WO2006077153A2 - Thermoset materials with improved impact resistance - Google Patents
Thermoset materials with improved impact resistance Download PDFInfo
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- WO2006077153A2 WO2006077153A2 PCT/EP2006/000564 EP2006000564W WO2006077153A2 WO 2006077153 A2 WO2006077153 A2 WO 2006077153A2 EP 2006000564 W EP2006000564 W EP 2006000564W WO 2006077153 A2 WO2006077153 A2 WO 2006077153A2
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
- C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
- C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
- C08L2666/04—Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
- C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
- C08L2666/14—Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
Definitions
- thermoset materials with improved impact resistance.
- a thermoset material is defined as being formed of polymer chains of variable length bonded to one another via covalent bonds, so as to form a three-dimensional network.
- Thermoset materials can be obtained, for example, by reaction of a thermosetting resin, such as an epoxy, with a hardener of amine type.
- Thermoset materials exhibit numerous advantageous properties which allow them to be used as structural adhesives or as a matrix for composite materials or in applications for protecting electronic components.
- the materials of the invention comprise a thermoset resin and a block copolymer having at least one block predominantly composed of units of methyl methacrylate which is copolymerized with a water-soluble polymer. These materials can be manufactured by dissolution of the copolymer in the thermosetting resin, followed by addition of the hardener and crosslinking under hot conditions.
- the epoxy materials have a high crosslinking density, which provides them with a high glass transition temperature Tg, which confers excellent tnermomechanical properties on the material.
- Tg glass transition temperature
- Numerous solutions have been developed to attempt to respond to this problem.
- epoxy materials with high Tg values are the most difficult. Numerous studies have been devoted to the impact strengthening of these epoxy materials with high Tg values and these studies conclude that the addition of rubber to an epoxy material with a high Tg value does not have a strengthening effect.
- DDS denotes diaminodiphenyl sulphone
- MCDEA 4,4'-methylenebis(3-chloro- 2,6-diethylaniline).
- BADGE denotes bisphenol A diglycidyl ether.
- CTBN Carboxyl-terminated random copolymer of butadiene and acrylonitrile
- ATBN Amino-terminated random copolymer of butadiene and acrylonitrile.
- These products are oligomers based on butadiene and on acrylonitrile which are terminated either by carboxyl functional groups or by amine functional groups.
- Butadiene has a very low Tg 1 which is favourable for producing good strengthening with regard to impacts, but it is immiscible with epoxy resins.
- a certain percentage of acrylonitrile is copolymerized with the butadiene in order for the product formed to be initially miscible with the epoxy resin and thus to be able to be easily incorporated in the latter.
- preformed core-shell particles these are preformed particles with an elastomer core, with a glass transition temperature of less than -2O 0 C, and a rigid shell, with a glass transition temperature of greater than 5O 0 C, which may or may not carry reactive functional groups.
- a reactive functional group is defined as a chemical group capable of reacting with the oxirane functional groups of epoxy molecules or with the chemical groups of the hardener. Mention may be made, as non- limiting examples of reactive functional groups, of: oxirane functional groups, amine functional groups or carboxyl functional groups.
- These particles of well defined size are added to the reactants (epoxy and hardener). After reaction, the material formed is characterized by a dispersion of these particles within the thermoset matrix.
- the elastomer particles in the material obtained have the same size as at the start, before the reaction. This result is well known; mention may be made, as examples of the prior art describing it, of, for example, the article by Maazouz et al., Polymer Bulletin 33, pages 67-74, 1994, and by Sue et a!., Rubber-Toughened Plastics, 1993, pages 259-291 (cf. page 261). These preformed particles are obtained by a two-stage emulsion synthesis; the elastomer core is synthesized during the first stage and the shell is grafted onto the core during the second stage.
- thermoset material + fibres or thermoset material + fillers thermoset material + fibres or thermoset material + fillers.
- thermoset matrix in which are evenly distributed PEE cylinders all having the same diameter of 5 to 10 nanometres, the cylinders themselves being surrounded by a shell (or by a sheath) of PEO with a thickness of a few nanometres.
- PCL-b-PDMS-b-PCL and (PCL) 2 -b-PDMS-b-(PCL) 2 .
- K ⁇ nczol et al. Journal of Applied Polymer Science, vol. 54, pages 815-826, 1994 have studied blends between an epoxy/anhydride system and a PCL-b- PDMS-b-PCL or (PCL) 2 -b-PDMS-b-(PCL) 2 multiblock copolymer, where PCL denotes polycaprolactone and PDMS polydimethylsiloxane.
- thermoplastic/thermoset blends where the thermoplastic is either PPE (polyphenylene ether) or PEI (polyetherimide) and the thermoset system is the BADGE/MCDEA pair. These blends are brittle.
- the authors have found that the use of a maleized copolymer comprising SEBS blocks, modified beforehand by reaction with a monoamine or a diamine (such as MCDEA) 1 made it possible to improve the impact strength of the thermoplastic/thermoset blend.
- Patent application WO 01/92415 discloses a thermoset material with improved impact resistance comprising:
- thermoset resin • 99 to 20% of a thermoset resin
- an impact modifier comprising at least one copolymer chosen from copolymers comprising S-B-M, B-M and M-B-M blocks, in which:
- each block is connected to the other by means of a covalent bond or of an intermediate molecule connected to one of the blocks via a covalent bond and to the other block via another covalent bond,
- M is a PMMA homopolymer or a copolymer comprising at least 50% by weight of methyl methacrylate
- the B block is either polybutadiene or poly(butyl acrylate) and the S block is polystyrene.
- thermoset materials with improved impact resistance. Furthermore, these materials remain transparent and the Tg is maintained or is not lowered by more than 12°C. It is possible, in addition to the block copolymer predominantly composed of methyl methacrylate units, to add other block copolymers or impact modifiers, such as core-shells or functionalized elastomers. Depending on the nature of these modifiers added in addition, the material may not remain transparent but the impact strength is very greatly improved. However, it has been found that, if the blocks based on methyl methacrylate units comprise a water-soluble monomer, then the thermoset material is easier to produce.
- thermoset material with improved impact resistance comprising, by weight: • 99 to 20% of a thermoset resin, • 1 to 80% of an impact modifier comprising at least one copolymer chosen from copolymers comprising A-B-C and A-B blocks, in which: each block is connected to the other by means of a covalent bond or of an intermediate molecule connected to one of the blocks via a covalent bond and to the other block via another covalent bond, A is a copolymer of methyl methacrylate and of at least one water-soluble monomer,
- C is either (i) a PMMA (homopolymer or copolymer) this PMMA comprising optionally a water-soluble monomer or (ii) a polymer based on vinyl monomers or mixture of vinyl monomers, B is incompatible or partially compatible with the thermoset resin and incompatible with the A block and the optional C block and its glass transition temperature Tg is less than the operating temperature of the thermoset material.
- the invention also relates to the use of these impact modifiers in thermo- sets. [Detailed description of the invention]
- thermoset material it is defined as being formed of polymer chains of variable length bonded to one another via covalent bonds, so as to form a three-dimensional network.
- thermoset formulations of bismaleimide type are, for example: methylenedianiline + benzophenone dianhydride + nadic imide methylenedianiline + benzophenone dianhydride + phenylacetylene methylenedianiline + maleic anhydride + maleimide.
- thermoset material advantageously originates from the reaction of a thermosetting epoxy resin and of a hardener. It is also defined as any product from the reaction of an oligomer carrying oxirane functional groups and of a hardener.
- the reactions involved during the reaction of these epoxy resins result in a crosslinked material corresponding to a three-dimensional network which is more or less dense according to the basic characteristics of the resins and hardeners employed.
- epoxy resin hereafter denoted by E, is understood to mean any organic compound having at least two functional groups of oxirane type which can be polymerized by ring opening.
- epoxy resins denotes any conventional epoxy resin which is liquid at room temperature
- epoxy resins can be monomeric or polymeric, on the one hand, aliphatic, cycloaliphatic, heterocyclic or aromatic, on the other hand. Mention may be made, as examples of such epoxy resins, of resorcinol diglycidyl ether, bisphenol A diglycidyl ether, triglycidyl-p-amino- phenol, bromobisphenol F diglycidyl ether, the triglycidyl ether of m-amino- phenol, tetraglycidylmethylenedianiline, the triglycidyl ether of (trihydroxy- phenyl)methane, polyglycidyl ethers of phenol-formaldehyde novolak, poly- glycidyl ethers of ortho-cresol novolak and tetraglycidyl ethers of tetraphenyl- ethane.
- Epoxy resins having at least 1.5 oxirane functional groups per molecule or more particularly epoxy resins comprising between 2 and 4 oxirane functional groups per molecule are preferred.
- hardeners As regards the hardener, use is generally made, as hardeners, of hardeners for epoxy resins which react at room temperature or at temperatures higher than room temperature. Mention may be made, as non-limiting examples, of:
- aromatic or aliphatic polyamines including diaminodiphenyl sulphone (DDS), methylenedianiline, 4,4'-methylenebis(3-chloro-2,6-diethyl- aniline) (MCDEA) or 4,4'-methylenebis(2,6-diethylaniline) (M-DEA),
- DDS diaminodiphenyl sulphone
- MCDEA 4,4'-methylenebis(3-chloro-2,6-diethyl- aniline)
- M-DEA 4,4'-methylenebis(2,6-diethylaniline)
- A is a copolymer of methyl methacrylate and of at least one water-soluble monomer.
- water-soluble monomers of acrylic or methacrylic acid, the amides derived from these acids, such as, for example, dimethylacrylamide, 2-methoxy- ethyl acrylate or methacrylate, 2-aminoethyl acrylates or methacrylates which are optionally quatemized, polyethylene glycol (PEG) (meth)acrylates, water- soluble vinyl monomers, such as N-vinylpyrrolidone, or any other water-soluble monomer.
- PEG polyethylene glycol
- the polyethylene glycol group of the polyethylene glycol (meth)acrylates has a mass ranging from 400 g/mol to 10,000 g/mol.
- the proportion of MMA can be, by moles, from 10 to 95% for 90 to 5% of water-soluble monomer.
- the proportion of MMA is, by moles, from 60 to 90% for 40 to 10% of water-soluble monomer.
- the A block can comprise other monomers which can be acrylic monomers. These monomers may be reactive.
- reactive monomer is understood to mean: a chemical group capable of reacting with the oxirane functional groups of the epoxy molecules or with the chemical groups of the hardeners.
- the reactive monomer can be (meth)acrylic acid or any other hydrolysable monomer resulting in these acids. Mention may be made, among the other monomers which can constitute the A block, as non-limiting examples, of glycidyl methacrylate or tert-butyl methacrylate.
- the Tg of B is advantageously less than 0 0 C and preferably less than -4O 0 C.
- the monomer used to synthesize the elastomeric B block can be a diene chosen from butadiene, isoprene, 2,3-dimethyl-1 ,3-butadiene, 1 ,3-pentadiene or 2-phenyl-1 ,3-butadiene.
- B is advantageously chosen from poly(dienes), in particular poly(butadiene), poly(isoprene) and their random copolymers, or from partially or completely hydrogenated poly(dienes).
- the B blocks can also be hydrogenated. This hydrogenation is carried out according to the usual techniques.
- the monomer used to synthesize the elastomeric B block can also be an alkyl (meth)acrylate.
- the following Tg values (between brackets following the name of the acrylate) are obtained: ethyl acrylate ( ⁇ 24°C), butyl acrylate (-54°C), 2-ethylhexyl acrylate (-85 0 C), hydroxyethyl acrylate (-15°C) and 2-ethylhexyl methacrylate (-10 0 C).
- Butyl acrylate is advantageously used.
- the acrylates are different from those in the A block in order to observe the condition that B and A are incompatible.
- the B blocks are preferably predominantly composed of 1 ,4- polybutadiene.
- the A-B diblock has a number-average molar mass which can be between 10,000 g/mol and 500,000 g/mol, preferably between 20,000 and 200,000 g/mol.
- the A-B diblock is advantageously composed of a fraction by mass of A of between 5 and 95% and preferably between 15 and 85%.
- C is either (i) a PMMA (homopolymer or copolymer) this PMMA comprising optionally a water-soluble monomer or (ii) a polymer based on vinyl monomers or mixture of vinyl monomers.
- the monomers and optionally comonomers of the C block are chosen from the same family of monomers and optionally comonomers as those of the A block of the A-B diblock.
- the presence of the water- soluble monomer is not obligatory.
- C can be either a PMMA homopolymer, either a PMMA copolymer (by way of example a copolymer of MMA and another acrylate such as methyl acrylate or ethyl acrylate), either a copolymer of MMA, a water-soluble monomer and optionally another monomer.
- the two A and C blocks of the A-B-C triblock can be identical or different. They may also be different in their molar masses but composed of the same monomers. If the C block comprises a water-soluble monomer, it can be identical to or different from the water-soluble monomer of the A block.
- C blocks of those which derive from vinylaromatic compounds, such as styrene, ⁇ -methylstyrene or vinyltoluene, and those which derive from alkyl esters of acrylic and/or methacrylic acids having from 1 to 18 carbon atoms in the alkyl chain.
- vinylaromatic compounds such as styrene, ⁇ -methylstyrene or vinyltoluene
- alkyl esters of acrylic and/or methacrylic acids having from 1 to 18 carbon atoms in the alkyl chain.
- the B block is composed of the same monomers and optionally comonomers as the B block of the A-B diblock.
- the B blocks of the A-B-C triblock and of the A-B diblock can be identical or different.
- the A-B-C triblock has a number-average molar mass which can be between 10,000 g/mol and 500,000 g/mol, preferably between 20,000 and 200,000 g/mol.
- the A-B-C triblock has the following compositions, expressed as fraction by mass, the total being 100%: A+C: between 10 and 80% and preferably between 15 and 70%, B: between 90 and 20% and preferably between 85 and 30%.
- copolymers A-B-C and A-B can be manufactured by any polymerization means and in particular by controlled radical polymerization.
- Controlled radical polymerization is known.
- Conventional radical polymerizations do not make possible access to polymers and copolymers possessing controlled architecture due in particular to the low lifetimes of the radicals, to their high reactivity and to the lack of stereochemistry of the intermediate entities.
- the term "controlled radical polymerization” is understood to mean a conventional radical polymerization in which at least one of the stages chosen from initiation, propagation, termination and transfer is controlled. Mention may be made, as example of control, of the reversible deactivation of the growing macroradicals. This reversible deactivation can be brought about by the addition of nitroxides to the reaction medium.
- a persistent radical is, for example, TEMPO (2,2,6,6-tetramethyl-1-piperidinyloxy), which captures the macroradicals and generally results in homopolymers of very narrow polydispersities, thus conferring a living nature on the radical polymerization.
- the proportion of the impact modifier is advantageously from 5 to 20% by weight for 95 to 80% of thermoset resin.
- the proportion of the impact modifier is from 5 to 15% by weight for 95 to 85% of thermoset resin.
- the materials of the invention can be prepared by blending the thermoset resin, not yet crosslinked, and the block copolymer using a conventional blending device.
- the materials of the invention can be prepared using a conventional stirred reactor.
- the thermosetting epoxy resin is introduced into the reactor and brought for a few minutes to a temperature sufficient to be fluid.
- the block copolymer is subsequently added and kneaded at a temperature sufficient to be fluid until it has completely dissolved. The kneading time depends on the nature of the copolymer added.
- the hardener is then added and blending is carried out for a further 5 minutes at a temperature sufficient to be fluid in order to obtain a homogeneous blend.
- the epoxy- hardener reaction begins during this blending and it must therefore be arranged to be as short as possible. These blends are subsequently cast and cured in a mould.
- thermoset materials It would not be departing from the scope of the invention to add the usual additives to the thermoset materials.
- Epoxy resin various epoxide prepolymers were used:
- TGDDM tetraglycidylmethyienedianiline
- An amine hardener which is an aromatic diamine, 4,4'-methylenebis-
- An amine hardener which is an aromatic diamine, diaminodiphenyl sulphone (DDS) with a mass of 248 g/mol, sold by the company Aldrich.
- SBM it is an S-B-M triblock copolymer in which S is polystyrene, B is polybutadiene and M is PMMA, comprising 24% as fraction by mass of polystyrene, 26% as fraction by mass of polybutadiene and 50% by mass of poly(methyl methacrylate), obtained by anionic polymerization successively of a polystyrene block with a number-average molar mass of 21 ,000 g/mol, of a polybutadiene block with a mass of 22,000 g/mol and of a poly(methyl methacrylate) block with a number-average molar mass of 43,000 g/mol.
- This product was prepared according to the procedure disclosed in EP 524,054 and in EP 749,987. This product exhibits three glass transitions, one of -9O 0 C, another of 95 0 C and the third of 130 0 C.
- MBuAM-1 it is a triblock copolymer in which M is PMMA and BuA is a butyl acrylate homopolymer.
- This copolymer can also be denoted by A-B-C, in which the A and C blocks are identical and are PMMA and the B block is a butyl acrylate homopolymer.
- This copolymer is obtained by controlled radical polymerization.
- the number-average molar mass of the butyl acrylate is 22,000 g/mol and the weight-average molar mass of the complete copolymer is 140,000 g/mol.
- MBuAM-2 it is an A-B-C triblock copolymer in which M is a copolymer of methyl methacrylate (MMA) and of dimethylacrylamide (DMA) with a molar ratio of 80% of MMA and of 20% of DMA.
- This copolymer can also be denoted by A-B-C, in which the A and C blocks are identical and are copolymers of methyl methacrylate (MMA) and of dimethyl acrylamide (DMA) and the B block is a butyl acrylate homopolymer.
- the blends comprising 10% of additives are precured for 14 hours at 135°C and postcured for 4 hours at 220 0 C. Measurement of the impact strengthening - measurement of KIC
- the KIC was measured at room temperature on notched three-point bending samples according to the procedure provided by Williams and Cawood (Polymer Testing, 9 (1990), 15-26).
- the test specimens are prenotched with a diamond saw.
- a finer crack is produced on the samples, clamped in a vice, using a razor blade, the razor blade being given a gentle tap which leads to cracking. This makes it possible to obtain a very fine crack root, similar to a natural crack.
- the total depth of the notch is measured using a binocular magnifier.
- Tg was measured by dynamic mechanical analysis on postcured samples using a Rheometrics device (Rheometrics Solid Analyser, RSAII).
- the samples which are parallelepipedal in shape (1 x 2.5 x 34 mm 3 ), are subjected to a temperature sweep between 50 and 250 0 C at a stress frequency of 1 Hz.
- the glass transition temperature is taken at the maximum of tan ⁇ .
- Example 1 (comparative)
- a blend based on TGDDM - MDEA comprising 10% of MBuAM-1 is prepared according to the blending protocol described above. The results are listed in Table 1.
- the unmodified BADGE-DDS system exhibits a Tg of 22O 0 C and a KIC of
- the unmodified TGDDM-MDEA system exhibits a Tg of 235°C and a KIC of
- the unmodified BADGE-Jeffamine T 403 system exhibits a Tg of 7O 0 C and a
Abstract
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Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2007551629A JP5142726B2 (en) | 2005-01-20 | 2006-01-18 | Thermosetting resin material with excellent impact strength |
ES06706368T ES2386968T3 (en) | 2005-01-20 | 2006-01-18 | Thermostable materials with improved impact resistance |
US11/813,799 US7767757B2 (en) | 2005-01-20 | 2006-01-18 | Thermoset materials with improved impact resistance |
EP06706368A EP1866369B1 (en) | 2005-01-20 | 2006-01-18 | Thermoset materials with improved impact resistance |
CN2006800027281A CN101107314B (en) | 2005-01-20 | 2006-01-18 | Thermoset materials with improved impact resistance |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
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FR0500572 | 2005-01-20 | ||
FR0500572A FR2880895B1 (en) | 2005-01-20 | 2005-01-20 | THERMODURA MATERIALS IMPROVED IMPROVED SHOCK |
US66413705P | 2005-03-22 | 2005-03-22 | |
US60/664,137 | 2005-03-22 | ||
FR0502911 | 2005-03-24 | ||
FR0502911A FR2880894B1 (en) | 2005-01-20 | 2005-03-24 | THERMODURA MATERIALS IMPROVED IMPROVED SHOCK |
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WO2006077153A2 true WO2006077153A2 (en) | 2006-07-27 |
WO2006077153A3 WO2006077153A3 (en) | 2006-11-02 |
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US (1) | US7767757B2 (en) |
EP (1) | EP1866369B1 (en) |
JP (1) | JP5142726B2 (en) |
KR (1) | KR101261847B1 (en) |
WO (1) | WO2006077153A2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
KR20070104560A (en) | 2007-10-26 |
US20080051511A1 (en) | 2008-02-28 |
KR101261847B1 (en) | 2013-05-07 |
EP1866369A2 (en) | 2007-12-19 |
JP5142726B2 (en) | 2013-02-13 |
US7767757B2 (en) | 2010-08-03 |
JP2008528718A (en) | 2008-07-31 |
WO2006077153A3 (en) | 2006-11-02 |
EP1866369B1 (en) | 2012-06-06 |
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