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GB2076706A - Producing a composite center electrode - Google Patents

Producing a composite center electrode Download PDF

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Publication number
GB2076706A
GB2076706A GB8113703A GB8113703A GB2076706A GB 2076706 A GB2076706 A GB 2076706A GB 8113703 A GB8113703 A GB 8113703A GB 8113703 A GB8113703 A GB 8113703A GB 2076706 A GB2076706 A GB 2076706A
Authority
GB
United Kingdom
Prior art keywords
cup
billet
composite
closed
open
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.)
Granted
Application number
GB8113703A
Other versions
GB2076706B (en
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.)
Federal Mogul Ignition LLC
Original Assignee
Champion Spark Plug Co
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 Champion Spark Plug Co filed Critical Champion Spark Plug Co
Publication of GB2076706A publication Critical patent/GB2076706A/en
Application granted granted Critical
Publication of GB2076706B publication Critical patent/GB2076706B/en
Expired legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01TSPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T21/00Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs
    • H01T21/02Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs of sparking plugs
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01TSPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T13/00Sparking plugs
    • H01T13/20Sparking plugs characterised by features of the electrodes or insulation

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Spark Plugs (AREA)
  • Extrusion Of Metal (AREA)
  • Forging (AREA)

Abstract

A composite center electrode for a spark plug is formed from a corrosion-resistant metal cup (41) having a closed end, walls (43) extending upwardly from the closed end to an open end (44) and a cavity (45) extending concentrically therein. A composite billet is formed having closed and filled ends by inserting into the open end of the cup (41) a billet (47) of a metal having a high thermal conductivity and which fits tightly within the cup walls (43) adjacent the closed cup end (42), but terminating short of the open cup end (44). The cup walls (43) adjacent the open cup end are rolled radially inwardly. The composite billet is extruded into an electrode blank having an upper headed portion (63) and a lower portion (64) of reduced diameter extending longitudinally therefrom. <IMAGE>

Description

SPECIFICATION Method for producing a composite center electrode This invention relates to an improved method for producing a composite center electrode for a spark plug. Methods for producing composite center electrodes have previously been known.
Referring to Figure 1, one such method involves first forming a cup 10 from a corrosion-resistant metal, such as nickel. The cup 10 has a closed end 11, walls 12 extending upwardly from the closed end 11 to an open end 13 and a cavity 14 extending concentrically therein to a lower surface 1 5. A composite billet is then formed by positioning interiorly of the cup 10 a close-fitting right circular cylindrical billet 1 6 of a metal having a high thermal conductivity, such as copper.The billet 1 6 fits tightly within the cup walls 12 to form a composite billet indicated generally at 1 7 in Figure 2, having closed and filled ends 1 8 and 1 9. The method further involves inserting the closed end 1 8 of the composite billet 1 7 into a die 20 in Figure 3, having a stepped bore 21 including an upper bore 22 in which the billet 17 fits closely and an extrusion orifice 23 of reduced diameter relative to the upper bore 22. Pressure is then applied to a plunger 24 to force all except a terminal portion 25 (Figure 4) of the billet 17 through the extrusion orifice 23.An electrode blank 26 thus formed has the unextruded terminal portion 25 as an upper headed portion, a lower portion 27 of reduced diameter extending longitudinally therefrom, and a copper core 28 positioned therein. After the electrode blank 26 is removed from the die 20, it is suitable for use as a composite center electrode for a spark plug. If desired, however, the upper headed portion 25 can be shaped by cold-working or further extrusion into a more desirable electrode head configuration. An electrode assembly is formed by welding a metal rod (not illustrated) to the upper headed portion 25 of the electrode blank 26. The primary disadvantage of the method just described is the difficulty involved in welding the metal rod to the head 25 because the amount of nickel remaining after the copper core 28 has been extruded therein is insufficient.
The present invention is based on the discovery of an improved method for producing a composite center electrode for a spark plug. The improvement involves controlling the positions and the relative sizes of the billet and of the cup so that the former fits tightly within the cup wails adjacent the closed cup end, but terminating short of the open cup end so that the cup walls extend thereabove at the open cup end, and rolling the cup walls adjacent the open cup end radially inwardly to form the composite billet. Increasing the height of the cup walls with respect to the height of the billet inserted therein ensures the availability of sufficient nickel to form the upper headed portion of the electrode blank, while rolling the cup walls adjacent the open cup end radially inwardly ensures that the nickel will sufficiently enclose the billet contained therein during extrusion.
The method includes the additional improvement wherein the closed end of the composite billet is first inserted into a die having a stepped bore including an upper bore in which the billet fits closely and an extrusion orifice of reduced diameter equal to that of a desired electrode head, and is then forced through the extrusion orifice to form an elongated composite billet having closed and filled ends, whereupon the closed end of the elongated composite billet is inserted into a second die having a stepped bore including an upper bore in which the billet fits closely and an extrusion orifice of reduced diameter, and all except an upper headed portion adjacent the filled end of the elongated billet is forced through the extrusion orifice to form the composite center electrode.Therefore, the upper headed portion of the composite center electrode does not need shaping because the composite billet was first extruded to the desired diameter.
It is an object of the invention to provide a method for producing a composite centre electrode for a spark plug in which an upper headed portion of an electrode blank contains sufficient nickel to which a metal rod can be welded.
It is a further object of the invention to provide a method for producing a composite center electrode for a spark plug in which an upper headed portion of an electrode blank does not need shaping because it is formed from a composite billet which has first been extruded to the desired head diameter.
In the accompanying drawings Figure 1 is a partially schematic, vertical sectional view showing a corrosion-resistant metal cup and a right circular cylindrical billet of metal of high thermal conductivity prior to being inserted into the cup in accordance with a previously known method.
Figure 2 is a sectional view showing a composite billet formed from the cup and billet of Figure 1.
Figure 3 is a partially schematic, vertical sectional view showing the composite billet of Figure 2 inserted into a bore of a die having within the bore an extrusion orifice.
Figure 4 is a sectional view showing an electrode blank formed from the composite billet of Figure 3 after all except a terminal portion thereof is forced through the extrusion orifice.
Figure 5 is a partially schematic, vertical sectional view showing a right circular cylindrical billet of corrosion-resistant metal inserted into a cavity of a die in accordance with the present invention.
Figure 6 is a sectional view showing a cup formed by back-extruding the billet of Figure 5.
Figure 7 is a partially schematic, vertical sectional view showing a right circular cylindrical billet of metal of high thermal conductivity prior to being inserted into the cup of Figure 6.
Figure 8 is a sectional view showing the billet of Figure 7 inserted into the cup in Figure 7.
Figure 9 is a partially schematic, vertical sectional view showing the billet and the cup of Figure 8 inserted into a cavity of a die.
Figure 10 is a partially schematic, vertical sectional view showing a composite billet formed from the cup and the billet within the cavity of the die of Figure 9, and inserted into a bore of a die having within the bore an extrusion orifice.
Figure 11 is a sectional view showing an electrode blank formed from the composite billet of Figure 10 after all except an upper headed portion thereof is forced through the extrusion orifice.
Figure 12 is a partially schematic, vertical sectional view showing the electrode blank of Figure 11 positioned in a die having a stepped bore including an upper bore, a shearing shoulder, a second shoulder and a lower bore.
Figure 1 3 is a partially schematic, vertical sectional view showing a composite center electrode formed by shearing the upper headed portion of the electrode blank of Figure 12.
Figure 14 is a partially schematic, vertical sectional view showing a composite billet formed from the cup and the billet within the cavity of the die of Figure 9, and inserted into a bore of a die having within the bore an extrusion orifice equal in diameter to that of a desired electrode head.
Figure 1 5 is a sectional view showing an elongated composite billet formed by forcing the composite billet of Figure 14 through the extrusion orifice and, thereabove, a second composite billet in a partially deformed condition.
Figure 1 6 is a partially schematic, vertical sectional view showing the elongated composite billet of Figure 1 5 inserted into a bore of a die having within the bore an extrusion orifice, and Figure 1 7 is a sectional view showing a composite center electrode formed from the elongated billet of Figure 1 6 after all except an upper headed portion thereof is forced through the extrusion orifice.
Referring now in more detail to the drawings, and, in particular to Figure 5, a back-extruder 29 comprises a die 30 positioned on a platen 31 and having a right circular bore 32 extending therethrough. The back-extruder 29 also comprises a piston 33 extending through the platen 31 in structural relationship with a floating ejector 34 which closes a lower opening of the bore 32, and a plunger 35 having a diameter less than that of the bore 32 and insertable therein, and having a lower surface 36. A cavity 37 is formed by walls of the bore 32 and an upper surface 38 of the floating ejector 34.
The first step of the method involves forming a cup from a right circular cylindrical billet of a corrosion-resistant metal, such as nickel or nickel alloy. The cup can be formed by drilling or backextrusion, the latter of which is preferred and comprises the following sub-steps. A right circular cylindrical billet 39 of nickel alloy having an upper end 40 is sized to fit tightly against the walls of the bore 32 when inserted therein. After the billet 39 is inserted into the cavity 37 of the bore 32 and superposed on the upper surface 38 of the floating ejector 34, the plunger 35 is inserted therein against the upper end 40 of the billet 39.
Pressure is then applied to the plunger 35 which pierces the billet 39 and causes back-extrusion thereof to form a cup 41 as illustrated in Figure 6.
The cup 41 has a closed end 42, walls 43 extending upwardly from the closed end 42 to an open end 44 and a cavity 45 extending concentrically therein to a lower surface 46 which corresponds to the shape of the lower surface 36 of the plunger 35. After the plunger 35 is withdrawn from the cavity 45 of the cup 41, pressure is applied to the piston 33 which causes the floating ejector 34 to force the cup 41 out of the cavity 37 of the die 30.
The next step of the method involves forming a composite billet. Referring to Figure 7, a closefitting right circular cylindrical billet 47 of a metal having a high thermal conductivity, e.g., copper, is inserted, as indicated by an arrow, into the open end 44 of the cup 41 and fits closely within the cup walls 43. The copper billet 47 is compressed within the cavity 45 of the cup 41 into closefitting relationship with the lower surface 46 thereof, as shown in Figure 8. The copper billet 47 fits tightly within the cup walls 43 adjacent the closed end 42, but terminates short of the open cup end 44 so that the cup walls 43 extend thereabove at the open end 44. Referring to Figure 9, a die indicated at 48 has a cavity 49 extending longitudinally therein to a lower concave surface 50.After the open cup end 44 is inserted into the cavity 49 of the die 48, a plunger 51 is inserted therein against the closed end 42. Force is then applied to the plunger 51 to roll the cup walls 43 adjacent the open cup end 44 radially inwardly to substantially enclose the billet 47 and to form a composite billet 52 having closed and inwardly turned ends 53 and 54 as illustrated in Figure 10.
The next step of the method involves forming an electrode blank from the composite billet 52.
Referring to Figure 10, a forward-extruder 55 comprises a die 56 having a stepped bore 57 including an upper bore 58 in which the billet 52 fits closely and an extrusion orifice 59 of reduced diameter relative to the upper bore 58. The forward-extruder 55 also comprises a plunger 60 having a diameter equal to that of the upper bore 58 and insertable therein, and a lower surface 61.
After the closed end 53 of the billet 52 is inserted into the upper bore 58 of the die 56, the plunger 60 is inserted therein against the inwardly turned end 54 of the billet 52. Referring to Figure 11, pressure is then applied on the plunger 60 which forces all except a terminal portion of the billet 52 through the extrusion orifice 59 of the die 56 to form an electrode blank 62. The electrode blank 62 has the unextruded terminal portion of the billet 52 as an upper headed portion 63 and a lower portion 64 of reduced diameter extending longitudinally therefrom, and a copper core 65 extending therein. After the electrode blank 62 is removed from the die 56, it is suitable for use as a composite center electrode for a spark plug.If desired, however, the upper headed portion 63 can be shaped by cold-working, further extruding, or shearing into a more desirable electrode head configuration. The latter of these is preferred.
The final step of the method involves shearing and shaping the upper headed portion 63 of the electrode blank 62. Referring to Figure 12, a shearing and forming apparatus indicated generally at 66 comprises a die 67 having a stepped bore 68 including a right circular upper bore 69 extending to a shearing shoulder 70 of reduced diameter, a central bore below the shearing shoulder 70 and extending to a second shoulder 71, and a lower bore 72 extending from the second shoulder 71 through the die 67. The first step of the improved method involves inserting the electrode blank 62 within the stepped bore 68. When the electrode blank 62 is so inserted, the upper headed portion 63 seats on the shearing shoulder 70 and fits closely within the upper bore 69, while the lower portion 64 fits closely within the lower bore 72.The shearing and forming apparatus 66 also comprises a plunger 73 having a diameter substantially equal to that of the shearing shoulder 70 and insertable therethrough, and a lower surface 74.
The plunger 73 is inserted concentrically within the upper bore 69 against the upper headed portion 63 of the electrode blank 62. Pressure is then applied to the plunger 73 to force the upper headed portion 63 of the electrode blank 62 past the shearing shoulder 70, leaving a ring 75 (Figure 13) of excess material, and against the second shoulder 71 (Figure 12) to form a desired composite center electrode indicated generally at 76 (Figure 13). The composite electrode 76 includes a head 77 and the rod 64 of the electrode blank 62 (Figures 11 and 12). The electrode head 77 (Figure 13) has an upper and under surface 78 and 79 conforming to the shape of the lower surface 74 (Figure 12) of the plunger 73 and the second shoulder 71 of the die 67 respectively.
Although the lower surface 74 of the plunger 73 is illustrated as being concave, it can be of any shape necessary to form the upper surface 78 (Figure 13) desired for the electrode head 77. The electrode head 77 also has a cylindrical surface 80 having a diameter equal to that of the shearing shoulder 70 (Figure 12) of the die 67. The composite center electrode 76 (Figure 13) is then removed from the die (Figure 12) through the upper bore 69 and is suitable for the desired use without further cold-working or extruding steps.
The method includes the additional improvement wherein the composite billet 52 (Figure 10) formed by the cup 41 and the billet 47 within the cavity 49 of the die 48 of Figure 9 is first extruded to the desired electrode head diameter. The first step of the method involves forming an elongated composite billet 52.
Referring to Figure 14, a forward-extruder 81 comprises a die 82 having a stepped bore 83 including an upper bore 84 in which the billet 52 fits closely and an extrusion orifice 85 of reduced diameter relative to the upper bore 84 and equal to that of the desired electrode head. The forwardextruder 81 also comprises a plunger 86 having a diameter equal to that of the upper bore 84 and insertable therein, and a lower surface 87. After the closed end 53 of the billet 52 is inserted into the upper bore 84 of the die 82, the plunger 86 is inserted therein against the inwardly turned end 54 of the billet 52. Pressure is then applied to the plunger 86 which forces all except a terminal portion of the billet 52 through the extrusion orifice 85 of the die 82.The plunger 86 is withdrawn from the die 82, and a second billet (not shown), similar to the first billet 52, is inserted therein and superposed on the inwardly turned end 54 of the first billet 52. The plunger 86 is then re-inserted into the upper bore 84 of the die 82 against the second billet. Referring to Figure 15, pressure is applied to the plunger 86 which compresses the second billet to an intermediate shape 88 and forces the remaining terminal portion of the first billet 52 through the extrusion orifice to form an elongated composite billet having closed and filled ends 90 and 91.
The final step of the method involves forming a composite center electrode from the elongated billet 89. Referring to Figure 16, a second forward extruder 92 comprises a die 93 having a stepped bore 94 including an upper bore 95 extending to a shoulder 96, and an extrusion orifice 97 of reduced diameter adjacent and below the shoulder 96. The forward-extruder 92 also comprises a plunger 98 having a diameter equal to that of the upper bore 95 and insertable therein, and a lower surface 99. After the closed end 90 of the elongated billet 89 is inserted into the upper bore 95 of the die 93, the plunger 98 is inserted therein against the filled end 91 of the elongated billet 89.Referring to Figure 17, pressure is then applied to the plunger 98 which forces all except a terminal portion of the elongated billet 89 through the extrusion orifice 97 of the die 93 to form a composite center electrode 1 00. The composite center electrode 100 has the unextruded terminal portion of the elongated billet 89 as a head 101, and a rod 102 extending longitudinally therefrom.
The electrode head 101 has an upper surface 103 conforming to the shape of the lower surface 99 of the plunger 98, a cylindrical side 104 having a diameter equal to that of the upper bore 95 of the die 93, and an under surface 105 conforming to the shape of the shoulder 96. Although the lower surface 99 of the plunger 98 is illustrated as being concave, it can be of any shape necessary to form the upper surface 103 desired for the electrode head 101. The composite center electrode 100 is then removed from the die 93 through the upper bore 95 and is suitable for the desired use without further cold-working or extruding steps.

Claims (4)

1. In a method for producing a composite center electrode for a spark plug, which method comprises the steps of forming from a corrosion resistant metal a cup having a closed end, walls extending upwardly from the closed end to an open end and a cavity extending concentrically therein, forming a composite billet having closed and filled ends by inserting into the open end of the cup a close-fitting right circular cylindrical billet of a metal having a high thermal conductivity and fitting tightly within the cup walls, extruding the composite billet into an electrode blank having an upper headed portion and a lower portion of reduced diameter extending longitudinally therefrom; the improvement wherein the positions and the relative sizes of the billet and of the cup are controlled so that the former fits tightly within the cup walls adjacent the closed cup end, but terminating short of the open cup end so that the cup walls extend thereabove at the open cup end, and the cup walls adjacent the open cup end are rolled radially inwardly to form the composite billet.
2. In a method as claimed in claim 1, wherein the open cup end, with the right circular cylindrical billet positioned in the cavity thereof, is first inserted into a die having a cavity extending longitudinally therein to a lower concave surface and into which the cup fits tightly, and then forced against the concave surface to roll the cup walls adjacent the open cup end radially inwardly to form the composite billet.
3. In a method as claimed in claim 1 or 2, wherein the closed end of the composite billet is first inserted into a die having a stepped bore including an upper bore in which the billet fits closely and an extrusion orifice of reduced diameter equal to that of a desired electrode head, and is then forced through the extrusion orifice to form an elongated composite billet having closed and filled ends, whereupon the closed end of the elongated composite billet is inserted into a second die having a stepped bore including an upper bore in which the billet fits closely and an extrusion orifice of reduced diameter, and all except an upper headed portion adjacent to the filled end of the elongated billet is forced through the extrusion orifice to form the composite center electrode.
4. A method for producing a composite center electrode for a spark plug substantially as described with reference to, and as illustrated in, Figs 5 to 17 of the accompanying drawings.
GB8113703A 1980-05-30 1981-05-05 Producing a composite center electrode Expired GB2076706B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15488480A 1980-05-30 1980-05-30

Publications (2)

Publication Number Publication Date
GB2076706A true GB2076706A (en) 1981-12-09
GB2076706B GB2076706B (en) 1984-06-27

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Family Applications (1)

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GB8113703A Expired GB2076706B (en) 1980-05-30 1981-05-05 Producing a composite center electrode

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JP (1) JPS5757480A (en)
BE (1) BE889012A (en)
CA (1) CA1198951A (en)
DE (1) DE3118793A1 (en)
FR (1) FR2483694A1 (en)
GB (1) GB2076706B (en)
IT (1) IT1142777B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4585421A (en) * 1983-11-23 1986-04-29 The National Machinery Company Method of making copper-clad bimetal electrodes for spark plugs
US4606730A (en) * 1983-09-21 1986-08-19 The National Machinery Company Bimetal electrodes for spark plugs or the like and method of making same
GB2172223A (en) * 1985-03-11 1986-09-17 Champion Spark Plug Co Composite center electrode for a spark plug and method for producing same
WO1997034563A2 (en) * 1996-03-21 1997-09-25 Farmacapsulas S.A. Pin bar and pin mold assemblies and deck plate assemblies for forming capsules and methods of manufacturing the same

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4904216A (en) * 1983-09-13 1990-02-27 Ngk Spark Plug Co., Ltd. Process for producing the center electrode of spark plug
JPS61237386A (en) * 1985-03-11 1986-10-22 チヤンピオン スパーク プラツグ コムパニー Manufacture of compound center electrode for spark plug
JP5279870B2 (en) * 2011-01-27 2013-09-04 日本特殊陶業株式会社 Spark plug electrode manufacturing method and spark plug manufacturing method

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS56920B2 (en) * 1972-04-04 1981-01-10
JPS48103445A (en) 1972-04-14 1973-12-25
DE2755120A1 (en) * 1977-12-10 1979-06-13 Atomic Energy Authority Uk Spark plug electrode mfr. - by melting metal core to metal sheath
GB2024665B (en) * 1978-07-07 1982-08-11 Ford Motor Co Spark plug electrode manufacture
GB2060454B (en) * 1979-10-15 1983-09-14 Champion Spark Plug Co Production of spark plug electrodes
US4575343A (en) 1980-04-09 1986-03-11 The National Machinery Company Bimetal electrode and method of making same
NL8101572A (en) * 1980-04-09 1981-11-02 Nat Marking Mach Co METHOD FOR MANUFACTURING A BIMETAL ELECTRODE

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4606730A (en) * 1983-09-21 1986-08-19 The National Machinery Company Bimetal electrodes for spark plugs or the like and method of making same
US4585421A (en) * 1983-11-23 1986-04-29 The National Machinery Company Method of making copper-clad bimetal electrodes for spark plugs
GB2172223A (en) * 1985-03-11 1986-09-17 Champion Spark Plug Co Composite center electrode for a spark plug and method for producing same
US4684352A (en) * 1985-03-11 1987-08-04 Champion Spark Plug Company Method for producing a composite spark plug center electrode
WO1997034563A2 (en) * 1996-03-21 1997-09-25 Farmacapsulas S.A. Pin bar and pin mold assemblies and deck plate assemblies for forming capsules and methods of manufacturing the same
WO1997034563A3 (en) * 1996-03-21 1998-02-12 Farmacapsulas S A Pin bar and pin mold assemblies and deck plate assemblies for forming capsules and methods of manufacturing the same
US5993185A (en) * 1996-03-21 1999-11-30 Farmacapsulas S.A. Deck plate assemblies for forming capsules

Also Published As

Publication number Publication date
FR2483694B1 (en) 1984-06-29
JPS5757480A (en) 1982-04-06
DE3118793C2 (en) 1990-05-03
BE889012A (en) 1981-09-16
FR2483694A1 (en) 1981-12-04
IT1142777B (en) 1986-10-15
CA1198951A (en) 1986-01-07
DE3118793A1 (en) 1982-04-29
IT8148542A0 (en) 1981-05-27
GB2076706B (en) 1984-06-27

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Date Code Title Description
PE20 Patent expired after termination of 20 years

Effective date: 20010504