JP2005532198A - ガラス繊維絶縁体用の高性能な難燃性クラフト表面仕上げ材 - Google Patents
ガラス繊維絶縁体用の高性能な難燃性クラフト表面仕上げ材 Download PDFInfo
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- JP2005532198A JP2005532198A JP2004519687A JP2004519687A JP2005532198A JP 2005532198 A JP2005532198 A JP 2005532198A JP 2004519687 A JP2004519687 A JP 2004519687A JP 2004519687 A JP2004519687 A JP 2004519687A JP 2005532198 A JP2005532198 A JP 2005532198A
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- Prior art keywords
- flame retardant
- laminate
- hdpe
- ldpe
- glass fiber
- 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.)
- Abandoned
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Abstract
Description
本発明は、熱絶縁バット(batts)の製造技術の改良に関する。
本発明は、ガラス繊維絶縁製品の製造方法を提供する。本発明の方法は、以下の工程、(a)難燃性クラフト紙の層を供給する工程、(b)この難燃性クラフト紙層を高密度ポリエチレン(HDPE)又はポリプロピレンのような高融点フィルムで被覆してHDPE-難燃性クラフト積層又はポリプロピレン-難燃性クラフト積層を形成する工程、(c)このHDPE-難燃性クラフト積層を低密度ポリエチレン(LDPE)のような低融点フィルムで被覆してLDPE-HDPE-難燃性クラフト積層又はLDPE-ポリプロピレン-難燃性クラフト積層を形成する工程、(d)LDPEが粘着性になるが、HDPE又はポリプロピレンは固体のままであるように、LDPE-HDPE-難燃性クラフト積層又はLDPE-ポリプロピレン-難燃性クラフト積層の温度を調整する工程、(e)ガラス繊維ウールの層を供給する工程、及び(f)LDPE-HDPE-難燃性クラフト積層又はLDPE-ポリプロピレン-難燃性クラフト積層のLDPE層をガラス繊維ウールと接触させて、LDPE-HDPE-難燃性クラフト積層又はLDPE-ポリプロピレン-難燃性クラフト積層を該ガラス繊維ウール層に結合してガラス繊維絶縁製品を形成する工程を含む。
熱絶縁バットは、例えば、アスファルト被覆クラフト紙表面仕上げ材(facing)に面したガラス繊維ウールのような低密度バルク絶縁材料の比較的厚い層で構成されることが多い。アスファルト被覆は、熱絶縁体の層を表面仕上げ材に接着させるため、また紙に防湿性(vapor barrier property)を与えるためにも使用される。代わりに、箔で裏打ちした紙をアスファルトで薄く被覆したガラス繊維ウールに張り付けることができる。防湿への別のアプローチは、設置絶縁体上に別個の100〜150μm(4〜6ミル)のポリエチレンフィルムを適用することである。Guardian Fiberglass, Inc.は、絶縁用途のポリプロピレンスクリムクラフトを製造している。
多くの方法で、表面仕上げ材をガラス繊維ブランケットに接着させることができる。例えば、溶剤ベース若しくは水ベース接着剤又はホットメルト接着剤を表面仕上げ材又はガラス繊維ウールブランケットの表面に塗布し、ガラス繊維ウールブランケットと表面仕上げ材を一緒にして2つの材料を面結合する。代わりに、ガラス繊維ウールブランケットに塗布する前に表面仕上げ材自体に接着性を与えることができる。例えば、表面仕上げ材の一面上の合成ポリマー又は瀝青層のような熱可塑性材料を当該目的で熱軟化させることができる。しかし、この文脈で最も一般的に使用される合成ポリマーであるポリエチレンの熱処理は、それが持っている防湿特性(vapor barrier property)を破壊しうる。
ASTMとして知られる組織は、名称E 96-00(2002年1月公表)の下で、紙及び他のシート材料のような水蒸気の通過が重要である材料の水蒸気透過を決定するための試験方法の解説を公表した。当該試験方法は、シート材料のPERM値を決定できる。PERM値は、該材料の水蒸気の透過及び浸透を反映する。
多くの慣習的な絶縁表面仕上げ製品は、一貫してPERM要求を満たし損なっている。
1.0より大きいPERM値は、本発明の目的では許容しえない。
安価かつ難燃性である、可撓性クラフト積層を有する絶縁製品が要望されている。
本発明は、一貫してPERMの要求を満たすガラス繊維絶縁体用の難燃性クラフト表面仕上げ材を提供する。
本発明の一実施形態は、低密度ポリエチレン(LDPE)の内側接着剤層が接着している、高密度ポリエチレン(HDPE)又はポリプロピレンの中心防湿層が接着している難燃性クラフト紙の外側支持体層を含んでなる可撓性平面積層品である。この可撓性平面積層品は、坪量146〜244kg/m2(30〜50lbs/ft2)を有する難燃性クラフト紙1リーマ(278.7平方メートル(3000平方フィート))当たり好ましくは0.91〜4.54kg(2〜10ポンド)、最も好ましくは3.18kg(7ポンド)のHDPEと、1.36〜4.54kg(3〜10ポンド)、最も好ましくは2.27kg(5ポンド)のLDPEを含む。この発明の可撓性平面積層品では、LDPEの軟化点は、HDPEの軟化点より-3.8℃(25゜F)〜51.7℃(125゜F)、好ましくは-3.8℃(25゜F)〜23.9℃(75゜F)低い。ポリプロピレンを防湿層として使用する場合、LDPEの軟化点は、ポリプロピレンの軟化点より-3.8℃(25゜F)〜65.6℃(150゜F)、好ましくは-3.8℃(25゜F)〜23.9℃(75゜F)低い。
本発明の利点は、以下に与える詳細な説明から、さらに明らかになるだろう。しかし、この詳細な説明から、当業者には本発明の精神及び範囲内の種々の変形及び変更が明らかになるので、詳細な説明及び特定の実施例は、本発明の好ましい実施形態を示すが、説明目的のためだけに与えられものと解釈すべきである。
本発明は、以下に与える詳細な説明と添付図面から、さらに完全に理解されるだろう。しかし、これらは説明のためだけに与えられるので、本発明を制限しない。
図1に示されるように、この発明の不浸透性表面仕上げ材10は、難燃性クラフト紙層12と、高密度ポリエチレン層14と、低密度ポリエチレン層16を含みうる。図2に示されるように、この発明の絶縁製品20は、不浸透性表面仕上げ材層10(ここで、層10は難燃性クラフト紙、HDPE、及びLDPEを含む)と、ガラス繊維ウール層25と、浸透性難燃性クラフト紙層27を含みうる。
本発明中の紙成分は、その即時利用能と低コスト、その固有強度と耐久性、及びその好ましいポリエチレンフィルムに容易に積層されるという能力のため、難燃性クラフト紙が好ましい。難燃性クラフト紙は、好適には、278.7平方メートル当たり13.61〜22.68kg(3000平方フィート当たり30〜50ポンド)、好ましくは278.7平方メートル当たり15.86〜18.14kg(3000平方フィート当たり35〜40ポンド)の坪量に相当する厚さを有する。好ましい実施形態では、仕様、17.24kg(38lbs)〜18.14kg(40lbs)斤量、さらに好ましくは17.24kg(38lbs)斤量、Natural Utility Flame Resistant Kraft paper(Wausau-Mosinee Paper Corporation, Mosines, WI)を使用する。難燃性材料で前処理するという条件で、箔及び箔スキムクラフト紙も使用しうる。当然、難燃性クラフト紙は、例えば製品情報を伝えるため、それ自体印刷可能である。
HDPEの比密度は約0.94である。本発明の高密度ポリエチレンフィルム成分は、好適には10〜50g/m2、好ましくは25〜35g/m2の坪量に相当する厚さを有する。この厚さは、一般に、繊維状のガラス繊維ウールブランケットの個々の繊維による浸透を妨げ、それによって製品の防湿特性を保持しながら絶縁製品への不必要な重さの付加を回避するのに十分である。ポリエチレンを防湿層として使用する場合、一般にHDPEの量と同量又はわずかに少ない量で使用する。
LDPEの比密度は、約0.9235である。本発明の低密度ポリエチレンフィルム成分は、好適には5〜40g/m2、好ましくは15〜25g/m2の坪量に相当する厚さを有する。この厚さは、一般に、繊維状のガラス繊維ウールブランケットへの接着を与えるのに十分である。
(ガラス繊維)
ガラス繊維ウールブランケットは、ガラス繊維ウール絶縁製品を製造するために伝統的に使用される1種以上の材料を含みうるが、スラグ又は玄武岩のような他の鉱物ウール絶縁材料も使用できる。しかし、本発明の文脈では、ガラス繊維が好ましい。本発明の絶縁製品を形成するためにガラス繊維ブランケットを使用する場合、ガラス繊維ブランケットはバインダー、例えばフェニル系樹脂バインダーを含み、好適には繊維化直後に繊維に適用する。
本発明の好ましい局面では、難燃性クラフト紙/HDPE積層の高密度ポリエチレン表面に低密度ポリエチレンを適用してから、90℃(194゜F)〜150℃(302゜F)、例えば約110℃(230゜F)に加熱する。この高温が作用して低密度ポリエチレンを軟化させ、ひいてはLDPEのガラス繊維ウールブランケットの繊維との直接結合をより感受性にする。この加熱工程は、例えばそれを赤外線ヒーターに通して運ぶことによって、又はそれを加熱ローラー、例えばオイル充填ローラー上を通過させることによって、或いはこれらのいずれかの組合せによって、被覆した表面仕上げ材を放射熱にさらすことによって実施することができる。
ガラス繊維ウールブランケットは、好ましくは約20〜330mmの厚さと、8〜40kg/m3(0.4〜2.5pcf)のかさ密度を有する。
絶縁体の意図そた部位で、圧縮かつ包装した絶縁製品の包装を解き、その元の厚さに戻してから、多くの絶縁状況のいずれの状況でも利用することができる。
1リーマ当たり坪量17.24kg(38ポンド)の難燃性クラフト紙の層を前記紙1リーマ当たり3.18kg(7ポンド)の割合のHDPEで被覆してHDPE-難燃性クラフト積層を形成した。このHDPE-難燃性クラフト積層を前記HDPE-難燃性クラフト積層1リーマ当たり2.27kg(5ポンド)の割合のLDPEで被覆してLDPE-HDPE-難燃性クラフト積層を形成した。このLDPE-HDPE-難燃性クラフト積層の温度を、LDPEが粘着性になるが、HDPEは固体のままであるように調整した。ガラス繊維ウールの層を供給した。LDPE-HDPE-難燃性クラフト積層のLDPE層をガラス繊維ウール層に圧着させ、次いで冷却して前記LDPE-HDPE-難燃性クラフト積層を前記ガラス繊維ウール層に結合してガラス繊維絶縁製品を形成した。
3つの試験片の結果は、0.3727、0.4410、及び0.3932であり、平均0.4023では、十分に1.0の目標最大値下だった。
1リーマ当たり坪量17.24kg(38ポンド)の難燃性クラフト紙の層を前記紙1リーマ当たり2.27kg(5ポンド)の割合のHDPEで被覆してHDPE-難燃性クラフト積層を形成した。このHDPE-難燃性クラフト積層を前記HDPE-難燃性クラフト積層1リーマ当たり1.81kg(4ポンド)の割合のLDPEで被覆してLDPE-HDPE-難燃性クラフト積層を形成した。このLDPE-HDPE-難燃性クラフト積層の温度を、LDPEが粘着性になるが、HDPEは固体のままであるように調整した。ガラス繊維ウールの層を供給した。LDPE-HDPE-難燃性クラフト積層のLDPE層をガラス繊維ウール層に圧着させ、次いで冷却して前記LDPE-HDPE-難燃性クラフト積層を前記ガラス繊維ウール層に結合してガラス繊維絶縁製品を形成した。
3つの試験片の結果は、1.1669、0.5309、及び1.1199であり、平均0.9392では、1.0の目標最大値下だった。
実施例1のLDPE保持表面仕上げ材を加熱ロール上を通すことによって、温度約110℃(230゜F)にし、即座に1.2mの幅、280mmの厚さ、及び約11.0kg/m3の密度を有するガラス繊維ブランケットと接触させる。結果の絶縁組立品を即座にローラーで加熱ロールに抗して圧縮して厚さ210mmにした。
結果の絶縁組立品をローラーの20m下線で、ブレードで横断方向に切って、1.2m×5.5mのサイズを有する長さの絶縁材料にした。即座に絶縁製品の5.5m長さを巻き、30mmの厚さに圧縮し、貯蔵及び輸送用に包装した。
上述したように製造した絶縁材料は、反復取扱いに耐える頑強な構造を有し、かつ該材料の全体構造を破壊しなければ表面仕上げはガラス繊維ブランケットから分離しえない。
Claims (17)
- 高融点ポリマーから本質的に一貫してなる防湿層が接着している難燃性クラフト紙の層を含む可撓性平面積層品であって、前記防湿層に、低融点ポリマーの接着剤層が接着されていることを特徴とする可撓性平面積層品。
- 前記高融点ポリマーが、高密度ポリエチレン(HDPE)又はポリプロピレンである、請求項1の可撓性平面積層品。
- 前記低融点ポリマーが、低密度ポリエチレンである、請求項2の可撓性平面積層品。
- 278.7平方メートル(3000平方フィート)当たり146〜244kg(30〜50ポンド)の坪量を有する難燃性クラフト紙278.7平方メートル(3000平方フィート)当たり、0.91〜4.54kg(2〜10ポンド)のHDPEと、1.36〜4.54kg(3〜10ポンド)のLDPEとを含む、請求項3の可撓性平面積層品。
- 難燃性クラフト紙278.7平方メートル(3000平方フィート)当たり、3.18kg(7ポンド)のHDPEと、2.27kg(5ポンド)のLDPEとを含む、請求項4の可撓性平面積層品。
- 前記防湿層が、HDPEであり、かつ前記LDPEの軟化点が、前記HDPEの軟化点より-3.8℃(25゜F)〜23.9℃(75゜F)低い、請求項3の可撓性平面積層品。
- 前記防湿層が、ポリプロピレンであり、かつ前記LDPEの軟化点が、前記HDPEの軟化点より-3.8℃(25゜F)〜23.9℃(75゜F)低い、請求項3の可撓性平面積層品。
- ガラス繊維絶縁製品の製造方法であって、以下の工程、
(a)難燃性クラフト紙の層を供給する工程、
(b)前記難燃性クラフト紙層を、高融点ポリマーで被覆して高融点ポリマー-難燃性クラフト積層を形成する工程、
(c)該高融点ポリマー-難燃性クラフト積層を、低融点ポリマーで被覆して低融点ポリマー-高融点ポリマー-難燃性クラフト積層を形成する工程、
(d)該低融点ポリマー-高融点ポリマー-難燃性クラフト積層の温度を、前記低融点ポリマーが粘着性になるが、前記高融点ポリマーが固体のままであるように調整する工程、
(e)ガラス繊維ウールの層を供給する工程、及び
(f)前記低融点ポリマー-高融点ポリマー-難燃性クラフト積層の前記低融点ポリマー層を、前記ガラス繊維ウール層と圧着させ、かつ冷却して前記低融点ポリマー-高融点ポリマー-難燃性クラフト積層を前記ガラス繊維ウール層に結合してガラス繊維絶縁製品を形成する工程、
を含むことを特徴とする方法。 - 前記高融点ポリマーが、高密度ポリエチレン(HDPE)又はポリプロピレンである、請求項8の方法。
- 前記低融点ポリマーが、低密度ポリエチレン(LDPE)である、請求項9の方法。
- 以下の工程、
(b)前記難燃性クラフト紙層を、前記紙278.7平方メートル(3000平方フィート)当たり0.91〜4.54kg(2〜10ポンド)のHDPE又はポリプロピレンで被覆してHDPE-難燃性クラフト積層又はポリプロピレン-難燃性クラフト積層を形成する工程、及び
(c)前記HDPE-難燃性クラフト積層又はポリプロピレン-難燃性クラフト積層を、前記HDPE-難燃性クラフト積層又はポリプロピレン-難燃性クラフト積層278.7平方メートル(3000平方フィート)当たり1.36〜4.54kg(3〜10ポンド)のLDPEで被覆してLDPE-HDPE-難燃性クラフト積層又はLDPE-ポリプロピレン-難燃性クラフト積層を形成する工程、
を含む、請求項10の方法。 - 前記温度を赤外線ヒーター、マイクロ波ヒーター、又は回転式ホットロールで調整する、請求項8の方法。
- ガラス繊維ウールの層と、可撓性平面積層とを含むガラス繊維絶縁製品であって、前記可撓性平面積層が、低密度ポリマーの内側接着剤層が接着している高融点ポリマーの中心防湿層に接着している難燃性クラフト紙の外側支持体層を含むことを特徴とするガラス繊維絶縁製品。
- 前記高融点ポリマーが、高密度ポリエチレン(HDPE)又はポリプロピレンである、請求項13のガラス繊維絶縁製品。
- 前記低融点ポリマーが、低密度ポリエチレンである、請求項14のガラス繊維絶縁製品。
- 前記可撓性平面積層が、278.7平方メートル(3000平方フィート)当たり146〜244kg(30〜50ポンド)の坪量を有する難燃性クラフト紙278.7平方メートル(3000平方フィート)当たり、0.91〜4.54kg(2〜10ポンド)のHDPEと、1.36〜4.54kg(3〜10ポンド)のLDPEとを含む、請求項15のガラス繊維絶縁製品。
- 前記可撓性平面積層が、難燃性クラフト紙278.7平方メートル(3000平方フィート)当たり、3.18kg(7ポンド)のHDPEと、2.27kg(5ポンド)とのLDPEを含む、請求項14のガラス繊維絶縁製品。
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Application Number | Priority Date | Filing Date | Title |
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US10/191,873 US6924243B2 (en) | 2001-05-29 | 2002-07-09 | High performance fire-retardant kraft facing for fiberglass insulation |
PCT/US2003/020526 WO2004005022A1 (en) | 2002-07-09 | 2003-06-30 | High performance fire-retardant kraft facing for fiberglass insulation |
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JP2005532198A5 JP2005532198A5 (ja) | 2006-08-17 |
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CA (1) | CA2492139A1 (ja) |
MX (1) | MXPA05000384A (ja) |
WO (1) | WO2004005022A1 (ja) |
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US6924243B2 (en) * | 2001-05-29 | 2005-08-02 | Owens Corning Fiberglas Technology, Inc. | High performance fire-retardant kraft facing for fiberglass insulation |
WO2003061966A1 (en) * | 2002-01-16 | 2003-07-31 | Ipg Technologies, Inc. | Multi-layered flame retardant wrap |
US6782922B1 (en) * | 2003-05-30 | 2004-08-31 | John Manville International, Inc. | Coated fibrous pipe insulation system |
US7685783B2 (en) * | 2004-01-30 | 2010-03-30 | Certainteed Corporation | Kit of parts for band joist insulation and method of manufacture |
US7703253B2 (en) * | 2004-01-30 | 2010-04-27 | Certainteed Corporation | Segmented band joist batts and method of manufacture |
US11536028B2 (en) | 2004-02-23 | 2022-12-27 | Huber Engineered Woods Llc | Panel for sheathing system and method |
US20050249910A1 (en) * | 2004-05-10 | 2005-11-10 | Campal Alberto C | Mineral wool covered with complexes formed of organic polymer laminates |
US7427575B2 (en) * | 2004-06-02 | 2008-09-23 | Owens Corning Intellectual Capital, Llc | Faced fibrous insulation |
DE102007051122A1 (de) * | 2007-10-24 | 2009-05-14 | Deutsche Rockwool Mineralwoll Gmbh & Co. Ohg | Nichtbrennbares Absorberelement für die Wärme- und/oder Schalldämmung sowie Verfahren zur Herstellung eines solchen Absorberelementes |
US20090107079A1 (en) * | 2007-10-30 | 2009-04-30 | Bowman David J | Structure having a confined space with improved thermal, fire and sound resistance properties |
US20100000170A1 (en) * | 2008-07-03 | 2010-01-07 | Parks Jerry M | Pre-Applied Waterless Adhesive On HVAC Facings With Sealable Flange |
US8946101B2 (en) * | 2009-02-10 | 2015-02-03 | Honeywell International Inc. | Enhanced barrier multifunctional coatings for nylon films |
US20100291395A1 (en) * | 2009-05-14 | 2010-11-18 | Sharkey Jr Dave J | Reflective building paper |
EP2394812A1 (en) * | 2010-04-19 | 2011-12-14 | DQ Concepts B.V. | Composite material and sheet material provided therewith |
MX2013000717A (es) | 2010-07-20 | 2013-02-21 | Owens Corning Intellectual Cap | Revestimiento polimerico pirorretardante. |
CN102146177B (zh) * | 2010-12-28 | 2012-12-12 | 武汉纺织大学 | 一种含有天然蛋白纤维粉体的阻燃树脂母料及其制备方法 |
US9234355B2 (en) | 2012-05-31 | 2016-01-12 | Huber Engineered Woods Llc | Insulated sheathing panel and methods for use and manufacture thereof |
CN104929257B (zh) * | 2015-03-04 | 2017-08-25 | 瞿浩荣 | 用于聚氨酯保温板的覆面玻璃纤维毡及其制备方法 |
CN112411780B (zh) * | 2015-04-17 | 2022-06-28 | 3M创新有限公司 | 耐火建筑物接合*** |
CN106247087A (zh) * | 2016-08-30 | 2016-12-21 | 苏州维艾普新材料股份有限公司 | 一种真空绝热板 |
CN106122686A (zh) * | 2016-08-31 | 2016-11-16 | 苏州维艾普新材料股份有限公司 | 一种真空绝热材料及芯材 |
WO2019111036A1 (en) | 2017-12-04 | 2019-06-13 | Annexair Inc. | Composite panel, composite material, impregnator and method for manufacturing a composite panel |
WO2019111037A1 (en) | 2017-12-04 | 2019-06-13 | Annexair Inc. | Composite panel, composite material, impregnator and method for manufacturing a composite panel |
EP3720709A4 (en) | 2017-12-04 | 2021-06-16 | Annexair Inc. | COMPOSITE PANEL, COMPOSITE MATERIAL, IMPREGNATOR AND PROCESS FOR MANUFACTURING A COMPOSITE PANEL |
US11739880B2 (en) | 2021-05-19 | 2023-08-29 | Samuel Gottfried | High temperature protection wrap for plastic pipes and pipe appliances |
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US6815380B2 (en) * | 2001-05-29 | 2004-11-09 | Owens Corning Fiberglas Technology, Inc. | High performance kraft facing for fiberglass insulation |
US6924243B2 (en) * | 2001-05-29 | 2005-08-02 | Owens Corning Fiberglas Technology, Inc. | High performance fire-retardant kraft facing for fiberglass insulation |
US20020182964A1 (en) | 2001-05-29 | 2002-12-05 | Snyder James G. | High performance kraft facing for fiberglass insulation |
US20030049986A1 (en) * | 2001-09-06 | 2003-03-13 | Qureshi Naseer Mohammad | Protective woven fabric with crease retention |
WO2003061966A1 (en) * | 2002-01-16 | 2003-07-31 | Ipg Technologies, Inc. | Multi-layered flame retardant wrap |
-
2002
- 2002-07-09 US US10/191,873 patent/US6924243B2/en not_active Expired - Fee Related
-
2003
- 2003-06-30 MX MXPA05000384A patent/MXPA05000384A/es active IP Right Grant
- 2003-06-30 WO PCT/US2003/020526 patent/WO2004005022A1/en active Application Filing
- 2003-06-30 AU AU2003247830A patent/AU2003247830A1/en not_active Abandoned
- 2003-06-30 EP EP03763046A patent/EP1523408A1/en not_active Withdrawn
- 2003-06-30 CA CA002492139A patent/CA2492139A1/en not_active Abandoned
- 2003-06-30 JP JP2004519687A patent/JP2005532198A/ja not_active Abandoned
Also Published As
Publication number | Publication date |
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CA2492139A1 (en) | 2004-01-15 |
US20020179265A1 (en) | 2002-12-05 |
AU2003247830A1 (en) | 2004-01-23 |
MXPA05000384A (es) | 2005-03-23 |
US6924243B2 (en) | 2005-08-02 |
EP1523408A1 (en) | 2005-04-20 |
WO2004005022A1 (en) | 2004-01-15 |
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