专利摘要:
The invention relates to a method for producing a composite material, to which a carrier layer (2) is connected to a top layer (1) of polyurethane or flexible PVC and the carrier layer (2) is a textile material, e.g. Woven, knitted or microfiber nonwoven fabric, or a leather, in particular a cow split leather, and the upper layer (1) comprises a number of interconnected polyurethane layers or of flexible PVC layers (1 ', 1' '). According to the invention, it is provided that channel-shaped recesses (6) for the passage of water vapor and / or air are formed in the composite of upper layer (1) and carrier layer (2) from the surface of the upper layer (1) by material removal with a laser such - That at least a portion of the recesses (6) penetrates the material of the upper layer (1) and / or before entering the material of the upper layer (1) free volume region of the carrier layer (2) ends.
公开号:AT517576A4
申请号:T51019/2015
申请日:2015-11-27
公开日:2017-03-15
发明作者:Schaefer Philipp;Kammerer Birgit
申请人:Hornschuch Ag K;
IPC主号:
专利说明:

Method for producing a composite material and composite material
The invention relates to a method for producing a composite material according to the preamble of claim 1. Furthermore, the invention relates to a composite material and objects, in particular formatting sections that are made or cut from this composite material and especially for seat covers or equipment for motor vehicles use.
Composite materials or molded sections produced therefrom, in particular as they are produced and used for motor vehicles, shoes, sick beds, should have sufficient permeability to air and / or water vapor. Currently, such composite materials are provided by punching or by needles with recesses for the passage of air and / or water vapor. The production by punching is expensive and the formation of small recesses or openings is difficult. The passages made by needles leave the substrate intact as opposed to punching; the trained
Passages, however, tend to close again.
When hot needles are used to permanently perforate the plastic upper layer of the composite material, incrustations form on the edges, causing the surface of the composite material to be rough, thereby affecting its feel.
Furthermore, only the same stereotypical arrangement and shape of the passage openings can be produced with the punches or needle rollers used for the formation of passages. A variation or a formation of a pattern or different deep perforations is not possible. It always results in the same image and the same distribution on the composite materials produced in sheets or plates. Only after the passage openings or recesses are formed, the tracks or plates are divided or cut in Formatzuschnitte.
As a material for producing the composite material, an at least two-layered upper layer of polyurethane or flexible PVC is bonded to a carrier layer. Such a composite material may e.g. also be a commercially available or known artificial leather, which is available as a sheet goods, which is processed into format cuts. The composition of the used for the upper class
Polyurethane or PVC may vary depending on the application. The same applies to the carrier layer, for a variety of materials is available.
The production of the composite material or of the composite of upper layer and carrier layer or an artificial leather takes place in a manner known per se. At best, the top layer produced on a release paper is directly bonded to the carrier layer or an optionally foamed middle layer of soft PVC or optionally foamed polyurethane is used to join the top layer and the carrier layer. The middle layer can also be a prepolymer or a PU high-solid, which cure in situ. It is also possible to apply the carrier to the not yet fully reacted or provided with a laminating topcoat and to connect by the pressure of the weight of the carrier layer together.
In order to eliminate the disadvantages of the previously provided with recesses or openings for air and / or water vapor composite materials, the invention provides that the recesses and openings are made with a laser or the material required for the formation of the recesses is removed by laser ablation. By laser ablation using a laser, the location and depth of the recesses can be made exactly.
Advantageously, it can be provided, in particular in the case of an uneven or grained or embossed surface, that at least 50% of the recesses formed penetrate the upper layer and extend at least as far as the carrier layer. For durability and strength, it is favorable if the upper layer comprises contiguous or successive soft PVC layers or polyurethane layers, wherein the individual layers of the upper layer in the formation of the recesses in the vicinity of the recesses connected to the laser or be welded.
Good strength and performance characteristics result when the composite is made to a thickness of 1.0 to 1.4 mm and / or when the topsheet and middle layer have a total combined thickness of 0.080 to 0.950 mm, preferably a total thickness of 0.010 up to 0.750 mm, be formed.
The arrangement and the contour of the recesses can be varied within the limits of the control of the laser. The design possibilities are increased if color-different pigments are added to the top layer and / or the individual layers of the top layer and / or the middle layer. For the production of the composite material, it is advantageous if the top layer in the form of at least one layer of flexible PVC or at least one layer of polyurethane, in particular of a crosslinked and solidified polyurethane dispersion, created and / or if between the top layer and the carrier layer to her Compound a middle layer of optionally foamed, soft PVC or, optionally foamed polyurethane is introduced and / or if the middle layer is partially introduced or pressed into the carrier layer in the connection of upper layer and carrier layer and / or if the upper layer with an adhesive layer with the backing layer is bonded and / or when the topsheet has adhesive properties and is applied to and bonded to the backing layer.
It can preferably be provided that the recesses are round, elliptical, rod-shaped or star-shaped in cross-section. For the strength of the material and for sufficient air and water vapor passage, it is advantageous if the recesses are formed with a largest dimension in the surface of the upper layer of 40 pm to 2.0 mm, preferably 80 pm to 0.90 mm, and / or if per surface unit, for example per cm2, a maximum of 35%, preferably a maximum of 28%, of the surface unit are provided with recesses. Thus, the strength of the composite material is not affected.
The procedure is such that the selection and the dimensions of the recesses are dimensioned such that the water vapor permeability of the composite material according to DIN EN ISO 14268 is greater than 1.2 mg / cm 2 h. For practice or processing, it is advantageous if the composite of top layer and carrier layer in the form of webs or plates is made or formed and after the webs or plates were divided into blanks of the desired shape and dimension, in the composite material blanks or Format parts the recesses are formed by laser machining.
It is possible to achieve a color design of the format sections if, in addition to the recesses penetrating the upper layer, additional recesses are formed in the upper layer which do not penetrate the upper layer but terminate in the layer located below the uppermost layer of the upper layer. If the individual layers of the top layer can contain color pigments of different colors, a multicolored pattern results.
The procedure according to the invention enables a particularly economical production of articles which can be produced at least partially using a composite material according to the invention. The composite material according to the invention, after its preparation, i. Production of the composite of upper layer and carrier layer, in Formatzuschnitte, ie blanks of desired dimensions divided and these pieces are subjected to laser processing or is produced only in these blanks the required number of recesses. Thus, it is not necessary, as hitherto, to be satisfied with a stereotypically recurring or regular arrangement of the recesses; the recesses can be made by means of a commercially available provided with a corresponding control unit laser in almost any shape and arrangement. The arrangement of the recesses can be adapted to the respective intended use. Above all, have the recesses produced by laser the advantage that the recesses do not go back, as is the case with recesses made with needles, since the required amount of material has been removed with the laser. Furthermore, the laser-treated surfaces are smooth, so that the dirt sensitivity of the material is reduced. It is also advantageous to apply to the top layer after lasering still a thin finish layer, for example, a PVC or PU layer which is thinner than 0.010 mm.
For example, it is possible to arrange 20 recesses with a diameter of 0.4 mm per cm 2 of a shaped cutout, of which 60% penetrate the upper layer. With such a design results in a water vapor permeability according to DIN EN ISO 14268 of 1.2 mg / cm2h. This exceeds the limit of 1 mg / cm2h set by the automotive industry.
In an application of trim pieces for car seats, e.g. also be provided that 48 recesses per cm2 are formed, each having a diameter of 0.1 mm. In turn, when 60% of the recesses penetrate the top layer into the polymer-free space of the carrier layer, the water vapor permeability is 2.1 mg / cm 2 h.
With a formation of 64 recesses / cm 2 with a diameter of 0.020 mm to 0.080 mm in a Formatsauschnitt with a distribution of about 1: 1 and an upper layer penetrating number of recesses of 60% results in a water vapor permeability of 1.7 mg / cm2h , For a seat, in particular for a middle track, a car seat in a dimension of 40x40 cm, about 6 recesses / cm2 are formed. This results in a corresponding size of the respective recesses readily and without unfavorable influence on the strength of the composite material, a sufficiently large air and water vapor permeability.
The water vapor permeability is determined predominantly by the top layer, since the carrier layers used have high air and / or water vapor permeability, but the top layer is impermeable to air and water vapor.
The shaped sections formed according to the invention from the composite material have, after lasering, the same tensile strength and elongation at break and the same bending stiffness as the material before lasering, since, in contrast to needling and / or perforation, the support is not weakened
Fig. 1 shows schematically a cross section through a Formatzuschnitt invention. Fig. 2 shows a detailed view. Fig. 3 shows the use of a formatting cut in a car seat. Fig. 4 shows a plan view of a provided with recesses of different dimensions Formatzuschnitt.
Fig. 1 shows a schematic section through a Formatzuschnitt 7, which has a top layer 1 made of soft PVC or polyurethane, which is connected to a carrier layer 2. The connection of these layers 1 and 2 can take place either directly or, as shown in FIG. 1, via a middle layer 3. The carrier layer 2 can be connected to a voluminous or voluminous further layer 4. The topsheet 1 may comprise a plurality of layers as shown; two layers 1 ', 1 "are shown, and the layers T, 1", 2 and / or 3 may have different colors or be doped with different color pigments. It can be provided that the outer layer T of the upper layer 1 is compact and at least one layer of soft PVC and that the inner layer 1 "of the upper layer 1 is at least one layer of foamed soft PVC or that the outer layer T of the upper layer 1 is compact and at least one layer
Polyurethane, in particular a layer of a crosslinked and solidified polyurethane dispersion, and that the inner layer 1 "of the upper layer 1 is at least one layer of foamed polyurethane.
Recesses 6 are introduced into the upper layer 1 from the surface of the upper layer 1. For this purpose, the corresponding amount of material of the upper layer 1 and the optionally present middle layer 3 is removed with a laser. The penetration depth is determined by the laser energy. For a given laser energy, there is a certain penetration depth. In the area of elevations 5, as e.g. in the case of a grained or embossed upper layer 1, a number of recesses 6 'will at most not penetrate the upper layer 1 or will only reach into the middle layer 3. However, such recesses 6 'can serve to form a pattern, in particular if the color of the layer 1 "is different than the color of the layer 1. However, it should be provided that the number of recesses 6 penetrating the upper layer 1 is at least 50% of all produced recesses amounts.
In particular, if the surface of the upper layer 1 is flat, the laser can be controlled so that it makes additional recesses 6 'in addition to the number of desired, the upper layer 1 penetrating recesses 6' to form an optionally colored pattern.
Fig. 2 shows schematically different design options of the recesses 6 and 6 '. The recesses 6, 6 'can have in cross-section the most varied geometrical shapes that can be formed by the laser, which can optionally be arranged in zones.
Further, a surface unit 8 of a format cut 7 is indicated in FIG. 2, within which a certain number of recesses 6 should not be exceeded. The number of recesses 6 per unit area 8 should be selected such that no more than 35% of the area of the unit area is claimed by the recesses 6.
Fig. 3 shows a car seat, which was made with a cut form 7 tailored from a composite material, wherein the Formatzuschnitt was provided with recesses 6 in the manner according to the invention. The dimensions of the illustrated recesses 6 are not true to scale but only illustrative. such
Molding blanks 7 are laser-finished after they have been cut into the predetermined shape from the composite material of upper layer 1 and backing layer 2. These cut-to-size pieces 7 provided with the recesses 6 are then filled with other materials 10, e.g. Fabrics or artificial leather, which usually have no recesses 6 and, for example, in the side areas of the car seat are used or installed, connected, e.g. sewn or glued together.
FIG. 4 shows a plan view of a surface of a molding blank 7 provided with recesses 6. The recesses 6 have different dimensions and are distributed irregularly or grouped together in such a way that a kind of flat pattern is produced.
The recesses 6 and 6 'may have different geometric shapes. They can follow a surface texture or be arranged as an image. In the image-like arrangement according to FIG. 4, zones with recesses 6 of different diameters and also small zones in which no recesses 6 and / or 6 'are arranged are present.
The lasering takes place on a commercial laser engraving machine. The extraction of the vapors, e.g. Hydrochloric acid in PVC, takes place immediately where they arise; the vapors are led into a water tank and neutralized. For the construction of the composite material it is advantageous if the largest dimension of the recesses in the surface of the top layer 1 is 40 μm to 2.0 mm, preferably 80 μm to 0.90 mm, and / or if per unit area, e.g. per cm 2, a maximum of 35%, preferably a maximum of 28%, the area of this unit area of recesses 6 are taken. This is achieved according to the invention, the water vapor permeability of the composite material according to DIN EN ISO 14268 is greater than 1.2 mg / cm2h.
By selecting the recesses 6 and their diameter, the air and / or water vapor permeability over the surface of a Formatsuschnittes 7 can be easily adjusted to desired values without affecting the material strength.
The top layer 1 is advantageously made up of two layers 1 ', 1 ", and the layers T, 1" can be constructed of a layer of the respective material.
权利要求:
Claims (30)
[1]
claims
1. A process for producing a composite material, to which a carrier layer (2) is bonded to a top layer (1) made of polyurethane or plasticized PVC, and the carrier layer (2) is a textile material, e.g. Woven, knitted or microfibrous fleece, or a leather, in particular a cow split leather, and the top layer (1) comprises a number of interconnected polyurethane layers or of soft PVC layers (1 ', 1 "), characterized that in the composite of upper layer (1) and carrier layer (2) from the surface of the upper layer (1) channel-shaped recesses (6) for the passage of water vapor and / or air are formed by material removal with a laser such that at least a part the recesses (6) penetrates the material of the upper layer (1) and / or ends before entry into the volume region of the carrier layer (2) which is free of the material of the upper layer (1).
[2]
2. The method according to claim 1, characterized in that at least 50% of the formed recesses (6) penetrate the upper layer (1) and at least extend to the carrier layer (2).
[3]
3. The method according to claim 1 or 2, characterized in that the upper layer (1) adjacent to each other or successive layers of soft PVC or polyurethane layers (f, 1 ") and that the individual layers (1 ', 1" ) of the upper layer (1) in the formation of the recesses (6) in the contact region (9) of the recesses (6) are connected or welded together by the laser.
[4]
4. The method according to any one of claims 1 to 3, characterized in that the composite material (7) is created with a thickness of 1.0 to 1.4 mm and / or that the upper layer (1) and the middle layer (3) with a total combined thickness of 0.080 to 0.950 mm, preferably with a total thickness of 0.010 to 0.750 mm, are formed.
[5]
5. The method according to any one of claims 1 to 4, characterized in that the upper layer (1) in the form of at least one layer of flexible PVC or at least one layer of polyurethane, in particular of a crosslinked and solidified polyurethane dispersion is created.
[6]
6. The method according to any one of claims 1 to 5, characterized in that the upper layer (1) and / or the individual layers (1 ', 1 ") of the upper layer (1) and / or the middle layer (3) added differently colored pigments become.
[7]
7. The method according to any one of claims 1 to 6, characterized in that between the upper layer (1) and the carrier layer (2) for their connection, a middle layer (3) of optionally foamed soft PVC or, optionally foamed polyurethane is introduced.
[8]
8. The method according to any one of claims 1 to 7, characterized in that in the connection of upper layer (1) and carrier layer (2) the middle layer (3) is partially introduced or pressed into the carrier layer (2) or that the upper layer ( 1) with an adhesive layer to the carrier layer (2) is connected or that the upper layer (1) has adhesive properties and applied to the carrier layer (2) and is connected thereto.
[9]
9. The method according to any one of claims 1 to 8, characterized in that the recesses (6) are formed in cross-section round, elliptical, rod-shaped or star-shaped.
[10]
10. The method according to any one of claims 1 to 9, characterized in that the recesses (6) having a largest dimension in the surface of the upper layer (1) of 40 pm to 2.0 mm, preferably 80 pm to 0.90 mm, be formed.
[11]
11. The method according to any one of claims 1 to 10, characterized in that per unit area (8), for example, per cm2, a maximum of 35%, preferably at most 28%, of the surface unit (8) are provided with recesses (6).
[12]
12. The method according to any one of claims 1 to 11, characterized in that the selection and the dimensions of the recesses (6) are dimensioned such that the water vapor permeability of the composite material (7) according to DIN EN ISO 14268 greater than 1.2 mg / cm2h is.
[13]
13. The method according to any one of claims 1 to 12, characterized in that the carrier layer (2) with a volume-providing base layer (4), e.g. a nonwoven layer is connected.
[14]
14. The method according to any one of claims 1 to 13, characterized in that the composite of upper layer (1) and carrier layer (2) is produced or formed in the form of webs or plates and that after the webs or plates in Formatzuschnitte or blanks desired shape and dimension were divided in the composite blanks the recesses (6) are formed by laser machining.
[15]
Composite material comprising a backing layer (2) joined to a top layer (1) of polyurethane or flexible PVC, said backing layer (2) comprising a textile material, e.g. Woven, knitted or microfiber nonwoven fabric, or a leather, in particular a cow split leather, and the topsheet (1) comprises a number of interconnected layers (1 ', 1 ") of flexible PVC or of polyurethane, in particular produced by a process of Claims 1 to 14, characterized in that - in the composite material (7) starting from the surface of the upper layer (1) channel-shaped recesses (6) are made or formed for the passage of water vapor and / or air with a laser, and - that at least a part of the recesses (6) penetrates the material of the upper layer (1) and / or ends before entry into the volume region of the carrier layer (2) free of the material of the upper layer (1).
[16]
16. Composite material according to claim 15, characterized in that at least 50% of the formed recesses (6) penetrate the upper layer (1) and extend at least as far as the carrier layer (2).
[17]
17. A composite material according to claim 15 or 16, characterized in that adjacent to each other or successive layers (1 ', 1 ") made of soft PVC or layers (1', 1") of polyurethane of the upper layer (1) in the formation of Recesses (6) in the peripheral region (9) of the recesses (6) are connected or welded together.
[18]
18. Composite material according to one of claims 15 to 17, characterized in that the thickness of the composite material (7) is 1.0 to 1.4 mm and / or that the upper layer (1) and the middle layer (3) together have a thickness of 0.080 to 0.950 mm, preferably having a total thickness of 0.010 to 0.750 mm.
[19]
19. Composite material according to one of claims 15 to 18, characterized in that - the outer layer (1 ') of the upper layer (1) is compact and at least one layer of soft PVC and that the inner layer (V) of the upper layer (1) at least one layer of foamed flexible PVC or - that the outer layer (1 ') of the upper layer (1) is compact and at least one layer of polyurethane, in particular a layer of a crosslinked and solidified polyurethane dispersion, and that the inner layer (Γ) of the upper layer (1) is at least one layer of foamed polyurethane.
[20]
20. Composite material according to one of claims 15 to 19, characterized in that between the upper layer (1) and the carrier layer (2) a middle layer (3) of optionally foamed soft PVC or optionally foamed polyurethane is arranged.
[21]
21. Composite material according to one of claims 15 to 20, characterized in that the middle layer (3) has partially penetrated into the carrier layer (2) or that the top layer (1) is connected to the carrier layer (2) with an adhesive layer or that the Upper layer (1) has adhesive properties and is applied to and bonded to the carrier layer (2).
[22]
22. Composite material according to one of claims 15 to 21, characterized in that the upper layer (1) and / or the middle layer (3) and / or the layers (1 ', 1 ") of the upper layer (1) optionally contain differently colored color pigments ,
[23]
23. Composite material according to one of claims 15 to 22, characterized in that the recesses (6, 6 ') in cross section are round, elliptical, rod-shaped or star-shaped.
[24]
24. Composite material according to one of claims 15 to 23, characterized in that the largest dimension of the recesses (6, 6 ') in the surface of the upper layer (1) 40 pm to 2.0 mm, preferably 80 pm to 0.90 mm , is.
[25]
Composite material according to one of Claims 15 to 24, characterized in that per unit area (8), e.g. per cm 2, a maximum of 35%, preferably 28%, of the area of this surface unit (8) of recesses (6) are taken.
[26]
26. Composite material according to one of claims 15 to 25, characterized in that the water vapor permeability of the composite material (7) according to DIN EN ISO 14268 is greater than 1.2 mg / cm2h.
[27]
Composite material according to any one of Claims 15 to 26, characterized in that the carrier layer (2) is provided with a volume-providing base layer (4), e.g. a nonwoven layer is connected.
[28]
28. A composite material according to any one of claims 15 to 27, characterized in that the composite material (7) is in the form of a Formatzuschnittes or cut or split.
[29]
29. Items at least partially manufactured with a Formatzuschnitt of composite material according to any one of claims 15 to 28, in particular car seat covers or upholstery, vehicle headrests, shoes and beds.
[30]
30. Formatsuschnitt, made of a composite material according to any one of claims 15 to 27.
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同族专利:
公开号 | 公开日
CN108472919A|2018-08-31|
WO2017089081A1|2017-06-01|
AT517576B1|2017-03-15|
EP3380316B1|2020-07-22|
EP3380316A1|2018-10-03|
PT3380316T|2020-08-13|
US20180345634A1|2018-12-06|
引用文献:
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法律状态:
优先权:
申请号 | 申请日 | 专利标题
ATA51019/2015A|AT517576B1|2015-11-27|2015-11-27|Method for producing a composite material and composite material|ATA51019/2015A| AT517576B1|2015-11-27|2015-11-27|Method for producing a composite material and composite material|
PT167887082T| PT3380316T|2015-11-27|2016-11-02|Method for producing a composite material and composite material|
CN201680069331.8A| CN108472919A|2015-11-27|2016-11-02|Method for manufacturing composite material and composite material|
PCT/EP2016/076338| WO2017089081A1|2015-11-27|2016-11-02|Method for producing a composite material and composite material|
EP16788708.2A| EP3380316B1|2015-11-27|2016-11-02|Method for producing a composite material and composite material|
US15/779,113| US20180345634A1|2015-11-27|2016-11-02|Method for producing a composite material and composite material|
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