JPH11273431A - Reflector base for lighting equipment and reflector for lighting equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reflector substrate for a lighting fixture, which is lightweight and excellent in surface smoothness, safety, moldability, heat resistance and handling performance, and to provide a low-cost and high-quality reflector for the lighting fixture, which does not require a pretreatment at the time of forming a reflecting layer, and is suitable for mass production and lightweight, and has high specular performance, and also is excellent in heat resistance, radiative performance, safety and handling performance. SOLUTION: This reflector material 1 for a lighting fixture has such a characteristic that it is composed of a mold of an aromatic polyimide film or an aromatic polyamide film. And this reflector for the lighting fixture 8 is composed by forming a reflecting layer 10 by the vapor deposition of reflecting material, on the reflector base member 1 comprising a mold of an aromatic polyimide film or an aromatic polyamide film.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reflector base for lighting equipment used mainly as a lamp reflector for headlights and fog lights of automobiles, and a reflector for lighting equipment formed from this base material. .

[0002]

2. Description of the Related Art As headlights (headlights) and fog light reflectors (lamp reflectors) for automobiles, injection moldings or compression moldings of metals such as glass and aluminum and plastics such as polyphenylene sulfide and unsaturated polyester resin are used. BACKGROUND ART A material in which a metal reflective layer using a reflective material such as aluminum, nickel-chromium alloy, titanium oxide, or the like is formed on a reflector base made of a molded body or the like is mainly used.

That is, a light bulb such as a halogen bulb or a xenon bulb is used as a light source for a headlight (headlight) and a fog light of an automobile, and the temperature near the base of the bulb is heated to 200 ° C. or more. Because
As the reflector base material, an injection molded article or a compressed molded article (reinforced resin molded article) of glass, metal, or plastic having improved heat resistance by mixing an inorganic reinforcing material such as glass fiber or calcium carbonate is used. -ing

[0004] However, those using glass as a reflector base material have problems such as heavy weight and easy breakage.

[0005] In addition, in the case of using a metal and a reinforced resin molded body as a reflector base material, in order to improve the reflector surface performance (smoothness) in addition to the large weight, a resin is deposited before vapor deposition of a reflective substance. It requires secondary processing such as a coat, and has a problem that the number of manufacturing steps is large.

[0006] In addition, those using a reinforced resin molded body as a reflector base material are lighter in weight than those using a metal as a reflector base material, but from the viewpoint of base material strength and restrictions on molding technology. Since the base material itself has a low heat radiation property and a lamp with a structure that easily accumulates heat, such as a projector type, there is concern about heat retention in maintaining the shape, and a rise in the temperature inside the housing. To shorten the life of the bulb itself.

Further, when a reinforced resin molded body is used as a reflector base material, a gas such as a chlorine compound may be generated when the lamp is turned on and heated, and this gas adheres and solidifies to a front lens such as a headlight. It also included the problem of fogging the lens and degrading lamp performance.

On the other hand, Japanese Utility Model Publication No. Sho 62-10887 discloses that
A sheet-made reflector composed of a film sheet that has been mirror-finished by aluminum vapor deposition is described, and it is disclosed that this sheet-made reflector does not require pretreatment such as degreasing to obtain specularity, Since the film sheet used here is polyethylene having poor heat resistance,
It was impossible to apply this sheet-made reflector as a reflector such as a headlamp using a high heat-generating lamp such as a halogen bulb in view of a heat-resistant shape retaining force.

Further, Japanese Patent Publication No. 5-88481 discloses that
A reflector is described in which a visible light-reflecting infrared transmitting multilayer film is formed on a reflector substrate made of a film made of a polyimide resin and a polyetherketone resin, and this reflector is lightweight and breaks the substrate made of a film. It is disclosed that in addition to the bulkiness, the use of polyimide resin and the like can withstand the heat generated by halogen bulbs, etc., but this reflecting mirror forms a visible light reflecting infrared transmitting multilayer film on the base material. However, it cannot be used as a reflector for automobile headlights and fog lights.

[0010]

SUMMARY OF THE INVENTION The present invention has been achieved as a result of studying to solve the problems in the prior art described above.

Accordingly, a first object of the present invention is to provide a reflector base material for lighting equipment which is lightweight and has excellent surface smoothness, safety, moldability, heat resistance, and handleability.

A second object of the present invention is that pretreatment at the time of forming the reflective layer is unnecessary, suitable for mass production, lightweight, has high specularity, and is excellent in heat resistance, heat dissipation, safety and handling. Another object of the present invention is to provide a low-cost and high-quality reflector for lighting equipment.

[0013]

In order to achieve the first object, the reflector base for lighting equipment of the present invention is characterized by comprising a molded article of an aromatic polyimide film or an aromatic polyamide film. Is what you do.

Since the reflector base material for lighting equipment of the present invention is formed of a specific plastic film molded body having excellent heat resistance, its surface smoothness is good and no pretreatment is required at the time of forming the reflection layer. It can be obtained at a low cost by a simple molding method such as hot stamping and the like, and is excellent in safety and handleability because it is extremely lightweight and hard to break.

In the reflector base for lighting equipment of the present invention, the molded body is formed by press-molding the film, and the molded body forms a reflection surface, a main body portion and an outer flange portion. It is a preferable condition to have the inner flange portion and the inner flange portion, and the above effects can be further enhanced by applying these conditions.

In order to achieve the second object,
The reflector for lighting equipment of the present invention is characterized in that a reflecting layer is formed by depositing a reflecting material on a reflector base made of a molded article of an aromatic polyimide film or an aromatic polyamide film. is there.

The reflector for lighting equipment of the present invention is obtained by forming a reflective layer by vapor deposition on a reflector base made of a specific plastic film molded body having excellent heat resistance and surface smoothness. There is no need to perform pre-treatment such as resin coating before the reflective layer is deposited, it can be obtained at low cost by mass production, and it is extremely lightweight and hard to break, causing degassing which is a practical obstacle when lighting the lamp Because of its absence, it not only excels in heat dissipation, safety and handleability, but also has high heat resistance and specularity, and exhibits high quality performance as a lamp reflector.

In the reflector for lighting equipment according to the present invention, the reflecting layer is formed by vapor deposition of aluminum or silver, and the molded body forms the reflecting surface, the main body, the outer flange, and the inner flange. It is preferable that at least the main body has a reflective layer and that the main body be used as a lamp reflector. By applying these conditions, the above effects can be further enhanced.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The reflector base for lighting equipment and the reflector for lighting equipment according to the present invention will be described below in further detail with reference to the drawings.

FIG. 1 is a partially cutaway perspective view showing an example of a reflector base for lighting equipment of the present invention, and FIG. 2 is a partially cutaway side view showing one example of a reflector for lighting equipment of the present invention.

As shown in FIG. 1, the reflector substrate 1 for lighting equipment of the present invention is made of a molded body obtained by subjecting an aromatic polyimide film or an aromatic polyamide film to a hot stamping process. It has a main body part 2, an outer flange part 4, and an inner flange part 6 forming a part, and this example is configured as a lamp reflector base of a headlight for an automobile.

In the reflector substrate 1 for lighting equipment,
The surface smoothness of the main body 2 maintains the smoothness of the film as it is, and has sufficient performance to obtain a reflecting surface for a floodlight without any pretreatment.

In the case where the strength of the main body 2 is problematic, a frame formed by plastic injection molding, metal pressing, FRP, or the like can be easily reinforced by attaching the frame to the outside of the main body 2. it can.

In the embodiment shown in FIG. 1, the main body 2 has a simple reflecting surface shape consisting of a paraboloid of revolution. However, depending on the purpose, the main body 2 may have a formable shape such as a polyhedron. For example, an arbitrary shape can be selected.

The reflector 8 for lighting equipment shown in FIG.
A reflective material such as aluminum is deposited on the inner peripheral surface of the reflector base material 1 shown in FIG.
0 is formed. In the step of forming the reflective layer 10, the reflector substrate 1 maintains the smoothness of the film as it is, so that there is no need to perform any pretreatment such as resin coating or degreasing.

In the reflector for lighting equipment 2 shown in FIG. 2, an insertion opening 12 for a light bulb (not shown) is opened at the center of the inner flange portion 6 and the periphery of the insertion opening 12 is formed. A lamp reflector is formed by forming the inner flange 6a.

In the reflector substrate 1 shown in FIG. 1, the outer flange portion 4 is formed in the final shape of the reflector 8 shown in FIG. 2, but a plurality of reflectors are industrially formed on one film. It is also possible to form the base materials 1 side by side, perform a vapor deposition process, and then separate the outer flange parts 4 while adjusting the outer shape.

In the above structure, an aromatic polyimide film or an aromatic polyamide film having excellent heat resistance is used as a film forming the reflector base 2 for lighting equipment. The thickness supplied as a normal film, for example, about several micrometers to several hundred micrometers can be used.

As the film, any of a stretched film and an unstretched film can be used. However, a film containing an inorganic or organic additive for the purpose of improving workability is generally used for the surface smoothness of the reflector substrate 1. Is undesirably reduced.

Then, the reflector substrate 1 for lighting equipment of the present invention
Can be obtained by molding the film into a desired shape by means such as heating embossing, vacuum molding and high-pressure gas spray molding, but this molding method does not damage the substrate surface. If so, there is no particular limitation, and among them, the hot stamping is most advantageous in terms of the process.

Aluminum or silver is most suitable as a metal deposited on the reflector substrate 1 for a lighting device as a reflector from the viewpoint of reflectance, but a chemically stable metal compound may be appropriately used. Alternatively, chromium, nickel-chromium alloy, or the like can be used as a base material for improving the adhesion strength to a reflective material or a film.

As a vapor deposition means for forming the reflective layer 10, a vacuum vapor deposition method, a sputtering method, an electron beam method, an ion plating method and the like can be used, but the present invention is not particularly limited to these. . Further, a protective film may be further formed on the obtained reflective layer 10 by coating, vapor deposition, or the like before use.

The shape of the reflector 8 for lighting equipment of the present invention may be any shape used as a headlight or a fog light, and the reflection layer 10 is formed only on the portion of the reflector substrate 1 that needs reflection. May be used.

In addition, the reflective layer 10 can be formed on the side opposite to the electric bulb with respect to the reflector substrate 1. In this case, by providing the reflective layer 10 outside the electric bulb, the aromatic polyimide film and the aromatic polyimide film can be formed. The primary color of the group III polyamide film, yellow, can be obtained as reflected light.

[0035]

EXAMPLES The present invention will be described more specifically with reference to the following examples. "Kapton" (trade name of DuPont, USA)
Using an aromatic polyimide film (thickness: 75 to 125 micrometers), a hot stamping molding was used to obtain a reflector substrate (lamp reflector substrate) for an automobile headlight having the shape shown in FIG.

The surface smoothness of the obtained lamp reflector base material was sufficient to maintain the smoothness of the film and obtain a reflecting surface for a light projector.

Next, with respect to the lamp reflector base material,
Aluminum was deposited by a known vacuum deposition method to form a reflective layer having a thickness of 0.3 μm. In this reflective layer forming step, no pretreatment such as resin coating or degreasing was performed, but an extremely smooth vapor deposition surface could be formed.

Then, an insertion opening for a light bulb was opened at the center of the inner flange portion, and an inner flange was formed around the insertion opening.

The smoothness of the obtained reflection layer is extremely high.
When used as a headlight lamp reflector, sufficient reflected light could be obtained.

Moreover, the reflector for lighting equipment is extremely light in weight compared to other parts of the headlight, and the aromatic polyimide film has excellent heat dissipation properties and is thin, so that the heat of the lamp can be reduced. Squeezing was reduced, and the durability of the reflector and the lamp was improved.

[0041]

As described above, since the reflector base material for lighting equipment of the present invention is formed of a specific plastic film molded body having excellent heat resistance, it has good surface smoothness and good reflection. Pretreatment at the time of layer formation is unnecessary, and it can be obtained at a low cost by a simple molding method such as hot stamping. In addition, it is extremely lightweight and hard to break, so it has excellent safety and handling properties. .

Further, the reflector for lighting equipment of the present invention is obtained by forming a reflective layer by vapor deposition on a reflector base made of a specific plastic film molded body having excellent heat resistance and surface smoothness. It is not necessary to perform pretreatment such as resin coating before depositing the reflective layer,
It can be obtained at low cost by mass production, and is extremely lightweight and hard to break, and does not cause degassing that is a practical obstacle when the lamp is turned on, so it has excellent heat dissipation, safety and handling properties, as well as heat resistance It has high performance and high specularity and exhibits high quality performance, and can be advantageously used as a lamp reflector for a headlight, a fog light or a large floodlight of an automobile.

[Brief description of the drawings]

FIG. 1 is a partially broken perspective view showing an example of a reflector base for lighting equipment of the present invention.

FIG. 2 is a partially cutaway side view showing an example of a reflector for lighting equipment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Reflector base material for lighting equipment 2 Main body part 4 Outer flange part 6 Inner flange part 6a Inner flange 8 Reflector for lighting equipment 10 Reflective layer 12 Light bulb insertion port

Claims (7)

[Claims] 1. A reflector substrate for lighting equipment, comprising a molded article of an aromatic polyimide film or an aromatic polyamide film. 2. The reflector base for a lighting device according to claim 1, wherein the molded body is formed by subjecting the film to hot stamping or vacuum forming. 3. The reflector base for lighting equipment according to claim 1, wherein the molded body has a main body part, an outer flange part and an inner flange part forming a reflection surface. 4. A reflector for lighting equipment, wherein a reflector is formed by depositing a reflector on a reflector base made of a molded article of an aromatic polyimide film or an aromatic polyamide film. 5. The reflector for lighting equipment according to claim 4, wherein the reflection layer is formed by vapor deposition of aluminum or silver. 6. The molded product has a main body, an outer flange, and an inner flange that form a reflection surface, and at least a reflection layer is formed on the main body. 6. The reflector for lighting equipment according to 5. 7. The reflector for lighting equipment according to claim 4, wherein the reflector is used as a lamp reflector.