This disclosure relates generally to a method and apparatus for wrapping a load, and more particularly, to a method and apparatus for holding packaging material during the wrapping process.
Loads have been wrapped with packaging material by securing a leading end portion of the packaging material to the load or a turntable clamp, dispensing the packaging material, and providing relative rotation between the load and a packaging material dispenser to cause the load to be enveloped by the packaging material. The relative rotation can be provided several different ways. Either the load can be rotated on a turntable, or the dispenser can be rotated around the stationary load. Wrapping usually employs a web of packaging material as the packaging material.
Semi-automatic wrapping machinery requires the operator to attach a leading end portion of the packaging material to the load. This is typically accomplished by collapsing the leading end portion into a rope, then inserting the rope between the layers of the load or tying the end of the packaging material to the edge of the supporting wood pallet or any suitable outcropping on the load. This attachment must be relatively strong since it provides the resistance to pulling the packaging material from the packaging material dispenser during the initiation of the relative rotation between the load and the packaging material dispenser. The attachment or tying of the packaging material makes packaging material removal more difficult after the load has been shipped to its destination.
Automatic wrapping machines typically use packaging material clamps that grip the packaging material web between two opposed surfaces and use electrical or pneumatic actuators to open and close the clamps. Such packaging material clamps create a “tenting” effect during wrapping due to the distance between the clamp and the load during wrapping, resulting in wasted packaging material and loosely wrapped loads. Such clamps are expensive and may require costly maintenance for the electrical and mechanical actuators.
Other machines have used a vacuum device that uses suction to hold the packaging material. This arrangement grips the packaging material, but requires that the packaging material be placed in a flat manner against the vacuum device in order for the vacuum device to provide its full gripping force on the packaging material. Also, the vacuum device may damage the packaging material if the suction generated is too high, while the packaging material may be pulled off the vacuum device if the suction is too low. Furthermore, the vacuum device may have difficulty gripping a roped portion of the packaging material, where the strength of the packaging material is concentrated.
In light of these drawbacks, there is a need for a method and apparatus for wrapping a load with packaging material that operates as effectively as those previously developed but which can be manufactured at a lower cost.
According to one aspect of the disclosure, an apparatus for clamping packaging material is provided. The apparatus may include a packaging material holder. The packaging material holder may include a first jaw, and a second jaw, opposing the first jaw. The packaging material holder may also include a jaw opening between the first and second jaws, configured to receive a portion of packaging material. The apparatus may also include a packaging material insertion tool configured to insert the portion of packaging material into the jaw opening for clamping.
According to another aspect of the disclosure, an apparatus for automatically positioning a leading end portion of a length of packaging material proximate a load is provided. The apparatus may include a packaging material holder including a jaw opening configured to receive the leading end portion. The apparatus may also include an insertion tool configured to insert the leading end portion into the jaw opening for clamping. The apparatus may further include a support arm configured to movably support the packaging material holder and allow movement of the packaging material holder toward the load to position the leading end portion proximate the load.
According to another aspect of the disclosure, an apparatus for automatically positioning a leading end portion of a length of packaging material proximate a load may include a packaging material holder including an opening. The packaging material holder may be mounted for linear travel in a direction transverse to a longitudinal axis of a conveyor for supporting the load. The apparatus may also include a finishing assembly configured for substantially linear travel. The finishing assembly may include a cutting assembly for cutting the packaging material to form a new leading end portion and a new tail end portion, a wipedown assembly configured to press the new tail end portion against the wrapped load, and an insertion tool configured to insert the new leading end portion into the opening of the packaging material holder.
According to another aspect of the disclosure, a method for automatically connecting a leading end portion of a length of packaging material to a load is provided. The method may include moving a packaging material holder clamping a leading end of the packaging material between jaws adjacent to a side of the load. The method may also include overwrapping the leading end. The method may further include releasing the overwrapped leading end. The method may further include automatically inserting a new leading end between the jaws with an insertion tool at an end of a wrapping cycle.
According to another aspect of the disclosure, a method for automatically clamping a leading end portion of a length of packaging material is provided. The method may include cutting a length of film extending from a corner of a wrapped load to a packaging material dispenser to form a leading end portion of packaging material extending from the packaging material in the packaging material dispenser, and a tail end portion extending to the wrapped load. The method may also include actuating an insertion tool to insert the leading end portion into a packaging material holder, and clamping the leading end portion with the packaging material holder.
According to another aspect of the disclosure, a method for wrapping a load with packaging material, is provided. The method may include positioning the load on a load support surface, pressurizing at least one inflatable bladder to engage the leading end portion within a packaging material holder, and moving the packaging material holder toward the load. The method may also include providing relative rotation between a packaging material dispenser and the load to wrap the packaging material around the load and the packaging material holder. The method may further include depressurizing the at least one inflatable bladder to release the leading end portion, and rotating the packaging material holder relative to the layers of packaging material wrapped around the load to move the packaging material holder away from the load.
According to another aspect of the disclosure, a method for wrapping a load with packaging material, is provided. The method may include positioning a leading end of film in a restricted jaw opening of a packaging material holder, and pressurizing at least one portion of the packaging material holder to fix the leading end relative to the restricted jaw opening. The method may also include wrapping packaging material around the load and the packaging material holder holding the leading end, and depressurizing the at least one portion of the packaging material holder to release the leading end.
According to yet another aspect of the disclosure, an apparatus for wrapping a load with packaging material is provided. The apparatus may include a packaging material holder. The packaging material holder may include a first jaw, a second jaw, opposing the first jaw, and a jaw opening between the first and second jaws. The jaw opening may be configured to receive a portion of packaging material. The apparatus may also include an assembly configured to engage the packaging material and insert the portion of packaging material into the jaw opening for clamping.
According to yet another aspect of the disclosure, a method for automatically clamping packaging material is provided. The method may include engaging at least a portion of a length of packaging material extending from a corner of a wrapped load to a packaging material dispenser with an assembly. The method may also include moving the engaged packaging material into a jaw opening between a first jaw and a second jaw of a packaging material holder. The method may also include clamping the engaged packaging material in the jaw opening of the packaging material holder
According to yet another aspect of the disclosure, an apparatus for wrapping a load with packaging material is provided. The apparatus may include a packaging material holder. The packaging material holder may include a first inflatable element and a second inflatable element. The apparatus may also include an element configured to position packaging material between the first and second inflatable elements.
According to yet another aspect of the present disclosure, an apparatus for wrapping a load with packaging material is provided. The apparatus may include a packaging material holder. The packaging material holder may include a substantially rigid element including an opening, and at least one inflatable element configured to at least partially fill the opening. The apparatus may include an element configured to position packaging material in the opening.
According to yet another aspect of the present disclosure, a method for wrapping a load with packaging material is provided. The method may include pressurizing at least one inflatable element to at least partially fill an opening in a rigid element of a packaging material holder, and positioning packaging material in the opening with an element.
Additional aspects and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the disclosure. The aspects and other advantages of the disclosure will be realized and attained by the method and apparatus particularly pointed out in the written description and claims as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed. The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of the specification, illustrate an embodiment of the disclosure, and together with the description serve to explain the principles of the disclosure.
Reference will now be made to the present embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
According to the disclosure, and as shown in
The dimensions of restricted jaw opening 136 may vary depending on several factors. For example, restricted jaw opening 136 may be large enough so that a length of packaging material 104 that is received therein does not slip out of restricted jaw opening 136 during clamping. Restricted jaw opening 136 may be small enough so that packaging material holder 106, which defines restricted jaw opening 136, can be moved away from load 102, and out from underneath one or more layers of packaging material 104 wrapped around load 102, without damaging the wrapped layers of packaging material 104, damaging the integrity of load 102, and/or requiring excessive forces to accomplish the movement. It is contemplated that in one embodiment, the space defined by restricted jaw opening 136 may have a height of between approximately 5 inches to 8 inches, for receiving a length of approximately 5 inches to 8 inches of a 20 inch to 30 inch tall web of packaging material 104. That 5 inches to 8 inches of packaging material 104 may include a roped or rolled cable portion of packaging material 104. It should be understood that when packaging material 104 is manually gathered or collapsed, the entire manually gathered or collapsed portion of packaging material 104 may be received in restricted jaw opening 136. It is also contemplated that in one embodiment, the spaced defined by restricted jaw opening 136 may have a width of approximately ⅝ inches.
First jaw 110 may include a first inflatable bladder 114 mounted thereon. For example, first inflatable bladder 114 may be mounted in a recess, opening, or channel 116 in first jaw 110. In one embodiment, channel 116 may extend longitudinally along first jaw 110, and away from restricted jaw opening 136. Alternatively, first inflatable bladder 114 may be mounted on or attached to a surface of first jaw 110 without being received in a channel. For example, first inflatable bladder 114 may be attached to first jaw 110 with an adhesive, bracket, and/or any other suitable attachment member.
Second jaw 112 may include a second inflatable bladder 118 mounted thereon. For example, second inflatable bladder 118 may be mounted in a recess, opening, or channel 120 in second jaw 112. In one embodiment, channel 120 may extend longitudinally along second jaw 112, and away from restricted jaw opening 136. Alternatively, second inflatable bladder 118 may be mounted on or attached to a surface of second jaw 112 without being received in a channel. For example, second inflatable bladder 118 may be attached to second jaw 112 with an adhesive, bracket, and/or any other suitable attachment member.
First inflatable bladder 114 and second inflatable bladder 118 may be made of an elastomeric material, such as, for example, rubber. First inflatable bladder 114 and second inflatable bladder 118 may extend longitudinally in substantially the same direction as first jaw 110 and second jaw 112, respectively, and each may have a height of between approximately 5 inches to 8 inches. Other size bladders may be used depending upon the size of the space defined by restricted jaw opening 136, and the number of bladders used to occlude the opening.
When pressurized, first inflatable bladder 114 may expand toward second jaw 112, and pressurization of second inflatable bladder 118 may cause it to expand toward first jaw 110. As the first and second inflatable bladders 114 and 118 expand, they may fill or occlude the spaced defined by restricted jaw opening 136. Thus, when first inflatable bladder 114 and second inflatable bladder 118 are pressurized, their opposing surfaces may come into contact with one another in restricted jaw opening 136, and these opposing surfaces may exert a clamping or trapping force on leading end 108 of packaging material 104 when it is positioned in restricted jaw opening 136 while bladders 114 and 118 are pressurized. The clamping or trapping force is a product of bladders 114 and 118 being expanded within restricted jaw opening 136. Since the space between jaws 110 and 112 is fixed, bladders 114 and 118 push against one another, eliminating the space between bladders 114 and 118.
Leading end 108 of packaging material 104 may include a portion of packaging material 104 that has been manually gathered or collapsed, and that gathered or collapsed portion may include substantially the entire height of packaging material 104. Alternatively, leading end 108 may include a portion of packaging material 104 that has been roped or rolled into a cable, and another portion that has a non-roped or rolled configuration. It is contemplated that in one embodiment, the roped or rolled portion of packaging material 104 may include between approximately 3 to 5 inches of packaging material 104. However, it is possible for any suitable amount of packaging material to be held within packaging material holder 106—e.g., any amount that will allow packaging material holder 106 to hold packaging material 104 during start-up of a wrapping cycle.
First inflatable bladder 114 and second inflatable bladder 118 are shown in the pressurized condition in
First inflatable bladder 114 and second inflatable bladder 118 are shown in a depressurized condition in
First jaw 110 and second jaw 112 may include low friction outer surfaces. The low friction outer surfaces may be made from a non-stick material, such as Teflon™, or smooth metal, to minimize any undesirable frictional engagement between the outer surfaces and packaging material 104. Additionally or alternatively, first jaw 110 and/or second jaw 112 may have low-friction panels 122 and 124, shown in
Packaging material holder 106 may include a packaging material cutter 126, shown in
To facilitate this insertion of packaging material 104, first inflatable bladder 114 and second inflatable bladder 118 may be shaped such that when pressurized, a gap exists between their upper portions, allowing a manually gathered or collapsed portion of packaging material 104 to be forced down between first inflatable bladder 114 and second inflatable bladder 118 while they are pressurized. Additionally or alternatively, top portions of first inflatable bladder 114 and second inflatable bladder 118 may be sloped to facilitate insertion of the gathered or collapsed portion, as shown in
A support arm assembly 128 may be provided for moving packaging material holder 106 toward or away from load 102, which may be positioned on a load support surface 138, such as a conveyor 140 (see
Support arm 130 may be coupled to a fluid conduit 132, as shown in
Support arm 130 may be rotatable, and as such, may move packaging material holder 106 between a position distant from load 102, near packaging material dispenser 166 (shown in
Support arm 130 may be moveable above load support surface 138. As embodied herein, load support surface 138 may include the surface that supports load 102 during the wrapping process. As shown in
Support arm 130 may swing through an arc in a horizontal plane above load support surface 138 as it moves packaging material holder 106 back and forth between the distant and near positions. Alternatively, support arm 130 may slide on top of load support surface 138 as it moves packaging material holder 106 back and forth between the distant and near positions. Movement of support arm 130 may be driven by an arm actuation assembly 142, shown in
As shown in
While in the upright position, packaging material holder 106 may hold packaging material 104 above support arm 130. Support arm 130 and packaging material holder 106 are thus arranged such that packaging material holder 106 holds the packaging material 104 away from support arm 130 so that support arm 130 does not engage the packaging material or interfere with the wrapping process. It is also contemplated that support arm assembly 128 may include a guard 164, as shown in
A packaging material dispenser 166 may be provided for dispensing packaging material 104. Packaging material dispenser 166 may dispense a sheet of packaging material 104 in a web form. Packaging material dispenser 166 may house a roll 168 of packaging material 104, and may also include one or more packaging material dispensing rollers 170 and 172. Packaging material dispensing rollers 170 and 172 may include prestretch rollers for stretching the packaging material 104 longitudinally and/or transversely, to position, dispense, and stretch packaging material 104 as it is being dispensed from roll 168. Packaging material dispenser 166 may be vertically moveable relative to load 102, in addition to being rotatable relative to load 102 in the direction indicated by arrow 174. This combination of vertical and rotating movement allows packaging material dispenser 166 to wrap packaging material 104 spirally about load 102. While stretch wrap packaging material is described here, it should be understood that various other packaging material such as non-stretch wrap, netting, strapping, banding, or tape can be used as well. Further, it should be understood that packaging material is also commonly referred to as film, web, or film web, and such terms are interchangeable with “packaging material.”
Apparatus 100 may also include a relative rotation assembly 176, in this case, a rotatable arm, as shown in
Apparatus 100 may also include means for severing packaging material 104 between load 102 and packaging material holder 106. As shown in
Apparatus 100 may further include a wipedown assembly 180, shown in
Cutting assembly 178 and/or wipedown assembly 180 may also be coupled to an insertion tool 182, also mounted on rotatable body 179. As shown in
During the end portion of the wrapping cycle, packaging material 104 may extend from a corner of load 102 to packaging material dispenser 166, as shown in
Bladders 114 and 118 may be depressurized when insertion tool 182 forces new leading end portion 108 into restricted jaw opening 136. After leading end portion 108 has been inserted, bladders 114 and 118 may be fully pressurized. It is contemplated that at full pressurization, bladders 114 and 118 may exert approximately 8 pounds of pressure on leading end portion 108. Alternatively, at least one of bladders 114 and 118 may be at least partially pressurized before or during the period where insertion tool 182 forces new leading end portion 108 into restricted jaw opening 136, such that insertion tool 182 and/or new leading end portion 108 may engage at least one of bladders 114 and 118 during insertion.
The motion of insertion tool 182 is shown in
Insertion tool 182 may have a height of between approximately 5 inches to 8 inches to insert between approximately 5 inches to 8 inches of packaging material 104 into restricted jaw opening 136. The portion of packaging material 104 inserted into restricted jaw opening 136 by insertion tool 182 may be in the form of a fold or pleat including approximately 1.25 inches of packaging material 104 widthwise. It is contemplated that under different wrapping conditions, more or less film may be gathered or pleated when inserted into packaging material holder 106.
If insertion tool 182 is a flat plate, as shown in
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
Wrapping apparatus 400 may also include a packaging material dispenser 466, with components, similar to those described with respect to
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
According to another embodiment of the present disclosure, in which similar numerals designate components similar to those shown in
Support arm 730 may be configured to swing in and opposite to the direction indicated by an arrow 734, over load support surface 738, to move packaging material holder 706 between a radially outward position (shown in
Wrapping apparatus 700 may also include a packaging material dispenser (not shown), with components, similar to those described with respect to
It is contemplated that the rotation assembly 790, including rotatable body 779 and cutting assembly 778, wipedown assembly 780, and/or insertion tool 782 may be at least partially, or completely, within a wrapping zone of wrapping apparatus 700. The wrapping zone of a wrapping apparatus may include an area circumscribed by a packaging material dispenser as the packaging material dispenser rotates relative to a load. A portion of the wrapping zone of wrapping apparatus 700 is shown in dotted line in
A method for wrapping a load according to the present disclosure will now be described. Load 102 may be conveyed onto load support surface 138. Packaging material holder 106 may be in the distant position (e.g., away from load 102), and may be held there by piston 146 acting on leg portion 150 of support arm assembly 128 as piston 146 is in its extended position, as shown in
Relative rotation assembly 176 may begin to rotate packaging material dispenser 166 in the direction of arrow 174 about load 102. As relative rotation assembly 176 begins to rotate packaging material dispenser 166, piston 146 may be retracted, allowing spring 154 and/or leading end portion 108 to exert a force upon packaging material holder 106. That force may cause rotation of packaging material holder 106 and support arm 130 above load support surface 138 in the direction of arrow 134, toward the “near” position shown in
As packaging material holder 106 reaches its near position, relative rotation assembly may continue to rotate packaging material dispenser 166 about load 102. As packaging material dispenser 166 dispenses packaging material 104 during this rotation, it may overwrap packaging material holder 106, positioned adjacent the side of load 102, with a layer or layers of packaging material (see
Once packaging material holder 106 has reached the distant position, cutting assembly 178, wipedown assembly 180, and insertion tool 182, may be actuated. Cutting assembly 178 may sever packaging material 104 that extends between load 102 and packaging material dispenser 166. Wipedown assembly 180 may press tail end portion 107 of packaging material 104 onto the layers of packaging material 104 wrapped about load 102. As shown in
With the embodiment of
With the embodiment of
Another method for wrapping a load according to the present disclosure will now be described. Load 402 may be conveyed onto load support surface 438. Packaging material holder 406 may be in the distant position (e.g., away from load 402). Leading end portion 408 of a sheet of packaging material 404 may be positioned between and engaged by first inflatable bladder 414 and second inflatable bladder 418, and thus, may be clamped in restricted jaw opening 436 of packaging material holder 406, as shown in
Relative rotation assembly 476 may begin to rotate packaging material dispenser 466 in the direction of arrow 474 about load 402. As relative rotation assembly 476 begins to rotate packaging material dispenser 466, packaging material holder 406 and support arm 430 may be moved above load support surface 438 toward the direction indicated by arrow 434, toward the “near” position shown in FIG. 15. In one embodiment, packaging material holder 406 may continue to move toward load 402 until it touches a side of load 402, whereupon its radially inward movement may stop.
As packaging material holder 406 reaches its near position, relative rotation assembly may continue to rotate packaging material dispenser 466 about load 402. As packaging material dispenser 466 dispenses packaging material 404 during this rotation, it may overwrap packaging material holder 406, positioned adjacent the side of load 402, with a layer or layers of packaging material (see
Packaging material holder 406 may travel back to the “near” position adjacent to or abutting load 402 in the direction indicated by arrow 434 during the final rotation of packaging material dispenser 466 relative to load 402. This is shown in
Since packaging material holder 406 is in the near position during cutting, wipedown, and clamping, the length of a tail end portion of packaging material 404 may be minimized. Additionally, as the distance between packaging material holder 406 and load 402 becomes larger, the stress on the layers of packaging material 404 used to overwrap packaging material holder 406 increases. If the stress is too high, packaging material 404 may tear, or the containment force exerted on load by packaging material 404 may decrease. However, if, as in this embodiment, the distance between packaging material holder 406 and load 402 is made smaller, such as when packaging material holder 406 comes near or touches the side of load 402, the stress on the layers of packaging material 404 overwrapping packaging material holder 406 may be reduced.
With the embodiment of
With the embodiment of
A method for wrapping load 702 with the embodiment shown in
A relative rotation assembly (not shown) may begin to rotate a packaging material dispenser (not shown) in the direction of arrow 774 about load 702. As the relative rotation assembly begins to rotate the packaging material dispenser, actuation assembly 742 may rotate packaging material holder 706 and support arm 730 above load support surface 738 in the direction of arrow 734, toward the near position as shown in
As packaging material holder 706 reaches its near position, the relative rotation assembly may continue to rotate the packaging material dispenser about load 702. As packaging material dispenser dispenses packaging material 704 during this rotation, it may overwrap packaging material holder 706 with a layer or layers of packaging material, similar to what is shown in
Once packaging material holder 706 has reached the distant position, rotatable body 779, cutting assembly 778, wipedown assembly 780, and insertion tool 782, may be actuated. Rotatable body 779, cutting assembly 778, wipedown assembly 780, and insertion tool 782 may rotate from the substantially horizontal position shown in
Cutting assembly 778 may sever packaging material 704 that extends between load 702 and the packaging material dispenser to form a new leading end portion 708 that is held by packaging material holder 706. When in the substantially vertical position, wipedown assembly 780 may rotate from the position shown in
The disclosed wrapping apparatuses and methods may be useful for wrapping loads, and in particular, for the automatic wrapping of loads. The use of the above-described pneumatic packaging material clamps to grip packaging material, and the use of the above-described support arm assemblies, provide clamping in a robust manner, in that they may clamp packaging material in a wide variety of conditions. Furthermore, they may provide clamping without producing an undesirable amount of “tenting” (i.e., stretching of packaging material overwrapping the packaging material clamps) during wrapping, due to the distance between the clamps and their respective loads during wrapping. This may result in a reduction in wasted packaging material, and a reduction in the number of loosely wrapped loads. Furthermore, the pneumatic packaging material clamps require few components. As such, they are relatively inexpensive, and may be easy to maintain. In addition, it is contemplated that wrapping apparatuses without clamps, or those with known clamps, may be retrofitted to include the above-described pneumatic packaging material clamps.
Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
This application is a continuation of U.S. patent application Ser. No. 12/473,191 filed May 27, 2009 (Pending), which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/071,964 filed May 28, 2008, the disclosures of which are expressly incorporated by reference herein in their entirety.
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Number | Date | Country |
---|---|---|
2717647 | Nov 1978 | DE |
3820048 | Dec 1989 | DE |
0430902 | Jun 1991 | EP |
0517502 | Dec 1992 | EP |
0583167 | Feb 1994 | EP |
0630813 | Dec 1994 | EP |
0671324 | Sep 1995 | EP |
0867368 | Sep 1998 | EP |
2493802 | May 1982 | FR |
2601612 | Jan 1988 | FR |
2601612 | Jan 1988 | FR |
2639906 | Jun 1990 | FR |
2014107 | Aug 1979 | GB |
2216489 | Oct 1989 | GB |
9906279 | Feb 1999 | WO |
Entry |
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Canadian Intellectual Property Office, Office Action, Apr. 2, 2015, pp. 1-4, Canadian Intellectual Property Office, Gatineau, Quebec, Canada. |
Number | Date | Country | |
---|---|---|---|
20140215968 A1 | Aug 2014 | US |
Number | Date | Country | |
---|---|---|---|
61071964 | May 2008 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 12473191 | May 2009 | US |
Child | 14249950 | US |