WO2004040096A1 - Composite tool insert - Google Patents

Composite tool insert Download PDF

Info

Publication number
WO2004040096A1
WO2004040096A1 PCT/IB2003/003921 IB0303921W WO2004040096A1 WO 2004040096 A1 WO2004040096 A1 WO 2004040096A1 IB 0303921 W IB0303921 W IB 0303921W WO 2004040096 A1 WO2004040096 A1 WO 2004040096A1
Authority
WO
WIPO (PCT)
Prior art keywords
tool insert
substrate
cutting edge
protective layer
support ring
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2003/003921
Other languages
French (fr)
Inventor
Klaus Tank
Raymond Albert Chapman
Roy Derrick Achilles
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Element Six Pty Ltd
Original Assignee
Element Six Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Element Six Pty Ltd filed Critical Element Six Pty Ltd
Priority to AU2003260823A priority Critical patent/AU2003260823A1/en
Priority to DE60335415T priority patent/DE60335415D1/en
Priority to AT03809805T priority patent/ATE491858T1/en
Priority to EP03809805A priority patent/EP1579103B1/en
Priority to US10/533,269 priority patent/US7594553B2/en
Priority to CA2504523A priority patent/CA2504523C/en
Publication of WO2004040096A1 publication Critical patent/WO2004040096A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
    • E21B10/5676—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts having a cutting face with different segments, e.g. mosaic-type inserts
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00—Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/06—Cutting windows, e.g. directional window cutters for whipstock operations
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool

Definitions

  • THIS invention relates to a tool insert.
  • diamond compacts also known as PCD
  • PCD diamond compacts
  • the use of diamond compacts, also known as PCD, as cutting elements are well known in the art and used extensively in various cutting, drilling, milling and other abrasive operations due to the high abrasion resistant properties of diamond cutters.
  • the diamond cutters are not always suitable for all substrates encountered. For instance, it is well established that diamond cutters cannot be used satisfactorily for milling or drilling through ferrous substrates such as steel. As a result, the use of diamond cutters in certain down the hole drilling operations is not suitable as milling through a steel casing, which is used to line the vertical borehole or shaft, is required.
  • tungsten carbide cutters are typically used in the drill bit to mill through the steel casing. Once through the casing, the tungsten carbide inserts have to be replaced with abrasive resistant cutters such as diamond cutters in order to drill into the bedrock. This means that the drill bit has to be removed and replaced with an appropriate bit. As the drill strings that have to be removed are very long, this is a time consuming exercise that results in costly downtime.
  • a tool insert comprises:
  • a substrate having a support surface and a support ring extending laterally from the support surface, the support ring being sized to define a recess within the confines thereof and a shelf about the periphery thereof;
  • a layer of ultra-hard abrasive material located within the recess and bonded to the substrate and the support ring, the layer of ultra-hard abrasive material having a top surface, a portion of the periphery of the top surface providing a primary cutting edge for the tool insert;
  • a protective layer bonded to the shelf about the support ring so as to protect the primary cutting edge, a periphery of the protective layer providing a secondary cutting edge for the tool insert, the depth of the protective layer being selected so as to be sufficient to protect the primary cutting edge whilst cutting, milling or drilling through a first substance but to expose the primary cutting edge upon encountering a second substance.
  • Figure 1 is a sectional side view of an embodiment of a tool insert of the invention
  • Figure 2 is a plan view of the tool insert of figure 2; and Figure 3 is a schematic sectional side view of a rotary drill bit in a subterranean rock drilling operation.
  • the tool insert comprises a tungsten carbide substrate 10, a PCD layer 12 located within a recess 14 and surrounded by an annular section or ring 16 of tungsten carbide extending laterally from a support surface 17, and a protective layer or ring 18 surrounding the ring 16.
  • the protective ring 18 may be formed of a different grade of tungsten carbide to that of the substrate 10 or, alternatively, be formed of tool steel or other appropriate material. The choice of material is dependent on the substance or substrate to be milled, drilled or cut before exposing the PCD layer 12.
  • the protective ring 18 can be formed in situ or, alternatively, can be formed as a separate ring component which is attached to the tool insert.
  • the protective ring 18 may be attached to the tool insert, which has been machined to accept the ring, for example by brazing, press fitting, shrink fitting, or any other convenient method.
  • the protective ring 18 includes a cutting edge 20 for cutting through a first substance or substrate such as the steel casing or lining used in a subterranean drilling operation.
  • the PCD layer 12 includes a cutting edge 22 for cutting through a second substance or substrate such as bedrock.
  • the tungsten carbide of the substrate 10 and the ring 16 is selected for its properties in forming the PCD layer 12 whilst the protective ring 18 is selected so as to optimize the drilling, milling or cutting through the relevant first substance or substrate.
  • the annular ring 16 of tungsten carbide may act as a further protective layer for the cutting edge 22 of the PCD layer 12, its primary function is to optimize the formation of the PCD layer 12 in a conventional high pressure/high temperature process.
  • the use of the tool insert will be described with regards to its use in the directional drilling of holes in a subterranean bedrock. It is to be understood, however, that the tool insert may be used in any application where a first substance or substrate, which is not suited for cutting, drilling or milling by a PCD cutter, is to be cut, drilled or milled to expose a second substance or substrate to which the PCD cutter is suited.
  • a drill assembly 30 consists of a rotary drill string 32 and a rotary drill bit 34, of the drag bit kind in this case.
  • the drill bit 34 is directed down a passage 36 within a steel tubular casing 38.
  • the steel casing 38 is anchored in a borehole or shaft 40 drilled into a subterranean bedrock 42.
  • a deflector 46 which is attached to the casing 38 and which has previously been positioned adjacent the region 'X', causes the bit 34 to change direction in this manner.
  • the deflector 46 is supported by an anchor 48.
  • the protective layer or ring 18 is used to mill through the casing 38, whereafter it and the support ring 16 are quickly consumed to expose the cutting edge 22 of the PCD layer, which is suited to cutting through the subterranean bedrock.
  • the layer of ultra-hard abrasive material will generally be a layer of PCD, although it may also be PCBN where the second substrate requires it.
  • the layer may also be a layer of diamond produced by chemical vapour deposition, called CVD diamond.
  • the substrate of the tool insert will generally be a cemented carbide substrate.
  • Such substrates are well known in the art and are generally cemented tungsten carbide substrates.
  • the tool insert configuration may, where appropriate, be altered or adapted in different applications, provided that the desired purpose, i.e. of protecting the primary cutting edge of a PCD or PCBN layer whilst milling a window through a first substrate and exposing the PCD or PCBN cutting edge once a second substrate is encountered, is achieved.

Landscapes

  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Fluid Mechanics (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Earth Drilling (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Drilling Tools (AREA)
  • Mechanical Coupling Of Light Guides (AREA)
  • Surgical Instruments (AREA)

Abstract

A tool insert comprises a substrate (10) having a support surface and a support ring extending laterally from the support surface. The support ring is sized to define a recess (14) within the confines thereof and a shelf about the periphery thereof. A layer (12) of ultra-hard abrasive material is located within the recess and bonded to the substrate and the support ring (16), and presents a primary cutting edge (22) for the tool insert. A protective layer (18) is bonded to the shelf about the support ring so as to protect the primary cutting edge. The protective layer provides a secondary cutting edge (20) for the tool insert, the depth of the protective layer being selected so as to be sufficient to protect the primary cutting edge whilst cutting, milling or drilling through a first substance but to expose the primary cutting edge upon encountering a second substance.

Description

COMPOSITE TOOL INSERT
BACKGROUND OF THE INVENTION
THIS invention relates to a tool insert.
The use of diamond compacts, also known as PCD, as cutting elements are well known in the art and used extensively in various cutting, drilling, milling and other abrasive operations due to the high abrasion resistant properties of diamond cutters. The diamond cutters, however, are not always suitable for all substrates encountered. For instance, it is well established that diamond cutters cannot be used satisfactorily for milling or drilling through ferrous substrates such as steel. As a result, the use of diamond cutters in certain down the hole drilling operations is not suitable as milling through a steel casing, which is used to line the vertical borehole or shaft, is required.
As PCD is not suitable for drilling through the steel casing due to reactions with the ferrous materials, an alternative drill bit insert is required. Accordingly, tungsten carbide cutters are typically used in the drill bit to mill through the steel casing. Once through the casing, the tungsten carbide inserts have to be replaced with abrasive resistant cutters such as diamond cutters in order to drill into the bedrock. This means that the drill bit has to be removed and replaced with an appropriate bit. As the drill strings that have to be removed are very long, this is a time consuming exercise that results in costly downtime. SUMMARY OF THE INVENTION
According to the invention, a tool insert comprises:
a substrate having a support surface and a support ring extending laterally from the support surface, the support ring being sized to define a recess within the confines thereof and a shelf about the periphery thereof;
a layer of ultra-hard abrasive material located within the recess and bonded to the substrate and the support ring, the layer of ultra-hard abrasive material having a top surface, a portion of the periphery of the top surface providing a primary cutting edge for the tool insert; and
a protective layer bonded to the shelf about the support ring so as to protect the primary cutting edge, a periphery of the protective layer providing a secondary cutting edge for the tool insert, the depth of the protective layer being selected so as to be sufficient to protect the primary cutting edge whilst cutting, milling or drilling through a first substance but to expose the primary cutting edge upon encountering a second substance.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:
Figure 1 is a sectional side view of an embodiment of a tool insert of the invention;
Figure 2 is a plan view of the tool insert of figure 2; and Figure 3 is a schematic sectional side view of a rotary drill bit in a subterranean rock drilling operation.
DESCRIPTION OF EMBODIMENTS
Referring to figures 1 and 2, of the accompanying drawings, an embodiment of a tool insert of the invention is shown. The tool insert comprises a tungsten carbide substrate 10, a PCD layer 12 located within a recess 14 and surrounded by an annular section or ring 16 of tungsten carbide extending laterally from a support surface 17, and a protective layer or ring 18 surrounding the ring 16.
The protective ring 18 may be formed of a different grade of tungsten carbide to that of the substrate 10 or, alternatively, be formed of tool steel or other appropriate material. The choice of material is dependent on the substance or substrate to be milled, drilled or cut before exposing the PCD layer 12. The protective ring 18 can be formed in situ or, alternatively, can be formed as a separate ring component which is attached to the tool insert. The protective ring 18 may be attached to the tool insert, which has been machined to accept the ring, for example by brazing, press fitting, shrink fitting, or any other convenient method.
The protective ring 18 includes a cutting edge 20 for cutting through a first substance or substrate such as the steel casing or lining used in a subterranean drilling operation. The PCD layer 12 includes a cutting edge 22 for cutting through a second substance or substrate such as bedrock. In this arrangement, the tungsten carbide of the substrate 10 and the ring 16 is selected for its properties in forming the PCD layer 12 whilst the protective ring 18 is selected so as to optimize the drilling, milling or cutting through the relevant first substance or substrate. Although the annular ring 16 of tungsten carbide may act as a further protective layer for the cutting edge 22 of the PCD layer 12, its primary function is to optimize the formation of the PCD layer 12 in a conventional high pressure/high temperature process.
For convenience, the use of the tool insert will be described with regards to its use in the directional drilling of holes in a subterranean bedrock. It is to be understood, however, that the tool insert may be used in any application where a first substance or substrate, which is not suited for cutting, drilling or milling by a PCD cutter, is to be cut, drilled or milled to expose a second substance or substrate to which the PCD cutter is suited.
Referring to figure 3 a drill assembly 30 consists of a rotary drill string 32 and a rotary drill bit 34, of the drag bit kind in this case.
The drill bit 34 is directed down a passage 36 within a steel tubular casing 38. The steel casing 38 is anchored in a borehole or shaft 40 drilled into a subterranean bedrock 42.
In order for the rotary drill bit 34 to drill a horizontal or angled hole into the bedrock 42 in the region indicated by an 'X', it is necessary for the drill bit 34 to be redirected from a vertical direction of movement to a horizontal or angled direction of movement, along the arrow 44. A deflector 46, which is attached to the casing 38 and which has previously been positioned adjacent the region 'X', causes the bit 34 to change direction in this manner. The deflector 46 is supported by an anchor 48.
In order to drill through the casing 38, typically cemented tungsten carbide cutters have traditionally been used. Once a window 50 has been milled through the casing 38, the drill bit 34 is withdrawn and replaced with a drill bit having abrasion resistant cutters such as PCD cutters. This time consuming operation is obviated by using tool inserts or cutters of the invention. The protective layer or ring 18 is used to mill through the casing 38, whereafter it and the support ring 16 are quickly consumed to expose the cutting edge 22 of the PCD layer, which is suited to cutting through the subterranean bedrock. The layer of ultra-hard abrasive material will generally be a layer of PCD, although it may also be PCBN where the second substrate requires it. The layer may also be a layer of diamond produced by chemical vapour deposition, called CVD diamond.
The substrate of the tool insert will generally be a cemented carbide substrate. Such substrates are well known in the art and are generally cemented tungsten carbide substrates.
The tool insert configuration may, where appropriate, be altered or adapted in different applications, provided that the desired purpose, i.e. of protecting the primary cutting edge of a PCD or PCBN layer whilst milling a window through a first substrate and exposing the PCD or PCBN cutting edge once a second substrate is encountered, is achieved.

Claims

1. A tool insert comprising:
a substrate having a support surface and a support ring extending laterally from the support surface, the support ring being sized to define a recess within the confines thereof and a shelf about the periphery thereof;
a layer of ultra-hard abrasive material located within the recess and bonded to the substrate and the support ring, the layer of ultra-hard abrasive material having a top surface, a portion of the periphery of the top surface providing a primary cutting edge for the tool insert; and
a protective layer bonded to the shelf about the support ring so as to protect the primary cutting edge, a periphery of the protective layer providing a secondary cutting edge for the tool insert, the depth of the protective layer being selected so as to be sufficient to protect the primary cutting edge whilst cutting, milling or drilling through a first substance but to expose the primary cutting edge upon encountering a second substance.
2. A tool insert according to claim 1 , wherein the support ring is integrally formed with the substrate.
3. A tool insert according to claim 1 or claim 2, wherein the substrate is a tungsten carbide substrate.
4. A tool insert according to claim 3, wherein the protective layer is formed of tungsten carbide of a different grade to that of the substrate, or of tool steel, or of another suitable material dependent on the first substance to be milled.
5. A tool insert according to any one of the preceding claims, wherein the protective layer is formed in situ during the formation of the tool insert.
6. A tool insert according to any one of the preceding claims, wherein the protective layer is formed as a separate ring component which is bonded to the shelf portion of the support surface of the substrate.
PCT/IB2003/003921 2002-10-30 2003-09-12 Composite tool insert Ceased WO2004040096A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
AU2003260823A AU2003260823A1 (en) 2002-10-30 2003-09-12 Composite tool insert
DE60335415T DE60335415D1 (en) 2002-10-30 2003-09-12 COMPOSITE TOOL USE
AT03809805T ATE491858T1 (en) 2002-10-30 2003-09-12 COMPOSITE TOOL USE
EP03809805A EP1579103B1 (en) 2002-10-30 2003-09-12 Composite tool insert
US10/533,269 US7594553B2 (en) 2002-10-30 2003-09-12 Composite tool insert
CA2504523A CA2504523C (en) 2002-10-30 2003-09-12 Composite tool insert

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA2002/8778 2002-10-30
ZA200208778 2002-10-30

Publications (1)

Publication Number Publication Date
WO2004040096A1 true WO2004040096A1 (en) 2004-05-13

Family

ID=32231604

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2003/003921 Ceased WO2004040096A1 (en) 2002-10-30 2003-09-12 Composite tool insert

Country Status (8)

Country Link
US (1) US7594553B2 (en)
EP (1) EP1579103B1 (en)
CN (1) CN100396878C (en)
AT (1) ATE491858T1 (en)
AU (1) AU2003260823A1 (en)
CA (1) CA2504523C (en)
DE (1) DE60335415D1 (en)
WO (1) WO2004040096A1 (en)

Cited By (1)

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Publication number Priority date Publication date Assignee Title
WO2008120937A1 (en) * 2007-03-30 2008-10-09 Iljin Diamond Co., Ltd. Sintered body for excavating tool

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KR100942983B1 (en) * 2007-10-16 2010-02-17 주식회사 하이닉스반도체 Semiconductor device and manufacturing method
US7994485B2 (en) * 2008-04-08 2011-08-09 Carestream Health, Inc. Apparatus and method for fluorescence measurements using spatially structured illumination
US20100288564A1 (en) * 2009-05-13 2010-11-18 Baker Hughes Incorporated Cutting element for use in a drill bit for drilling subterranean formations
US8887839B2 (en) * 2009-06-25 2014-11-18 Baker Hughes Incorporated Drill bit for use in drilling subterranean formations
US8757299B2 (en) * 2009-07-08 2014-06-24 Baker Hughes Incorporated Cutting element and method of forming thereof
EP2452037A2 (en) 2009-07-08 2012-05-16 Baker Hughes Incorporated Cutting element for a drill bit used in drilling subterranean formations
EP2479002A3 (en) 2009-07-27 2013-10-02 Baker Hughes Incorporated Abrasive article
CA2797137C (en) 2010-04-23 2015-06-30 Baker Hughes Incorporated Cutting elements for earth-boring tools, earth-boring tools including such cutting elements and related methods
GB2482151A (en) * 2010-07-21 2012-01-25 Element Six Production Pty Ltd Method of making a superhard construction
WO2012012774A2 (en) * 2010-07-23 2012-01-26 National Oilwell DHT, L.P. Polycrystalline diamond cutting element and method of using same
US9175521B2 (en) 2010-08-24 2015-11-03 Varel Europe S.A.S. Functionally leached PCD cutter and method for fabricating the same
US8936115B2 (en) * 2010-08-24 2015-01-20 Varel Europe S.A.S. PCD cutter with fins and methods for fabricating the same
US9650837B2 (en) 2011-04-22 2017-05-16 Baker Hughes Incorporated Multi-chamfer cutting elements having a shaped cutting face and earth-boring tools including such cutting elements
US8991525B2 (en) 2012-05-01 2015-03-31 Baker Hughes Incorporated Earth-boring tools having cutting elements with cutting faces exhibiting multiple coefficients of friction, and related methods
US9428966B2 (en) 2012-05-01 2016-08-30 Baker Hughes Incorporated Cutting elements for earth-boring tools, earth-boring tools including such cutting elements, and related methods
US9482057B2 (en) 2011-09-16 2016-11-01 Baker Hughes Incorporated Cutting elements for earth-boring tools, earth-boring tools including such cutting elements and related methods
US9243452B2 (en) 2011-04-22 2016-01-26 Baker Hughes Incorporated Cutting elements for earth-boring tools, earth-boring tools including such cutting elements, and related methods
US8807247B2 (en) 2011-06-21 2014-08-19 Baker Hughes Incorporated Cutting elements for earth-boring tools, earth-boring tools including such cutting elements, and methods of forming such cutting elements for earth-boring tools
US12312867B2 (en) * 2020-02-05 2025-05-27 Baker Hughes Oilfield Operations Llc Cutting element with improved mechanical efficiency
CN112122769B (en) * 2020-09-23 2024-06-25 苏州万智新能源科技有限公司 Coping ware, coping device and friction stir welding system

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US6187068B1 (en) * 1998-10-06 2001-02-13 Phoenix Crystal Corporation Composite polycrystalline diamond compact with discrete particle size areas
GB2361936A (en) * 2000-02-08 2001-11-07 Smith International Composites with ordered microstructures
US20020074168A1 (en) * 2000-09-20 2002-06-20 Matthias Terry R. Polycrystalline diamond cutters with working surfaces having varied wear resistance while maintaining impact strength

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US4255165A (en) * 1978-12-22 1981-03-10 General Electric Company Composite compact of interleaved polycrystalline particles and cemented carbide masses
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US5979571A (en) * 1996-09-27 1999-11-09 Baker Hughes Incorporated Combination milling tool and drill bit
US6187068B1 (en) * 1998-10-06 2001-02-13 Phoenix Crystal Corporation Composite polycrystalline diamond compact with discrete particle size areas
WO2000036264A1 (en) * 1998-12-15 2000-06-22 De Beers Industrial Diamond Division (Proprietary) Limited Tool component
GB2361936A (en) * 2000-02-08 2001-11-07 Smith International Composites with ordered microstructures
US20020074168A1 (en) * 2000-09-20 2002-06-20 Matthias Terry R. Polycrystalline diamond cutters with working surfaces having varied wear resistance while maintaining impact strength

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WO2008120937A1 (en) * 2007-03-30 2008-10-09 Iljin Diamond Co., Ltd. Sintered body for excavating tool

Also Published As

Publication number Publication date
CA2504523A1 (en) 2004-05-13
DE60335415D1 (en) 2011-01-27
US20060099895A1 (en) 2006-05-11
US7594553B2 (en) 2009-09-29
AU2003260823A1 (en) 2004-05-25
CN1714224A (en) 2005-12-28
EP1579103A1 (en) 2005-09-28
CA2504523C (en) 2011-03-01
ATE491858T1 (en) 2011-01-15
CN100396878C (en) 2008-06-25
EP1579103B1 (en) 2010-12-15

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