JP5035652B2 - 分散体の製造方法、分散体、塗料、塗膜、及びフィルム - Google Patents
分散体の製造方法、分散体、塗料、塗膜、及びフィルム Download PDFInfo
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- JP5035652B2 JP5035652B2 JP2012514668A JP2012514668A JP5035652B2 JP 5035652 B2 JP5035652 B2 JP 5035652B2 JP 2012514668 A JP2012514668 A JP 2012514668A JP 2012514668 A JP2012514668 A JP 2012514668A JP 5035652 B2 JP5035652 B2 JP 5035652B2
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- B01F33/80—Mixing plants; Combinations of mixers
- B01F33/836—Mixing plants; Combinations of mixers combining mixing with other treatments
- B01F33/8361—Mixing plants; Combinations of mixers combining mixing with other treatments with disintegrating
- B01F33/83613—Mixing plants; Combinations of mixers combining mixing with other treatments with disintegrating by grinding or milling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/12—Esters of monohydric alcohols or phenols
- C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
- C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
- C08F220/1802—C2-(meth)acrylate, e.g. ethyl (meth)acrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof
- C08F222/10—Esters
- C08F222/1006—Esters of polyhydric alcohols or polyhydric phenols
- C08F222/106—Esters of polycondensation macromers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- 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
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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Description
内部にメディアが充填されたベッセル(p)、
回転シャフト(q)、
前記回転シャフト(q)と同軸状に回転軸を有し、前記回転シャフトの回転駆動により回転する攪拌翼(r)、
前記ベッセル(p)に設置されたスラリーの供給口(s)、
前記ベッセル(p)に設置されたスラリーの排出口(t)、及び
前記回転シャフトがベッセルを貫通する部分に配設された軸封装置(u)とを有する湿式ボールミルであって、前記軸封装置(u)が2つのメカニカルシールユニットを有し、かつ、該2つのメカニカルシールユニットのシール部が外部シール液によりシールされた構造を有する湿式ボールミルを用いることにより、多官能のアクリレートモノマーやオリゴマーを分散媒として用いても、アクリロイル基の重合による増粘やゲル化が生じず、無機微粒子の粉砕と樹脂への安定分散が可能となり、その結果、経時安定性に優れ、高不揮発分率であり、硬化塗膜が高硬度と高い透明性とを兼備する無機微粒子分散型樹脂組成物を簡便かつ効率的に製造できること等を見出し、本発明を完成させるに至った。
内部にメディアが充填されたベッセル(p)、
回転転シャフト(q)、
前記回転シャフト(q)と同軸状に回転軸を有し、前記回転シャフトの回転駆動により回転する攪拌翼(r)、
前記ベッセル(p)に設置されたスラリーの供給口(s)、
前記ベッセル(p)に設置されたスラリーの排出口(t)、及び
前記回転シャフトがベッセルを貫通する部分に配設された軸封装置(u)とを有する湿式ボールミルであって、前記軸封装置(u)が2つのメカニカルシールユニットを有し、かつ、該2つのメカニカルシールユニットのシール部が外部シール液によりシールされた構造を有する湿式ボールミルを用い、
前記供給口(s)から前記ベッセル(p)に供給し、前記ベッセル(p)内で回転シャフト(q)及び攪拌翼(r)を回転させて、メディアとスラリーとを攪拌混合することにより、スラリー中の無機微粒子(C)の粉砕と、該無機微粒子(C)の活性エネルギー線硬化型化合物(A)及び活性エネルギー線硬化型化合物(B)への分散を行い、次いで前記排出口から排出することを特徴とする分散体の製造方法に関する。
カラム ; 東ソー株式会社製ガードカラムHXL−H
+東ソー株式会社製 TSKgel G5000HXL
+東ソー株式会社製 TSKgel G4000HXL
+東ソー株式会社製 TSKgel G3000HXL
+東ソー株式会社製 TSKgel G2000HXL
検出器 ; RI(示差屈折計)
データ処理:東ソー株式会社製 SC−8010
測定条件: カラム温度 40℃
溶媒 テトラヒドロフラン
流速 1.0ml/分
標準 ;ポリスチレン
試料 ;樹脂固形分換算で0.4重量%のテトラヒドロフラン溶液をマイクロフィルターでろ過したもの(100μl)
前記アクリル重合体のポリ(メタ)アクリレート(E1)の原料として用いるエポキシ基を有する(メタ)アクリル系重合体(e1)は、例えば、(メタ)アクリロイル基及びエポキシ基を有する重合性単量体(G)の単独重合反応や、他の重合性単量体(H)との共重合反応によって得られる。
前記アクリル重合体のポリ(メタ)アクリレート(E2)の原料として用いるカルボキシル基を有する(メタ)アクリル系重合体(e3)は、例えば、(メタ)アクリロイル基及びカルボキシル基を有する重合性単量体(J)の単独重合反応や、他の重合性単量体(K)との共重合反応によって得られる。
前記アクリル重合体のポリ(メタ)アクリレート(E3)の原料として用いる水酸基を有する(メタ)アクリル系重合体(e5)は、例えば、(メタ)アクリロイル基及び水酸基を有する重合性単量体(L)の単独重合反応や、他の重合性単量体(M)との共重合反応によって得られる。
本願発明で用いる無機微粒子(C)は、特に限定されるものではないが、例えば、シリカ、アルミナ、ジルコニア、チタニア、チタン酸バリウム、三酸化アンチモン等が挙げられる。これらはそれぞれ単独で用いても良いし、二種類以上を併用しても良い。
本発明の分散体の製造方法は、前記したスラリーを、
内部にメディアが充填されたベッセル(p)、
回転シャフト(q)、
前記回転シャフト(q)と同軸状に回転軸を有し、前記回転シャフトの回転駆動により回転する攪拌翼(r)、
前記ベッセル(p)に設置されたスラリーの供給口(s)、
前記ベッセル(p)に設置されたスラリーの排出口(t)、及び
前記回転シャフトがベッセルを貫通する部分に配設された軸封装置(u)とを有する湿式ボールミルであって、前記軸封装置(u)が2つのメカニカルシールユニットを有し、かつ、該2つのメカニカルシールユニットのシール部が外部シール液によりシールされた構造を有する湿式ボールミルを用い、
前記供給口(s)から前記ベッセル(p)に供給し、前記ベッセル(p)内で回転シャフト(q)及び攪拌翼(r)を回転させて、メディアとスラリーとを攪拌混合することにより、スラリー中の無機微粒子(C)の粉砕と、該無機微粒子(C)の活性エネルギー線硬化型化合物(A)及び活性エネルギー線硬化型化合物(B)への分散を行い、次いで前記排出口から排出することを特徴とする。
カラム ; 東ソー株式会社製ガードカラムHXL−H
+東ソー株式会社製 TSKgel G5000HXL
+東ソー株式会社製 TSKgel G4000HXL
+東ソー株式会社製 TSKgel G3000HXL
+東ソー株式会社製 TSKgel G2000HXL
検出器 ; RI(示差屈折計)
データ処理:東ソー株式会社製 SC−8010
測定条件: カラム温度 40℃
溶媒 テトラヒドロフラン
流速 1.0ml/分
標準 ;ポリスチレン
試料 ;樹脂固形分換算で0.4重量%のテトラヒドロフラン溶液をマイクロフィルターでろ過したもの(100μl)
撹拌装置、冷却管、滴下ロートおよび窒素導入管を備えた反応装置に、メチルイソブチルケトン500質量部を仕込み、撹拌しながら系内温度が110℃になるまで昇温し、次いで、グリシジルメタアクリレート250質量部、メチルメタクリレート80質量部、エチルアクリレート40質量部およびt−ブチルパーオキシ−2−エチルヘキサノエート(日本乳化剤株式会社製「パーブチルO」)5.5質量部からなる混合液を2時間かけて滴下ロートより滴下した後、110℃で15時間保持した。次いで、90℃まで降温した後、メトキノン5質量部およびアクリル酸130質量部を仕込んだ後、トリフェニルホスフィン2.6質量部を添加後、さらに100℃まで昇温して8時間保持し、アクリルアクリレートA1のメチルイソブチルケトン溶液997質量部を得た。該アクリルアクリレート1の各性状値は以下のようであった。不揮発分:50.7質量%、ガードナー粘度(25℃):Z4−Z5、ガードナーカラー:1以下、酸価:1.5、GPCによるスチレン換算重量平均分子量(Mw):24,000、固形分換算の理論アクリル当量:180g/eq
撹拌装置、冷却管、滴下ロートおよび窒素導入管を備えた反応装置に、メチルイソブチルケトン500質量部を仕込み、撹拌しながら系内温度が110℃になるまで昇温し、次いで、グリシジルメタアクリレート180質量部、メチルメタアクリレート230質量部、n−ブチルメタクリレート10質量部およびt−ブチルパーオキシ−2−エチルヘキサノエート(日本乳化剤株式会社製「パーブチルO」)17.2質量部からなる混合液を2時間かけて滴下ロートより滴下した後、110℃で15時間保持した。次いで、90℃まで降温した後、メトキノン5質量部およびアクリル酸80質量部を仕込んだ後、トリフェニルホスフィン2.6質量部を添加後、さらに100℃まで昇温して8時間保持し、アクリルアクリレート2のメチルイソブチルケトン溶液997質量部を得た。該アクリルアクリレートA2の各性状値は以下のようであった。不揮発分:50.7質量%、ガードナー粘度(25℃):U、ガードナーカラー:1以下、酸価:1.0、GPCによるスチレン換算重量平均分子量(Mw):7,400、固形分換算の理論アクリル当量:400g/eq
前記合成例1で得たアクリルアクリレートA1のメチルイソブチル溶液60質量部(60質量部中アクリルアクリレートA1は30.42質量部)、ジペンタエリスリトールヘキサアクリレート(以下、「DPHA」と略記する)30質量部、アエロジルR711(日本アエロジル株式会社製「アエロジルR711」、平均一次粒子径12nmのシリカ微粒子)40質量部、及びMIBK70質量部を配合しスラリーを得た。該スラリーは100質量部中にMIBK49.8質量部を含む。
1.硬化塗膜の作成方法
前記塗料を、トリアセチルセルロース(TAC)フィルム(膜厚40um)上にバーコーターで塗布し(膜厚10μm)、70℃で1分乾燥させ、窒素下で高圧水銀灯を用いて250mJ/cm2の照射量で通過させて硬化させることにより、硬化塗膜を有する試験片を得た。
2.鉛筆硬度試験方法
上記試験片の硬化被膜をJIS K 5400に従い荷重500gの鉛筆引っかき試験によって評価した。
1.硬化塗膜の作成方法
上記鉛筆硬度試験の場合と同様の方法で塗膜を作成した。
2.透明性試験方法
スガ試験機株式会社製「ヘーズコンピュータHZ−2」を用いて塗膜のヘーズ値を測定した。ヘーズ値が低いほど塗膜の透明性は高い。
前記塗料を、40℃、20℃、及び−20℃の3つの温度条件下で14日間貯蔵し、それぞれの温度条件下における貯蔵安定性を試験した。
○:凝集物が見られない
×:凝集物が見られる
スラリーの組成を表1−1及び表1−2に示す配合とした以外は実施例1と同様にして塗料を得た。これらについて実施例1と同様の試験を行った。結果を表1−1及び1−2に示す。
表1−2に示す配合で得られたスラリーを450kg用い、図1に示した湿式ボールミルY(内容量:10L)を用い、かつ、図3に示した循環式分散サイクルにより混合・分散を行った。
スラリーの組成を表1−2に示す配合とした以外は実施例15と同様にして塗料を得、実施例1と同様の試験を行った。結果を表1−2に示す。
・アエロジルR711:日本アエロジル株式会社製「アエロジル711」一次平均粒子径12nmのシリカ微粒子
・アエロジル50:日本アエロジル社株式会社製「アエロジル50」一次平均粒子径30nmのシリカ微粒子
・アエロジル200:日本アエロジル株式会社製「アエロジル200」一次平均粒子径12nmのシリカ微粒子
・アエロジル300:日本アエロジル株式会社製「アエロジル300」一次平均粒子径7nmのシリカ微粒子
・アエロジルR7200:日本アエロジル株式会社製「アエロジル7200」一次平均粒子径12nmのシリカ微粒子
・アエロジルNAX50:日本アエロジル株式会社製「アエロジルNAX50」一次平均粒子径30nmのシリカ微粒子
・アエロジルR8200:日本アエロジル株式会社製「アエロジル8200」一次平均粒子径12nmのシリカ微粒子
・UEP100:第一稀元素化学工業株式会社製「UEP100」一次平均粒子径6nmのジルコニア微粒子
・SPZ100:第一稀元素化学工業株式会社製「SPZ100」一次平均粒子径20nmのジルコニア微粒子
・T−1:三菱マテリアル電子化成株式会社製「T−1」一次粒子径20nmのスズ−アンチモン系酸化物の微粒子
・Al2O3:CIKナノテック株式会社製「ナノテックAl2O3」一次平均粒子径30nmのアルミナ微粒子
前記合成例1で得たアクリルアクリレートA1のメチルイソブチルケトン溶液60質量部(60質量部中アクリルアクリレートA1は30.42質量部)、UEP100(第一稀元素化学工業株式会社製「UEP100」、平均一次粒子径6nmのジルコニア微粒子)40質量部、及びMIBK70質量部を配合しスラリーを得た。該スラリーは100質量部中にMIBK58.6質量部を含む。
前記合成例1で得たアクリルアクリレートA1のメチルイソブチルケトン溶液60質量部(60質量部中アクリルアクリレートA1は30.42質量部)、ジペンタエリスリトールヘキサアクリレート30質量部、MEK−ST(日産化学株式会社製「MEK−ST」、コロイダルシリカ)40質量部、MIBK70質量部、及び光開始剤(チバスペシャルティケミカルズ社製「イルガキュア#184」)4質量部を混合し、塗料を得た。該塗料について、実施例1と同様の試験を行い、結果を表2に示した。
前記合成例1で得たアクリルアクリレートA1のメチルイソブチルケトン溶液60質量部(60質量部中アクリルアクリレートA1は30.42質量部)、アエロジルR711(日本アエロジル株式会社製「アエロジルR711」、平均一次粒子径12nmのシリカ微粒子)40質量部、及びMIBK70質量部を配合しスラリーを得た。該スラリーは100質量部中にMIBK49.8質量部を含む。
表2に示す配合でスラリーを得、比較例3と同様に分散を行ったところ、ミル内でゲル化が生じてしまい分散体は得られなかった。
(※)比較例1で化合物(B)は、化合物(A)、無機微粒子(C)、及び有機溶剤(S)からなる分散体に後添加した。
q1・・・・・シャフト
r1・・・・・攪拌翼
s1・・・・・スラリーの供給口
t1・・・・・スラリーの排出口
u1・・・・・軸封装置
1・・・・・・軸封装置のハウジング
2・・・・・・スクリーンタイプのセパレータ
3・・・・・・回転環
4・・・・・・固定環
5・・・・・・外部シール液供給口
6・・・・・・外部シール液排出口
7・・・・・・ベッセル外部シール液タンク
8・・・・・・ポンプ
9・・・・・・回転環3と固定環4との間に形成される間隙
10・・・・・スプリング
11・・・・・液封空間
Y・・・・・・湿式ボールミル
12・・・・・ストックタンク
13・・・・・ポンプ
14・・・・・モータ
15・・・・・製品タンク
16・・・・・バルブ
17・・・・・バルブ
18・・・・・圧縮空気又は窒素の導入口であるバルブ
19・・・・・バルブ
p2・・・・・ベッセル
q2・・・・・シャフト
r2・・・・・攪拌翼
s2・・・・・スラリーの供給口
t2・・・・・スラリーの排出口
u2・・・・・軸封装置
20・・・・・インペラタイプのセパレータ
21・・・・・軸封装置のハウジング
22・・・・・回転環
23・・・・・固定環
24・・・・・液封空間
25・・・・・外部シール液供給口
26・・・・・外部シール液排出口
27・・・・・外部シール液タンク
28・・・・・ポンプ
29・・・・・回転環22と固定環23との間に形成される間隙
30・・・・・スプリング
31・・・・・ストックタンク
32・・・・・ポンプ
33・・・・・モータ
34・・・・・製品タンク
35・・・・・バルブ
36・・・・・バルブ
37・・・・・圧縮空気又は窒素の導入口であるバルブ
38・・・・・バルブ
p3・・・・・ベッセル
q3・・・・・シャフト
r3・・・・・攪拌翼
s3・・・・・スラリーの供給口
t3・・・・・スラリーの排出口
u3・・・・・軸封装置
39・・・・・軸封装置のハウジング
40・・・・・回転スクリーンタイプのセパレータ
41・・・・・回転環
42・・・・・固定環
43・・・・・スプリング
44・・・・・回転環41と固定環42との間に形成される間隙
Claims (19)
- 重量平均分子量(Mw)が3,000〜100,000の範囲であり、分子構造中に(メタ)アクリロイル基を有し、(メタ)アクリロイル当量が100g/eq〜600g/eqの範囲である活性エネルギー線硬化型化合物(A)と、分子構造中に(メタ)アクリロイル基を3〜6個有し、分子量が100〜600の範囲である活性エネルギー線硬化型化合物(B)と、無機微粒子(C)とを必須の成分として含有するスラリーを、
内部にメディアが充填されたベッセル(p)、
回転シャフト(q)、
前記回転シャフト(q)と同軸状に回転軸を有し、前記回転シャフトの回転駆動により回転する攪拌翼(r)、
前記ベッセル(p)に設置されたスラリーの供給口(s)、
前記ベッセル(p)に設置されたスラリーの排出口(t)、及び
前記回転シャフトがベッセルを貫通する部分に配設された軸封装置(u)とを有する湿式ボールミルであって、前記軸封装置(u)が2つのメカニカルシールユニットを有し、かつ、該2つのメカニカルシールユニットのシール部が外部シール液によりシールされた構造を有する湿式ボールミルを用い、
前記供給口(s)から前記ベッセル(p)に供給し、前記ベッセル(p)内で回転シャフト(q)及び攪拌翼(r)を回転させて、メディアとスラリーとを攪拌混合することにより、スラリー中の無機微粒子(C)の粉砕と、該無機微粒子(C)の活性エネルギー線硬化型化合物(A)及び活性エネルギー線硬化型化合物(B)への分散を行い、次いで前期排出口から排出することを特徴とする分散体の製造方法。 - 前記湿式ボールミルに配設された軸封装置(u)が、前記回転シャフト(q)に固定された回転環と、前記軸封装置(u)のハウジングに固定された固定環とが、一対としてシール部を形成する様に配設された構造を有するメカニカルシールユニットを2つ有し、かつ、2つのメカニカルシールユニット間には液封空間と、これに連通する外部シール液供給口と外部シール液排出口とを有するものであって、前記外部シール液供給口から外部シール液(R)が供給され前記液封空間に液密に充填されると共に、前記シール部において回転環と固定環との間に形成される間隙が外部シール液(R)で満たされる様にシールされた状態で、スラリー中の無機微粒子(C)の粉砕と、該無機微粒子(C)の活性エネルギー線硬化型化合物(A)及び活性エネルギー線硬化型化合物(B)への分散を行う請求項1記載の分散体の製造方法。
- 前記活性エネルギー硬化型化合物(A)が分子構造中に水酸基を有し、水酸基価が90〜280mgKOH/gの範囲である請求項1記載の分散体の製造方法。
- 前記活性エネルギー線硬化型化合物(A)が、アクリル重合体のポリ(メタ)アクリレート(E)である請求項1記載の分散体の製造方法。
- 前記無機微粒子(C)がシリカ、アルミナ、ジルコニア、チタニア、チタン酸バリウム、三酸化アンチモンからなる群方選ばれる1種類以上の無機微粒子である請求項1記載の分散体の製造方法。
- 前記無機微粒子(C)の平均一次粒子径が、メジアン径で5〜300nmの範囲である請求項1記載の分散体の製造方法。
- 前記無機微粒子(C)がシリカである請求項5記載の分散体の製造方法。
- 前記メディアの平均粒子径がメジアン系で10〜1,000μmの範囲である請求項1記載の分散体の製造方法。
- 前記メディアがジルコニア微粒子である請求項1記載の分散体の製造方法。
- 0℃〜50℃の温度条件下で行うことを特徴とする請求項1記載の分散体の製造方法。
- 前記攪拌翼(r)の先端部の周速が5〜20m/secの範囲である請求項1記載の分散体の製造方法。
- 前記供給口から前記ベッセル内にスラリーを供給する際のスラリーの流量が、ベッセル容量1リットル当たり1〜100L/時間の範囲である請求項1記載の分散体の製造方法。
- 前記メディアがメジアン径400〜1,000μmの範囲であるジルコニア微粒子を用いて行うプレ分散工程と、前記メディアがメジアン径15〜400μmの範囲であるジルコニア微粒子を用いて行う本分散工程との2段階の分散工程からなる請求項1記載の分散体の製造方法。
- 前記湿式ボールミルが、更に、前記供給口と前記排出口とを繋ぐ循環路を有し、分散工程が連続的に行われる請求項1記載の分散体の製造方法。
- 請求項1〜14のいずれか一つに記載の分散体の製造方法により得られた分散体。
- 請求項15記載の分散体と、光重合開始剤(P)含むことを特徴とする塗料。
- 請求項16記載の塗料を用いて得られる塗膜。
- プラスチックフィルムの片面又は両面に請求項17記載の塗膜を塗布、活性エネルギー線を照射して形成されたフィルム。
- 前記プラスチックフィルムがトリアセチルセルロース(TAC)フィルムである請求項18記載のフィルム。
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R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |