AU2012224772A1 - Composite elements - Google Patents
Composite elements Download PDFInfo
- Publication number
- AU2012224772A1 AU2012224772A1 AU2012224772A AU2012224772A AU2012224772A1 AU 2012224772 A1 AU2012224772 A1 AU 2012224772A1 AU 2012224772 A AU2012224772 A AU 2012224772A AU 2012224772 A AU2012224772 A AU 2012224772A AU 2012224772 A1 AU2012224772 A1 AU 2012224772A1
- Authority
- AU
- Australia
- Prior art keywords
- foil
- core
- composite element
- outer layer
- element according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 41
- 239000006260 foam Substances 0.000 claims abstract description 32
- 239000011148 porous material Substances 0.000 claims abstract description 11
- 239000011888 foil Substances 0.000 claims description 87
- 238000000034 method Methods 0.000 claims description 25
- 230000008569 process Effects 0.000 claims description 24
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 13
- 230000001070 adhesive effect Effects 0.000 claims description 13
- 239000011496 polyurethane foam Substances 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 12
- 229920003023 plastic Polymers 0.000 claims description 12
- 239000004033 plastic Substances 0.000 claims description 12
- 239000004433 Thermoplastic polyurethane Substances 0.000 claims description 11
- -1 polypropylene Polymers 0.000 claims description 11
- 238000005057 refrigeration Methods 0.000 claims description 11
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 230000004888 barrier function Effects 0.000 claims description 7
- 229920001577 copolymer Polymers 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 7
- 229920000877 Melamine resin Polymers 0.000 claims description 5
- 239000007789 gas Substances 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 5
- 238000000926 separation method Methods 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 4
- 239000004964 aerogel Substances 0.000 claims description 4
- 239000003063 flame retardant Substances 0.000 claims description 4
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 4
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 230000003319 supportive effect Effects 0.000 claims description 3
- 239000002033 PVDF binder Substances 0.000 claims description 2
- 238000003475 lamination Methods 0.000 claims description 2
- 238000001465 metallisation Methods 0.000 claims description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 claims description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 claims 1
- 239000002905 metal composite material Substances 0.000 claims 1
- 239000012815 thermoplastic material Substances 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 39
- 238000000465 moulding Methods 0.000 description 10
- 229920002877 acrylic styrene acrylonitrile Polymers 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 238000009413 insulation Methods 0.000 description 7
- 239000000178 monomer Substances 0.000 description 6
- RZVAJINKPMORJF-UHFFFAOYSA-N Acetaminophen Chemical compound CC(=O)NC1=CC=C(O)C=C1 RZVAJINKPMORJF-UHFFFAOYSA-N 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 238000009792 diffusion process Methods 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- YAAQEISEHDUIFO-UHFFFAOYSA-N C=CC#N.OC(=O)C=CC=CC1=CC=CC=C1 Chemical compound C=CC#N.OC(=O)C=CC=CC1=CC=CC=C1 YAAQEISEHDUIFO-UHFFFAOYSA-N 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 239000012948 isocyanate Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 239000002174 Styrene-butadiene Substances 0.000 description 2
- 239000002318 adhesion promoter Substances 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 2
- 239000002775 capsule Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 2
- 150000002513 isocyanates Chemical class 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 239000004926 polymethyl methacrylate Substances 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920003009 polyurethane dispersion Polymers 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000011115 styrene butadiene Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000004711 α-olefin Substances 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229920005832 Basotect® Polymers 0.000 description 1
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- GYCMBHHDWRMZGG-UHFFFAOYSA-N Methylacrylonitrile Chemical compound CC(=C)C#N GYCMBHHDWRMZGG-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000001588 bifunctional effect Effects 0.000 description 1
- 230000002146 bilateral effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000003851 corona treatment Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- GOAJGXULHASQGJ-UHFFFAOYSA-N ethene;prop-2-enenitrile Chemical group C=C.C=CC#N GOAJGXULHASQGJ-UHFFFAOYSA-N 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000000499 gel Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 229920005669 high impact polystyrene Polymers 0.000 description 1
- 239000004797 high-impact polystyrene Substances 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 229920000592 inorganic polymer Polymers 0.000 description 1
- 239000002346 layers by function Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 239000011087 paperboard Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 230000003763 resistance to breakage Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000012205 single-component adhesive Substances 0.000 description 1
- 150000003384 small molecules Chemical class 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
Classifications
-
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- B32B5/18—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 characterised by features of a layer of foamed material
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
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- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
- E04B1/803—Heat insulating elements slab-shaped with vacuum spaces included in the slab
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D23/00—General constructional features
- F25D23/06—Walls
- F25D23/065—Details
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D23/00—General constructional features
- F25D23/08—Parts formed wholly or mainly of plastics materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
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- B32B2255/00—Coating on the layer surface
- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
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- B32B2255/00—Coating on the layer surface
- B32B2255/20—Inorganic coating
- B32B2255/205—Metallic coating
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- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
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- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/304—Insulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2509/00—Household appliances
- B32B2509/10—Refrigerators or refrigerating equipment
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B2001/7691—Heat reflecting layers or coatings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D2201/00—Insulation
- F25D2201/10—Insulation with respect to heat
- F25D2201/14—Insulation with respect to heat using subatmospheric pressure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/24—Structural elements or technologies for improving thermal insulation
- Y02A30/242—Slab shaped vacuum insulation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
- Y02B80/10—Insulation, e.g. vacuum or aerogel insulation
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Acoustics & Sound (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Laminated Bodies (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
The invention relates to a composite element containing a) a core made of a foam or a porous material, b) a top coat applied to the core a), and c) a film c) which differs from the top coat b) and is made of a thermoplastic material.
Description
Composite elements Description 5 The invention relates to composite elements composed of a plastics-foil-coated core made of foam or of a porous material. Composite elements made of a foam core surrounded by at least one outer layer are well known. They have decorative functions, but are preferably used for thermal insulation, for 0 example on buildings or in refrigeration equipment. Refrigeration equipment is very important in both the commercial sector and the private sector. It is mostly produced by manufacturing a casing into which a liquid mixture made of a rigid polyurethane foam system is introduced, and the system hardens in the casing to give the 5 polyurethane. "Vacuum insulation panels" also abbreviated to VIPs, have been used in recent times to reduce thermal conductivity. These, too, are mostly introduced into the casings and are surrounded there with rigid polyurethane foam. ?0 These processes are inconvenient. In particular when VIPs are incorporated, a fixing process is necessary. During transport and during further handling, and also during the foaming process around VIPs, there is also the risk of damage to the VIPs, for example in the region of the welds. !5 The Permaskin process is a known method for use of a plastics foil to sheath substrates. It is described by way of example in WO 01/32400. Here, a molding is arranged in a chamber between two thermoplastic foils separated from one 0 another, and is fixed, and then the air is evacuated from the chamber, and the foil is thus pressed on to the surface of the molding, while a vacuum is maintained between the foils. The foil here is preferably heated, in particular to a temperature above the softening point of the foil. The rigid polyurethane foams used in the thermal/low-temperature-insulation sector can in 5 principle also be used as substrate. The application WO 2008/135550 describes this. Bilaterally coated rigid foam elements thus produced exhibit increased loadbearing capability, resistance to breakage, and resistance to weathering, and also improved feel, and barrier action with respect to the ingress of liquids. The example given coats a rigid foam made of Neopolen. Reference is made to the fact that rigid polyurethane foams can be used. The rigid foams used 0 do not have any further previously applied functional layers.
2 However, moldings produced in this way have only inadequate long-term insulation properties, because of gas-exchange processes. Furthermore, resistance to mechanical loads is only low, examples being loads that can arise on contact with pointed or sharp-edged articles. 5 The object of the present invention was to provide composite elements which can be used for refrigeration equipment and which optionally permit the incorporation of VIPs. They are intended to be easy to produce, and to have good mechanical strength and low intrinsic weight. A further intention is that it be possible to apply decorative layers. o Surprisingly, the object was achieved via the subject matter of the invention, namely a composite element comprising a) a core made of a foam or of a porous material, 5 b) an outer layer applied to the core a), and, c) a foil made of a thermoplastic and differing from the outer layer b). The invention further provides the production of the composite elements, and also the use 0 thereof, in particular for producing refrigeration equipment. The core a) is preferably one selected from the group comprising foams and porous materials. The foams a) are preferably selected from the group comprising melamine-formaidehyde !5 foams, rigid open-cell polyurethane foams, and rigid closed-cell polyurethane foams. The porous materials are preferably monolithic organic or inorganic polymers, hereinafter also termed monoliths. Among the monoliths, particular preference is given to aerogels. Aerogels are gels which have pores and have been dried under supercritical conditions. In one preferred embodiment of the invention, the core a) is a foam, in particular a rigid foam. The foams are open-cell or closed-cell foams, and this varies with the application sector of the composite elements. The open-cell foams can be melamine-formaldehyde foams or rigid polyurethane foams, preferably rigid polyurethane foams, and in particular rigid open-cell 35 polyurethane foams. For the purposes of the invention, rigid foams are foams to DIN 7726 (05/1982), where these exhibit relatively high resistance to deformation under compressive load (compressive stress for 10% compression, or compressive strength to DIN 53421, 06/1984, a 80 kPa). [0 The rigid polyurethane foams used as core a) are known. The open-cell foams, which can be evacuated, have also been widely described, for example in EP 2072548. The foams can be 3 used as core a) without further pretreatment. WO 2006/120183 says that the foam can be compressed to improve ease of evacuation. The melamine-formaldehyde foams are likewise known, for example from EP 74593. Products 5 of this type are marketed by way of example by BASF SE as Basotect*. Aerogels that can be used as core a) are described by way of example in WO 2007/065847. The outer layer b) is preferably selected from the group comprising barrier layers with respect to 0 gases, also termed diffusion barriers, where water vapor is also regarded as gas, flame retardant layers, and mechanically supportive layers. The diffusion barriers preferably involve foils impermeable to water vapor and to other gases. 5 The flame-retardant barriers preferably involve thin-layer mats made of mineral wool, alkali metal silicate layers, as described by way of example in WO 2006/040097, or layers made of other known flame retardants, such as phosphorus, graphite, melamine, or antimony trioxide. The mechanically supportive coatings preferably involve single- or multilayer systems made of ?0 paperboard, plastic, or sheetmetal, and these can optionally also have been reinforced by a honeycomb structure located thereunder. It is particularly preferable that, as described, the diffusion barriers used as outer layer b) involve foils. ?5 The outer layer b) can, in the simplest case, involve a metal layer, preference being given here to foils made of aluminum. The outer layer b) is preferably a composite foil. It is particularly preferable that the outer layer b) involves a multilayer composite foil with a 30 metal layer applied by metallization or by lamination. It is particularly preferable that the metal layer of the foil used as outer layer b) is composed of aluminum. 35 Accordingly, the outer layer b) is in particular an aluminum foil or an aluminum composite foil. The foil used as outer layer b) is in particular itself composed of polyester, polyvinyl chloride, polyolefins, such as polyethylene or polypropylene, or polyvinyl alcohol. [0 In the sector of vacuum insulation panels, for the subsequent sealing process, preference is given to aluminum composite foils b), composed of an aluminum layer with a thickness of about 6 micrometers and of a polyethylene layer, or to metalized high-barrier laminates composed of 4 Al-metalized polyethylene laminates or of Al-metalized polyethylene terephthalate laminates, where the thickness of the Al layer here is only from 30 to 100 nm. The metalized high-barrier laminates are composed at least of two Al layers in order to inhibit ingress of small molecules, e.g. water, by lengthening the diffusion paths. However, in the case of thermal insulation 5 applications of the composite elements, the thickness of the metal layer should certainly not exceed a number of micrometers, since otherwise the heat loss through thermal bridging, and in particular through dissipation at corners, becomes excessive. In one preferred embodiment of the invention, the outer layer b) is a foil which completely 0 encloses the core a). It is particularly preferable that the outer layer b) is, as described, a gas impermeable foil. In this embodiment of the invention, the core a) has preferably been evacuated. In this embodiment, it is preferable that the abovementioned open-cell foams are used as core 5 a), examples being melamine-formaldehyde foams and rigid open-cell polyurethane foams. The core a) has been completely sheathed by the outer layer b), and has been sealed so as to be gastight. As stated above, the foil c) is composed of a thermoplastic. This is preferably selected from the 0 group comprising polyvinyl chloride, styrene copolymers, polypropylene, polyvinylidene fluoride, thermoplastic polyurethane (TPU), and polymethyl methacrylate (PMMA), and mixtures made of thermoplastic polyurethane and of styrene copolymers. Foils of this type are known and are described by way of example in W02004/098878. 5 The thickness of the foils c) used is preferably from 50 to 750 pm, with preference from 100 to 500 pm, and with particular preference from 200 to 350 pm. They can be produced from the corresponding starting materials in pellet form, by the known processes of foil production. Blow foils or cast foils can be involved here, and for production of cast foils here the extrusion 0 process is preferred. In order to improve adhesive properties, the foils can have been subjected to a Corona treatment on one or else on both sides. 5 W02008/135550 describes a specific embodiment of the foil c). This is composed of mixtures comprising thermoplastic polyurethane (TPU) and an acrylonitrile-styrene-acrylate copolymer (ASA). Said mixtures (1) comprise from 1% by weight to 40% by weight, preferably from 3% by weight 0 to 30% by weight, particularly preferably from 5% by weight to 25% by weight, of (A) thermoplastic polyurethane, in particular based on aliphatic isocyanate, and from 60% by weight to 99% by weight, preferably from 70% by weight to 97% by weight, particularly preferably from 5 75% by weight to 95% by weight, of (B) acrylonitrile-styrene-acrylate copolymer (ASA) and/or acrylonitrile-ethylene homo- or copolymer-styrene (AES) material, preferably acrylonitrile styrene-acrylate copolymer (ASA), based in each case on the total weight of the mixture (1), preferably based on the total of the weights of (A) and (B) in the mixture (1). 5 The ASA (B) is preferably based on: (B1) from 10 to 90% by weight of at least one graft rubber based on (B11) from 50 to 95% by weight of a graft base produced using 0 (8111) from 70 to 99.9% by weight of at least one alkyl acrylate (B112) from 0.1 to 30% by weight of at least one at least bifunctional crosslinking agent, (8113) from 0 to 29.9% by weight of at least one other copolymerizable monomer, (B12) from 5 to 50% by weight of a graft shell based on (8121) from 65 to 90% by weight, preferably from 70 to 80% by weight, of at least one 5 vinylaromatic monomer, (B122) from 10 to 35% by weight, preferably from 20 to 30% by weight, of at least one polar, copolymerizable unsaturated monomer, preferably acrylonitrile and/or methacrylonitrile, (B123) from 0 to 25% by weight of at least one other copolymerizable comonomer, 0 (82) from 10 to 90% by weight of at least one copolymer produced with the components (B21) from 60 to 85% by weight of at least one vinylaromatic monomer, (822) from 15 to 40% by weight of at least one polar, copolymerizable unsaturated monomer, and (B23) from 0 to 9% by weight of at least one comonomer, 5 where the weight data relating to (81) and (B2) are based on the weight of (B), the weight data relating to (B11 and B12) are based on the weight of (B1), the weight data relating to (B111), (8112), and (B113) are based on the weight of component (B11), (B121), (8122), and (8123) are based on the weight of (812), and the weight data for (821), (B22), and (823) are based on 0 the weight of (B2). AES materials are composed of a matrix made of polystyrene and acrylonitrile and optionally other monomers. in respect of the above data relating to preferred component B, AES materials differ from ASA materials in component B11, which in the case of the AES materials can be 5 based on ethylene homo- or copolymers. Examples of copolymers that can be used are C3-C20-alpha-olefins, preferably C3-C8-alpha-olefins. Handbuch der Technischen Polymerchemie [Handbook of Industrial Polymer Chemistry], VCH Verlag, 1993, in particular page 490, provides a detailed description of production processes for AES plastics, and also a suitable constitution for these materials. 0 The TPU is preferably an aliphatic TPU, where the isocyanate used is in particular hexamethylene 1,6-diisocyanate (HDI).
6 An adhesive is preferably applied between the foils b) and c) in order to improve the adhesion between the two foils. 5 Adhesives used are preferably aqueous systems based on polyurethane, and these can be single-component or two-component systems. Single-component adhesives that can be used are mostly polyurethane dispersions. These are known and commercially available, and an example that may be mentioned here is Jowapur@ 0 150.50 from Jowat. Two-component adhesives that can be used are mostly combinations of polyurethane dispersions, for example Jowapur@ 150.30, with isocyanates, such as Jowat@ 195.40 from Jowat. However, adhesives based on acrylate or on epoxy resin are also suitable for use here. 5 The adhesive can be applied by the conventional methods, such as spreader application, roller application, or spray application, particular preference being given here to the spray application process. A drying time of 20 minutes at room temperature after application of the adhesive is sufficient for the systems described. :0 It is also possible that the location of the adhesive is on one of the foils b) and c), preferably on the foil c). A two-layer foil with an adhesion promoter based on elastomeric styrene-butadiene block polymers is particularly suitable, examples of these being described in WO-A 96/23823 and WO-A 97/46608 for the coating of rigid foams by the process of the invention. When the adhesive foils mentioned are used it is generally possible to omit use of any additional 5 adhesive. It is preferable to use coextruded two-layer foils composed of a backing layer, for example polystyrene, HIPS, ASA, polyamide, polypropylene, polyethylene, or polyester, and of an adhesion-promoter layer made of an elastomeric thermoplastic, such as the styrene butadiene block polymers mentioned. 0 The dimensions of the composite elements are generally from DIN A4 format up to a few square meters. The layer thickness of the composite elements usually ranges from 50 to 2000 mm. The production of composite elements preferably uses the process described in WO 01/32400. 15 Said process generally comprises the steps of - provision of a core, - application of the layer b), 10 7 - arrangement of the coated core made of foam or of a porous material a) in a chamber with at least one foil c) and securing of the same, with separation between the foil c) and the coated core, 5 - evacuation of the air from the chamber, - heating of the plastics foil c), and - pressing the plastics foil c) on to the surface of the coated core a), and 0 - removal of the composite element. In many cases the layer b) can be applied to the core a) in a separate process. 5 When foils are used as outer layer b), the application of the foil used as outer layer b) can also take place immediately prior to introduction into the apparatus for application of the foil c). It is also possible to apply the foils b) and c) in the same apparatus. M0 If the intention is to evacuate the core a), the evacuation process and the sealing with component b) can take place prior to application of the foil c). A process of this type would comprise the steps ?5 al) provision of a core made of foam or of porous material a), b1) use of a foil b) to sheath the core, ci) evacuation of the core a) and airtight sealing of the foil b), 30 d1) arrangement of the coated core a) in a chamber with at least one foil c) and securing of the same, with separation between the foil c) and the coated core, el) evacuation of the air from the chamber, 35 fi) heating of the plastics foil c), and g1) pressing the plastics foil c) on to the surface of the coated core a), 10 hi) removal of the composite element.
8 In another embodiment of the process of the invention, the core-evacuation process can take place in the apparatus for application of the foil c). A process of this type would comprise the steps of: 5 A) provision of a core made of foam or of porous material a), B) use of a foil b) to sheath the core, 0 C) arrangement of the coated core a) in a chamber with at least one foil c) and securing of the same, with separation between the foil c) and the coated core, D) evacuation of the air from the chamber, 5 E) airtight sealing of the foil b), F) heating of the plastics foil c), and G) pressing of the plastics foil c) on to the surface of the coated core a), 20 H) removal of the composite element. This embodiment of the process of the invention is simpler than separate application of component b) to the core a), and takes less time. 25 Between steps d) and e) it is preferable to apply an adhesive to the coated core and/or the foil c). It is preferable that, in step f), the foil c) is heated beyond the softening point. 30 It is preferable that steps b) and c) are undertaken in the same apparatus. For the process of the invention for the bilateral coating of the core a) with a plastics foil it is essential that '5 - the molding is arranged and secured in a capsule between foils, with separation, - the air is evacuated from the capsule, and - the foils are thus pressed on to opposite areas of the molding, while a vacuum is maintained between the foils. This reduces the risk of surface defects, such as creases or 0 misalignments.
9 The foils c) can be applied on one side of the composite element. It is preferable that a foil c) is applied on two opposite sides of the molding. The foil c) here can be flush with the edge of the molding, and in another embodiment of the invention the foil c) can have been deflected over the edge of the molding. The foil c) can also completely surround the molding here. 5 The composite elements of the invention are versatile. By way of example, they can be used in the construction industry, for example in the thermal insulation of buildings. The foil c) here serves not only for decorative purposes but also to protect the core a) from the effects of weathering. 0 Desired properties of the composite element can be achieved as desired, for example in relation to flame retardancy, by virtue of the different outer layers b). The moldings of the invention can be used with particular advantage in the production of 5 refrigeration equipment. The composite elements can be produced in the shape of the walls and doors of refrigeration equipment. Said components can then be assembled to give the finished refrigeration equipment, thus considerably simplifying the production of the refrigeration equipment. Here again, the color and the decorative effect of the refrigeration equipment can be varied via the foil c). Protection of the surface is also achieved. 0 The use of evacuated composite elements can moreover reduce the thermal conductivity of the refrigeration equipment.
Claims (16)
1. A composite element comprising 5 a) a core made of a foam or of a porous material, b) an outer layer applied to the core a), and, c) a foil c) made of a thermoplastic and differing from the outer layer b). 0
2. The composite element according to claim 1, wherein the core a) is a foam selected from the group comprising melamine-formaldehyde foams, rigid open-cell polyurethane foams, and rigid closed-cell polyurethane foams. 5
3. The composite element according to claim 1, wherein the core a) is an aerogel.
4. The composite element according to any of claims 1 to 3, wherein the outer layer b) is selected from the group comprising barrier layers with respect to gases, flame-retardant layers, and mechanically supportive layers. 0
5. The composite element according to any of claims 1 to 4, wherein the outer layer b) is a metal foil or an metal-composite foil.
6. The composite element according to any of claims I to 5, wherein the outer layer b) is a 5 multilayer composite foil with a metal layer applied by metallization or by lamination.
7. The composite element according to any of claims 1 to 6, wherein the metal layer of the outer layer b) is composed of aluminum. 0
8. The composite element according to any of claims 1 to 7, wherein the outer layer b) is a foil which completely encloses the core a), and wherein the core a) has been evacuated.
9. The composite element according to any of claims 1 to 8, wherein the foil c) has been applied only at two opposite sides of the composite element. 5
10. The composite element according to any of claims 1 to 9, wherein an adhesive has been applied between the outer layer b) and the foil c).
11. The composite element according to any of claims I to 10, wherein the material for the foil 0 c) has been selected from the group comprising polyvinyl chloride, styrene copolymers, polypropylene, polyvinylidene fluoride, thermoplastic polyurethane (TPU), and polymethyl 11 methacrylate (PMMA), and mixtures made of thermoplastic polyurethane and of styrene copolymers.
12. A process for producing composite elements according to any of claims I to 11, 5 comprising the following steps: al) provision of a core made of foam or of porous material a), b1) use of a foil b) to sheath the core, 0 c1) evacuation of the core a) and airtight sealing of the foil b), d1) arrangement of the coated core a) in a chamber with at least one foil c) and securing of the same, with separation between the foil c) and the coated core, 5 el) evacuation of the air from the chamber, f1) heating of the plastics foil c), and 0 g1) pressing of the plastics foil c) on to the surface of the coated core a), hi) removal of the composite element.
13. The process according to claim 12, wherein, between steps d1l) and el), an adhesive is .5 applied to the coated core and/or the foil c).
14. The process according to claim 12 or 13, wherein, in step f1), the foil c) is heated beyond the softening point. 30
15. The process according to any of claims 12 to 14, wherein steps b1) and ci) are undertaken in the same apparatus.
16. The use of the composite elements according to any of claims 1 to 11 for producing refrigeration equipment.
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EP11156998 | 2011-03-04 | ||
EP11156998.4 | 2011-03-04 | ||
PCT/EP2012/053393 WO2012119892A1 (en) | 2011-03-04 | 2012-02-29 | Composite elements |
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AU2012224772A1 true AU2012224772A1 (en) | 2013-09-19 |
AU2012224772B2 AU2012224772B2 (en) | 2015-09-03 |
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EP (1) | EP2681044A1 (en) |
JP (1) | JP2014508057A (en) |
KR (1) | KR20140009451A (en) |
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AU (1) | AU2012224772B2 (en) |
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ZA (1) | ZA201307355B (en) |
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2012
- 2012-02-29 JP JP2013555857A patent/JP2014508057A/en active Pending
- 2012-02-29 EP EP12706833.6A patent/EP2681044A1/en not_active Withdrawn
- 2012-02-29 RU RU2013144410/05A patent/RU2013144410A/en not_active Application Discontinuation
- 2012-02-29 MX MX2013008937A patent/MX2013008937A/en not_active Application Discontinuation
- 2012-02-29 AU AU2012224772A patent/AU2012224772B2/en not_active Ceased
- 2012-02-29 WO PCT/EP2012/053393 patent/WO2012119892A1/en active Application Filing
- 2012-02-29 CN CN2012800109431A patent/CN103402754A/en active Pending
- 2012-02-29 KR KR1020137026345A patent/KR20140009451A/en not_active Application Discontinuation
- 2012-02-29 IN IN6932CHN2013 patent/IN2013CN06932A/en unknown
- 2012-02-29 BR BR112013019576A patent/BR112013019576A2/en not_active IP Right Cessation
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2013
- 2013-10-02 ZA ZA2013/07355A patent/ZA201307355B/en unknown
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AU2012224772B2 (en) | 2015-09-03 |
BR112013019576A2 (en) | 2017-06-13 |
WO2012119892A1 (en) | 2012-09-13 |
ZA201307355B (en) | 2014-12-23 |
JP2014508057A (en) | 2014-04-03 |
IN2013CN06932A (en) | 2015-08-07 |
CN103402754A (en) | 2013-11-20 |
KR20140009451A (en) | 2014-01-22 |
EP2681044A1 (en) | 2014-01-08 |
MX2013008937A (en) | 2013-10-01 |
RU2013144410A (en) | 2015-04-10 |
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