cm/s的流速通过每个测试样本。图8示出了比较测试的图解表示。柱A表示165g/m2的基础介质基底12,而柱B表示包括纳米纤维层20的165g/m2的基础介质基底12。柱C表示比较性的基础介质基底,而柱D表示包括纳米纤维层的比较性基础介质基底。具有和不具有纳米纤维层20的基础介质基底12具有比具有和不具有纳米纤维层的比较性基础基底更高的效率。
根据EN 1822(1998)测试方法,在平片材压降测试中,将基础介质基底12和包括纳米纤维层20的基础介质基底12的平片材与具有和不具有纳米纤维层的比较性基础介质基底相比较。引导包含DEHS颗粒的空气以约5.3cm/s的流速通过每个试验样本。图9示出了比较测试的图解表示。柱A表示比较性的基础介质基底,而柱B表示包括纳米纤维层的比较性基础介质基底。柱C表示165g/m2的基础介质基底12,而柱D表示包括纳米纤维层20的165g/m2的基础介质基底12。具有和不具有纳米纤维层20的基础介质基底12具有比具有和不具有纳米纤维层的比较性基础基底更低的压降。
由过滤介质10形成的上述过滤元件50能够用于在几乎任何应用中过滤空气流,例如用于过滤气体涡轮机入口空气。过滤介质10的独特构造比已知的过滤介质更加耐用,并且提供相对更低的压降积累,因为在过滤和反向清洁操作期间,由施加在过滤介质上的力所造成的过滤介质的挠曲更少。与已知过滤元件的约50-55%的效率相比,过滤元件50能够产生大于约70%的大部分穿透粒度的气溶胶或粉尘(约0.3至约0.4微米)的平均捕集效率。纳米纤维层20还具有比已知过滤介质更高的基重,其使得过滤介质10在反向脉冲清洁下比已知过滤介质更有效地清洁。此外,高基重的纳米纤维层20提供耐用的三维表面过滤层,其具有大量曲折的路径,其允许高效且精细的颗粒捕集,而不限制气流或者增加压降。
实施例1和2和比较实施例3-7的示例性过滤介质示出了过滤介质10的实施方案与已知过滤介质的比较。为实施例1和2及比较实施例3-7的每种过滤介质测量效率、阻力和品质因子。根据EN-1822(1998)测试规程测量效率,根据EN-1822(1998)测量阻力,并且如上所述计算品质因子Qf。
实施例1是包含圆形纤维和三叶形纤维的纺粘的聚酯双层基础介质基底,而实施例2是实施例1的基础介质基底加上通过电吹制纺丝工艺形成的2g/m2的纳米纤维层。比较实施例3为已知的干法成网聚酯基础介质基底,而比较实施例4为比较实施例3的已知的干法成网聚酯基础介质基底加上2g/m2的纳米纤维层。比较实施例5是湿法成网的合成纸加上<0.5g/m2的纳米纤维层。比较实施例6是湿法成网的合成纸,而比较实施例7是实施例6的湿法成网的合成纸加上20g/m2的熔喷纤维层。所述实施例结果示于下表I中。当将实施例2与比较实施例4、5和7中的复合材料相比时,靠减小阻力未牺牲效率,其产生相关的高品质因子值。
表I
效率根据EN 1822(1998)以0.3微米、5.3cm/s表面速度测得。
阻力根据EN-1822(1998)测得。
品质因子由下式定义:Qf=-25000·log(P/100)/Δp
该书面描述使用实施例来公开本发明,包括最好的模型,并且还使本领域的任何技术人员能够实践本发明,包括制备和使用任何装置或体系并且实施任何引入的方法。本发明可取得专利的范围由本权利要求限定,并且可包括本领域的技术人员遇到的其它实例。如果此类其它的实例具有与本权利要求的字面意义无区别的结构元件,或者它们包括与本权利要求的字面意义无实质区别的等同结构元件,打算将它们包括在本权利要求的范围内。
Claims (14)
1.制备复合过滤介质结构的方法,所述方法包括:
通过纺粘工艺形成包含多根合成纤维的非织造织物垫;
用压花压延辊压延所述非织造织物垫以形成包括多个基本上平行的不连续粘结区域线条的粘结区域图案以将所述合成纤维粘结在一起以形成非织造织物,所述非织造织物具有根据EN1822(1998)测试规程测量的35%至小于50%的过滤效率;以及
通过电吹制纺丝聚合物溶液施加纳米纤维层以在所述非织造织物的至少一侧上形成多根纳米纤维以形成复合过滤介质,所述复合过滤介质具有根据EN1822(1998)测试规程测量的70%的最小过滤效率,其中所述非织造织物由包含圆形和三叶形纤维横截面的双层构成。
2.根据权利要求1的方法,其中所述非织造织物与所述纳米纤维层的组合为基本上电中性的。
3.根据权利要求1的方法,其中施加纳米纤维层包括通过电吹制纺丝工艺、静电纺丝工艺、离心纺丝工艺或熔喷工艺施加纳米纤维层。
4.根据权利要求3的方法,其中所述纳米纤维层包含以下中的至少一种:聚酯、聚酰胺、聚烯烃、热塑性聚氨酯、聚醚酰亚胺、聚苯醚、聚苯硫醚、聚砜和芳族聚酰胺。
5.根据权利要求1的方法,其中压延所述非织造织物垫包括由具有100g/m2至300g/m2的基重的非织造织物压延所述非织造织物垫。
6.根据权利要求1的方法,其中施加纳米纤维层包括施加多根具有500nm或更小的平均直径的纳米纤维以形成具有0.6g/m2至20g/m2的基重的纳米纤维层。
7.根据权利要求1的方法,其中施加纳米纤维层包括施加多根具有500nm或更小的平均直径的纳米纤维以形成具有1.5g/m2至2.5g/m2的基重的纳米纤维层。
8.根据权利要求1的方法,其中用压花压延辊压延所述非织造织物垫形成粘结区域图案,所述粘结区域图案包括多个基本上平行的不连续的粘结区域线条。
9.根据权利要求1的方法,其中通过纺粘工艺形成包含多根合成纤维的非织造织物垫包括形成包含多根具有18至30微米的平均直径的合成纤维的非织造织物垫。
10.根据权利要求1的方法,其中所述非织造织物具有根据EN-1822(1998)测量的小于2.5mm水柱的阻力,并且所述复合过滤介质结构具有根据EN-1822(1998)测量的具有小于4.0mm水柱的阻力。
11.根据权利要求10的方法,其中所述复合过滤介质结构的品质因子Qf大于370。
12.根据权利要求10的方法,其中所述复合过滤介质结构的品质因子Qf大于440。
13.根据权利要求1的方法,其中所述纳米纤维层包含多根纳米纤维,所述纳米纤维利用所述电吹制纺丝工艺由聚合物形成,所述聚合物包含以下中的至少一种:聚酰亚胺、聚酰胺、聚芳酰胺、聚苯并咪唑、聚醚酰亚胺、聚丙烯腈、聚对苯二甲酸乙二醇酯、聚丙烯、聚苯胺、聚环氧乙烷、聚萘二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、苯乙烯丁二烯橡胶、聚苯乙烯、聚氯乙烯、聚乙烯醇、聚偏1,1-二氯乙烯、聚乙烯基丁烯、以及它们的共聚物或衍生化合物。
14.根据权利要求1的方法,所述方法还包括使所述复合过滤介质打褶。
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- 2009-08-03 CN CN200980129811.9A patent/CN102112197B/zh active Active
- 2009-08-03 EP EP09791100.2A patent/EP2321028B1/en active Active
- 2009-08-03 JP JP2011521380A patent/JP5730198B2/ja active Active
- 2009-08-03 WO PCT/US2009/052581 patent/WO2010014986A2/en active Application Filing
- 2009-08-03 KR KR1020117004729A patent/KR101643431B1/ko active IP Right Grant
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Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1048335A1 (de) * | 1999-04-30 | 2000-11-02 | FiberMark Gessner GmbH & Co. | Staubfilterbeutel, enthaltend Nanofaservlies |
WO2002012604A2 (en) * | 2000-08-03 | 2002-02-14 | Bba Nonwovens Simpsonville, Inc. | Process and system for producing multicomponent spunbonded nonwoven fabrics |
WO2006071979A1 (en) * | 2004-12-28 | 2006-07-06 | E.I. Dupont De Nemours And Company | Filtration media for filtering particulate material from gas streams |
Also Published As
Publication number | Publication date |
---|---|
US7922959B2 (en) | 2011-04-12 |
JP2011529779A (ja) | 2011-12-15 |
KR101643431B1 (ko) | 2016-07-27 |
EP2321028B1 (en) | 2018-02-28 |
WO2010014986A3 (en) | 2010-06-10 |
WO2010014986A2 (en) | 2010-02-04 |
EP2321028A2 (en) | 2011-05-18 |
CN102112197A (zh) | 2011-06-29 |
JP5730198B2 (ja) | 2015-06-03 |
BRPI0911818A2 (pt) | 2015-10-06 |
KR20110049836A (ko) | 2011-05-12 |
US20100025892A1 (en) | 2010-02-04 |
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