Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are incorporated by reference under 37 CFR 1.57 and made a part of this specification.
Certain embodiments discussed herein relate to an attic fan, and more particularly, to an attic fan that automatically adjusts its operation to maximize cooling efficiency.
Attic fans are intended to cool hot attics by exhausting super-heated air from the attic and drawing cooler outside air into the attic. Attic fans are mounted on an attic gable wall or slope of a roof and push hot attic air through a vent to the outside. Attic vents near the floor of the attic (e.g., soffit vents or other types of vents) allow cooler outside air to flow into the attic to replace the air that is vented from the attic by the attic fan. Overheated attics can cause premature failure of building materials (e.g., roofing, sheathing, joists, rafters, insulation, air conditioning ducts, etc.). Cooling the attic can reduce the cost of cooling the living space. Attic fans can also help to control the damage caused by moisture and humidity in the attic.
What is needed is an attic fan cooling system that improves the energy efficiency of the attic fan and the cooling of the attic and living space.
The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized.
The present disclosure discloses various embodiments of a smart attic fan assembly designed to approach cooling efficiency and energy savings in a proactive way instead of the traditional reactive approach. The smart attic fan assembly's proactive approach will achieve less cost of use of fan, longer life cycle, less over heating of attic, which will reduce energy cost of cooling of attic and living space, helping reduction of premature failure of roofing, structure, wood members, insulation, etc., as well as reducing moisture and humidity problems in attics.
In some embodiments, the smart attic fan assembly includes a motor, a fan blade assembly, a condition sensor, and a control unit. The motor is configured to rotate a fan drive shaft. The fan blade assembly is rotationally secured to the fan drive shaft so that rotation of the fan drive shaft causes the fan blade assembly to rotate. The control unit is electrically coupled to the condition sensor and configured to receive a condition sensor signal transmitted by the condition sensor. The control unit is electrically coupled to the motor and configured to transmit a change in speed at which the motor rotates the fan drive shaft.
In some embodiments, the smart attic fan assembly can include one or more of the following features: The motor signal changes the speed based on the condition sensor signal. The condition sensor can comprise a temperature sensor or a humidistat. The smart attic fan assembly further includes a user interface that allows a desired temperature setting to be selected. The user interface is electronically coupled to the control unit and configured to transmit a user interface signal to the control unit to inform the control unit of the desired temperature setting. The control unit is configured to determine a target speed based on the condition sensor signal, determine a present speed based on the speed sensor, send a first motor signal to increase the speed when the target speed is greater than the present speed, send a second motor signal to decrease the speed when the target speed is less than the present speed, and send a third motor signal to keep unchanged the speed when the target speed equals the present speed. In certain embodiments, the condition sensor is a temperature sensor mounted directly on the motor. In certain embodiments, the condition sensor is a temperature sensor mounted on a bracket that connects the motor to a housing of the smart attic fan assembly. In certain embodiments, the smart attic fan assembly further includes a housing that circumferentially surrounds the motor. The condition sensor can be a temperature sensor that is mounted on a surface of the housing that faces the motor. The condition sensor is a temperature sensor that is mounted directly on a portion of a building structure to which the attic fan assembly is attached. The motor can be an electronically commutated motor.
In some embodiments, an energy efficient, smart attic fan system is disclosed. The attic fan system comprises a fan motor, a condition sensor, and a controller. The condition sensor is strategically located to sense one or more ambient conditions in an attic. The condition sensor communicates the one or more ambient conditions to the controller, which in turn modulates the speed of the fan motor in response to the one or more ambient conditions so as to maintain the one or more ambient conditions within a predetermined range.
In some embodiments, a method of operating an attic fan assembly is disclosed. The method includes rotating a fan at a first speed to create an airflow that exhausts air from an attic; detecting a temperature of the air in the airflow; comparing the temperature to a target temperature; rotating the fan at a second speed when the temperature is higher than the target temperature, the second speed being greater than the first speed; rotating the fan at a third speed when the temperature is lower than the target temperature, the third speed being less than the first speed; and maintaining the fan at the first speed when the temperature is equal to the target temperature.
The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through the use of the accompanying drawings.
Embodiments of systems, components and methods of assembly and manufacture will now be described with reference to the accompanying figures, wherein like numerals refer to like or similar elements throughout. Although several embodiments, examples and illustrations are disclosed below, it will be understood by those of ordinary skill in the art that the inventions described herein extend beyond the specifically disclosed embodiments, examples and illustrations, and can include other uses of the inventions and obvious modifications and equivalents thereof. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner simply because it is being used in conjunction with a detailed description of certain specific embodiments of the inventions. In addition, embodiments of the inventions can comprise several novel features and no single feature is solely responsible for its desirable attributes or is essential to practicing the inventions herein described.
Certain terminology may be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “above” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “left,” “right,” “rear,” and “side” describe the orientation and/or location of portions of the components or elements within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the components or elements under discussion. Moreover, terms such as “first,” “second,” “third,” and so on may be used to describe separate components. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.
Embodiments of the present disclosure provide for an energy-efficient, automated attic fan cooling system. In some aspects, the present disclosure is directed to a programmable attic fan that maximizes energy-efficiency by adjusting operational parameters of the fan to prevent or reduce overheating of an attic space. In some arrangements, the smart attic fan assemblies disclosed herein adjust operational parameters of the fan motor in response to conditions (e.g., temperature, humidity) detected by sensors located at one or more strategically selected locations inside the attic space, inside the living space, or outside of the structure. As described in more detail below, the systems and methods disclosed herein minimize energy consumption of the attic fan motor during the ventilation of the attic. The systems and methods reduce the energy consumption required to maintain a temperature of an attic space at a desired setpoint or within a desired range of temperatures having a minimum temperature setpoint and a maximum temperature setpoint. The systems and methods reduce the energy consumption required to maintain the humidity of an attic space at a desired setpoint or within a desired range of humidity having a minimum humidity setpoint and a maximum humidity setpoint. In certain arrangements, the apparatuses, methods, and cooling systems disclosed herein provide energy-efficient ventilation regimes that minimize heat conduction from an attic to a living space.
As discussed in more detail below, the smart attic fan assembly 100 can be adapted to rotate the fan blade assembly 300 at different revolutions per minute (rpm). In certain arrangements, the operation of the motor 200 can be controlled by the control unit 400. For example, the control unit 400 can send a motor signal 402 to the motor 200 to control the speed (e.g., rpm) at which the motor 200 drives rotation of the fan blade assembly 300. In some arrangements, the motor 200 is an ECM and the control unit 400 controls the operation of the motor 200 by controlling the armature current of the motor 200. As discussed below, the control unit 400 can adjust the speed (e.g., rpm) of the fan blade assembly 300 in response to information received by the control unit 400 from one or more sensors 600 of the smart attic fan assembly 100. The control unit 400 can include one or more electrical circuits and/or processors. The control unit 400 can include a printed circuit board (PCB).
The smart attic fan assembly 100 can include a speed sensor 602 that is adapted to detect the rpm of the fan blade assembly 300. The speed sensor 602 can be an infrared sensor that detects the passing of a light or dark mark on the rotating fan drive shaft 302. The speed sensor 602 can be a voltage sensor or a current sensor. The control unit 400 can be programmed to covert a voltage or a current detected by the speed sensor 602 to a speed of the fan blade assembly 300. For example, the fan blade assembly 100 can have a speed sensor 602 that detects a voltage supplied to the motor 200. The control unit 400 can be programmed to have a look-up table or characteristic curve that allows the control unit 400 to convert the detected voltage from the speed sensor 602 to a corresponding rpm value for the fan blade assembly 300. The speed sensor 602 can detect a voltage or a current supplied to the motor 200 or to another component of the smart attic fan assembly 100. In some arrangements, the speed sensor 602 is a Hall effect sensor that detects the passing of a magnet on the rotating fan drive shaft 302. The speed sensor 602 can send a fan speed signal 404 to the control unit 400, as shown in
With continued reference to
The user interface 500 can include a display 506. The display 506 can display the reading of a sensor 600 of the smart attic fan assembly 100. The user interface 500 can include a toggle button 508 that allows a user to scroll through the readings for each of the multiple sensors 600 of the smart attic fan assembly 100. For example, the smart attic fan assembly 100 can include a temperature sensor 604 located on or in the user interface 500. The temperature sensor 604 can inform the user or the control unit 400 of the current temperature of the room in which the smart attic fan assembly 100 is installed. In some arrangements, the display 506 can show the current reading from the speed sensor 602 to inform a viewer or the control unit 400 of the current rpm of the fan blade assembly 300. The smart attic fan assembly 100 can include a humidistat 606. The humidistat 606 can be located on or in the user interface 500. The humidistat 606 can inform the user or the control unit 400 of the humidity of the room in which the smart attic fan assembly 100 is installed. The display 506 can show the current reading from the humidistat 606.
The smart attic fan assembly 100 can include a temperature sensor 604 located at a location other than on or in the user interface 500. For example, the smart attic fan assembly 100 can include a temperature sensor 604 located outside the building structure to inform the control unit 400 of the current outside temperature. The smart attic fan assembly 100 can include multiple temperature sensors 604 located at different locations. In some arrangements, a first temperature sensor 604 can be located near the floor of the attic and a second temperature sensor 604 can be located near the roof of the attic. In certain arrangements, the smart attic fan assembly 100 includes a temperature sensor 604 located within the living space of the building structure. The toggle button 508 can allow a user to scroll through the temperature readings for each of the multiple temperature sensors 604. The temperature sensor 604 can send a temperature signal 408 to the control unit 400. The control unit 400 can receive the temperature signal 408 from the temperature sensor 604. The temperature signal 408 can inform the control unit 400 of the temperature at the location of the temperature sensor 604.
The smart attic fan assembly 100 can include a humidistat 606 located at a location other than on or inside the user interface 500. For example, the smart attic fan assembly 100 can include a humidistat 606 located outside the building structure to inform the user or the control unit 400 of the current humidity outside. The smart attic fan assembly 100 can include multiple humidistats 606 located at different locations. In some arrangements, a first humidistat 606 can be located in the attic space and a second humidistat 606 can be located inside the living space of the building structure or outside of the building structure. The toggle button 508 can allow a user to scroll through the humidity readings for each of the multiple humidistats 606. The humidistat 606 can send a humidity signal 410 to the control unit 400. The control unit 400 can receive the humidity signal 410 from the humidistat 606. The humidity signal 410 can inform the control unit 400 of the humidity at the location of the humidistat 606.
The user interface 500 can be adapted to allow a user to set operational setpoints for the smart attic fan assembly 100. The operational setpoints can define conditions that trigger the smart attic fan assembly 100 to perform an action (e.g., turn on fan, speed up fan, pulse fan, slow down fan). The smart attic fan assembly 100 can compare the operational setpoints to a reading (e.g., temperature, humidity) detected by a sensor 600. For example, the user interface 500 can allow a user to set an operational setpoint for a desired temperature in the attic. The smart attic fan assembly 100 can compare the desired temperature in the attic to a reading from a temperature sensor 604 located in an air flow path of the smart attic fan assembly 100. The smart attic fan assembly 100 can speed up the rpm of the motor 200 if the temperature in the attic exceeds the desired temperature. The smart attic fan assembly 100 can slow down the rpm of the motor 200 if the temperature in the attic is below the desired temperature. In some arrangements, the user interface 500 can allow a user to set an operational setpoint for a desired humidity in the attic. The smart attic fan assembly 100 can compare the desired humidity in the attic to a reading from a humidity sensor 604 located in the attic. The smart attic fan assembly 100 can start or speed up the rpm of the motor 200 if the humidity in the attic exceeds the desired humidity. The smart attic fan assembly 100 can stop or slow down the rpm of the motor 200 if the humidity in the attic is below the desired humidity. The smart attic fan assembly 100 can include a humidistat 606 located outside of the building structure. The smart attic fan assembly 100 can compare the reading of the humidistat 606 located outside of the building structure to the desired humidity in the attic. The smart attic fan assembly 100 can start or speed up the rpm of the motor 200 if the humidity outside of the building structure is less than the desired humidity in the attic. The smart attic fan assembly 100 can stop or slow down the rpm of the motor 200 if the humidity outside of the building structure is greater than the desired humidity in the attic.
As shown in
The smart attic fan assembly 100 can include a wireless transmitter and/or a wireless receiver (not shown) that allows the smart attic fan assembly 100 to communicate with a mobile device 1000 (e.g., smart phone, tablet, etc.). The mobile device 1000 can send a signal 1002 to the smart attic fan assembly 100 to check or change the operation of the smart attic fan assembly 100. For example, a user can have a mobile device 1000 that includes a software application (app) that allows the user to increase or decrease the speed of the motor 200.
The smart attic fan assembly 100 can include a bracket 108 that secures the motor 200 to the housing 102. In the illustrated embodiment, the housing 102 is substantially cylindrical and the bracket 108 holds the motor 200 substantially coaxial with the cylindrical housing 102. The smart attic fan assembly 100 can include a grill 110 that covers the inflow end of the housing 102. The grill 110 can have an open wireframe structure that is arranged so that the grill 110 does not substantially interfere with air flow through the housing 102. The housing 102 can include a port 112 that allows the power cord 700 to pass through the housing 102 to reach the motor 200. In the illustrated embodiment, the user interface 500 is attached to a junction box 704 that supplies power to the smart attic fan assembly 100.
With continued reference to
As shown in
As described above with regard to
In some arrangements, the smart attic fan assembly 100 can increase its rpm as the attic 22 warms, to prevent the attic 22 from overheating. For example, the smart attic fan assembly 100 can operate at a low rpm (e.g., 30% of full rpm or less than 10% Watts) when the temperature of the attic air near the roof 34 is above a first temperature. The smart attic fan assembly 100 can operate at a moderate rpm (e.g., 50% of full rpm or less than 25% Watts) when the temperature of the attic air near the roof 34 is above a second temperature, the second temperature being hotter than the first temperature. The smart attic fan assembly 100 can operate at a high rpm (e.g., 100% of full rpm or 100% Watts) when the temperature of the attic air near the roof 34 is above a third temperature, the third temperature being hotter than the second temperature. Ramping up the rpm in response to the present temperature conditions of the attic 22 can allow the smart attic fan assembly 100 to cool the attic 22 more efficiently compared to a simple thermostat-controlled fan that only runs at full power and only turns on once the attic air crosses a certain temperature. Ramping up the rpm in response to the present temperature conditions of the attic 22 can avoid having to frequently switch the fan on and off. Frequent switching of the fan on and off is inefficient because the motor must repeatedly re-establish fan inertia that is wasted when the fan is shut off. Frequent switching of the fan on and off can impose more wear on fan components. A simple thermostat-controlled fan can attempt to reduce the frequency of the fan switching on and off by increasing the hysteresis of the thermostat, i.e., the range between the “fan-on” setpoint temperature and the “fan-off” setpoint temperature. Increasing the thermostat hysteresis can result in the attic 22 becoming overheated before the thermostat signals the fan to turn on. The smart attic fan assembly 100 can avoid overheating of the attic 22 by ramping up the rpm in response to the present temperature conditions of the attic 22. The smart attic fan assembly 100 can avoid motor wear by avoiding frequent switching on and off of the motor 200. The smart attic fan assembly 100 can improve efficiency by preserving fan inertia.
Table 1 shows illustrative, non-limiting data for power consumption and air flow of a smart attic fan assembly 100. In the illustrated embodiment, the smart attic fan assembly 100 produces an air flow of 2830 cubic feet per minute (CFM) when the smart attic fan assembly 100 is operating at full power, which corresponds to a fan speed of 1550 rpm. The power consumption of the smart attic fan assembly 100 when it is operating at full power is 163 Watts.
Table 2 shows illustrative, non-limiting data for power consumption and air flow of a smart attic fan assembly 100 that is programmed to turn on when the smart attic fan assembly 100 detects a relative humidity of 60%. In some embodiments, the smart attic fan assembly 100 can be programmed to turn on when the smart attic fan assembly detects a relative humidity other than 60% (e.g., 40%, 50%, 65%, 70%, 80%). In the illustrated embodiment, the smart attic fan assembly 100 that is programmed to turn off when the smart attic fan assembly 100 detects a relative humidity of 55%. In some embodiments, the smart attic fan assembly 100 can be programmed to turn off when the smart attic fan assembly 100 detects a relative humidity other than 55% (e.g., 20%, 40%, 50%, 60%, 70%).
As discussed in more detail below, the smart attic fan assembly 100 can be programmed to respond to environmental conditions (e.g., humidity, temperature). For example, the smart attic fan assembly 100 can include a central processor that receives input from a humidistat sensor and a temperature sensor. The central processor can output a signal to the motor 200 of the smart attic fan assembly 100 based on the input received from the humidistat sensor and the temperature sensor. In some embodiments, the central processor can be programmed to give greater weight to the input from the temperature sensor when evaluating the output signal to send to the motor 200. In some embodiments, the central processor can be programmed to give greater weight to the input from the humidistat when evaluating the output signal to send to the motor 200. In certain variants, the central processor can output a signal to the motor 200 of the smart attic fan assembly 100 based on the input received from only one type of sensor (e.g., a temperature sensor). In some embodiments, the central processor can output a signal to the motor 200 of the smart attic fan assembly 100 based on the input received from only one sensor (e.g., a single temperature sensor).
In some arrangements, the smart attic fan assembly 100 can adjust its operation in response to a detected temperature gradient. For example, the smart attic fan assembly 100 can compare a reading from a first temperature sensor 604a near the roof to a reading from a second temperature sensor 604b near the floor 32 to detect a temperature difference. The smart attic fan assembly 100 can operate at a low rpm (e.g., 30% full power) when the temperature difference is above a first value and below a second value. The smart attic fan assembly 100 can operate at a moderate rpm (e.g., 50% full power) when the temperature difference is above a second value and below a third value. The smart attic fan assembly 100 can operate at a high rpm (e.g., 100% full power) when the temperature difference is above the third value.
In some arrangements, the smart attic fan assembly 100 can adjust its operation to promote mixing of air within the attic 22. For example, the smart attic fan assembly 100 can rapidly pulse between a low rpm (e.g., 30% full power) and a high rpm (e.g., 100% full power) mode of operation in order to promote mixing of attic air. Mixing of air within the attic 22 can promote lowering the temperature of the air near the attic floor 32, thereby reducing heat conduction from the attic 22 into the living space 36.
In some arrangements, the smart attic fan assembly 100 can adjust its operation to avoid mixing of air within the attic 22. For example, the smart attic fan assembly 100 can slowly ramp up from a low rpm (e.g., 30% full power) to a high rpm (e.g., 100% full power) to maintain a laminar draw of air that removes more air from the space near the roof 34 compared to the space near the floor 32. The smart attic fan assembly 100 can avoid mixing of the air within the attic 22 in order to minimize heat transfer between attic air near the roof 34 and attic air near the floor 32, thereby reducing heat conduction from the attic 22 into the living space 36.
With continued reference to
Referring again to
In some arrangements, the logic path 800 can include an override step 812 that allows an input from a mobile device 1000 or the user interface 500 (shown in
As mentioned, the smart attic fan assembly 100 can be used to reduce or avoid overheating of the attic 22 as well as to reduce humidity in the attic 22. In cold weather or in winter, the smart attic fan assembly 100 can remove humid air from the attic 22 to avoid or prevent condensation on the building materials of the attic 22 (e.g., insulation, joists, rafters, etc.). In winter, the smart attic fan assembly 100 can be set to keep the attic cold to avoid ice dams forming on the roof. For example, in winter months, the temperature set point of the smart attic fan assembly 100 can be set to a low temperature to avoid warm air accumulating in the attic 22. Warm air in the attic 22 can cause ice dams to form by causing snow to melt near the warmer peak of the roof and to refreeze near the cooler eaves of the roof. In winter months, the smart attic fan assembly 100 can be set to keep the moisture low in the attic. For example, in winter months, the humidity set point of the smart attic fan assembly 100 can be set to a low humidity level to avoid humid air accumulating in the attic and condensing on the building materials of the attic 22. Preventing humid air from condensing on the building materials of the attic 22 can prolong the life of the attic building materials, as discussed above.
All of the features disclosed in this specification (including any accompanying exhibits, claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The disclosure is not restricted to the details of any foregoing embodiments. The disclosure extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. For example, the actual steps or order of steps taken in the disclosed processes may differ from those shown in the figure. Depending on the embodiment, certain of the steps described above may be removed, others may be added. For instance, the various components illustrated in the figures may be implemented as software or firmware on a processor, controller, ASIC, FPGA, or dedicated hardware. Hardware components, such as processors, ASICs, FPGAs, and the like, can include logic circuitry. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.
Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, or steps. Thus, such conditional language is not generally intended to imply that features, elements, or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Likewise the term “and/or” in reference to a list of two or more items, covers all of the following interpretations of the word: any one of the items in the list, all of the items in the list, and any combination of the items in the list. Further, the term “each,” as used herein, in addition to having its ordinary meaning, can mean any subset of a set of elements to which the term “each” is applied. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application.
Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the disclosure is not intended to be limited to the implementations shown herein, but is to be accorded the widest scope consistent with the principles and features disclosed herein. Certain embodiments of the disclosure are encompassed in the claim set listed below or presented in the future.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | 15486250 | Apr 2017 | US |
Child | 17527007 | US |