JP3763324B2 - Manufacturing method of resin edge composite material - Google Patents

Manufacturing method of resin edge composite material Download PDF

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Publication number
JP3763324B2
JP3763324B2 JP14105796A JP14105796A JP3763324B2 JP 3763324 B2 JP3763324 B2 JP 3763324B2 JP 14105796 A JP14105796 A JP 14105796A JP 14105796 A JP14105796 A JP 14105796A JP 3763324 B2 JP3763324 B2 JP 3763324B2
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JP
Japan
Prior art keywords
resin
decorative
edge composite
resin edge
resin layer
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 - Fee Related
Application number
JP14105796A
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Japanese (ja)
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JPH09300495A (en
Inventor
松岡  功
建 近藤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aica Kogyo Co Ltd
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Aica Kogyo Co Ltd
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Filing date
Publication date
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Priority to JP14105796A priority Critical patent/JP3763324B2/en
Publication of JPH09300495A publication Critical patent/JPH09300495A/en
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Description

【0001】
【産業上の利用分野】
本発明は樹脂エッジ複合材の製法に関する。
【0002】
【従来の技術】
従来、住宅関連商品用の部材として木質系基材の表面に化粧板を接着したものが広く一般に使用されており、中でも木質系基材の木口面の強度を補い、木口面を塗装する煩わしさを省くため木質系基材の表面に化粧材を接着し、周縁に樹脂層を形成した樹脂エッジ複合ボードが近年知られている。
【0003】
【発明が解決しようとする課題】
しかしながら、樹脂エッジ複合ボードの多くは木質系基材の表面に化粧材を接着した後、溝を形成し樹脂を注入する方式であるため、0.6〜1.2mmと薄い化粧材を用いる場合には化粧材に至る深さで溝を切削するのに精度を必要とし作業中に木質系基材からはみ出た化粧材の一部が破損することがあった。従って0.6mm以下の薄物化粧材はほとんど対応できなかった。
【0004】
また、仕上がった樹脂エッジ複合ボードは化粧材と樹脂エッジ材との境界が木質系基材上あるいはその近辺に存在するため、長期にわたり使用していると、温度、湿度の影響を受けやすい木質系基材の寸法収縮により化粧材と樹脂エッジ材との境界にすき間が生じ、このすき間から水が侵入し木質系基材に至ることがあった。その結果、木質系基材が膨潤して化粧材と樹脂エッジ材との境界に段差が生じたり樹脂エッジ複合ボードが変形することがあり、耐水性が必要とされる台所用としてはいささか不都合であった。
【0005】
【課題を解決するための手段】
本発明はかかる前記の課題を解決するために検討されたもので、次の(A)〜(C)のステップに基づく樹脂エッジ複合材(9)の製法である。
(A)木質系基材(1)に凹溝を形成し該凹溝に合成樹脂を注入するステップ、
(B)該合成樹脂を硬化させた後、樹脂層(3)を面取り加工して、樹脂エッジ基材(4)を得るステップ、
(C)該樹脂エッジ基材(4)の表面に化粧材(5)を接着し、該樹脂層(3)の表面に、化粧材(5)の端部が位置するように端面を仕上げるステップ。
以下、本発明について詳細に説明する。
【0006】
本発明に用いる木質系基材(1)としては、合板、パーティクルボード、MDF(中密度繊維板)、集成材、あるいはこれらを組み合わせた複合材などが適用できる。厚みや材の選定は強度、取り扱い性を考慮して定められる。
【0007】
木質系基材(1)に形成された凹溝に注入される合成樹脂としては、木質系基材(1)に接着性を有する樹脂で補強効果のある樹脂であればよく、例えばエポキシ樹脂、ウレタン樹脂、ポリエステル樹脂などの熱硬化性樹脂、及び通常の接着剤やコーキング剤が適用できるが、中でもエポキシ系、ウレタン系、ポリエステル系などからなる高樹脂分で常温硬化型の熱硬化性樹脂が作業性、密着性、硬化後の強度などの点から望ましく、更にガラス繊維、合成繊維、炭素繊維からなるチップ状または糸状の繊維類を添加したものが耐衝撃強度の点で優れている。また、各種充填剤、着色剤、増量剤を添加して変性した樹脂を使用してもよい。
【0008】
木質系基材(1)の側面に前記の合成樹脂を硬化せしめて樹脂層(3)が形成された樹脂エッジ基材(4)に化粧材(5)を接着するには、木質系基材(1)、樹脂層(3)、化粧材(5)の三者に適する従来公知の接着剤を用いて貼り合わせ加圧成形すればよく、例えば水性ビニールウレタン系の接着剤、ウレタン系の接着剤、酢酸ビニール系の接着剤、ユリア系の接着剤、エポキシ系の接着剤、合成ゴム系の接着剤を用いて真空成形すればよい。
【0009】
とりわけ真空成形する際には樹脂エッジ基材(4)の上に化粧材(5)を置いた時位置合わせを必要とするため接着剤を塗布した直後はタックがなく加熱することにより接着力を発揮するウレタン系の接着剤が好ましい。条件的には、温度100〜160℃、圧力1〜3kg/cm2、時間1分〜5分程度で行えばよく、木質系基材(1)や化粧材(5)が破損することなく曲がり接着できればよい。
【0010】
化粧材(5)としては耐熱性、耐水性、耐衝撃性などの表面物性に優れ、常温もしくは加熱条件下で1〜50mmRの曲げ性を有するのであれば特に制約はなく、例えば、化粧板用の原紙をメラミン樹脂、グアナミン樹脂、ジアリルフタレート樹脂、不飽和ポリエステル樹脂などを主成分とする樹脂液で含浸処理し、コア材とともに熱圧成形して得られるメラミン樹脂化粧板やジアリルフタレート樹脂化粧板などの熱硬化性樹脂化粧板が挙げられる。
【0011】
化粧材(5)の樹脂層(3)側の端部(8a、8b)は、木質系基材(1)と遠く離れ水滴が侵入し木質系基材に至らない位置であれば図2、図3に示されるように樹脂層(3)の上曲面(6)、下曲面(7)上の任意の位置でさしつかえない。
以下、本発明を実施例と図面に基づいて詳細に説明する。
【0012】
【実施例】
実施例1
木質系基材(1)として厚み21mmのMDF(中密度繊維板)を選択し凹溝を切削し、凹溝に合成樹脂として不飽和ポリエステル樹脂を注入し硬化させた後、樹脂層(3)を上曲面(6)が50mmR、下曲面(7)が3mmRとなるように面取り加工して樹脂エッジ基材(4)を得た。次いで、ウレタン系の接着剤(商品名 アイカアイボンW―654 アイカ工業株式会社製)を塗布し、化粧材(5)として厚み0.45mmのジアリルフタレート樹脂化粧板を置き、位置を調整した後、真空プレス機を用いて温度140℃、時間3分、圧力1kg/cm2の条件で成形した。しかる後、図2に示されるように樹脂層(3)の上曲面(6)上に化粧材(5)の端部(8a)が位置するように端面を仕上げて実施例1の樹脂エッジ複合材(9)を得た。
【0013】
実施例2
図3に示されるように上曲面(6)が30mmR、下曲面(7)が15mmRとなるように面取り加工し、樹脂層(3)の下曲面(7)上に化粧材(5)と樹脂層の端部(8b)が位置するように端面を仕上げ以外は実施例1と同様に加工して実施例2の樹脂エッジ複合材(9´)を得た。
【0014】
比較例1
実施例1と同質のMDF、熱硬化性樹脂、接着剤、化粧材を用いて図4に示されるように化粧材の端部(8c)と樹脂層が面一になるように加工したものを比較例1の樹脂エッジ複合ボード(10)とした。
【0015】
比較例2
実施例1と同質のMDF、熱硬化性樹脂、接着剤、化粧材を用いて図5に示されるように化粧材の端部(8c)と樹脂層が面一になるように加工したものを比較例2の樹脂エッジ複合ボード(10´)とした。
【0016】
評価結果を表1に示す。
【表1】
耐水性;JAS耐水A試験(80±3℃の温水中1時間、60±3℃の恒温器中2時間の工程を2回繰り返し、室温に達するまで放置)に基づき化粧材を接着した面を上にして1日1試験、5日間連続で実施し目視にて外観を確認した。
化粧材と樹脂層との境界部については目視、指触にて確認し、隙間が生じたものについては隙間を隙間ゲ−ジにて測定した。
【0017】
【発明の効果】
本発明の製法で得られる樹脂エッジ複合材(9、9´)は化粧材(5)の樹脂層(3)側の端部(8a、8b)が木質系基材(1)上ではなく、また樹脂層と面一でもなく樹脂層(3)の表面面上にあるため寸法変化の影響を受けることが極めて少なく、また水が侵入しても木質系基材に至ることがなく、従って剥離を生じたり変形することがない。
【0018】
また、本発明の製法においては木質系基材(1)に凹溝を形成し該凹溝に合成樹脂を注入し、樹脂層(3)を形成した後、該樹脂層(3)の全面もしくは一部を含みながら表面に化粧材(5)を接着しているので作業中木質系基材からはみ出た化粧材(5)の一部がなく破損することがない。
【0019】
加えて本発明の製法では化粧材に至る深さで溝を切削する工程がないので0.6mm以下の薄い化粧材でも充分対応することができる。
【図面の簡単な説明】
【図1】 実施例1の樹脂エッジ複合材(9)の斜視図を示す。
【図2】 図1中のA−A線に沿う要部拡大構成断面図を示す。
【図3】 実施例2の樹脂エッジ複合材(9´)の要部拡大構成断面図を示す。
【図4】 比較例1の樹脂エッジ複合ボード(10)の構成断面図を示す。
【図5】 比較例2の樹脂エッジ複合ボード(10´)の構成断面図を示す。
【符号の説明】
1 木質系基材
3 樹脂層
4 樹脂エッジ基材
5 化粧材
6 上曲面
7 下曲面
8a 化粧材の端部
8b 化粧材の端部
8c 化粧材の端部
9 樹脂エッジ複合材
9´ 樹脂エッジ複合材
10 樹脂エッジ複合ボード
10´ 樹脂エッジ複合ボード
[0001]
[Industrial application fields]
The present invention relates to a method for producing a resin edge composite material.
[0002]
[Prior art]
Conventionally, materials for housing-related products that have a decorative board bonded to the surface of a wooden base material have been widely used. In recent years, a resin edge composite board in which a decorative material is bonded to the surface of a wooden base material and a resin layer is formed on the periphery has been known.
[0003]
[Problems to be solved by the invention]
However, most of the resin edge composite boards are a method in which a decorative material is bonded to the surface of a wooden base material, and then a groove is formed and the resin is injected. Therefore, a thin decorative material of 0.6 to 1.2 mm is used. In some cases, accuracy is required to cut the groove at a depth reaching the decorative material, and a part of the decorative material protruding from the wooden base material may be damaged during the work. Therefore, a thin cosmetic material of 0.6 mm or less could hardly cope.
[0004]
In addition, the finished resin edge composite board has a boundary between the decorative material and the resin edge material on or in the vicinity of the wooden base material, so if it is used for a long time, it will be susceptible to temperature and humidity. Due to the dimensional shrinkage of the base material, there is a gap at the boundary between the decorative material and the resin edge material, and water may invade from the gap to the woody base material. As a result, the woody base material may swell and a step may be formed at the boundary between the decorative material and the resin edge material, or the resin edge composite board may be deformed, which is somewhat inconvenient for kitchen use where water resistance is required. there were.
[0005]
[Means for Solving the Problems]
The present invention has been studied to solve the above-mentioned problems, and is a method for producing a resin edge composite material (9) based on the following steps (A) to (C).
(A) A step of forming a concave groove in the wooden substrate (1) and injecting a synthetic resin into the concave groove,
(B) After curing the synthetic resin, chamfering the resin layer (3) to obtain a resin edge substrate (4);
(C) A step of bonding a decorative material (5) to the surface of the resin edge substrate (4), and finishing the end surface so that the end of the decorative material (5) is positioned on the surface of the resin layer (3). .
Hereinafter, the present invention will be described in detail.
[0006]
As the woody base material (1) used in the present invention, plywood, particle board, MDF (medium density fiber board), laminated material, or a composite material combining these can be applied. Thickness and material selection are determined in consideration of strength and handleability.
[0007]
The synthetic resin to be injected into the groove formed in the wooden substrate (1) may be any resin that has an adhesive effect on the wooden substrate (1) and has a reinforcing effect, such as an epoxy resin, Thermosetting resins such as urethane resins and polyester resins, and normal adhesives and caulking agents can be applied. Among them, room temperature curable thermosetting resins with high resin content such as epoxy, urethane and polyester It is desirable from the viewpoint of workability, adhesion, strength after curing, and the addition of chip-like or thread-like fibers made of glass fiber, synthetic fiber, and carbon fiber is excellent in terms of impact strength. In addition, resins modified by adding various fillers, colorants, and extenders may be used.
[0008]
In order to bond the decorative material (5) to the resin edge substrate (4) having the resin layer (3) formed by curing the synthetic resin on the side surface of the wooden substrate (1), the wooden substrate (1) A resin layer (3) and a decorative material (5) may be bonded and pressure-molded using a conventionally known adhesive suitable for the three types, for example, an aqueous vinyl urethane adhesive, urethane adhesive Vacuum forming may be performed using an adhesive, a vinyl acetate adhesive, a urea adhesive, an epoxy adhesive, or a synthetic rubber adhesive.
[0009]
In particular, when vacuum forming is performed, positioning is required when the decorative material (5) is placed on the resin edge base material (4). A urethane-based adhesive that exhibits is preferable. Conditionally, it may be performed at a temperature of 100 to 160 ° C., a pressure of 1 to 3 kg / cm 2 , and a time of about 1 to 5 minutes, and the wooden base material (1) and the decorative material (5) are bent without being damaged. It only needs to be able to adhere.
[0010]
The decorative material (5) is not particularly limited as long as it has excellent surface properties such as heat resistance, water resistance and impact resistance, and has a bendability of 1 to 50 mmR at room temperature or under heating conditions. Melamine resin decorative board and diallyl phthalate resin decorative board obtained by impregnating the base paper with a resin solution containing melamine resin, guanamine resin, diallyl phthalate resin, unsaturated polyester resin, etc. as the main component and hot pressing with the core material And a thermosetting resin decorative board.
[0011]
If the end (8a, 8b ) on the resin layer (3) side of the decorative material (5) is far from the woody base material (1), water droplets may enter and not reach the woody base material as shown in FIG. As shown in FIG. 3, the resin layer (3) may be placed at any position on the upper curved surface (6) and the lower curved surface (7).
Hereinafter, the present invention will be described in detail based on examples and drawings.
[0012]
【Example】
Example 1
After selecting MDF (medium density fiberboard) with a thickness of 21 mm as the woody base material (1), cutting the groove, injecting an unsaturated polyester resin as a synthetic resin into the groove and curing, resin layer (3) Was chamfered so that the upper curved surface (6) was 50 mmR and the lower curved surface (7) was 3 mmR to obtain a resin edge substrate (4). Next, after applying a urethane adhesive (trade name Aika Aibon W-654 manufactured by Aika Kogyo Co., Ltd.), placing a diallyl phthalate resin decorative board with a thickness of 0.45 mm as a decorative material (5), and adjusting the position, Molding was performed using a vacuum press at a temperature of 140 ° C., a time of 3 minutes, and a pressure of 1 kg / cm 2 . Thereafter, as shown in FIG. 2, the end surface is finished so that the end (8a) of the decorative material (5) is positioned on the upper curved surface (6 ) of the resin layer (3), and the resin edge composite of Example 1 is finished. Material (9) was obtained.
[0013]
Example 2
As shown in FIG. 3, chamfering is performed so that the upper curved surface (6) is 30 mmR and the lower curved surface (7) is 15 mmR, and the decorative material (5) and the resin are formed on the lower curved surface (7) of the resin layer (3). except that an end portion of the layer (8b) has finished the end face so as to be positioned is to obtain a resin edge composite material of example 2 was processed in the same manner as in example 1 (9 ').
[0014]
Comparative Example 1
What was processed so that the edge part (8c) of a cosmetic material and a resin layer might become the same as FIG. 4 using MDF, thermosetting resin, adhesive agent, and cosmetic material of the same quality as Example 1. The resin edge composite board (10) of Comparative Example 1 was obtained.
[0015]
Comparative Example 2
What was processed so that the edge part (8c) of a cosmetic material and a resin layer might become the same as shown in FIG. 5 using MDF, thermosetting resin, adhesive agent, and cosmetic material of the same quality as Example 1. The resin edge composite board (10 ′) of Comparative Example 2 was obtained.
[0016]
The evaluation results are shown in Table 1.
[Table 1]
Water resistance: The surface to which the cosmetic material was adhered based on the JAS water resistance A test (1 hour in 80 ± 3 ° C. warm water, 2 hours in a 60 ± 3 ° C. incubator twice, left until reaching room temperature) The test was conducted 1 test per day for 5 consecutive days, and the appearance was visually confirmed.
The boundary part between the decorative material and the resin layer was confirmed visually or by touch, and the gap was measured with a gap gauge for the gaps.
[0017]
【The invention's effect】
In the resin edge composite material (9, 9 ') obtained by the production method of the present invention, the end portion ( 8a, 8b) on the resin layer (3) side of the decorative material (5) is not on the wood base (1), Also, since it is not flush with the resin layer and is on the surface of the resin layer (3), it is very unlikely to be affected by dimensional changes, and even when water enters, it does not reach the woody base material. Does not cause peeling or deformation.
[0018]
Moreover, in the manufacturing method of this invention, after forming a ditch | groove in a wood type base material (1), inject | pouring a synthetic resin into this ditch | groove and forming a resin layer (3), the whole surface of this resin layer (3) or Since the decorative material (5) is adhered to the surface while including a part, the decorative material (5) that protrudes from the woody base material during operation is not partially damaged.
[0019]
In addition, since the manufacturing method of the present invention does not include a step of cutting the groove at a depth reaching the decorative material, even a thin decorative material having a thickness of 0.6 mm or less can sufficiently cope with it.
[Brief description of the drawings]
FIG. 1 shows a perspective view of a resin edge composite material (9) of Example 1. FIG.
FIG. 2 shows an enlarged cross-sectional view of a main part taken along line AA in FIG.
FIG. 3 is an enlarged cross-sectional view of a main part of a resin edge composite material (9 ′) of Example 2.
FIG. 4 is a structural cross-sectional view of a resin edge composite board (10) of Comparative Example 1;
FIG. 5 is a structural cross-sectional view of a resin edge composite board (10 ′) of Comparative Example 2;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Wood type base material 3 Resin layer 4 Resin edge base material 5 Cosmetic material 6 Upper curved surface 7 Lower curved surface 8a End portion 8b of cosmetic material End portion 8c End portion of cosmetic material 9 Resin edge composite material 9 'Resin edge composite Material 10 Resin edge composite board 10 'Resin edge composite board

Claims (1)

次の(A)〜(C)のステップに基づく樹脂エッジ複合材(9)の製法。
(A)木質系基材(1)に凹溝を形成し該凹溝に合成樹脂を注入するステップ、
(B)該合成樹脂を硬化させた後、樹脂層(3)を面取り加工して、樹脂エッジ基材(4)を得るステップ、
(C)該樹脂エッジ基材(4)の表面に化粧材(5)を接着し、該樹脂層(3)の表面に、化粧材(5)の端部が位置するように端面を仕上げるステップ。
A method for producing a resin edge composite material (9) based on the following steps (A) to (C).
(A) A step of forming a concave groove in the wooden substrate (1) and injecting a synthetic resin into the concave groove,
(B) After curing the synthetic resin, chamfering the resin layer (3) to obtain a resin edge substrate (4);
(C) A step of bonding a decorative material (5) to the surface of the resin edge base material (4) and finishing the end surface so that the end of the decorative material (5) is positioned on the surface of the resin layer (3). .
JP14105796A 1996-05-10 1996-05-10 Manufacturing method of resin edge composite material Expired - Fee Related JP3763324B2 (en)

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Application Number Priority Date Filing Date Title
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JP3763324B2 true JP3763324B2 (en) 2006-04-05

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