Title of Invention

SYNTHETIC FIBER AND THE PRODUCTION PROCESS THEREOF

Abstract

The present invention provides a synthetic fiber paper, the synthetic fiber paper comprises poly (phenyiene terephthal amide) fiber, polyethylene glycol terephthalate fiber and powdered mica. The synthetic fiber paper has high-temperature resistance, high strength, low-deformability, resistivity against fire, burning resistance, resistance in chemical corrosion and excellent property of electric insulation, it can be widely applied in the field of mechano-electronics product, aviation, aerospace, military' project for national defence, high-tech areas for civil use, high-voltage equipment high temperature circumstance as insulting material, it often can be used in composite materials with special use as structural material. The present invention alsO provided a process for preparing this synthetic fiber paper.

Full Text

Synthetic Fiber Paper and Process for Its Preparation Field of the Invention This invention relates to a synthetic fiber paper, particularly to a fiber paper made of aromatic polyamidc synthetic fiber as main raw material; this invention also relates to u process for preparing the synthetic fiber paper. Description of the Prior Art The synthetic fiber paper of aromatic polyamide in a paper-like material made of synthetic fiber of aromatic polyamide as ruw materinl through a special papermaking technology. Owing to high-temperature resistance. high strength, low-deformability, fosistivity against fire, hurtling resistance, resistance to chemical corrosion and excellent property of insulator. it has been widely used in mime high-tech areas such as mcchano-electronic product. aviation, aerospace clc. A1 present, (he fiber paper of momatic polyumite- mid on the market, trade name being called as "Nomex Brand paper" , uses the fiN-i of poly (m-phcnylnir mctaphthtil uiitide). However, there is no any satisfied process for preparing the suid s>nihctic fiber paper has been disclosed yet. Summary of Hit Invention In view of the shortage of the prior mt, the object of (he present invention is to provide a synthetic fiber paper made of poly (p-phenylene tcrcphthal amide) as raw material. This fiber paper has high-temperature resistance, high strength, low-deformability, resistivity against fire, burning resistance, resistance to chemical corrosion and excellent property of insulation. The another object of the present invention is to provide a process for preparing a synthetic fiber paper made of poly (p-phenylene terephthal amide) fiber as raw material. The present invention provides a synthetic fiber paper comprises (parts by weight): Poly (p-phenylem- lecephlhal amide) fiber 50 - 80 Polyethylene glycol terephthalate fiber 20 - 50 Powdered mica 0-50 Preferably, the above-mentioned synthetic fiber paper comprises (parts by weight): i Poly (p-phenylene terephthal amide) fiber 70 - 80 Polyethylene glycoi terephthalate fiber 20 - 30 The no-stuffing synthetic fiber paper can be produced in proportion as aforesaid content. More preferably, the above-mentioned synthetic fiber paper comprises(parts by weight): Poly (p-phenylene terephthal amide) fiber 60 - 70 Polyethylene glycoi terephthalate fiber 30 - 40 Powdered mica 0-10 The low stuffing synthetic fiber paper can be produced in proportion as aforesaid content. Powdered mica with 5-20 ?? is preferably used in present invention. More preferably, the above-mentioned synthetic fiber paper comprises (parts by weight): Poly (p-plimylcne terephthal amide) fiber 50 - 60 Polyethylene glycoi terephthalatc fiber 40 - 50 Powdered win 10-50 The high Mulling synthetic fiber paper can be produced in proportion as aforesaid content. The said poiy (p-phenylcnc terephthal amide) liber is 1.5 - 2.0 D in size, 4-6 m/rn in length. The polyeihylene glycol terephthalate liber is 1.5 - 2.0 D in size and 4-6 m/m in length The process for preparing the synthetic fiber paper comprising the following steps of compounding and :pulping, papermaking shaping, dehydrating, drying preheating, prepressing, high-pressure hot-roiling, trimming, wherein the untreated poly (p-phenylene terephthal amide) fiber and the polyethylene glycoi terephthalate fiber are in proportion loosened and dissociated before the step of compounding and pulping, then mixing with the treated poly (p-phenylene terephthal amide) fiber to compound and pulp. The proportion between the said untreated poly (p-phenylene terephthal amide) fiber and the tivaied poly (p-phenylene terephthal amide) fiber is preferably 1:1 - 0.2 by weight, more preferably is 1: 0.34 by weight. In the said process, before compounding and pulping, the powdered mica should be also mixed with the processing additives to be a homogeneous material. 2 The said processing additives are an inorganic gel and/or polyethylene glycol oxide. In the process of present invention, the preheating temperature is 240 - 250 °C, the prepressing pressure is 1 - 2 Mpa, the temperature of high-pressure hot rolling is 255 -265 °C and the linear pressure is 500 - 3000 N/cm. Detailed Description of the Invention The poly (p-phenylene terephthal amide) fiber (Aromatic polyamide fiber 1414) is a structure fiber with general formula as follow: It can be prodiurti by a process comprising following steps: terephthalyl chloride and p-phenylene dumine as raw material, are polycondensed in NMP - CaCl2 as solvent under low temperature to poly (p-phenykm1 terephthal amide) resin, then undergoing liquul crystal spinning, being cut to length us required, or is precipitated directly to shun fiber. The fiber has outstanding high strength (the highest tensile strength 200 OSHXMX. shearing 0.2V, elongation nt rupture 3%), high modulus of elasticity (up to 67 KN/mm2), high hot resistance (decomposition point 500°C), resistivity against fire, burning resistance, resistance to chemical corrosion and excellent property of insulation, therefore the synthetic fiber paper made of poly (p-phenylene terephthal amide) as a main component of structural fiber also has the above-mentioned outstanding excellent properties. Because of insufficient binding force of the synthetic fibers, the synthetic fibers can not be papermaking shaping as a plant fiber docs. Binding of the synthetic fibers depends mainly on adhesion of melted liber. However the poly (p-phenylene terephthal amide) fiber docsn' t have a distinct melting point, therefore during papermaking shaping some fiber having lower melting point present as crosslinking fiber has to be added. When the paper blank of synthetic fiber is rolled at nearly melting point of the crosslinking fibei. the soft and meited crosslinking fiber binds the unmelted poly (p-phenylene terephthal amide) fiber to form net-like material, so as to be finalized. In ihis invention the polyethylene glycol terephthalate fiber (polyester fiber) is used as the 3 crosslinking fibre. Its structural formula: The sonening point of the noer is 238 - 2410C, melting point is 255 - 260°C. The fiber has higher softening temperature than using temperature of the synthetic fiber paper 220°C, and higher strength, excellent electric insulation. That the polyethylene glycol terephthalate fiber is added properly as a crosslinking fiber doesn't drop the physical mechanical index and electric insulation of the synthetic fiber paper too much. While stuffing is used, the amount of the crosslinking fiber used in the present invention preferably increases to 40 - 50 parts by weight, most preferably increases to 30 parts by weight. When the synthetic fiber paper is used in place where there are high-voltage and frequent or uninterrupted corona discharge being used, it is necessary to add and mix the powdered mica while papermaking, the ability for products resisting to corona discharge is strengthened by stuffing of powdered mica. The proportion of stuffing level depends on its uses, varying'from 0 to 50 parts by weight. While the stuffing level reaches 50 parts by weight (high stuffing), the product also has the properties of mica besides the properties of original high strength and high-temperature resistance etc. In the process for preparing the synthetic fiber paper of the present invention in order to increase dispersion of fiber in water, while mixing and pulping, a micro level of high viscosity material should be added to gets the pulp slurry to have some viscosity increases the movement resistance of fiber in the pulp, delays the twining and flocculating of fiber, so as to improve dispersing and suspending of the fiber in pulp, finally achieves the aim of increasing homogeneity of the synthetic fiber paper. The micro-level of residual viscosity increaser in the paper blank for papermaking shaping makes the fiber some adhesion, so that it makes the paper blank retain initial strength before finalizing, and will not get rupture in the process of transporting pulling apart from a foundation fabric. The process of papermaking can run smoothly. The viscosity increaser used in this invention can be selected from a group consisting of inorganic gel SM and polyethylene glycol Oxide PO. They can be either used separately, or as combination. The amount of it is about 0.3 - 0.8%. It can be able to be adjusted, depending on the viscosity of viscosity increaser, the type, gauge of paper and the type of papermaking machine. In general, the use level for thick paper is adequately more than for thin. The use level for stuffing paper is more than for no 4 - stuffing. In order to improve the homogeneity of paper blank for papermaking, it is very necessary for the poly (p-phenylene terephthal amide) fiber to have surface-preparation. This surface-preparation changes the properties of fiber surface, enhances an affinity of fiber to~water, so that the dispersing and suspending fiber in water persists for a longer time. There are many process for treating poly (p-phenylene terephthal amide) fiber. Here is a mechanical process or a mechanico-chemical combined process is used. It means that the poly (p-phenylene terephthal amide) fiber is beaten by a beater, then it will be shorn and torn to reduce the length of fiber and to make its surface roughness. While beating the micro-level of processing additives also can be added, after that it will be mixed and beaten, it is what is called the mechanico-chemical combined process. In practical production, it is also possible to apply poly (p-phenylene terephthal amide) fiber in two different lengths combined (especially suitable for super short fiber which is directly produced by precipitating process). Same effect result can be achieved. Because the synthetic fiber paper should have both a better tensile strength, elongation rate, density, and a higher tearing strength, initial tear, at the same time, it also should have the property of the best homogeneity in the process of papermaking, in order to resolve the contradiction between demanding fiber length of the tearing strength and of tensile strength, in present invention, a certain amount of untreated poly (p-phenylene terephthal amide) (long fiber) as skeleton of paper blank compounded in part of treated poly (p-phenylene terephthal amide) fiber (short fiber) is compounded in part and stuffed in the skeleton of the poly (p-phenylene terephthal amide) fiber to be untreated the interweaving of long fiber with short fiber trends further towards homogeneity thereby enhances of papermaking homogeneity of the paper blank and the interweaving density of fibers. S Table-1. The effects of physical, mechanical properties of paper blank by compounding proportion of two types of poly (p-phynvlene terephthal amide) fibers It can be noted from table I that the tearing strength and initial tear increase as the use level of treated fibers increases, the tensile strength reduces as the use level of untreated fibers increases. The ratio of two types of poly (p-phenylene terephthal amide) fibers is preferably adjusted to 1: 0.34 thereby all relative properties are kept with satisfaction. When there are some special demands for the tearing strength and the tensile strength of paper due to different use, a satisfied products still can be produced through adjusting the ratio of two kinds of poly (p-phenylene terephthal amide) fibers based on the indication shown in table 1. After the synthetic fiber paper is dried, because of weak adhesive force between fibers, the fiber of paper blank is slack, its mechanical properties are weak, accordingly, it has to be given treated by the hot-rolling setting to make the crosslink fiber (short cut filament of polyester) with low melt point soften, melt, and under the pressure it will be made to bind with (he fiber net made of untreated poly (p-phenylene terephthal amide) liber and lo be finalized, thereby il will be made to have required properties. In order to make the paper blank have sufficient mechanical strength to bear the strong tensile and prevent il fioin being rupture when hot-rolling at high pressure. More the step of hot-rolling at high pressure, the paper blank should be passed through the preheating roller to preheat it to the softening point of crosslinking fiber, and a lower prepressing pressure should he exerted on to make paper blank has sufficient mechanical strength Table 2. Hot-rollinu temDeniiurc and Dressure The higher the hot-rolling pressure is, the greater the density of the synthetic fiber paper will be. By means of changing the pressure of roller (linear pressure), a various types of products with different density can be obtained . When stuffing is being filled, in order to make the stuffing attain has enough adhesion, more crosslinking fiber should be made to be melted, at the same time the hot-rolling temperature should be properly to 265° C. The process can be operated smoothly by mixing the stuffing (powered mica) with micro-level of processing additives while stirred at high speed to form pulp, then the 6 result mixture was compounded into the pu!p of fiber paper. In order to prevent the crosslinking fiber from being over melted and the technical properties of synthetic fiber paper being affected. The temperature of preheating and hot-rolling should be controlled precisely at a point of temperature selected, the error in temperature is ±1 °C. Because the heat conductivity coefficient of paper blank is lower, its heat conduction is slow, the thicker the synthetic fiber paper is, the longer the preheating lime will be. The synthetic fiber paper of the present invention is a kind of new synthetic imitciial with high performance. It is a paper-like material made of the synthetic fiber of iititmalic polyamide as main component and produced by special papermaking 111 imology. It has high-temperature resistance (suitable used to be at—190 - 310°C, and i an be used for long time below 220 °C), high strength, low-deformability, resistivity -1'iiinsi fire, burning resistance, resistivity to chemical corrosion and excellent property 1 electric insulation. The low-density, middle-density, high-density paper of synthetic IM-I can he produced by the means of changing the character of fiber, the ratio of two itris. hot-rolling pressure as required according to the different use. The type of no-stuffing, low-stuffing and high-stuffing products can be produced means of changing the proportion of stuff lo be added. The products also can be n.tdr lo have different timkness gauge (0.05 10mm) (if more than 1.0mm, be called hlier paperboard) and different width gauge. The present invention can provide a .i ties of products with ditlerent type and different gauge to meet the needs in different •« i hmcal areas. The synthetic fiber paper in the present invention can be widely applied in the field of mechano-eIecironies, aviation, aerospace, military project for national il'leiise. high-tech areas for civil use, high-voltage equipment, high-temperature » in umstance as insulating material, besides, it often can be used in composite material with special use as structural material. Brief Description of Drawings Figure 1 is a flow diagram process for preparation of the present invention. 7 Examples Example 1 According to following proportion, the synthetic fiber paper of example 1 was produced by a process of the present invention. Poly (p-phenylene terephthal amide) fiber 70kg Polyethylene glycol terephthalate fiber 30kg The above-mentioned poly (p-phenylene terephthal amide) fiber comprises 52kg of untreated poly (p-phenylene terephthal amide) fiber having 1.5D in size and 6m/m in length and 18kg of the treated poly (p-phenylene terephthal amide) fiber. The polyethylene glycol terephthalate fiber is 1.5D in size and 6m/m in length. The above-mentioned process of the present invention comprises: Referring to figure 1. the untreated poly (p-phenylene lerephthal amide) fiber were subjected to be loosened and dissociated, then was compounded with the treated poly {p-phenyicne terephthal amide) fiber to make pulp, through the steps of papermaking shaping, dehydrating, diving, preheating and prepressing at 245°C and under 2Mpa, hot-rolling under 600N nn of linear pressure and at 260°C so as to make a no-stuffing synthetic fiber papa with low density of 0.3 - 0.5 g/cm ; then trimming, rolling-up, to obtain the product. 1 he wasiewater from dehydrating can he recycled after it was treated u1-* required. Example 2 According to the process indicated as cxamplel, except that the hot-rolling pu-ssure during the stage of high pressure hot-rolling was 1200 N/cm. Finally a no-stuffing middle-dcnsit) synthetic fiber paper having density of 0.5 - 0.99g/m was obtained. Example 3 The same ratio of two synthetic fiber papers and process as described for example I were used except thut the linear pressure at high-pressure hot-rolling is 3000N/cm. if t tnally no-stuffing high density synthetic fiber paper having density of 0.9 - 1.2g/cm was obtained. Example 4 According to following proportion, the synthetic fiber paper of example 4 was pioduced by a process substantially same as the process described in example 1: Poly (p-phenylene terephthal amide) fiber 65kg 8 Polyethylene glycol terephthalate fiber 30kg Powdered mica (5 - 10 ?m in graininess) 1 kg The above-mentioned poly (p-phenylene terephthai amide) fiber comprises 45kg of untreated poly (p-phenylene terephthai amide) fiber with 1.5D in size and 6m/m in length .and 20kg of treated poly (p-phenylene terephthai amide) fiber. The polyethylene glycol terephthalate fiber with 1.5D in size and 4m/m in length is adopted. The process of example 4 is substantially same as the process described in example I, except that before compounding and pulping, powdered mica, water and micro-level of processing additives—polyethylene glycol oxide have to be mixed and homogenized, (lion they are added 1o the above-mentioned composition consisting of poly f|i phenylene terephthai amide) fiber and polyethylene glycol terephthalate fiber to be made compound and pulp; preheating temperature is 250"C prepressing pressure is 15Mpa; the temperature' «u the high-pressure hot-rolling is 265 °C, the linear pressure is 1500N/cm. Example 5 According to following proportion, compound and manufacture the synthetic fiber paper in example 5 was produced Poly (p-phenylene tm-phthal amide) fiber 50kg Polyethylene glycol u-rephthalale fiber 50kg Powdered mica (5 10?m graininess) 50kg The above-mentioned poly (p-phenylenc terephthai amide) fiber comprises 40kg of iintii-iitcd poly (p-phenylene terephthai amide) fiber having 1.5D in size and 6m/m in length and 10kg of treated poly (p-phenylene terephthai amide) fiber. The polyethylene plvcol terephthalate fiber adopted is2.0D in size and 6m/m in length. The process used in example 5 is same as the process described in example 4. Example 6 According to the following proportion, compound and manufacture the synthetic liber paper of example 6 wns produced: Poly (p-phenylene terephthai amide) fiber 60kg Polyethylene glycol lerephthalate fiber 40kg Powdered mica (10- 15 ?m in graininess) 10kg The above-mentioned poly (p-phenylene terephthai amide) fiber comprises 45kg of the untreated poly (p-phenylene terephthai amide) fiber having 2D in size and 6m/m in 4 length and 15kg of the treated poly (p-phenylene terephthal amide) fiber. The polyethylene glycol terephthalate fiber used is 2D in size and 6m/m in length. The process of example 6 is substantially same as the process described in example 4, except that the high-pressure hot-rolling was carried out at 265 °C and 2000N/cm of the linear pressure. Example 7 According to following proportion, compound and manufacture the synthetic fiber paper of example 7 was produced: Poly (p-phr.nylcne terephthal amide) fiber 60kg Polyethylene glycol terephthalate fiber 40kg Powdered uiti a (10 -20?m ingrainincss) 10kg The above MM.¦uiioned poly (p-phenylene terephthal amide) fiber comprises 40kg of the untreated poly * p-phenylene terephthal amide) fiber having 1.5D in size and 6m/m in length and 'li^i of the treated poly {p-phenylene terephlhal amide) liber. The polyethylene »»lw I lerephthalate fiber adopted is 1.5D in size and 4m/m in length. The priHUn t! >" process of example 7 is substantially same as the process described in example u Examplt N According t following proportion, compound and manufacture the synthetic fiber paper of example it was produced: Poly (;• mi. u\ k-ne terephthal amide) fiber 50kg Polye?!'\ ¦ Powdc. ¦'¦ '»iii a (10 - 20 ?m in grainincss) 50kg The ahi-M- uu-mentoned poly (p-phenylene terephthal amide) fiber comprises 30kg of the untreated poly (p-phenylene terephthal amide) fiber having 1.5D in size and 6m/m in length a-i-l l0l.|^ of the treated poly (p-phenylene terephlhal amide) fiber. The polyethylene >.>luol terephthalate fiber used was 1.5D in size and 5m/m in length. The pro* ess ui example 8 is substantially same as the process described in example 6. Example9 According to following proportion, compound and manufacture the synthetic fiber paper of the example 9 was produced Poly (p-phenylene terephthal amide) fiber 50kg 10 length and 15kg of the treated poly (p-phenylene terephthal amide) fiber. The polyethylene glycol terephthalate fiber used is 2D in size and 6m/m in length. The process of example 6 is substantially same as the process described in example 4, except that the high-pressure hot-rolling was carried out at 265 °C and 2000N/cm of the linear pressure. Example 7 According to following proportion, compound and manufacture the synthetic fiber paper of example 7 was produced: Poly (p-phi nylene terephthal amide) fiber 60kg Polyethylene ylycol terephthalate fiber 40kg Powdered i linn (10 -20 ?m in graininess) 10kg The above mentioned poly (p-phenylene terephthal amide) fiber comprises 40kg of the untreated poly (p-phenylene terephthal amide) fiber having I.5D in size and 6m/m in length and Mil. ^ of the treated poly (p-phenylene terephthal amide) fiber. The polyethylene t>\\- ¦ I terephthalate fiber adopted is 1.5D in size and 4m/m in length. The prt*!ut *> m process of example 7 is substantially same as the process described in example i-Exttmplt 8 According following proportion, compound and manufucture the synthetic fiber paper of example it was produced: Poly ({• .'¦>. ..\ Ifiii' terephthal amide) fiber 50kg PolycU.\ M -> ulyrol terephthalate fiber 50kg Powdf« •'¦ 'mi o(10- 20 ?m in graininess) 50kg The above- mentioned poly (p-phenylene terephthal amide) fiber comprises 30kg of the untreated poly (p-phenylcne terephthal amide) fiber having 1.5D in size and 6m/m in length .t'i>l MH.)- of the treated poly (p-phenylene terephlhal amide) fiber. The polyethylene ulw o| terephthalate fiber used was 1.5D in size and 5m/m in length. The process of example 8 is substantially same as the process described in example 6. Examnlr 9 According to following proportion, compound and manufacture the synthetic fiber paper of the example 9 was produced Poly (p-phenylene terephthal amide) fiber 50kg 10 WE CLAIM : 1. A synthetic fiber paper comprising : Poly (p-phenylene terephthal amide) fiber 50 - 80 parts by weight Polyethylene glycol terephthalate fiber 20 - 50 parts by weight Powdered mica 0-50 parts by weight 2. Synthetic fiber paper according to claim 1, wherein said synthetic fiber paper comprising : Poly (p-phenylene terephthal amide) fiber 70 - 80 parts by weight Polyethylene glycol terephthalate fiber 20 - 30 parts by weight 3. Synthetic fiber paper according to claim 1, wherein said synthetic fiber paper comprising : Poly (p-phenylerie terephthal amide) fiber 60 - 70 parts by weight Polyethylene glycol terephthalate fiber 30 - 40 parts by weight Powdered mica 0 - 10 parts by weight 4. tf. Synthetic fiber paper according to claim 1, wherein said synthetic fiber paper comprising : Poly (p-phenylene terephthal amide) fiber 50 - 60 parts by weight Polyethylene glycol terephthalate fiber 40-50 parts by weight Powdered mica 10-50 parts by weight 5. Synthetic fiber paper according to any one of claim 1-4, wherein said poly (p- phenylene terephthal amide) fiber is 1.5 - 2.0D in size and 4-6 m/m in length and said polytheylene glycol terephthalate fiber is 1.5 - 2.0D in size and 4-6 m/m in length. 12 6. A process for preparing the synthetic fiber paper comprising the following steps (i) compounding and pulping; (ii) papermaking shaping; (iii) dehydrating; (iv) drying; (v) preheating; (vi) prepressing; (vii) high-pressure hot-rolling; (viii) and trimming wherein, the untreated poly (p-phenylene terephthal amide) fiber and the polyethylene glycol terephthalate fiber are in proportion loosened and dissociated before the step of compounding and pulping; and the powdered mica is mixed with the processing additives to homogenous mixture,then mixing with the treated poly (p-phenylene terephthal amide) fiber to compound and pulp; and said preheating temperature is 240 - 250; and said high-pressure hot-rolling temperature is 255-265. 13 7. The process according to claim 1, wherein the proportion of the untreated poly (p- phenylene terephthal amide) fiber to the treated poly (p-phenylene terephthal amide) fiber is 1:1 - 0.2 by weight. 8. The process according to claim 2, wherein the proportion of the untreated poly (p- phenylene terephthal amide) fiber to the treated poly (p-phenylene terephthal amide) fiber is 1:0.34 by weight. 9. The process according to claim 1, wherein said processing additives is inorganic gel and/or polyethylene glycol oxide. 10. The process according to any one of claim 1 ~ 4, wherein said prepressing pressure is 1 - 2Mpa; and said linear pressure is 500 - 3000N/cm. The present invention provides a synthetic fiber paper, the synthetic fiber paper comprises poly (phenyiene terephthal amide) fiber, polyethylene glycol terephthalate fiber and powdered mica. The synthetic fiber paper has high-temperature resistance, high strength, low-deformability, resistivity against fire, burning resistance, resistance in chemical corrosion and excellent property of electric insulation, it can be widely applied in the field of mechano-electronics product, aviation, aerospace, military' project for national defence, high-tech areas for civil use, high-voltage equipment high temperature circumstance as insulting material, it often can be used in composite materials with special use as structural material. The present invention alsO provided a process for preparing this synthetic fiber paper.

Documents:

in-pct-2001-00748-kol abstract.pdf

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in-pct-2001-00748-kol correspondence.pdf

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in-pct-2001-00748-kol priority document others.pdf

in-pct-2001-00748-kol reply f.e.r.pdf

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in-pct-2001-748-kol-granted-abstract.pdf

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in-pct-2001-748-kol-granted-correspondence.pdf

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in-pct-2001-748-kol-granted-letter patent.pdf

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