WO2010037410A1 - Laminated connector - Google Patents
Laminated connector Download PDFInfo
- Publication number
- WO2010037410A1 WO2010037410A1 PCT/EP2008/008398 EP2008008398W WO2010037410A1 WO 2010037410 A1 WO2010037410 A1 WO 2010037410A1 EP 2008008398 W EP2008008398 W EP 2008008398W WO 2010037410 A1 WO2010037410 A1 WO 2010037410A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- stripes
- connector according
- stripe
- bonding
- contact
- 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
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
- H01R35/02—Flexible line connectors without frictional contact members
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G5/00—Installations of bus-bars
- H02G5/002—Joints between bus-bars for compensating thermal expansion
Definitions
- the invention concerns a laminated connector as used for connections carrying high currents, e.g., for connecting a generator circuit breaker with adjoining sections of an insulated phase bus duct.
- Laminated connectors consisting essentially of copper or some other metal or alloy like aluminium or stainless steel are well known in the art, see, e.g., EP 0 695 012 Al, EP 0 959 546 Al and JP 2000-316 224 A.
- a laminated connector according to the generic part of claim 1 is known where, at opposite end portions, the copper stripes are connected by press-welding to form solid contact blocks.
- Each contact block is covered completely by a silver layer for improving contact with adjoining sections of a conductor.
- the silver layer is applied after the welding step by electro-plating. Unless this step is carried out with the greatest care, however, fluids used therein can penetrate between the copper stripes where their residues may cause corrosion during storage and, as a consequence, quick deterioration of the connector under the thermal and mechanical strains occurring during use. Summary of the invention
- the plating step is also simplified as the individual stripes are easier to handle than the connector as a whole. Silver can be applied more selectively, e.g., only to the exposed surfaces of the uppermost and lowermost stripes.
- That the bonding step is simple and takes very little time, allowing faster and cheaper production, is another advantage of the connector according to the invention.
- Fig. 1 shows a top view of a laminated connector according to the invention
- Fig. 2 shows a side view of the laminated connector of Fig. 1,
- Fig. 3 shows an enlarged top view of an end portion of the laminated connector of Fig. 1,
- Fig. 4 shows an enlarged cross section along IV-IV in Fig. 3
- Fig. 5 shows an enlarged cross section along V-V in Fig. 3.
- the laminated connector essentially consists of a stack 1 of congruent rectangular stripes, preferably of copper or a copper alloy although other materials of high electrical conductivity, in particular, metals or alloys like aluminium or stainless steel, are also possible.
- the stripes are unconnected at a wavy middle section of the stack 1 which exhibits two lateral minor crests 2a, b and at the centre an opposite major crest 3, the waviness improving the flexibility of the connector, they are rigidly connected at end portions, forming contact blocks 4a, b there.
- Each of the contact blocks 4a, b is provided with two through holes 5 which can each take up a bolt for connection with adjoining rigid conductors, e.g., sections of an insulated phase bus duct connecting a generator to a generator circuit breaker.
- the stripes 6 (Figs. 4, 5) have congruent patterns of rectangular bonding deformations 7, with superposed bonding deformations 7 in the stack 1 of stripes 6 being virtually equal, each with a displaced plane bottom portion 8 separated form the surrounding parts of the stripe 6 by straight longitudinal boundaries 9 where the stripe 6 is disrupted, the bottom portion 8 being entirely separated from the adjacent part of the same, and complementary straight perpendicular boundaries 10 where the deformation is more gradual such that the stripe 6 is continuous, the bottom portion 8 being connected to the adjacent portion of the same.
- the bottom portion 8 is in each case, in a direction perpendicular to a plane of the stripe 6, displaced with respect to the surrounding portion of the same by a distance which is at least as large as the thickness of the stripe 6, preferably at least twice as large .
- the bonding deformations 7 are, two at each side, arranged close to the lateral edges of the contact blocks 4a, b.
- the uppermost stripe and the lowermost stripe each carry, on the exposed upper and lower surfaces, respectively, of their end portions a silver coating 11 providing a contact surface 12 which improves the electrical contact with adjoining conductors .
- the stack 1 typically has a length of between 100mm and 250mm, a breadth of between 20mm and 50mm and a thickness of between 3mm and 15mm.
- the stripes 6 are all of the same shape and dimension and may have a thickness of between 0.1mm and 0.5mm, e.g., 0.2mm each.
- the bonding deformations 7 are, e.g., between 5mm and 10mm long with their breadth between lmm and 3mm.
- the displacement distance i.e., the distance of the position of the bottom portion 8 with respect to the surrounding portion of the stripe 6 perpendicular to the plane defined by the latter is typically between 0.5mm and 2mm.
- the distance of the crests 2a, b, 3 from a middle plane defined by the contact blocks 4a, b is between 5mm and 30mm.
- the thickness of the silver coating is typically about 5 ⁇ m.
- the laminated connector is produced from the stripes 6 in that silver coatings are applied to one surface of a stripe which is to become the uppermost stripe at its end portions and in the same way to one surface of a stripe which is to become the lowermost stripe to later form contact surfaces.
- the stack 1 is formed with the silver-coated surface portions of the uppermost stripe and the lowermost stripe facing upwards and downwards, respectively.
- the contact blocks 4a, b are then punch-formed, i.e., the end portions of the stack 1 are bonded in that they are pressed each by a stamp exhibiting a plane surface with isolated protrusions for forming the bonding deformations against a base with a parallel plane surface provided with complementary holes or recesses. In this way the congruent oblong bonding deformations 7 are produced in every one of the stripes 6.
- the end portions of the stripes 6 are held tightly together by the bonding deformations 7, forming the rigid contact blocks 4a, b.
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- Contacts (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
Abstract
End portions of a stack (1) of stripes (6) with a thickness of between 0.1mm and 0.5mm consisting essentially of copper are bonded by punch-forming to form rigid contact blocks (4a) with top and bottom surfaces each covered by a silver coating (11) applied before the bonding to provide contact surfaces (12). At the punch-forming step congruent oblong bonding deformations (7) are produced in each stripe (6), each with a bottom portion which is displaced by a distance of at least the thickness of the stripe and usually between 0.5mm and 2mm with respect to the surrounding portion of the stripe (6). Each bonding deformation (7) is delimited by longitudinal boundaries where the stripe is disrupted and perpendicular boundaries where it is continuous.
Description
D E S C R I P T I O N
IAMINATED CONNECTOR
Field of the invention
The invention concerns a laminated connector as used for connections carrying high currents, e.g., for connecting a generator circuit breaker with adjoining sections of an insulated phase bus duct.
Prior art
Laminated connectors consisting essentially of copper or some other metal or alloy like aluminium or stainless steel are well known in the art, see, e.g., EP 0 695 012 Al, EP 0 959 546 Al and JP 2000-316 224 A.
A laminated connector according to the generic part of claim 1 is known where, at opposite end portions, the copper stripes are connected by press-welding to form solid contact blocks. Each contact block is covered completely by a silver layer for improving contact with adjoining sections of a conductor.
The silver layer is applied after the welding step by electro-plating. Unless this step is carried out with the greatest care, however, fluids used therein can penetrate between the copper stripes where their residues may cause corrosion during storage and, as a consequence, quick deterioration of the connector under the thermal and mechanical strains occurring during use.
Summary of the invention
It is the object of the invention to provide a laminated connector of the generic type which is resistant under the thermal and mechanical strain to which it is unavoidably subjected during use and to provide a method for manufacturing such laminated flexible connector. These objects are achieved by the features of the characterising portions of the independent claims. The end portions of the connector are formed into a rigid block by punch-forming which is a fast and reliable method of bonding the stripes of the connector.
As this process is a purely mechanical cold forming step where the stripes are not subjected to high temperatures or extreme pressure it is possible to apply the silver layer beforehand using any method desired. The isolated stripes can, where necessary, be cleaned afterwards. Potentially corrosive residues are therefore easy to avoid.
The plating step is also simplified as the individual stripes are easier to handle than the connector as a whole. Silver can be applied more selectively, e.g., only to the exposed surfaces of the uppermost and lowermost stripes.
That the bonding step is simple and takes very little time, allowing faster and cheaper production, is another advantage of the connector according to the invention.
Due to the bonding by punch-forming a corrosion in the contact zone of the end portions between the stripes of the laminated, flexible connector can be mainly prevented and high electric conductivity is feasible over long period. In particular for circuit breakers and generator breakers which
carry several tens of thousand of ampere a permanent and high electric conductivity of the linking parts can be provided with the inventive laminating connector.
Brief description of the drawings
In the following the invention is described in more detail with reference to drawings referring to an embodiment of the invention where
Fig. 1 shows a top view of a laminated connector according to the invention,
Fig. 2 shows a side view of the laminated connector of Fig. 1,
Fig. 3 shows an enlarged top view of an end portion of the laminated connector of Fig. 1,
Fig. 4 shows an enlarged cross section along IV-IV in Fig. 3, and
Fig. 5 shows an enlarged cross section along V-V in Fig. 3.
Description of the preferred embodiments
The laminated connector essentially consists of a stack 1 of congruent rectangular stripes, preferably of copper or a copper alloy although other materials of high electrical conductivity, in particular, metals or alloys like aluminium or stainless steel, are also possible. Whereas the stripes are unconnected at a wavy middle section of the stack 1 which exhibits two lateral minor crests 2a, b and at the
centre an opposite major crest 3, the waviness improving the flexibility of the connector, they are rigidly connected at end portions, forming contact blocks 4a, b there. Each of the contact blocks 4a, b is provided with two through holes 5 which can each take up a bolt for connection with adjoining rigid conductors, e.g., sections of an insulated phase bus duct connecting a generator to a generator circuit breaker.
The stripes 6 (Figs. 4, 5) have congruent patterns of rectangular bonding deformations 7, with superposed bonding deformations 7 in the stack 1 of stripes 6 being virtually equal, each with a displaced plane bottom portion 8 separated form the surrounding parts of the stripe 6 by straight longitudinal boundaries 9 where the stripe 6 is disrupted, the bottom portion 8 being entirely separated from the adjacent part of the same, and complementary straight perpendicular boundaries 10 where the deformation is more gradual such that the stripe 6 is continuous, the bottom portion 8 being connected to the adjacent portion of the same. The bottom portion 8 is in each case, in a direction perpendicular to a plane of the stripe 6, displaced with respect to the surrounding portion of the same by a distance which is at least as large as the thickness of the stripe 6, preferably at least twice as large .
The bonding deformations 7 are, two at each side, arranged close to the lateral edges of the contact blocks 4a, b. The uppermost stripe and the lowermost stripe each carry, on the exposed upper and lower surfaces, respectively, of their end portions a silver coating 11 providing a contact surface 12 which improves the electrical contact with adjoining conductors .
The stack 1 typically has a length of between 100mm and 250mm, a breadth of between 20mm and 50mm and a thickness of between 3mm and 15mm. The stripes 6 are all of the same shape and dimension and may have a thickness of between 0.1mm and 0.5mm, e.g., 0.2mm each. The bonding deformations 7 are, e.g., between 5mm and 10mm long with their breadth between lmm and 3mm. The displacement distance, i.e., the distance of the position of the bottom portion 8 with respect to the surrounding portion of the stripe 6 perpendicular to the plane defined by the latter is typically between 0.5mm and 2mm. The distance of the crests 2a, b, 3 from a middle plane defined by the contact blocks 4a, b is between 5mm and 30mm. The thickness of the silver coating is typically about 5μm.
Other dimensions of the stripes and other arrangements, shapes and dimensions of the bonding deformations are, of course, possible. The latter can, for instance, be smaller, in particular shorter, and more equally distributed over the surface of the contact block, also covering the area between the through holes.
The laminated connector is produced from the stripes 6 in that silver coatings are applied to one surface of a stripe which is to become the uppermost stripe at its end portions and in the same way to one surface of a stripe which is to become the lowermost stripe to later form contact surfaces. Then the stack 1 is formed with the silver-coated surface portions of the uppermost stripe and the lowermost stripe facing upwards and downwards, respectively. The contact blocks 4a, b are then punch-formed, i.e., the end portions of the stack 1 are bonded in that they are pressed each by a stamp exhibiting a plane surface with isolated protrusions for forming the bonding deformations against a base with a
parallel plane surface provided with complementary holes or recesses. In this way the congruent oblong bonding deformations 7 are produced in every one of the stripes 6. The end portions of the stripes 6 are held tightly together by the bonding deformations 7, forming the rigid contact blocks 4a, b.
List of reference symbols
I stack 2a, b crests 3 crest
4a, b contact blocks
5 through holes
6 stripe
7 bonding deformation 8 bottom portion
9 longitudinal boundary
10 perpendicular boundary
II silver coating 12 contact surface
Claims
1. Laminated connector comprising a stack (1) of stripes
(6) of electrically conductive material and having opposite end portions where the stripes (6) are rigidly connected so as to form a contact (4a, 4b) , with at least an upper surface and an opposite lower surface of the contact (4a; 4b) carrying a coating (11) for providing a contact surface (12) of the contact (4a; 4b), characterised in that the contact (4a, 4b) at the end portions of the stacked stripes (6) are punch- formed.
2. Connector according to claim 1, characterised in that the stripes (6) are congruent and oblong and in that the electrically conductive material is a metal.
3. Connector according to claim 1 or 2, characterised in that the contact (4a; 4b) is a contact block.
4. Connector according to any of the claim 1 to 3, characterised in that the coating (11) is a silver coating.
5. Connector according to any of the preceding claim 1, characterised in that the stripes (6) essentially consist of copper.
6. Connector according to claim 3 or 4, characterised in that the stripes (6) are of essentially the same thickness and, at the end portions forming the contact blocks (4a, 4b) , exhibit congruent bonding deformations
(7) produced by the punch-forming where the stripe (6) is perpendicularly displaced with respect to a surrounding portion of the stripe (6) by a displacement distance amounting to at least the thickness, preferably to at least twice the thickness, of the stripes ( 6) .
7. Connector according to claim 6, characterised in -that each bonding deformation (7) is delimited by at least one boundary section where the stripe (6) is disrupted and by at least one complementary boundary section where the stripe (6) is continuous.
8. Connector according to claim 6 or 7, characterised in
-thai: at least in part the bonding deformations (7) are situated close to lateral edges of the stripes (6) .
9. Connector according to one of claims 6 to 8, characterised in that the bonding deformations (7) are of essentially oblong shape.
10. Connector according to claim 9, characterised in that the length of each bonding deformation (7) is between 5mm and 10mm and its breadth between lmm and 3mm.
11. Connector according to one of claims 6 to 10, characterised in that the displacement distance of each bonding deformation (7) is between 0.5mm and 2mm.
12. Connector according to one of claims 1 to 11, characterised in that the thickness of each stripe (6) is between 0.1mm and 0.5mm.
12. Connector according to one of claims 1 to 11, characterised in that between the contact blocks (4a, 4b) the stack (1) is wavy, preferably forming three crests (2a, 2b, 3) .
13. Circuit breaker, in particular a generator breaker comprising a least one flexible laminated connector according to any of the preceding claims for carrying high currents.
14. Method of manufacturing a laminated connector comprising the steps of:
- providing a number of electrically conductive stripes (6) having opposite end portions forming the contact
(4a; 4b),
- applying an electrically conductive coating to one surface of one of the stripes (6) which is to become the uppermost stripe and to one surface of one of the stripes (6) which is to become the lowermost stripe in order to provide a outer contact surface (12), -forming the stack (1) of stripes (6) with the coated surface portions of the uppermost stripe and of the lowermost stripe facing upwards and downwards respectively,
- providing a bonding at the contacts (4a, 4b) i.e. the end portions of the stacked stripes (6) by punch- forming.
15. Method of manufacturing a laminated connector according to claim 14, characterized in that punch-forming comprises the step of:
- pressing each end portion by a stamp exhibiting a plane surface with isolated protrusions for forming bonding deformations (7) against a base with a parallel plane surface provided with complementary holes or recesses .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/EP2008/008398 WO2010037410A1 (en) | 2008-10-03 | 2008-10-03 | Laminated connector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/EP2008/008398 WO2010037410A1 (en) | 2008-10-03 | 2008-10-03 | Laminated connector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2010037410A1 true WO2010037410A1 (en) | 2010-04-08 |
Family
ID=40756977
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2008/008398 Ceased WO2010037410A1 (en) | 2008-10-03 | 2008-10-03 | Laminated connector |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2010037410A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021233876A1 (en) * | 2020-05-20 | 2021-11-25 | Elonroad Ab | Connector and connector arrangement for an electrical road track |
| EP4220866A1 (en) * | 2022-01-26 | 2023-08-02 | Aptiv Technologies Limited | Power terminal with a multilayered structure and set of power terminals having various numbers of layers |
Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2706744A (en) * | 1950-01-14 | 1955-04-19 | Ite Circuit Breaker Ltd | Enclosed electrical bus systems |
| US3911567A (en) * | 1973-04-06 | 1975-10-14 | Fischer Ag Georg | Method of manufacturing an electric conductor of metal strips |
| GB1590698A (en) * | 1976-12-08 | 1981-06-10 | Square D Co | Circuit breaker assembly |
| FR2565871A1 (en) * | 1984-06-15 | 1985-12-20 | Eaton Controls Spa | Flexible lamella for electronic relay |
| US4760632A (en) * | 1985-09-14 | 1988-08-02 | Eugen Rapp | Method and apparatus for joining plates by stamping pressing and swaging dies |
| US4979285A (en) * | 1990-07-20 | 1990-12-25 | Martin Benson D | Method of connecting a stack of laminations for electric motors |
| EP0982809A2 (en) * | 1998-08-27 | 2000-03-01 | Delphi Technologies, Inc. | Electric terminal for a flat electrical conductor and a method of connection |
| US6163949A (en) * | 1996-06-05 | 2000-12-26 | L.H. Carbide Corporation | Method for manufacturing long, slender lamina stack from nonuniform laminae |
-
2008
- 2008-10-03 WO PCT/EP2008/008398 patent/WO2010037410A1/en not_active Ceased
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2706744A (en) * | 1950-01-14 | 1955-04-19 | Ite Circuit Breaker Ltd | Enclosed electrical bus systems |
| US3911567A (en) * | 1973-04-06 | 1975-10-14 | Fischer Ag Georg | Method of manufacturing an electric conductor of metal strips |
| GB1590698A (en) * | 1976-12-08 | 1981-06-10 | Square D Co | Circuit breaker assembly |
| FR2565871A1 (en) * | 1984-06-15 | 1985-12-20 | Eaton Controls Spa | Flexible lamella for electronic relay |
| US4760632A (en) * | 1985-09-14 | 1988-08-02 | Eugen Rapp | Method and apparatus for joining plates by stamping pressing and swaging dies |
| US4979285A (en) * | 1990-07-20 | 1990-12-25 | Martin Benson D | Method of connecting a stack of laminations for electric motors |
| US6163949A (en) * | 1996-06-05 | 2000-12-26 | L.H. Carbide Corporation | Method for manufacturing long, slender lamina stack from nonuniform laminae |
| EP0982809A2 (en) * | 1998-08-27 | 2000-03-01 | Delphi Technologies, Inc. | Electric terminal for a flat electrical conductor and a method of connection |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021233876A1 (en) * | 2020-05-20 | 2021-11-25 | Elonroad Ab | Connector and connector arrangement for an electrical road track |
| EP4220866A1 (en) * | 2022-01-26 | 2023-08-02 | Aptiv Technologies Limited | Power terminal with a multilayered structure and set of power terminals having various numbers of layers |
| US12424781B2 (en) | 2022-01-26 | 2025-09-23 | Aptiv Technologies AG | Power terminal with a multilayered structure and set of power terminals having various numbers of layers |
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