CA2271242C - Interactive thermal insulating system having a layer treated with a coating of energy absorbing phase change material adjacent a layer of fibers containing energy absorbing phase change material - Google Patents
Interactive thermal insulating system having a layer treated with a coating of energy absorbing phase change material adjacent a layer of fibers containing energy absorbing phase change material Download PDFInfo
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- CA2271242C CA2271242C CA 2271242 CA2271242A CA2271242C CA 2271242 C CA2271242 C CA 2271242C CA 2271242 CA2271242 CA 2271242 CA 2271242 A CA2271242 A CA 2271242A CA 2271242 C CA2271242 C CA 2271242C
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Classifications
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- 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
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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D20/00—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00
- F28D20/02—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 using latent heat
- F28D20/023—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 using latent heat the latent heat storage material being enclosed in granular particles or dispersed in a porous, fibrous or cellular structure
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- 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
- B32B2307/72—Density
-
- 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
- B32B2437/00—Clothing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2270/00—Thermal insulation; Thermal decoupling
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/14—Thermal energy storage
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/24992—Density or compression of components
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2041—Two or more non-extruded coatings or impregnations
- Y10T442/2123—At least one coating or impregnation contains particulate material
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2041—Two or more non-extruded coatings or impregnations
- Y10T442/2123—At least one coating or impregnation contains particulate material
- Y10T442/2131—At least one coating or impregnation functions to fix pigments or particles on the surface of a coating or impregnation
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2213—Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3472—Woven fabric including an additional woven fabric layer
- Y10T442/3528—Three or more fabric layers
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3472—Woven fabric including an additional woven fabric layer
- Y10T442/3528—Three or more fabric layers
- Y10T442/3537—One of which is a nonwoven fabric layer
Abstract
An interactive thermal insulating system of the present invention includes at least three layers. The first layer is a high density layer comprising a substrate is coated with a polymer binder in which a plurality of microspheres containing a phase change material are dispersed. The second layer is a low density fibrous mesh in which individual fibers contain a plurality of microspheres containing a phase change material dispersed therein. A third layer is a flexible substrate. The fibrous mesh is sandwiched between the coated layer and the third layer. The layers are bonded together by stitching at regular intervals, lamination, or other methods of connection.
Most preferably, the phase change materials contained in the microspheres include paraffinic hydrocarbons.
Most preferably, the phase change materials contained in the microspheres include paraffinic hydrocarbons.
Description
INTERACTIVE THERMAL INSULATING SYSTEM HAVING A LAYER
TREATED WITH A COATING OF ENERGY ABSORBING PHASE CHANGE
MATERIAL ADJACENT A LAYER 01= FIBERS CONTAINING ENERGY
ABSORBING PHASE (~HANGE MATERIAL
Field of the Invention This invention relates to thermal insulating fabric systems. More particularly, this invention relates to thermal insulating fabric systems containing energy absorbing, temperature stabilizing phase change materials suitable for clothing construction.
Related Ap~licaticns The present application contains subject matter which is related to the subject matter of U.S. Patent Application Serial No. 08/477,824 filed June 7, 1995 and to U.S. Patent Application Serial No. 08/259,964 filed June 14, 1994, both of which are entitled FABRIC. COATING CONTAINING ENERGY
ABSORBING PHASE CHANGE MATERIAL AND METHOD OF
MANUFACTURING SAME and are incorporated herein by reference.
Back4round of the Invention Cold protective clothing, for example, overalls and jackets, are designed to protect those working or playing in low temperature environments against substantial body heat loss. Referring now to FIG. 1, it can be seen that such garments are constructed from a fabric system 10 which typically includes an outer shell 11, an insulative layer 12 of batting, down, other insulation, and a lining layer 14. With this configuration, the heat loss from the body through the garment layers is slowed by the air spaces of insulative layer 12. Because the thermal insulation of the garment is provided mainly by the batting and is directly related to the volume of air trapped therein, insulative capability of such garments is typically increased by increasing the thickness of the insulative layer.
Clothing utilizing such conventional construction for cold weather 3 o applications hav ~ some deficiencies, however. For example, increasing the thickness of the insulative layer can make cold weather clothing so bulky as to be impractical to wear when tasks have to be performed by the wearer.
Also, conventional cold weather clothing can become uncomfortable when the wearer is involved in alternating periods of inactivity and intense activity.
TREATED WITH A COATING OF ENERGY ABSORBING PHASE CHANGE
MATERIAL ADJACENT A LAYER 01= FIBERS CONTAINING ENERGY
ABSORBING PHASE (~HANGE MATERIAL
Field of the Invention This invention relates to thermal insulating fabric systems. More particularly, this invention relates to thermal insulating fabric systems containing energy absorbing, temperature stabilizing phase change materials suitable for clothing construction.
Related Ap~licaticns The present application contains subject matter which is related to the subject matter of U.S. Patent Application Serial No. 08/477,824 filed June 7, 1995 and to U.S. Patent Application Serial No. 08/259,964 filed June 14, 1994, both of which are entitled FABRIC. COATING CONTAINING ENERGY
ABSORBING PHASE CHANGE MATERIAL AND METHOD OF
MANUFACTURING SAME and are incorporated herein by reference.
Back4round of the Invention Cold protective clothing, for example, overalls and jackets, are designed to protect those working or playing in low temperature environments against substantial body heat loss. Referring now to FIG. 1, it can be seen that such garments are constructed from a fabric system 10 which typically includes an outer shell 11, an insulative layer 12 of batting, down, other insulation, and a lining layer 14. With this configuration, the heat loss from the body through the garment layers is slowed by the air spaces of insulative layer 12. Because the thermal insulation of the garment is provided mainly by the batting and is directly related to the volume of air trapped therein, insulative capability of such garments is typically increased by increasing the thickness of the insulative layer.
Clothing utilizing such conventional construction for cold weather 3 o applications hav ~ some deficiencies, however. For example, increasing the thickness of the insulative layer can make cold weather clothing so bulky as to be impractical to wear when tasks have to be performed by the wearer.
Also, conventional cold weather clothing can become uncomfortable when the wearer is involved in alternating periods of inactivity and intense activity.
For example, when a person skiing down a ski slope is wearing a conventional winter jacket skis, the person's metabolic heat rate increases substantially. This heat cannot be released as required to maintain comfort, because the insulation layer works against such release. The person tends to overheat and may perspire. The perspiration can wet the liner and the insulative layers. Then, when the person stops skiing, such as when a skier sits in a chair lift and rides to the top of the ski slope, insulative capabilities of the jacket are decreased by the dampnEas and the skier becomes chilled during the chair lift ride. Fundamentally, the conventional cold weather l0 clothing discussed above has a generally static response, and is unable to response variously to changing wearing conditions.
New materials have been developed in an attempt to address special clothing and other thermal regulating system requirements. For example, microencapsulated phase change materials have been described as a suitable component for substrate coatings when exceptional heat transfer and storage capabilities are desired. In pari:icular, U.S. Patent No. 5,290,904 for "Fabric with Reversible Enhanced Theri~nal Properties" to Colvin, et al., incorporated herein by reference teachEa that substrates coated with a binder containing microcapsules filled with enE~rgy absorbing phase change material enables the substrate to exhibit extendE;d or enhanced heat retention or storage properties. Substrates coated with a binder containing microencapsulated phase change materials are referred to herein as microPCM-coated substrates.
Also by way of example, microencapsulated phase change materials have been described as a suitable component for inclusion in fibers, when exceptional heat transfer and storage capabilities are desired. In particular, U.S. Patent No. 4,756,958 for "Fiber wish Reversible Enhanced Thermal Properties and Fabrics Made Therefrom " to Bryant, et al., also incorporated herein by reference, teaches that a fiber with integral microspheres filled with 3 o phase change material or plastic crystals has enhanced thermal properties at predetermined temperatures. This patent further teaches that such fibers may be woven to form a fabric having the enhanced thermal storage properties, and that articles of manufaci:ure may be formed therefrom.
Fabrics manufactured from such fibers .are referred to herein as microPCM-containing fabrics.
Generally speaking, phase chan~3e materials have the capability of absorbing or releasing thermal energy to reduce or eliminate heat transfer at the temperature stabilizing range of the particular temperature stabilizing material. The phase change material inhibits or stop the flow of thermal energy through the coating during the time the phase change material is absorbing or releasing heat, typically daring the material's change of phase.
This action is transient, i.e., it will be effective as a barrier to thermal energy until the total latent heat of the temperature stabilizing material is absorbed or released during the heating or cooling process. Thermal energy may be 1 o stored or removed from the phase change material, and can effectivel,: be recharged by a source of heat or cold. By selecting an appropriate phase change material, a substrate can be co<~ted or a fiber manufactured incorporating a phase change material, for use in a particular application where the stabilization of temperatures is desired.
Exemplary paraffinic hydrocarbon phase change materials suitable for use in the coatings or in fibers are shown in Table I, with the number of carbon atoms in such materials directly related to the respective melting and crystallization points.
TABLE I
Compound No. CrystallizationMelting Carbon AtomsPoint Point n-Eicosane 20 30.6 C 36.1 C
n-Octadecane 18 25.4 C 28.2 C
n-Heptadecane 17 21.5 C 22.5 C
n-Hexadecane 16 16.2 C 18'.5 C
The patents identified above teach how phase change materials such as the above-listed paraffinic hydrocarbons any preferably formed into microspheres and encapsulated in a single or multi-layer shell of gelatin or other material.
Encapsulated microsphere diameters ovf 1 to 100 microns are preferred, most preferably from 10 to 60 microns. Microspheres may also be bound in a silica matrix of sub-micron diameters.
Newer fabrics incorporating phase change materials as identified above are beginning to be individually incorporated into commercially available clothing. However, a configuration which is especially adapted to 4.
provide a supe-ior thermal response in low temperature conditions where variable activity levels or weather conditions occur is not yet available.
Thus, there remains a continuing need for materials which can provide a dynamic thermal response.
It is against this background that the significant improvements and advancement of the present invention have taken place in the field of substrates incorporating energy absorbing and releasing temperature stabilizing phase change materials.
Objects of the Invention It is the principal object of the prEaent invention to provide a dynamic thermal regulating system which is suitable for use in clothing and adaptable to changing working and wearing conditions.
It is another object of the presenvr invention to provide a dynamic thermal regulating system in which clothing may be comfortably worn for longer wearing times.
It is another object of the present; invention to provide a dynamic thermal regulating system adapted for use in cold temperature environments.
Is yet another object of the present invention to provide a dynamic thermal regulating system having the aforementioned qualities and also 2 o exhibiting reduced thickness of construction for enhanced freedom of movement of the wearer.
It is a still further object of the prE~sent invention to provide a thermal regulating system in a configuration whiich can be incorporated into clothing using conventional clothing patterns and styles.
2 5 Summary of the Invention An interactive thermal insulating system of the present invention includes at least three layers. The first layer is a high density layer comprising a substrate is coated with a polymer binder in which a plurality of microspheres containing a phase chance material are dispersed. The 3 o second layer is a low density fibrous mesh in which individual fibers contain a plurality of microspheres containing a phase change material dispersed therein. A third layer is a flexible substrate. The fibrous mesh is sandwiched between the coated layer and the third layer. The layers are bonded together by stitching at regular intervals, lamination, or other methods of connection.
35 Most preferably, the phase change materials contained in the microspheres include paraffinic hydrocarbons.
In a preferred embodiment of the interactive thermal insulating system of the present invention especially adapted for use in cold weather clothing, the coated first layer constitutes the lining of the clothing, with the uncoated 5 said of the first layer adjacent the body of the wearer. The outer layer constitutes the outer shell of the clothing. The phase change material encapsulated in the microspheres of the coated lining have an average melting temperature which is slightly higher than the average skin temperature, i.e., in the range of 92°F to 96°F, with 92°F to 94°F a preferred 1 o range, and 90°F to 98° F an acceptable range. A most preferred average crystallization temperature of this phase change material is at most 86°F, with 84°F to 88°F a preferred range, and 80°F to 89° F
an acceptable range.
Preferably, for cold weather clothing applications, the average melting temperature of the phase change material encapsulated in microspheres which are dispersed in the fibrous second layer is less than the average melting temperature of phase change material in the coating layer. The preferred average melting temperature of the phase change material contained in microcapsules in the fibers of the second layer is 84°F to 88°F, with a preferred crystallization temperatures for this material in the range of 2 0 76°F to 84°F.
Brief Description of the Drawings FIG. 1 is an exploded isometric view illustrating the layers of a conventional fabric configuration from which cold weather clothing may be manufactured.
FIG. 2 is an exploded isometric view illustrating the first coated layer, the second fibrous layer" and a third covering layer of a thermal regulating system of the present invention.
FIG. 3 is an enlarged detail view of the first and second layers of the thermal regulating system shown in FIG. 2.
3o FIG. 4 is an enlarged detail end view of a fiber of the second layer shown in FIG. 3.
Detailed Description of the Invention In accordance with the present application, and with reference to FIGS. 2 and 3, an interactive thermal insulating system 20 of the present 3 5 invention includes a first layer 21, a second layer 22 and a third layer 23.
New materials have been developed in an attempt to address special clothing and other thermal regulating system requirements. For example, microencapsulated phase change materials have been described as a suitable component for substrate coatings when exceptional heat transfer and storage capabilities are desired. In pari:icular, U.S. Patent No. 5,290,904 for "Fabric with Reversible Enhanced Theri~nal Properties" to Colvin, et al., incorporated herein by reference teachEa that substrates coated with a binder containing microcapsules filled with enE~rgy absorbing phase change material enables the substrate to exhibit extendE;d or enhanced heat retention or storage properties. Substrates coated with a binder containing microencapsulated phase change materials are referred to herein as microPCM-coated substrates.
Also by way of example, microencapsulated phase change materials have been described as a suitable component for inclusion in fibers, when exceptional heat transfer and storage capabilities are desired. In particular, U.S. Patent No. 4,756,958 for "Fiber wish Reversible Enhanced Thermal Properties and Fabrics Made Therefrom " to Bryant, et al., also incorporated herein by reference, teaches that a fiber with integral microspheres filled with 3 o phase change material or plastic crystals has enhanced thermal properties at predetermined temperatures. This patent further teaches that such fibers may be woven to form a fabric having the enhanced thermal storage properties, and that articles of manufaci:ure may be formed therefrom.
Fabrics manufactured from such fibers .are referred to herein as microPCM-containing fabrics.
Generally speaking, phase chan~3e materials have the capability of absorbing or releasing thermal energy to reduce or eliminate heat transfer at the temperature stabilizing range of the particular temperature stabilizing material. The phase change material inhibits or stop the flow of thermal energy through the coating during the time the phase change material is absorbing or releasing heat, typically daring the material's change of phase.
This action is transient, i.e., it will be effective as a barrier to thermal energy until the total latent heat of the temperature stabilizing material is absorbed or released during the heating or cooling process. Thermal energy may be 1 o stored or removed from the phase change material, and can effectivel,: be recharged by a source of heat or cold. By selecting an appropriate phase change material, a substrate can be co<~ted or a fiber manufactured incorporating a phase change material, for use in a particular application where the stabilization of temperatures is desired.
Exemplary paraffinic hydrocarbon phase change materials suitable for use in the coatings or in fibers are shown in Table I, with the number of carbon atoms in such materials directly related to the respective melting and crystallization points.
TABLE I
Compound No. CrystallizationMelting Carbon AtomsPoint Point n-Eicosane 20 30.6 C 36.1 C
n-Octadecane 18 25.4 C 28.2 C
n-Heptadecane 17 21.5 C 22.5 C
n-Hexadecane 16 16.2 C 18'.5 C
The patents identified above teach how phase change materials such as the above-listed paraffinic hydrocarbons any preferably formed into microspheres and encapsulated in a single or multi-layer shell of gelatin or other material.
Encapsulated microsphere diameters ovf 1 to 100 microns are preferred, most preferably from 10 to 60 microns. Microspheres may also be bound in a silica matrix of sub-micron diameters.
Newer fabrics incorporating phase change materials as identified above are beginning to be individually incorporated into commercially available clothing. However, a configuration which is especially adapted to 4.
provide a supe-ior thermal response in low temperature conditions where variable activity levels or weather conditions occur is not yet available.
Thus, there remains a continuing need for materials which can provide a dynamic thermal response.
It is against this background that the significant improvements and advancement of the present invention have taken place in the field of substrates incorporating energy absorbing and releasing temperature stabilizing phase change materials.
Objects of the Invention It is the principal object of the prEaent invention to provide a dynamic thermal regulating system which is suitable for use in clothing and adaptable to changing working and wearing conditions.
It is another object of the presenvr invention to provide a dynamic thermal regulating system in which clothing may be comfortably worn for longer wearing times.
It is another object of the present; invention to provide a dynamic thermal regulating system adapted for use in cold temperature environments.
Is yet another object of the present invention to provide a dynamic thermal regulating system having the aforementioned qualities and also 2 o exhibiting reduced thickness of construction for enhanced freedom of movement of the wearer.
It is a still further object of the prE~sent invention to provide a thermal regulating system in a configuration whiich can be incorporated into clothing using conventional clothing patterns and styles.
2 5 Summary of the Invention An interactive thermal insulating system of the present invention includes at least three layers. The first layer is a high density layer comprising a substrate is coated with a polymer binder in which a plurality of microspheres containing a phase chance material are dispersed. The 3 o second layer is a low density fibrous mesh in which individual fibers contain a plurality of microspheres containing a phase change material dispersed therein. A third layer is a flexible substrate. The fibrous mesh is sandwiched between the coated layer and the third layer. The layers are bonded together by stitching at regular intervals, lamination, or other methods of connection.
35 Most preferably, the phase change materials contained in the microspheres include paraffinic hydrocarbons.
In a preferred embodiment of the interactive thermal insulating system of the present invention especially adapted for use in cold weather clothing, the coated first layer constitutes the lining of the clothing, with the uncoated 5 said of the first layer adjacent the body of the wearer. The outer layer constitutes the outer shell of the clothing. The phase change material encapsulated in the microspheres of the coated lining have an average melting temperature which is slightly higher than the average skin temperature, i.e., in the range of 92°F to 96°F, with 92°F to 94°F a preferred 1 o range, and 90°F to 98° F an acceptable range. A most preferred average crystallization temperature of this phase change material is at most 86°F, with 84°F to 88°F a preferred range, and 80°F to 89° F
an acceptable range.
Preferably, for cold weather clothing applications, the average melting temperature of the phase change material encapsulated in microspheres which are dispersed in the fibrous second layer is less than the average melting temperature of phase change material in the coating layer. The preferred average melting temperature of the phase change material contained in microcapsules in the fibers of the second layer is 84°F to 88°F, with a preferred crystallization temperatures for this material in the range of 2 0 76°F to 84°F.
Brief Description of the Drawings FIG. 1 is an exploded isometric view illustrating the layers of a conventional fabric configuration from which cold weather clothing may be manufactured.
FIG. 2 is an exploded isometric view illustrating the first coated layer, the second fibrous layer" and a third covering layer of a thermal regulating system of the present invention.
FIG. 3 is an enlarged detail view of the first and second layers of the thermal regulating system shown in FIG. 2.
3o FIG. 4 is an enlarged detail end view of a fiber of the second layer shown in FIG. 3.
Detailed Description of the Invention In accordance with the present application, and with reference to FIGS. 2 and 3, an interactive thermal insulating system 20 of the present 3 5 invention includes a first layer 21, a second layer 22 and a third layer 23.
First layer 21 is a flexible substrate 31 treated with a coating 32 in which are dispersed microspheres 33 containing a phase change material 34. Second layer 22 is a fibrous mat of fibers 42 in which are dispersed microspheres 43 containing a phase change material 44. Third layer 23 is a flexible substrate.
First, second and third layers 21, 22 and 23 are fastened together by stitching at regularly spaced intervals.
In a preferred embodiment of the interactive thermal insulating system of the present invention especially adapted for use in cold weather clothing, coated first layer 21 constitutes the lining of the clothing. First layer 21 is to preferably a nylon taffeta approximately 0.1 millimeter (mm) in thickness, which is coated with a polyurethane coating 32 approximately 0.1 mm in thickness which contains 2 ounces (oz) per square meter (m2) of 10 micron non-ballooning microspheres 33, resulting in a fabric density of approximately 160 grams (g) per m2. The preferred phase change material 34 includes paraffinic hydrocarbons having an average melting temperature of 93°F.
Second layer 22 is preferably a batting of acrylic fibers approximately 12 mm thick, of which approximately 10% of the total weight is non-ballooning microspheres containing paraffinic hydrocarbons having an average melting temperature of 86°F. Second layer 22 has an overall density of 2 o approximately 140 g/m'. Third layer 23 is a 0.2 mm thick nylon woven shell material having an average density of 140 g/mz. The average weight of the interactive thermal insulating system 20 of the present invention is approximately 440 g/m2.
The degree of thermal assistancE~ providing interactive insulative assistance of each of the first, second and third layers 21, 22 and 23 and of the multi-layer system 20 was tested to determine the basic thermal insulation effect (BTR) of the textile substrate and the dynamic insulation effect (DTR) by the phase change material. For each layer 21, 22 and 23 and for the system 20, the total thermal regulating effect (TTR) was obtained by summing BTR + DTR. Testing was conducted by measuring both insulations effects in separate steps. First, basic thermal insulation of the substrate was tested with a transient thermal measuring technique. Second, the dynamic thermal insulation effect of the phase change material was measured by a technique in which heat emission is translated into insulation terms. Data obtained thereby measured are given in thermal resistance values in the units clo and _, r m2 * K / W, whereby 1 clo = 0.155 mz * K I W and 1 m2 * K / W = 6.45 clo.
Data resulting from the tests is summarized in TABLE II.
TABLE II
1 Layer 21 2 Layer 22 3rd Layer System 20 Thickness0.2 mm 12 mrn 0.2 mm 12.4 mm Density 160 g/mz 140 g/m2 140 glmz 440 g/mz BTR 0.011 clo 1.075 c;lo 0.019 clo 1.105 clo DTR 0.003 clo 0.795 c;lo - 1.354 clo TTR 0.014 clo 1.870 c;lo 0.019 clo 2.459 clo The dynamic thermal resistance (DTR) of the system 20 at 1.354 clo was significantly greater than a total of the individual DTR values of each of individual layer 21, 22 and 23, which, if added together, would have resulted in a total DTR of 0.798 (0.795 + 0.003). The magnitude of the improvement in DTR of the system 20 over the total of individual DTRs for the layers 21, l0 and 23 was unexpected.
In comparison, an exemplary conventional fabric systems 10 used in cold weather jackets, was similarly testE~d. Data resulting from these tests is summarized in TABLE III.
TABLE III
1 Layer 11 2 Layer 12 arc! Layer System 10 Thickness0.2 mm 24 mm 0.2 mm 24.4 mm Density 80 g/m~ 220 g/rnz 140 g/mz 440 g/mz BTR 0.020 clo 1.323 clo 0.015 clo 1.362 clo DTR - - - -Tl'R~ 0.020 clo 1.323 clo 0.015 clo 1.362 clo The thermal insulation effect of fabric system 10 is based only on the basic thermal insulation effect of the substrate, because no phase change material was included in the system. However, it should be noted that despite the fact that the thickness of interactive thermal insulating system 20 of the present invention was approximately 1/2 of the i,hickness of the fabric system 10, the total insulation effect was nearly twice as much.
With regard to the preferred embodiments of interactive thermal insulating system 20 of the present invention for use in cold weather clothing, it is most preferred that the average melt:ing temperature of phase change material 34 encapsulated in microspheres 33 be at or slightly higher than the average skin temperature, i.e., in the range of 92°F to 94°F, with 92°F to 96°F
a preferred range, and 90°F to 98° F an acceptable range. A most preferred average crystallization/freezing temperature of phase change material 34 is at most 86°F, with 84°F to 88°F a preferred range, and 80°F to 89° F an acceptable range. Preferably, for cold weather clothing applications, the average melting temperature of phase change material 44 encapsulated in 1 o microspheres 43 is less than the average melting temperature of phase change material 34. A preferable range of average melting temperature of phase change material 44 is 84°F to 88°F, with a preferred crystallization temperatures for this material in the range of 76°F to 84°F. It can appreciated that by selecting two different phase change materials with different melting and freezing ranges as described above, the high density layer supports heat absorption and the low density of the batting supports heat emission.
In the cold temperature clothing configuration described above, the wearer's body functions as a heat source, creating a microclimate in the area adjacent the closest layer of clothing to the skin . High density coated layer 2 0 21 acts as a heat pump, efficiently receiving and conducting heat to lower density batting layer 22. High density coated layer 21 thereby acts quickly to stabilize the microclimate next to the we<~rers skin. Lower density batting layer 22 functions like a heat sink or thermal storage system, absorbing energy to melt phase change material 44. System 20 is responsive to bursts of activity in which the wearer's metabolic rate may increase dramatically. In this way, an interactive insulative capability is achieved with the present invention, and the skin temperature of a person wearing cold weather clothing incorporating system 20 is stabilized in a highly improved manner.
It should be understood that the lower density second layer 22 has 3o been described above in connection with a fibrous batting in which microencapsulated PCMs are dispersed in the fibers. However, alternative configurations of low density materials containing microencapsulated PCMs are also contemplated. For example, second layer 22 may be a foam in which microencapsulated PCMs are dispersed throughout.
As can now be readily appreciated, when the interactive thermal ~
insulating system of the present invention is incorporated in clothing, such clothing may be comfortably worn for longer wearing times. In particular, an improved thermal regulating clothing system is provided which especially adapted for use in cold temperature environments. Thickness of cold weather clothing is reduced, thereby allowing for enhanced freedom of movement of a wearer in cold temperature environments. Conventional clothing patterns and styles may be used with the new fabric configurations of the present invention.
Presently preferred embodiments of the present invention and many of 1 o its improvements have been described with a degree of particularity. It should be understood that this description has been made by way of preferred examples, and that the invention is defined by the scope of the following claims.
First, second and third layers 21, 22 and 23 are fastened together by stitching at regularly spaced intervals.
In a preferred embodiment of the interactive thermal insulating system of the present invention especially adapted for use in cold weather clothing, coated first layer 21 constitutes the lining of the clothing. First layer 21 is to preferably a nylon taffeta approximately 0.1 millimeter (mm) in thickness, which is coated with a polyurethane coating 32 approximately 0.1 mm in thickness which contains 2 ounces (oz) per square meter (m2) of 10 micron non-ballooning microspheres 33, resulting in a fabric density of approximately 160 grams (g) per m2. The preferred phase change material 34 includes paraffinic hydrocarbons having an average melting temperature of 93°F.
Second layer 22 is preferably a batting of acrylic fibers approximately 12 mm thick, of which approximately 10% of the total weight is non-ballooning microspheres containing paraffinic hydrocarbons having an average melting temperature of 86°F. Second layer 22 has an overall density of 2 o approximately 140 g/m'. Third layer 23 is a 0.2 mm thick nylon woven shell material having an average density of 140 g/mz. The average weight of the interactive thermal insulating system 20 of the present invention is approximately 440 g/m2.
The degree of thermal assistancE~ providing interactive insulative assistance of each of the first, second and third layers 21, 22 and 23 and of the multi-layer system 20 was tested to determine the basic thermal insulation effect (BTR) of the textile substrate and the dynamic insulation effect (DTR) by the phase change material. For each layer 21, 22 and 23 and for the system 20, the total thermal regulating effect (TTR) was obtained by summing BTR + DTR. Testing was conducted by measuring both insulations effects in separate steps. First, basic thermal insulation of the substrate was tested with a transient thermal measuring technique. Second, the dynamic thermal insulation effect of the phase change material was measured by a technique in which heat emission is translated into insulation terms. Data obtained thereby measured are given in thermal resistance values in the units clo and _, r m2 * K / W, whereby 1 clo = 0.155 mz * K I W and 1 m2 * K / W = 6.45 clo.
Data resulting from the tests is summarized in TABLE II.
TABLE II
1 Layer 21 2 Layer 22 3rd Layer System 20 Thickness0.2 mm 12 mrn 0.2 mm 12.4 mm Density 160 g/mz 140 g/m2 140 glmz 440 g/mz BTR 0.011 clo 1.075 c;lo 0.019 clo 1.105 clo DTR 0.003 clo 0.795 c;lo - 1.354 clo TTR 0.014 clo 1.870 c;lo 0.019 clo 2.459 clo The dynamic thermal resistance (DTR) of the system 20 at 1.354 clo was significantly greater than a total of the individual DTR values of each of individual layer 21, 22 and 23, which, if added together, would have resulted in a total DTR of 0.798 (0.795 + 0.003). The magnitude of the improvement in DTR of the system 20 over the total of individual DTRs for the layers 21, l0 and 23 was unexpected.
In comparison, an exemplary conventional fabric systems 10 used in cold weather jackets, was similarly testE~d. Data resulting from these tests is summarized in TABLE III.
TABLE III
1 Layer 11 2 Layer 12 arc! Layer System 10 Thickness0.2 mm 24 mm 0.2 mm 24.4 mm Density 80 g/m~ 220 g/rnz 140 g/mz 440 g/mz BTR 0.020 clo 1.323 clo 0.015 clo 1.362 clo DTR - - - -Tl'R~ 0.020 clo 1.323 clo 0.015 clo 1.362 clo The thermal insulation effect of fabric system 10 is based only on the basic thermal insulation effect of the substrate, because no phase change material was included in the system. However, it should be noted that despite the fact that the thickness of interactive thermal insulating system 20 of the present invention was approximately 1/2 of the i,hickness of the fabric system 10, the total insulation effect was nearly twice as much.
With regard to the preferred embodiments of interactive thermal insulating system 20 of the present invention for use in cold weather clothing, it is most preferred that the average melt:ing temperature of phase change material 34 encapsulated in microspheres 33 be at or slightly higher than the average skin temperature, i.e., in the range of 92°F to 94°F, with 92°F to 96°F
a preferred range, and 90°F to 98° F an acceptable range. A most preferred average crystallization/freezing temperature of phase change material 34 is at most 86°F, with 84°F to 88°F a preferred range, and 80°F to 89° F an acceptable range. Preferably, for cold weather clothing applications, the average melting temperature of phase change material 44 encapsulated in 1 o microspheres 43 is less than the average melting temperature of phase change material 34. A preferable range of average melting temperature of phase change material 44 is 84°F to 88°F, with a preferred crystallization temperatures for this material in the range of 76°F to 84°F. It can appreciated that by selecting two different phase change materials with different melting and freezing ranges as described above, the high density layer supports heat absorption and the low density of the batting supports heat emission.
In the cold temperature clothing configuration described above, the wearer's body functions as a heat source, creating a microclimate in the area adjacent the closest layer of clothing to the skin . High density coated layer 2 0 21 acts as a heat pump, efficiently receiving and conducting heat to lower density batting layer 22. High density coated layer 21 thereby acts quickly to stabilize the microclimate next to the we<~rers skin. Lower density batting layer 22 functions like a heat sink or thermal storage system, absorbing energy to melt phase change material 44. System 20 is responsive to bursts of activity in which the wearer's metabolic rate may increase dramatically. In this way, an interactive insulative capability is achieved with the present invention, and the skin temperature of a person wearing cold weather clothing incorporating system 20 is stabilized in a highly improved manner.
It should be understood that the lower density second layer 22 has 3o been described above in connection with a fibrous batting in which microencapsulated PCMs are dispersed in the fibers. However, alternative configurations of low density materials containing microencapsulated PCMs are also contemplated. For example, second layer 22 may be a foam in which microencapsulated PCMs are dispersed throughout.
As can now be readily appreciated, when the interactive thermal ~
insulating system of the present invention is incorporated in clothing, such clothing may be comfortably worn for longer wearing times. In particular, an improved thermal regulating clothing system is provided which especially adapted for use in cold temperature environments. Thickness of cold weather clothing is reduced, thereby allowing for enhanced freedom of movement of a wearer in cold temperature environments. Conventional clothing patterns and styles may be used with the new fabric configurations of the present invention.
Presently preferred embodiments of the present invention and many of 1 o its improvements have been described with a degree of particularity. It should be understood that this description has been made by way of preferred examples, and that the invention is defined by the scope of the following claims.
Claims (15)
1. A thermal insulating articles comprising:
a first layer comprising a substrate coated with a polymer binder in which a first plurality of microspheres containing a phase change material are dispersed;
a second layer adjacent and attached to said first layer, comprising a fabric of fibers, said fibers having a second plurality of microspheres containing a phase change material dispersed therein; and a flexible third layer adjacent and attached to said second layer.
a first layer comprising a substrate coated with a polymer binder in which a first plurality of microspheres containing a phase change material are dispersed;
a second layer adjacent and attached to said first layer, comprising a fabric of fibers, said fibers having a second plurality of microspheres containing a phase change material dispersed therein; and a flexible third layer adjacent and attached to said second layer.
2. The article of claim 1 wherein said phase change material contained in said first and second plurality of microspheres comprises paraffinic hydrocarbons.
3. The article of claim 2 wherein said first layer further includes a coated surface and an opposing uncoated surface, with said coated surface is adjacent said second layer.
4. The article of claim 3 wherein the first plurality of microspheres contain paraffinic hydrocarbons having an average melting point which is between 90°F and 98° F; the second plurality of microspheres contain paraffinic hydrocarbons having an average melting point which is less than the average melting point of the first plurality of microspheres, and the article is specially adapted for use in clothing to be worn by a person, with said substrate of said first layer a flexible fabric, said first layer adapted to be positioned close to the person's skin and said third layer adapted to be positioned farther away from the person's skin than said first and second layers.
5. The article of claim 4 wherein said average melting point of said first plurality of microspheres is between 92°F and 96°F.
6. The article of claim 4 wherein said average melting point of said first plurality of microspheres is between 92°F and 94°F.
7. The article of claim 6 wherein said first plurality of microspheres contain paraffinic hydrocarbons having an average crystallization point which is approximately 86°F and said second plurality of microspheres contain paraffinic hydrocarbons having an average crystallization point which is below said average crystallization point of said paraffinic hydrocarbons of said first plurality of microspheres.
8. The article of claim 5 wherein said first plurality of microspheres contain paraffinic hydrocarbons having an average crystallization point which of from 84°F to 88°F.
9. The article of claim 4 wherein said first plurality of microspheres contain paraffinic hydrocarbons having an average crystallization point which of from 80°F to 89°F.
10. The article of claim 4 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
11. The article of claim 5 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
12. The article of claim 6 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
13. The article of claim 7 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
14. The article of claim 8 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
15. The article of claim 9 wherein said first layer has an average density, said second layer has an average density, and said first layer density is greater than said second layer density.
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US08/970,555 US6077597A (en) | 1997-11-14 | 1997-11-14 | Interactive thermal insulating system having a layer treated with a coating of energy absorbing phase change material adjacent a layer of fibers containing energy absorbing phase change material |
PCT/US1998/015892 WO1999025549A1 (en) | 1997-11-14 | 1998-07-30 | Interactive thermal insulating system |
Publications (2)
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CA2271242A1 CA2271242A1 (en) | 1999-05-14 |
CA2271242C true CA2271242C (en) | 2005-01-25 |
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US (2) | US6077597A (en) |
EP (1) | EP1028846B1 (en) |
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DE (1) | DE69823690T2 (en) |
WO (1) | WO1999025549A1 (en) |
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-
1997
- 1997-11-14 US US08/970,555 patent/US6077597A/en not_active Expired - Lifetime
-
1998
- 1998-07-30 EP EP98938171A patent/EP1028846B1/en not_active Expired - Lifetime
- 1998-07-30 JP JP2000520963A patent/JP3522688B2/en not_active Expired - Fee Related
- 1998-07-30 WO PCT/US1998/015892 patent/WO1999025549A1/en active IP Right Grant
- 1998-07-30 CA CA 2271242 patent/CA2271242C/en not_active Expired - Fee Related
- 1998-07-30 DE DE1998623690 patent/DE69823690T2/en not_active Expired - Lifetime
-
1999
- 1999-06-11 US US09/330,807 patent/US6217993B1/en not_active Expired - Lifetime
Also Published As
Publication number | Publication date |
---|---|
JP3522688B2 (en) | 2004-04-26 |
EP1028846B1 (en) | 2004-05-06 |
US6217993B1 (en) | 2001-04-17 |
US6077597A (en) | 2000-06-20 |
DE69823690T2 (en) | 2005-04-28 |
CA2271242A1 (en) | 1999-05-14 |
JP2001523596A (en) | 2001-11-27 |
EP1028846A4 (en) | 2003-06-04 |
WO1999025549A1 (en) | 1999-05-27 |
EP1028846A1 (en) | 2000-08-23 |
DE69823690D1 (en) | 2004-06-09 |
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