USRE45450E1 - Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material - Google Patents

Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material Download PDF

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USRE45450E1
USRE45450E1 US13/845,639 US200513845639A USRE45450E US RE45450 E1 USRE45450 E1 US RE45450E1 US 200513845639 A US200513845639 A US 200513845639A US RE45450 E USRE45450 E US RE45450E
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Prior art keywords
glass wool
glass
mat
fibers
water
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US13/845,639
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English (en)
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Toru Murakami
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Panasonic Corp
Mag Isover KK
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Panasonic Corp
Mag Isover KK
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05Filamentary, e.g. strands
    • B29C47/0014
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209Inorganic fibres
    • D04H1/4218Glass fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00Other non-woven fabrics
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/04Arrangements using dry fillers, e.g. using slag wool which is added to the object to be insulated by pouring, spreading, spraying or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/06Arrangements using an air layer or vacuum
    • F16L59/065Arrangements using an air layer or vacuum using vacuum
    • B29C47/88
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/88Thermal treatment of the stream of extruded material, e.g. cooling
    • 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
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249924Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Definitions

  • the present invention relates to a method for producing a glass wool molded product, a glass wool molded product obtained by this production method, and a vacuum heat insulation material, into which the glass wool molded product has been incorporated as a core.
  • Glass wool molded products are lightweight and have functions such as heat insulating properties, sound insulating properties, or sound absorbency. Thus, such glass wool molded products are widely used in various fields such as in heat insulation materials used for building materials, in heat insulation materials used for automobiles, in refrigerators, or in freezers, for the purposes of thermal insulation, cold insulation, heat shielding, sound insulation, etc.
  • soda lime is singly used as a material glass in production of a glass wool. Otherwise, an alkali borosilicate glass produced by adding several percents of boric acid to the soda lime is also used as such a material glass.
  • the material glass is thermally melted by high-speed rotation of a spinner having a large number of pores on the lateral face thereof, and the thus melted material glass is blown off in a fibrous state, so that the material glass can be air-cooled to obtain a glass wool.
  • a small amount of binder is sprayed on the surfaces of fibers so that it can be applied thereto.
  • organic binders such as a phenol resin, an epoxy resin, an acryl resin or starch
  • inorganic binders such as liquid glass, boric acid or colloidal silica
  • the handling ability of a glass wool molded product used as a core or the smoothing properties of the surface of the vacuum heat insulation material can be improved by addition of a binder.
  • a binder if such a binder is used, the cost of the binder as a material and the number of production processes increase to lead to increases in capital investment spending and energy consumption, and as a result, the production cost is also increased.
  • an inorganic binder particularly, boric acid
  • the degree of vacuum decreases due to volatilization of bound water, so that the vacuum heat insulation material cannot maintain its heat insulation performance.
  • a binder in order to stabilize the performance of a vacuum heat insulation material for a long period of time, it is necessary to increase the amount of a gas adsorbent or addition of high performance adsorbent (which is expensive). Such factors also cause cost increase.
  • the use of an organic binder is also problematic in that the heat resistance of a glass wool is 350° C. at maximum.
  • a felt-like product that contains no binders has been proposed as a means for improving heat resistance.
  • Such a felt-like product is resistant to a temperature between 400° C. and 450° C.
  • a glass wool used as a core generally has an area density between 1500 and 3500 g/m 2 , and thus it has high heat insulating properties.
  • the obtained glass wool product has a thickness between 70 and 100 mm. Further, the product has not been sufficiently molded, so that it is problematic in terms of extremely poor handling ability.
  • Patent Document 1 describes a production method, which comprises subjecting glass wools to press molding at a temperature higher than the temperature at which the glass wools are thermally deformed, so that an aggregate of glass fibers can be subjected to plastic deformation in a pressurized state, thereby maintaining the form thereof.
  • Patent Document 2 describes a method of molding laminated glass white wools (which are glass wools that contain no binders) within a temperature range that is 20° C. higher than the deformation point thereof.
  • Patent Document 3 describes a core formed by the adherence of inorganic fibers as a result of an intermolecular interaction caused by Si—OH groups.
  • Patent Document 1 Japanese Patent No. 3580315
  • Patent Document 2 National Publication of International Patent Application No. 2003-532845
  • Patent Document 3 Japanese Patent No. 3578172
  • Patent Documents 1 and 2 since press molding is carried out at a temperature higher than the thermal deformation temperature of glass wools, the tensile stress on the fiber surface is alleviated, and thus the fiber strength is significantly decreased, so that the glass wools can easily be converted to powders. As a result, there is concern that problems regarding a decrease in handling ability during the production process or deterioration in work environment will occur. Moreover, there are also various problems caused by the release of fibrous powders during the recovery and recycling processes of a vacuum heat insulation material.
  • a method for producing a glass wool molded product comprising the steps of: processing a glass material into fibers so as to obtain a glass wool, gathering such glass wool to form a glass wool mat, supplying water to the glass wool mat so that the water content of the glass wool mat becomes 0.1% to 7.0% by mass, and subjecting the glass wool mat having said water content to press molding while maintaining a temperature between 250° C. and 450° C.
  • the above described water may be supplied immediately after a glass material is processed into fibers so as to obtain a glass wool or before the press molding, or both immediately after formation of such a glass wool and before the press molding.
  • the glass wool molded product of the present invention may be obtained by the aforementioned production method, and it may be preferably used as a core of a vacuum heat insulation material.
  • the glass wool molded product produced by the method of the present invention has good handling ability.
  • the glass wool molded product of the present invention is used as a core of a vacuum heat insulation material, since no gas is generated from any binder under vacuum, the vacuum heat insulation material can maintain its degree of vacuum.
  • FIG. 1 is a graph showing the relationship between a heating temperature and the fiber strength of glass wools (fiber diameter: 4 ⁇ m);
  • FIG. 2 is a cross-sectional view showing an example of a vacuum heat insulation material, in which the glass wool molded product of the present invention is used.
  • the most important characteristic of the method for producing the glass wool molded product of the present invention is that the water content of a glass wool is adjusted within a specific range for the press molding step.
  • the present inventors In production of a felt-like glass wool molded product that contains no binders, the present inventors have attempted to spray water to glass wools during a glass wool-gathering process so as to wet the glass wools with the added water, thereby suppressing the release of the glass wools during the glass wool-gathering process.
  • the inventors have found that if the amount of water sprayed is excessive, the compressed and packed glass wool does not return to its original form during storage.
  • the present inventors have focused on the finding that when above a certain level of water is added to glass wools, the glass wools can be maintained in a board form having a density the same as that obtained when they have just been compressed, thereby completing the present invention.
  • the glass wools can be maintained in a board form without using binders because of the following mechanism. That is to say, sodium oxide contained in a glass that forms the glass wool is leached-out by water added to the surface of the glass wool. The leached-out sodium oxide is dissolved in the peripheral adhesive water, so as to generate sodium hydroxide. The generated sodium hydroxide easily reacts with silicon dioxide that is a main ingredient of the glass wool, so as to generate sodium silicate.
  • This sodium silicate is liquid glass that is well known as an inorganic binder. Accordingly, a portion of the glass wool molded product of the present invention acts as a binder without addition of any conventional binder, and thus fibers bind to one another by action of such a binder. Therefore, the obtained molded product can be maintained in the form of a molded product for a long period of time.
  • pressurization and heat treatments are carried out during the molding process. It is sufficient that the heating temperature applied during such pressurization and heat treatments is lower than the thermal deformation temperature of a glass wool.
  • the fiber diameter thereof is preferably 2 to 8 ⁇ m, and more preferably 3 to 5 ⁇ m. If such a fiber diameter is less than 2 ⁇ m, a specific energy consumption required for formation of fibers is significantly deteriorated. In contrast, if such a fiber diameter exceeds 8 ⁇ m, the thermal conductivity of the fibers is decreased, and thereby the heat insulation performance becomes poor.
  • a known glass material is used, such a glass material is processed into fibers by a known method so as to obtain a glass wool, and such glass wools are gathered to form a glass wool mat.
  • the water content of such a glass wool mat is relatively high.
  • the aforementioned water content is between 0.1% and 7.0% by mass, and preferably between 0.3% and 3.0% by mass.
  • water is supplied to glass wools immediately after formation of fibers. It may also be possible to supply water to a glass wool mat before press molding. Otherwise, it is also preferable that water be supplied, both immediately after formation of fibers and before press molding. If the water content of the glass wool mat is less than 0.1% by mass, the amount of sodium silicate generated becomes small, and thus a good molded product cannot be obtained. On the other hand, if the above water content exceeds 7.0% by mass, water may move in the mat, and it may be thereby unevenly distributed. Thus, a board molded product with stably quality cannot be obtained, and further, certain energy becomes necessary for evaporating a large amount of water.
  • a heating temperature be maintained at least during the press molding of a glass wool mat. Further, it is preferable that such a heating temperature be maintained until the press molding is completed after water has been supplied to glass wools.
  • a heating temperature is between 250° C. and 450° C., and preferably between 300° C. and 400° C. If the heating temperature is lower than 250° C., an enormous time is required for the surface reaction of water with the glass wools, and the productivity is thereby decreased. On the other hand, if the heating temperature exceeds 450° C., although molding properties are improved, the stress of the glass wools is alleviated by heating, and only a fragile board can be obtained, thereby decreasing handling ability.
  • FIG. 1 a graph showing the relationship between such a heating temperature and the fiber strength of glass wools (fiber diameter: 4 ⁇ m) is as shown in FIG. 1 .
  • the heating temperature exceeds 450° C., the fiber strength becomes 10 kgf or less, and thus that the fiber strength significantly decreases when compared with 45 kgf, the fiber strength at an ordinary temperature.
  • this temperature is 100° C. or more lower than the thermal deformation temperatures of the glass wools used in Patent Documents 1 and 2.
  • FIG. 2 is a cross-sectional view showing an example of a vacuum heat insulation material, in which the glass wool molded product of the present invention is used.
  • a vacuum heat insulation material 1 is produced by coating a core 3 with a jacketing material 2 , which is formed with a rigid or flexible plastic sheet, a metal leaf, a film onto which a metal film has been evaporated, etc.
  • the glass wool molded product of the present invention is used as the core 3 .
  • the density of the glass wool molded product is appropriately between 150 and 300 kg/m 3 .
  • the core 3 portion is retained in a vacuum state or in a highly decompressed state.
  • Such a vacuum heat insulation material 1 is used as a heat insulation material in refrigerators or freezers.
  • it can also be used in architectural coating materials, automobile bodies, etc. for the purposes of heat insulation and heat shielding.
  • a glass made from common soda lime was processed into fibers having a fiber diameter of 4 ⁇ m by melting and centrifugation, so as to obtain a glass wool.
  • water was sprayed onto the glass wool. Thereafter, such glass wools were gathered to form a mat on a conveyor. At that time, the water content of the glass wool mat was 1.5% by mass, and the bulk density was 1300 g/m 2 .
  • both ends of the thus gathered glass wool were cut with a slitter, so as to obtain a section having a length of 1600 mm.
  • the thus obtained section was then cut with a chopper, so as to obtain a section having a width of 1600 mm, thereby obtaining a glass wool section with 1600 mm square.
  • eight of the glass wool sections were laminated on a polyethylene slip sheet with a thickness of 25 ⁇ m, followed by compression and packing with a roll-up machine.
  • the thus compressed and packed glass wool mats were laminated, and they were then subjected to press molding under heating at 350° C. for 10 minutes. After completion of the compression, the resultant product was cooled, so as to produce a glass wool board of interest.
  • the thus produced glass wool board had a density of 125 kg/m 3 and a thickness of 20 mm.
  • the water content of the compressed and packed glass wool mat was 1.4% by mass immediately before the aforementioned press molding, and thus its water content was hardly decreased after the aforementioned glass wool-gathering process.
  • the glass wool board produced in the present example maintained a density of 125 kg/m 3 , even after it had been left for 24 hours. Thus, the product did not return toward its uncompressed state after the molding process. In addition, when the glass wood board was broken with hands, pulverization of the fibers did not occur, and thus it was confirmed that the glass wood board did not deteriorate.
  • the method for producing the glass wool molded product of the present invention has functions such as good heat insulating properties, sound insulating properties or sound absorbency, and also has form-retaining properties, without using conventional binders.
  • glass wool molded product of the present invention can be widely used in various fields such as heat insulation materials used for building materials, heat insulation materials used for automobiles, heat insulation materials for refrigerators or freezers, etc.
US13/845,639 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material Active 2026-01-12 USRE45450E1 (en)

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Application Number Priority Date Filing Date Title
US13/845,639 USRE45450E1 (en) 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
JP2005167022A JP3712129B1 (ja) 2005-06-07 2005-06-07 グラスウール成形体の製造方法、グラスウール成形体及び真空断熱材
JP2005-167022 2005-06-07
US11/921,806 US7846371B2 (en) 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material
PCT/JP2005/019496 WO2006132001A1 (ja) 2005-06-07 2005-10-24 グラスウール成形体の製造方法、グラスウール成形体及び真空断熱材
US13/845,639 USRE45450E1 (en) 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material

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US11/921,806 Ceased US7846371B2 (en) 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material

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US11/921,806 Ceased US7846371B2 (en) 2005-06-07 2005-10-24 Method for producing glass wool molded product, glass wool molded product, and vacuum insulation material

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US (2) USRE45450E1 (de)
EP (1) EP1892452B1 (de)
JP (1) JP3712129B1 (de)
CN (1) CN101287944B (de)
WO (1) WO2006132001A1 (de)

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KR101001217B1 (ko) * 2009-06-19 2010-12-17 (주)엘지하우시스 흡음형 방음 패널
DE102010019074A1 (de) * 2010-04-30 2011-11-03 Va-Q-Tec Ag Evakuiertes Flächengebilde zur Wärmedämmung
US20130084445A1 (en) 2011-09-30 2013-04-04 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous material
WO2013153416A1 (en) 2012-04-13 2013-10-17 Mag-Isover K.K. Glass wool compact production method, glass wool compact, and vaccumed heat insulator
CN102679094A (zh) * 2012-05-29 2012-09-19 成都思摩纳米技术有限公司 一种基于真空绝热板的封装方法、设备和系统
JPWO2014133037A1 (ja) 2013-02-26 2017-02-02 マグ・イゾベール株式会社 真空断熱材
JP2014210995A (ja) * 2013-04-18 2014-11-13 マグ・イゾベール株式会社 グラスウール成形体の製造方法
FR3005465B1 (fr) * 2013-05-07 2015-04-17 Saint Gobain Isover Dispositif et procede de fabrication de fibres minerales par centrifugation interne
DE102013104712A1 (de) 2013-05-07 2014-11-13 Saint-Gobain Isover Verfahren zur Herstellung von Vakuum-Isolations-Paneelen
CN106145660B (zh) * 2015-04-01 2018-11-30 福建赛特新材股份有限公司 一种玻璃棉真空绝热板芯材的在线干法生产系统及方法
EP3298318A4 (de) * 2015-05-19 2019-01-09 Owens Corning Intellectual Capital, LLC Isolierpad für rohrleitungen und behälter
DE102015122756A1 (de) 2015-12-23 2017-06-29 Saint-Gobain Isover Verfahren zur Herstellung von Vakuum-Isolations-Paneelen
CN106247087A (zh) * 2016-08-30 2016-12-21 苏州维艾普新材料股份有限公司 一种真空绝热板
CN106122686A (zh) * 2016-08-31 2016-11-16 苏州维艾普新材料股份有限公司 一种真空绝热材料及芯材
CA3035326A1 (en) * 2016-09-02 2018-03-08 Nisshin Steel Co., Ltd. Vacuum insulation panel
CN107816601B (zh) * 2016-09-12 2021-08-20 松下电器产业株式会社 真空隔热件
JP6860582B2 (ja) * 2016-09-16 2021-04-14 サン−ゴバン イゾベール グラスウール及びそれを用いた真空断熱材
JP6091692B1 (ja) 2016-09-20 2017-03-08 サン−ゴバン イゾベール 無機繊維積層体、それを用いた真空断熱材、及びその製造方法
DE102019201461A1 (de) * 2019-02-05 2020-08-06 Technische Universität Bergakademie Freiberg Stützkernmaterial für Vakuum-Isolationspaneele
GB2607097A (en) * 2021-05-28 2022-11-30 Knauf Insulation Mineral wool insulation
CN113846422A (zh) * 2021-10-14 2021-12-28 南京航空航天大学 一种低树脂高强度高隔声超细玻璃棉毡的制备方法

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JP3712129B1 (ja) 2005-11-02
CN101287944B (zh) 2012-05-30
EP1892452B1 (de) 2012-02-15
US7846371B2 (en) 2010-12-07
JP2006342839A (ja) 2006-12-21
EP1892452A1 (de) 2008-02-27
CN101287944A (zh) 2008-10-15
WO2006132001A1 (ja) 2006-12-14
EP1892452A4 (de) 2008-12-10

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