WO2018070356A1 - 化粧シート及びその製造方法、並びに化粧材 - Google Patents
化粧シート及びその製造方法、並びに化粧材 Download PDFInfo
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- WO2018070356A1 WO2018070356A1 PCT/JP2017/036537 JP2017036537W WO2018070356A1 WO 2018070356 A1 WO2018070356 A1 WO 2018070356A1 JP 2017036537 W JP2017036537 W JP 2017036537W WO 2018070356 A1 WO2018070356 A1 WO 2018070356A1
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- WIPO (PCT)
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- layer
- thermoplastic resin
- surface protective
- decorative sheet
- protective layer
- Prior art date
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Definitions
- the present invention relates to a method for manufacturing a decorative sheet, a decorative sheet obtained by the manufacturing method, and a decorative material provided with the decorative sheet.
- Decorative sheets have been developed and developed in the process of residential construction developing as an industry.
- prefabricated architecture has played a leading role in apartments, condominiums, and individual houses that are collective housing.
- houses have been made of materials based on local characteristics, such as wood and stone, and people have lived in styles rooted in their own culture, but with the development of the housing industry, the transition from natural materials to artificial materials has progressed. Has been done.
- the heavy use of high-grade wood and stone materials can lead to deforestation and environmental problems, which is another factor that increases the demand for decorative sheets.
- the present invention has been made in view of the above circumstances, and provides a decorative sheet that exhibits scratch resistance while maintaining quality such as appearance, and has good bendability, a manufacturing method thereof, and a cosmetic material. Objective.
- the decorative sheet of 1 aspect of this invention for solving the said subject is a thermoplastic resin base material layer, a design pattern layer, a transparent thermoplastic resin layer, and A surface protective layer is formed at least in this order,
- the outermost surface of the surface protective layer has a test result of 3 or more according to European standard EN16094, The total thickness is 40 ⁇ m or more and less than 500 ⁇ m.
- the decorative material of one embodiment of the present invention for solving the above problems includes a thermoplastic resin base material layer, a pattern layer, a transparent thermoplastic resin layer, and a surface protective layer formed in this order at least.
- the outermost surface of the surface protective layer has a test result of 3 or more according to European standard EN16094, A decorative sheet having a total thickness of 40 ⁇ m or more and less than 500 ⁇ m; An adhesive layer provided on the surface of the thermoplastic resin substrate layer of the decorative sheet opposite to the pattern layer; And a base material bonded to the thermoplastic resin base material layer by the adhesive layer.
- the manufacturing method of the decorative sheet of one aspect of the present invention for solving the above problems includes a step of forming a pattern layer on one surface side of the thermoplastic resin base layer, Forming a transparent thermoplastic resin layer on the pattern layer; Forming one or more surface protective layers on the transparent thermoplastic resin layer,
- the step of forming the surface protective layer comprises applying a coating solution containing an ultraviolet curable resin and irradiating with ultraviolet light having a wavelength of 365 nm at an integrated light quantity of 100 mJ / cm 2 or more and less than 400 mJ / cm 2. Is a step of forming The total thickness was set to 40 ⁇ m or more and less than 500 ⁇ m.
- a decorative sheet that exhibits scratch resistance while maintaining quality such as appearance, and has good bendability, a manufacturing method thereof, and a cosmetic material.
- a decorative sheet (hereinafter sometimes referred to as a sheet) 10 of the present embodiment includes a thermoplastic resin base layer 1 and a pattern provided on the surface 1a side of the thermoplastic resin base layer 1.
- Pattern layer 2 transparent adhesive layer 3 provided on pattern layer 2, transparent thermoplastic resin layer 4 provided on transparent adhesive layer 3, and surface protection formed on transparent thermoplastic resin layer 4 Layer 7.
- the outermost layer located at least on the outermost side of the surface protective layer 7 is mainly composed of an ionizing radiation curable resin.
- the ionizing radiation curable resin is a synthetic resin that chemically changes from a liquid to a solid in response to the energy of ionizing radiation (for example, ultraviolet rays, ⁇ rays, ⁇ rays, or ⁇ rays).
- An example of the ionizing radiation curable resin is an ultraviolet curable resin.
- the surface protective layer 7 may be a single layer film or a laminated film in which a plurality of layers are laminated.
- FIG. 1 illustrates a case where the surface protective layer 7 is a laminated film in which two layers of a first surface protective layer 5 and a second surface protective layer 6 are laminated. This is the outermost layer located on the outermost side of the surface protective layer 7.
- the decorative sheet 10 further includes a thermoplastic resin back surface layer 8 provided on the back surface 1 b side of the thermoplastic resin base material layer 1.
- a thermoplastic resin back surface layer 8 provided on the back surface 1 b side of the thermoplastic resin base material layer 1.
- a thermoplastic resin back surface layer 8 a thermoplastic resin base material layer 1, a design pattern layer 2, a transparent adhesive layer 3, and a transparent thermoplastic resin layer 4 are laminated in this order.
- the total thickness of the decorative sheet 10 is preferably 40 ⁇ m or more and less than 500 ⁇ m, and more preferably 60 ⁇ m or more and 425 ⁇ m or less.
- thermoplastic resin base material layer 1 is made of, for example, a colored thermoplastic resin.
- thermoplastic resin for example, vinyl chloride resin, acrylic resin, polyolefin-based polypropylene resin or polyethylene resin can be used.
- polyolefin resins can be preferably used in terms of environmental compatibility, processability, and cost.
- grade and composition of the resin can be selected in consideration of ease of sheeting, printability, and suitability for bending.
- the thermoplastic resin base material layer 1 is preferably a polyolefin resin, a polyester resin or an acrylic resin having a thickness of 10 ⁇ m or more and 200 ⁇ m or less.
- the thickness of the thermoplastic resin base material layer 1 is thinner than 10 ⁇ m, the concealability and workability may be lowered.
- the thickness of the thermoplastic resin base material layer 1 is thicker than 200 ⁇ m, performance such as bending workability may be deteriorated.
- the thermoplastic resin base material layer 1 is colored, the base material to which the decorative sheet is bonded is concealed, and the hue can be appropriately selected as the background color of the pattern layer 2.
- thermoplastic resin when sheeted, it can be colored by mixing and kneading a colorant such as a pigment.
- a colored layer can be provided under the pattern layer 2 by using a coating or printing technique as a solid ink layer before the pattern layer 2 is provided.
- Pattern pattern layer 2 can be provided using a known printing technique.
- printing for forming the pattern layer 2 can be performed with a roll-to-roll printing apparatus.
- the printing method is not particularly limited, but for example, a gravure printing method can be used in consideration of productivity and picture quality.
- Any design pattern may be used in consideration of the design as a cosmetic material, and various wood grain patterns are often used for wood-based patterns. Cork patterns other than wood grain patterns are often used. It can also be. For example, if it is an image of a stone floor such as marble, it may be used as a pattern such as a marble stone.
- an artificial pattern such as an artificial pattern or a geometric pattern using these as a motif can also be used.
- the printing ink for forming the pattern layer 2 is not particularly limited, but an ink corresponding to the printing method can be appropriately selected and used. In particular, it is preferable to select in consideration of adhesion to the thermoplastic resin substrate layer 1, printability, and weather resistance as a decorative material. If necessary, an adhesive layer (not shown) may be provided on the pattern layer 2 for the purpose of improving the adhesion between the pattern layer 2 and the transparent adhesive layer 3.
- the resin used for the adhesive layer (not shown) is not particularly limited. For example, a two-component curable urethane resin or the like can be used, and can be provided using a coating apparatus or a gravure printing apparatus.
- the transparent adhesive layer 3 is provided for the purpose of strengthening the adhesion between the thermoplastic resin substrate layer 1 and the pattern layer 2 and the transparent thermoplastic resin layer 4. When this adhesion is strong, it is possible to give the decorative sheet 10 bending workability that follows a curved surface or a right angle surface.
- the transparent adhesive layer 3 is colorless and transparent or colored and transparent, and may be colored to such an extent that visible light can be transmitted.
- the transparent adhesive layer 3 is preferably a polyethylene resin or a polypropylene resin having a thickness of 5 ⁇ m or more and 30 ⁇ m or less. If the thickness of the transparent adhesive layer 3 is less than 5 ⁇ m, the peel strength may decrease due to insufficient adhesive force.
- the transparent adhesive layer 3 is more preferably a polyethylene resin or a polypropylene resin having a thickness of 10 ⁇ m to 30 ⁇ m.
- the transparent thermoplastic resin layer 4 can be made of, for example, vinyl chloride resin, acrylic resin, polyolefin-based polypropylene resin or polyethylene resin. Of these, polyolefin resins can be preferably used in terms of environmental compatibility, processability, and cost. In addition, the grade and composition of the resin can be selected in consideration of ease of sheeting, printability, and suitability for bending. In particular, in bending workability, it is important to select in consideration that whitening and cracking of the bent portion do not occur.
- the transparent adhesive layer 3 and the transparent thermoplastic resin layer 4 can be formed by, for example, co-extrusion and extruding both at the same time.
- the transparent thermoplastic resin layer 4 has an effect that the decorative sheet has a thickness and depth that are designed to increase, and can improve the weather resistance and wear resistance of the decorative sheet.
- the transparent thermoplastic resin layer 4 is colorless and transparent or colored and transparent, and may be colored to such an extent that visible light can be transmitted.
- the transparent thermoplastic resin layer 4 is preferably a polyethylene resin or a polypropylene resin having a thickness of 30 ⁇ m to 200 ⁇ m. If the thickness of the transparent thermoplastic resin layer 4 is less than 30 ⁇ m, performance such as scratch resistance and abrasion resistance may be deteriorated. Moreover, when the thickness of the transparent thermoplastic resin layer 4 is thicker than 200 ⁇ m, the performance such as bending workability may be deteriorated.
- the transparent thermoplastic resin layer 4 is more preferably a polyethylene resin or a polypropylene resin having a thickness of 50 ⁇ m or more and 150 ⁇ m or less.
- a surface protective layer 7 is formed on the transparent thermoplastic resin layer 4.
- the outermost layer located at least on the outermost side of the surface protective layer 7 is mainly composed of at least one of an ionizing radiation curable resin and a thermosetting resin.
- the thickness of the surface protective layer 7 is 3 micrometers or more and 50 micrometers or less, for example.
- two layers of a first surface protective layer 5 and a second surface protective layer 6 are provided as an example of the surface protective layer 7.
- the surface protective layer 7 may be a single layer film or a laminated film in which a plurality of layers are laminated.
- FIG. 1 illustrates the case where the surface protective layer 7 is a laminated film in which two layers are laminated.
- the outermost layer is the second surface protective layer 6 (outermost layer).
- the second surface protective layer 6 positioned at least on the outermost side of the surface protective layer 7 includes an ultraviolet curable resin and has a wavelength of 365 nm ultraviolet light, and an integrated light quantity of 100 mJ / cm 2 or more and 400 mJ / cm 2. It is formed by irradiation with less than 2 .
- the ultraviolet curable resin is a synthetic resin that chemically changes from a liquid to a solid in response to ultraviolet energy. If the ultraviolet energy is small, the curing is sweet and becomes a semi-solid state. Conversely, if the energy is large, the heat is generated and the sheet becomes defective due to flare and wrinkles.
- examples of the ultraviolet curable resin include polyfunctional HDI isocyanurate oligomers.
- examples of the thermosetting resin include a combination of a polyfunctional acrylic polyol (main agent) and an HDI isocyanate compound (curing agent).
- each layer including the surface protective layer 7 may include a matting material, for example, a silica filler.
- the UV curable resin is not particularly limited, and is a transparent polymer mainly containing a prepolymer (including oligomer) and / or a monomer containing a radical polymerizable double bond capable of undergoing a polymerization and crosslinking reaction upon irradiation with ultraviolet rays. Can be used. These prepolymers or monomers can be used alone or in combination.
- the curing reaction is usually a cross-linking curing reaction.
- a compound having in the molecule a radically polymerizable unsaturated group such as a (meth) acryloyl group or (meth) acryloyloxy group, or a cationically polymerizable functional group such as an epoxy group.
- a polyene / thiol prepolymer based on a combination of polyene and polythiol is also preferable.
- the (meth) acryloyl group means an acryloyl group or a methacryloyl group.
- Examples of the prepolymer having a radically polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, triazine (meth) acrylate, and silicone (meth) acrylate. Etc. These molecular weights are usually preferably about 250 to 100,000.
- Examples of the monomer having a radical polymerizable unsaturated group include, as monofunctional monomers, methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, phenoxyethyl (meth) acrylate, and the like.
- polyfunctional monomer examples include diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, dipentaerythritol tetra ( And (meth) acrylate, dipentaerythritol penta (meth) acrylate, and dipentaerythritol hexa (meth) acrylate.
- Examples of the prepolymer having a cationic polymerizable functional group include prepolymers of epoxy resins such as bisphenol type epoxy resins and novolac type epoxy compounds, and vinyl ether type resins such as fatty acid type vinyl ethers and aromatic vinyl ethers.
- Examples of the thiol include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.
- Examples of the polyene include those in which allyl alcohol is added to both ends of polyurethane by diol and diisocyanate.
- the ultraviolet light source for example, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, a metal halide lamp can be used.
- the wavelength of ultraviolet light is usually preferably 190 to 380 nm.
- the surface protective layer 7 has an important role in determining the superiority or inferiority in terms of bending workability, scratch resistance and cleanability.
- the role of the outermost layer is important, and the physical properties of the outermost layer are directly connected to the scratch resistance of the sheet.
- the second surface protective layer 6 (outermost layer) located at least on the outermost surface of the surface protective layer 7 contains an ultraviolet curable resin and has a wavelength of 365 nm ultraviolet light, and the integrated light quantity is 100 mJ / cm 2 or more and 400 mJ / cm.
- the outermost surface of the surface protective layer 7 exhibits a test result of 3 or more according to European standard EN16094.
- the “outermost surface” refers to the outermost surface of the first surface protective layer 5 when the surface protective layer 7 is a single layer, and the surface protective layer 7 is composed of a plurality of layers. Indicates the outermost surface of the outermost layer (for example, the second surface protective layer 6).
- the decorative sheet 10 is softened or contracted by heat rays emitted from the light source, heat generated when the surface protective layer 7 is cured, or heat generated by the heat absorption of the decorative sheet 10 itself. As a result, it becomes a cause of defects of the decorative sheet such as flare and wrinkles. Therefore, as a result of intensive studies on this point, the inventors have determined that the outermost surface of the surface protective layer 7 satisfies the conditions of the test results of the above standards, and the total thickness of the decorative sheet 10 is 40 ⁇ m or more and less than 500 ⁇ m.
- the outermost surface of the surface protective layer 7 has a test result of 3 or more according to the European standard EN16094, and the overall thickness of the decorative sheet 10 is 40 ⁇ m or more and less than 500 ⁇ m. And a decorative sheet with good bendability can be provided.
- the manufacturing method of the decorative sheet 10 of the present embodiment includes the following steps (1) to (3).
- Step of forming a pattern layer on one surface side of the thermoplastic resin substrate layer (2) Step of forming a transparent thermoplastic resin layer on the pattern layer (3)
- One layer on the transparent thermoplastic layer Step of forming the above surface protective layer
- a coating solution containing an ultraviolet curable resin is applied to emit ultraviolet light having a wavelength of 365 nm, and the integrated light quantity is 100 mJ / cm 2 or more and 400 mJ / cm 2. It is the process of forming the said surface protective layer by irradiating with less than.
- the whole thickness of the decorative sheet 10 is produced as 40 micrometers or more and less than 500 micrometers.
- the thickness is more preferably 60 ⁇ m or more and 425 ⁇ m or less.
- the said thermoplastic resin base material layer is polyolefin resin or polyester-type resin whose thickness is 10 micrometers or more and 200 micrometers or less.
- the transparent thermoplastic resin layer is preferably a polyolefin resin or a polyester resin having a thickness of 30 ⁇ m to 200 ⁇ m.
- the step of forming the surface protective layer includes the step of forming one or more first surface protective layers on the transparent thermoplastic resin layer, and the first surface. You may make it consist of the process of forming the 2nd surface protective layer used as an outermost layer on a protective layer.
- the coating liquid containing the ultraviolet curable resin is applied onto the transparent thermoplastic resin layer, and the wavelength 365 nm ultraviolet rays are applied, and the integrated light quantity is 100 mJ / cm 2 or more and 400 mJ / and forming a second surface protection layer by irradiating below cm 2.
- the thickness of the first surface protective layer is preferably 1 ⁇ m or more and less than 30 ⁇ m.
- the step of forming the surface protective layer by applying a coating liquid containing an ultraviolet curable resin and irradiating with ultraviolet light having a wavelength of 365 nm at an integrated light quantity of 100 mJ / cm 2 or more and less than 400 mJ / cm 2 .
- a coating liquid containing an ultraviolet curable resin and irradiating with ultraviolet light having a wavelength of 365 nm at an integrated light quantity of 100 mJ / cm 2 or more and less than 400 mJ / cm 2 By providing the surface protective layer as a step and setting the total thickness to 40 ⁇ m or more and less than 500 ⁇ m, it is possible to provide a decorative sheet that exhibits scratch resistance while maintaining quality such as appearance and has good bendability. it can.
- the decorative material 20 of the present embodiment includes the decorative sheet 10 and the wooden substrate 12 described above.
- the decorative sheet 10 is provided on the one surface 12 a side of the wooden substrate 12 to constitute the decorative material 20.
- An adhesive layer 11 is provided between the wooden substrate 12 and the decorative sheet 10, and the wooden substrate 12 and the decorative sheet 10 are bonded by the adhesive layer 11.
- the adhesive layer 11 and the wooden substrate 12 will be described more specifically.
- Wood base material The wood base material 12 is a plywood, a particle board, a medium density fiber board (MDF), or a hard board, for example.
- the thickness of the wooden substrate 12 is, for example, 1 mm or more and 50 mm or less.
- Adhesive layer The adhesive layer 11 includes any type of adhesive such as a thermoplastic resin, a thermosetting resin, and a rubber (elastomer). These can be used by appropriately selecting known ones or commercially available products.
- the integrated light amount of ultraviolet light having a wavelength of 365 nm is 100 mJ / cm 2 or more and less than 400 mJ / cm 2 .
- the outermost surface of the surface protective layer has a test result according to European standard EN16094 of 3 or more, and the overall thickness of the decorative sheet is 40 ⁇ m or more and less than 500 ⁇ m, thereby improving the quality such as appearance. It is possible to provide a decorative sheet and a decorative material that exhibit scratch resistance while maintaining good bending properties.
- Example 1 A decorative sheet similar to that shown in FIG. 1 was prepared by the following material configuration and procedure.
- a 25 ⁇ m polypropylene film was prepared as a thermoplastic resin substrate layer.
- One side of this polypropylene film was provided with a gravure ink (“Lamister” manufactured by Toyo Ink Manufacturing Co., Ltd.) as a pattern layer printed by a gravure printing machine.
- a gravure ink (“Lamister” manufactured by Toyo Ink Manufacturing Co., Ltd.)
- the thickness after drying the two-component urethane primer resin containing silica powder is 1 ⁇ m. Gravure coating.
- a two-component urethane resin adhesive having a polyester polyol as a main component and isophorone diisocyanate as a curing agent was applied onto the pattern layer so that the coating amount after drying was 1 g / m 2 . .
- a transparent adhesive layer maleic acid-modified polypropylene resin
- a thermosetting acrylic urethane resin manufactured by DIC Graphics Co., Ltd.
- an ultraviolet curable urethane acrylate resin manufactured by DIC Graphics
- a thermosetting acrylic urethane resin manufactured by DIC Graphics
- this coated resin was cured by ultraviolet irradiation (high pressure mercury lamp, 300 mJ / cm 2 ) to produce a decorative sheet.
- Example 2 The procedure of Example 1 except that the thickness of the entire decorative sheet was changed to 160 ⁇ m, the thickness of the thermoplastic resin base layer was changed to 60 ⁇ m, the thickness of the transparent thermoplastic resin layer was changed to 85 ⁇ m, and the integrated light quantity by ultraviolet irradiation was changed to 200 mJ / cm 2.
- a decorative sheet of Example 2 was produced in the same manner as described above.
- Example 3 The procedure of Example 1 except that the thickness of the entire decorative sheet is 215 ⁇ m, the thickness of the thermoplastic resin substrate layer is 60 ⁇ m, the thickness of the transparent thermoplastic resin layer is 140 ⁇ m, and the integrated light quantity by ultraviolet irradiation is changed to 200 mJ / cm 2.
- a decorative sheet of Example 3 was produced in the same manner as described above.
- Example 4 The procedure of Example 1 except that the thickness of the entire decorative sheet was changed to 425 ⁇ m, the thickness of the thermoplastic resin substrate layer was changed to 60 ⁇ m, the thickness of the transparent thermoplastic resin layer was changed to 350 ⁇ m, and the integrated light quantity by ultraviolet irradiation was changed to 100 mJ / cm 2.
- a decorative sheet of Example 4 was produced in the same manner as described above.
- Example 5 The decorative sheet of Example 5 was prepared in the same manner as in Example 1, except that the thickness of the entire decorative sheet was changed to 40 ⁇ m, the thickness of the thermoplastic resin base layer was changed to 10 ⁇ m, and the thickness of the transparent thermoplastic resin layer was changed to 15 ⁇ m. Produced.
- Example 6 The decorative sheet of Example 6 was prepared in the same manner as in Example 1 except that the thickness of the entire decorative sheet was changed to 495 ⁇ m, the thickness of the thermoplastic resin substrate layer was changed to 60 ⁇ m, and the thickness of the transparent thermoplastic resin layer was changed to 420 ⁇ m. Produced.
- Example 7 The procedure of Example 1 except that the thickness of the entire decorative sheet was changed to 160 ⁇ m, the thickness of the thermoplastic resin base layer was changed to 60 ⁇ m, the thickness of the transparent thermoplastic resin layer was changed to 85 ⁇ m, and the integrated light quantity by ultraviolet irradiation was changed to 380 mJ / cm 2.
- a decorative sheet of Example 7 was produced in the same manner as described above.
- Comparative Example 1 The decorative sheet of Comparative Example 1 was prepared in the same manner as in Comparative Example 1 except that the thickness of the entire decorative sheet was changed to 35 ⁇ m, the thickness of the thermoplastic resin base layer was changed to 10 ⁇ m, and the thickness of the transparent thermoplastic resin layer was changed to 10 ⁇ m. Produced.
- Comparative Example 2 The procedure of Example 1 except that the thickness of the entire decorative sheet was changed to 575 ⁇ m, the thickness of the thermoplastic resin substrate layer was changed to 60 ⁇ m, the thickness of the transparent thermoplastic resin layer was changed to 500 ⁇ m, and the integrated light quantity by ultraviolet irradiation was changed to 100 mJ / cm 2. In the same manner, a decorative sheet of Comparative Example 2 was produced.
- Example 3 The procedure of Example 1 except that the thickness of the entire decorative sheet is 215 ⁇ m, the thickness of the thermoplastic resin substrate layer is 60 ⁇ m, the thickness of the transparent thermoplastic resin layer is 140 ⁇ m, and the integrated light quantity by ultraviolet irradiation is changed to 80 mJ / cm 2. In the same manner, a decorative sheet of Comparative Example 3 was produced.
- Comparative Example 4 The procedure of Example 1 except that the thickness of the entire decorative sheet was changed to 425 ⁇ m, the thickness of the thermoplastic resin base layer was 60 ⁇ m, the thickness of the transparent thermoplastic resin layer was 350 ⁇ m, and the integrated light quantity by ultraviolet irradiation was changed to 400 mJ / cm 2. In the same manner, a decorative sheet of Comparative Example 4 was produced.
- ⁇ Micro scratch test> The test method conforms to the European standard “EN 16094”. Of the two test methods, ie, MSR-A and MSR-B, each of 5 grades of 1 to 5, 2 or less was evaluated as x, 3 as ⁇ , and 4 or more as ⁇ . The evaluation results are shown in Table 1.
- the decorative materials of Examples 1 to 7 in which the total thickness of the sheet was 40 ⁇ m or more and less than 500 ⁇ m were excellent in scratch resistance (micro scratch test), sheet appearance, and bendability.
- the cosmetic materials of Examples 1 to 3, 5 to 7 were particularly excellent in scratch resistance (micro scratch test).
- the decorative materials of Examples 2 to 4 were particularly excellent in sheet appearance, and the decorative materials of Examples 1, 2, 5, and 7 were particularly excellent in bendability. Therefore, according to the present invention, it is possible to provide a method for manufacturing a decorative sheet, a decorative sheet, and a decorative material that exhibit scratch resistance while maintaining quality such as appearance and that have good bendability.
- the decorative sheet, the manufacturing method thereof, and the decorative material according to the present invention are suitable for application to flooring materials such as houses, stores, offices, and gymnasiums, and can also be applied to other uses. .
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Abstract
Description
古来、住宅は木材や石材など地域の特性による材料を用い、また固有の文化に根ざした様式が人々の住まいであったが、住宅産業の発展とともに工業化が進み天然素材から人工素材への転換が行われてきた。あるいは近年では、高級な木材や石材を多用することが、森林破壊や環境問題に繋がる恐れがあることも、化粧シートの需要を拡大させる一要因となっている。
このように、化粧シートを化粧板等の化粧材に加工する際には、化粧シートのシワやフレアといった品質の不具合がないことを要求されることが多い。
本発明は、上記事情に鑑みてなされたものであり、外観などの品質を保ったまま耐傷付き性を発現し、折り曲げ性も良好な化粧シート及びその製造方法、並びに化粧材を提供することを目的とする。
本発明は、本発明者による上記知見に基づくものであり、上記課題を解決するための本発明の一態様の化粧シートは、熱可塑性樹脂基材層、絵柄模様層、透明熱可塑性樹脂層及び表面保護層が少なくともこの順に形成され、
上記表面保護層の最外面は、欧州規格EN16094による試験結果が3以上であり、
全体の厚みが40μm以上500μm未満である。
上記表面保護層の最外面は、欧州規格EN16094による試験結果が3以上であり、
全体の厚みが40μm以上500μm未満である化粧シートと、
上記化粧シートの上記熱可塑性樹脂基材層における上記絵柄模様層とは反対側の面に設けられる接着剤層と、
上記接着剤層によって上記熱可塑性樹脂基材層に接着される基材とを備える。
上記絵柄模様層上に透明熱可塑性樹脂層を形成する工程と、
上記透明熱可塑性樹脂層上に一層以上の表面保護層を形成する工程とを含み、
上記表面保護層を形成する工程は、紫外線硬化型樹脂を含む塗布液を塗工して波長365nm紫外線を、積算光量が100mJ/cm2以上400mJ/cm2未満で照射することによって上記表面保護層を形成する工程であり、
全体の厚みを40μm以上500μm未満とした。
以下、本発明の一実施形態について、図面を参照して説明する。
<構成>
図1に示すように、本実施形態の化粧シート(以下、シートということがある)10は、熱可塑性樹脂基材層1と、熱可塑性樹脂基材層1の表面1a側に設けられた絵柄模様層2と、絵柄模様層2上に設けられた透明接着層3と、透明接着層3上に設けられた透明熱可塑性樹脂層4と、透明熱可塑性樹脂層4上に形成された表面保護層7と、を有する。表面保護層7の少なくとも最も外側に位置する最外層は、主成分が電離放射線硬化型樹脂である。
また、この化粧シート10は、熱可塑性樹脂基材層1の裏面1b側に設けられた熱可塑性樹脂裏面層8をさらに有する。図1に示す化粧シート10において、熱可塑性樹脂裏面層8、熱可塑性樹脂基材層1、絵柄模様層2、透明接着層3及び透明熱可塑性樹脂層4が、この順に積層されている。なお、化粧シート10の全体の厚みは40μm以上500μm未満が好ましく、60μm以上425μm以下がより好ましい。
(1)熱可塑性樹脂基材層
熱可塑性樹脂基材層1は、例えば着色した熱可塑性樹脂からなる。熱可塑性樹脂としては、例えば塩化ビニル樹脂、アクリル樹脂、またポリオレフィン系のポリプロピレン樹脂あるいはポリエチレン樹脂、などを用いることができる。なかでも環境適合性や加工性、価格の点でポリオレフィン系樹脂を好ましく用いることができる。樹脂のグレードや組成は、そのほかにシーティングの容易さや印刷適性、曲げ加工に対する適性を考慮して選択することができる。
熱可塑性樹脂基材層1を着色する場合には、化粧シートを貼り合せる基材を隠蔽し、また絵柄模様層2の下地色として色相を適宜、選択することができる。例えば熱可塑性樹脂のシーティングに際して、顔料などの着色剤を混合、練りこむなどしておくことで着色ができる。あるいは絵柄模様層2を設ける前にベタインキ層として、コーティングあるいは印刷の手法を用いて絵柄模様層2の下に着色層を設けることもできる。
絵柄模様層2は、既知の印刷手法を用いて設けることができる。熱可塑性樹脂基材層1が巻取りの状態で用意できる場合には、ロールツーロールの印刷装置で絵柄模様層2の形成のための印刷を行うことができる。印刷手法は特に限定するものではないが、生産性や絵柄の品位を考慮すれば、例えばグラビア印刷法を用いることができる。
絵柄模様は、化粧材としての意匠性を考慮して任意の絵柄模様を採用すればよく、木質系の絵柄であれば各種木目が好んで用いられることが多く、木目以外にもコルクを絵柄模様とすることもできる。例えば大理石などの石材の床をイメージしたものであれば大理石の石目などの絵柄模様として用いられることもある。また天然材料の絵柄模様以外にそれらをモチーフとした人工的絵柄模様や幾何学模様などの人工的絵柄模様も用いることができる。
また、必要な場合には、絵柄模様層2と透明接着層3との接着性向上を目的として、絵柄模様層2の上に接着層(不図示)を設けても良い。この接着層(不図示)に用いる樹脂は特に限定するものではないが、例えば2液硬化型ウレタン樹脂などを用いることができ、コーティング装置やグラビア印刷装置などを用いて設けることができる。
透明接着層3は、熱可塑性樹脂基材層1及び絵柄模様層2と、透明熱可塑性樹脂層4との接着を強固にする目的で設けられる。この接着が強固であることによって、化粧シート10に対し、曲面や直角面に追随する曲げ加工性を付与することができる。透明接着層3は、無色透明又は有色透明であり、可視光が透過可能な程度に着色されていてもよい。
透明接着層3は、厚みが5μm以上30μm以下の、ポリエチレン系樹脂又はポリプロピレン系樹脂であることが好ましい。透明接着層3の厚みが5μmよりも薄いと、接着力の不足により剥離強度が低下する恐れがある。また、透明接着層3の厚みが30μmよりも厚いと、耐傷性や耐荷重性等の性能が低下する恐れがある。透明接着層3は、厚みが10μm以上30μm以下の、ポリエチレン系樹脂又はポリプロピレン系樹脂であることがより好ましい。
透明熱可塑性樹脂層4は、例えば塩化ビニル樹脂、アクリル樹脂、またポリオレフィン系のポリプロピレン樹脂あるいはポリエチレン樹脂、などを用いることができる。なかでも環境適合性や加工性、価格の点でポリオレフィン系樹脂を好ましく用いることができる。
上記樹脂のグレードや組成は、そのほかにシーティングの容易さや印刷適性、曲げ加工に対する適性を考慮して選択することができる。特に曲げ加工性においては曲げ部の白化や割れが発生しないことを考慮して選択することが重要である。
透明接着層3と透明熱可塑性樹脂層4の形成は、例えば共押し出しで両者を同時に押し出して形成することができる。透明熱可塑性樹脂層4によって、化粧シートは意匠的に厚みや深みが出る効果を有するほか、化粧シートの耐候性、耐磨耗性能を向上させることができる。透明熱可塑性樹脂層4は、無色透明又は有色透明であり、可視光が透過可能な程度に着色されていてもよい。
透明熱可塑性樹脂層4上には、表面保護層7が形成されている。上述したように、この表面保護層7の少なくとも最も外側に位置する最外層は、主成分が電離放射線硬化型樹脂及び熱硬化型樹脂の少なくとも何れか一方である。また、表面保護層7の厚みは、例えば3μm以上50μm以下である。本実施形態では、表面保護層7の一例として、第1の表面保護層5及び第2の表面保護層6の2層が設けられている。
ここで、紫外線硬化型樹脂とは、紫外線のエネルギーに反応して、液体から固体に化学的に変化する合成樹脂のことである。この紫外線エネルギーが少ないと硬化が甘く半固体状になり、逆にエネルギーが多いと発熱してフレアやシワといったシートの不具合の要因となってしまう。
紫外線源としては、例えば、超高圧水銀灯、高圧水銀灯、低圧水銀灯、カーボンアーク灯、ブラックライト、メタルハライドランプ等の光源が使用できる。紫外線の波長としては、通常190~380nmが好ましい。
そこで、発明者らは、この点に関して鋭意検討を重ねてきた結果、表面保護層7の最外面が上記規格の試験結果の条件を満たした上で、化粧シート10全体の厚みが40μm以上500μm未満であれば、100mJ/cm2以上の紫外線エネルギーによる化粧シート10の不具合を抑制できるとの知見を得た。
したがって、表面保護層7の最外面は、欧州規格EN16094による試験結果が3以上を呈し、化粧シート10全体の厚みが40μm以上500μm未満であることによって、外観などの品質を保ったまま耐傷付き性を発現し、折り曲げ性も良好な化粧シートを提供することができる。
本実施形態の化粧シート10の製造方法としては、以下の(1)~(3)の工程を含む。
(1)熱可塑性樹脂基材層の一方の面側に絵柄模様層を形成する工程
(2)絵柄模様層上に透明熱可塑性樹脂層を形成する工程
(3)透明熱可塑性樹脂層上に一層以上の表面保護層を形成する工程
ここで、上記(3)の工程は、紫外線硬化型樹脂を含む塗布液を塗工して波長365nm紫外線を、積算光量が100mJ/cm2以上400mJ/cm2未満で照射することによって上記表面保護層を形成する工程である。
また、上記熱可塑性樹脂基材層は、厚みが10μm以上200μm以下のポリオレフィン系樹脂又はポリエステル系樹脂であることが好ましい。
また、上記透明熱可塑性樹脂層は、厚みが30μm以上200μm以下のポリオレフィン系樹脂又はポリエステル系樹脂であることが好ましい。
その場合、第2表面保護層を形成する工程が、紫外線硬化型樹脂を含む塗布液を上記透明熱可塑性樹脂層上に塗工して波長365nm紫外線を、積算光量が100mJ/cm2以上400mJ/cm2未満で照射することによって第2表面保護層を形成する工程とする。なお、このような構成においては、第1表面保護層の膜厚が1μm以上30μm未満であることが好ましい。
次に、本発明の一実施形態に係る化粧材について説明する。
図2に示すように、本実施形態の化粧材20は、上述した化粧シート10と、木質基材12とを備える。例えば、木質基材12の一方の面12a側に化粧シート10が設けられて化粧材20が構成されている。
木質基材12と化粧シート10の間には接着層11が設けられており、この接着層11により木質基材12と化粧シート10とが接着されている。
(1)木質基材
木質基材12は、例えば合板、パーティクルボード、中密度繊維板(MDF)、又はハードボード等である。木質基材12の厚みは、例えば1mm以上50mm以下である。
(2)接着層
接着層11は、例えば熱可塑性樹脂系、熱硬化型樹脂系、ゴム(エラストマー)系等のいずれのタイプの接着剤を含む。これらは、公知のものや、市販品を適宜選択して使用することができる。
本発明の実施形態によれば、表面保護層を形成する工程において、紫外線硬化型樹脂を含む塗布液を塗工後に、波長365nmの紫外線を積算光量が100mJ/cm2以上400mJ/cm2未満で照射し、全体の厚みを40μm以上500μm未満としたことで、外観などの品質を保ったまま耐傷付き性を発現し、折り曲げ性も良好な化粧シートの製造方法を提供することができる。
また、本発明の実施形態によれば、表面保護層の最外面を、欧州規格EN16094による試験結果が3以上とし、化粧シート全体の厚みが40μm以上500μm未満とすることで、外観などの品質を保ったまま耐傷付き性を発現し、折り曲げ性も良好な化粧シート及び化粧材を提供することができる。
上記の実施形態では、図1に示した化粧シート10から、化粧材20を構成する場合について説明した。しかしながら、本実施形態では、化粧シート10における木質基材12が設けられる側とは反対側に、接着材層などを介して防湿シートを備えた化粧材を構成してもよい。このような構成であっても、上記の実施形態の効果を得ることができる。
以下の材料構成及び手順によって、図1と同様な化粧シートを作成した。
(1)熱可塑性樹脂基材層として、25μmのポリプロピレンフィルムを用意した。このポリプロピレンフィルムの片面に、絵柄模様層としてグラビアインキ(東洋インキ製造(株)製「ラミスター」)で木目印刷をグラビア印刷機により印刷して設けた。
(2)次に、熱可塑性樹脂基材層の絵柄模様層が形成された面とは反対側の面に、シリカ粉末を含有する2液ウレタン系プライマー樹脂を乾燥後の厚みが1μmとなるようにグラビア塗工した。
(4)次に、透明接着層(マレイン酸変性ポリプロピレン樹脂)4μm、及びホモポリプロピレン(プライムポリマー(株)製)を主成分とした透明熱可塑性樹脂層20μmを、透明接着層が絵柄模様層側になるように共押出ラミネートした。
(5)次に、透明熱可塑性樹脂層の表面に第1の表面保護層として、熱硬化型アクリルウレタン樹脂(DICグラフィックス(株)製)を乾燥後の厚み3μmで塗工した。
化粧シート全体の厚みを160μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを85μm、紫外線照射による積算光量を200mJ/cm2に変更した以外は、実施例1の手順と同様にして実施例2の化粧シートを作製した。
(実施例3)
化粧シート全体の厚みを215μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを140μm、紫外線照射による積算光量を200mJ/cm2に変更した以外は、実施例1の手順と同様にして実施例3の化粧シートを作製した。
化粧シート全体の厚みを425μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを350μm、紫外線照射による積算光量を100mJ/cm2に変更した以外は、実施例1の手順と同様にして実施例4の化粧シートを作製した。
(実施例5)
化粧シート全体の厚みを40μm、熱可塑性樹脂基材層の厚みを10μm、透明熱可塑性樹脂層の厚みを15μmに変更した以外は、実施例1の手順と同様にして実施例5の化粧シートを作製した。
化粧シート全体の厚みを495μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを420μmに変更した以外は、実施例1の手順と同様にして実施例6の化粧シートを作製した。
(実施例7)
化粧シート全体の厚みを160μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを85μm、紫外線照射による積算光量を380mJ/cm2に変更した以外は、実施例1の手順と同様にして実施例7の化粧シートを作製した。
化粧シート全体の厚みを35μm、熱可塑性樹脂基材層の厚みを10μm、透明熱可塑性樹脂層の厚みを10μmに変更した以外は、比較例1の手順と同様にして比較例1の化粧シートを作製した。
(比較例2)
化粧シート全体の厚みを575μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを500μm、紫外線照射による積算光量を100mJ/cm2に変更した以外は、実施例1の手順と同様にして比較例2の化粧シートを作製した。
化粧シート全体の厚みを215μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを140μm、紫外線照射による積算光量を80mJ/cm2に変更した以外は、実施例1の手順と同様にして比較例3の化粧シートを作製した。
(比較例4)
化粧シート全体の厚みを425μm、熱可塑性樹脂基材層の厚みを60μm、透明熱可塑性樹脂層の厚みを350μm、紫外線照射による積算光量を400mJ/cm2に変更した以外は、実施例1の手順と同様にして比較例4の化粧シートを作製した。
実施例1~7、及び比較例1~4の各化粧シートを、厚み3mmのMDF(広葉樹)の表面に貼り合わせた。化粧シートをMDFに貼り合わせる際、接着剤として2液水性エマルジョン接着剤(中央理化工業(株)製「リカボンド」(質量比BA-10L/BA-11B=100:2.5))をウェット状態で100g/m2の坪量で塗工した。このように接着剤を用いて貼り合わせた後、24時間養生して化粧材とした。
得られた化粧材を以下の方法により評価した。評価結果を表1に示す。
試験方法は欧州規格「EN 16094」に準じる。2種類の試験方法すなわちMSR-AとMSR-Bの、それぞれ1~5の5段階での評価のうち、2以下を×、3を○、4以上を◎とした。評価結果を表1に示す。
フレア、シワの程度を評価した。評価結果を表1に示す。なお、評価基準は、下記のとおりである。
◎:シートにフレア又はシワがほぼ全く見られない場合。
○:シートにフレア又はシワが見られない場合。
×:シートにフレア又はシワが見られる場合。
化粧シートを90度に折り曲げ、大きなクラックが発生した場合を×、クラックが少量発生した場合を○、クラックが発生しない場合を◎として評価した。評価結果を表1に示す。
よって、本発明によれば、外観などの品質を保ったまま耐傷付き性を発現し、折り曲げ性も良好な化粧シートの製造方法、化粧シート、及び化粧材を提供することができる。
2 絵柄模様層
3 透明接着層
4 透明熱可塑性樹脂層
5 第1の表面保護層
6 第2の表面保護層(最外層)
7 表面保護層
10 化粧シート
11 接着層
12 木質基材
20 化粧材
Claims (7)
- 熱可塑性樹脂基材層、絵柄模様層、透明熱可塑性樹脂層及び表面保護層が少なくともこの順に形成され、
前記表面保護層の最外面は、欧州規格EN16094による試験結果が3以上であり、
全体の厚みが40μm以上500μm未満であることを特徴とする化粧シート。 - 前記熱可塑性樹脂基材層は、厚みが10μm以上200μm以下のポリオレフィン系樹脂又はポリエステル系樹脂である請求項1に記載の化粧シート。
- 前記透明熱可塑性樹脂層は、厚みが30μm以上200μm以下のポリオレフィン系樹脂又はポリエステル系樹脂である請求項1又は2に記載の化粧シート。
- 前記表面保護層が、前記透明熱可塑性樹脂層上に形成される一層以上の第1表面保護層と、最外層となる第2の表面保護層とからなり、
第1表面保護層が膜厚1μm以上30μm未満で形成されている請求項1~3のいずれか一項に記載の化粧シート。 - 請求項1~4のいずれか一項に記載の化粧シートと、
前記化粧シートの前記熱可塑性樹脂基材層における前記絵柄模様層とは反対側の面に設けられる接着剤層と、
前記接着剤層によって前記熱可塑性樹脂基材層に接着される基材とを備えることを特徴とする化粧材。 - 熱可塑性樹脂基材層の一方の面側に絵柄模様層を形成する工程と、
前記絵柄模様層上に透明熱可塑性樹脂層を形成する工程と、
前記透明熱可塑性樹脂層上に一層以上の表面保護層を形成する工程とを含み、
前記表面保護層を形成する工程は、紫外線硬化型樹脂を含む塗布液を塗工して波長365nm紫外線を、積算光量が100mJ/cm2以上400mJ/cm2未満で照射することによって前記表面保護層を形成する工程であり、
全体の厚みを40μm以上500μm未満としたことを特徴とする化粧シートの製造方法。 - 前記表面保護層を形成する工程が、前記透明熱可塑性樹脂層上に一層以上の第1表面保護層を形成する工程と、第1表面保護層上に最外層となる第2表面保護層を形成する工程とからなり、
第2表面保護層を形成する工程が、紫外線硬化型樹脂を含む塗布液を前記透明熱可塑性樹脂層上に塗工して波長365nm紫外線を、積算光量が100mJ/cm2以上400mJ/cm2未満で照射することによって第2表面保護層を形成する工程である請求項6に記載の化粧シートの製造方法。
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JPH09290487A (ja) * | 1996-04-24 | 1997-11-11 | Toppan Printing Co Ltd | 表面強化化粧紙とその製造方法 |
JP2001047572A (ja) * | 1999-08-04 | 2001-02-20 | Dainippon Printing Co Ltd | 建材用化粧シート |
JP2001129937A (ja) * | 1999-11-05 | 2001-05-15 | Dainippon Printing Co Ltd | 建材用化粧シート |
JP2008106591A (ja) * | 2006-03-30 | 2008-05-08 | Dainippon Printing Co Ltd | 床材用化粧シートの製造方法 |
WO2012133667A1 (ja) * | 2011-03-31 | 2012-10-04 | 大日本塗料株式会社 | 複層塗膜及び該複層塗膜の製造方法 |
JP2014084684A (ja) * | 2012-10-26 | 2014-05-12 | Toli Corp | 床材、及び床材の製造方法 |
JP2015010426A (ja) * | 2013-07-01 | 2015-01-19 | 東リ株式会社 | 床材 |
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JPH09262934A (ja) * | 1995-09-20 | 1997-10-07 | Dainippon Printing Co Ltd | リコート用化粧シート及びリコート用化粧材 |
JP3388437B2 (ja) * | 2000-02-18 | 2003-03-24 | 大日本印刷株式会社 | 化粧シート |
KR100881006B1 (ko) * | 2006-03-30 | 2009-02-03 | 다이니폰 인사츠 가부시키가이샤 | 바닥재용 화장 시트의 제조 방법 |
US10259204B2 (en) * | 2010-04-30 | 2019-04-16 | Columbia Insurance Company | Resilient flooring product and methods of making same |
KR101974216B1 (ko) * | 2010-04-30 | 2019-04-30 | 쇼 인더스트리즈 그룹, 인코포레이티드 | 비-비닐 탄성 플로어링 제품 및 그 제조 방법 |
JP5521876B2 (ja) * | 2010-08-06 | 2014-06-18 | 大日本印刷株式会社 | 化粧シート及びこれを用いた金属化粧板 |
CN115339186A (zh) * | 2015-02-20 | 2022-11-15 | 肖氏工业集团公司 | 弹性地板产品以及其制造方法 |
JP6992762B2 (ja) * | 2016-10-11 | 2022-01-13 | 凸版印刷株式会社 | 化粧シートの製造方法 |
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JPH09290487A (ja) * | 1996-04-24 | 1997-11-11 | Toppan Printing Co Ltd | 表面強化化粧紙とその製造方法 |
JP2001047572A (ja) * | 1999-08-04 | 2001-02-20 | Dainippon Printing Co Ltd | 建材用化粧シート |
JP2001129937A (ja) * | 1999-11-05 | 2001-05-15 | Dainippon Printing Co Ltd | 建材用化粧シート |
JP2008106591A (ja) * | 2006-03-30 | 2008-05-08 | Dainippon Printing Co Ltd | 床材用化粧シートの製造方法 |
JP5045180B2 (ja) | 2006-03-30 | 2012-10-10 | 大日本印刷株式会社 | 床材用化粧シートの製造方法 |
WO2012133667A1 (ja) * | 2011-03-31 | 2012-10-04 | 大日本塗料株式会社 | 複層塗膜及び該複層塗膜の製造方法 |
JP2014084684A (ja) * | 2012-10-26 | 2014-05-12 | Toli Corp | 床材、及び床材の製造方法 |
JP2015010426A (ja) * | 2013-07-01 | 2015-01-19 | 東リ株式会社 | 床材 |
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EP3527367A4 (en) | 2019-09-25 |
CN109789679A (zh) | 2019-05-21 |
US10710346B2 (en) | 2020-07-14 |
US20190176446A1 (en) | 2019-06-13 |
EP3527367A1 (en) | 2019-08-21 |
JPWO2018070356A1 (ja) | 2019-07-25 |
KR20190070315A (ko) | 2019-06-20 |
KR102449688B1 (ko) | 2022-10-05 |
CN109789679B (zh) | 2022-11-08 |
JP6992762B2 (ja) | 2022-01-13 |
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