JP6260892B2 - Molding material for light reflector, light reflector, lighting fixture, and method of manufacturing light reflector - Google Patents

Description

  Conventionally, it is known to use a light reflector (reflector) to reflect light emitted from a light emitting element such as a light emitting diode. As one of resins used for producing a light reflector, an unsaturated polyester is known (Patent Document 1). The unsaturated polyester is composed of an unsaturated polyester (alkyd) and a crosslinking agent such as styrene. Since unsaturated polyester is a thermosetting resin, when it is used, there is an advantage that the heat-reflective discoloration of the light reflector is increased.

  Furthermore, Patent Document 1 improves the flowability of the molding material by using crystalline unsaturated polyester as the unsaturated polyester, thereby improving the light reflectance by high filling of white pigment and inorganic filler, heat resistance It is disclosed to improve discoloration, improve storage shape stability, and the like.

Japanese Patent No. 5153952

  According to the results of the study by the present inventors, when a crystalline unsaturated polyester is simply contained as a thermosetting resin in a molding material for a light reflector, the light reflector is burred or the light reflector is light reflective. However, it may decrease. Further, while the required level of heat discoloration of the light reflector is increasing, the level cannot be sufficiently cleared only by using the crystalline unsaturated polyester.

The present invention has been made in view of the above-mentioned reasons, and has a good moldability, hardly causes burrs, and can further improve the light reflectivity of the light reflector, and the light reflector for this light reflector. It aims at providing the light reflector formed from a molding material, a lighting fixture provided with this light reflector, and the manufacturing method of this light reflector .

  The molding material for light reflectors according to the first aspect includes an unsaturated polyester resin and a white pigment, and the unsaturated polyester resin has a crystalline unsaturated polyester having a melting point in the range of 65 to 100 ° C. , Diallyl phthalate, isodiallyl phthalate, and a crosslinking component composed of one or more compounds selected from the group consisting of polymers of at least one of diallyl phthalate and isodiallyl phthalate.

  In the molding material for light reflectors according to the second aspect, in the first aspect, the ICI viscosity of the unsaturated polyester resin at 150 ° C. is in the range of 1 to 10 Pa · s.

  The molding material for light reflectors according to the third aspect contains an epoxy resin in the first or second aspect.

  The molding material for light reflectors according to the fourth aspect contains a phosphorus-based antioxidant in any one of the first to third aspects.

  The light reflector according to the fifth aspect is formed from the molding material for reflector according to any one of the first to fourth aspects.

  The lighting fixture which concerns on a 6th aspect is provided with the light reflection body which concerns on a 5th aspect.

  According to the present invention, the moldability when producing the light reflector from the molding material for the light reflector is good, the burr is not easily generated in the light reflector, and the light reflectance of the light reflector is improved. Its heat discoloration is also improved.

It is sectional drawing which shows a light-emitting device provided with the light reflector in one Embodiment of this invention. It is a top view which shows the light-emitting device shown in FIG. It is a perspective view which shows the base material and molded object which are used for the adhesiveness in an Example.

  The light reflector molding material according to the present embodiment (hereinafter referred to as a molding material) is used for manufacturing the light reflector 1. This molding material contains an unsaturated polyester resin and a white pigment.

  The unsaturated polyester resin contains an unsaturated polyester and a crosslinking agent. In this embodiment, unsaturated polyester contains the crystalline unsaturated polyester which has melting | fusing point within the range of 65-100 degreeC. Furthermore, a crosslinking agent contains a specific component (crosslinking component). The crosslinking component comprises one or more compounds selected from the group consisting of diallyl phthalate, isodiallyl phthalate, and a polymer of at least one of diallyl phthalate and isodiallyl phthalate.

  That is, in this embodiment, unsaturated polyester resin contains the crystalline unsaturated polyester which has melting | fusing point within the range of 65-100 degreeC, and a crosslinking component.

  When the unsaturated polyester resin contains a crosslinking component, volatilization of the crosslinking agent from the molding material is suppressed. For this reason, generation | occurrence | production of the odor from a molding material is suppressed and a working environment is improved. Further, the stability of the composition of the molding material is increased.

  In addition, the combination of the crystalline unsaturated polyester and the crosslinking component as described above brings the melting point of the crystalline unsaturated polyester close to the softening point of the crosslinking component. Is obtained. Furthermore, the glass transition point of the light reflector is increased, and the heat discoloration of the light reflector is increased.

  In addition, when the melting point of the crystalline unsaturated polyester is 100 ° C. or lower, the heating temperature at the time of heating and kneading can be 100 ° C. or lower. It is easy to melt. For this reason, the molding material which does not contain hardened | cured material is prepared easily.

  Moreover, the fall of the light reflectance of a light reflector is suppressed because melting | fusing point of crystalline unsaturated polyester is 65 degreeC or more. The reason is presumed as follows. When the molding material is pulverized by the pulverizer, if the crystalline unsaturated polyester is melted by heat generated by the pulverizer or frictional heat, the molding material becomes a slurry. When the slurry-like molding material collides with a metal part such as a rotor blade in the pulverizer, the molding material is easily rubbed in contact with the metal part. If it does so, hard components, such as a white pigment in a molding material, an inorganic filler, and a metal part will rub against each other, metal powder will arise from a metal part, and this will become easy to mix in a molding material. This metal powder is considered to cause a decrease in the light reflectance of the light reflector. However, when the melting point of the crystalline unsaturated polyester is 65 ° C. or higher, the crystalline unsaturated polyester is difficult to melt when the molding material is pulverized by the pulverizer. In this case, when the molding material collides with a metal part such as a rotor blade, the molding material is easily crushed quickly, and therefore, the friction between the molding material and the metal part is less likely to occur. For this reason, it becomes difficult for a metal powder to mix in a molding material, and, thereby, the fall of the light reflectivity of a light reflector is suppressed.

  Furthermore, the crystalline unsaturated polyester having a melting point within the range of 65 to 100 ° C. can impart an appropriate fluidity to the molding material when the molding material is molded, thereby improving the moldability. Burrs are less likely to occur in the light reflector.

  As described above, according to the present embodiment, a highly uniform molding material can be easily obtained, and the moldability when producing a light reflector from this molding material is good and burrs are less likely to occur in the light reflector. Furthermore, the light reflectance and heat discoloration of the light reflector are improved.

  The molding material according to this embodiment will be described in more detail.

  In this embodiment, the crystalline unsaturated polyester is an unsaturated polyester having crystallinity, has a melting point, is a solid at room temperature, and is a liquid having a low viscosity above the melting point. The crystalline unsaturated polyester has crystallinity, for example, when the crystalline unsaturated polyester is heated and melted and then cooled to room temperature at a rate of −10 ° C./min. And confirmed. In addition, this crystalline property is observed using a polarizing microscope when a crystalline unsaturated polyester is heated and melted and then cooled to room temperature at a rate of −10 ° C./min. Is also confirmed. Such confirmation of crystallinity is performed, for example, using a microscope cooling and heating stage manufactured by Linkam.

  The crystalline unsaturated polyester can be obtained, for example, by dehydration condensation of a polybasic acid containing an unsaturated polybasic acid and a glycol.

  The unsaturated polybasic acids are selected from the group consisting of, for example, maleic acid, maleic anhydride, fumaric acid, citraconic acid, mesaconic acid, itaconic acid, tetrahydrophthalic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, and glutaconic acid One or more compounds can be included. In particular, the unsaturated polybasic acids preferably contain fumaric acid. In this case, the moldability of the molding material and the heat discoloration of the light reflector are particularly improved.

  Polybasic acids may contain saturated polybasic acids in addition to unsaturated polybasic acids. Saturated polybasic acids are, for example, phthalic acid, phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid, azelaic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, endomethylenetetrahydrophthalic anhydride, It can contain at least one selected from the group consisting of het acid and tetrabromophthalic anhydride. In particular, the saturated polybasic acid preferably contains at least one of isophthalic acid and terephthalic acid. In this case, the moldability of the molding material and the heat discoloration of the light reflector are particularly improved.

  Examples of glycols include ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, propylene glycol, diethylene glycol, and triethylene. It may contain at least one selected from the group consisting of glycol, dipropylene glycol, neopentyl glycol, hydrogenated bisphenol A, bisphenol A propylene oxide compound, cyclohexane dimethanol, and dibromoneopentyl glycol. In particular, the glycol contains at least one selected from the group consisting of ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, and cyclohexanedimethanol. It is preferable to do. In this case, the moldability of the molding material and the heat discoloration of the light reflector are particularly improved.

  A crystalline unsaturated polyester is obtained by appropriately selecting the types and ratios of the above polybasic acids and glycols. In order to obtain a crystalline unsaturated polyester, it is particularly preferable that the unsaturated polybasic acid contains fumaric acid. When saturated polybasic acids are used, the saturated polybasic acids preferably contain at least one of isophthalic acid and terephthalic acid. The glycols contain at least one selected from the group consisting of ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, and cyclohexanedimethanol. It is preferable. It is particularly preferred if the unsaturated polybasic acids contain fumaric acid, the saturated polybasic acids contain terephthalic acid and the glycols contain 1,4-butanediol and 1,5-pentanediol.

  The acid value of the crystalline unsaturated polyester is preferably in the range of 5 to 40 mg-KOH / g.

  It is preferable that the unsaturated polyester in the molding material contains only the crystalline unsaturated polyester, but the unsaturated polyester contains non-crystalline unsaturated polyester (non-crystalline unsaturated polyester) in addition to the crystalline unsaturated polyester. You may contain. However, the ratio of the crystalline unsaturated polyester to the total amount of the crystalline unsaturated polyester and the amorphous unsaturated polyester is preferably 40% by mass or more. In this case, an increase in the viscosity of the molding material during molding is moderately suppressed, and good moldability is ensured.

  The crosslinking component will be described. As described above, the crosslinking component comprises one or more compounds selected from the group consisting of diallyl phthalate, isodiallyl phthalate, and a polymer of at least one of diallyl phthalate and isodiallyl phthalate.

  When the molding material contains a crosslinking component, the glass transition point of the light reflector is increased, and thus the heat discoloration of the light reflector is improved. This is considered due to the structural characteristics of the crosslinking component. In particular, it is assumed that the crosslinking component having two ethylenically unsaturated bonds per molecule contributes to the improvement of the glass transition point. In addition, since the cross-linking component is low in volatility, the molding material hardly emits odor, and the composition does not easily change due to volatilization of the cross-linking component. Further, when the molding material contains a crosslinking component, an increase in viscosity at the molding of the molding material is moderately suppressed. Thereby, generation | occurrence | production of the burr | flash in a light reflector is suppressed.

The weight average molecular weight of the crosslinking component is preferably in the range of 2 × 10 ^{4 to} 6 × 10 ⁴ . The weight average molecular weight is a polystyrene conversion value measured by gel permeation chromatography. Moreover, it is preferable that the melt viscosity at 120 degreeC of a crosslinking component exists in the range of 1-10 kPa / s. Moreover, it is preferable that the iodine value of a crosslinking component exists in the range of 50-100. Moreover, it is preferable that the softening point of a crosslinking component exists in the range of 50-110 degreeC.

  The crosslinking agent in the molding material preferably contains only a crosslinking component, but the crosslinking agent may contain a compound other than the crosslinking component. For example, the crosslinking agent may contain a known compound blended as a crosslinking agent in a conventional unsaturated polyester resin. For example, the crosslinking agent is a vinyl polymerizable monomer such as styrene, vinyl toluene, divinylbenzene, α-methylstyrene, methyl methacrylate, vinyl acetate; triallyl cyanurate, diallyltetrabromophthalate, phenoxyethyl acrylate, 2 A polymerizable monomer such as hydroxyethyl acrylate and 1,6-hexanediol diacrylate; and one or more compounds selected from the group consisting of prepolymers obtained by polymerizing one or more compounds among these polymerizable monomers. Can be contained.

  The ratio of the crosslinking component with respect to the total amount of the crystalline unsaturated polyester and the crosslinking component is not particularly limited, but is preferably in the range of 10 to 40% by mass. In this case, moldability is further improved by moderately suppressing an increase in the viscosity of the molding material during molding. Further, by appropriately adjusting the crosslinking point, the curability of the molding material is improved, and the heat-resistant yellowing and mechanical properties of the light reflector are improved. More preferably, this ratio is in the range of 20 to 40% by mass.

  The molding material may contain a curing catalyst. In this case, a crosslinked structure is efficiently formed by the reaction between the crystalline unsaturated polyester and the crosslinking component. For this reason, the moldability of the molding material and the shape stability of the light reflector are enhanced. The curing catalyst can contain at least one of a curing accelerator and a polymerization initiator, for example.

  The polymerization initiator can contain, for example, a heat-decomposable organic peroxide used for a molding material. Examples of the organic peroxide include t-butylperoxy-2-ethylhexyl monocarbonate, 1,1-di (t-hexylperoxy) cyclohexane, 1,1-di (t-butylperoxy) -3,3, Contains one or more compounds selected from the group consisting of 5-trimethylcyclohexane, t-butylperoxyoctate, benzoyl peroxide, methyl ethyl ketone peroxide, acetylacetone peroxide, t-butylperoxybenzoate, and dicumyl peroxide can do. In particular, the polymerization initiator preferably contains an organic peroxide having a 10-hour half-life temperature of 100 ° C. or higher. Specifically, the polymerization initiator particularly preferably contains dicumyl peroxide.

  When an unsaturated polyester resin is used, the molding material may contain a polymerization inhibitor for adjusting the curing conditions. Polymerization inhibitors include, for example, hydroquinone, monomethyl ether hydroquinone, toluhydroquinone, di-t-4-methylphenol, monomethyl ether hydroquinone, phenothiazine, t-butylcatechol, quinones such as parabenzoquinone, pyrogallol, 2,6-di- t-butyl-p-cresol, 2,2-methylene-bis- (4-methyl-6-t-butylphenol), 1,1,3-tris- (2-methyl-4-hydroxy-5-t-butylphenyl) One or more compounds selected from the group consisting of phenolic compounds such as butane can be contained.

  The molding material may contain only the unsaturated polyester resin as the thermosetting resin, but may further contain other thermosetting resins. However, the ratio of the unsaturated polyester resin to the total thermosetting resin is preferably 50% by mass or more.

  The molding material may further contain an epoxy resin as a thermosetting resin. In this case, the adhesion between the light reflector and the metal is improved. For this reason, when the light reflector is combined with a metal member such as a lead frame, the light reflector is prevented from being detached from the metal member. For this reason, the yield at the time of manufacture of a light reflector improves. In the present embodiment, the epoxy resin contains at least one compound selected from a monomer having an epoxy group, a prepolymer, and a polymer.

  When the molding material contains an epoxy resin, the ratio of the epoxy resin to the entire molding material is preferably in the range of 1 to 50% by mass, and more preferably in the range of 1 to 10% by mass.

  The epoxy resin can contain an appropriate compound as long as it has two or more epoxy groups in one molecule. For example, the epoxy resin can contain an epoxy resin synthesized from epichlorohydrin and bisphenol A or various novolacs, an alicyclic epoxy resin, or the like. In particular, the epoxy equivalent of the epoxy resin is preferably in the range of 100 to 300, and the softening point is preferably in the range of 60 to 110 ° C.

  In particular, the epoxy resin preferably contains triglycidylpropyl isocyanate (tris- (2,3-epoxypropyl) -isocyanurate, TEPIC). Triglycidyl propyl isocyanate is, for example, (2R, 2R, 2S) form ((2R, 2R, 2S) -tris- (2,3-epoxypropyl) -isocyanurate), (2S, 2S, 2R) form ((2S , 2S, 2R) -tris- (2,3-epoxypropyl) -isocyanurate), (2R, 2R, 2R) isomer ((2R, 2R, 2R) -tris- (2,3-epoxypropyl) -isocyanate Nurate) and (2S, 2S, 2S) isomer ((2S, 2S, 2S) -tris- (2,3-epoxypropyl) -isocyanurate) can be contained. Ratio of the total amount of substances of (2R, 2R, 2S) and (2S, 2S, 2R) to the total amount of substances of (2R, 2R, 2R) and (2S, 2S, 2S) The value of is preferably 4 or more. In this case, triglycidyl propyl isocyanate exhibits good fluidity at a relatively low heating temperature of about 100 ° C. For this reason, the molding material is easily kneaded at the time of preparation of the molding material, and the fluidity of the molding material is improved during the production of the light reflector using the molding material. The higher the ratio value, the better. Thereby, the light reflectivity of the light reflector is improved and the fluidity during molding of the molding material is further increased. The ratio value is particularly preferably 5 or more, more preferably 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 15 or more, or 19 or more. However, since it is difficult to obtain an optically pure compound, the ratio value is preferably 999 or less, more preferably 99 or less, 50 or less, or 25 or less.

  The epoxy resin may further contain a compound other than triglycidylpropyl isocyanate. For example, epoxy resins obtained by epoxidizing phenol and aldehyde novolak resins such as phenol novolac type epoxy resins and orthocresol novolak type epoxy resins; bisphenol A, bisphenol F, bisphenol S, alkyl-substituted biphenols Diglycidyl ether of compounds such as glycidylamine type epoxy resins obtained by reaction of polyamines such as diaminodiphenylmethane and isocyanuric acid with epichlorohydrin; linear aliphatic epoxy obtained by oxidizing olefinic bonds with peracids such as peracetic acid And one or more compounds selected from the group consisting of alicyclic epoxy resins.

  The ratio of triglycidylpropyl isocyanate to the total amount of the epoxy resin is preferably 30% by mass or more. It is also preferred that the epoxy resin contains only triglycidyl propyl isocyanate.

  When an epoxy resin is used, it is preferable that the molding material further contains a curing agent for the epoxy resin. The curing agent can contain, for example, one or more compounds selected from the group consisting of an acid anhydride curing agent, an isocyanuric acid derivative, and a phenol curing agent. The molecular weight of the curing agent is preferably in the range of 100 to 400. Moreover, it is preferable that the value of ratio of the equivalent of a hardening | curing agent with respect to the epoxy equivalent of an epoxy resin exists in the range of 0.5-2.0.

When an epoxy resin is used, the molding material may further contain a curing accelerator. Examples of the curing accelerator include tertiary amines such as 1,8-diaza-bicyclo (5,4,0) undecene-7, triethylenediamine, tri-2,4,6-dimethylaminomethylphenol; Imidazoles such as -4-methylimidazole and 2-methylimidazole; triphenylphosphine, tetraphenylphosphonium tetraphenylborate, tetra-n-butylphosphonium-o, o-diethylphosphorodithioate, tetra-n-butylphosphonium-tetra One or more compounds selected from the group consisting of phosphorus compounds such as phenylborate; quaternary ammonium salts; organometallic salts; and derivatives of the above compounds can be contained. In particular, the curing accelerator preferably contains one or more compounds selected from the group consisting of tertiary amines, imidazoles, and phosphorus compounds.
Is preferably used.

  The content of the curing accelerator is preferably 0.01 to 8.0% by mass and more preferably 0.1 to 3.0% by mass with respect to the epoxy resin.

  The white pigment imparts light reflectivity to the light reflector 1 formed from the molding material. The white pigment contains one or more materials selected from the group consisting of, for example, titanium oxide, barium titanate, strontium titanate, aluminum oxide, magnesium oxide, zinc oxide, zinc sulfide, barium sulfate, magnesium carbonate, and barium carbonate. can do.

  In particular, the white pigment preferably contains one or more materials selected from the group consisting of titanium oxide, barium titanate, barium sulfate, zinc oxide, and zinc sulfide. It is also preferable that the white pigment contains aluminum oxide having a high thermal conductivity.

  When the white pigment contains titanium oxide, the titanium oxide can contain one or more materials selected from, for example, anatase type titanium oxide, rutile type titanium oxide, and brucite type titanium oxide. In particular, since rutile type titanium oxide is excellent in thermal stability, it is preferable that the titanium oxide contains rutile type titanium oxide.

  The surface of the white pigment may be surface-treated with a fatty acid, a coupling agent or the like. In this case, aggregation, oil absorption and the like of the white pigment are suppressed, and the filling property of the white pigment in the molding material is increased.

  The average particle size of the white pigment is preferably 2.0 μm or less. The average particle size is preferably 0.01 μm or more. This average particle size is also preferably in the range of 0.03 to 1.0 μm, preferably in the range of 0.1 to 0.7 μm, and in the range of 0.2 to 0.5 μm. It is also preferable. The average particle diameter of the white pigment is measured by a laser diffraction scattering method.

  The ratio of the white pigment to the thermosetting resin in the molding material is preferably 100% by mass or more. In this case, the heat-reflecting color of the light reflector 1 is particularly high, and the light reflectivity of the light reflector 1 is particularly high. Moreover, it is preferable that the quantity of this white pigment is 300 mass% or less. In this case, the moldability of the molding material is particularly high. It is particularly preferable that the amount of the white pigment is in the range of 150 to 250% by mass.

  The molding material may further contain an inorganic filler excluding the white pigment. In this case, the light reflectivity of the light reflector 1 is further increased, and the shape stability of the light reflector 1 is further increased. Further, the inorganic filler can increase the thermal conductivity of the light reflector 1. Thereby, discoloration, deterioration, etc. due to heat of the light reflector 1 are further suppressed.

  The inorganic filler can contain, for example, one or more materials selected from the group consisting of silica, calcium carbonate, magnesium carbonate, barium carbonate, calcium hydroxide, aluminum hydroxide, magnesium oxide, barium sulfate, and mica. .

  In particular, the inorganic filler preferably contains silica. In this case, the light reflectivity of the light reflector 1 is further increased, and the shape stability of the light reflector 1 is further increased. Silica can contain, for example, one or more materials selected from fused silica powder, spherical silica powder, crushed silica powder, and crystalline silica powder. In particular, the silica preferably contains fused silica.

  It is also preferable that the inorganic filler contains a thermally conductive inorganic filler. In this case, the thermal conductivity of the light reflector becomes particularly high, and therefore, discoloration, deterioration, etc. due to heat of the light reflector 1 are further suppressed. The thermally conductive inorganic filler can contain one or more materials selected from the group consisting of thermally conductive fillers such as crystalline silica, alumina, silicon nitride, boron nitride, and aluminum nitride.

  The thermally conductive inorganic filler preferably contains a metal-containing filler, and particularly preferably contains an aluminum-containing filler. The aluminum-containing filler can contain, for example, aluminum hydroxide.

  The inorganic filler may contain hollow particles such as inorganic foam particles and silica balloons.

  The surface of the inorganic filler may be surface treated with a fatty acid, a coupling agent or the like. In this case, aggregation of the white pigment, oil absorption and the like are suppressed, and the filling property of the inorganic filler in the molding material is increased.

  The average particle size of the inorganic filler is preferably 100 μm or less. In this case, the moldability of the molding material is particularly good, and the heat discoloration and moisture resistance of the light reflector 1 are particularly high. This average particle size is preferably 0.1 μm or more. In this case, the handleability of the molding material is improved. The average particle size of the inorganic filler is more preferably 80 μm or less, and further preferably 50 μm or less. The average particle size of the inorganic filler is more preferably 0.3 μm or more. Furthermore, when the average particle size of the inorganic filler is in the range of 8 to 20 μm, the injection moldability of the molding material is particularly good. The average particle size of the inorganic filler is measured by a laser diffraction / scattering method.

  The ratio of the inorganic filler to the thermosetting resin in the molding material is preferably 40% by mass or more. In this case, the shape stability of the light reflector 1 is particularly high. The proportion of the inorganic filler is preferably 300% by mass or less. In this case, the moldability of the molding material is particularly high. It is particularly preferable if the ratio of the inorganic filler is in the range of 50 to 250% by mass.

  The ratio of the total amount of the white pigment and the inorganic filler to the entire molding material is preferably within the range of 40 to 80% by mass. In this case, the moldability of the molding material is particularly high, and the heat discoloration and light reflectivity of the light reflector 1 are particularly high. It is particularly preferable if this ratio is in the range of 50 to 70% by mass.

  The ratio of the white pigment to the total of the white pigment and the inorganic filler is preferably 30% by mass or more. In this case, the light reflectivity of the light reflector 1 is particularly high. This ratio is preferably 95% by mass or less. This ratio is more preferably in the range of 35 to 90% by mass, and further preferably in the range of 40 to 85% by mass.

  The total ratio of the white pigment and the inorganic filler to the thermosetting resin is preferably 500% by mass or less. In this case, the fluidity of the molding material during molding is particularly high. The total ratio of the white pigment and the inorganic filler is preferably 100% by mass or more. In this case, the light reflectivity of the light reflector 1 is particularly high. The total ratio of the white pigment and the inorganic filler is more preferably in the range of 100 to 400% by mass, and still more preferably in the range of 200 to 300% by mass.

  The molding material may contain a reinforcing material. In this case, curing shrinkage during molding of the molding material is suppressed, the strength of the light reflector 1 is increased, and the dimensional stability of the light reflector 1 is further increased. The reinforcing material can contain, for example, a reinforcing material used for FRP (Fiber Reinforced Plastics) such as BMC (Bulk Molding Compound) and SMC (Sheet Molding Compound).

  The reinforcing material contains, for example, one or more materials selected from glass fiber, vinylon fiber, aramid fiber, polyester fiber, wollastonite, potassium titanate whisker, carbonate whisker such as calcium carbonate, and hydrotalcite can do. In particular, the reinforcing material preferably contains glass fiber.

  Glass fiber is, for example, silicate glass, E glass (alkali-free glass for electricity), C glass (chemical alkali-containing glass), A glass (acid-resistant glass), S glass (high strength glass). One or more materials selected from the group consisting of glass fibers and the like can be contained. The glass fiber may be a long fiber (roving) or a short fiber (chopped strand). The glass fiber may be subjected to a surface treatment. In particular, the glass fiber is in the range of 3 to 6 mm in length after the E glass fiber having a fiber diameter of 10 to 15 μm is converged with a sizing agent such as vinyl acetate and subsequently surface-treated with a silane coupling agent. It is preferable to contain chopped strands cut into pieces.

  The amount of the reinforcing material with respect to 100 parts by mass of the thermosetting resin is preferably in the range of 10 to 200 parts by mass. In this case, curing shrinkage during molding of the molding material is particularly suppressed, and the strength of the light reflector 1 is particularly high. The amount of the reinforcing material is more preferably in the range of 20 to 100 parts by mass, and further preferably in the range of 30 to 80 parts by mass.

  The molding material preferably contains an antioxidant. In this case, discoloration of the light reflector is further suppressed, and the light reflectivity over time of the light reflector is further less likely to occur. The antioxidant can contain, for example, one or more compounds selected from the group consisting of phenolic antioxidants and phosphorus antioxidants. The antioxidant preferably does not contain a compound that produces a chromophore.

  It is particularly preferred that the molding material contains a phosphorus-based antioxidant. In this case, yellowing at the time of processing and yellowing over time of the light reflector are further suppressed, and thereby a decrease in light reflectance of the light reflector is further suppressed. In particular, when the molding material contains triglycidyl isocyanurate and further contains a phosphorus-based antioxidant, a decrease in the light reflectance of the light reflector is greatly suppressed.

  Phosphorous antioxidants are, for example, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, 3,9-bis (2,6-di-tert-butyl-4-methylphenoxy)- Selected from the group consisting of 2,4,8,10-tetraoxa-3,9-diphosphaspiro [5.5] undecane, bis (nonylphenyl) pentaerythritol-di-phosphite and distearyl pentaerythritol-di-phosphite One or more compounds may be contained. The proportion of the phosphorus-based antioxidant in the molding material is preferably in the range of 0.1 to 0.5% by mass.

  The molding material may contain a release agent. The mold release agent can contain one or more materials selected from the group consisting of commonly used fatty acids, fatty acid metal salts, minerals, and the like. In particular, the release agent preferably contains a fatty acid-based or fatty acid metal salt-based material having excellent heat discoloration.

  The release agent preferably contains one or more materials selected from the group consisting of stearic acid, zinc stearate, aluminum stearate, and calcium stearate.

  The amount of the release agent with respect to 100 parts by mass of the thermosetting resin is preferably in the range of 1 to 15 parts by mass. In this case, the good releasability of the light reflector 1 during molding and the excellent appearance of the light reflector 1 are compatible, and the light reflectivity of the light reflector 1 is particularly high.

  The molding material may contain appropriate additives such as a colorant, a thickener, a flame retardant, and a flexibility imparting agent in addition to the above components.

  The molding material may be solid. In this case, the storage stability and handling properties of the molding material are increased. For example, the molding material may be granular or powdery. In particular, the molding material is preferably solid at 30 ° C. or lower. In this case, the molding material can be easily processed into a granular shape by pulverization, extrusion pellet processing, or the like. It is also preferred that the molding material has shape retention at 50 ° C. or lower. In this case, handling property of the molding material and workability when using the molding material are particularly improved.

  The molding material may be prepared without a solvent. In this case, a solid molding material can be easily obtained.

  In the preparation of the molding material, for example, the raw materials as described above are first blended at a predetermined ratio and mixed with a mixer such as a mixer or a blender to obtain a mixture. This mixture is kneaded by a kneader, an extruder or the like capable of being heated and pressurized. As the kneader, for example, a pressure kneader, a heat roll, an extruder, or the like is used. The heating temperature at the time of kneading is preferably in the range of 80 to 120 ° C. In this case, the crystalline polyester is melted without being cured, so that the uniformity of the molding material is increased. Subsequently, the bulk material of the mixture is pulverized and sized, or further granulated as necessary to obtain molding materials such as granules, powders, and pellets. At the time of pulverization, the crystalline polyester is difficult to melt in the present embodiment, so that the light reflectance of the light reflector due to metal rubbing is suppressed from decreasing.

  A light reflector is obtained by molding and curing the molding material. As a molding method, an appropriate melt heating molding method such as an injection molding method, an injection compression molding method, or a transfer molding method can be applied. In particular, it is preferable to apply a transfer molding method that is inexpensive and easy to mass-produce. In the transfer molding method, the mold temperature is preferably in the range of 130 to 180 ° C., the transfer pressure is in the range of 5 to 15 MPa, and the curing time is preferably in the range of 30 to 180 seconds. Moreover, a post-cure process may be performed as needed.

  The unsaturated polyester resin in the molding material preferably has an ICI viscosity (high shear viscosity) at 150 ° C. in the range of 1 to 10 Pa · s. In this case, moderate fluidity is imparted to the molding material at the time of molding, the moldability becomes particularly good, and the generation of burrs is effectively suppressed. More preferably, this ICI viscosity is in the range of 0.2 to 6 Pa · s. If the above-mentioned crystalline unsaturated polyester and the crosslinking component are used, the ICI viscosity of the unsaturated polyester resin can be easily adjusted by appropriately adjusting the composition thereof.

  In the present embodiment, it is preferable that the maximum value of the protrusion size of the burr generated in the evaluation molded body is 5 mm or less by appropriately adjusting the fluidity during molding of the molding material. In this case, for example, since burrs are less likely to occur on the inner surface of the recess of the light reflector, it is possible to suppress the burr from hindering mounting of the light emitting element in the recess. Further, when the light emitting element on the light reflector is electrically connected to an appropriate conductor by a known method such as a wire bonding method, the burr is less likely to become an obstacle. The maximum value of the burr protrusion dimension in the molded article for evaluation is preferably 3 mm or less, and more preferably 1 mm or less.

  In FIG.1 and FIG.2, the example of the lighting fixture 6 provided with the light reflector 1 is shown. The lighting fixture 6 includes a light reflector 1, a metal lead frame 2, and a light emitting element 3. In this example, the light reflector 1 and the lead frame 2 are combined by embedding the metal lead frame 2 in the light reflector 1. In addition, the structure of the light reflector formed from the resin molding material for light reflectors which concerns on this embodiment, and a lighting fixture is not restricted only to this example.

  The light reflector 1 includes a base portion 11 and a protruding portion 12 that protrudes from the upper surface of the base portion 11. The protrusion 12 is formed with a recess 13 that opens on the upper surface thereof. The metal lead frame 2 is embedded in the base portion 11. The metal lead frame 2 includes a first lead 21 and a second lead 22. Each of the first lead 21 and the second lead 22 is exposed in the recess 13 at the bottom surface of the recess 13. The first lead 21 and the second lead 22 are disposed with a space in the base portion 11 so that the first lead 21 and the second lead 22 are electrically insulated from each other. . The first lead 21 and the second lead 22 are exposed to the outside also on the lower surface of the base portion 11. An insulating member 5 is provided on the lower surface of the base portion 11 at a position extending from the first lead 21 to the second lead 22. Suppresses the short circuit between.

  For example, a light emitting diode is used as the light emitting element 3, but is not limited thereto. The light emitting element 3 is mounted on the first lead 21 in the recess 13. Further, in the recess 13, the light emitting element 3 and the first lead 21 are electrically connected by the first wire 41, and the light emitting element 3 and the second lead 22 are connected by the second wire 42. Has been.

  The inner peripheral surface 14 of the recess 13 of the light reflector 1 is inclined so that the inner diameter of the recess 13 increases toward the opening side. For this reason, the light emitted from the light emitting element 3 is easily reflected by the inner peripheral surface 14 of the recess 13 in the light reflector 1, and as a result, the light extraction efficiency from the lighting fixture 6 is increased.

  In this lighting fixture 6, if necessary, the inside of the recess 13 may be sealed with a transparent resin, and the opening of the recess 13 may be covered with a transparent cover.

  The light reflector 1 in which the metal lead frame 2 is embedded is manufactured by, for example, an insert molding method. That is, for example, a metal lead is disposed inside the transfer molding die, and in this state, the light reflector 1 is formed by transfer molding the resin molding material for the light reflector in the transfer molding die. .

[Examples and Comparative Examples]
The raw materials shown in the following table were uniformly mixed using a sigma blender, and then kneaded with a hot roll heated to 100 ° C. to obtain a sheet-like kneaded product. The kneaded product was cooled, ground and sized. Thereby, a granular molding material was obtained. In the table, the blending amount of the raw materials is shown in parts by mass.

  Details of the raw materials shown in the table below are as follows.

Unsaturated polyester / crystalline unsaturated polyester A: melting point 55 ° C.
Crystalline unsaturated polyester B: melting point 65 ° C.
Crystalline unsaturated polyester C: melting point 75 ° C.
Crystalline unsaturated polyester D: melting point 100 ° C.
Crystalline unsaturated polyester E: melting point 105 ° C.
Amorphous unsaturated polyester: manufactured by Nippon Iupika Co., Ltd., product name Iupika 8552L, melting point 80 ° C.

Crosslinking agent / diallyl phthalate prepolymer: manufactured by Daiso Corporation, product name isopap, weight average molecular weight (polystyrene equivalent value) 3 × 10 ^{4 to} 5 × 10 ⁴ , melt viscosity at 120 ° C. 1 kPa · s, iodine value 78, softening point 50-80 ° C.
Diallyl phthalate monomer: manufactured by Daiso Corporation, product name DUP monomer, molecular weight 246.3, viscosity at 30 ° C., 8.5 mPa · s, iodine value 202, liquid at room temperature.
-Styrene: Styrene monomer, manufactured by Asahi Kasei Chemicals Corporation.

Epoxy resin / triglycidyl propyl isocyanate: epoxy equivalent 100, (total amount of (2R, 2R, 2S) isomer and (2S, 2S, 2R) isomer): ((2R, 2R, 2R) isomer and (2S, 2S, 2S) total substance amount) = 75: 25, melting point 105 ° C., manufactured by Nissan Chemical Industries, Ltd., product name TEPIC-S.

Curing agent / HHPA: Hexahydrophthalic anhydride Curing accelerator / dicumyl peroxide: manufactured by NOF Corporation.

White pigment / titanium oxide: rutile titanium oxide, average particle size 0.4 μm, manufactured by Tyoxide Japan Co., Ltd., product name Tioxide RTC-30.

Inorganic filler / silica: fused silica, average particle size 25 μm, manufactured by Denki Kagaku Kogyo Co., Ltd., product name FB-820.
Aluminum oxide: average particle size 0.5 μm, manufactured by Denki Kagaku Kogyo Co., Ltd., product name DAW-05.

Fibrous filler / glass fiber: average fiber diameter 3 mm, manufactured by Owens Corning Japan, product name CS03IE830A.

Mold release agent / zinc stearate: Sakai Chemical Industry Co., Ltd., product name SZ-P.

Antioxidant / HCA: Phosphorous antioxidant, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, manufactured by Sanko Co., Ltd.
AO-60: hindered phenol antioxidant, manufactured by ADEKA Corporation, product name ADK STAB AO-60.

[Evaluation]
1. Properties The state of the unsaturated polyester resin at 50 ° C., 70 ° C. and 90 ° C. was observed while heating the unsaturated polyester resin in each Example and Comparative Example from room temperature. From the results, it was evaluated whether the unsaturated polyester resin at each temperature was a solid, a liquid, or a solid-liquid mixed state. In this test, if it is a liquid at 90 ° C., it becomes easy to melt the crystalline unsaturated polyester without proceeding the curing reaction when the molding material is heated and kneaded, and a molding material containing no cured product is easy. Once prepared, it can be evaluated.

2. ICI viscosity (150 ° C)
The ICI viscosity at 150 ° C. of the unsaturated polyester resin in each example and comparative example was measured.

3. Odor The presence or absence of odor in the molding materials obtained in each of the examples and comparative examples was evaluated by sensory test. As a result, “A” was evaluated when no odor was felt, and “B” was evaluated when odor was felt.

4). Manufacturability Feeder stability: The molding materials obtained in each of Examples and Comparative Examples were transported using a capacitive feeder (product number 502 manufactured by Kuma Engineering Co., Ltd.). In this case, the time for continuous transportation without so-called bridge was measured.

  Kneading stability: In each example and comparative example, the molding material was kneaded with a kneader (manufactured by Kurimoto Steel Works, product number S2KRC). The case where the current load value of the kneader during the kneading was within ± 1 A was evaluated as “A”, and the case where it was not was evaluated as “B”.

  Continuous grindability: In each example and comparative example, the molding material was ground with a grinding device. In this case, the pulverization time required until coloring due to mixing of metal powder in the molding material was observed was measured.

5. Light reflectance The sample for evaluation was produced by carrying out the transfer molding of the molding material obtained in each example and comparative example. The transfer molding conditions were a mold temperature of 150 ° C., a transfer pressure of 8 MPa, and a curing time of 90 seconds. The dimensions of the evaluation sample were 5 cm in diameter and 1 mm in thickness.

  The light reflectance (initial light reflectance) at a wavelength of 460 nm of this evaluation sample was measured using a spectrocolorimeter CM-3500d manufactured by Konica Minolta.

  Subsequently, the sample for evaluation was subjected to a heat treatment at 150 ° C. for 1000 hours, and then the light reflectance (light reflectance after heating) of the sample for evaluation was measured.

6). Storage Stability The molding materials obtained in each of the examples and comparative examples were analyzed by differential scanning calorimetry (DSC) immediately after preparation, and the calorific value during heat generation was measured. Further, after storing the molding material at a temperature of 20 ° C. for one month, the amount of heat of the molding material during heat generation was measured. As a result, the case where the calorific value of the molding material after storage was 80% or more of the calorific value of the molding material immediately after preparation was evaluated as “A”, and the case where it was less than 80% was evaluated as “B”.

7). Burr Evaluation Samples for evaluation were prepared by transfer molding the molding materials obtained in each Example and Comparative Example. The transfer molding conditions were a mold temperature of 150 ° C., a transfer pressure of 8 MPa, and a curing time of 90 seconds. The presence or absence of burrs and the extent of this evaluation sample were observed. As a result, “A” indicates that no burr is observed or the protrusion dimension of the burr is 0.5 mm or less, and “B” indicates that the burr protrusion dimension is 0.5 mm or more and less than 5 mm. The case of 5 mm or more was evaluated as “C”.

8). Deflection temperature under load A sample for evaluation was produced by transfer molding the molding material obtained in each example and comparative example. The transfer molding conditions were a mold temperature of 150 ° C., a transfer pressure of 8 MPa, and a curing time of 180 seconds. Moreover, the dimension of the sample for evaluation was made into the size based on ASTM. The deflection temperature under load (high load) of this evaluation sample was measured according to ASTM D-648.

9. Adhesiveness The base material 7 which consists of a silver plating copper substrate of the dimension of 12 mm x 49 mm x 1.5 mm was prepared. By molding the molding material obtained in each example and comparative example by transfer molding (insert molding), as shown in FIG. The overlapping width of the base material 7 and the molded body 8 is 12 mm. The transfer molding conditions are a mold temperature of 150 ° C., a transfer pressure of 8 MPa, and a curing time of 180 seconds. The shear adhesion strength was measured by applying stress in the direction of the arrow in FIG. 3 to each of the substrate 7 and the molded body 8.

1 Light reflector 6 Lighting equipment

Claims (7)

Contains an unsaturated polyester resin and a white pigment,
The unsaturated polyester resin is
A crystalline unsaturated polyester having a melting point in the range of 65-100 ° C;
Containing one or more compounds selected from the group consisting of diallyl phthalate, isodiallyl phthalate, and a polymer of at least one compound of diallyl phthalate and isodiallyl phthalate ,
The unsaturated polyester resin is Ru solid der at 70 ° C. light reflective-body molding material. The molding material for light reflectors according to claim 1 whose ICI viscosity in 150 ° C of said unsaturated polyester resin is in the range of 1-10 Pa.s. Light reflected-body molding material according to claim 1 or 2 containing d epoxy resin. The molding material for light reflectors as described in any one of Claims 1 thru | or 3 containing a phosphorus antioxidant. The light reflector formed from the molding material for light reflectors as described in any one of Claims 1 thru | or 4. A lighting fixture comprising the light reflector according to claim 5. A method for manufacturing a light reflector, comprising: transfer molding the molding material for a light reflector according to any one of claims 1 to 4.