(19) TZZ __T

(11) EP 2 415 664 B1

(12) EUROPEAN PATENT SPECIFICATION

(45) Date of publication and mention (51) Int Cl.: of the grant of the patent: B64C 1/40 (2006.01) B64C 7/00 (2006.01) 15.01.2014 Bulletin 2014/03 B64C 1/26 (2006.01)

(21) Application number: 11176204.3

(22) Date of filing: 01.08.2011

(54) -to-body fairing with spray-on foam Flügel-Rumpf-Flugzeugverkleidung mit aufsprühbarem Schaum Carénage aile/ d’avion avec mousse pulvérisable

(84) Designated Contracting States: • Hoffman, Herbert L. AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Seattle, WA Washington 98105 (US) GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO • Poling, Hugh W. PL PT RO RS SE SI SK SM TR Seattle, WA Washington 98125 (US)

(30) Priority: 04.08.2010 US 850036 (74) Representative: Boult Wade Tennant Verulam Gardens (43) Date of publication of application: 70 Gray’s Inn Road 08.02.2012 Bulletin 2012/06 London WC1X 8BT (GB)

(73) Proprietor: The Boeing Company (56) References cited: Chicago, IL 60606-2016 (US) EP-A1- 0 435 650 US-A- 5 985 362 US-A1- 2006 145 006 US-A1- 2008 149 767 (72) Inventors: US-A1- 2009 184 200 US-B1- 6 722 611 • Lin, Juhn-Shyue Renton, WA Washington 98055 (US)

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 2 415 664 B1

Printed by Jouve, 75001 PARIS (FR) 1 EP 2 415 664 B1 2

Description foam. FIG. 1A is a cross-sectional view of a portion of a TECHNICAL FIELD fairing panel of the wing to body fairing, with a spray- on foam layer provided on an interior panel surface [0001] The disclosure generally relates to wing to body 5 of the fairing panel. fairings in aircraft. More particularly, the disclosure re- FIG. 2 is a perspective view of a portion of a fairing lates to a wing to body fairing with foam which reduces panel of the wing to body fairing, with a spray-on vibration, fatigue and cabin noise in an aircraft and a foam layer deposited on the fairing panel. method of reducing cabin noise or reducing panel vibra- FIG. 2A is a cross-sectional view of a portion of a tion in an aircraft. 10 fairing panel of the wing to body fairing, with insula- tion pins extending from the interior panel surface BACKGROUND and a spray- on foam layer provided on the insulation pins and the interior panel surface of the fairing pan- [0002] In modem commercial aircraft, heavy insulation el. blankets may be placed on wing to body fairings to reduce 15 FIG. 3 is a flow diagram of an illustrative embodiment cabin noise to acceptable levels by damping vibration of of a method of reducing cabin noise or reducing pan- the wing to body fairing panels. However, insulation blan- el vibration in an aircraft. kets may contribute excessive weight to the fairings. FIG. 4 is a flow diagram of an aircraft production and Moreover, insulation blankets may not be effective in service methodology. damping vibration of the fairing panels during operation 20 FIG. 5 is a block diagram of an aircraft. of the aircraft. [0003] Therefore, a wing to body fairing with foam DETAILED DESCRIPTION which reduces vibration, fatigue and cabin noise in an aircraft and a method of reducing cabin noise or reducing [0009] The following detailed description is merely ex- panel vibration in an aircraft are needed. 25 emplary in nature and is not intended to limit the de- scribed embodiments or the application and uses of the SUMMARY described embodiments. As used herein, the word "ex- emplary" or "illustrative" means "serving as an example, [0004] The disclosure is generally directed to a fairing instance, or illustration." Any implementation described with spray-on foam, which reduces vibration, fatigue and 30 herein as "exemplary" or "illustrative" is not necessarily cabin noise in an aircraft. An illustrative embodiment of to be construed as preferred or advantageous over other the fairing includes a fairing body having a fairing interior implementations. All of the implementations described and an interior surface and an insulating foam layer pro- below are exemplary implementations provided to ena- vided on the interior surface of the fairing body. ble persons skilled in the art to practice the disclosure [0005] US 2009/0184200 A1 discloses such a fairing 35 and are not intended to limit the scope of the appended with the features of the preamble of claim 1. claims. Furthermore, there is no intention to be bound by [0006] The disclosure is further generally directed to a any expressed or implied theory presented in the pre- method, not claimed, of reducing cabin noise or reducing ceding technical field, background, brief summary or the panel vibration in an aircraft. An illustrative embodiment following detailed description. of the method, not claimed, includes providing a fairing 40 [0010] Referring initially to FIGS. 1-2A, an illustrative having a fairing body with an interior surface, providing embodiment of the wing to body fairing with foam, here- an insulating foam, applying the spray- on insulation foam inafterfairing, isgenerally indicated by reference numeral to the interior surface of the fairing body and installing 1. In some embodiments, the fairing 1 may be a wing to the fairing on an aircraft. body fairing (WTBF) of a commercial aircraft, for example [0007] In some embodiments, not claimed, the method 45 and without limitation. The fairing 1 may include a fairing of reducing cabin noise or reducing panel vibration in an body 1a having a fairing interior 5. In some embodiments, aircraft may include providing a fairing having a fairing the fairing body 1a may have multiple fairing panels 2 body including a plurality of fairing panels with an interior which are assembled into the fairing body 1a according surface; providing a spray-on insulation foam; spraying to the knowledge of those skilled in the art. Each fairing the spray-on insulation foam on the interior surface of 50 panel 2 may have an exterior panel surface 3 which gen- the fairing body; and installing the fairing on an aircraft. erally faces away from the fairing interior 5 of the fairing body 1a and an interior panel surface 4 which generally BRIEF DESCRIPTION OF THE DRAWINGS faces the fairing interior 5 of the fairing body 1a. The fairing body 1a may have a fairing edge 6. [0008] 55 [0011] Referring to figure 1A, at least one insulation foam layer 8 may be sprayed on the interior panel sur- FIG. 1 is a bottom perspective view of an illustrative faces 4 of the fairing panels 2 of the fairing body 1a. In embodiment of a wing to body fairing with spray- on some embodiments, the insulation foam layer 8 may be

2 3 EP 2 415 664 B1 4 closed cell polyurethane spray- on insulation foam which the art. During operation of the aircraft, the insulation is sprayed onto the interior panel surfaces 4 of the fairing foam layer 8 may reduce wing-to-body fairing vibration, panels 2. A polyurethane foam which is suitable for the fatigue and cabin noise by dissipating energy via a damp- spray-oninsulation foamlayer 8is TIGER FOAM@ which ing and mass effect. can be obtained from Commercial Thermal Solutions, 5 [0015] Referring next to FIG. 3, a flow diagram 300 of Inc. of Spring Lake, NJ (www.tigerfoam.com). In some an illustrative embodiment of a method of reducing cabin embodiments, the insulation foam layer 8 may be applied noise or reducing panel vibration in an aircraft is shown. to the interior panel surfaces 4 of the fairing panels 2 In block 302, a foam may be provided. In some embod- usingan alternativeapplication method. Forexample and iments, the foam may be a closed cell polyurethane without limitation, the insulation foam layer 8 may be a 10 spray-on insulation foam, for example and without limi- prepared foam layer which is applied to the interior panel tation. A polyurethane foam which is suitable for the surfaces 4 using adhesive and pressure. The insulation spray-on foam layer is TIGER FOAM@ which can be foam layer 8 may be contiguously applied to the interior obtained from Commercial Thermal Solutions, Inc. of panel surfaces 4 of the fairing panels 2. Therefore, the Spring Lake, NJ (www.tigerfoam.com). In some embod- insulation foam layer 8 may be continuous generally15 iments, the foam may be a prepared foam layer. In block throughout the entire surface area which is represented 304, a wing to body fairing having wing to body fairing by the interior panel surfaces 4 of the fairing panels 2. panels may be provided. In block 306, the foam may be [0012] As shown in FIG. 1A, in some embodiments the applied to the interior surfaces of the wing to body panels insulation foam layer 8 may have a core foam portion 9. of the fairing by spraying or by application using adhesive A tapered foam portion 10 may extend outwardly from 20 and pressure to form an insulation foam layer on the in- the edges of the core foam portion 9 toward the fairing terior surfaces of the wing to body panels. In some em- edge 6 of the fairing body 1a. Taper is used to control bodiments, the insulation foam layer may have a core weight and enhance handling durability. Edges are not foam portion and a tapered foam portion which extends so important relative to center portion for foam benefit. from the edges of the core foam portion. In block 308, A fairing flange 2a may extend between the tapered foam 25 the fairing may be installed on an aircraft. During opera- portion 10 and the fairing edge 6. The fairing flange 2a tion of the aircraft, the insulation foam layer may reduce may facilitate attachment of the fairing body 1a to the wing-to-body fairing vibration, fatigue and cabin noise by structural elements (not shown) of an aircraft (not shown) dissipating energy via a damping effect. according to the knowledge of those skilled in the art. [0016] In block 304a, in some embodiments insulation The insulation foam layer 8 may be omitted from the fair- 30 pins may be provided. In block 304b, the insulation pins ing flange 2a. The insulation foam layer 8, which is a may be installed on the interior surfaces of the wing body closed cell polyurethane foam, may have a density of panels of the fairing prior to application of the foam on about 28, 0323109045 kg/m 3 (1.75 lb/ft3), or a density in the interior surfaces of the wing to body fairing panels in the range between about 24,027695061 kg/m3 - (1.50 block 306. The insulation pins may ensure that the insu- and about 2.0 lb/ft3). In some embodiments, the core 35 lation foam layer remains on each fairing panel through- foam portion 9 of the insulation foam layer 8 may have out the service life of the fairing panels. a thickness of about 5,08 cm (2 inches). The thickness [0017] Referring next to FIGS. 4 and 5, embodiments of the tapered foam portion 10 may decrease from about of the disclosure may be used in the context of an aircraft 5,08 cm (2 inches to 0 inches) from the core foam portion manufacturing and service method 78 as shown in FIG. 9 to the fairing flange 2a. The main feature is to eliminate 40 4 and an aircraft 94 as shown in FIG. 5. During pre- corners that may interfere with the handling of the panel production, exemplary method 78 may include specifica- (s). Spray on foam insulation is typically not uniform in tion and design 80 of the aircraft 94 and material pro- thickness upon application. Secondary machining to a curement 82. During production, component and sub- specific thickness dimension is typically needed. In one assembly manufacturing 84 and system integration 86 embodiment the spray on foam may not be machined 45 of the aircraft 94 takes place. Thereafter, the aircraft 94 and the resulting thickness may range from 1,27 cm - may go through certification and delivery 88 in order to 7,62 cm (0.5 to 3 inches). be placed in service 90. While in service by a customer, [0013] As shown in FIG. 2A, in some applications in- the aircraft 94 may be scheduled for routine maintenance sulation pins 12 may be installed on the interior panel and service 92 (which may also include modification, surface 4 of each fairing panel 2. The insulation pins 12 50 reconfiguration, refurbishment, and so on). may ensure that the insulation foam layer 8 remains on [0018] Each of the processes of method 78 may be each fairing panel 2 throughout the service life of the performed or carried out by a system integrator, a third fairing panels 2 while also ensuring the transfer of vibra- party, and/or an operator (e.g., a customer). For the pur- tion energy from panel to foam. poses of this description, a system integrator may include [0014] After the insulation foam layer 8 is applied to 55 without limitation any number of aircraft manufacturers the interior panel surfaces 4 of the fairing panels 2, the and major-system subcontractors; a third party may in- fairing 1 may be installed on a commercial aircraft (not clude without limitation any number of vendors, subcon- shown) according to the knowledge of those skilled in tractors,and suppliers; and anoperator may be an airline,

3 5 EP 2 415 664 B1 6 leasing company, military entity, service organization, er having a core foam portion and a tapered foam portion and so on. extending from said core foam portion on said interior [0019] Afurther embodiment of method78 may include surface of said fairing body comprises spraying a spray- receiving an assembled aircraft having fairing. The air- on insulation foam layer having a core foam portion with craft may further include a wing to body faring. The air- 5 a thickness of about 5,08 cm (2 inches) and a tapered craft may further have a wing to body fairing where lo- foam portion extending from said core foam portion with cated aft of a wheel well. The aircraft may further have a thickness of about 0 cm - 5,08 cm (0 inches to about 2 a wing to body fairing where located aft of a wheel well inches) on said interior surface of said fairing body. The where the wheel well include a opening that exposes the method may further comprise providing a fairing having interior of the wheel well to the exterior of the aircraft. 10 a fairing body with an interior surface comprises providing The method may include removing a panel of the faring a fairing having a fairing body and a fairing flange having and applying a foam insulation to an interior surface of a fairing edge extending from said fairing body and the panel. The method may further include machining wherein said spraying said spray-on insulation foam on the foam to a desired thickness and shape. The method said interior surface of said fairing body comprises omit- may further include a spraying on a foam insulation ma- 15 ting said spray- on insulation foam from said fairing flange terial that bonds to the surface of the panel. from said tapered foam portion to said fairing edge. [0020] As shown in FIG. 5, the aircraft 94 produced by [0023] A fairing embodied may comprise a fairing body exemplary method 78 may include an 98 with a having a fairing interior and an interior surface; and an plurality of systems 96 and an interior 100. Examples of insulation foam layer provided on said interior surface of high-level systems 96 include one or more of a propulsion 20 said fairing body. The fairing may further comprise a fair- system 102, an electrical system 104, a hydraulic system ing body comprises a plurality of fairing panels each hav- 106, and an environmental system 108. Any number of ing an interior panel surface, and wherein said insulation other systems may be included. Although an aerospace foam layer is provided on said interior panel surface of example is shown, the principles of the invention may be said plurality of fairing panels. The fairing may further applied to other industries, such as the automotive in- 25 comprise an insulation foam layer comprising a closed dustry. cell polyurethane foam layer. The fairing may further [0021] The apparatus embodied herein may be em- comprise a wing to body fairing. The fairing may further ployed during any one or more of the stages of the pro- comprise an insulation foam layer comprising a core duction and service method 78. For example, compo- foam portion and a tapered foam portion extending from nents or subassemblies corresponding to production30 said core foam portion. The fairing may further comprise process 84 may be fabricated or manufactured in a man- a core foam portion having a thickness of about 5,08 cm ner similar to components or subassemblies produced (2 inches). The fairing may further comprise a tapered while the aircraft 94 is in service. Also one or more ap- foam portion having a thickness of about 0 cm - 5,08 cm paratus embodiments may be utilized during the produc- (0 inches to about 2 inches). The fairing may further com- tion stages 84 and 86, for example, by substantially ex- 35 prise a fairing flange having a fairing edge extending from pediting assembly of or reducing the cost of an aircraft said fairing body and wherein said spray-on insulation 94. Similarly, one or more apparatus embodiments may foam layer is omitted from said fairing flange from said be utilized while the aircraft 94 is in service, for example tapered foam portion to said fairing edge. and without limitation, to maintenance and service 92. [0024] Although the embodiments of this disclosure [0022] A method of reducing cabin noise in an aircraft 40 have been described with respect to certain exemplary may comprise providing a fairing having a fairing body embodiments, it is to be understood that the specific em- with an interior surface, applying an insulation foam to bodiments are for purposes of illustration and not limita- the interior surface of the fairing body, and the method tion, as othervariations will occur to those ofskill in the art. further comprising removing said fairing from an assem- bled aircraft. The method may further comprise, installing 45 said fairing having the applied insulation foam on said Claims aircraft. The method may further comprise providing in- sulation foam comprises providing a spray-on poly- 1. A wing to body aircraft fairing (1), comprising: urethane insulation foam. The method may further com- prise providing a spray-on polyurethane insulation foam 50 a fairing body (1 a) including a plurality of fairing comprises providing a closed- cell spray-on polyurethane panels, each of the plurality of fairing panels (2) insulation foam. The method may further comprise ap- having: plying said insulation foam to said interior surface of said fairing body comprises spraying a spray-on insulation an interior panel surface (4); foam layer having a core foam portion and a tapered55 a spray-on insulation foam layer (8) contig- foam portion extending from said core foam portion on uously provided on the interior panel sur- said interior surface of said fairing body. The method may face, characterized by the insulation foam further comprise spraying a spray- on insulation foam lay- layer being continuous generally through-

4 7 EP 2 415 664 B1 8

out the entire interior panel surface and Verkleidungspanele (2) aufweist: comprising a core foam portion (9) and a tapered foam portion (10), the tapered foam eine innere Paneloberfläche (4); portion extending from the core foam por- eine aufgespritzte Schaumschicht (8), die tion and being tapered toward an edge (6) 5 zusammenhängend an der inneren Pane- of the fairing panel; and loberfläche aufgebracht ist, gekennzeich- a fairing flange (2a) extending between the net dadurch, dass die Isolierschaum- tapered foam portion and the edge of the schicht im Allgemeinen über die gesamte fairing panel, the spray-on insulation foam innere Paneloberfläche kontinuierlich ist layer being omitted from the fairing flange. 10 und einen Kernschaumbereich (9) und ei- nen abgeschrägten Schaumbereich (10) 2. The wing to body aircraft fairing of claim 1 wherein aufweist, wobei sich der abgeschrägte the insulation foam layer comprises a closed cell Schaumbereich von dem Kernschaumbe- polyurethane foam layer. reich weg erstreckt und in Richtung einer 15 Kante (6) des Verkleidungspanels abge- 3. The wing to body aircraft fairing of claim 1 wherein schrägt ist; und the core foam portion has a thickness that ranges einen Verkleidungsflansch (2a), der sich from 1,27 cm - 7,62 cm. zwischen dem abgeschrägten Schaumbe- reich und der Kante des Verkleidungspa- 4. The wing to body aircraft fairing of claim 1 wherein 20 nels erstreckt, wobei die aufgespritzte Iso- the core foam portion has a thickness of about 5,08 lierschaumschicht an dem Verkleidungs- cm and wherein said tapered foam portion has a flansch weggelassen ist. thickness of about 0 cm to about 5,08 cm. 2. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- 5. The wing to body aircraft fairing of claim 1 further 25 spruch 1, wobei die Isolierschaumschicht eine ge- comprising a plurality of insulation pins extending schlossenzellige Polyurethanschaumschicht um- from the interior panel surface. fasst.

6. The wing to body aircraft fairing of claim 5, wherein 3. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- the plurality of insulation pins are configured to retain 30 spruch 1, wobei der Kernschaumbereich eine Dicke the insulation foam layer on the fairing panel and to im Bereich von 1,27 cm bis 7,62 cm aufweist. transfer vibration energy from the fairing panel to the insulation foam layer. 4. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- spruch 1, wobei der Kernschaumbereich eine Dicke 7. The wing to body aircraft fairing of claim 6 wherein 35 von etwa 5,08 cm aufweist und wobei der abge- the insulation foam layer 8 comprises a closed cell schrägte Schaumbereich eine Dicke im Bereich von polyurethane foam layer. etwa 0 bis 5,08 cm aufweist.

8. The wing to body aircraft fairing of claim 6 wherein 5. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- the core foam portion has a thickness that ranges 40 spruch 1, die ferner mehrere Isolationsstifte auf- from 1,27 cm to 7,62 cm. weist, die sich von der inneren Verkleidungsoberflä- che erstrecken. 9. The wing to body aircraft fairing of claim 6 wherein the core foam portion has a thickness of about 5,08 6. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- cm and wherein said tapered foam portion has a45 spruch 5, wobei die mehreren Isolationsstifte aus- thickness of about 0 cm to about 5,08 cm. gebildet sind, den Isolierschaumbereich an dem Ver- kleidungspanel zu halten und Schwingungsenergie 10. Anaircraft comprising the wing tobody aircraft fairing von dem Verkleidungspanel auf die Isolierschaum- of any of the preceding claims. schicht zu übertragen. 50 7. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- Patentansprüche spruch 6, wobei die Isolierschaumschicht 8 eine ge- schlossenzellige Polyurethanschaumschicht um- 1. Flügel-zu-Rumpf-Luftfahrzeugverkleidung (1), die fasst. aufweist: 55 8. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- einen Verkleidungskorpus (1a), der mehrere spruch 6, wobei der Kernschaumbereich eine Dicke Verkleidungspanele umfasst, wobei jedes der im Bereich von 1,27 cm bis 7,62 cm aufweist.

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9. Flügel-zu-Rumpf-Luftfahrzeugverkleidung nach An- 6. Carénage d’aéronef aile/fuselage selon la revendi- spruch 6, wobei der Kernschaumbereich eine Dicke cation 5, dans lequel la pluralité des axes d’isolation von etwa 5,08 cm aufweist und wobei der abge- sont configurés pour retenir la couche de mousse schrägte Schaumbereich eine Dicke im Bereich von d’isolation sur le panneau de carénage et pour trans- etwa 0 bis 5,08 cm aufweist. 5 férer l’énergie de vibration du panneau de carénage à la couche de mousse d’isolation. 10. Luftfahrzeug, das eine Flügel-zu-Rumpf-Luftfahr- zeugverkleidung nach einem der vorhergehenden 7. Carénage d’aéronef aile/fuselage selon la revendi- Ansprüche aufweist. cation 6, dans lequel la couche d’isolation en mousse 10 8 comprend une couche de mousse de polyuréthane à alvéoles fermés. Revendications 8. Carénage d’aéronef aile/fuselage selon la revendi- 1. Carénage d’aéronef aile/fuselage (1), comprenant : cation 6, dans lequel la portion de mousse centrale 15 a une épaisseur qui est dans la plage de 1,27 cm à un corps de carénage (1a) incluant une pluralité 7,62 cm. de panneauxde carénage, chacun de la pluralité de panneaux de carénage (2) ayant : 9. Carénage d’aéronef aile/fuselage selon la revendi- cation 6, dans lequel la portion de mousse centrale une surface de panneau intérieure (4) ; 20 a une épaisseur d’environ 5,08 cm, et où ladite por- une couche de mousse d’isolation à pulvé- tion de mousse effilée a une épaisseur d’environ 0 riser (8) réalisée d’une manière contigüe sur cm à environ 5,08 cm. la surface de panneau intérieure, caracté- risé en ce que la couche de mousse d’iso- 10. Aéronef comprenant le carénage d’aéronef aile/fu- lation est continue généralement sur l’en- 25 selage selon l’une quelconque des revendications semble des surfaces de panneaux intéri- précédentes. eurs et comprenant une portion de mousse centrale (9) et une portion de mousse effilée (10), la portion de mousse effilée s’étendant de la portion de mousse centrale et dimi- 30 nuant vers un bord (6) du panneau de carénage ; et une bride de carénage (2a) s’étendant entre la portion de mousse effilée et le bord du panneau de carénage, la couche de mous- 35 se d’isolation à pulvériser étant omise sur la bride de carénage.

2. Carénage d’aéronef aile/fuselage selon la revendi- cation1, danslequel lacouche de mousse d’isolation 40 comprend une couche en mousse de polyuréthane à alvéoles fermés.

3. Carénage d’aéronef aile/fuselage selon la revendi- cation 1, dans lequel la portion de mousse centrale 45 a une épaisseur qui est dans la plage de 1,27 cm à 7,62 cm.

4. Carénage d’aéronef aile/fuselage selon la revendi- cation 1, dans lequel la portion de mousse centrale 50 a une épaisseur d’environ 5,08 cm, et où la portion de mousse effilée a une épaisseur d’environ 0 cm à environ 5,08 cm.

5. Carénage d’aéronef aile/fuselage selon la revendi- 55 cation 1, comprenant en outre une pluralité d’axes d’isolation s’étendant depuis la surface intérieure des panneaux.

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• US 20090184200 A1 [0005]

10