EP0010408B1 - Method of preparing abrasive foam material - Google Patents
Method of preparing abrasive foam material Download PDFInfo
- Publication number
- EP0010408B1 EP0010408B1 EP19790302194 EP79302194A EP0010408B1 EP 0010408 B1 EP0010408 B1 EP 0010408B1 EP 19790302194 EP19790302194 EP 19790302194 EP 79302194 A EP79302194 A EP 79302194A EP 0010408 B1 EP0010408 B1 EP 0010408B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- sheet
- stencil
- resin
- foam
- holes
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D15/00—Hand tools or other devices for non-rotary grinding, polishing, or stropping
- B24D15/04—Hand tools or other devices for non-rotary grinding, polishing, or stropping resilient; with resiliently-mounted operative surface
Definitions
- the invention relates to the production of an open-cell foam polymeric material with an abrasive surface, which can be used, for example, to make scouring and cleaning pads for domestic use.
- FR-A-1,465,778 describes the production of such an abrasive surface on a foam sheet by the application of a hardenable resin to the surface of the sheet.
- the resin penetrates from the surface of the sheet so that there is a progressive decrease in hardness from the surface into the body of the foam.
- the hardening resin can be applied in discrete areas, for example as a pattern of circular areas separated by untreated, and therefore soft, areas of foam.
- a method of providing an abrasive surface on a sheet of compressible open-cell foam polymeric material by the application of a hardenable resin to the surface of the sheet characterized in that a stencil (11) having a multiplicity of holes (12) is arranged on the surface of the foam sheet (1 ⁇ ), pressure is applied to impress the stencil into the sheet (Fig. 1), the hardenable resin is applied to the surface of the stencil remote from the foam sheet so that the resin contacts the foam sheet in the region of the holes in the stencil, the stencil is removed and the resin (14) is allowed or caused to harden.
- the resin is incorporated into the sheet of compressible foam material in the region of the holes in the stencil and does not project from the surface of the sheet.
- the resin which can contain an abrasive substance, is applied in such a way as not to fill the cells of the foam material.
- the resin coating thus hardens the cell structure in the regions in which it is incorporated but should not create a continuous hard surface which closes the cells at the surface. It is however likely to reduce communication between the cells of an open foam structure in the region in which it is incorporated. Since the body of the foam sheet remains unaltered it will absorb the cleaning fluid and supply it to the hardened abrasive regions.
- the sheet of foam material is provided with a pattern of regions of hardened resin which do not adversely affect the flexibility of the foam sheet.
- the resin being impregnated in the foam material, is unlikely to become separated from the sheet of foam material. Since the resin is applied in a multiplicity of distinct regions it is less likely to crack than if applied as a continuous superficial coating.
- a sheet of compressible foam plastics material 10 which is of the "open-cell" type in which neighbouring cells communicate with each other.
- the foam sheet is preferably of polyurethane although there are many alternative materials, for example various rubbers, plasticised P.V.C., modified cellulose.
- a typical polyurethane foam material has the following characteristics:-
- a stencil 11 having a multiplicity of holes 12 in a regular pattern is arranged against a surface of the sheet and pressure is applied to the stencil to impress it into the sheet as shown in Fig. 1.
- the stencil 11 is made of a rigid material, for example a metal or a rigid plastics material, and its thickness is typically in the range 0.5 to 2.0 mm through this dimension is not critical.
- the holes 12 can be of any shape but for convenience will usually be circular and have diameters approximately in the range 2 to 10 mm, or perhaps up to 15 mm. A typical example has circular holes of 8 mm diameter at 12 mm spacing between centres.
- the holes have an area approximately in the range 3 to 150 but preferably less than 80 square mm. It will be appreciated that the area of one hole in the stencil is small compared to the area of, for example, a scouring pad for domestic use, which is one of the articles which can be produced directly from the finished sheet of abrasive foam material.
- the total area of the holes 12 is preferably between 25 and 60% of the total area of the stencil. However if the shape of the holes approximates to a square or rectangle it is possible to increase the total area of the holes to as much as 90% of the total area of the stencil.
- a hardenable liquid resin is applied to the stencil 11 and spread over the stencil by means of a rigid spreader member, for example a metal or hard rubber blade.
- the resin preferably comprises an epoxy resin and an example of the constituents of a suitable resin is as follows:-
- DER 321 is a product of the Dow Chemical Company available through Casa Chemicals Ltd.
- "Synolide 960” is a product of General Mills Corpn. available from Cray Valley Products Ltd. 200 mesh is a sieve size which passes particles of up to 75 ⁇ m diameter.
- resins may be used depending on the intended use of the finished abrasive foam sheet and examples of alternative resins are natural and synthetic rubbers, acrylics, P.V.C., and phenolformaldehyde resins. Similarly the amount and type of abrasive filler used can be varied and resins containing no abrasive filler can be used.
- the spreader member As the spreader member is drawn across the stencil 11 it comes into contact with the foam material where it protrudes through the holes 12, and smears resin into the material.
- the stencil 11 is then removed from the sheet of foam material 10 which is then exposed to conditions suitable for hardening the resin associated with the sheet.
- the sheet To harden the example of a resin described above, the sheet should be heated to 125°C for about 5 minutes.
- Fig. 2 shows the material produced by this method.
- the sheet of foam material 10 is provided with an abrasive surface 13 comprising a multiplicity of distinct regions of hardened resin 14 corresponding to the holes 12 in the stencil 11.
- the resin is incorporated into the sheet of material 10 and does not substantially project above the surface of the sheet. This is due to the compression of the material by the stencil and the working of the resin into protruding areas of foam material as they are engaged by the spreader member.
- the foam material expands and, since the material is of the "open-cell” type, the liquid resin is drawn into the sheet from cell to cell with the result that, in general, the cells which contain resin are not filled by the resin but have the cell walls coated. The cell structure is thus retained, which is important for the cleaning action of the product.
- the cell diameters are preferably in the range 0.25 to 2.0 mm.
- the resin is incorporated in the cells of the foam material and in use of a part of the sheet, for example as a scouring pad, the resin is much less likely to get separated from the foam material than if it is applied as a superficial coating.
- a continuous superficial coating of resin is also prone to splitting, which does not occur if resin is applied in a pattern of distinct small regions.
- the surface structure of the cells of the foam sheet, within the regions of hardened resin 14, contributes an abrasive effect, as does the discontinuity of the resin-impregnated regions and the presence of any abrasive material in the resin.
- Products made using very thin section polyurethane foams are too weak and dimensionally unstable to be durable.
- foams can, however, be easily modified and strengthened by lamination to a lightweight fabric (e.g. cotton or synthetic), either woven or non-woven. These fabrics would have weights of 20-100 g/m 2 .
- a further improvement in strength occurs during the coating/printing process, as the liquid resin will completely penetrate the thin foam and adhere to the fabric laminated to the back of the foam.
- the resulting product can either be used as an abrasive or cleaning cloth, or further laminated to blocks of polyurethane or other rigid foams and cut up into pads.
- Typical films are: poly(ethylene), poly(ethylene vinyl acetate), plasticised poly(vinyl chloride) and its copolymers, natural rubber - hydrochloride, etc.
- Film thicknesses are typically 25-50 microns.
- the film is fused to the foam surface at 120-160°C for 5-20 seconds at about 2 kg/cm 2 depending upon the particular film used and thickness of the coated foam.
- cleaning or scouring pads can be made from a sheet of abrasive foam material according to the invention simply by cutting the sheets into pads of a suitable size for the intended use. Sheets having differing abrasive characteristics may be produced as described above. Cleaning or scouring pads cut from a sheet of abrasive foam may be used to clean, for example, cooking utensils, baths, kitchen sinks, paintwork, and vehicle windscreens. For these purposes they must be used with a liquid, for example water.
Description
- The invention relates to the production of an open-cell foam polymeric material with an abrasive surface, which can be used, for example, to make scouring and cleaning pads for domestic use.
- FR-A-1,465,778 describes the production of such an abrasive surface on a foam sheet by the application of a hardenable resin to the surface of the sheet. The resin penetrates from the surface of the sheet so that there is a progressive decrease in hardness from the surface into the body of the foam. The hardening resin can be applied in discrete areas, for example as a pattern of circular areas separated by untreated, and therefore soft, areas of foam.
- In accordance with the present invention there is provided a method of providing an abrasive surface on a sheet of compressible open-cell foam polymeric material by the application of a hardenable resin to the surface of the sheet characterized in that a stencil (11) having a multiplicity of holes (12) is arranged on the surface of the foam sheet (1µ), pressure is applied to impress the stencil into the sheet (Fig. 1), the hardenable resin is applied to the surface of the stencil remote from the foam sheet so that the resin contacts the foam sheet in the region of the holes in the stencil, the stencil is removed and the resin (14) is allowed or caused to harden.
- By the use of this method the resin is incorporated into the sheet of compressible foam material in the region of the holes in the stencil and does not project from the surface of the sheet. The resin, which can contain an abrasive substance, is applied in such a way as not to fill the cells of the foam material. The resin coating thus hardens the cell structure in the regions in which it is incorporated but should not create a continuous hard surface which closes the cells at the surface. It is however likely to reduce communication between the cells of an open foam structure in the region in which it is incorporated. Since the body of the foam sheet remains unaltered it will absorb the cleaning fluid and supply it to the hardened abrasive regions.
- Hence the sheet of foam material is provided with a pattern of regions of hardened resin which do not adversely affect the flexibility of the foam sheet. The resin, being impregnated in the foam material, is unlikely to become separated from the sheet of foam material. Since the resin is applied in a multiplicity of distinct regions it is less likely to crack than if applied as a continuous superficial coating.
- The invention will be further described by way of example and with reference to the accompanying drawings, in which:-
- Fig. 1 is a section through a sheet of compressible foam polymeric material and a stencil used in the method according to the invention; and
- Fig. 2 is a section through the sheet of foam polymeric material shown in Fig. 1, provided with an abrasive surface by a method according to the invention.
- In the drawings is shown a sheet of compressible
foam plastics material 10 which is of the "open-cell" type in which neighbouring cells communicate with each other. The foam sheet is preferably of polyurethane although there are many alternative materials, for example various rubbers, plasticised P.V.C., modified cellulose. A typical polyurethane foam material has the following characteristics:- - Density: 15 to 45 kg/m 3
- Hardness to B.S. 3667: 20 to 30
- Elongation at break: 100 to 300%
- Tensile strength: 69 to 138 kPa (10 to 20 p.s.i.)
- Cell Diameters: 0.25 to 2.00 mm
- To provide the sheet of
foam material 10 with an abrasive surface, astencil 11 having a multiplicity ofholes 12 in a regular pattern is arranged against a surface of the sheet and pressure is applied to the stencil to impress it into the sheet as shown in Fig. 1. Thestencil 11 is made of a rigid material, for example a metal or a rigid plastics material, and its thickness is typically in the range 0.5 to 2.0 mm through this dimension is not critical. Theholes 12 can be of any shape but for convenience will usually be circular and have diameters approximately in the range 2 to 10 mm, or perhaps up to 15 mm. A typical example has circular holes of 8 mm diameter at 12 mm spacing between centres. - Hence the holes have an area approximately in the range 3 to 150 but preferably less than 80 square mm. It will be appreciated that the area of one hole in the stencil is small compared to the area of, for example, a scouring pad for domestic use, which is one of the articles which can be produced directly from the finished sheet of abrasive foam material. The total area of the
holes 12 is preferably between 25 and 60% of the total area of the stencil. However if the shape of the holes approximates to a square or rectangle it is possible to increase the total area of the holes to as much as 90% of the total area of the stencil. - Sufficient pressure is applied to the
stencil 11 to ensure that foam material protrudes through theholes 12 and projects from the opposite face of the stencil as shown in Fig. 1. -
- DER 321 is a product of the Dow Chemical Company available through Casa Chemicals Ltd. "Synolide 960" is a product of General Mills Corpn. available from Cray Valley Products Ltd. 200 mesh is a sieve size which passes particles of up to 75 µm diameter.
- Other resins may be used depending on the intended use of the finished abrasive foam sheet and examples of alternative resins are natural and synthetic rubbers, acrylics, P.V.C., and phenolformaldehyde resins. Similarly the amount and type of abrasive filler used can be varied and resins containing no abrasive filler can be used.
- As the spreader member is drawn across the
stencil 11 it comes into contact with the foam material where it protrudes through theholes 12, and smears resin into the material. Thestencil 11 is then removed from the sheet offoam material 10 which is then exposed to conditions suitable for hardening the resin associated with the sheet. To harden the example of a resin described above, the sheet should be heated to 125°C for about 5 minutes. - Fig. 2 shows the material produced by this method. The sheet of
foam material 10 is provided with anabrasive surface 13 comprising a multiplicity of distinct regions of hardenedresin 14 corresponding to theholes 12 in thestencil 11. The resin is incorporated into the sheet ofmaterial 10 and does not substantially project above the surface of the sheet. This is due to the compression of the material by the stencil and the working of the resin into protruding areas of foam material as they are engaged by the spreader member. In addition, when the stencil is removed the foam material expands and, since the material is of the "open-cell" type, the liquid resin is drawn into the sheet from cell to cell with the result that, in general, the cells which contain resin are not filled by the resin but have the cell walls coated. The cell structure is thus retained, which is important for the cleaning action of the product. The cell diameters are preferably in the range 0.25 to 2.0 mm. - As can be seen in Fig. 2, the resin is incorporated in the cells of the foam material and in use of a part of the sheet, for example as a scouring pad, the resin is much less likely to get separated from the foam material than if it is applied as a superficial coating. A continuous superficial coating of resin is also prone to splitting, which does not occur if resin is applied in a pattern of distinct small regions. The surface structure of the cells of the foam sheet, within the regions of hardened
resin 14, contributes an abrasive effect, as does the discontinuity of the resin-impregnated regions and the presence of any abrasive material in the resin. - Products made using very thin section polyurethane foams (i.e. 2-5 mm) are too weak and dimensionally unstable to be durable. Such foams can, however, be easily modified and strengthened by lamination to a lightweight fabric (e.g. cotton or synthetic), either woven or non-woven. These fabrics would have weights of 20-100 g/m2. A further improvement in strength occurs during the coating/printing process, as the liquid resin will completely penetrate the thin foam and adhere to the fabric laminated to the back of the foam.
- The resulting product can either be used as an abrasive or cleaning cloth, or further laminated to blocks of polyurethane or other rigid foams and cut up into pads.
- Since the structure of the foam and nature of the polymer constituting the foam are retained during the printing and hardening process, the eventual durability of the product is dependent upon the strength of the particular foam used. Therefore, when the cheapest polyurethane foams are used, they are found to be less durable than the better quality foams. However, it has been found that useful products of good durability can be made from the cheapest, lightest density polyurethane foams if a thin film of thermoplastic resin is fused onto the abrasive surface. This film strengthens the foam surface considerably and does not interfere too much with the abrasive properties of the hardened areas on the working surface.
- Typical films are: poly(ethylene), poly(ethylene vinyl acetate), plasticised poly(vinyl chloride) and its copolymers, natural rubber - hydrochloride, etc.
- Film thicknesses are typically 25-50 microns.
- The film is fused to the foam surface at 120-160°C for 5-20 seconds at about 2 kg/cm2 depending upon the particular film used and thickness of the coated foam.
- It will be appreciated that cleaning or scouring pads can be made from a sheet of abrasive foam material according to the invention simply by cutting the sheets into pads of a suitable size for the intended use. Sheets having differing abrasive characteristics may be produced as described above. Cleaning or scouring pads cut from a sheet of abrasive foam may be used to clean, for example, cooking utensils, baths, kitchen sinks, paintwork, and vehicle windscreens. For these purposes they must be used with a liquid, for example water.
The thickness of the sheet is preferably in the range from 2 mm to 50 mm.
Claims (6)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB4045278 | 1978-10-13 | ||
GB7840452 | 1978-10-13 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0010408A1 EP0010408A1 (en) | 1980-04-30 |
EP0010408B1 true EP0010408B1 (en) | 1983-02-16 |
Family
ID=10500311
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19790302194 Expired EP0010408B1 (en) | 1978-10-13 | 1979-10-12 | Method of preparing abrasive foam material |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0010408B1 (en) |
JP (1) | JPS5553537A (en) |
DE (1) | DE2964833D1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2596678A1 (en) * | 1986-04-08 | 1987-10-09 | Siderurgie Fse Inst Rech | Method and device for grinding or polishing mill rolls |
US5769700A (en) * | 1996-09-10 | 1998-06-23 | Norton Company | Grinding wheel |
US5849051A (en) * | 1997-11-12 | 1998-12-15 | Minnesota Mining And Manufacturing Company | Abrasive foam article and method of making same |
US5863305A (en) * | 1996-05-03 | 1999-01-26 | Minnesota Mining And Manufacturing Company | Method and apparatus for manufacturing abrasive articles |
US6007590A (en) * | 1996-05-03 | 1999-12-28 | 3M Innovative Properties Company | Method of making a foraminous abrasive article |
US6017831A (en) * | 1996-05-03 | 2000-01-25 | 3M Innovative Properties Company | Nonwoven abrasive articles |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE8104890U1 (en) * | 1981-02-21 | 1981-08-27 | Jöst, Peter, 6941 Abtsteinach | WORK GLOVES WITH ABRASIVE MAT |
EP2173752B2 (en) | 2007-06-13 | 2022-07-13 | Incyte Holdings Corporation | Salts of the janus kinase inhibitor (r)-3-(4-(7h-pyrrolo(2,3-d)pyrimidin-4-yl)-1h-pyrazol-1-yl)-3-cyclopentylpropanenitrile |
EP3419492A2 (en) | 2016-02-26 | 2019-01-02 | 3M Innovative Properties Company | Consumer scrubbing article with solvent-free texture layer and method of making same |
EP3522763A1 (en) | 2016-10-06 | 2019-08-14 | The Procter and Gamble Company | Method of manufacturing an abrasive sponge for cleaning |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1446998A (en) * | 1921-12-05 | 1923-02-27 | John A Vincent | Metal cleaning and polishing device |
US1495839A (en) * | 1923-04-12 | 1924-05-27 | Earl R Gribben | Cleaning material |
US1896638A (en) * | 1926-08-30 | 1933-02-07 | Asbestos Wood & Shingle Co | Apparatus for coating sheet material with granular material |
US2596565A (en) * | 1946-09-23 | 1952-05-13 | William E Kautenberg | Reinforced sponge and method of reinforcing it |
US2804728A (en) * | 1954-11-18 | 1957-09-03 | Politzer Alfred | Abrasive article |
US3256075A (en) * | 1961-10-20 | 1966-06-14 | Minnesota Mining & Mfg | Abrasive sponge |
FR1465778A (en) * | 1964-12-24 | 1967-01-13 | Collo Rheincollodium Koln G M | Process for the manufacture of a cleaning part and in particular a pot cleaning plate, as well as the cleaning parts corresponding to those obtained by the present process or a similar process |
US3630800A (en) * | 1966-07-01 | 1971-12-28 | Johnson & Johnson | Method of manufacturing an improved wiping cloth |
US3619843A (en) * | 1969-05-26 | 1971-11-16 | American Cyanamid Co | Sponges with dry impregnants |
CH571932A5 (en) * | 1975-02-05 | 1976-01-30 | Schnueriger Karl | |
DE2529837A1 (en) * | 1975-07-04 | 1977-01-27 | Collo Gmbh | CLEANING CLOTH FOR HOUSEHOLD PURPOSES, FOR CAR CARE ETC. |
-
1979
- 1979-10-11 JP JP13128579A patent/JPS5553537A/en active Pending
- 1979-10-12 EP EP19790302194 patent/EP0010408B1/en not_active Expired
- 1979-10-12 DE DE7979302194T patent/DE2964833D1/en not_active Expired
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2596678A1 (en) * | 1986-04-08 | 1987-10-09 | Siderurgie Fse Inst Rech | Method and device for grinding or polishing mill rolls |
US5863305A (en) * | 1996-05-03 | 1999-01-26 | Minnesota Mining And Manufacturing Company | Method and apparatus for manufacturing abrasive articles |
US6007590A (en) * | 1996-05-03 | 1999-12-28 | 3M Innovative Properties Company | Method of making a foraminous abrasive article |
US6017831A (en) * | 1996-05-03 | 2000-01-25 | 3M Innovative Properties Company | Nonwoven abrasive articles |
US5769700A (en) * | 1996-09-10 | 1998-06-23 | Norton Company | Grinding wheel |
US5849051A (en) * | 1997-11-12 | 1998-12-15 | Minnesota Mining And Manufacturing Company | Abrasive foam article and method of making same |
Also Published As
Publication number | Publication date |
---|---|
JPS5553537A (en) | 1980-04-19 |
DE2964833D1 (en) | 1983-03-24 |
EP0010408A1 (en) | 1980-04-30 |
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