The invention relates to an electronic circuit comprising at least two electronic components on a common flexible substrate, wherein the at least two electronic components in each case have at least one electrical functional layer composed of identical functional layer material. The invention furthermore relates to a method for the manufacture of an electronic circuit comprising at least two electronic components on a common flexible substrate, wherein the at least two electronic components are in each case formed with at least one electrical functional layer composed of identical functional layer material.
WO 2004/032257 A2 discloses a method for the manufacture of a film, wherein the film comprises at least one component using organic technology, in particular one or a plurality of field effect transistors. The structuring of one or a plurality of layers of the component is effected in this case by thermal replication or UV replication. In this case, a layer to be replicated which is applied in large-area fashion is partially severed by the replication and an electrical functional layer structured in patterned fashion is formed. However, a large-area layer application of the layer to be replicated is not always possible, for space reasons, and furthermore leads to an increased material consumption.
Electrical functional layers that are applied to a substrate already in the final form are realized for example by means of printing methods. The application of printing methods in the manufacture of electronic components enables said components to be mass-produced inexpensively at high process speeds. A speed of the substrate in the printing direction during printing of at least 0.5 m/min, preferably within the range of 5 to 200 m/min, is preferably chosen. In order to ensure electrical values that are as uniform as possible and the functionality of the electronic component, the individual electrical functional layers from which the electronic component is constructed must be formed one after another and in this case be positioned one above another in the correct position and arrangement in accordance with a predetermined layout.
Furthermore, with regard to the electrical properties and short response times of a component it is necessary to minimize the layer thicknesses of electrical functional layers. In order to be able to achieve this for example in the case of printed electrical functional layers, it is necessary to use printing media of ever lower viscosity.
At the high process speeds required during the formation of an electrical functional layer using a medium of low viscosity, firstly the problem then arises that inexact edges for the electrical functional layer are formed during the only partial, that is to say patterned application of an electrical functional layer. The edge or the margin of the electrical functional layer is unsharp in the region of the separating line since the printing medium, opposite to the direction of movement of the substrate, is pressed, pulled or spun beyond the desired, ideal boundary line on account of the high process speed. The smearing is all the worse, the lower the viscosity of the medium. However, the effect is always present (microscopically), that is to say also in the case of printing media of high viscosity. The more critical the dimensions, the more pronounced this effect is even in the case of media of high viscosity. Moreover, functional layers that smear out in the printing direction do not permit precise alignment of further functional layers that are to be arranged above them.
At the high process speeds required during the formation of an electrical functional layer using a medium of low viscosity, the problem furthermore arises that during application in already structured form, that is to say in the end form for the respective functional layer, it is not possible to form a sufficiently uniform layer thickness over the area of the respective functional layer. The effect particularly occurs in the vicinity of the edge of the functional layer.
It is an object of the invention, then, to provide an electronic circuit and a method for the manufacture of an electronic circuit which overcome the disadvantages of the prior art.
The object is achieved for the electronic circuit comprising at least two electronic components on a common flexible substrate, wherein the at least two electronic components in each case have at least one electrical functional layer composed of identical functional layer material, by virtue of the fact that the electrical functional layers composed of identical functional layer material are formed from layer regions of a layer formed in strip-type fashion on the substrate.
The object is achieved for the method for the manufacture of an electronic circuit comprising at least two electronic components on a common flexible substrate, wherein the at least two electronic components in each case are formed with at least one electrical functional layer composed of identical functional layer material, by virtue of the fact that at least one strip-type layer is formed on the substrate, and in that the electrical functional layers composed of identical functional layer material are formed from layer regions of an individual strip-type layer.
A strip-type application of functional layer material on a substrate enables a space-saving and at the same time uniformly thick layer application with clean contours. A substrate which is prepared in this way and which is provided with at least one strip-type layer composed of functional layer material can be used diversely and can be adapted individually to the respective desired electronic circuit.
It has proved to be particularly worthwhile if the layer formed in strip-type fashion on the substrate is formed in a continuous process on the substrate in a specific application direction. The layer formed in strip-type fashion on the substrate is preferably a printed layer or a layer formed by applying a liquid medium on the substrate.
In particular, in this case the continuous process used is a printing method, in particular a printing method from the group of intaglio printing, relief printing, screen printing, or the continuous process used is some other coating method (for example blade coating, spin-coating, spraying or inkjet printing) that applies a liquid medium for forming the at least one strip-type layer to the substrate. During the printing of a strip-type layer, the application direction therefore corresponds to the printing direction. In particular, it is preferred for the method according to the invention if a printing tool that is unrolled on the substrate at least in regions is used for printing the at least one strip-type layer. By way of example, printing rollers or flexible rubber tools such as pads are suitable here as printing tools.
In this case, a printing medium or liquid medium having a dynamic viscosity of less than 200 mPas, in particular less than 50 mPas, as considered at a temperature of 20° C., is preferred for forming the at least one strip-type layer. Media of such low viscosity make it possible to form extremely thin electrical functional layers whilst at the same time improving the performance features of the electronic component produced therewith.
It has proved to be worthwhile if a first electronic component of the at least two electronic components has a first electrical functional layer, and a second electronic component of the at least two electronic components has a second electrical functional layer, wherein the first and the second electrical functional layer are formed from identical functional layer material, wherein the first and the second electrical functional layer are arranged on the substrate in such a way that they are arranged one after another or alongside one another in the application direction.
It is particularly preferred if the layer formed in strip-type fashion on the substrate is a semiconducting or an electrically insulating layer, in particular an organic semiconducting or an organic electrically insulating layer. However, an electrically conductive, if appropriate organic electrically conductive, strip-type layer can also be used.
Polythiophene, for example, is suitable as organic semiconductor material. Polyvinyl phenol, inter alia, has proved to be worthwhile as organic insulation material. Inorganic semiconductor or insulation material can be vapor-deposited, sputtered or inserted by means of pastes containing semiconducting or electrically insulating inorganic particles, in particular nanoparticles.
It is particularly advantageous to form the substrate with a plurality of strip-type layers which are arranged parallel alongside one another and which are formed from different functional layer materials. By means of a subsequent coating of individual regions with further, if appropriate in turn strip-type layers, it is possible to construct therefrom the components required for forming the electronic circuit.
For forming the individual components of the electronic circuit it may become necessary for the layer formed in strip-type fashion on the substrate to be interrupted and/or subdivided into mutually independent layer regions, wherein, as seen over the cross section of the layer formed in strip-type fashion on the substrate, at least one continuous opening is formed in the layer formed in strip-type fashion on the substrate.
In this case, it has proved to be worthwhile if the layer formed in strip-type fashion on the substrate is subdivided in the application direction and/or perpendicular to the application direction. The use of a laser beam, embossing, cutting, grinding or scratching have proved to be worthwhile as suitable methods for structuring the at least one strip-type layer.
Preferably, the at least one opening in the layer formed in strip-type fashion on the substrate forms a via by means of which an electrical contact is formed between electrical functional layers arranged, as seen perpendicular to the substrate plane (x-y plane), above and below the layer formed in strip-type fashion on the substrate. This therefore enables a connection in the third dimension (z plane) between functional layers.
It has proved to be expedient if an opening has a width within the range of 1 μm to 10 mm, preferably of 50 μm to 2 mm. Such dimensions can be realized with high accuracy for example by intaglio or relief printing when using the method according to the invention. Such widths ensure a sufficient electrical isolation of layer regions of a strip-type layer and furthermore a sufficient material uptake capacity (for example for taking up printing paste) during the formation of plated-through holes by means of such an opening.
It has proved to be worthwhile if at least one electronic component is formed as a transistor, in particular as a field effect transistor. In particular, it has proved to be worthwhile if the at least two electronic components are in each case formed as field effect transistors, wherein the field effect transistors in each case have a semiconducting electrical functional layer composed of identical functional layer material, which are formed from layer regions of a semiconducting layer formed in strip-type fashion on the substrate, and wherein the field effect transistors in each case have an electrically insulating electrical functional layer composed of identical functional layer material, which are formed from layer regions of an electrically insulating layer formed in strip-type fashion on the substrate.
Furthermore, it has proved to be advantageous if at least one electronic component is formed as a diode. In particular, it is advantageous if the at least two electronic components are in each case formed as diodes, wherein the diodes in each case have a semiconducting electrical functional layer composed of identical functional layer material, which are formed from layer regions of a semiconducting layer formed in strip-type fashion on the substrate.
Furthermore, it has proved to be worthwhile if at least one electronic component is formed as a nonreactive resistor. In particular, it is advantageous if the at least two electronic components are in each case formed as nonreactive resistors, wherein the resistors in each case have a functional layer composed of identical functional layer material, which are formed from layer regions of a layer formed in strip-type fashion on the substrate.
Furthermore, it has proved to be advantageous if at least one electronic component is formed as a capacitor. In particular, it is advantageous if the at least two electronic components are in each case formed as capacitors, wherein the capacitors in each case have an electrically insulating functional layer composed of identical functional layer material, which are formed from layer regions of an electrically insulating layer formed in strip-type fashion on the substrate.
For continuous processes, in particular, it has proved to be expedient if the flexible substrate is formed in tape-type fashion. At least during the formation of the at least one strip-type layer, the substrate can thereby be transported conveniently from roll to roll. In this case, the uncoated flexible substrate is wound up onto a roll, the substrate is unwound from the roll and guided for example through a printing machine, printed in the process and finally wound up as printed substrate onto a further roll. This makes it possible to process long substrate tapes, wherein the positioning with respect to the printing machine only has to be performed once at the beginning of a new substrate roll.
In this case, it is particularly preferred if the at least one layer formed in strip-type fashion on the substrate is arranged parallel to a longitudinal side of the tape-type substrate, that is to say that the application direction is arranged parallel to a longitudinal side of the tape-type substrate. As a result, a strip-type layer can be formed continuously on the substrate from the start of the roll to the end of the roll, thereby increasing the uniformity of the layer (with regard to layer thickness, width and surface roughness).
The flexible substrate can be formed in multilayered fashion. It is particularly preferred if the flexible substrate used is an elongated plastic film, which is multilayered, if appropriate. By way of example, plastic films composed of polyester, polyethylene, polyethylene terephthalate (PET) or polyimide are suitable in this case. It has proved to be worthwhile if a thickness of the flexible substrate within the range of 6 μm to 200 μm, preferably within the range of 12 μm to 50 μm, is chosen.
It has proved to be worthwhile if at least two, in particular two to twenty, layers formed in strip-type fashion on the substrate are arranged parallel to one another on the substrate. In this case, the width of such a strip-type layer is preferably 50 μm to 2000 μm. The preferred distance between two strip-type layers arranged adjacent and parallel to one another is in this case 2000 μm to 50 000 μm.
It is particularly preferred if the at least two layers formed in strip-type fashion on the substrate, as seen in the substrate cross section, are arranged in one plane and/or in different planes on the substrate. Three-dimensional circuits can thereby be produced in a simple manner.
It is advantageous if the at least two electronic components in each case have at least two electrical functional layers composed of different functional layer materials, wherein in each case one of the at least two electrical functional layers of the at least two components is formed by a structuring of a strip-type layer that is therefore used jointly by the at least two electronic components. This ensures an optimum arrangement of components and utilization of strip-type layers.
It has proved to be worthwhile that a first electronic component of the at least two electronic components has a first electrical functional layer, and wherein a second electronic component of the at least two electronic components has a second electrical functional layer, wherein the first and the second electrical functional layer are formed from identical functional layer material, wherein the first and the second electrical functional layer are arranged on the substrate in such a way that they are arranged one after another or alongside one another as seen in the application direction.
Preferably, the layer formed in strip-type fashion on the substrate is formed with a layer thickness within the range of 1 nm to 300 μm, in particular within the range of 1 nm to 300 nm.
The at least two electronic components usually furthermore have electrically conductive, in particular organic or metallic, functional layers. The latter can be formed by means of printing, vapor disposition or sputtering (before or after the formation of strip-type layers) on the uncoated substrate or an already coated substrate.
Electrically conductive materials, in particular conductive polymers or metals or metal alloys, e.g. composed of vapor-deposited or sputtered gold or silicon, or conductive pastes with gold, silver or conductive inorganic nanoparticles are appropriate in this case. Here conductive “organic” materials are considered to be all types of organic, organometallic and inorganic plastics. Accordingly, a restriction in the dogmatic sense to organic material as material containing carbon is not envisaged, rather the use of silicones, for example, is also conceived of. Furthermore, the term is not intended to be subject to any restriction whatsoever with regard to the molecular size, in particular to polymeric and/or oligomeric materials, rather the use of “small molecules” is also entirely possible. Polyaniline or polypyrrol, inter alia, have proved to be worthwhile as electrically conductive organic materials.
The electronic circuit is preferably an organic circuit. However, it has equally proved to be worthwhile if the organic circuit has components having only organic electrical functional layers, and/or has components having organic and inorganic electrical functional layers.
a to 7b are intended to elucidate the invention by way of example. Thus:
a shows a tape-type substrate with four strip-type layers,
b shows a cross section through the substrate from
a shows a tape-type substrate with one strip-type layer,
b shows the substrate from
a shows a tape-type substrate with one strip-type layer,
b shows the substrate from
a shows a tape-type substrate with one strip-type layer and further electrical functional layers,
b shows a cross section through the substrate from
a shows a tape-type substrate with a subdivided strip-type layer and further strip-type electrical functional layers,
b shows a longitudinal section through the substrate from
a shows a tape-type substrate with a subdivided strip-type layer and a further strip-type layer,
b shows a cross section through the substrate from
a shows an excerpt from an electronic circuit in plan view,
b shows a cross section through the circuit in
a shows a flexible tape-type substrate 1 composed of PET with four strip-type layers 2a, 2b, 2c, 2d arranged longitudinally on the tape-type substrate 1 and parallel to one another. The four strip-type layers 2a, 2b, 2c, 2d are printed onto the substrate 1 by the intaglio printing method, the arrow on the left in
b shows the cross section A-A′ through the substrate 1 and the four strip-type layers 2a, 2b, 2c, 2d in
a shows a flexible tape-type substrate 1 with one strip-type layer 2b composed of organic semiconducting functional layer material, here polythiophene. The strip-type layer 2b is printed longitudinally on the substrate 1, the arrow on the left in the figure denoting the application direction. The illustration identifies layer regions 3a of the strip-type layer 2b which are oriented in the longitudinal direction of the substrate 1 and in which, after the formation of the strip-type layer 2b, a cut is to be effected by means of a laser in order to provide the strip-type layer 2b with openings 4a (see
b then shows the substrate 1 and the strip-type layer 2b from
a likewise shows a flexible tape-type substrate 1 with one strip-type layer 2b composed of organic semiconducting functional layer material, here polythiophene. The strip-type layer 2b is printed longitudinally on the substrate 1, the arrow on the left in the figure denoting the application direction. The illustration identifies layer regions 3b in the strip-type layer 2b which are oriented in the transverse direction of the substrate 1 and in which, after the formation of the strip-type layer 2b, a cut is to be effected by means of a laser in order to provide the strip-type layer 2b with openings 4b (see
b then shows the substrate 1 and the strip-type layer 2b from
a shows a flexible tape-type substrate 1 composed of PET with a printed, organic semiconducting and strip-type layer 2b, here composed of polythiophene, and further, electrically conductive functional layers 5a, 5b composed of sputtered gold. In this case, the functional layer 5b composed of gold was formed directly on the substrate 1, the strip-type layer 2b was printed in a manner oriented longitudinally on the tape-type substrate 1 and, finally, the functional layer 5a was formed from gold. A unit comprising electrically conductive functional layers 5a, 5b and organic semiconducting layer 2b arranged in between forms a respective diode. A strip-type electrically insulating layer—not shown here—could optionally be arranged here over the whole area between the organic semiconducting layer 2b and the electrically conductive functional layer 5a, said electrically insulating layer having a via or an opening in the region between the organic semiconducting layer 2b and the electrically conductive functional layer 5b. A direct contact between the organic semiconducting layer 2b and the electrically conductive functional layer 5a is possible by means of the via.
b shows the cross section B-B′ through the substrate 1 and the layers 5a, 2b, 5b arranged thereon from
a shows a flexible tape-type substrate 1 with a strip-type layer 2d composed of electrically insulating functional layer material, here polyvinyl phenol. A strip-type layer 2a composed of electrically conductive functional layer material is formed in regions on the substrate 1 in the longitudinal direction, here by printing. The strip-type layer 2a composed of electrically conductive functional layer material is furthermore overprinted with a strip-type layer 2d composed of electrically insulating functional layer material that is formed over the entire length of the substrate 1. A laser treatment of the strip-type layer 2d composed of electrically insulating functional layer material is then effected, wherein an opening 4b is formed perpendicular to the longitudinal direction of the substrate 1. A region of the strip-type layer 2a is uncovered as a result of the formation of the opening 4b. In a next step, the two strip-type layers 2c are formed simultaneously by printing, said layers likewise being formed from electrically conductive functional layer material. An electrically conductive connection between the strip-type layer 2a and the strip-type layer 2c arranged on the left is formed in the region of the opening 4b (also see
b shows the longitudinal section C-C′ through the substrate 1 from
a shows a flexible tape-type substrate 1 composed of PET with a strip-type layer 5a composed of electrically conductive functional layer material, here polyaniline or gold, said strip-type layer having been repeatedly subdivided by means of a laser. Thus, openings 4b running in rectilinear fashion and openings 4c running in meandering fashion were formed and two further strip-type layers, one a semiconducting layer 2b (not illustrated) and furthermore a layer 2d composed of electrically insulating functional layer material, here polyvinyl phenol, were formed one above another. In
b shows the cross section D-D′ through the substrate 1 from
a shows an excerpt from an electrical circuit, here a ring oscillator circuit, in plan view. Situated on a substrate 1 are electrically conductive functional layers 2a covered by a thin organic, semiconducting functional layer 2b applied over the whole area. Situated on the organic, semiconducting functional layer 2b is an electrically insulating functional layer 2d applied over the whole area in strip-type fashion, the electrically insulating functional layer having an opening 4b in the region in which the section E-E′ is placed, which opening was subsequently formed by means of a laser. Situated on the electrically insulating layer 2d is a further electrically conductive layer 2c, shown in phantom with dashed lines to illustrate its relative position, which is formed in strip-type fashion. In the region of the opening in the electrically insulating layer 2d, the electrically conductive layer 2c is in each case in contact with the electrically conductive functional layer 2a since the semiconducting layer 2b is made so thin that an electrical contact or a short circuit between the conductive layers 2a and 2c is formed in the region of said opening. In the region of the circuit in which the electrically conductive layer 2a, the semiconducting layer 2b, the electrically insulating layer 2d and the electrically conductive layer 2c are arranged one above another and additionally in the region of the comb structures within the electrically conductive layer 2a, an organic field effect transistor is formed in each case.
The section through the substrate 1 and the layers arranged thereon in the region E-E′ is illustrated in
The illustrations in
Number | Date | Country | Kind |
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10 2005 044 306 | Sep 2005 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2006/008930 | 9/13/2006 | WO | 00 | 4/10/2008 |
Publishing Document | Publishing Date | Country | Kind |
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WO2007/031303 | 3/22/2007 | WO | A |
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37 05 109 | Aug 1987 | DE |
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42 43 832 | Jun 1994 | DE |
43 12 766 | Oct 1994 | DE |
196 29 291 | Jan 1997 | DE |
196 48 937 | May 1997 | DE |
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195 06 907 | Sep 1998 | DE |
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198 16 860 | Nov 1999 | DE |
199 18 193 | Nov 1999 | DE |
198 51 703 | May 2000 | DE |
100 06 257 | Sep 2000 | DE |
199 20 593 | Nov 2000 | DE |
199 21 024 | Nov 2000 | DE |
199 33 757 | Jan 2001 | DE |
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199 35 527 | Feb 2001 | DE |
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100 12 204 | Sep 2001 | DE |
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201 11 825 | Feb 2002 | DE |
100 43 204 | Apr 2002 | DE |
100 45 192 | Apr 2002 | DE |
100 47 171 | Apr 2002 | DE |
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100 61 297 | Jun 2002 | DE |
101 17 663 | Oct 2002 | DE |
101 20 687 | Oct 2002 | DE |
101 20 686 | Nov 2002 | DE |
101 26 859 | Dec 2002 | DE |
101 26 860 | Dec 2002 | DE |
101 51 440 | Feb 2003 | DE |
101 41 440 | Mar 2003 | DE |
101 53 656 | May 2003 | DE |
101 63 267 | Jul 2003 | DE |
102 09 400 | Oct 2003 | DE |
102 19 905 | Dec 2003 | DE |
102 29 168 | Jan 2004 | DE |
699 13 745 | Oct 2004 | DE |
103 30 064 | Dec 2004 | DE |
103 30 063 | Feb 2005 | DE |
103 35 336 | Mar 2005 | DE |
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103 40 641 | Apr 2005 | DE |
0 108 650 | May 1984 | EP |
0 128 529 | Dec 1984 | EP |
0 268 370 | May 1988 | EP |
0 268 370 | May 1988 | EP |
0 350 179 | Jan 1990 | EP |
0 418 504 | Mar 1991 | EP |
0 435 029 | Jul 1991 | EP |
0 442 123 | Aug 1991 | EP |
0 460 242 | Dec 1991 | EP |
0 501 456 | Sep 1992 | EP |
0 501 456 | Sep 1992 | EP |
0 511 807 | Nov 1992 | EP |
0 528 662 | Feb 1993 | EP |
0 588 721 | Mar 1994 | EP |
0 603 939 | Jun 1994 | EP |
0 615 256 | Sep 1994 | EP |
0 685 985 | Dec 1995 | EP |
0 716 458 | Jun 1996 | EP |
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0 690 457 | Dec 1999 | EP |
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0 989 614 | Mar 2000 | EP |
1 052 594 | Nov 2000 | EP |
1 065 725 | Jan 2001 | EP |
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1 083 775 | Mar 2001 | EP |
1 102 335 | May 2001 | EP |
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1 113 502 | Jul 2001 | EP |
1 134 694 | Sep 2001 | EP |
1 170 851 | Jan 2002 | EP |
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1 237 207 | Sep 2002 | EP |
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362065477 | Mar 1987 | JP |
63205943 | Aug 1988 | JP |
01169942 | Jul 1989 | JP |
2969184 | Dec 1991 | JP |
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05152560 | Jun 1993 | JP |
05259434 | Oct 1993 | JP |
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WO 9316491 | Aug 1993 | WO |
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WO 9506240 | Mar 1995 | WO |
WO 9531831 | Nov 1995 | WO |
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WO 9910769 | Mar 1999 | WO |
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Number | Date | Country | |
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20120057311 A9 | Mar 2012 | US |