Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
  • D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
  • B05D1/305—Curtain coating
• • 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
  • 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
  • B32B5/02—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 structural features of a fibrous or filamentary layer
  • B32B5/022—Non-woven fabric
• • 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
  • 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
• • 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
  • 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
  • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/245—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
• • 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
  • 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
  • B32B7/08—Interconnection of layers by mechanical means
  • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
• • 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
  • 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
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
  • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
  • D06N3/0093—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by applying resin powders; by sintering
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/16—Flocking otherwise than by spraying
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D2252/00—Sheets
  • B05D2252/02—Sheets of indefinite length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D2503/00—Polyurethanes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
  • B05D3/0406—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases the gas being air
  • B05D3/0413—Heating with air
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
  • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
  • B05D3/065—After-treatment
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/04—Inorganic
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/12—Gel
  • B32B2266/126—Aerogel, i.e. a supercritically dried gel
• • 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
  • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
  • B32B2307/102—Insulating
• • 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
  • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
  • B32B2307/206—Insulating
• • 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
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/304—Insulating
• • 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
  • B32B2307/73—Hydrophobic

Definitions

• the invention relates to a method for applying an airgel-containing insulation layer to an article.
• the insulation layer can be used for thermal insulation (also referred to as heat or thermal insulation), but also for structure-borne and impact sound insulation or insulation from vibrations.
• an aerogel refers to a gel that is formed with air as the dispersion medium. This includes three types of aerogels, which differ in the way they are dried.
• airgel describes a wet gel that is dried by evaporation above the characteristic critical point (i.e. at temperatures above the critical evaporation temperature and/or starting from pressures above the critical pressure).
• the characteristic critical point i.e. at temperatures above the critical evaporation temperature and/or starting from pressures above the critical pressure.
• a wet gel that is dried under subcritical conditions for example with the formation of a liquid-vapor boundary phase
• a xerogel a wet gel that is dried under subcritical conditions, for example with the formation of a liquid-vapor boundary phase
• the material has high porosity with a large surface area in combination with a very small pore size.
• airgel also includes dried gel products that were obtained in a freeze-drying process. These are regularly referred to as cryogels.
• the typical structures of the aerogel arise during the sol-gel transition.
• the external form can only be achieved by crushing such as being changed by grinding.
• the material is too brittle for most other types of forming.
• airgel compositions include both organic and inorganic aerogels.
• the inorganic aerogels are often based on metal oxides such as silicon oxide (silica), carbide (carbides) and aluminum oxide (alumina).
• organic aerogels include carbon aerogels and polymeric aerogels, such as polyamide aerogels.
• aerogels with very good thermal insulation properties have a particularly low density, which ranges from 0.01 g/cm 3 to 0.3 g/cm 3 , for example.
• Such materials can have a thermal conductivity of 12mW/mK or even less under normal conditions, ie at room temperature of 20°C and mean atmospheric pressure of 1013.25 hPa. Due to their low density, however, pure aerogels and airgel particles are extremely fragile and at the same time difficult to handle in further processing.
• Prior art WO2012/013817 A1 describes a specific method of aerogel-containing composites.
• a composite with improved mechanical strength is primarily to be produced.
• fibers in an amount of 3 to 80 wt% of the total weight of the starting material and airgel particles in an amount of 10 to 75 wt% of the total weight of the starting material are provided as raw materials and mixed together in a first stream of air.
• This is intended to produce a particularly homogeneous mixture, which increases the mechanical strength of the composite produced later.
• a chemical binder can be added as another raw material.
• the composite additionally comprises a layer of fleece or felt onto which the mixed raw materials are applied and pressed with this layer.
• DE 195 48 128 A1 further describes a composite that has at least one layer of fiber fleece with thermoplastic fiber material and airgel particles.
• the initial problem is that the high porosity of aerogels leads to low mechanical stability both of the gel (from which the airgel is dried) and of the aerogel itself.
• the solution here is to bind the airgel particles to the melted thermoplastic fibers.
• the melted thermoplastic fibers connect the fibers to one another to form a stable fleece when they solidify.
• Staple fibers are used to produce the non-woven fabric. While the fleece is laid according to the known methods, i.e. during the fleece production process, the aerogranulate is sprinkled in, with care being taken to ensure that the granulate grains are distributed as homogeneously as possible. This is achieved by commercially available scattering devices. A comparable method is also known from EP 0799353 B1. However, sprinkling is only possible here in a sealed working chamber or the airgel granules must be sufficiently large and therefore heavy to achieve an undesired distribution in the air and a targeted application.
• the publications DE 197 02 240 A1 and EP 0 850 206 B1 describe a method for producing an airgel composite body, in which the airgel particles are bonded with a binder (DE'240 A1) or an adhesive (EP'206 B1). and possibly mixed with fibers.
• the composite body preferably comprises three layers, of which the middle one contains airgel.
• the proportion of airgel particles in the at least one airgel-containing layer should be in the range from 5 to 97 percent by volume (vol%).
• the binder in the at least one airgel-containing layer forms a matrix which connects or encloses the airgel particles and runs as a continuous phase through the at least one airgel-containing layer and optionally through the entire composite.
• Binders can be, for example, adhesives or plastics or bicomponent fibers, with the binder preferably not penetrating into the interior of the porous airgel particles in order to minimize their heat-conducting properties to affect.
• the airgel particles can be sprayed with and thus coated with the binder.
• the airgel particles and possibly fibers can also be mixed with the binder.
• US 2018/0313001 A1 describes a method for producing a synthetic fiber with a proportion of airgel particles of about 0.1 to 15 percent by weight (hereinafter also wt%) and a proportion of 85 to 99.9 wt%. of a polymer known.
• the airgel particles and the polymer are mixed together and extruded together or otherwise formed into an intermediate product (for example into pellets).
• the production methods described above have proven to be very complex and cost-intensive, in particular since the handling of airgel particles is problematic in industrial processing due to their low intrinsic weight. Furthermore, in a large number of the methods described, the airgel is introduced into or applied to the end product during its manufacture. As a result, the area of application is limited, subsequent application or application of an airgel-containing layer to a finished article is no longer possible.
• the airgel is applied to the finished product in a solution and then has to be dried in a complex drying process, which must ensure that the heat-insulating properties of the airgel are not impaired.
• a complex drying process which must ensure that the heat-insulating properties of the airgel are not impaired.
• the present invention proposes a solution with the features of claim 1.
• a method for applying at least one airgel-containing insulation layer to an article according to claim 1 is proposed according to the invention.
• a method for applying at least one airgel-containing insulation layer to an article according to claim 1 is proposed according to the invention.
• the insulation layer comprises airgel particles and a binder.
• the method includes the steps of providing the article to be coated; Mixing the airgel particles with particles of a powdered binder and/or a powdered solid, such as expanded glass, to form a powdered particle mixture; Applying the airgel particles mixed with the powdered binder and/or the powdered solid (the particle mixture) to the article to be coated by sprinkling the airgel particles onto or onto the article to be coated, and activating the binder of the at least one insulation layer in order to provide connection with the article.
• the airgel particles are contained in the particle mixture in a proportion of 5 to 95 percent by weight of the particle mixture.
• the article comprises a textile surface to which the at least one airgel-containing insulation layer is to be applied.
• the airgel particles (of the particle mixture) mixed with the powdered binder and/or the powdered solid can also be blown onto or sucked onto the article to be coated.
• articles or products that are in particular finished with the present method can be subsequently provided with an insulating layer.
• layer does not refer to a closed surface, but also includes the partial, gap-prone application of a particle mixture with airgel particles.
• the airgel particles which are decisively responsible for the thermal insulation, do not have to be introduced into the article as part of the production process, but can be applied to the article subsequently with the aid of a binding agent.
• the subsequent application of an insulating layer thus significantly increases the scope of the present invention compared to the solutions known from the prior art. Of course, if necessary, several insulation layers can be applied in this way.
• the at least one insulation layer includes both the airgel particles and a binder.
• the binder can be applied to the article separately, for example brushed or doctored on, and/or mixed with the airgel particles as a powdered particle mixture.
• a special feature of the present invention according to the invention can be seen in the fact that the airgel particles in the particle mixture according to the invention can be scattered, blown up or sucked in.
• a noteworthy advantage of aerogels can be seen in the fact that they have very good insulation properties. These result in particular from the particularly low density of airgel materials, which ranges from 0.01 g/cm 3 to 0.3 g/cm 3 , for example. Due to their low density, however, pure aerogels and airgel particles are extremely fragile and at the same time difficult to handle in further processing. If you tried to sprinkle them on a surface without special pre-treatment, their own weight would not be sufficient to enable targeted application to the surface.
• the airgel particles are therefore mixed with particles of a powdered binder and/or a powdered solid prior to application to the article to be coated.
• the airgel particles detachably adhere to the particles of the admixed powder.
• responsible for this are, among other things, microstructures on the particle surfaces, which support mechanical adhesion. If necessary, charge differences and the Van der Walls forces also have a supporting effect.
• the airgel particles are weighed down by the adhering particles of the particle mixture and the mixture of airgel particles and the particles of the admixed powder can be applied to a surface of a surface without the negative effects and disadvantages mentioned of too low a density applied to the article to be coated, in particular sprinkled on.
• the particle mixture is in powder form, a very precise metering of the airgel particles per area can be achieved, with the particle mixture in the insulation layer not having any significant adverse effect on the properties of the item for the user of the finished item, in particular the surface properties such as flexibility in textiles. surface roughness and the like.
• the particle mixture can also be blown up or sucked in (in the case of an air-permeable surface to be coated) to apply the airgel particles, since the increased weight of the particle mixture compared to pure airgel particles has also proven to be advantageous for handling has, whereby in practice so far sprinkling has shown to be the simplest solution.
• the particles can be mixed in a wide variety of ways and by means of any type of mixing device, for example in a closed mixing container into which the particles to be mixed are filled and which is moved to mix the particles (rotation, translation, oscillation and mixed forms of these are conceivable).
• a stirring element can also be provided inside the mixing container, which in turn can be moved relative to the mixing container (rotation, translation, oscillation and mixed forms of these are also conceivable here).
• Mixing in a mixing container with the aid of heated air is also possible in view of the low density of the airgel particles a conceivable variant, in particular since mixing in an air stream is used for a particularly homogeneous mixing result and, in the case of a specified air temperature that is above the activation temperature, possibly for activating the surface of binder particles (as described below as a conceivable embodiment). can be.
• the mixing process is carried out until there is a desired, approximately homogeneous distribution of the airgel particles in the particle mixture.
• the mixing process can be regulated both via the duration and, for example, via the speed or the type of mixing movement of the mixing device.
• the admixed particles can be particles of a powdered binder.
• binders are understood not only as chemical binders in the narrower sense, but also as substances in a broader sense that create or promote chemical bonds at phase boundaries of other substances or trigger or increase effects such as cohesion, adsorption and adhesion or friction. They connect substances by absorbing, accumulating, holding them together, crosslinking or gluing them. This also includes substances that are commonly referred to as adhesives.
• the binder according to the invention can also comprise a binder system with several binders.
• Binders with low thermal conductivity are presently preferred to achieve thermal insulation. If the article to be coated is not intended to insulate thermally, or not primarily, but rather to provide sound insulation, for example, other binders can also be preferred.
• the choice of binder depends on the desired properties of the article to be coated. For example, a binder can also be selected that is particularly flame retardant or non-combustible in order to achieve the most favorable fire class possible for the article to be coated.
• silicone resin adhesives can be used for the specific application.
• the binder is used as a solid powder when admixed with the airgel particles. Because the admixed particles are also in powder form, the advantages associated therewith, in particular an exact dosing of the airgel particles, are retained. This also ensures that the particles of the powdered binder essentially do not penetrate into the interior of the porous airgel particles and thus do not significantly impair the desired insulation properties.
• a binding agent can also be applied directly to the article in order to connect the subsequently scattered particle mixture with the airgel particles and other powdery particles to the article surface.
• Binders according to the present invention can thus z. B. both physically setting and chemically curing one-component adhesives and chemically curing two- or multi-component adhesives.
• binders are hot-melt adhesives, dispersion adhesives, solvent-based adhesives, plastisols, thermosetting epoxy resins, reactive hot-melt adhesives such as ethylene-vinyl acetate copolymers and polyamides, formaldehyde condensates, polyimides, polybenzimidazoles, cyanoacrylates, polyvinyl alcohols, polyvinyl butyrals, polyethylene waxes, anaerobic adhesives, called moisture-curing silicones and light and UV-curing systems, methacrylates, two-component silicones, cold-curing epoxy resins and cold-curing polyurethanes.
• binders can also be, for example, transparent or translucent plastics such as polymethyl methacrylates (PMMA, e.g. Degalan TM , Plexiglas TM ), cycloolefin copolymers (COC, e.g. Topas TM ), polyvinyl butyrals (e.g. B. Mowital TM), polycarbonates and polyethylene terephthalates (PET, z. B. Hostaglas TM), with polyvinyl butyrals, polyvinyl alcohols and polymethyl methacrylates being preferred.
• PMMA polymethyl methacrylates
• COC cycloolefin copolymers
• COC e.g. Topas TM
• polyvinyl butyrals e.g. B. Mowital TM
• PET z. B. Hostaglas TM
• binders can also be of a fibrous nature, e.g. B. bicomponent fibers.
• the particle mixture with the airgel particles and the particles of a powdered binder and/or a powdered solid comprises at least 5 to 95 percent by weight of airgel particles—preferably 5 to 70 percent by weight, particularly preferably 30 to 65 percent by weight and in particular 40 to 60 percent by weight of the particle mixture.
• the insulation layer can also comprise other materials and substances, for example additional amounts of connection accelerators, lubricants, pigments, plasticizers or curing accelerators can be used to achieve certain properties.
• connection accelerators for example, materials and methods known to those skilled in the art can be used to achieve a fire class that is as favorable as possible, e.g. B. flame retardants, fire protection paints - varnishes, foils and laminations.
• this can also include a protective layer that is able to protect at least the area with the applied airgel particles from external influences, such as mechanical abrasion or the like, and can be applied to the applied airgel particles.
• the particle mixture can also contain particles of another powdered solid, for example expanded glass particles or the like.
• expanded glass has the advantage that this material is comparatively inexpensive to produce and has many advantages in use.
• Expanded glass is obtained from recycled waste glass and is already used in the production of lightweight concrete, lightweight plaster, lightweight masonry mortar and in thermal insulation panels, thermal insulation fill, plaster base panels, curtain wall systems and decorative paints.
• Expanded glass is foamed glass with small, gas-filled pores and can be produced with grain sizes of 0.04-16 mm. The granules have a closed lattice structure.
• expanded glass In contrast to the angular, broken foam glass (gravel), which is produced in a similar process but compressed under pressure, expanded glass (granulate) consists of balls/round grains, which enable versatile processing. Fillers made of expanded glass are very light and yet pressure-resistant, thermally insulating, alkali-resistant, non-flammable, have a high resilience and are not attacked by rodents, vermin and fungi.
• the binder which is mixed in particle form with the airgel particles, can also be used to connect the airgel particles to the article to be coated.
• binders that can be activated and/or cured by thermal warming or heating.
• alternative configurations in which other activation mechanisms are used are also conceivable.
• the particle mixture or the binder particles before, during and/or after the mixing of the particles.
• the mixture can remain in powder form if the heating is kept brief and the binder particles are only heated on the surface.
• the resultant sticky particle surface of the binder particles is wetted by the adhesion of the airgel particles and the mixture remains scatterable and powdery.
• the mixture can be sprinkled onto the article to be coated, for example onto a textile surface, and then heated to such an extent or further that the binder particles are activated again or further and reliable binding of the airgel Allow particles to the article surface.
• the binder particles can be solidified and hardened simply by cooling the binder below the melting temperature or with the aid of other measures, for example further heating, use of UV rays or the like. In this way, the airgel particles are firmly bonded to the surface of the article to be coated.
• a binder can be applied to the article to be coated, detached from the particle mixture.
• This can be a binder of the same type as that which can be admixed to the airgel particles in powder form, or it can be of a different type.
• the binder can be present in a non-solid or non-powder form in order to simplify binding of the particle mixture to the article to be coated.
• a spreadable binder can be applied in liquid or paste form to the article to be coated.
• the article has been impregnated with a binder or has been coated with a binder in the form of an adhesive fleece, which enables the applied particle mixture to adhere.
• the article can also have a surface that acts as a binder through activation, in particular through thermal heating. For example, in the case of a textile surface, this can contain fibers that are suitable for binding the particle mixture to the textile surface through thermal activation.
• this binder to be applied to the article to be coated one preferably selects one or the other which essentially does not penetrate into the interior of the porous airgel particles.
• the penetration of the binder into the interior of the airgel particles can In addition to the selection of the binding agent, this can also be influenced by regulating the temperature and the processing time.
• the step of activating the binder can include thermally heating the particle mixture and/or the article to be coated in order to activate and/or subsequently solidify the binder(s).
• the particle mixture can be heated in order to improve the adhesion of the particles, in particular the airgel particles, to the added binder particles and/or to the powdered solid particles and in this way to improve the handling of the particle mixture.
• the article to be coated with the already applied particle mixture and/or before the application of the particle mixture can be heated, for example to activate an additional binder applied to the article or to activate the particle mixture applied to the article.
• the insulation layer can also be cured by means of thermal heating. Alternatively, however, the insulation layer can also be solidified, for example by cooling, using UV light or other known means.
• a method for improving the handling of airgel particles is also provided in order to be able to apply them to the article by sprinkling, inflating or sucking, for example for applying at least one airgel-containing insulation layer to an article according to the method described above, the airgel particles being mixed with a powdered binder and/or a powdered solid, such as expanded glass, to form a particle mixture prior to the application step.
• the comparatively very light airgel particles are weighed down by the adhering further powdered material particles, which detachably adhere to the airgel particles in the mixed state.
• microstructures on the particle surfaces which support mechanical adhesion.
• the airgel particles are weighed down by the adhering particles of the particle mixture and the mixture of airgel particles and the particles of the admixed powder can be used in industrial processing methods without the negative effects and disadvantages of too low a density already mentioned above.
• the airgel particles in the particle mixture are detachably connected to the particles of the powdered binder and/or the powdered solid at least by physical adhesion.
• improved adhesion can also be achieved by slightly activating the powdered binder.
• the airgel particles can have an open porosity with up to 99% air content, in particular around 95% air content.
• the airgel particles can have a density of less than 1 g/cm 3 , for example less than 0.5 g/cm 3 and particularly advantageously less than 0.15 g/cm 3 .
• the airgel particles can have pores with a pore size in the range of 2 to 50 nm (mesoporous Particles), preferably in the range of 20-40nm.
• the airgel particles themselves can have different sizes in a range from, for example, 5 ⁇ m to 5 mm, in particular in a range from 8 ⁇ m to 4 mm.
• the article to be coated can comprise a textile surface to which the at least one insulation layer is to be applied.
• All types of textiles can be used as a textile surface, regardless of the type of manufacture, the structure of the substance or the extraction of the starting substances, ie the textile surface includes any form of textile fabric, ie fabric made of fibers such as felt, fleece and wadding , and from threads, such as braids, woven fabrics, nets, knitted fabrics and warp-knitted fabrics. Furthermore, these can include fibers obtained from synthetic or natural raw materials.
• the textile surface can be produced by knitting, weaving, spinning, felting, knitting, laying or fulling.
• the textile surface as a carrier layer for the at least one insulating layer.
• non-combustible or flame-retardant carrier materials such as melamine resin fibers or the like, can be used in order to increase the fire protection effect of the article.
• the mechanical strength of the article or the insulating effect can be improved by choosing a suitable carrier material as the textile surface and by choosing the processing method for the textile surface.
• the insulation layer can include an additional protective layer, which serves to protect the airgel particles from external influences. It is thus possible to provide an additional protective layer at least in certain areas to protect the insulating layer.
• the additional protective layer can be, for example, an additional textile protective layer, for example in the form of a fleece layer or a wadding.
• the additional protective layer can also comprise a non-textile layer, for example a foam or a film.
• the additional protective layer can be glued, pressed and/or needled to the insulation layer, depending on the type of protective layer and configuration of the insulation layer.
• a nonwoven fabric or cotton wool can be placed on the textile surface as an additional protective layer after the insulation layer has been applied and needled to the textile surface.
• the fibers of the fleece or wadding can be intertwined with each other and with those of the textile surface, whereby the fleece is attached to the textile surface and its fibers are simultaneously compressed and strengthened by a large number of special needles arranged in a needle board or needle bar ( Barbed needles, fork needles or the like) is inserted and pricked out.
• the additional protective layer can also be bonded to the insulation layer, in particular to the binder contained therein, directly or via an additional binder.
• the protective layer can thus be placed on the insulation layer while the binder of the insulation layer or an additional binder is activated in the boundary area between the protective layer and the insulation layer and, if necessary, can be reliably connected to the latter by additional pressing.
• the protective layer itself can also contain an activatable binder for connection to the insulating layer.
• the additional protective layer for example, mechanical abrasion of the applied insulation layer can be avoided, which can be particularly advantageous if the textile surface of the article can be exposed to strong mechanical stresses during use. Furthermore, the insulation effect can be further improved by the additional layer.
• the additional layer in particular the textile protective layer, other properties of the article, in addition to the mechanical strength and the insulating effect, can also be improved; for example, non-combustible or flame-retardant fibers can be used to increase the fire protection effect.
• the textile protective layer in addition to the nonwoven mentioned as an example, textiles of all kinds can of course also be used, regardless of the type of production, the structure of the textile fabric or the extraction of the starting substances, i.e. the textile protective layer can be fabrics made of fibers such as felts , fleeces and waddings, and fabrics made of threads, such as braids, woven fabrics, nets, knitted fabrics and warp-knitted fabrics. Furthermore, these can include fibers obtained from synthetic or natural raw materials.
• the textile protective layer can be produced by knitting, weaving, spinning, felting, knitting, laying or fulling.
• a protective layer can comprise a solid structure, such as the fleece layer described above, for example a textile protective layer, a film or the like which can be connected to the article, a foam or a coating to be applied, such as an impregnation, a protective lacquer or the like.
• the airgel particles can in particular comprise a silicate airgel (SiO 2 airgel).
• SiO 2 airgel silicate airgel
• This material has a number of positive properties, such as poor flammability, low electrical conductivity and very low thermal conductivity.
• the material is non-toxic and translucent or transparent, as well as elastic, which means that it can be used in a variety of conceivable applications and articles, such as in the field functional textiles, heat-insulating containers and housings (e.g. of electrical devices), as well as in house construction and the like.
• the airgel particles can include graphite, plastic (e.g. resorcinol-formaldehyde RF, polyurethane PU, polyester PES) and biopolymers (e.g. lignin, cellulose).
• plastic e.g. resorcinol-formaldehyde RF, polyurethane PU, polyester PES
• biopolymers e.g. lignin, cellulose
• the airgel particles can have hydrophobic surface groups.
• hydrophobic groups are covalently present, in particular on the inner surface of the aerogels, which are not split off under the action of water.
• Preferred groups for permanent hydrophobization are trisubstituted silyl groups of the general formula - Si (R) 3, most preferably trialkyl and / or triarylsilyl groups, wherein each R is independently a non-reactive organic radical such as C1-C18 alkyl or C6-C 4 aryl , Preferably Ci-C6-alkyl or phenyl, in particular methyl, ethyl, cyclohexyl or phenyl, which can additionally be substituted with functional groups.
• trimethylsilyl groups is particularly advantageous for rendering the aerogel permanently hydrophobic.
• These groups can be introduced as described in WO 94/25149, or by gas-phase reaction between the airgel and, for example, an activated trialkylsilane derivative, such as a chlorotrialkylsilane or a hexaalkyldisilazane (compare R. Iler, The Chemistry of Silica, Wiley & Sons, 1979).
• an activated trialkylsilane derivative such as a chlorotrialkylsilane or a hexaalkyldisilazane (compare R. Iler, The Chemistry of Silica, Wiley & Sons, 1979).
• the airgel particles have a thermal conductivity of less than 25 mW/mK, in particular less than 15 mW/mK, for example 12 mW/mK.
• the invention also relates to a coated article to which at least one airgel-containing insulation layer is applied using a method as described above, the insulation layer comprising airgel particles and a binder.
• the insulation layer is applied to an outside of the finished article.
• the finished article comprises a textile, with the proportion of airgel particles on the coated article being at least 0.5 percent by weight.
• the present invention relates to the use of a coated article as described above in the field of thermal insulation, fire protection, soundproofing, electrical insulation and/or in the field of absorption of gases, vapors and liquids.
• thermal insulation describes the reduction in the passage of thermal energy through the at least one insulation layer in order to protect a room or a body from cooling down or heating up.
• terms such as “comprising”, “having” or “with” do not exclude any other features or steps.
• terms “a” or “the” indicating a singular number of features or features do not exclude a plurality of features or steps, and vice versa.
• Figure 1 is a longitudinal sectional view of the method according to the invention with a
• FIG. 2 shows an arrangement for applying an insulating layer to an article using the method according to the invention.
• FIG. 3 shows a flow chart of the production method according to the invention.
• FIG. 1 shows, in a highly schematized manner, an article which has been provided with an insulating layer containing airgel in accordance with the method of the present invention.
• the aerogels are contained in particle form in the insulation layer and can be applied to a finished article without this subsequently having to be subjected to a complex drying process to produce the airgel structure.
• the airgel particles are scattered onto the article, blown up or sucked onto it.
• the article in the present exemplary embodiment comprises a hydrojet fleece 10 to which an insulating layer 20 has been applied.
• a hydrojet fleece 10 to which an insulating layer 20 has been applied.
• nonwoven nonwovens that are placed under high pressure are swirled, intertwined and solidified by water jets.
• This type of mechanical strengthening creates a very uniform pore structure.
• the application of at least one insulation layer according to the invention to other surfaces is of course also possible.
• the article to be covered with at least one airgel-containing insulation layer is not limited to articles with a textile surface, but can have all conceivable types of materials and shapes.
• the decisive factor here is that the airgel particles are not introduced into the article, in this case the nonwoven fabric, as part of the manufacturing process of the article, but are subsequently applied to it.
• the airgel particles are Particles 22 and the particulate binder 24 are mixed together to form a particle mixture 26 which is applied to the article, in this case to the water jet nonwoven 10 .
• particles of a powdered solid, e.g. expanded glass particles can also be mixed with the airgel particles 22.
• the premixed particle mixture 26 can be scattered by means of a scattering device (in FIG. 2: “powder scatterer”) 30 onto the hydrogen fleece 10 unwound from a unwinding device.
• a scattering device in FIG. 2: “powder scatterer”
• a larger surface of an article can be provided with an airgel-containing insulation layer 20 by continuously guiding the surface under the scattering device 30, for example by means of the shown unwinding device 60a and winding device 60b.
• Alternative conveying devices are of course also conceivable, such as the discontinuous application of an insulating layer containing airgel to individual articles.
• the size of the binder particles 24 of the particulate or powder-form binder 24 can be similar to the particle size of the airgel particles 22, as shown in FIGS. 1 and 2, or significantly larger or smaller in deviation therefrom.
• the only decisive factor is that the particles 24 or 32 of the particle mixture 26 mixed with the airgel particles 22 are able to at least partially adhere to the airgel particles 22 in order to make them easier to handle industrially, in particular scatterable, and that the particle mixture is suitable for a good dosability composed of powdered components.
• the mechanical adhesion of the airgel particles 22 to the admixed particles 24 (and the charge adhesion) is supplemented by, for example, a cohesive adhesion. so can the binder particles 24 are activated, for example by thermal heating, and in this way develop a binding effect on their surface, which enables the airgel particles 22 to adhere cohesively, for example.
• a first heating or activation can take place before the mixing (Figure 3: Step S100) with the airgel particles 22 ( Figure 3: Step S400a), so that the binder particles (24) are added in the already activated state and mixed with the airgel particles (22), or as part of the mixing (FIG. 3: S100) of the particle mixture (FIG. 3: step S400b).
• the binders in the particle mixture 26 can also be activated during the application of the particle mixture 26 (FIG. 3: S200), for example when inflated with warm air or with the aid of a UV lamp or the like (step S400c).
• the activation can also take place (S400di-3) before, during or after the application of a protective layer (FIG. 3: step S300).
• the activation can also take place at the same time as the step of solidifying the insulation layer 20 according to step S600 (step S400e). In this case, the activation and subsequent curing of the binder is carried out in one operation, for example by heating.
• the composite of article 10 and particle mixture 26 can be formed in a method step following the application ( Figure 3: S200). are heated and optionally pressed, for example in a double belt press 40, as shown in FIG.
• the admixed binder 24 can be activated (possibly again or further) and combine with the fibers of the hydrogen fleece 10 and (possibly further) with the airgel particles 22 associate.
• the pressing of this composite also enables a reduction in the cavities between the particle mixture and the article surface and thus improves the binding effect.
• the binder particles 24 can (if present) be completely melted in the composite with the article or only be heated for activation and at least partially still be present in particulate form in the applied and fixed insulation layer.
• the finished product can, for example, be cooled in a cooling field 50, as shown in FIG. 2, in order to solidify the insulation layer.
• a drying process or a curing process can also be carried out in step S600 to solidify the insulation layer.
• FIG. 2 shows a method according to the invention for applying an insulating layer containing airgel to a textile surface of an article.
• the airgel particles 22 are admixed with a powdered binder.
• other particulate solids can also be mixed in.
• expanded glass particles FIG. 2: reference number 32
• at least mechanical adhesion to the airgel particles takes place, as a result of which the airgel particles are weighed down and thus made easier to process.
• connection to the surface of the article to be impacted can take place by means of a binder applied to the article (indicated by the reference number 34 in FIG. 2).
• this can be brushed, sprayed or placed on the surface of the article to be acted upon using an optional application device 36 (step S500).
• the binding agent 34 can already be activated before the application (S400fi) and/or activated during the application (S400f 2 ).
• the particle mixture 26 can then be applied to this, or the binder is only applied with the particle mixture 26 or as part of one of the following process steps and/or activated in combination with the applied particle mixture 26 (shown as an example as S400g), for example by heating.
• a binder 34 is applied to the surface of the article 10 to be acted upon can also be combined with the embodiment in which a particulate binder (also binder particles or binder particles 24) is added to the particle mixture 26 .
• the binder particles 24 may or may not be chemically identical or similar to the binder 34 applied to the surface of the article 10 .
• a further protective layer for example a textile protective layer in the form of a fleece, here a hydrogen fleece 28 (FIG. 2), can be placed on the composite of particle mixture 26 and article surface. This can be heated and pressed together with the composite of particle mixture 26 and article 10 .
• the additional protective layer can also be needled and/or glued (not shown) to a textile surface of the article, such as the hydrojet nonwoven 10 in the embodiment shown.
• FIG. 3 also shows in particular that the step of activating the binder S400 can take place at different points in time (and also several times).
• the powdered binder 24 can be activated, for example by means of a warm air stream, before or during the addition to the airgel particles 22 (S400a), during the mixing of the particle mixture according to S100 (S400b) or when the particle mixture 26 is applied the article 10 according to step S200 (S400c).
• the powdered binder 24 as part of the particle mixture 26 applied to the article 10 can only be activated shortly before, during or after the application of the protective layer according to method step S300 (S400di-3) or during the solidification of the insulating layer according to S600 (S400e).
• the binding agent 34 which can be applied to the article 10 separately from the airgel particles 22, can in turn be activated before or during the application of the binding agent S500 (S400fi- 2 ) or afterwards (S400gi- 2 ).
• the type of activation can also play a role here. For example, if the binding agent 34 is only spreadable as a result of its activation, activation before application or during application (S400f) makes sense. However, if the binding agent 34 can be applied to the article independently of its activation, for example in the form of an impregnation on the surface of the article 10, then (possibly renewed) activation after the application of the binding agent 34 can also be advantageous (S400gi- 2 ).
• step S100 50 g of a polyurethane hotmelt (as particulate binder 24) are mixed with 30 g of airgel silicate particles 22 at 80° C. to form a particle mixture 26, as shown in FIG.
• step S200 the particle mixture 26 is scattered onto a 60 g/m 2 water jet fleece 10 (with an application of 80 g/m 2 ) and covered with a second fleece 28 in a further step S300.
• the two layers of hydrogen fleece 10 and 28 with the intermediate layer of binder particles 24 and airgel particles 22 are then pressed under pressure (0.6 N/cm 2 ) for 60 seconds at 150° C. in a subsequent step.
• the heating under pressure serves to further activate the binding agent 24 (S400d3).
• the insulation layer 20 solidifies in a final step S600.
• a terpolymer hotmelt (as binder particles 24) are mixed with 60 g of airgel silicate particles 22 in a first step S100 without the influence of temperature.
• the particle mixture 26 is then scattered onto a 50 g/m 2 water jet fleece 10 (with an application of 120 g/m 2 ) and covered with a second fleece 28 in a subsequent step S300.
• the two layers of hydrogen fleece 10 and 28 with the intermediate layer of binder particles 24 and airgel particles 22 are then pressed together under pressure (0.6 N/cm 2 ) at 160° C. for 45 seconds.
• the heating under pressure in turn serves to activate the binder 24 (S400d3).
• the insulation layer 20 solidifies in a final step S600.
• a third example in a first step S100 without the influence of temperature, 30 g airgel silicate particles 22, 30 g expanded glass (with a diameter of approx. 0.1-0.3 mm as powdered solid particles) and 30 g hotmelt (as particulate binder 24) are joined together a particle mixture 26 mixed.
• a 50 g/m 2 water-jet nonwoven 10 is coated with an activated (S400f) EVA hotmelt as a further binder 34 by means of a slot die (as application device 36).
• the application or layer thickness is 20g/m 2 .
• a subsequent step S200 the particle mixture 26 is sprinkled into the liquid binding agent 34 applied to the article 10 (with a coverage of 60 g/m 2 ).
• a further step S300 the composite of article 10 with a binder coating and scattered particle mixture 26 is covered with a second fleece 28 and pressed under pressure at 150° C. for 45 seconds (0.6 N/cm 2 ). The heating under pressure serves both to further activate the binding agent 34 (S400g 2 ) and to activate the particulate binder 24 (S400d3).
• the insulation layer 20 solidifies in a final step S600.
• a particle mixture 26 without the influence of temperature.
• a 30 g/m 2 paper (as article 10) is impregnated with a melamine resin (as an additional binder) in a step S500.
• the particle mixture 26 is then sprinkled into the not yet dried melamine film (with an application of 8 g/m 2 ).
• the impregnated paper with the scattered particle mixture 26 is then dried at 140° C. for 60 seconds, ie the melamine film is cured.
• the heating under pressure serves to solidify the insulation layer 20 in a final step S600.
• Table 1 determined values for the thermal resistance for examples 1, 2 and 5
• a terpolymer hotmelt (as binder particles 24) are mixed with 50 g of airgel silicate particles 22 in a first step S100 without the influence of temperature.
• the particle mixture 26 is then scattered onto a 50 g/m 2 water jet fleece 10 (with an application of 90 g/m 2 ) and covered with a second fleece 28 in a subsequent step S300.
• the two layers of hydrogen fleece 10 and 28 with the intermediate layer of binder particles 24 and airgel particles 22 are then pressed together under pressure (0.6 N/cm 2 ) at 160° C. for 45 seconds.
• the heating under pressure in turn serves to activate the binder 24 (S400d3).
• the insulation layer 20 solidifies in a final step S600.
• the bonded article is additionally mechanically strengthened in a needling process.
• a hotmelt equipped with flame retardant (as binder particles 24) are mixed with 30 g of airgel silicate particles 22.
• the particle mixture 26 is then scattered onto a 50 g/m 2 Pyrotex water jet fleece 10 (with a coverage of 80 g/m 2 ) and covered with a second (identical) fleece 28 in a subsequent step S300.
• the two layers of hydrogen fleece 10 and 28 with the The intermediate layer of binder particles 24 and airgel particles 22 are then pressed under pressure (0.6 N/cm 2 ) at 160° C. for 45 seconds.
• the heating under pressure in turn serves to activate the binder 24 (S400d3).
• the insulation layer 20 solidifies in a final step S600.
• the bonded article is additionally mechanically strengthened in a needling process.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
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• Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)
• Laminated Bodies (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Silicon Compounds (AREA)
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• 2020
  • 2020-07-15 DE DE102020118734.3A patent/DE102020118734A1/de active Pending
• 2021
  • 2021-06-23 JP JP2023502714A patent/JP2023533817A/ja active Pending
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  • 2021-06-23 US US18/015,811 patent/US20230256706A1/en active Pending
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