JP6256835B2 - Molding material for light reflector, light reflector and lighting apparatus - 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 resin is known (Patent Document 1). Unsaturated polyester resin is comprised from unsaturated polyester (alkyd) and crosslinking agents, such as styrene. Since the unsaturated polyester resin is a thermosetting resin, if it is used, there is an advantage that the heat discoloration of the light reflector is increased.

  Furthermore, Patent Document 1 improves the flowability of the molding material by using a crystalline unsaturated polyester as the unsaturated polyester, thereby improving the light reflectivity 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

  In recent years, the required level of heat discoloration of light reflectors has been increasing, but it has become impossible to sufficiently clear the level only by using conventional crystalline unsaturated polyester.

  The present invention has been made in view of the above reasons, and a light reflector molding material capable of improving the light reflectance of the light reflector, a light reflector formed from the light reflector molding material, and It aims at providing a lighting fixture provided with this light reflector.

The molding material for light reflectors according to the first aspect contains an unsaturated polyester resin composed of an unsaturated polyester and a crosslinking agent, and a white pigment,
The unsaturated polyester contains a first unsaturated polyester having one or more groups selected from the group consisting of 1,4-cyclohexanedicarboxylic acid residue and cyclohexane 1,4-dimethanol residue. And

  The molding material for light reflectors according to the second aspect is the sum of the groups in the first aspect with respect to the total amount of all polyol residues and all polybasic acid residues in the first unsaturated polyester. The ratio is 60 mol% or more.

  The molding material for light reflectors according to the third aspect is the ratio of the cyclohexane 1,4-dimethanol residue to the total polyol residues in the first unsaturated polyester in the first or second aspect. Is in the range of 50 to 100 mol%.

  The molding material for light reflectors according to the fourth aspect is the 1,4-cyclohexane for all polybasic acid residues in the first unsaturated polyester in any one of the first to third aspects. The ratio of the dicarboxylic acid residue is in the range of 0 to 30 mol%.

  The molding material for light reflectors according to the fifth aspect is any one of the first to fourth aspects, wherein the aromatic ring content of the first unsaturated polyester is in the first unsaturated polyester. It is characterized by being 30 mol% or less with respect to all polybasic acid residues.

  The molding material for light reflectors according to a sixth aspect is characterized in that, in any one of the first to fifth aspects, the first unsaturated polyester has crystallinity.

  The molding material for light reflectors according to a seventh aspect is characterized in that, in the sixth aspect, the melting point of the first unsaturated polyester is in the range of 70 to 120 ° C.

  The molding material for light reflectors according to an eighth aspect is characterized in that, in any one of the first to seventh aspects, the crosslinking agent contains a compound having a boiling point of 150 ° C. or higher.

The molding material for light reflectors according to the ninth aspect is any one of the first to eighth aspects, wherein the first unsaturated polyester has an ICI viscosity at 150 ° C. of 1 to 5 Pa · s. It is within the range.

  The molding material for light reflectors according to a tenth aspect is characterized in that, in any one of the first to ninth aspects, the ratio of the white pigment is in the range of 15 to 40% by mass.

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

  A luminaire according to a twelfth aspect includes the light reflector according to the eleventh aspect and a light emitting element.

  According to the present invention, the heat discoloration of the light reflector is 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.

  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.

  Unsaturated polyester resin consists of unsaturated polyester and a crosslinking agent.

  In this embodiment, the unsaturated polyester contains a first unsaturated polyester having one or more groups selected from the group consisting of 1,4-cyclohexanedicarboxylic acid residue and cyclohexane 1,4-dimethanol residue. To do. For this reason, the heat-resistant discoloration property of a light reflector improves. Thereby, the sustainability of the high light reflectivity of the light reflector is further improved.

  The first unsaturated polyester is synthesized, for example, by dehydration condensation of a monomer containing at least one of 1,4-cyclohexanedicarboxylic acid and cyclohexane 1,4-dimethanol.

  Selected from the group consisting of 1,4-cyclohexanedicarboxylic acid residues and cyclohexane 1,4-dimethanol residues relative to the total amount of all polyol residues and all polybasic acid residues in the first unsaturated polyester The total proportion of the one or more groups to be used is preferably 30 mol% or more. In this case, the linear portion and aromatic ring that cause discoloration in the first unsaturated polyester are sufficiently reduced, and the heat discoloration resistance of the light reflector is particularly increased. If this ratio is 75 mol% or less, it is especially preferable. Moreover, it is also preferable that this ratio exists in the range of 35 mol% or more and 70 mol% or less.

  Moreover, it is preferable that the ratio of the cyclohexane 1, 4- dimethanol residue with respect to all the polyol residues in a 1st unsaturated polyester exists in the range of 50-100 mol%. Moreover, it is preferable that the ratio of the 1, 4- cyclohexane dicarboxylic acid residue with respect to all the polybasic acid residues in a 1st unsaturated polyester exists in the range of 0-30 mol%.

  In addition, a group having an aromatic ring with respect to the total amount of all polyol residues and all polybasic acid residues in the first unsaturated polyester, that is, a polyol residue having an aromatic ring and a polybasic having an aromatic ring. The ratio of the total with acid residues is preferably 15 mol% or less. In this case, the heat discoloration of the light reflector is particularly high. It is particularly preferred if the first unsaturated polyester does not have a group having an aromatic ring.

  In addition, an aromatic ring means the heterocyclic ring which has a benzene ring, its condensed ring, and aromaticity. Examples of the condensed ring of the benzene ring include a naphthalene ring and an anthracene ring. Examples of the heterocyclic ring having aromaticity include a pyridine ring and a pyrrole ring.

  The first unsaturated polyester preferably has crystallinity. That is, the first unsaturated polyester is preferably a crystalline unsaturated polyester.

  When the first unsaturated polyester has crystallinity, the storage stability of the molding material is increased. That is, the molding material has high stability at a temperature below the melting point of the first unsaturated polyester. Furthermore, good moldability can be obtained by improving the fluidity of the molding material during molding. Moreover, when the 1st unsaturated polyester has crystallinity, while being able to raise the light reflectivity of a light reflector, the sustainability of a high light reflectivity can be raised.

  In the present embodiment, the crystalline unsaturated polyester is an unsaturated polyester having crystallinity, having a melting point lower than room temperature, a solid at room temperature, and a liquid having a low viscosity above the melting point. . The first unsaturated polyester has crystallinity, for example, when the first unsaturated polyester is heated and melted and then cooled to room temperature at a rate of −10 ° C./min. Confirmed by occurring. In addition, this crystallinity is observed using a polarizing microscope that polarization characteristics occur when the first 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 1,4-cyclohexanedicarboxylic acid residue and the cyclohexane 1,4-dimethanol residue are difficult to inhibit the crystallinity. For this reason, having a 1 or more group selected from the group which consists of a 1, 4- cyclohexane dicarboxylic acid residue and a cyclohexane 1, 4- dimethanol residue means that the 1st unsaturated polyester has crystallinity. It is effective for.

  The melting point of the first unsaturated polyester is preferably in the range of 70 to 120 ° C. When the melting point of the first unsaturated polyester is 120 ° C. or less, it is easy to melt the first unsaturated polyester without proceeding the curing reaction during the heat-kneading for preparing the molding material. For this reason, the molding material which does not contain hardened | cured material is prepared easily. Moreover, the fall of the light reflectivity of a light reflector is suppressed because melting | fusing point of a 1st unsaturated polyester is 70 degreeC or more. The reason is presumed as follows. When the molding material is pulverized by the pulverizer, if the first 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 first unsaturated polyester is 70 ° C. or higher, the first 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 first unsaturated polyester having a melting point in the range of 70 to 120 ° C. can impart an appropriate fluidity to the molding material when the molding material is molded, thereby improving the moldability. At the same time, burrs are less likely to occur in the light reflector.

  The melting point of the first unsaturated polyester is a temperature at which a peak of heat of fusion appears when differential scanning calorimetry (DSC) is performed while raising the temperature of the first unsaturated polyester.

  The structure of the first unsaturated polyester will be described in more detail.

  The first unsaturated polyester has a polybasic acid residue and a polyol residue, and the polybasic acid residue includes an unsaturated polybasic acid residue.

  The first unsaturated polyester is synthesized, for example, by subjecting a polybasic acid containing an unsaturated polybasic acid and a polyol to a dehydration condensation reaction. In this case, the first unsaturated polyester has a polybasic acid residue derived from polybasic acids and a polyol residue derived from polyols.

  The molar ratio of the polybasic acid residue to the polyol residue in the first unsaturated polyester is, for example, in the range of 1: 1.1 to 1: 1.2. That is, the first unsaturated polyester is synthesized, for example, by a dehydration condensation reaction between a polybasic acid including an unsaturated polybasic acid and a polyol at a molar ratio of 1: 1.1 to 1: 1.2. The

  Unsaturated polybasic acid residues include, for example, maleic acid residues, fumaric acid residues, citraconic acid residues, mesaconic acid residues, itaconic acid residues, tetrahydrophthalic acid residues, methyltetrahydrophthalic acid residues, and glutaconic residues. One or more groups selected from the group consisting of acid residues can be contained. In particular, it is preferable that the unsaturated polybasic acid contains a fumaric acid residue. In this case, the heat discoloration of the light reflector is particularly improved.

  The ratio of unsaturated polybasic acid residues to all polybasic acid residues is preferably in the range of 70 to 100 mol%.

  The polybasic acid residue may contain an unsaturated polybasic acid residue and a saturated polybasic acid residue. Saturated polybasic acid residues include, for example, 1,4-cyclohexanedicarboxylic acid residue, phthalic acid residue, isophthalic acid residue, terephthalic acid residue, succinic acid residue, adipic acid residue, sebacic acid residue, azelain Contains one or more groups selected from the group consisting of acid residues, tetrahydrophthalic acid residues, methyltetrahydrophthalic acid residues, endomethylenetetrahydrophthalic acid residues, heptic acid residues, and tetrabromophthalic acid residues can do.

  In particular, the saturated polybasic acid residue preferably contains a 1,4-cyclohexanedicarboxylic acid residue. That is, as described above, the first unsaturated polyester preferably has a 1,4-cyclohexanedicarboxylic acid residue. In this case, the heat discoloration of the light reflector is particularly improved. The ratio of 1,4-cyclohexanedicarboxylic acid residue to all polybasic acid residues is preferably in the range of 0 to 30 mol%. In this case, the ratio of the unsaturated polybasic acid residue to the total polybasic acid residue can be sufficiently high because the ratio of the 1,4-cyclohexanedicarboxylic acid residue is 30 mol% or less. Thereby, the thermosetting property of unsaturated polyester resin is fully ensured. Moreover, the glass transition temperature of a light reflector is maintained high by ensuring the high crosslinking density of the hardened | cured material of unsaturated polyester resin. Moreover, it is more preferable if the ratio of the 1, 4- cyclohexane dicarboxylic acid residue with respect to all the polybasic acid residues exists in the range of 1-30 mol%, and it is still more preferable if it exists in the range of 10-30 mol%. In this case, the heat discoloration of the light reflector is particularly improved.

  Moreover, it is preferable that the ratio of the polybasic acid residue which has an aromatic ring with respect to all the polybasic acid residues in a 1st unsaturated polyester is 30 mol% or less. In this case, the heat discoloration of the light reflector is further improved.

  The polyol residue is, for example, cyclohexane 1,4-dimethanol residue, ethylene glycol residue, 1,3-propanediol residue, 1,4-butanediol residue, 1,3-butanediol residue, 1, 5-pentanediol residue, 1,6-hexanediol residue, propylene glycol residue, diethylene glycol residue, triethylene glycol residue, dipropylene glycol residue, neopentyl glycol residue, hydrogenated bisphenol A residue, One or more groups selected from the group consisting of a bisphenol A propylene oxide compound residue, a dibromoneopentyl glycol residue and a trimethylolpropane residue can be contained.

  In particular, the polyol residue preferably contains a cyclohexane 1,4-dimethanol residue. That is, as described above, the first unsaturated polyester preferably has a cyclohexane 1,4-dimethanol residue. In this case, the heat discoloration of the light reflector is particularly improved. The ratio of cyclohexane 1,4-dimethanol residues to all polyol residues is preferably in the range of 50 to 100 mol%, more preferably in the range of 70 to 100 mol%. The cyclohexane 1,4-dimethanol residue has an action of increasing the melting point of the unsaturated polyester. For this reason, the composition of polyol residues other than cyclohexane 1,4-dimethanol residues and the composition of polybasic acid residues in the unsaturated polyester are designed so that the melting point of the unsaturated polyester does not become excessively high. It is preferable.

  The polyol residue is an ethylene glycol residue, neopentyl glycol residue, 1,3-propanediol residue, 1,4-butanediol residue, 1,5-pentanediol residue, 1,6-hexanediol residue. It is also preferable to contain one or more groups selected from the group consisting of a group and a cyclohexanedimethanol residue. In this case, the heat discoloration of the light reflector is particularly improved.

  The polyol residue may contain a trifunctional or higher functional polyol residue. The trifunctional or higher functional polyol residue can contain, for example, a trimethylolpropane residue. The ratio of trifunctional or higher polyol residues to all polyol residues is preferably in the range of 0 to 50 mol%.

  It is preferable that the acid value of a 1st unsaturated polyester exists in the range of 5-40 mg-KOH / g.

  The polybasic acid residue in the first unsaturated polyester is derived from the polybasic acids in the raw material monomer, and the polyol residue in the first unsaturated polyester is derived from the polyol in the raw material monomer. That is, the first unsaturated polyester is synthesized, for example, by subjecting a raw material monomer containing a polybasic acid and a polyol to a dehydration condensation reaction. Further, in this raw material monomer, the polybasic acid contains 1,4-cyclohexanedicarboxylic acid, or the polyol contains cyclohexane 1,4-dimethanol, or the polybasic acid contains 1,4-cyclohexanedicarboxylic acid. And the polyol contains cyclohexane 1,4-dimethanol.

  It is particularly preferred if the unsaturated polyester in the molding material contains only the first unsaturated polyester, but the unsaturated polyester is either 1,4-cyclohexanedicarboxylic acid residue or cyclohexane 1,4-dimethanol residue. May also contain an unsaturated polyester (second unsaturated polyester). However, the ratio of the first unsaturated polyester to the whole unsaturated polyester is preferably 40% by mass or more.

  The crosslinking agent is a component that builds a crosslinked structure between the chains of the unsaturated polyester by reacting with the unsaturated polyester. Examples of the crosslinking agent include vinyl polymerizable monomers such as styrene, vinyl toluene, divinyl benzene, α-methyl styrene, methyl methacrylate, and vinyl acetate; diallyl phthalate, isodiallyl phthalate, triallyl cyanurate, diallyl tetrabromophthalate Methacrylate-based and acrylate-based polymerizable monomers such as phenoxyethyl acrylate, 2-hydroxyethyl acrylate, and 1,6-hexanediol diacrylate; and prepolymers obtained by polymerizing one or more compounds among these polymerizable monomers One or more compounds selected from the group consisting of can be contained.

  In particular, the crosslinking agent preferably contains a compound having a boiling point of 150 ° C. or higher. In this case, 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. More preferably, the crosslinking agent contains a compound having a boiling point of 150 ° C. or higher. In particular, the crosslinking agent is selected from the group consisting of diallyl phthalate, isodiallyl phthalate, diethylene glycol diacrylate, diethylene glycol dimethacrylate, and polymers of these compounds as a compound having a boiling point of 140 ° C. or higher or a boiling point of 150 ° C. or higher. It is preferable to contain one or more compounds. The polymer is a polymer of one or more compounds selected from the group consisting of diallyl phthalate, isodiallyl phthalate, diethylene glycol diacrylate, and diethylene glycol dimethacrylate. In this case, 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 difference between the melting point of the first unsaturated polyester and the softening point of the cross-linking agent is reduced, so that a highly uniform molding material can be easily obtained by heating and kneading. Furthermore, the glass transition point of the light reflector is increased, and the heat discoloration of the light reflector is increased.

  The compound having a boiling point of 150 ° C. or higher includes a compound that does not boil at normal pressure and has a thermal decomposition temperature of 150 ° C. or higher.

  The ratio of the crosslinking agent to the total amount of the unsaturated polyester and the crosslinking agent is appropriately set, but is preferably in the range of 1 to 60% by mass, and more preferably in the range of 3 to 55% by mass. More preferably, it is in the range of 5 to 50% by mass.

  When an unsaturated polyester resin is used, the composition may contain a curing catalyst. In this case, a crosslinked structure is efficiently constructed by the reaction between the unsaturated polyester and the crosslinking agent. For this reason, the moldability of the composition and the shape stability of the light reflector are enhanced. The curing catalyst can contain, for example, one or more compounds selected from the group consisting of a curing accelerator and a polymerization initiator.

  The molding material may contain a curing catalyst. In this case, a crosslinked structure is efficiently formed by the reaction between the 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.

  The molding material may contain a polymerization inhibitor. 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.

  Although a molding material may contain only unsaturated polyester resin as a thermosetting resin, you may further contain other thermosetting resins, for example, an epoxy resin. However, the ratio of the unsaturated polyester resin to the total thermosetting resin is preferably 50% by mass or more.

  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 in the molding material is preferably in the range of 15 to 40% by mass. 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.

  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 unsaturated polyester melts 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, in this embodiment, the crystalline unsaturated polyester is difficult to melt, so that a reduction in light reflectance of the light reflector due to metal rubbing is suppressed.

  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 crystalline unsaturated polyester in the molding material preferably has an ICI viscosity (high shear viscosity) at 150 ° C. in the range of 1 to 5 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. If the above-mentioned first unsaturated polyester and crosslinking agent are used, the ICI viscosity of the unsaturated polyester resin can be easily adjusted by appropriately adjusting the composition thereof.

  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 and lighting fixture produced from the molding material which concerns on this embodiment 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.

  The light emitting element 3 is, for example, a light emitting diode, 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 molding material is transfer molded in the transfer molding die, whereby the light reflector 1 is formed.

[Unsaturated polyester]
The raw material monomer having the composition shown in Table 1 below was put in a container, and the raw material monomer was reacted while purging the condensed water while raising the temperature while replacing the inside of the container with an inert gas. When the acid value of the product was confirmed to be in the range of 5-40 mg-KOH / g, the reaction was terminated. Thereby, a crystalline unsaturated polyester was obtained.

  Table 1 also shows the melting point of each crystalline unsaturated polyester and the ICI viscosity at 150 ° C. The melting point is a value measured by raising the temperature of the crystalline unsaturated polyester by differential scanning calorimetry (DSC) at 10 ° C. per minute.

[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.

  The details of the raw materials shown in the table below, other than the crystalline unsaturated polyester, are as follows.

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., boiling point 150 ° C. or higher.
Diallyl phthalate monomer: manufactured by Daiso Co., Ltd., product name DUP monomer, molecular weight 246.3, viscosity at 30 ° C. 8.5 mPa · s, iodine value 202, liquid at room temperature, boiling point 150 ° C. or higher (boiling point 158 ° C. under 4 mmHg reduced pressure) .
Diethylene glycol dimethacrylate: manufactured by Shin-Nakamura Chemical Co., Ltd., product name 2G, molecular weight 242.3, viscosity 5 mPa · s at 25 ° C., liquid at room temperature, boiling point 150 ° C. or higher (boiling point 150 ° C. under reduced pressure of 8 mmHg).
Styrene: styrene monomer, manufactured by Asahi Kasei Chemicals Corporation, boiling point 145 ° C.

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. 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.

2. 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”.

1 Light reflector 6 Lighting equipment

Claims (9)

An unsaturated polyester resin comprising an unsaturated polyester and a crosslinking agent, and a white pigment;
The unsaturated polyester contains a first unsaturated polyester having one or more groups selected from the group consisting of 1,4-cyclohexanedicarboxylic acid residue and cyclohexane 1,4-dimethanol residue;
Wherein the first unsaturated Poriesu Te le has a crystallinity,
The proportion of the 1,4-cyclohexanedicarboxylic acid residues to the total polybasic acid residue of the first unsaturated polyester is state, and are within the scope of 1 to 30 mol%,
The ratio of the total of the said group with respect to the total amount of all the polyol residues and all the polybasic acid residues in said 1st unsaturated polyester is 30 mol% or more and 75 mol% or less, The light characterized by the above-mentioned. Molding material for reflectors. The molding for light reflectors according to claim 1, wherein the ratio of the cyclohexane 1,4-dimethanol residue to the total polyol residues in the first unsaturated polyester is in the range of 50 to 100 mol%. material. The ratio of the group which has an aromatic ring with respect to the total amount of all the polyol residues and all the polybasic acid residues in said 1st unsaturated polyester is 15 mol% or less, The light reflection of Claim 1 Molding material for body. The molding material for light reflectors according to any one of claims 1 to 3 , wherein the melting point of the first unsaturated polyester is in a range of 70 to 120 ° C. The molding material for light reflectors as described in any one of Claims 1 thru | or 4 in which the said crosslinking agent contains the compound which has a boiling point of 150 degreeC or more. The molding material for light reflectors according to any one of claims 1 to 5 , wherein the first unsaturated polyester has an ICI viscosity at 150 ° C in a range of 1 to 5 Pa · s. The molding material for light reflectors as described in any one of Claims 1 thru | or 6 whose ratio of the said white pigment exists in the range of 15-40 mass%. The light reflector formed from the molding material for light reflectors as described in any one of Claims 1 thru | or 7 . A lighting fixture comprising the light reflector according to claim 8 and a light emitting element.