US20030207116A1 - Sandwich elements and the use thereof - Google Patents

Sandwich elements and the use thereof Download PDF

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Publication number
US20030207116A1
US20030207116A1 US10/420,199 US42019903A US2003207116A1 US 20030207116 A1 US20030207116 A1 US 20030207116A1 US 42019903 A US42019903 A US 42019903A US 2003207116 A1 US2003207116 A1 US 2003207116A1
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US
United States
Prior art keywords
sandwich element
core layer
element according
fiber
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/420,199
Other languages
English (en)
Inventor
Klaus Franken
Reiner Paul
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayer AG
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to BAYER AKTIENGESELLSCHAFT reassignment BAYER AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PAUL, REINER, FRANKEN, KLAUS
Publication of US20030207116A1 publication Critical patent/US20030207116A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered 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
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • B32B15/14Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/02Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/24Layered 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
    • B32B5/245Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/24Layered 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
    • B32B5/26Layered 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 also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered 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
    • B32B7/04Interconnection of layers
    • B32B7/06Interconnection of layers permitting easy separation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/40Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/08Cars
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]

Definitions

  • the invention relates to sandwich elements with at least one predetermined breaking-point at which the sandwich element breaks in the event of an impact and also to their use in the automotive field.
  • Sandwich elements can be employed, for example, in the automotive field as roof, bonnet, tailgate, door or floor-panel modules and also as load floors, rear parcel shelves or interior-trim components; an advantage in this connection is their high flexural rigidity with, at the same time, low area weight in comparison with structural elements of massive construction.
  • structural elements that extend predominantly in a plane display high rigidity and strength values when loaded in that plane.
  • these high strength values in the plane are disadvantageous.
  • the present invention therefore provides constructional elements that exhibit, on the one hand, a low weight and, on the other hand, a high flexural rigidity and flexural strength and that, in addition, in the event of an accident (a crash, in particular a rear-end crash) do not transmit the energy of the crash into the passenger cell and hence endanger the occupants.
  • the present invention provides a sandwich element with at least one predetermined breaking-point, the sandwich element made of
  • a core layer preferably constructed from at least one ply
  • At least one delamination means is included in at least a portion of the sandwich element on a first (tension) side of the sandwich element, and wherein the delamination means is disposed between the exterior layer located on the first (tension) side and the core layer or contained in the outermost third of the core layer on the first (tension) side of the sandwich element.
  • the first (tension) side is that side of the sandwich element that is subjected to tensile stresses in the event of a flexural load.
  • fibrous materials that are interspersed with plastics (such as, for example, polycarbonates, polyamides, polyurethanes, polyesters, polypropylene, polyethylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, acrylonitrile/butadiene/styrene copolymers and blends thereof, epoxy resins, in particular polyurethane resin), such as glass-fiber mats, glass-fiber fleeces, glass-fiber random layers, glass-fiber cloth, cut or ground glass fibers and mineral fibers, natural-fiber mats, natural-fiber knitted fabric, cut natural fibers and also fibrous mats, fibrous fleeces and fibrous knitted fabric based on polymer fibers, carbon fibers or aramide fibers and also mixtures thereof.
  • plastics such as, for example, polycarbonates, polyamides, polyurethanes, polyesters, polypropylene, polyethylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, acrylonitrile
  • Plastics such as, for example, polycarbonates, polyamides, polyurethanes, polyesters, polyethers, copolymers, polypropylene, polyethylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, acrylonitrile/butadiene/styrene copolymers and blends thereof can also be employed.
  • metal sheets, plastic sheets, wood panels or wood veneers can be employed. Glass-fiber mats with polyurethane resin applied to them preferably find application in the present invention.
  • thermoformable and also thermosetting polyurethane and thermoplastic foamed materials paper honeycombs, metal honeycombs or plastic honeycombs with honeycomb or corrugated structure may preferably be employed in the present invention.
  • a delamination means means having a decoupling effect (loosening the adhesion between exterior layer and core layer or weakening the core layer on the tension side), which are introduced either (a) in situ in the course of manufacture of the sandwich elements or (b) subsequently, may preferably be disposed between the exterior layers and the core layer.
  • Suitable materials in case (a) include, but are not limited to, paper, cardboard, plastic foils and sheets or sheet-metal foils and plates, textile, plastic or metal foils provided with adhesive layers on one side, wood panels or wood veneers, impermeable textiles or naturally or synthetically based woven fabrics as well as solid or liquid films acting as separating agents as well as adhesive-free or coupling-agent-free zones.
  • an adhesive-free zone for example, may act as delamination means.
  • An adhesive-free zone or a zone with low adhesion or without adhesion can be produced by a delamination means which was inserted during the manufacture of the sandwich element being removed.
  • Suitable in case (b) are subsequent, mechanical or thermal, locally limited separation, such as sawing, cutting, splitting or lasing, of the core layer and of the exterior layer on the tension side, so that a zone without adhesion is formed.
  • the decoupling is more preferably obtained by means of delamination means that are described in case (a).
  • the sandwich elements according to the present invention may find particular application in the automotive field as roof modules, bonnets, tailgate modules, door modules or floor-panel modules, more particularly as load floors, rear parcel shelves or interior-trim components.
  • the flexural strength is the limit of the flexural load, the exceeding of which results in failure of the structural element.
  • the flexural rigidity is the resistance of a structural element to flexure.
  • Comparative Example 1 a compression test was carried out in the plane of the sheet (crash direction) on samples without predetermined breaking-point, and in Example 2, on samples with predetermined breaking-points according to the invention.
  • Comparative Example 3 the flexural rigidity and flexural strength were determined on samples without predetermined breaking-point, and in Example 4, on samples with predetermined breaking-point according to the invention.
  • Examples 5 and 6 show, on the basis of compression tests, how the breaking behavior can be controlled by modification of the type and geometry of the predetermined breaking-point according to the invention.
  • Polyol 1 polyether polyol with an OH-value of 865, prepared by addition of propylene oxide onto trimethylolpropane as initiator.
  • Polyol 2 polyether polyol with an OH-value of 1000, prepared by addition of propylene oxide onto trimethylolpropane as initiator.
  • Polyol 3 polyether polyol with an OH-value of 42, prepared by addition of 86% propylene oxide and 14% ethylene oxide onto propylene glycol as initiator.
  • Polyisocyanate polymeric MDI with an isocyanate content of 31.5 wt. % (DESMODUR 44V20L, Bayer AG).
  • Stabilizer silicone stabilizer POLYURAX SR242, Osi Crompton Witco Specialities, Frankfurt.
  • Catalyst amine catalyst THANCAT AN10, Air Products GmbH, Hattingen.
  • Dyestuff BAYDUR Schwarzpaste DN, Bayer AG, Leverkusen.
  • Polyurethane Formulation 1 Polyol 1 30 parts by weight Polyol 2 20 parts by weight Polyol 3 33 parts by weight catalyst 2.8 parts by weight stabilizer 1.3 parts by weight acetic acid 0.3 parts by weight dyestuff 3.3 parts by weight polyisocyanate 140 parts by weight
  • the polyol mixture formed from Polyols 1 to 3 has an average OH-value of 568 mg KOH/g.
  • the delamination means was cut to a width of 15 mm and a length of 1,000 mm and was stuck onto one side parallel to the course of the paper corrugations in the middle of the core layer. Then there were placed on both sides chopped glass-fiber mats having an area weight of 450 g/m 2 which were treated at room temperature by spraying on 450 g/m 2 of polyurethane formulation 1.
  • This sandwich element was introduced into a flat tool heated to 130° C. and subsequently press-molded to a thickness of 19.4 mm.
  • the tool was opened and the finished sandwich element was taken out.
  • the size of this sandwich element amounted to about 1,000 mm ⁇ 1,000 mm.
  • three rectangular samples with a size of 400 mm ⁇ 180 mm were sawn out of the sheet, the longer edge of the sample being at right angles to the course of the paper corrugations of the core layer.
  • the samples were sawn out in such a way that the delamination means was located in the middle of the samples. With the exception of the delamination means, these samples were produced so as to be identical to those from Comparative Example 1.

Landscapes

  • Laminated Bodies (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Battery Mounting, Suspending (AREA)
  • Body Structure For Vehicles (AREA)
US10/420,199 2002-05-02 2003-04-22 Sandwich elements and the use thereof Abandoned US20030207116A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10219711 2002-05-02
DE10219711.3 2002-05-02

Publications (1)

Publication Number Publication Date
US20030207116A1 true US20030207116A1 (en) 2003-11-06

Family

ID=28798978

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/420,199 Abandoned US20030207116A1 (en) 2002-05-02 2003-04-22 Sandwich elements and the use thereof

Country Status (9)

Country Link
US (1) US20030207116A1 (ja)
EP (1) EP1359005B1 (ja)
JP (1) JP2004001505A (ja)
KR (1) KR20030086418A (ja)
CN (1) CN1454772A (ja)
AT (1) ATE316461T1 (ja)
CA (1) CA2427037A1 (ja)
DE (1) DE50302259D1 (ja)
ES (1) ES2257615T3 (ja)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050280173A1 (en) * 2004-06-22 2005-12-22 Bayer Materialscience Ag Process for the production of polyurethane molded articles
US20060150540A1 (en) * 2004-12-28 2006-07-13 Intelligent Engineering (Bahamas) Limited Sandwich plate risers
US20130115410A1 (en) * 2010-07-20 2013-05-09 Mark Whiter Composite materials
US8550536B2 (en) 2009-11-25 2013-10-08 Weber Automotive Ag-Holding Tailgate from fibre-reinforced thermoplastic plastic
CN104284771A (zh) * 2012-05-09 2015-01-14 帝斯曼知识产权资产管理有限公司 塑料发动机罩
US20160176157A1 (en) * 2014-12-22 2016-06-23 Magna Steyr Fahrzeugtechnik Ag & Co Kg Sandwich component

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DE20311028U1 (de) * 2003-07-17 2003-09-25 Webasto Vehicle Sys Int Gmbh Heckklappe für ein Kraftfahrzeug
DE10356547A1 (de) * 2003-12-04 2005-07-07 Benteler Automobiltechnik Gmbh Laderaumboden
US7690720B2 (en) 2008-01-31 2010-04-06 Gm Global Technology Operations, Inc. Energy absorbing vehicle hood assembly with asymmetric sandwich inner structure
DE102009006130B4 (de) * 2009-01-26 2011-09-15 Daimler Ag Verbundbauteil mit Deckschicht
DE102009048000A1 (de) * 2009-10-01 2011-09-15 Bayer Materialscience Ag Verbundwerkstoff aus offenzelligem Hartschaum
DE102010037817A1 (de) * 2010-09-28 2012-03-29 Thyssenkrupp Steel Europe Ag Struktur- oder Fahrwerkteil eines Kraftfahrzeugs
WO2012167879A2 (de) * 2011-06-06 2012-12-13 Webasto Ag Fahrzeug-bauteil
DE102011118851A1 (de) * 2011-11-18 2013-05-23 Vpw Nink Gmbh Schichtverbund-Profilplatte mit Schichten aus PVC-U oder Blends aus PVC mit C-PE, Styrolhaltigen Copolymeren und Polyacrylaten mit einem PVC-Anteil von mindestens 10 %
JP6020310B2 (ja) * 2013-04-02 2016-11-02 トヨタ自動車株式会社 複合材とそれを用いたフードパネル
DE102016204624A1 (de) * 2016-03-21 2017-09-21 Bayerische Motoren Werke Aktiengesellschaft Sandwich-Verbundbauteil zur Verwendung als Ladeboden oder Hutablage eines Kraftfahrzeuges
CN106184399B (zh) * 2016-08-23 2019-01-29 北京新能源汽车股份有限公司 车辆的顶盖、车辆和车辆的顶盖的制造方法
DE102020111721A1 (de) 2020-04-29 2021-11-04 Bayerische Motoren Werke Aktiengesellschaft Trennwandelement für ein Kraftfahrzeug

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US6537413B1 (en) * 1998-06-05 2003-03-25 Peguform France Method of making a reinforced composite panel of the cellular-core sandwich type, and a panel obtained by performing such a method
US6893453B2 (en) * 2002-12-17 2005-05-17 Kimberly-Clark Worldwide, Inc. Thermal therapy pad with variable heat control

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US3591444A (en) * 1967-07-04 1971-07-06 Bayer Ag Heavy-duty foam laminates
US3909582A (en) * 1971-07-19 1975-09-30 American Can Co Method of forming a line of weakness in a multilayer laminate
US4025686A (en) * 1975-06-26 1977-05-24 Owens-Corning Fiberglas Corporation Molded composite article and method for making the article
US5049439A (en) * 1990-05-25 1991-09-17 Fibre Converters, Inc. Thermoformable article
US5506035A (en) * 1993-03-26 1996-04-09 The Procter & Gamble Company Superabsorbent polymer foam
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US6013730A (en) * 1994-06-07 2000-01-11 Fiberite, Inc. At least trifunctional epoxy resin reacted with solid rubber mixed with epoxy resin and curing agent
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US6537413B1 (en) * 1998-06-05 2003-03-25 Peguform France Method of making a reinforced composite panel of the cellular-core sandwich type, and a panel obtained by performing such a method
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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050280173A1 (en) * 2004-06-22 2005-12-22 Bayer Materialscience Ag Process for the production of polyurethane molded articles
US20060150540A1 (en) * 2004-12-28 2006-07-13 Intelligent Engineering (Bahamas) Limited Sandwich plate risers
US7849643B2 (en) * 2004-12-28 2010-12-14 Intelligent Engineering (Bahamas) Limited Structural step unit with run portion and rise portion
US8550536B2 (en) 2009-11-25 2013-10-08 Weber Automotive Ag-Holding Tailgate from fibre-reinforced thermoplastic plastic
US20130115410A1 (en) * 2010-07-20 2013-05-09 Mark Whiter Composite materials
US9707736B2 (en) * 2010-07-20 2017-07-18 Hexcel Composites Limited Composite materials
US10118365B2 (en) 2010-07-20 2018-11-06 Hexcel Composites Limited Composite materials
CN104284771A (zh) * 2012-05-09 2015-01-14 帝斯曼知识产权资产管理有限公司 塑料发动机罩
US10266676B2 (en) 2012-05-09 2019-04-23 Dsm Ip Assets B.V. Plastic engine cover
US20160176157A1 (en) * 2014-12-22 2016-06-23 Magna Steyr Fahrzeugtechnik Ag & Co Kg Sandwich component
RU2635225C2 (ru) * 2014-12-22 2017-11-09 Магна Штайр Фарцойгтехник Аг Унд Ко. Кг Многослойная деталь
US10300676B2 (en) * 2014-12-22 2019-05-28 Magna Steyr Fahrzeugtechnik Ag & Co Kg Sandwich component

Also Published As

Publication number Publication date
KR20030086418A (ko) 2003-11-10
EP1359005B1 (de) 2006-01-25
ES2257615T3 (es) 2006-08-01
DE50302259D1 (de) 2006-04-13
EP1359005A1 (de) 2003-11-05
CN1454772A (zh) 2003-11-12
JP2004001505A (ja) 2004-01-08
CA2427037A1 (en) 2003-11-02
ATE316461T1 (de) 2006-02-15

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