CN101160425A - 用于汽车应用的聚合物/wucs毡片 - Google Patents
用于汽车应用的聚合物/wucs毡片 Download PDFInfo
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- CN101160425A CN101160425A CNA2005800466848A CN200580046684A CN101160425A CN 101160425 A CN101160425 A CN 101160425A CN A2005800466848 A CNA2005800466848 A CN A2005800466848A CN 200580046684 A CN200580046684 A CN 200580046684A CN 101160425 A CN101160425 A CN 101160425A
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- dehydration
- adhesive material
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- wet
- thermoplastic
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
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- B32—LAYERED PRODUCTS
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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Abstract
提供一种由热塑性粘合材料和增强纤维束形成的声和热吸收性短切纤维毡片(295)。增强纤维优选为湿法应用的短切玻璃纤维(WUCS)。热塑性粘合材料可以为熔点低于增强纤维的任何热塑性或热固性材料。可以通过部分开松WUCS纤维以及使热塑性粘合材料成丝,将增强纤维和热塑性粘合纤维共混,使增强纤维和热塑性粘合纤维成型为片材,以及粘合该片材,从而形成该短切纤维毡片。粘合过程中,片材被加热到高于热塑性粘合纤维熔点但低于玻璃纤维熔点的温度。熔融的热塑性粘合纤维起胶水的作用,使玻璃纤维保持束状。由此形成的短切纤维毡片可以用作汽车应用中的增强材料。
Description
本发明的技术领域和工业实用性
本发明一般性涉及声学产品,以及更具体地涉及一种声和热吸收性短切纤维毡片,其由热塑性粘合材料和增强纤维束形成并且可以用作汽车和工业应用中的增强材料。
发明背景
隔音材料用于各种需要衰减来自外源的噪声的环境中。例如,隔音材料已经用于各种应用中,例如用于器具中以降低散发到住房周围区域的声音,用于汽车中以降低发动机的机械声音和路面噪音,以及用于办公楼以衰减由工作场所,例如由电话交谈或由办公设备运转产生的声音。常规隔音材料包括例如泡沫塑料、压缩纤维、玻璃纤维絮垫、毡以及纤维,例如熔喷法纤维的无纺网的各种材料。隔音通常依赖于声音吸收(能够吸收入射声波)和传输损耗(能够反射入射声波)来提供充分的声音衰减。
汽车中,绝缘材料也依赖于热屏蔽性能来降低或防止热量由汽车中的各个热源(例如发动机、变速器、排气装置等)向车辆的客舱传递。这种绝缘材料通常在汽车中用作车顶衬垫(headliner)、隔板衬垫或防火壁衬垫。衬垫通常由(1)提供所需机械强度性能的一个或多个绝缘材料层和(2)允许汽车中的简便安装以及适当功能特性的一个或多个刚性材料附加层的层压材料形成。
层压材料常规地可以通过将松散的短切玻璃纤维层沉积到位于移动式传送带上的稀纱布(scrim)上的粘合剂层上而形成。然后将第二个粘合剂层放置在玻璃纤维顶部使玻璃纤维保持在原位。如果该层压材料将用于形成汽车的车顶衬垫,那么将聚氨酯板放置在第二粘合剂上,以及将粘合剂、短切玻璃纤维和粘合剂的顺次层放置在该聚氨酯板上。该层状的材料然后通过层压烘箱,在其中施加热量和压力以形成随后可以形成车顶衬垫的复合材料。
这些层压复合材料的制造商所面对的一个问题是将短切玻璃纤维均匀分布到一个或多个粘合剂层上。如果不能形成玻璃纤维的均匀分布,那么最终的复合材料可能具有非所需的性能。使用松散的短切玻璃纤维的常规方法的另一个问题是在制造工艺过程中添加短切玻璃纤维是缓慢的和昂贵的。此外,如果纤维接触到成形加工层压材料的工人,松散的玻璃具有刺激皮肤的可能性。
与使用松散的短切玻璃纤维有关的问题的一种解决方案是用玻璃毡片替代松散的短切玻璃纤维。在一种常规方法中,玻璃纤维粗纱在传送带系统上切断以及将薄的粘合剂纺粘材料放置在玻璃上面。短切玻璃纤维的第二层位于该纺粘材料上,形成短切玻璃纤维/纺粘粘合剂/短切玻璃纤维的三明治状材料。该三层材料穿过层压烘箱形成短切玻璃毡片。然后使用该毡片生产车顶衬垫,作为用于其它常规方法的松散的短切玻璃纤维的替代。但是,使用短切粗纱的常规毡片制造昂贵。此外,该毡片没有多孔结构来辅助最终产品的声学特性。
因此,本领域中对于显示优越的声音衰减性能、具有改进的结构、声学和热性能以及轻便和成本低廉的在汽车应用中用作衬垫中的增强材料的无纺毡片存在需求。
发明概述
本发明的一个目的是提供一种形成短切纤维毡片的方法,该短切纤维毡片包括增强纤维束和热塑性粘合材料。为形成短切纤维毡片,湿的增强纤维束被部分开松或“疏松”,但并不成丝,以及通过从增强纤维除去水而至少部分脱水。干燥的增强纤维束优选在高速空气流中与热塑性粘合材料混合,形成增强纤维束和热塑性粘合材料的基本上均匀的混合物。在至少一个示例性实施方案中,热塑性粘合材料为纤维束形式,并在与脱水的增强纤维束混合之前通过开松设备成丝。增强纤维束和热塑性粘合材料的混合物然后例如通过使该混合物穿过片材成型机而成型为片材。该片材然后可以被加热到高于热塑性粘合材料熔点但低于增强纤维束熔点的温度,以使热塑性材料至少部分地熔融以及将脱水的增强纤维束与热塑性粘合材料粘合。此外,粘合剂可以在将增强纤维束与热塑性粘合材料粘合之前加入到片材中。在本发明的一些其中热塑性材料为热塑性粘合纤维或双组分纤维的实施方案中,片材可以经历针刺工艺,以在将增强纤维束与热塑性粘合材料粘合之前将脱水的增强纤维束与热塑性粘合纤维机械结合,或者其可以代替纤维粘合。由此形成的短切纤维毡片可以用作汽车应用中的增强材料,例如用于机动车辆的车顶衬垫。
本发明的另一个目的是提供一种适合用于汽车应用的低重量的隔音和隔热的无纺短切纤维毡片。短切纤维毡片由基本上均匀分布的脱水的湿增强纤维束和至少一种热塑性粘合材料形成。湿增强纤维可以为有机、无机、热塑性或热固性纤维,并且可以具有约11到约75mm的长度和约8到约35微米的直径。增强纤维优选为湿法应用的短切玻璃纤维。热塑性粘合材料可以为任何热塑性材料,只要该热塑性材料的熔点低于增强纤维的熔点。热塑性粘合材料和增强纤维束由部分熔融的热塑性粘合材料粘合。热塑性粘合材料可以为纤维形式,或者可以为薄片、颗粒或粉末形式。增强纤维束可以约80到约98wt%的量存在于短切纤维毡片中,以及热塑性粘合材料可以全部纤维的约2到约20wt%的量存在。此外,短切纤维毡片优选具有约80到约500g/m2的重量分布。
本发明的又一个目的是提供一种形成层压复合材料的方法,包括在移动式传送带上沉积稀纱布、第一粘合剂层、第一短切玻璃毡片层、第二粘合剂层、聚氨酯板、第三粘合剂层、根据本发明的第二短切纤维毡片层和最终粘合剂层的连续层。该层状的复合材料产品然后可以穿过层压烘箱,在其中施加热量和压力以形成最终的层压复合材料。层压复合材料可以进一步加工成复合材料产品,例如汽车的衬垫。例如,层压复合材料可以修整和模塑成为车顶衬垫。在进一步的加工步骤中,为了美观性目的,车顶衬垫织物材料,例如布料、乙烯基树脂、皮革或壁纸可以施加于该车顶衬垫。
本发明的进一步目的是提供一种形成层压复合材料的方法,该层压复合材料可以形成汽车的车顶衬垫。在第一装配线中,制成由稀纱布、第一粘合剂、根据本发明的短切纤维毡片和第二粘合剂的顺次层形成的第一层压产品。在第二装配线中,制成由聚氨酯泡沫材料、第三粘合剂层、短切纤维毡片层、第四粘合剂层和稀纱布形成的第二层压产品。第一和第二装配线可以在线会合,使得第二粘合剂层靠近聚氨酯泡沫材料设置。由此形成的层状复合材料由稀纱布、第一粘合剂层、第一短切纤维毡片层、第二粘合剂层、聚氨酯泡沫材料层、第三粘合剂层、第二短切纤维毡片层、第四粘合剂层和第二稀纱布层的连续层构成。该层状复合材料产品可以穿过层压烘箱,在其中施加热量和压力以形成最终的层压复合材料。层压复合材料可以进一步由常规方法加工成复合材料产品,例如汽车的衬垫。例如,层压复合材料可以修整和例如通过模塑工艺成型为车顶衬垫。为了美观性目的,泡沫塑料或织物然后可以施加于该车顶衬垫。
本发明的一个优点是通过改变用于短切纤维毡片的增强纤维和/或热塑性粘合纤维的重量、长度和/或直径,短切纤维毡片能够使毡片的物理性能最佳化和/或得到调整。因此,可以制造多种短切纤维毡片和由短切纤维毡片形成的复合材料产品。
本发明的另一个优点是短切纤维毡片具有均匀的或基本上均匀的增强纤维束和热塑性粘合纤维的分布,其提供改进的强度、声学和热性能、劲度、耐冲击性和声学吸收性。
本发明的又一个优点是与常规短切玻璃纤维毡片相比,本发明的短切纤维毡片具有更均匀的重量一致性和均匀的性能。
本发明的另一个优点是当湿法应用的短切玻璃纤维用作增强纤维时,玻璃纤维可以容易地开松并纤维化,由于玻璃纤维中存在水分,而几乎不产生静电。此外,因为干燥纤维通常在切断之前在分开的步骤中加以干燥和包装,所以相比干燥的短切纤维,湿法应用的短切玻璃纤维制造相对低廉。因此,使用湿法应用的短切玻璃纤维使得可以较低成本制造衬垫。
根据考虑以下详细说明,本发明的上述和其它目的、特征和优点将更加充分地呈现。但是应清楚地理解,附图是为了说明性目的,以及并不被认为是限定本发明的界限。
附图简述
当考虑本发明的以下详细公开时,特别是当结合附图考虑时,本发明的优点将是显而易见的,其中:
图1为根据本发明的一个方面,说明在干法成网工艺中使用湿增强纤维的步骤的流程图;
图2为根据本发明的至少一个示例性实施方案,使用湿增强纤维形成短切纤维毡片的气流成网工艺的示意图;
图3为根据本发明的一个方面,用于制备玻璃/聚氨酯层状复合材料产品的干燥聚氨酯层压工艺的示意图;
图4为由图3中所绘示例性工艺形成的玻璃/聚氨酯层状复合材料产品的示意图;
图5为根据本发明的至少一个其它示例性实施方案,用于制备玻璃/聚氨酯层压复合材料产品的湿聚氨酯层压工艺的示意图;和
图6为由图5中所绘示例性工艺形成的玻璃/聚氨酯层状复合材料产品的示意图。
本发明的详细说明和优选实施方案
除非另外规定,在此使用的所有科技术语具有与由本发明所属领域技术人员通常理解的相同含义。虽然与在此所述的那些相似或等效的任何方法和材料都可以用于本发明的实践或测试,但是在此描述优选的方法和材料。
附图中,为了清楚性,线、层和区域的粗度可以放大。应当注意在各附图中发现的相同数字表示相同元件。仅为了解释的目的,在此使用术语“顶部”、“底部”、“侧面”等。应理解,当例如层、区域、基材或板的元件被称为在另一个元件“上”时,其可以直接位于另一个元件上或者也可以存在插入的元件。如果元件或层被描述为“邻近”或“靠近”另一个元件或层,那么应理解,该元件或层可以直接邻近或直接靠近另一个元件或层,或者可以存在插入的元件。还应理解,当例如层、区域或基材的元件被称为在另一个元件之上时,其可以直接位于另一个元件之上,或者可以存在插入的元件。
术语“片材”和“毡片”在此可互换使用。此外,术语“热塑性结合纤维”和“热塑性粘合纤维”可互换使用,以及术语“增强纤维”和“增强用纤维”可互换使用。
本发明涉及一种由增强纤维和热塑性粘合材料形成的短切纤维毡片。增强纤维可以为适合提供优良结构质量以及优良声学和热性能的任何纤维类型。增强纤维可以为任何有机、无机、热塑性或热固性纤维类型,只要增强纤维的熔点大于热塑性粘合纤维的熔点。增强纤维的适合实例包括玻璃纤维、羊毛玻璃纤维(wool glass fiber)、天然纤维、金属纤维、陶瓷纤维、矿物纤维、碳纤维、石墨纤维、尼龙纤维、人造纤维素纤维和聚合物类热塑性材料,例如但不限于聚酯纤维、聚乙烯纤维、聚丙烯纤维、聚对苯二甲酸乙二醇酯(PET)纤维、聚苯硫醚(PPS)纤维、聚氯乙烯(PVC)纤维和乙烯-乙酸乙烯酯/氯乙烯(EVA/VC)纤维及其混合物。短切纤维毡片可以完全由一种增强纤维类型(例如天然纤维或玻璃纤维)形成,或者可选地,多于一种的增强纤维类型可以用于形成短切纤维毡片。如结合本发明使用的,术语“天然纤维”表示从植物的任何部分,包括但不限于茎、种子、叶、根或韧皮提取的植物纤维。优选,增强纤维材料为玻璃纤维。
增强纤维可以为具有约11到约75mm长,优选约12到约30mm长的不连续长度的短切纤维。另外,增强纤维可以具有约8到约35微米,优选约12到约23微米的直径。此外,增强纤维可以在短切纤维毡片内具有彼此不同的长度(长径比)和直径。增强纤维可以全部纤维的约80到约98wt%的量,优选以约85到约95wt%的量存在于短切纤维毡片中。
热塑性粘合材料可以为熔点低于增强纤维的任何热塑性或热固性材料。适合用于短切纤维毡片的热塑性和热固性粘合材料的非限制实例包括聚酯纤维、聚乙烯纤维、聚丙烯纤维、聚对苯二甲酸乙二醇酯(PET)纤维、聚苯硫醚(PPS)纤维、聚氯乙烯(PVC)纤维、乙烯-乙酸乙烯酯/氯乙烯(EVA/VC)纤维、丙烯酸低级烷基酯聚合物纤维、丙烯腈聚合物纤维、部分水解的聚乙酸乙烯酯纤维、聚乙烯醇纤维、聚乙烯吡咯烷酮纤维、苯乙烯丙烯酸酯纤维、聚烯烃、聚酰胺、聚硫化物、聚碳酸酯、人造纤维、尼龙、酚醛树脂、环氧树脂和丁二烯共聚物,例如苯乙烯/丁二烯橡胶(SBR)和丁二烯/丙烯腈橡胶(NBR)。一种或多种热塑性或热固性材料类型可以用来形成短切纤维毡片。此外,如果热塑性粘合材料为热塑性粘合纤维,那么纤维可以用酸性基团官能化,例如通过用例如马来酸或丙烯酸的酸羧基化,或者热塑性粘合纤维可以通过添加酸酐基团或乙酸乙烯酯官能化。热塑性粘合材料也可以为薄片、颗粒或粉末的形式,而不是热塑性聚合物纤维形式。
热塑性粘合材料也可以为多组分纤维的形式,例如双组分聚合物纤维、三组分聚合物纤维或塑料涂布的矿物纤维,例如热塑性塑料涂布的玻璃纤维。双组分纤维可以壳-芯、并排、天星状或扇形嵌段结构排列。优选,双组分纤维形成壳-芯结构,其中壳由第一种聚合物纤维形成,其基本上包围由第二种聚合物纤维形成的芯。并不需要壳纤维完全包围芯纤维。第一种聚合物纤维的熔点低于第二种聚合物纤维的熔点,使得当将双组分纤维加热到高于第一种聚合物纤维(壳纤维)的熔点并且低于第二种聚合物纤维(芯纤维)的熔点的温度时,第一种聚合物纤维将软化或熔融,而第二种聚合物纤维保持完好。第一种聚合物纤维(壳纤维)的这种软化将使第一种聚合物纤维变为粘性的,并且将第一种聚合物纤维自身以及可能紧密相邻的其它纤维粘合。
很多材料的组合物可用于制备双组分聚合物纤维,例如但不限于使用聚酯、聚丙烯、聚硫化物、聚烯烃和聚乙烯纤维的组合物。用于双组分纤维的特定聚合物组合物包括聚对苯二甲酸乙二醇酯/聚丙烯、聚对苯二甲酸乙二醇酯/聚乙烯和聚丙烯/聚乙烯。其它非限制双组分纤维实例包括共聚聚酯聚对苯二甲酸乙二醇酯/聚对苯二甲酸乙二醇酯(coPET/PET)、聚对苯二甲酸1,4-环己烷二甲酯/聚丙烯(PCT/PP)、高密度聚乙烯/聚对苯二甲酸乙二醇酯(HDPE/PET)、高密度聚乙烯/聚丙烯(HDPE/PP)、线性低密度聚乙烯/聚对苯二甲酸乙二醇酯(LLDPE/PET)、尼龙6/尼龙6,6(PA6/PA6,6)和二醇(glycol)改性的聚对苯二甲酸乙二醇酯/聚对苯二甲酸乙二醇酯(6PETg/PET)。
双组分聚合物纤维可以具有约1到约18旦尼尔的wt%和约2到约4mm的长度。优选的是第一种聚合物纤维(壳纤维)的熔点为约150到约400°F,和更优选为约170到约300°F。第二种聚合物纤维(芯纤维)具有更高的熔点,优选高于约350°F。
热塑性粘合材料可以全部纤维的约2到约20wt%,以及优选约2到约5wt%的量存在于短切纤维毡片中。
短切纤维毡片可以通过干法成网工艺形成,例如Enamul Haque的名为“Development Of Thermoplastic Composites Using Wet UseChopped Strand Glass In A Dry Laid Process”的美国专利公开号2005-0082721中描述的干法成网工艺。在优选实施方案中,用于形成短切纤维毡片的增强纤维为湿增强纤维,以及最优选为湿法应用的短切玻璃纤维。用作增强纤维的湿法应用的短切玻璃纤维可以由本领域已知的常规方法形成。理想的是湿法应用的短切玻璃纤维的含水量为约5到约30%,和更优选为约5到约15%。
形成短切纤维毡片的示例性工艺在图1中概括性说明,其包括部分开松增强纤维和热塑性粘合纤维(步骤100),使增强纤维和热塑性粘合纤维共混(步骤110),将增强纤维和热塑性粘合纤维成型为片材(步骤120),任选地针刺该片材以产生片材结构完整性(步骤130),以及将增强纤维和热塑性粘合纤维粘合(步骤140)。
增强纤维和形成热塑性粘合材料的纤维通常以单根纤维的束的形式聚集。在形成短切纤维毡片过程中,增强纤维束和热塑性粘合纤维束由开松系统,例如工业中常用的束开松系统部分地开松。开松系统用来分离聚集的纤维并增强纤维-纤维之间的接触。
现在参看图2,可以最好地看到湿增强纤维和热塑性粘合纤维的开松。湿增强纤维200被进料到第一开松系统220,热塑性粘合纤维210被进料到第二开松系统230,分别至少部分地开松湿增强纤维束和热塑性粘合纤维束。理想的是第一开松系统220部分开松湿增强纤维200束,但不使其成丝。应当注意虽然图1和2中所绘示例性工艺显示由第二开松系统230开松热塑性粘合纤维210,如果热塑性粘合纤维210以成丝的形式(未示出)存在或得到,而不是以束的形式存在或得到,那么热塑性粘合纤维210可以直接送入纤维传输系统250。这种实施方案被认为在本发明的范围内。
第一和第二开松系统220、230优选为束开松机,但是可以为适合开松热塑性粘合纤维210束和湿增强纤维200束的任何开松机类型。开松机的设计取决于待开松的纤维的类型和物理特性。用于本发明的的适合开松机包括有或者没有称重设备的任何常规标准型束开松机。当部分开松的纤维穿过束开松机时,称重设备用来对其进行连续称重,以监测传递到下一个工艺步骤上的纤维量。束开松机可以装有多个精细的开松机、一个或多个刺辊转筒或锯齿转筒、进料辊和/或进料辊和凸杆的组合。
在可选实施方案中,其中热塑性粘合材料为薄片、颗粒或粉末形式(图2中未示出),而不是热塑性粘合纤维,第二开松系统230可以用适合于将粉末状或片状热塑性粘合材料分布到用于与增强纤维200混合的纤维传输系统250的设备替换。适合的设备将是本领域技术人员容易确定的。在其中除了热塑性粘合纤维210之外还使用薄片、颗粒或粉末形式的树脂的实施方案中(图2中未示出),用于分布薄片、颗粒或粉末的设备通常不替换第二开松系统230。热塑性薄片、颗粒或粉末可以直接进料到用于将增强纤维束和热塑性粘合材料混合的纤维传输系统250中。
部分开松的湿增强纤维200然后可以由第一开松系统220计量加入或进料到冷凝装置240以从湿纤维除去水。在示例性实施方案中,除去大于约70%的自由水(增强纤维外部的水)。但是优选由冷凝装置240除去基本上所有的水。应当注意,当在此使用时,短语“基本上所有的水”用来表示除去所有的或几乎所有的自由水。冷凝装置240可以为本领域已知的任何已知干燥或除水设备,例如但不限于空气干燥器、烘箱、辊、空吸泵、加热的转鼓式干燥器、红外加热源、热鼓风机或微波发射源。
增强纤维200束和热塑性粘合纤维210由纤维传输系统250共混在一起。在优选实施方案中,纤维在高速空气流中共混。纤维传输系统250既用作将热塑性粘合纤维210和增强纤维200束运输到片材成型机270的管道,又用作在空气流中将纤维基本上均匀混合的管道。理想的是尽可能均匀地分布增强纤维200和热塑性粘合纤维210。进入纤维传输系统250中空气流的增强纤维200和热塑性粘合纤维210的比率可以由以上关于第一和第二开松系统220、230所述的称重设备控制,或者由纤维穿过第一和第二开松系统220、230的量和/或速率控制。在优选实施方案中,存在于空气流中的增强纤维200与热塑性粘合纤维210的比率为90∶10(分别对应增强纤维200和热塑性粘合纤维210)。
增强纤维200和热塑性粘合纤维210的混合物可以由纤维传输系统250中的空气流输送到片材成型机270,在其中纤维成型为片材。一个或多个片材成型机可以用于形成短切纤维毡片。在本发明的一些实施方案中,共混的纤维在进入片材成型机270之前,由纤维传输系统250输送到填充箱塔260,其中增强纤维200束和热塑性粘合纤维210例如通过计算机监测的电子称重设备按体积进料到片材成型机270。填充箱塔260可以位于片材成型机270内部或者其可以设置在片材成型机270外部。填充箱塔260也可以包括挡板以在进入片材成型机270之前进一步共混和混合增强纤维200和热塑性粘合纤维210。在一些实施方案中,带有冷凝器和分布传送带的片材成型机270可以用来得到进料到填充箱塔260的更高纤维进料和穿过填充箱塔260的提高的空气体积。为了得到开松纤维的改进的横向分布,分布器传送带可以相对片材方向横向运行。结果,热塑性粘合纤维210和增强纤维200束可以在几乎没有或没有压力并且纤维断裂最小的情况下输送进填充箱塔260中。
由片材成型机270形成的片材以所需比例和重量分布包含基本上均匀分布的增强纤维200和热塑性粘合纤维210的束。由片材成型机270形成的片材的重量分布为约80到约500g/m2,优选的重量分布为约80到约300g/m2。
在本发明的一个或多个实施方案中,离开片材成型机270的片材任选地在针刺制毡设备280中进行针刺工艺,在其中倒刺针或叉形针以向下和/或向上运动形式推进穿过片材的纤维,将增强纤维200和热塑性粘合纤维210缠结或缠绕,并赋予毡片机械强度和完整性。针刺制毡设备280可以包括送网机构、带有针板的针板横梁、倒刺制毡针数为每米机宽约500针到每米机宽约7,500针、托板、底板和卷取机构。增强纤维200和热塑性粘合纤维210的机械互锁通过使倒刺制毡针反复穿入和穿出片材而得到。与选定用于本发明工艺的特定增强纤维和聚合物纤维一起使用的最佳针刺选择将是本领域技术人员容易确定的。
虽然热塑性粘合剂材料210用于将增强纤维200彼此粘合,但是可以在片材穿过热粘合系统290之前添加粘合剂树脂285作为额外的粘合剂。粘合剂树脂285可以为树脂粉末、薄片、颗粒、泡沫或液体喷雾形式。粘合剂树脂285可以由任何适合的方式添加,例如溢流和提取方法或者通过在片材上喷涂粘合剂树脂285。添加到片材的粘合剂树脂285的量可以根据短切纤维毡片的所需性能变化。催化剂,例如氯化铵、对甲苯、磺酸、硫酸铝、磷酸铵或硝酸锌可以用来改进固化速率和固化的粘合剂树脂285的质量。
单独的或除了在此所述的其它粘合方法之外,可以用来进一步粘合增强纤维200的其它方法为胶乳粘合。在胶乳粘合中,由单体,例如乙烯(Tg-125℃)、丁二烯(Tg-78℃)、丙烯酸丁酯(Tg-52℃)、丙烯酸乙酯(Tg-22℃)、乙酸乙烯酯(Tg30℃)、氯乙烯(Tg80℃)、甲基丙烯酸甲酯(Tg105℃)、苯乙烯(Tg105℃)和丙烯腈(Tg130℃)形成的聚合物用作粘合剂。较低的玻璃化转变温度(Tg)产生较软质的聚合物。胶乳聚合物可以在片材进入热粘合系统290之前以喷雾形式添加。一旦片材进入热粘合系统290,胶乳聚合物熔融并将增强纤维200粘合在一起。
可以单独使用或与在此所述的其它粘合方法结合使用的另一种任选的粘合方法为化学粘合。液体类粘合剂、粉末粘合剂、泡沫以及在一些情况下,有机溶剂可以用作化学粘合剂。化学粘合剂的适合实例包括但不限于丙烯酸酯聚合物和共聚物、苯乙烯-丁二烯共聚物、乙酸乙烯酯-乙烯共聚物及其结合物。例如,聚乙酸乙烯酯(PVA)、乙烯-乙酸乙烯酯/氯乙烯(EVA/VC)、丙烯酸低级烷基酯聚合物、丁苯橡胶、丙烯腈聚合物、聚氨酯、环氧树脂、聚氯乙烯、聚偏二氯乙烯、偏二氯乙烯与其它单体的共聚物、部分水解的聚乙酸乙烯酯、聚乙烯醇、聚乙烯吡咯烷酮、聚酯树脂和苯乙烯丙烯酸酯可以用作化学粘合剂。化学粘合剂可以通过浸渍、涂布或喷涂片材而均匀施加。
在片材离开片材成型机270之后或任选的片材针刺之后,片材可以穿过热粘合系统290以将增强纤维200和热塑性粘合纤维210粘合并形成短切纤维毡片295。但是,应理解如果片材在针刺制毡设备280中针刺并且增强纤维200和热塑性粘合纤维210机械结合,那么片材可以不需要穿过热粘合系统290来形成短切纤维毡片295。
在热粘合系统290中,片材被加热至高于热塑性粘合纤维210熔点但低于增强纤维200熔点的温度。当双组分纤维用作热塑性粘合纤维210时,热粘合系统290中的温度升高到高于壳纤维的熔融温度但低于增强纤维200的熔融温度的温度。将热塑性粘合纤维210加热到高于其熔点的温度,或者在其中热塑性粘合纤维210为双组分纤维的情况下,将热塑性粘合纤维210加热到高于壳纤维熔点的温度使热塑性粘合纤维210变为粘合剂,并使热塑性粘合纤维210自身和与相邻增强纤维200粘合。熔融的热塑性粘合纤维210起胶水的作用,使分散的玻璃纤维保持束状。如果热塑性粘合纤维210完全熔融,那么熔融的纤维可以包封增强纤维200。只要热粘合系统290内的温度不升高到增强纤维和/或芯纤维的熔点,那么这些纤维将在热粘合系统290和短切纤维毡片295内保持纤维状形式。
热粘合系统290可以包括本领域已知的任何已知加热和/或粘合方法,例如烘箱粘合、使用强制空气的烘箱粘合、红外加热、热压延、带压延、超声波粘合、微波加热和加热转鼓。任选地,这些粘合方法的两种或更多种可以组合用于将增强纤维200和热塑性粘合纤维210粘合。热粘合系统290的温度根据使用的特定热塑性粘合纤维210、粘合剂树脂和/或胶乳聚合物的熔点以及在片材中是否存在双组分纤维加以变化。从热粘合系统290排出的短切纤维毡片295包含分散的热塑性粘合纤维和束状增强纤维。当湿法应用的短切玻璃纤维用作湿增强纤维200时,从热粘合系统290排出的短切纤维毡片295包含分散的热塑性粘合纤维210和束状玻璃长丝。
在可选实施方案(未示出)中,短切纤维毡片由湿法成网方法形成。例如,将增强纤维和热塑性粘合纤维分散在包含粘合剂以及分散剂、粘度调节剂、消泡剂和/或其它化学试剂的水溶液中并且搅拌形成淤浆。位于淤浆中的热塑性粘合纤维和增强纤维然后沉积到运动筛网上,在其中水被除去。任选地,该毡片在烘箱中干燥。该毡片然后可以浸入粘合剂组合物中,用粘合剂组合物浸渍该毡片。该毡片然后穿过固化烘箱以除去任何残留水,固化粘合剂,和至少部分熔融热塑性粘合纤维以将增强纤维和热塑性粘合纤维粘合在一起。得到的短切纤维毡片为分散的热塑性纤维和束状玻璃长丝的组合物。
在另一个可选实施方案(未示出)中,短切纤维毡片由例如上述但并不使用热塑性粘合纤维的湿法成网方法形成。在这种实施方案中,结合剂在固化烘箱中的固化足以提供增强纤维的完整性和形成短切纤维毡片。
短切纤维毡片295可以用于许多应用,例如汽车应用中的增强材料,例如车顶衬垫、发动机罩衬垫、地板衬垫、装饰板、包裹架、遮光罩、仪表板结构、门衬垫等,用于船舶工业(造船)的手工lay-up、真空和压力袋、冷压模具、匹配的金属压型模具和离心浇铸。短切纤维毡片295也可以用于许多非结构性声学应用,例如用于器具、办公室屏风和隔断、天花板面砖和建筑镶板。
在本发明的一个示例性实施方案中,短切纤维毡片295用于干燥聚氨酯泡沫层压工艺以形成衬垫,例如汽车用车顶衬垫。用于生产汽车用衬垫的干燥聚氨酯泡沫层压工艺的一个实例在图3中说明。第一粘合剂层320进料到位于移动式传送带300上的稀纱布310上。由辊330进料的短切纤维毡片295层压到第一粘合剂层320上并由第二粘合剂层340覆盖,使得短切纤维毡片295的第一层夹在第一和第二粘合剂层320、340之间。然后由聚氨酯泡沫材料分配装置360将半刚性聚氨酯泡沫材料,例如聚氨酯泡沫板350设置在第二粘合剂层340上,并且将第三粘合剂层370设置在聚氨酯板350上。应当理解其它结构板或结构层可以代替聚氨酯泡沫板350,以及包括这些结构板或结构层的层状复合材料产品395被认为在本发明的范围内。然后将第二短切纤维毡片层沉积在第三粘合剂层370上。将最终粘合剂层380设置在第二短切纤维毡片层上,由此将第二短切纤维毡片层设置在第三粘合剂层370和最终粘合剂层380之间。由此,如图4中示意性描绘的层状复合材料产品395可以由稀纱布310、第一粘合剂层320、由短切玻璃纤维毡片295形成的层、第二粘合剂层340、聚氨酯板350、第三粘合剂层370、由短切纤维毡片295形成的第二层和最终粘合剂层380的连续层形成。
层状复合材料产品395可以穿过层压烘箱(未示出),在其中施加热和压力以形成最终的层压复合材料(未示出)。层压复合材料可以进一步由常规方法加工成复合材料产品,例如汽车的衬垫。例如,层压复合材料可以修整和例如在模塑工艺中成型为车顶衬垫。在另外的加工步骤中,为了美观性目的,车顶衬垫织物材料,例如布料、乙烯基树脂、皮革、泡沫塑料或壁纸可以设置在最终粘合剂层380上。
第一、第二、第三和最终粘合剂层分别由第一、第二、第三和第四粘合剂形成。粘合剂优选为薄膜形式,但可以为粉末形式。适合的粘合剂实例包括但不限于聚乙烯或其衍生物、乙烯和乙酸乙烯酯的共聚物(EVA)、乙烯和乙酸的共聚物(EAA)、酸改性的聚乙烯、共聚酰胺和丙烯酸乙酯。第一、第二、第三和最终粘合剂层可以由相同的粘合剂或不同的粘合剂形成。
在另一个示例性实施方案中,短切纤维毡片295可以用于湿聚氨酯泡沫层压工艺,用于生产汽车用衬垫。这种湿聚氨酯泡沫层压工艺的一个实例在图5中说明。在第一装配线400中,第一液体粘合剂层410经由粘合剂分配装置420沉积到稀纱布310上。由辊330进料的短切纤维毡片295层压到第一液体粘合剂层410上并由第二液体粘合剂层430覆盖,使得短切纤维毡片295的层夹在第一和第二液体粘合剂层410、430之间。由此产生的第一层压材料产品可以由稀纱布310、第一液体粘合剂层410、短切纤维毡片295的层和第二液体粘合剂层430的顺次层形成。
在第二装配线435中,第三液体粘合剂层440经由粘合剂分配装置420沉积到半刚性聚氨酯泡沫材料(例如聚氨酯泡沫板350)上。应当理解其它结构板或结构层可以代替聚氨酯泡沫板350,以及包括这些结构板或结构层的层状复合材料产品460被认为在本发明的范围内。由辊330进料的短切纤维毡片295被层压到第三液体粘合剂层410上并由第四液体粘合剂层450覆盖。然后将稀纱布310设置在第四液体粘合剂层450上以形成第二层压材料产品,其包括聚氨酯板350、第三液体粘合剂层440、由短切纤维毡片295形成的层、第四液体粘合剂层450和稀纱布310的顺次层。
如图5中描绘的,第一和第二装配线可以一定方式在线会合,使得第二粘合剂层430邻近于聚氨酯板350设置。图6中示意性描绘的层状复合材料产品460可以由稀纱布310、第一液体粘合剂层410、由短切玻璃纤维毡片295形成的层、第二液体粘合剂层430、聚氨酯板350、第三液体粘合剂层440、由短切玻璃纤维毡片295形成的第二层、第四液体粘合剂层450和稀纱布310的连续层形成。形成第一液体粘合剂层410、第二液体粘合剂层430、第三液体粘合剂层440和第四液体粘合剂层450的第一、第二、第三和第四液体粘合剂优选为聚氨酯类粘合剂,以及粘合剂彼此可以相同或不同。层状复合材料产品460可以穿过层压烘箱(未示出),在其中施加热和压力以形成最终的层压复合材料(未示出)。层压复合材料可以进一步由常规方法加工成复合材料产品,例如汽车的衬垫。例如,层压复合材料可以修整和例如通过模塑工艺成型为车顶衬垫。为了美观性目的,泡沫塑料或织物然后可以施加于该车顶衬垫。应当理解,虽然上述干燥和湿的泡沫层压工艺已经以被认为是优选实施方案的形式加以描述,但是对于本领域技术人员可以确认的这些方法的其它变化和可选方案同样被认为是在本发明的范围内。
本发明的一个优点是与常规短切玻璃纤维毡片相比,如上所述形成的短切纤维毡片具有更均匀的重量一致性。本发明短切纤维毡片的均匀的重量一致性在最终产品中产生均匀的性能。例如,当由该毡片形成的车顶衬垫要具有DVD容量或从车顶衬垫侧面展开的防护气囊时,均匀的重量一致性是有利的。没有均匀的重量一致性,防护气囊不能以目标展开速率展开。
此外,本发明短切纤维毡片的均匀性能促进使用比传统短切玻璃纤维毡片重量更轻的增强材料。另外,本发明的短切纤维毡片提供改进的流动和整个车顶衬垫基材的一致性,其对于汽车制造商产生更大的设计和款式自由度。此外,根据本发明的短切纤维毡片通过提高拉伸比提供改进的模塑性能,并且其能够与车顶衬垫的形状一致并仍然提供均匀性能。
此外,通过改变用于短切纤维毡片的增强纤维和/或热塑性粘合纤维的重量、长度和/或直径,该短切纤维毡片具有使特定应用所需的物理性能(例如劲度或强度)最佳化和/或得到调整的能力。此外,增强纤维的上浆化学过程容易改造以配合热塑性粘合纤维的各种类型的性能。结果,可以形成多种短切纤维毡片和由短切纤维毡片形成的复合材料产品。此外,短切纤维毡片具有均匀的或基本上均匀的增强纤维束和粘合纤维的分布,由此提供改进的强度以及改进的声学和热性能、强度、劲度、耐冲击性和声学吸收性。
另外,使用湿法应用的短切玻璃纤维提供优于常规干法成网玻璃纤维工艺的成本。例如,因为干燥纤维通常在切断之前在分开的步骤中加以干燥和包装,所以相比干燥的短切纤维,湿法应用的短切玻璃纤维制造相对低廉。此外,由于玻璃纤维中存在水分,所以湿法应用的短切玻璃纤维可以容易地开松,而几乎不产生静电。结果,使用湿法应用的短切玻璃纤维使得可以较低成本制造短切纤维毡片。此外,因为增强(玻璃)纤维并未成丝,所以它们具有润湿片材中的其它组分(聚氨酯泡沫)的能力。如果增强纤维无法润湿片材的热塑性粘合组分(一种或多种),那么最终产品可能层离并且机械性能差。
本申请的发明已经在以上一般性地和根据特殊实施方案加以描述。虽然本发明已经以被认为是优选实施方案的形式加以阐明,但是可以在一般公开范围内选择本领域技术人员已知的多种可选方案。除了以下阐明的权利要求的叙述之外,本发明并不另外受到限制。
Claims (23)
1.一种形成隔音和隔热的短切纤维毡片的方法,该短切纤维毡片适合用于汽车应用中,该方法包括以下步骤:
至少部分开松湿增强纤维束(100);
从所述部分开松的湿增强纤维束除去至少一部分水以形成脱水的增强纤维束;
混合所述脱水的增强纤维束和热塑性粘合材料以形成所述脱水的增强纤维束和所述热塑性粘合材料的基本上均匀的混合物(110);
将所述脱水的增强纤维束和所述热塑性粘合材料的所述混合物成型为片材(120);和
将所述脱水的增强纤维束的至少一部分和所述热塑性粘合材料粘合以形成短切纤维毡片(140)。
2.权利要求1的方法,其中所述粘合步骤包括将所述片材加热到高于所述热塑性粘合材料熔点和低于所述脱水的增强纤维束熔点的温度,以使所述热塑性粘合材料至少部分熔融并将所述脱水的增强纤维束的至少一部分和所述热塑性粘合材料粘合。
3.权利要求2的方法,其中所述成型步骤包括使所述脱水的增强纤维束和所述热塑性粘合材料的所述混合物穿过片材成型机(270)。
4.权利要求3的方法,进一步包括在所述成型步骤之前,将所述脱水的增强纤维束和所述热塑性粘合材料的所述混合物输送到填充箱塔(260)的步骤,所述填充箱塔按体积将所述混合物进料到所述片材成型机。
5.权利要求2的方法,进一步包括在所述粘合步骤之前,使所述片材进行针刺工艺(280)以机械结合所述脱水的增强纤维束和所述热塑性粘合材料的步骤;和其中所述热塑性粘合材料为至少一种选自热塑性纤维、热固性纤维和双组分纤维的材料。
6.权利要求1的方法,其中所述粘合步骤包括使所述片材进行针刺工艺以机械结合所述脱水的增强纤维束和所述热塑性粘合材料;和其中所述热塑性粘合材料为至少一种选自热塑性纤维、热固性纤维和双组分纤维的材料。
7.权利要求1的方法,进一步包括在所述粘合步骤之前,添加粘合剂(285)的步骤,所述粘合剂选自树脂粉末、树脂薄片、胶乳聚合物、树脂颗粒、粘合剂泡沫和有机溶剂。
8.权利要求1的方法,进一步包括开松所述热塑性粘合材料的束以使所述热塑性粘合材料成丝的步骤,所述热塑性粘合材料为至少一种选自热塑性纤维、热固性纤维和双组分纤维的材料。
9.权利要求1的方法,其中所述湿增强纤维为湿法应用的短切玻璃纤维,以及所述热塑性粘合材料为至少一种选自热塑性纤维、热固性纤维和双组分纤维的材料。
10.一种适合用于汽车应用的隔音和隔热的无纺短切纤维毡片,包括:
脱水的湿增强纤维(200)束;和
熔点低于所述脱水的湿增强纤维束熔点的热塑性粘合材料(210),所述热塑性粘合材料将所述脱水的湿增强纤维束的至少一部分和所述热塑性粘合材料粘合;和
其中所述脱水的湿增强纤维束和所述热塑性粘合材料在整个所述短切纤维毡片中基本上均匀分布。
11.根据权利要求10的短切纤维毡片,其中所述增强纤维选自玻璃纤维、羊毛玻璃纤维、天然纤维、金属纤维、陶瓷纤维、矿物纤维、碳纤维、石墨纤维、尼龙纤维、人造纤维素纤维、聚合物类热塑性纤维及其结合物。
12.根据权利要求10的短切纤维毡片,其中所述脱水的湿增强纤维以全部纤维的约80到约98wt%的量存在于所述短切纤维毡片中,和所述热塑性粘合材料以全部纤维的约2到约20wt%的量存在于所述短切纤维毡片中。
13.根据权利要求12的短切纤维毡片,其中所述短切纤维毡片具有约80到约500g/m2的重量分布。
14.根据权利要求10的短切纤维毡片,其中所述脱水的湿增强纤维为脱水的湿法应用的短切玻璃纤维,和所述热塑性粘合材料为双组分纤维。
15.根据权利要求14的短切纤维毡片,其中所述双组分纤维选自聚对苯二甲酸乙二醇酯/聚丙烯、聚对苯二甲酸乙二醇酯/聚乙烯、聚丙烯/聚乙烯、共聚聚酯聚对苯二甲酸乙二醇酯/聚对苯二甲酸乙二醇酯(coPET/PET)、聚对苯二甲酸1,4-环己烷二甲酯/聚丙烯(PCT/PP)、高密度聚乙烯/聚对苯二甲酸乙二醇酯(HDPE/PET)、高密度聚乙烯/聚丙烯(HDPE/PP)、线性低密度聚乙烯/聚对苯二甲酸乙二醇酯(LLDPE/PET)、尼龙6/尼龙6,6(PA6/PA6,6)和二醇改性的聚对苯二甲酸乙二醇酯/聚对苯二甲酸乙二醇酯(6PETg/PET)。
16.一种形成层压复合材料的方法,包括以下步骤:
在稀纱布(310)上设置由第一粘合剂形成的第一粘合剂层(320);
在所述第一粘合剂层上沉积第一短切纤维毡片层(340),所述短切纤维毡片包括脱水的湿增强纤维束和熔点低于所述脱水的湿增强纤维熔点的热塑性粘合材料,所述热塑性粘合材料已经进行热处理至至少部分熔融,并将所述脱水的湿增强纤维束的至少一部分和所述热塑性粘合材料粘合;
在所述第一短切纤维毡片层上设置由第二粘合剂形成的第二粘合剂层(340);和
在所述第二粘合剂层上设置泡沫材料(350)以形成层压复合材料。
17.权利要求16的方法,进一步包括以下步骤:
在所述泡沫材料上沉积由第三粘合剂形成的第三粘合剂层(370);
在所述第三粘合剂层上设置第二短切纤维毡片层(295);和
在所述第二短切纤维毡片层上设置由第四粘合剂形成的第四粘合剂层(380)。
18.权利要求17的方法,进一步包括形成所述短切纤维毡片的步骤,所述形成步骤包括:
部分开松湿增强纤维(200)束;
从所述部分开松的湿增强纤维束除去至少一部分水以形成所述脱水的湿增强纤维束;
混合所述脱水的湿增强纤维束和所述热塑性粘合材料以形成所述脱水的湿增强纤维束和所述热塑性粘合材料的基本上均匀的混合物(250);
将所述脱水的湿增强纤维束和所述热塑性粘合材料的所述混合物成型为片材(270);和
将所述脱水的湿增强纤维束的至少一部分和所述热塑性粘合材料粘合以形成所述短切纤维毡片(290)。
19.权利要求17的方法,其中所述第一、第二、第三和第四粘合剂具有选自薄膜和粉末的形式。
20.权利要求16的方法,其中所述泡沫材料为聚氨酯泡沫板。
21.权利要求17的方法,其中所述层压复合材料产品为汽车的车顶衬垫,以及所述方法进一步包括以下步骤:
修整所述层压复合材料产品;和
将所述修整的层压复合材料模塑成车顶衬垫。
22.权利要求21的方法,进一步包括在所述修整步骤之前,使所述层压复合材料产品穿过层压烘箱的步骤。
23.一种形成层压复合材料产品的方法,包括以下步骤:
形成第一层状材料(400),包括:
在第一稀纱布(310)上沉积由第一粘合剂形成的第一粘合剂层(410);
在所述第一粘合剂层上设置第一短切纤维毡片层(295),所述短切纤维毡片包括脱水的湿增强纤维束和熔点低于所述脱水的湿增强纤维熔点的热塑性粘合材料,所述热塑性粘合材料将所述脱水的湿增强纤维束和所述热塑性粘合材料粘合;和
在所述第一短切纤维毡片层上设置由第二粘合剂形成的第二粘合剂层(430);
形成第二层状材料(435),包括:
在泡沫材料层(350)上沉积由第三粘合剂形成的第三粘合剂层(440);
在所述第三粘合剂层上设置第二短切纤维毡片层(295);
在所述第二短切纤维毡片层上沉积由第四粘合剂形成的第四粘合剂层(450);和
在所述第四粘合剂层上设置第二稀纱布(310);和
设置所述第二层状材料和所述第一层状材料,使得所述泡沫材料层与所述第二粘合剂层邻近以形成所述层压复合材料产品。
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JP2004277951A (ja) * | 2003-03-18 | 2004-10-07 | Nippon Electric Glass Co Ltd | ガラスチョップドストランドマット及びそれを用いた自動車成形天井材 |
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US7279059B2 (en) * | 2004-12-28 | 2007-10-09 | Owens Corning Intellectual Capital, Llc | Polymer/WUCS mat for use in automotive applications |
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US20060137799A1 (en) * | 2004-12-29 | 2006-06-29 | Enamul Haque | Thermoplastic composites with improved sound absorbing capabilities |
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-
2004
- 2004-12-28 US US11/024,104 patent/US7279059B2/en not_active Expired - Fee Related
-
2005
- 2005-12-06 WO PCT/US2005/043963 patent/WO2006071464A1/en active Application Filing
- 2005-12-06 AT AT05853000T patent/ATE500368T1/de not_active IP Right Cessation
- 2005-12-06 JP JP2007549396A patent/JP2008525663A/ja not_active Ceased
- 2005-12-06 MX MX2007007966A patent/MX2007007966A/es active IP Right Grant
- 2005-12-06 DE DE602005026704T patent/DE602005026704D1/de active Active
- 2005-12-06 CN CNA2005800466848A patent/CN101160425A/zh active Pending
- 2005-12-06 CA CA002591883A patent/CA2591883A1/en not_active Abandoned
- 2005-12-06 KR KR1020077017509A patent/KR20070103405A/ko not_active Application Discontinuation
- 2005-12-06 EP EP05853000A patent/EP1831444B1/en not_active Revoked
-
2007
- 2007-08-30 US US11/897,409 patent/US20080050571A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
DE602005026704D1 (de) | 2011-04-14 |
KR20070103405A (ko) | 2007-10-23 |
CA2591883A1 (en) | 2006-07-06 |
EP1831444A1 (en) | 2007-09-12 |
MX2007007966A (es) | 2007-11-09 |
US7279059B2 (en) | 2007-10-09 |
WO2006071464A1 (en) | 2006-07-06 |
US20060141884A1 (en) | 2006-06-29 |
JP2008525663A (ja) | 2008-07-17 |
ATE500368T1 (de) | 2011-03-15 |
EP1831444B1 (en) | 2011-03-02 |
US20080050571A1 (en) | 2008-02-28 |
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