Core Lifter Assembly
A core lifter assembly includes a combination of a core lifter ring and a core lifter case. The ring has an axially extending portion of an outer generally frusto-conical configuration having an included taper angle β. The included taper angle β is also the taper angle of the outer circumferential surface of the ring. The included taper angle β may in alternate embodiments be ≧6°; ≧7°; ≧8°; or ≧10°. In one embodiment an upper limit of the included taper angle β may be about 30°. Thus in one embodiment the included taper angle β may be expressed by the relationship: 30°≧β≧6°. Further, the angle β may comprise any sub range within the aforementioned range of 6-30°. However in other embodiments the taper angle may exceed 30°.
The present invention relates to a core lifter assembly of a type used in core drilling.
BACKGROUND ARTA core lifter assembly is attached to a downhole end of a core barrel which in turn is carried by a core drill. When the core drill is in operation it cuts a core sample of the ground which passes through the core lifter assembly and into the core barrel. In order to retrieve the core sample once drilling has ceased the core drill is lifted from the toe of the hole. During this process the core lifter assembly grips the core so that the lifting force on the drill is transferred onto the core, breaking it from the ground. When the core barrel is retrieved either via use of a wireline, or by withdrawal of the entire core drill, the core sample is held in the core barrel by the core lifter assembly.
The core lifter assembly comprises two main components namely a core lifter case and a core lifter ring. An outer circumferential surface of the core lifter ring and an inner circumferential surface of the core lifter case are formed with complimentary tapered surfaces allowing the core lifter ring to slide axially relative to the core lifter case. The taper on the core lifter ring forms an included angle of about 4°-5°.
The core lifter ring is not a full or complete ring but commonly a split ring having a longitudinal slot. Also the ring is made of a resilient material which biases the ring toward a maximum diameter and corresponding maximum width of the slot. The slot opens to a maximum width when the core lifter ring is in an uphole position relative to the case. This is the position of the core lifter ring when an associated core drill is drilling a core sample and the core sample is entering the core barrel. During a core breaking operation the core drill is lifted in an uphole direction. However the ring is retarded by friction against the core with the effect that the case slides uphole relative to the ring. Due to the tapered surfaces of the case and ring the ring is now compressed about an outer circumferential surface of the core sample, and the width of the slot is reduced.
The core lifter ring can clamp the core sample so tightly that it is very difficult to remove the core sample once it is retrieved to the surface. In order for a drill rig operator to release the core sample from the core lifter they may strike the protruding core sample with a block of wood. If that does not succeed the operator may resort to use of a hammer or similar instrument to strike the end of the core sample.
Striking the end of the core sample usually results in damage to the end face of a sample. This is problematic as it makes it more difficult for a geologist to rotationally align the core sample with an adjacent sample. Further, the inability to easily release the core sample from the core barrel causes frustration to the drill rig operators and presents a significant safety risk.
Throughout this specification and claims the term “downhole end” is intended to denote a toe end of a bore hole while the expression “uphole end” is intended to denote a collar end. Accordingly the downhole end of a hole may be vertically above an uphole end where for example a hole is drilled upwardly or with at least a vertical upward inclination.
SUMMARY OF THE DISCLOSUREIn a first aspect there is disclosed a core lifter for a core drill comprising:
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- a core lifter ring having an axially extending portion having an outer generally frusto-conical configuration formed with an included taper angle β≧6°.
In a second aspect there is disclosed a core lifter for a core drill comprising:
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- a core lifter ring having N axially extending portions each having an outer generally frusto-conical configuration formed with an included taper angle β≧6° wherein N is an integer ≧1.
In a third aspect there is disclosed a core lifter for a core drill comprising:
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- a plurality of core lifter rings each ring having N axially extending portions each having an outer generally frusto-conical configuration formed with an included taper angle β≧6° wherein N is an integer ≧1.
In one embodiment the angle β≧7°.
In one embodiment the angle β≧8°.
In one embodiment the angle β≧10°.
In one embodiment the angle 30°≧β≧6°
In one embodiment one or more of the axially extending portions comprises a plurality of circumferentially alternating and generally axially extending grooves and splines formed on an inner circumferential surface or an outer circumferential surface of the one or more axially extending portions.
In one embodiment the grooves extend parallel to the central axis of the ring.
In one embodiment the grooves follow a spiral path between axially opposite ends of their corresponding axially extending portion.
In one embodiment the grooves extend to and reach a large outer diameter end of their corresponding axially extending portion.
In one embodiment the grooves extend to and reach a small outer diameter end of their corresponding axially extending portion.
In one embodiment the core lifter assembly comprises a core lifter case in which the or each core lifter ring is slidably retained.
In one embodiment of the third aspect the core lifter assembly comprises a core lifter case in which the plurality of core lifter rings are slidably retained in axially spaced relationship.
In one embodiment the core lifter case comprises a tapered section for each axially extending portion, each tapered section configured to engage a corresponding axially extending portion to cause a change in diameter of the core lifter ring associated with the axially extending portion in response to axial displacement of the associated core lifter ring relative to the tapered section.
In a fourth aspect there is disclosed a core lifter for a core drill comprising: a core lifter ring having opposite downhole and uphole ends spaced by an axial distance X, an interior circumferential surface having a substantially constant major diameter for the axial distance X, and an outer circumferential surface, the interior circumferential surface and outer circumferential surface configured to form a half angle θ≧3° for at least a portion of the distance X in at least two circumferentially spaced locations wherein at the locations a wall of the ring decreases in thickness in a direction from the uphole end to the downhole end.
In a fifth aspect there is disclosed a core lifter for a core drill comprising: a core lifter ring having opposite downhole and uphole ends spaced by an axial distance X, an interior circumferential surface having a substantially constant major diameter for the axial distance X, and an outer circumferential surface, the interior circumferential surface and outer circumferential surface configured to provide the ring with a half angle θ≧3° for at least a portion of the distance X wherein a wall of the ring decreases in thickness in a direction from the uphole end to the downhole end for the corresponding portion of the distance X.
In one embodiment the angle θ≧4°.
In one embodiment the angle θ≧5°.
In one embodiment the angle θ≧6°.
In one embodiment the angle 15°≧θ≧3°.
In one embodiment the portion of the distance X is X/N where N is an integer and wherein the ring comprises N number of integrally formed portions.
In one embodiment the outer circumferential surface of the ring for one or more of the N portions has a radius that is constant in a circumferential direction for any location along the central axis and continuously decreases in an axial direction from the uphole end to the downhole end.
In one embodiment one or more of the N portions comprises a plurality of circumferentially spaced recesses on the outer circumferential surface whereby an outer circumference of the ring in one or more of the N portions comprises alternating grooves and sloped splines wherein the angle θ is a measure of an angle of slope of the spline relative to a line co-axial with a central axis of the ring.
In an embodiment wherein N≧2 the axially extending portions are arranged to taper in a common direction. In this embodiment the core lifter may further comprise, between mutually adjacent axially extending portions, one or more transition zones extending from a small diameter end of one of the axially extending portions to a larger diameter end of the other axially extending portions.
In one embodiment the one or more transition zone comprises a tapered transition zone having a substantially frusto-conical circumferential surface.
In one embodiment the one or more transition zones comprise a cylindrical transition zone having a substantially cylindrical circumferential surface.
In one embodiment the one or more transition zone comprises a tapered transition zone having a substantially frusto-conical circumferential surface and a contiguous cylindrical transition zone having a substantially cylindrical circumferential surface.
In one embodiment the frusto-conical outer circumferential surface of the transition zone slopes at a half angle of 90°>α>3°.
In one embodiment α=−β/2.
In one embodiment α=β.
In one embodiment an axial length of the one or more transition zone is substantially the same as an axial length of an axially extending portion.
In an alternate embodiment where N≧2 the axially extending portions are arranged to taper in a common direction and with a small diameter end of one axially extending portion located immediately adjacent a large diameter end of another axially extending portion. In such an embodiment there may be provided a stepwise transition between mutually successive axially extending portions.
In one embodiment a wall of the core lifter ring is formed of substantially uniform thickness for the axial length of each of the grooves.
In a sixth aspect there is disclosed a method of manufacturing a core lifter ring comprising:
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- injection moulding a metallic material into a mould provided with a moulding cavity having a shape and configuration such that when the metallic material is injected into the cavity and subsequently set, the set material forms a core lifter ring having one or more axially extending portions each axially extending portion having an outer generally frusto-conical configuration formed with an included taper angle β≧6°.
In a seventh aspect there is disclosed a method of manufacturing a core lifter case comprising:
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- injection moulding a metallic material into a mould provided with a moulding cavity having a shape and configuration such that when the metallic material is injected into the cavity and subsequently set, the set material forms a core lifter case capable of receiving and working with a core lifter ring which has one or more axially extending portions each axially extending portion having an outer generally frusto-conical configuration formed with an included taper angle β≧6°.
Notwithstanding any other forms which may fall within the scope of the apparatus and method as set forth in the Summary, specific embodiments will now be described, by way of example only, with reference to the accompanying drawings in which:
The included taper angle β may in alternate embodiments be ≧6°; ≧7°; ≧8°; or ≧10°. In one embodiment an upper limit of the included taper angle β may be about 30°. Thus in one embodiment the included taper angle β may be expressed by the relationship: 30°≧β≧6°. Further, the angle β may comprise any sub range within the aforementioned range of 6-30°. However in other embodiments the taper angle may exceed 30°.
As shown most clearly in
In the present embodiment the outer circumferential surface 18a of ring 10a is a continuous smooth surface which progressively reduces in outer diameter in a direction from the large diameter end 22a to small diameter end 23a. However an interior circumferential surface 26a of the ring 10a is provided with alternating axially extending grooves 28a and splines 30a. The grooves 28a are formed to a depth and of a shape so that a wall thickness W (shown in
The free faces 32a of the splines 30a are radiused and lie on a common cylinder of the same radius. The actual radius of the circle will change depending on the relative juxtaposition of the ring 10a in the case 14a. Also although not shown in this embodiment the free faces 32a may be provided with texturing such as circumferential ribs, grooves, dimples or grit to assist in gripping a core passing through the ring 10a.
Referring to
When the ring 10a is in the retracted position shown in
During a core breaking action when a core drill, housing the core lifter assembly 12a, is lifted from the toe of the hole, in relative terms the ring 10a slides axially in a downhole direction in relation to the case 14a to a clamping position shown in
Due to the increased internal taper angle β once the core barrel with the associated core lifter assembly 12a is retrieved less force is required to revert the ring 10a to the retracted position to release the captured core than for a comparable prior art core lifter assembly.
The ring 10b is also provided with a longitudinal slot 24b and each portion 16b has a smooth continuous outer surface 18b. Grooves 28b and splines 30b are formed on the inner surface 26b of the ring 10b. Each of the grooves 28b has a generally concave channel surface 33b of constant radius in any transverse plane along its axial length. As a consequence, the thickness of a wall of ring 10b in axial section along a groove 28b is of a form of two contiguous wedges W1 and W2 shown on the right hand side of
A core lifter assembly 12b which utilises the ring 10b comprises a core lifter case 14b shown in
As in the first embodiment, when the ring 10b is in the retracted position shown in
During a core breaking action when a core drill housing the core lifter assembly 12b is lifted from the toe of the borehole, in relative terms, the ring 10b slides axially in a downhole direction relative to the case 14b to a clamping position shown in
It will be appreciated that as the angle β in the present embodiments is greater than that of the prior art, there is a quicker reduction in the wall thickness of the ring 10a along its axial length. Therefore in order to provide sufficient contact area between the interior surface 26a of the ring 10a and a core sample, and between the external tapered surface 18a of the ring 10a and the internal tapered surface 40a of the case 14a, to provide appropriate compressive force to grip the core sample, the ring 10a and case 14a must be formed of a greater wall thickness than a comparable prior art ring. This will lead to a reduced diameter core sample. This however can be avoided by virtue of the provision of two portions 16b in the ring 10b in accordance with the second embodiment. In this embodiment as each portion 16b is of a shorter axial length there is less reduction in the wall thickness for the portion 16b than the portion 16a. But to increase the area of the inner surface 26b to provide the appropriate clamping force on a core sample (i.e. on a par to that of a prior art ring), two portions 16b are provided. Thus substantially the same gripping force can be achieved as the prior art but the embodiments of the ring 10 are easier to release. As explained further below, a similar effect to the use of a ring 10 with multiple sections 16 is to provide multiple single portion rings 10 each having an included taper angle β as herein before described but of a reduced axial length to the comparable single portion ring 10a shown in
The ring 10c operates in an identical manner to the ring 10a, and the core lifter case 14c can be identical to the core lifter case 14a. Operation of the core lifter assembly 12c is also in essence identical to that of the assembly 12a. In particular 12c, as the ring 10c moves from its retracted position to its clamping position the internal diameter of the surface 26c reduces to effectively clamp onto an outer circumferential surface of a cut core. Release of the ring 10c upon retrieval of an associated core tube is rendered easier in comparison with the prior art by the provision of the greater taper angle β.
Due to the provision of the grooves 28c and splines 30c on an outer circumferential surface 18c of the ring 10c naturally the outer circumferential surface is no longer smoothly continuous as in the ring 10a. Conversely however the interior surface 26c of ring 10c is substantially continuous (save for the texturing provided by ribs 44c). The tapering of the outer circumferential surface of ring 10c is provided by a reduction in a radial section width of the splines 30c in a direction from the maximum diameter end 22c to the minimum diameter end 23c of the ring 10c.
Also as a result of the alternating grooves 28c and splines 30c the description of the outer surface 18c as being “substantially frusto-conical” is intended to refer to the general outer shape and configuration of an envelope encompassing the portion 16c.
The core lifter case 14d is identical to the case 14b. Thus the interaction between the ring 10d and case 14d and the consequential operation of the assembly 12d is in substance the same as that described herein above in relation to the assembly 12b.
With specific reference to
As shown in
As depicted in
It will be understood by those skilled in the art that the provision of the additional axially extending portion 40f provides additional surface area to the inner circumferential surface 26f in comparison for example to the ring 10e. This may assist in gripping a core in the event that the ground may be fractured or there are discontinuities in the surface of the core. However at the same time because of the increased taper angle β, retraction of the ring 10f to the position shown in 9a to release a captured core sample requires less force and effort in comparison with the prior art.
A further difference between the ring 10g and the ring 10d is that the splines 30g at the free small diameter end 23g extend axially beyond the adjacent grooves 28g. In a core lifter assembly comprising the ring 10g, the corresponding case will be substantially identical to case 14d.
In the embodiments described above which comprise grooves 28 and splines 30 on the outer circumferential surface the grooves and splines are shown as extending parallel to a central axis of the ring. However this is not an essential characteristic of the core lifter rings. As shown in
In the embodiments shown in
The transition zones 17i are also depicted as extending for an axial length the same as that of the portions 16i. However in alternate embodiments this need not necessarily be the case and indeed will not be the case where the angle |α|≠|β/2|.
The ring 10i is further provided with a single split or slot 24i which extends for the full axial length of the ring 10i.
A plurality of grooves 28i and splines 30i are formed in an axially extending direction in each of the portions 16i and 17i. The grooves 28i and splines 30i are arranged in an alternating manner circumferentially about each of the portions 16i and 17i. Further the grooves 28i and splines 30i in mutually adjacent portions 16i and 17i are axially aligned.
As depicted in
As shown in
The core lifter case 14i incorporated in the assembly 12i is provided with a plurality of alternating inclined surface portions 40i and 41i. The surface portions 40i taper at substantially the same angle as the outer surface 18i of the splines 30i on portions 16i. The intervening surface portions 41i taper in an opposite direction and at substantially the same angle as the outer surface portion 19i of the splines 30i on portions 17i. As with the other core lifter cases, the case 14i comprises a shoulder 38i which limits relative motion of the ring 10i in an uphole direction relative to the case 14i; and a thread 36i to enable threaded connection to a core barrel.
In this embodiment edges 50 delineating the grooves 28k from the splines 30k are not straight and are not parallel with each other. This is to be contrast for example with the grooves 28a and splines 30a in the embodiment shown in
The ring 10l may be made from a moulding process such as metal injection moulding or other techniques using powder metallurgy or amorphous metal alloys. The use of for example metal injection moulding enables high speed mass production with dimensional stability; and the forming of shapes, features and textures that are difficult to produce with conventional machining.
The metal injection moulding process for the manufacture of the ring 10l initially requires the construction of a mould having an interior configuration complimentary to the exterior shape and configuration of the ring 10l. Fine metal powders (typically less than 20 microns) are combined with a binder into a feedstock that is granulated and fed to a conventional injection moulding machine. The machine then injection moulds the molten feedstock into the mould. The process is similar to that of conventional plastic injection moulding and high pressure die casting.
The ring 10l may also be made by a process of injection moulding low melting point alloys or amorphous metal alloys which may not need to be powdered or combined with a binder.
The ring 10m may also be produced by similar moulding processes used for production of the ring 10l. The ring 10m is formed with three axially extending portions 16m each having an outer generally frusto-conical configuration. Moreover each portion 16m tapers at a half angle θ in the same range as that described in relation to the earlier embodiments. The two major differences between the rings 10m and 10l lie in the configuration of their respective outer surfaces 18 and interior surfaces 26. In particular ring 10m has an interior surface 26m with substantially constant inner diameter and formed with no recesses 28. The surface 26m may however be provided with texturing such as by way of provision of circumferential or helical grooves, grit, gnurling, dimples or the like to enhance friction between the ring 10m and a core cut by a drill incorporating the ring 10m.
The outer surface 18m of each portion 16m is formed with a pattern of triangular and diamond shaped recesses 52 and 54 respectively delineated between adjacent diamond shaped borders or ridges 56.
The interior and outer surface configurations of each of the rings 10l and 10m can be reversed. For example for the ring 10l the recesses 28l may be applied to the outer surfaces 18l while the interior surface 26l may be provided with texturing such as by way of provision of circumferential or helical grooves, grit, gnurling, dimples or the like. Likewise for ring 10m the pattern of triangular and diamond shaped recesses 52 and 54 and diamond shaped borders 56 may be moved to the interior surface 26m leaving the outer surface 18m as smooth continuous surfaces.
While only the rings 10l and 10m are depicted as being manufactured by a moulding process, each of the earlier embodiments of the rings 10a-10k may be similarly made from a moulding process or other techniques using powder metallurgy or amorphous metal alloys. Alternately the rings 10a-10m may be made by the metal working techniques including stamping, pressing, machining and 3D printing. In yet a further variation, embodiments of the rings 10a-10m may be made from non-metallic materials including but not limited to composite materials and plastics such as polyether ether ketone (PEEK). Indeed embodiments of the core lifter case 14a-14j may be made via the same manufacturing techniques as described above in relation to the manufacture of the rings 10a-10m.
Whilst a number of specific embodiments are described, it should be appreciated that the core lifter assembly may be embodied in many other forms. For example in a variation to the embodiment of the core lifter assembly 12e the two separate rings 10e could be replaced with separate rings in which the alternating grooves 28e and splines 30e are formed on an inner circumferential surface of the ring with the outer circumferential surface being continuous as shown in rings 10a and 10b. Also each separate ring can be provided with two or more axially extending portions 16. For example two or more rings 10d (
All such modifications and variations together with others that would be obvious to persons of ordinary skill in the art are deemed to be within the scope of the present invention the nature of which is to be determined from the above description and the appended claims.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Claims
1-39. (canceled)
40. A core lifter for a core drill comprising: at least one core lifter ring having at least one axially extending portion having an outer generally frusto-conical configuration formed with an included taper angle β≧6°.
41. A core lifter according to claim 40 wherein each core lifter ring has N axially extending portions with each portion having an outer generally frusto-conical configuration formed with an included taper angle β≧6° wherein N is an integer ≧I.
42. The core lifter according to claim 40 wherein the included taper angle satisfies 30°≧β≧6°.
43. The core lifter according to claim 41 wherein the included taper angle satisfies 30°≧β≧6°.
44. The core lifter according to claim 40 wherein one or more of the axially extending portions comprises a plurality of circumferentially alternating and generally axially extending grooves and splines formed on an inner circumferential surface or an outer circumferential surface of the one or more axially extending portions.
45. The core lifter according to claim 44 wherein the grooves (a) extend parallel to the central axis of the ring; or (b) follow a spiral path between axially opposite ends of their corresponding axially extending portion; or (c) extend to and reach a large outer diameter end of their corresponding axially extending portion; or (d) extend to and reach a small outer diameter end of their corresponding axially extending portion.
46. The core lifter according to claim 40 comprising a core lifter case in which the at least one core lifter ring is slidably retained.
47. The core lifter according to claim 46 wherein the core lifter case comprises a tapered section for each axially extending portion, with each tapered section configured to engage a corresponding axially extending portion to cause a change in diameter of the core lifter ring associated with the axially extending portion in response to axial displacement of the associated core lifter ring relative to the tapered section.
48. A core lifter for a core drill comprising a core lifter ring having opposite downhole and uphole ends spaced by an axial distance X, an interior circumferential surface having a substantially constant major diameter for the axial distance X, and an outer circumferential surface, wherein the interior circumferential surface and outer circumferential surface are configured to form a half angle θ≧3° for at least a portion of the distance X in at least two circumferentially spaced locations and wherein at the locations a wall of the ring decreases in thickness in a direction from the uphole end to the downhole end.
49. A core lifter for a core drill comprising a core lifter ring having opposite downhole and uphole ends spaced by an axial distance X, an interior circumferential surface having a substantially constant major diameter for the axial distance X, and an outer circumferential surface, wherein the interior circumferential surface and outer circumferential surface are configured to provide the ring with a half angle θ≧3° for at least a portion of the distance X wherein a wall of the ring decreases in thickness in a direction from the uphole end to the downhole end for the corresponding portion of the distance X.
50. The core lifter according to claim 48 wherein the half angle satisfies 15°≧θ≧3°.
51. The core lifter according to claim 49 wherein the half angle satisfies 15°≧θ≧3°.
52. The core lifter according to claim 48 wherein the portion of the distance X is X/N where N is an integer ≧I and wherein the ring comprises N number of integrally formed portions.
53. The core lifter according to claim 52 wherein the outer circumferential surface of the ring for one or more of the N portions has a radius that is constant in a circumferential direction for any location along the central axis and continuously decreases in an axial direction from the uphole end to the downhole end.
54. The core lifter according to claim 52 wherein one or more of the N portions comprises a plurality of circumferentially spaced recesses on the outer circumferential surface whereby an outer circumference of the ring in one or more of the N portions comprises alternating grooves and sloped splines wherein the angle θ is a measure of an angle of slope of the spline relative to a line co-axial with a central axis of the ring.
55. The core lifter according to claim 41 further comprising between mutually adjacent axially extending portions one or more transition zone extending from a small diameter end of one of the axially extending portions to a larger diameter end of the other axially extending portions.
56. The core lifter according to claim 55 wherein the one or more transition zone comprises (a) a tapered transition zone having a substantially frusto-conical circumferential surface; or (b) a cylindrical transition zone having a substantially cylindrical circumferential surface; or (c) a tapered transition zone having a substantially frusto-conical circumferential surface and a contiguous cylindrical transition zone having a substantially cylindrical circumferential surface.
57. The core lifter according to claim 55 wherein mutually adjacent axially extending portions are arranged in a manner such that a small diameter end of one axially extending portion is located immediately adjacent a large diameter end of an adjacent axially extending portion and a stepwise transition is formed between the one axially extending portion and the adjacent axially extending portion.
58. The core lifter according to claim 47 wherein each lifter ring comprises between mutually adjacent axially extending portions one or more transition zone extending from a small diameter end of one of the axially extending portions to a larger diameter end of the other axially extending portions and wherein the lifter case is provided with an intervening surface portion for each transition zone of an associated core lifter ring, each intervening surface portion being configured to match a corresponding transition zone of a core lifter ring associated with the transition zone to facilitate axial displacement of the associated core lifter ring.
59. The core lifter according to claim 44 wherein a wall of the core lifter ring is formed of substantially uniform thickness for the axial length of each of the grooves.
Type: Application
Filed: Sep 24, 2013
Publication Date: Sep 3, 2015
Applicant: CT Tech Pty Ltd (Mt. Richon, Western Australia)
Inventor: Shayne Beach (Mt. Richon)
Application Number: 14/428,812