JP2022523732A - 二成分繊維を含む軽量強化熱可塑性複合物品 - Google Patents
二成分繊維を含む軽量強化熱可塑性複合物品 Download PDFInfo
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- JP2022523732A JP2022523732A JP2021544584A JP2021544584A JP2022523732A JP 2022523732 A JP2022523732 A JP 2022523732A JP 2021544584 A JP2021544584 A JP 2021544584A JP 2021544584 A JP2021544584 A JP 2021544584A JP 2022523732 A JP2022523732 A JP 2022523732A
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Abstract
Description
本出願は、2019年2月1日に出願された米国仮特許出願第62/800,314号、および2019年7月15日に出願された米国仮特許出願第62/874,036号に関し、それらに対する優先権および利益を主張するものであり、これらの各々の開示全体は、参照により本明細書に組み込まれる。
いくつかの試料を、二成分繊維を含む複合物品の特性を判定するために、調整し、かつ試験した。試験された試料中で使用された材料、およびそれらの番号付けは、以下の表1に示される。PPは、ポリプロピレンを表す。試験されたポリマー繊維は、シェル中にLLDPEを有し、コア中にポリエチレンテレフタレートを有するコアシェル二成分繊維である。
実施例1の複合物品を、異なる厚さに成形した。以下の表2は、異なる物品に関する異なる厚さのいくつかを列挙する。MDは、機械方向と一致する、試験片の経度方向を表し、CDは、機械横断方向と一致する、試験片の経度方向を表す。
試験試料のピーク荷重値を、SAEJ949_200904を使用して測定した。3点曲げ試験は、試験試料のフィルム側が3点曲げ試験において荷重に向く状態で使用した。試験された試料に関する測定されたピーク荷重値は、以下の表3に示される。
試験試料の剛性値を、SAEJ949_200904を使用して測定した。3点曲げ試験は、試験試料のフィルム側が3点曲げ試験において荷重に向く状態で使用した。試験された試料に関する測定された剛性値は、以下の表4に示される。
試験試料の曲げ強度値を、SAEJ949_200904を使用して測定した。3点曲げ試験は、試験試料のフィルム側が3点曲げ試験において荷重に向く状態で使用した。試験された試料に関する測定された曲げ強度値は、以下の表5に示される。
790gsmの試料に関して、ST-12245aのMDおよびCD曲げ強度値(14.5および10.2)は、ST-12243cに関するMDおよびCD曲げ強度値(8.9および6.3)よりもはるかに高かった。これらの結果は、同等またはそれ以上の曲げ強度を提供する二成分繊維および微小球と一致する。
試験試料の曲げ弾性率値を、SAEJ949_200904を使用して測定した。3点曲げ試験は、試験試料のフィルム側が3点曲げ試験において荷重に向く状態で使用した。試験された試料に関する測定された曲げ弾性率値は、以下の表6に示される。
ガラス/二成分ポリマー繊維ハイブリッドLWRT(H-LWRT)および標準ガラス繊維LWRT(S-LWRT)シートは、同じ湿式レイドプロセスを使用することにより製造された。H-LWRT用のポリオレフィン樹脂、チョップドガラス繊維、および二成分ポリマー繊維を、水中に分散させた。十分に分散した樹脂および繊維の水性懸濁液を、ウェブ形成区分に移し、膨張剤を、連続ウェブに添加した。得られたウェブを、排水し、加熱し、表面材料(スクリムおよびフィルム)で積層させ、固めて、平らなLWRT複合シートを生成した。製造パラメータを調整することにより、様々な坪量(面密度)の材料を生成することができる。対照試料(S-LWRT)は、650g/m2の坪量を有し、これはHLWRTの坪量568g/m2よりも約14.4%重かった。
表7に示される試料の引張特性を評価するために、3.5mmの厚さを有する成形プラークを、パンチプレスによってドッグボーン引張試験片に切断した。図17は、引張弾性率を示すグラフであり、図18は、試料A(H-LWRT)、試料B(H-LWRT)、および対照(S-LWRT)の引張強度を示すグラフである。引張弾性率および引張強度の両方に関して、3つの試料はすべて、機械横断方向(CD)におけるものよりも機械方向(MD)において有意に優れた結果を示す。これは、主にヘッドボックス内で発生する、機械方向に有利な繊維配向バイアスに起因する可能性がある。ヘッドボックス内の流れは、せん断および伸長の両方の混在である。複雑な流れは、壁に近いせん断を特徴とし、ドメイン全体で機械方向に向かって伸びる可能性がある。その結果、繊維は、流れ方向に向かって強く整列させることができ、MDにおけるより良い機械的性能につながる。
曲げ試験を、3.5、4、5.5、および7mmに成形された試験片で実施した。図19Aおよび図19Bは、試料A(H-LWRT)、試料B(HLWRT)、および対照(S-LWRT)の間の、MDおよびCDの両方におけるピーク荷重を比較している。引張特性と同様に、MDにおけるピーク荷重の結果はまた、CDにおけるピーク荷重の結果よりも良い。多孔率の増加により、厚さが増加するにつれて、ピーク荷重は低下する。成形厚さの範囲全体を通して、3つの試料すべてが、非常に同等のピーク荷重結果を示す。これは、曲げピーク荷重を犠牲にすることのない最大82g/m2の重量減少は、二成分ポリマー繊維とガラス繊維をハイブリダイズさせることによって達成されることを示す。
Claims (64)
- 強化繊維、二成分繊維、ロフト剤、および熱可塑性材料から形成されたウェブを含むロフトコア層を含む、成形された多孔質複合物品であって、前記ウェブが、約20%~約80%の多孔度を含み、前記二成分繊維が、コアシェル配置を含み、前記コアシェル配置のシェルのシェル材料が、前記熱可塑性材料の融点と実質的に同様の融点を含み、前記コアシェル配置のコアのコア材料が、前記熱可塑性材料の前記融点よりも少なくとも摂氏20度高い融点を含み、前記成形された多孔質複合物品が、SAE J949_200904によって試験された際、機械方向および横断方向の両方において約2mm~約4mmの成形された厚さで、前記機械方向において10N~約40Nのピーク荷重および前記横断方向において約6N~約30Nのピーク荷重を含む、成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルまたはポリアミドを含むコアと、を含む、請求項1に記載の成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルを含むコアと、を含む、請求項2に記載の成形された多孔質複合物品。
- 前記ポリオレフィンが、ポリエチレンを含む、請求項3に記載の成形された多孔質複合物品。
- 前記ポリエチレンが、線状低密度ポリエチレンである、請求項4に記載の成形された多孔質複合物品。
- 前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項5に記載の成形された多孔質複合物品。
- 前記ポリアミドが、ナイロンを含む、請求項2に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項2に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリアミドが、ナイロンを含む、請求項2に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンを含み、前記強化繊維が、ガラス繊維を含み、前記二成分繊維が、前記シェル中に線状低密度ポリエチレンを含み、前記コア中にポリエステルまたはポリアミドを含み、前記コア中の前記ポリエステルまたはポリアミドの融点が、前記熱可塑性材料の融点よりも少なくとも摂氏20度高く、前記ロフト剤が、膨張可能な微小球を含む、請求項1に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約10N/cm~約50N/cmの前記機械方向における剛性および約7N/cm~約30N/cmの前記横断方向における剛性をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度および約4MPa~約11MPaの前記横断方向における曲げ強度をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約10N/cm~約50N/cmの前記機械方向における剛性および約7N/cm~約30N/cmの前記横断方向における剛性、ならびにSAE J949_200904によって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度および約4MPa~約11MPaの前記横断方向における曲げ強度をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約10N/cm~約50N/cmの前記機械方向における剛性および約7N/cm~約30N/cmの前記横断方向における剛性、ならびにSAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度、ならびに約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約10N/cm~約50N/cmの前記機械方向における剛性および約7N/cm~約30N/cmの前記横断方向における剛性、SAE J949_200904よって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度および約4MPa~約11MPaの前記横断方向における曲げ強度、ならびにSAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項10に記載の成形された多孔質複合物品。
- 前記物品が、自動車のヘッドライナとして構成されている、請求項1~17のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、自動車の内装構成要素として構成されている、請求項1~17のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、キュービクルパネル(cubicle panel)または家具パネルとして構成されている、請求項1~17のいずれか一項に記載の成形された多孔質複合物品。
- 強化繊維、二成分繊維、ロフト剤、および熱可塑性材料から形成されたウェブを含むロフトコア層を含む、成形された多孔質複合物品であって、前記ウェブが、約20%~約80%の多孔度を含み、前記二成分繊維が、コアシェル配置を含み、前記コアシェル配置のシェルのシェル材料が、前記熱可塑性材料の融点と実質的に同様の融点を含み、前記コアシェル配置のコアのコア材料が、前記熱可塑性材料の前記融点よりも少なくとも摂氏20度高い融点を含み、前記成形された多孔質複合物品が、SAE J949_200904によって試験された際、約10N/cm~約50N/cmの機械方向における剛性および約7N/cm~約30N/cmの横断方向における剛性を含む、成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルまたはポリアミドを含むコアと、を含む、請求項21に記載の成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルを含むコアと、を含む、請求項22に記載の成形された多孔質複合物品。
- 前記ポリオレフィンが、ポリエチレンを含む、請求項23に記載の成形された多孔質複合物品。
- 前記ポリエチレンが、線状低密度ポリエチレンである、請求項24に記載の成形された多孔質複合物品。
- 前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項25に記載の成形された多孔質複合物品。
- 前記ポリアミドが、ナイロンを含む、請求項22に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項22に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリアミドが、ナイロンを含む、請求項22に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンを含み、前記強化繊維が、ガラス繊維を含み、前記二成分繊維が、前記シェル中に線状低密度ポリエチレンを含み、前記コア中にポリエステルまたはポリアミドを含み、前記コア中の前記ポリエステルまたはポリアミドの融点が、前記熱可塑性材料の融点よりも少なくとも摂氏20度高く、前記ロフト剤が、膨張可能な微小球を含む、請求項21に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度および約4MPa~約11MPaの前記横断方向における曲げ強度をさらに含む、請求項30に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項30に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約6MPa~約17MPaの前記機械方向における曲げ強度および約4MPa~約11MPaの前記横断方向における曲げ強度、ならびにSAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項30に記載の成形された多孔質複合物品。
- 前記物品が、自動車のヘッドライナまたは自動車の内装構成要素として構成されている、請求項21~33のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、キュービクルパネルまたは家具パネルとして構成されている、請求項21~33のいずれか一項に記載の成形された多孔質複合物品。
- 強化繊維、二成分繊維、ロフト剤、および熱可塑性材料から形成されたウェブを含むロフトコア層を含む、成形された多孔質複合物品であって、前記ウェブが、約20%~約80%の多孔度を含み、前記二成分繊維が、コアシェル配置を含み、前記コアシェル配置のシェルのシェル材料が、前記熱可塑性材料の融点と実質的に同様の融点を含み、前記コアシェル配置のコアのコア材料が、前記熱可塑性材料の前記融点よりも少なくとも摂氏20度高い融点を含み、前記成形された多孔質複合物品が、SAE J949_200904によって試験された際、約6MPa~約17MPaの機械方向における曲げ強度および約4MPa~約11MPaの横断方向における曲げ強度を含む、成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルまたはポリアミドを含むコアと、を含む、請求項36に記載の成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルを含むコアと、を含む、請求項37に記載の成形された多孔質複合物品。
- 前記ポリオレフィンが、ポリエチレンを含む、請求項38に記載の成形された多孔質複合物品。
- 前記ポリエチレンが、線状低密度ポリエチレンである、請求項39に記載の成形された多孔質複合物品。
- 前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項40に記載の成形された多孔質複合物品。
- 前記ポリアミドが、ナイロンを含む、請求項37に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項37に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリアミドが、ナイロンを含む、請求項37に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンを含み、前記強化繊維が、ガラス繊維を含み、前記二成分繊維が、前記シェル中に線状低密度ポリエチレンを含み、前記コア中にポリエステルまたはポリアミドを含み、前記コア中の前記ポリエステルまたはポリアミドの融点が、前記熱可塑性材料の融点よりも少なくとも摂氏20度高く、前記ロフト剤が、膨張可能な微小球を含む、請求項36に記載の成形された多孔質複合物品。
- 前記成形された複合物品が、SAE J949_200904によって試験された際、約800MPa~約2000MPaの前記機械方向における曲げ弾性率および約500MPa~約1300MPaの前記横断方向における曲げ弾性率をさらに含む、請求項36に記載の成形された多孔質複合物品。
- 前記物品が、自動車のヘッドライナとして構成されている、請求項31~46のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、自動車の内装構成要素として構成されている、請求項31~46のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、キュービクルパネルとして構成されている、請求項31~46のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、家具パネルとして構成されている、請求項31~46のいずれか一項に記載の成形された多孔質複合物品。
- 強化繊維、二成分繊維、ロフト剤、および熱可塑性材料から形成されたウェブを含むロフトコア層を含む、成形された多孔質複合物品であって、前記ウェブが、約20%~約80%の多孔度を含み、前記二成分繊維が、コアシェル配置を含み、前記コアシェル配置のシェルのシェル材料が、前記熱可塑性材料の融点と実質的に同様の融点を含み、前記コアシェル配置のコアのコア材料が、前記熱可塑性材料の前記融点よりも少なくとも摂氏20度高い融点を含み、前記成形された多孔質複合物品が、SAE J949_200904によって試験された際、約800MPa~約2000MPaの機械方向における曲げ弾性率および約500MPa~約1300MPaの横断方向における曲げ弾性率を含む、成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルまたはポリアミドを含むコアと、を含む、請求項51に記載の成形された多孔質複合物品。
- 前記二成分繊維が、ポリオレフィンを含むシェルと、ポリエステルを含むコアと、を含む、請求項52に記載の成形された多孔質複合物品。
- 前記ポリオレフィンが、ポリエチレンを含む、請求項53に記載の成形された多孔質複合物品。
- 前記ポリエチレンが、線状低密度ポリエチレンである、請求項54に記載の成形された多孔質複合物品。
- 前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項55に記載の成形された多孔質複合物品。
- 前記ポリアミドが、ナイロンを含む、請求項52に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリエステルが、ポリエチレンテレフタレートを含む、請求項52に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンであり、前記シェルの前記ポリオレフィンが、線状低密度ポリエチレンを含み、前記ロフト剤が、膨張可能な微小球を含み、前記コアの前記ポリアミドが、ナイロンを含む、請求項52に記載の成形された多孔質複合物品。
- 前記熱可塑性材料が、ポリプロピレンを含み、前記強化繊維が、ガラス繊維を含み、前記二成分繊維が、前記シェル中に線状低密度ポリエチレンを含み、前記コア中にポリエステルまたはポリアミドを含み、前記コア中の前記ポリエステルまたはポリアミドの融点が、前記熱可塑性材料の融点よりも少なくとも摂氏20度高く、前記ロフト剤が、膨張可能な微小球を含む、請求項51に記載の成形された多孔質複合物品。
- 前記物品が、自動車のヘッドライナとして構成されている、請求項51~60のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、自動車の内装構成要素として構成されている、請求項51~60のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、キュービクルパネルとして構成されている、請求項51~60のいずれか一項に記載の成形された多孔質複合物品。
- 前記物品が、家具パネルとして構成されている、請求項51~60のいずれか一項に記載の成形された多孔質複合物品。
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US201962800307P | 2019-02-01 | 2019-02-01 | |
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US201962874036P | 2019-07-15 | 2019-07-15 | |
US62/874,036 | 2019-07-15 | ||
PCT/US2020/016036 WO2020160362A1 (en) | 2019-02-01 | 2020-01-31 | Lightweight reinforced thermoplastic composite articles including bicomponent fibers |
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JP2022523732A true JP2022523732A (ja) | 2022-04-26 |
JPWO2020160362A5 JPWO2020160362A5 (ja) | 2023-02-07 |
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EP (1) | EP3917746A4 (ja) |
JP (1) | JP2022523732A (ja) |
KR (1) | KR20220007847A (ja) |
CN (1) | CN114096389A (ja) |
AU (1) | AU2020214836A1 (ja) |
CA (1) | CA3128362A1 (ja) |
WO (1) | WO2020160362A1 (ja) |
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US5437899A (en) * | 1992-07-14 | 1995-08-01 | Composite Development Corporation | Structural element formed of a fiber reinforced thermoplastic material and method of manufacture |
US6156682A (en) * | 1998-09-18 | 2000-12-05 | Findlay Industries, Inc. | Laminated structures with multiple denier polyester core fibers, randomly oriented reinforcement fibers, and methods of manufacture |
WO2005104812A2 (en) * | 2004-02-06 | 2005-11-10 | Invista Technologies, S.A.R.L. | Moldable composite article |
EP1851092B1 (en) * | 2005-02-23 | 2012-06-06 | Li & S CO., LTD . | The member for headliner on motor vehicles of multilayer structure |
EP1847383A1 (en) * | 2006-04-21 | 2007-10-24 | Rieter Technologies AG | Acoustic composite and twin-shell lightweight trim part comprising such a composite |
CN106428218A (zh) * | 2015-08-11 | 2017-02-22 | 福特环球技术公司 | 车辆顶棚及成型方法 |
EP3374144A4 (en) * | 2015-11-11 | 2019-07-17 | Hanwha Azdel, Inc. | ACOUSTIC PREPREGS, CORE AND COMPOSITE ITEMS AND METHOD OF USE THEREOF |
WO2018111781A1 (en) * | 2016-12-12 | 2018-06-21 | Hanwha Azdel, Inc. | Composite articles including surface layers that provide enhanced formability |
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2020
- 2020-01-31 EP EP20747878.5A patent/EP3917746A4/en active Pending
- 2020-01-31 JP JP2021544584A patent/JP2022523732A/ja active Pending
- 2020-01-31 CA CA3128362A patent/CA3128362A1/en active Pending
- 2020-01-31 WO PCT/US2020/016036 patent/WO2020160362A1/en unknown
- 2020-01-31 AU AU2020214836A patent/AU2020214836A1/en active Pending
- 2020-01-31 KR KR1020217027652A patent/KR20220007847A/ko unknown
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WO2020160362A1 (en) | 2020-08-06 |
EP3917746A4 (en) | 2023-01-11 |
CA3128362A1 (en) | 2020-08-06 |
KR20220007847A (ko) | 2022-01-19 |
CN114096389A (zh) | 2022-02-25 |
EP3917746A1 (en) | 2021-12-08 |
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