WO2002044455A1 - Nonwoven material and method of manufacture therefor - Google Patents
Nonwoven material and method of manufacture therefor Download PDFInfo
- Publication number
- WO2002044455A1 WO2002044455A1 PCT/US2001/045460 US0145460W WO0244455A1 WO 2002044455 A1 WO2002044455 A1 WO 2002044455A1 US 0145460 W US0145460 W US 0145460W WO 0244455 A1 WO0244455 A1 WO 0244455A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibers
- nonwoven
- fiber
- mat
- thermoplastic
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/641—Sheath-core multicomponent strand or fiber 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/682—Needled nonwoven fabric
Definitions
- the present invention generally relates to nonwoven textiles, and in particular, to recyclable nonwoven textiles that are sewable.
- Nonwoven textiles are typically produced by making a mat of fibers, and securing those fibers together to form a textile.
- the fibers of the mat can be secured together through mechanical connecting, adhesive bonding, or thermal fusing.
- Nonwoven textiles are used in various applications such as backing material for fabrics in automotive applications or as a stand alone textile. To be used as a backing material for fabrics, the material will have properties that enable the ease of sewing the material. Additionally, there has been a recent interest in using only materials that are recyclable for applications such as automotive use. Therefore, it is one objective of the current invention to produce a nonwoven textile that is recyclable and has desirable sewability characteristics.
- FIG. 1 shows an enlarged cross-section of a nonwoven material illustrating one embodiment of the present invention
- FIG. 2 shows an enlarged cross-section of a first fiber from the nonwoven material in FIG. 1 ;
- FIG. 3 shows a block diagram of a process for forming the nonwoven in FIG. 1 ;
- FIG. 4 shows a test sample of an example material that has been folded open.
- FIG. 1 there is shown an enlarged cross-sectional view of a nonwoven textile 10 illustrating an embodiment of the present invention.
- the nonwoven textile 10 is highly flexible, which facilitates its ability to be used as a backing material for fabrics.
- the nonwoven textile 10 is also a recyclable and sewable material.
- the nonwoven textile also has superior seam strength. These properties permit the use of the nonwoven textile 10 as a backing material for fabrics such as fabrics used in automotive applications.
- seam strength is the ability of a material to retain its strength at a seam.
- the tensile strength of a material contributes to seam strength.
- One method of testing seam strength is to measure the gap between two sections of the material that have been sewn together, after having subjected the sewn together material to a specific number of flex cycles.
- the ultimate tensile strength of two sections of material sewn together, after having subjected the sewn together material to a specific number of flex cycles is another method of testing seam strength.
- the nonwoven textile 10 generally comprises a plurality of first fibers 20 intermixed with a plurality of second fibers 30.
- the first fibers 20 generally include a core material 21 and a sheath material 22.
- the core material 21 and the sheath material 22 of the first fibers 20 are preferably a thermoplastic, and more preferably, a thermoplastic that is recyclable such as polyester. Additionally, the core material 21 of the first fibers 20 has a higher melting point than the sheath material 22.
- the second fibers 30 are also preferably a thermoplastic material, and more preferably, a recyclable thermoplastic material such as polyester. The material of the second fibers 30 has a higher melting point than the sheath material 22 of the first fibers 20.
- the first fibers 20 and the second fibers 30 are intertwined within the nonwoven textile 10 through a process of needle punching. Additionally, at various crossing points of various first fibers 20 and the crossing of first fibers 20 with second fibers 30, a bond point 11 is created between the crossing fibers 20, 30, due to the melt fusing of the sheath material 22 in the first fibers 20.
- the nonwoven textile 10 is preferably 4-15 ounces per square yard, and includes a ratio of from about five to about twenty percent (5-20%) by weight of the first fibers 20 to the total weight of the combination of the first fibers 20 and the second fibers 30.
- the sheath material 22 of the first fibers 20 is preferably a low melt temperature thermoplastic, such as a low melt temperature polyester, that is between about 5 to about 15% of the total weight of the first fiber 20.
- the core material 21 of the first fiber 20 is preferably a high melt temperature thermoplastic, such as a high melt temperature polyester, that is between about 85 to about 95% of the total weight of the first fiber 20.
- the first fiber 20 is also preferably between about 4-6 denier.
- the second fiber 30 is preferably a high melt temperature polyester having a denier between about 3-12. The first fibers 20 and the second fibers 30 are mechanically locked with needle punches of between about 1.100 and about 1800 punches per square inch.
- FIG. 3 there is shown a block diagram illustrating one embodiment of a method for forming the nonwoven textile 10 in FIG. 1.
- the first fibers 20 are supplied from a first fiber supply 111
- second fibers 30 are supplied from a second fiber supply 112.
- the first fibers 20 and the second fibers 30 are blended in a blending step 120 with a ratio of from about five to about twenty percent (5-20%) by weight of the first fibers 20 to the total weight of the combination of first fibers 20 and second fibers 30.
- the blended fibers from step 120 are carded into a web form in the carding step 130.
- the web from the carding step 130 is cross lapped in cross lapping step 140 to insure crossing of the various fibers into a mat.
- the mat is needled in the needling step 150.
- the needling step 150 creates between about 1100 and about 1800 punches per square inch to entangle and mechanically lock together the fiber of the mat.
- the mat is subjected to heat in a heating step 160.
- the heating step 160 brings the fibers in the mat to a temperature greater than the lower melt temperature of the sheath material 22 in the first fibers 20, thereby softening the sheath material.
- adjacent second fibers 30 embed into the softened sheath material 22 of the first fibers 20, and sheath material 22 of adjacent first fibers 20 intermix, thereby forming bond points 11.
- the mat is cooled in a cooling step 170 below the melting point of the sheath material to produce the nonwoven textile 10.
- a first fiber having a core of high melt polyester and a sheath of low melt polyester is combined with second fibers of a high melt polyester.
- the high melt polyester core of the first fiber is about 90% of the weight of the first fiber.
- the first fiber was about a 4 denier fiber.
- the second fiber was about a 6 denier fiber.
- the first fibers and the second fibers were blended with a ratio of about five percent (5%) to about twenty percent (20%) by weight of the first fibers 10 to the total weight of the combined first fibers 10 and the second fibers 30. After the fibers were blended into a mat, carded, and cross lapped, the mat was needled punched at the rate of about 1 ,650 punches per inch.
- the mat After needling, the mat was subjected to a temperature of between about 275° and about 305° for a period of about 180 seconds.
- the high temperature was sufficient to cause the sheath material of the first fiber to flow around adjoining fibers and form random point bonds in the material.
- the resulting material became a recyclable nonwoven textile of polyester that is flexible and easier to sew than current technology.
- test nylon thread (13 lb.) test nylon thread, Material Standard MS-JZ3-2, with a No. 22 size sewing needle at about 0.24 stitches/mm (6 stitches/in.).
- Two sections 210 and 220 of the example material were configured into the test samples 200 according to FIG. 4.
- the two sections 210/220 of example material are sewn together at the seam 230 with the facing surfaces F1 and F2 contacting each other, and then folded open to the configuration in FIG. 4.
- Each section 210/220 includes tabs 211 and 221 with grasping points 212 and 222.
- the seam of various test samples were subjected to 10,000 cycles of flex for measuring the seam strength.
- Each cycle of flex is accomplished by grasping the grasping points of each tab 210/220, moving one of the two the grasping points 34.9 mm (1.375 inches) opposite of the other grasping point laterally along the seam 230 with 35.59 N (8 lbs) force at 42 cycles per minute.
- Each cycle produces a total of 139.6 mm (5.5 inches) movement of the grasping points 210/220 along the seam 230 (34.9 mm from center in each direction and back).
- Various samples of the example material were tested for the gap between the two sections at the seam after being subjected to the flex cycles.
- the gap between the two sections of material at the seams was about 1.0 mm (0.039 inches) or less for seams across the machine direction of the material, and the gap was about 1.5 mm (0.059 inches) or less for seams across the cross direction of the material.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2002227119A AU2002227119A1 (en) | 2000-11-30 | 2001-10-31 | Nonwoven material and method of manufacture therefor |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/726,680 US20020065013A1 (en) | 2000-11-30 | 2000-11-30 | Nonwoven material and method of manufacture therefor |
US09/726,680 | 2000-11-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2002044455A1 true WO2002044455A1 (en) | 2002-06-06 |
Family
ID=24919576
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/045460 WO2002044455A1 (en) | 2000-11-30 | 2001-10-31 | Nonwoven material and method of manufacture therefor |
Country Status (3)
Country | Link |
---|---|
US (1) | US20020065013A1 (en) |
AU (1) | AU2002227119A1 (en) |
WO (1) | WO2002044455A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6863477B2 (en) | 2003-02-12 | 2005-03-08 | Continental Commercial Products, Llc | Method and material for preventing erosion and maintaining playability of golf course sand bunkers |
ES2644455T3 (en) | 2007-08-17 | 2017-11-29 | Fiberweb, Llc | Non-woven fabric with adhesive surface from a single polymer system |
NL1041463B1 (en) * | 2015-09-08 | 2017-03-22 | Hunter Douglas Ind Bv | Linear Ceiling Panel. |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5298321A (en) * | 1991-07-05 | 1994-03-29 | Toyo Boseki Kabushiki Kaisha | Recyclable vehicular cushioning material and seat |
US5501898A (en) * | 1992-08-26 | 1996-03-26 | Firma Carl Freudenberg | Interior equipment part for vehicles |
US5723209A (en) * | 1995-04-05 | 1998-03-03 | Hoechst Trevira Gmbh & Co Kg | Rollable thermal insulation based on synthetic fiber |
US6048809A (en) * | 1997-06-03 | 2000-04-11 | Lear Automotive Dearborn, Inc. | Vehicle headliner formed of polyester fibers |
-
2000
- 2000-11-30 US US09/726,680 patent/US20020065013A1/en not_active Abandoned
-
2001
- 2001-10-31 AU AU2002227119A patent/AU2002227119A1/en not_active Abandoned
- 2001-10-31 WO PCT/US2001/045460 patent/WO2002044455A1/en active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5298321A (en) * | 1991-07-05 | 1994-03-29 | Toyo Boseki Kabushiki Kaisha | Recyclable vehicular cushioning material and seat |
US5501898A (en) * | 1992-08-26 | 1996-03-26 | Firma Carl Freudenberg | Interior equipment part for vehicles |
US5723209A (en) * | 1995-04-05 | 1998-03-03 | Hoechst Trevira Gmbh & Co Kg | Rollable thermal insulation based on synthetic fiber |
US6048809A (en) * | 1997-06-03 | 2000-04-11 | Lear Automotive Dearborn, Inc. | Vehicle headliner formed of polyester fibers |
Also Published As
Publication number | Publication date |
---|---|
AU2002227119A1 (en) | 2002-06-11 |
US20020065013A1 (en) | 2002-05-30 |
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