CN111201280A - Unsaturated polyester resin composition, molded article containing cured product thereof, and lamp reflector containing the molded article - Google Patents
Unsaturated polyester resin composition, molded article containing cured product thereof, and lamp reflector containing the molded article Download PDFInfo
- Publication number
- CN111201280A CN111201280A CN201880065135.2A CN201880065135A CN111201280A CN 111201280 A CN111201280 A CN 111201280A CN 201880065135 A CN201880065135 A CN 201880065135A CN 111201280 A CN111201280 A CN 111201280A
- Authority
- CN
- China
- Prior art keywords
- unsaturated polyester
- polyester resin
- inorganic filler
- resin composition
- molded article
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
- C08F283/01—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G on to unsaturated polyesters
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
- C08K5/098—Metal salts of carboxylic acids
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/06—Unsaturated polyesters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V7/00—Reflectors for light sources
- F21V7/22—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
- F21V7/28—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors characterised by coatings
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Macromonomer-Based Addition Polymer (AREA)
Abstract
The present invention provides an unsaturated polyester resin composition which has good resin fluidity during molding and can obtain a molded article having excellent dimensional accuracy, mechanical properties and surface smoothness. The present invention is an unsaturated polyester resin composition comprising (a) an unsaturated polyester resin, (b) an inorganic filler, (c) a metal soap, (d) a low shrinkage agent, (e) a fiber reinforcing material and (f) a curing agent, wherein the inorganic filler (b) is 250 to 600 parts by mass per 100 parts by mass of the unsaturated polyester resin (a), and the inorganic filler (b) comprises (b1) an inorganic filler having an average particle diameter of 0.5 to 5.0 [ mu ] m and (b2) an inorganic filler having an average particle diameter of 8.0 to 50.0 [ mu ] m, and the mass ratio of the inorganic filler (b 1): (b2) 25: 75-75: a ratio of 25 is contained.
Description
Technical Field
The present invention relates to an unsaturated polyester resin composition, a molded article containing a cured product thereof, and a lamp reflector containing the molded article. More specifically, the present invention relates to an unsaturated polyester resin composition used in the production of a lamp reflector used for an automobile headlamp or the like, a molded article containing a cured product thereof, and a lamp reflector containing the molded article.
Background
An unsaturated polyester resin composition obtained by adding a fiber reinforcement and an inorganic filler to an unsaturated polyester resin is widely used for manufacturing OA (office automation) equipment, frames of office equipment, lamp reflectors of automobile headlamps, and the like because the resin flowability during molding is good and a cured product having excellent dimensional accuracy, heat resistance, and mechanical strength can be provided.
Since the lamp light is reflected at a certain angle and is irradiated forward, the lamp light reflector may cause unevenness in light distribution when the surface smoothness of the reflective layer is insufficient.
In the process of producing a lamp reflector, an undercoat layer is formed by applying and curing an undercoat agent to the surface of a molded body (substrate) obtained by molding and curing an unsaturated polyester resin composition, and then a metal coating layer (reflective layer) of aluminum, zinc, or the like is formed on the undercoat layer by vapor deposition or the like. In order to prevent the unevenness of light distribution, it is considered that it is preferable to increase the thickness of the undercoat layer, but the thickness of the undercoat layer leads to an increase in manufacturing cost.
Therefore, unsaturated polyester resin compositions used for the production of lamp reflectors are required to have excellent resin flowability during molding, to obtain properties of cured products excellent in dimensional accuracy, heat resistance and mechanical strength, and to obtain cured products excellent in surface smoothness.
The unsaturated polyester resin composition is generally blended with an inorganic filler from the viewpoint of mechanical strength and cost (patent documents 1 to 2).
Documents of the prior art
Patent document
Disclosure of Invention
Problems to be solved by the invention
However, if the amount of the inorganic filler to be blended is increased, the mechanical strength of the unsaturated polyester resin composition is improved, but the resin flowability and the surface smoothness of the molded article tend to be reduced during the molding of the unsaturated polyester resin composition.
The present invention has been made to solve the above problems, and an object of the present invention is to provide an unsaturated polyester resin composition which has good resin fluidity during molding and can give a molded article having excellent dimensional accuracy, mechanical properties, and surface smoothness.
Means for solving the problems
The present inventors have conducted extensive studies to solve the above problems, and as a result, have found that a resin can be made to have good fluidity during molding and a molded article having excellent surface smoothness can be formed by blending a predetermined amount of an inorganic filler in an unsaturated polyester resin composition and using 2 types of inorganic fillers having different average particle diameters as the inorganic filler, thereby completing the present invention.
That is, the present invention relates to the following aspects [1] to [6 ].
【1】 An unsaturated polyester resin composition comprising (a) an unsaturated polyester resin, (b) an inorganic filler, (c) a metal soap, (d) a low shrinkage agent, (e) a fiber reinforcing material and (f) a curing agent,
the inorganic filler (b) is 250 to 600 parts by mass per 100 parts by mass of the unsaturated polyester resin (a),
the inorganic filler (b) comprises (b1) an inorganic filler having an average particle diameter of 0.5 to 5.0 [ mu ] m and (b2) an inorganic filler having an average particle diameter of 8.0 to 50.0 [ mu ] m, wherein the mass ratio of (b 1): (b2) 25: 75-75: a ratio of 25 is contained.
【2】 The unsaturated polyester resin composition according to [1], wherein the amount of the inorganic filler (b) is 350 to 450 parts by mass per 100 parts by mass of the unsaturated polyester resin (a).
【3】 The unsaturated polyester resin composition according to [1] or [ 2 ], wherein the (b) inorganic filler contains calcium carbonate.
【4】 The unsaturated polyester resin composition according to any one of [1] to [ 3 ], wherein the fiber reinforcement (e) is 70 to 120 parts by mass per 100 parts by mass of the unsaturated polyester resin (a).
【5】 A molded article comprising a cured product of the unsaturated polyester resin composition described in any one of [1] to [ 4 ].
【6】 A lamp reflector comprising the shaped body of [ 5 ], a primer layer disposed on the shaped body, and a metallic reflective layer disposed on the primer layer.
Effects of the invention
The present invention provides an unsaturated polyester resin composition which has good resin fluidity during molding and can obtain a molded article having excellent dimensional accuracy, mechanical properties and surface smoothness.
Drawings
FIG. 1a is a cross-sectional view of a luminaire having a lamp reflector.
FIG. 1b is an enlarged cross-sectional view taken along line a-a' of FIG. 1 a.
Detailed Description
One embodiment of the present invention is an unsaturated polyester resin composition containing (a) an unsaturated polyester resin, (b) an inorganic filler, (c) a metal soap, (d) a low shrinkage agent, (e) a fiber reinforcement, and (f) a curing agent.
The components are described below.
[ (a) unsaturated polyester resin ]
(a) The unsaturated polyester resin is generally obtained by dissolving a condensate (unsaturated polyester) obtained by an esterification reaction between a polyhydric alcohol and an unsaturated polybasic acid and a saturated polybasic acid as an optional component in a crosslinking agent (also referred to as a "reactive diluent"). The unsaturated polybasic acid means a polybasic acid having an ethylenic double bond capable of polymerization, and the saturated polybasic acid means a polybasic acid having no ethylenic double bond capable of polymerization. Such unsaturated polyester resins are generally known in the technical field of the present invention and are described in, for example, handbook of polyester resins (published by japan industrial news agency, 1988) and dictionary of coatings (compiled by japan color materials association, 1993).
The polyol used for the synthesis of the unsaturated polyester is not particularly limited, and any known polyol in the technical field of the present invention can be used. Examples of the polyhydric alcohol include ethylene glycol, propylene glycol, neopentyl glycol, butanediol, diethylene glycol, dipropylene glycol, triethylene glycol, pentanediol, hexanediol, neopentanediol (Neopentane diol), hydrogenated bisphenol a, glycerin, and the like. Among them, propylene glycol, neopentyl glycol, and bisphenol a or hydrogenated bisphenol a are preferable from the viewpoint of heat resistance, mechanical strength, and resin fluidity at the time of molding. These polyols may be used alone or in combination of plural kinds.
The unsaturated polybasic acid used for the synthesis of the unsaturated polyester is not particularly limited, and any unsaturated polybasic acid known in the art of the present invention can be used. Examples of the unsaturated polybasic acid include maleic anhydride, fumaric acid, citraconic acid, and itaconic acid. These unsaturated polybasic acids may be used alone or in combination of plural kinds. Among them, maleic anhydride and fumaric acid are more preferable from the viewpoint of heat resistance, mechanical strength, resin fluidity during molding, and the like.
The saturated polybasic acid used for the synthesis of the unsaturated polyester is not particularly limited, and a known saturated polybasic acid can be used. Examples of the saturated polybasic acid include phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid, tetrachlorophthalic anhydride, tetrabromophthalic anhydride, endomethylenetetrahydrophthalic anhydride, and chlorendic acid. These saturated polybasic acids may be used alone or in combination of plural kinds.
The unsaturated polyester can be synthesized by a known method using the raw materials as described above. Various conditions in the synthesis need to be appropriately set depending on the raw materials and the amounts thereof used, but generally, esterification may be carried out by pressurizing or depressurizing the raw materials in a stream of inert gas such as nitrogen at a temperature of 140 to 230 ℃. For the esterification reaction, an esterification catalyst may be used as needed. Examples of the catalyst include known catalysts such as manganese acetate, dibutyltin oxide, stannous oxalate, zinc acetate, and cobalt acetate. These catalysts may be used alone or in combination of plural kinds.
The weight average Molecular Weight (MW) of the unsaturated polyester is not particularly limited, but is preferably 3000 to 25000, more preferably 5000 to 20000, and further preferably 7000 to 18000. The "weight average molecular weight" in the present specification means a value determined by measuring at room temperature (23 ℃) under the following conditions using a gel permeation chromatography (Shodex (registered trademark) GPC-101 manufactured by Showa Denko K.K.) using a standard polystyrene calibration curve.
Column: showa Denko K.K. LF-804
Column temperature: 40 deg.C
A sample: 0.2% by mass of a tetrahydrofuran solution of an unsaturated polyester
Flow rate: 1 mL/min
Eluent: tetrahydrofuran;
a detector: RI-71S.
The crosslinking agent used in the unsaturated polyester resin (a) is not particularly limited as long as it has an ethylenic double bond polymerizable with the unsaturated polyester, and crosslinking agents known in the art of the present invention can be used. Examples of the crosslinking agent include styrene monomer, diallyl phthalate prepolymer, methyl methacrylate, triallyl isocyanurate, and the like. These crosslinking agents may be used alone or in combination of plural kinds.
(a) The amount of the crosslinking agent added to the unsaturated polyester resin is not particularly limited, but is preferably 25 to 70% by mass, more preferably 30 to 68% by mass, and even more preferably 35 to 65% by mass based on the total amount of the unsaturated polyester and the crosslinking agent, from the viewpoints of workability, polymerizability, shrinkage of a molded article, and freedom in adjustment of the amount of the crosslinking agent.
(a) The unsaturated polyester resin may contain a polymerization inhibitor such as hydroquinone, if necessary.
[ (b) inorganic Filler ]
As the inorganic filler (b), inorganic fillers known in the art of the present invention can be used. Examples of the inorganic filler (b) include calcium carbonate, silica, alumina, aluminum hydroxide, barium sulfate, wollastonite, clay, talc, mica, gypsum, anhydrous silicic acid, and glass powder. These inorganic fillers may be used alone or in combination of two or more.
(b) The inorganic filler preferably has a true density of 1 to 10g/cm3More preferably 1.5 to 8g/cm3And further preferably 2 to 5g/cm3. If the true density of the inorganic filler is 1g/cm3As described above, the mechanical properties of the molded article become better, and if the true density of the inorganic filler is 10g/cm3The kneading property is more preferable as follows.
The shape of the inorganic filler (b) is not particularly limited, and examples thereof include substantially spherical, ellipsoidal, scaly, and irregular shapes.
(b) The amount of the inorganic filler is 250 to 600 parts by mass, more preferably 300 to 550 parts by mass, still more preferably 350 to 500 parts by mass, and particularly preferably 350 to 450 parts by mass based on 100 parts by mass of the unsaturated polyester resin (a). (b) When the amount of the inorganic filler is 250 parts by mass or more, the mechanical properties of the molded article become better. Further, if the blending amount of the inorganic filler (b) is 600 parts by mass or less, the inorganic filler (b) is more uniformly dispersed in the unsaturated polyester resin composition, and therefore a uniform molded article can be produced.
[ (b1) and (b2) inorganic fillers having a specific average particle diameter ]
The inorganic filler contains (b1) an inorganic filler having an average particle diameter of 0.5 to 5.0 μm and (b2) an inorganic filler having an average particle diameter of 8.0 to 50.0 μm.
In the present specification, the term "average particle diameter" of the inorganic filler (b) means a particle diameter obtained by obtaining a specific surface area by an air permeation method using a constant pressure powder specific surface area measuring apparatus and substituting the specific surface area into the following formula. As the constant pressure powder specific surface area measuring apparatus, SS-100 manufactured by Shimadzu corporation was used.
Average particle diameter [ mu ] m](6 × 10000)/(true density g/cm)3]X specific surface area [ cm ]2/g])
(b1) The average particle diameter of (A) is more preferably 0.7 to 4.0 μm, still more preferably 0.8 to 3.0. mu.m. On the other hand, the average particle diameter of (b2) is more preferably 9.0 to 40.0. mu.m, and still more preferably 10.0 to 30.0. mu.m. When the average particle diameter of (b1) is 0.5 μm or more, the viscosity of the unsaturated polyester resin composition is suitable, and good resin fluidity is obtained during molding, and when it is 5.0 μm or less, the surface smoothness of the molded article can be improved. Further, if the average particle diameter of (b2) is 8.0 μm or more, the resin fluidity and the mechanical strength of the molded article during molding become better, and if it is 50.0 μm or less, the surface smoothness of the molded article is better maintained.
(b1) And (b2) in a mass ratio of 25: 75-75: 25. from the viewpoint of surface smoothness, it is preferably 30: 70-70: 30. more preferably 40: 60-60: 40.
[ (c) Metal soap ]
(c) The metal soap is a component generally used as a mold release agent in the technical field of the present invention. The metal soap (c) is not particularly limited, and those known in the art of the present invention can be used. Examples of the metal soap (c) include calcium stearate, zinc stearate, aluminum stearate, and magnesium stearate. They may be used alone or in combination of plural kinds.
(c) The amount of the metal soap is preferably 1 to 15 parts by mass per 100 parts by mass of the unsaturated polyester resin (a). (c) When the amount of the metal soap is 1 part by mass or more, the molded article has better releasability. On the other hand, if the amount of the metal soap (c) is 15 parts by mass or less, the metal soap (c) can be prevented from precipitating on the surface of the molded article, and a molded article having desired fogging properties and coating properties of the primer can be obtained.
[ (d) Low shrinkage agent ]
The low shrinkage agent (d) is not particularly limited, and any known low shrinkage agent in the technical field of the present invention can be used. Examples of the low shrinkage agent include thermoplastic polymers generally used as low shrinkage agents, such as polystyrene, polymethyl methacrylate, polyvinyl acetate, saturated polyester, and styrene-butadiene rubber. These low shrinkage agents may be used alone or in combination of two or more.
(d) The amount of the low shrinkage agent is preferably 10 to 40 parts by mass per 100 parts by mass of the unsaturated polyester resin (a). (d) When the amount of the low shrinkage agent is 10 parts by mass or more, the shrinkage of the molded article is small, and the desired dimensional accuracy can be obtained. On the other hand, if the amount of the (d) low shrinkage agent is 40 parts by mass or less, the mechanical properties of the molded article become better.
[ (e) fibrous reinforcing Material ]
(e) The fiber reinforcement is a fibrous material having an aspect ratio of 3 or more. The aspect ratio can be determined by the Japanese Industrial Standard JISR-8900-1: 2008 "particles for particle size measurement apparatus detection" in the specification.
(e) The fiber reinforcement is not particularly limited, and any fiber reinforcement known in the art of the present invention may be used. Examples of the fiber reinforcement (e) include various organic fibers and inorganic fibers such as glass fibers, pulp fibers, polyethylene terephthalate fibers, vinylon fibers, carbon fiber fibers, aramid fibers, and wollastonite. Among them, glass fibers are preferable, and chopped glass having a fiber length of about 1.5 to 25mm is more preferable.
(e) The amount of the fiber reinforcement is preferably 70 to 120 parts by mass per 100 parts by mass of the unsaturated polyester resin (a). (e) If the blending amount of the fiber reinforcement is 70 parts by mass or more, the mechanical properties of the molded article become better. On the other hand, if the blending amount of the fiber reinforcement (e) is 120 parts by mass or less, the fiber reinforcement (e) is more uniformly dispersed in the unsaturated polyester resin composition, and a homogeneous molded article can be produced.
[ (f) curing agent ]
(f) The curing agent is not particularly limited as long as it is a radical initiator capable of polymerizing an ethylenically unsaturated bond, and any curing agent known in the art of the present invention can be used. Examples of the curing agent (f) include organic peroxides such as t-butyl peroctoate, benzoyl peroxide, 1-di-t-butyl peroxy-3, 3, 5-trimethylcyclohexane, t-butyl peroxyisopropylcarbonate, t-butyl peroxybenzoate, dicumyl peroxide, and di-t-butyl peroxide. These curing agents may be used alone or in combination of two or more.
(f) The blending amount of the curing agent is not particularly limited, and may be appropriately set according to the raw materials used. (f) The amount of the curing agent is preferably 1 to 10 parts by mass, more preferably 1 to 8 parts by mass, and still more preferably 1 to 5 parts by mass, per 100 parts by mass of the unsaturated polyester resin (a).
[ other ingredients ]
The unsaturated polyester resin composition of the present invention may contain, in addition to the above components, components known in the art of the present invention such as a tackifier, a pigment, and a viscosity reducer, within a range not to impair the effects of the present invention.
The thickener is not particularly limited, and examples thereof include (b) metal oxides other than inorganic fillers, such as magnesium oxide, magnesium hydroxide, calcium hydroxide and calcium oxide, and isocyanate compounds. These tackifiers may be used alone or in combination of two or more.
[ Process for producing unsaturated polyester resin composition ]
The unsaturated polyester resin composition can be prepared by kneading the respective components by a method generally used in the technical field of the present invention, for example, by using a kneader or the like.
[ method for producing molded article of unsaturated polyester resin composition ]
The unsaturated polyester resin composition can be molded into a desired shape and cured to prepare a molded article. The molding and curing method is not particularly limited, and methods generally performed in the technical field of the present invention, such as compression molding, transfer molding, injection molding, and the like, can be used.
[ Lamp light Reflector ]
The molded product of the unsaturated polyester resin composition is suitable as a base material for a lamp reflector. Since the unsaturated polyester resin composition containing the 2 inorganic fillers having a specific average particle diameter has excellent surface smoothness of a molded article, the thickness of the primer layer necessary for preventing light distribution unevenness is small. Therefore, the manufacturing cost can be reduced.
The lamp reflector generally comprises a molded body (substrate) of an unsaturated polyester resin composition, an undercoat layer on the molded body, and a metal reflective layer on the undercoat layer.
Hereinafter, preferred embodiments of the lamp reflector will be described with reference to the drawings.
Fig. 1a is a cross-sectional view of a lamp including a lamp reflector according to an embodiment. In addition, FIG. 1b is an enlarged cross-sectional view taken along line a-a' of FIG. 1 a.
In fig. 1a, the lamp generally includes a lamp reflector, a light source 4 provided at a predetermined position of the lamp reflector, and a lens 5 provided at an opening of the lamp reflector. Here, as shown in fig. 1b, the lamp reflector includes a molded body 1 of an unsaturated polyester resin composition, an undercoat layer 2 on the molded body 1, and a metal reflective layer 3 on the undercoat layer 2. In this lamp, light generated by the light source 4 is reflected by the metal reflective layer 3.
The thickness of the undercoat layer 2 may be appropriately set according to the size of the lamp reflector required, and is usually 10 to 50 μm.
The primer for providing the undercoat layer 2 is not particularly limited, and any known primer in the art of the present invention can be used. This primer is also referred to as a primer composition, and is generally a resin composition containing a UV curable resin or a thermosetting resin. Examples of the UV-curable resin and the thermosetting resin include acrylic resins obtained by homopolymerization or copolymerization of polyfunctional monomers such as pentaerythritol triacrylate, pentaerythritol tetraacrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, dipentaerythritol hexaacrylate, and dipentaerythritol pentaacrylate. The primer may contain a polyester resin such as an unsaturated polyester resin, a vinyl-modified polyester resin, a phenol-modified polyester resin, an oil-and-fat-modified polyester resin, or a silicone-modified polyester resin, a curing agent, a solvent, or the like.
The thickness of the metal reflective layer 3 can be set appropriately according to the size of the lamp reflector required, and is usually set to be
The material for providing the metal reflective layer 3 is not particularly limited, and a metal reflective layer material known in the art of the present invention can be used. Examples of the material of the metal reflective layer 3 include aluminum, silver, zinc, and an alloy mainly composed of silver or zinc
The light source 4 and the lens 5 provided at a predetermined position of the lamp body are not particularly limited, and those known in the art of the present invention can be used.
[ method for manufacturing Lamp Reflector ]
The lamp reflector having such a configuration may be manufactured in the following manner.
First, the unsaturated polyester resin composition is molded and cured to obtain a molded article 1. The molded article 1 can be obtained by molding the unsaturated polyester resin composition into a predetermined shape by a known molding method such as compression molding, transfer molding, or injection molding, and curing the molded article.
Next, a release agent removing treatment is performed as necessary. The release agent can be removed by cleaning, heat treatment, flame treatment, or the like.
Next, a primer is applied to the molded body 1 and cured to form the primer layer 2. The method for applying the primer to the molded body 1 is not particularly limited, and known methods such as an air spray method and an airless spray method can be used. The curing method is also not particularly limited, and may be appropriately selected according to the kind of the primer.
Then, the metal reflective layer 3 is formed on the undercoat layer 2. The method for forming the metal reflective layer 3 on the undercoat layer 2 is not particularly limited, and a known method such as a vacuum deposition method can be used.
Further, the light source 4 and the wafer 5 are fixed at predetermined positions of the lamp body. The method for fixing the light source 4 and the wafer 5 is not particularly limited, and may be performed according to a known method.
Examples
The present invention will be specifically described below with reference to examples and comparative examples, but the present invention is not limited thereto.
(Synthesis of unsaturated polyester resin)
100 moles of propylene glycol, 30 moles of phthalic anhydride and 70 moles of maleic anhydride were charged into a reaction vessel equipped with a stirrer, a reflux condenser, a nitrogen inlet and a thermometer, and the mixture was reacted at 210 ℃ by a usual method until the acid value was 20 mgKOH/g. Then, 100 parts by mass of the reaction product was added with 0.015 part by mass of hydroquinone, and after cooling to 160 ℃, styrene monomer was further added to obtain an unsaturated polyester resin. Here, the styrene monomer was added so that it was 30 mass% in the unsaturated polyester resin. Further, the weight average Molecular Weight (MW) of the unsaturated polyester was 15000 as measured under the above conditions.
(examples 1 to 13)
The components were added in the addition compositions shown in Table 1, and kneaded at 25 ℃ for 30 minutes using a double arm kneader to obtain unsaturated polyester resin compositions. In addition, the unsaturated polyester resin (a) shown in tables 1 and 2 contains 30 mass% of styrene monomer.
Comparative examples 1 to 10
The components were added in the addition compositions shown in Table 2, and kneaded at 25 ℃ for 30 minutes using a double arm kneader to obtain unsaturated polyester resin compositions.
In the examples and comparative examples described above, calcium carbonate (8 types having average particle diameters of 0.5. mu.m, 1.0. mu.m, 2.0. mu.m, 5.0. mu.m, 8.0. mu.m, 10.0. mu.m, 20.0. mu.m, and 50.0. mu.m, respectively, and having true densities of 2.7g/cm was used as the inorganic filler (b)3) Zinc stearate was used as the metal soap (c), polystyrene (weight average molecular weight 200000) was used as the low shrinkage agent (d), chopped glass (fiber length 6mm) was used as the fiber reinforcement (e), and t-butyl peroxybenzoate was used as the curing agent (f).
The unsaturated polyester resin compositions of examples and comparative examples obtained in the above manner were evaluated for kneading property, in-mold flowability of the resin compositions, surface smoothness of molded articles, molding shrinkage and bending modulus. Further, the unsaturated polyester resin composition whose kneading property was evaluated as poor was not subjected to other evaluations. These evaluation methods are as follows. The results are shown in tables 1 and 2.
(1) Kneading property
When an unsaturated polyester resin composition was prepared by kneading the components at 25 ℃ for 30 minutes using a double-arm kneader, it was visually evaluated whether a uniform unsaturated polyester resin composition free from dispersion failure was obtained, and in this evaluation, ○ was indicated when the unsaturated polyester resin composition was uniform, and x was indicated when dispersion failure was present in the unsaturated polyester resin composition.
(2) In-mold flowability of resin composition
A spiral flow mold (a trapezoid having a cross-sectional shape of 6mm at the upper side, 8mm at the lower side and a height of 2 mm) was fixed to a transfer molding machine (manufactured by テクノマルシチ Co., Ltd.), a swirling flow test was conducted under conditions of a mold temperature of 160 ℃ and an injection pressure of 10MPa, and a flow length was measured. In this evaluation, the resin composition was evaluated to have good in-mold flowability when the flow length was 40cm or more.
(3) Surface smoothness of molded article
Transfer molding was carried out at a molding temperature of 160 ℃ under an injection pressure of 20MPa for a molding time of 1 minute (a transfer molding machine manufactured by テクノマルシチ Co., Ltd.) to prepare a transfer molded article (having a thickness of 117mm and a thickness of 3 mm). The transfer molded article was visually checked for appearance, and the case where the transfer molded article had glossy all over and had no pits was regarded as good, and the case where the transfer molded article had glossy all over or partially had no gloss or had pits all over or partially was regarded as poor.
(4) Molding shrinkage ratio
A shrinkage disk (φ 90 mm. times.11 mm) prescribed in JIS K-69115.7 was produced by compression molding (compression molding machine manufactured by テクノマルシチ, Inc.) at a molding temperature of 160 ℃, a molding pressure of 10MPa and a molding time of 3 minutes, and the molding shrinkage was calculated in accordance with JIS K-69115.7.
(5) Bending modulus of elasticity
A bending modulus test piece (90 mm. times.10 mm. times.4 mm) prescribed in JIS K-69115.17 was produced by compression molding (compression molding machine manufactured by テクノマルシチ Co., Ltd.) at a molding temperature of 160 ℃, a molding pressure of 10MPa and a molding time of 3 minutes, and the bending modulus was measured in accordance with JIS K-69115.17.
Description of the symbols
1 molded body, 2 primer layer, 3 metal reflective layer, 4 light source, 5 wafer
Claims (6)
1. An unsaturated polyester resin composition comprising (a) an unsaturated polyester resin, (b) an inorganic filler, (c) a metal soap, (d) a low shrinkage agent, (e) a fiber reinforcing material and (f) a curing agent,
the inorganic filler (b) is 250 to 600 parts by mass per 100 parts by mass of the unsaturated polyester resin (a),
the inorganic filler (b) comprises (b1) an inorganic filler having an average particle diameter of 0.5 to 5.0 [ mu ] m and (b2) an inorganic filler having an average particle diameter of 8.0 to 50.0 [ mu ] m, wherein the mass ratio of (b 1): (b2) 25: 75-75: a ratio of 25 is contained.
2. The unsaturated polyester resin composition according to claim 1, wherein the amount of the inorganic filler (b) is 350 to 450 parts by mass per 100 parts by mass of the unsaturated polyester resin (a).
3. The unsaturated polyester resin composition according to claim 1 or 2, wherein (b) the inorganic filler contains calcium carbonate.
4. The unsaturated polyester resin composition according to any one of claims 1 to 3, wherein the fiber reinforcement (e) is 70 to 120 parts by mass relative to 100 parts by mass of the unsaturated polyester resin (a).
5. A molded article comprising a cured product of the unsaturated polyester resin composition according to any one of claims 1 to 4.
6. A lamp reflector comprising the shaped body of claim 5, a primer layer on the shaped body, and a metal reflective layer on the primer layer.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2017-236705 | 2017-12-11 | ||
| JP2017236705 | 2017-12-11 | ||
| PCT/JP2018/037262 WO2019116691A1 (en) | 2017-12-11 | 2018-10-04 | Unsaturated polyester resin composition, molded article containing cured product thereof, and lamp reflector including said molded article |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN111201280A true CN111201280A (en) | 2020-05-26 |
Family
ID=66819119
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201880065135.2A Pending CN111201280A (en) | 2017-12-11 | 2018-10-04 | Unsaturated polyester resin composition, molded article containing cured product thereof, and lamp reflector containing the molded article |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPWO2019116691A1 (en) |
| CN (1) | CN111201280A (en) |
| WO (1) | WO2019116691A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP6919774B2 (en) * | 2019-06-25 | 2021-08-18 | Dic株式会社 | Molding materials, molded products and artificial marble |
| JPWO2022137686A1 (en) * | 2020-12-21 | 2022-06-30 |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63243121A (en) * | 1987-03-30 | 1988-10-11 | Hitachi Chem Co Ltd | Low-shrinkable unsaturated polyester resin composition |
| JPH08199004A (en) * | 1995-01-20 | 1996-08-06 | Fuji Electric Co Ltd | Polyester premix molding material |
| JPH1135813A (en) * | 1997-07-22 | 1999-02-09 | Hitachi Chem Co Ltd | Unsaturated polyester resin composition excellent in plating property and production of molding product using the same |
| JP2001114999A (en) * | 1999-10-22 | 2001-04-24 | Hitachi Chem Co Ltd | Unsaturated polyester resin composition and molding using same |
| CN104371237A (en) * | 2014-12-05 | 2015-02-25 | 上海昭和高分子有限公司 | Unsaturated polyester resin composition thickened by non-alkali metal systems and bulk molding compound with unsaturated polyester resin composition |
| CN106795252A (en) * | 2014-09-04 | 2017-05-31 | 昭和电工株式会社 | Unsaturated polyester resin compositions, lamp reflector and its manufacture method |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2011006542A (en) * | 2009-06-24 | 2011-01-13 | Showa Denko Kk | Unsaturated polyester resin composition and encapsulated motor |
| WO2013151151A1 (en) * | 2012-04-05 | 2013-10-10 | ジャパンコンポジット株式会社 | Molding material for lamp reflectors and molded article |
-
2018
- 2018-10-04 CN CN201880065135.2A patent/CN111201280A/en active Pending
- 2018-10-04 WO PCT/JP2018/037262 patent/WO2019116691A1/en active Application Filing
- 2018-10-04 JP JP2019558930A patent/JPWO2019116691A1/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63243121A (en) * | 1987-03-30 | 1988-10-11 | Hitachi Chem Co Ltd | Low-shrinkable unsaturated polyester resin composition |
| JPH08199004A (en) * | 1995-01-20 | 1996-08-06 | Fuji Electric Co Ltd | Polyester premix molding material |
| JPH1135813A (en) * | 1997-07-22 | 1999-02-09 | Hitachi Chem Co Ltd | Unsaturated polyester resin composition excellent in plating property and production of molding product using the same |
| JP2001114999A (en) * | 1999-10-22 | 2001-04-24 | Hitachi Chem Co Ltd | Unsaturated polyester resin composition and molding using same |
| CN106795252A (en) * | 2014-09-04 | 2017-05-31 | 昭和电工株式会社 | Unsaturated polyester resin compositions, lamp reflector and its manufacture method |
| CN104371237A (en) * | 2014-12-05 | 2015-02-25 | 上海昭和高分子有限公司 | Unsaturated polyester resin composition thickened by non-alkali metal systems and bulk molding compound with unsaturated polyester resin composition |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2019116691A1 (en) | 2019-06-20 |
| JPWO2019116691A1 (en) | 2020-12-24 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP6022561B2 (en) | Unsaturated polyester resin composition and molded article thereof, and lamp reflector | |
| JP5308737B2 (en) | Unsaturated polyester resin composition for lamp reflector and molded product thereof, and lamp reflector | |
| JP6590342B2 (en) | Unsaturated polyester resin composition, lamp reflector and method for producing the same | |
| WO2013018360A1 (en) | Thermoplastic resin composition for reflective material, reflective plate, and light-emitting diode element | |
| JP4673298B2 (en) | Low specific gravity unsaturated polyester resin composition for lamp reflector and molded product thereof | |
| JP4598822B2 (en) | Unsaturated polyester resin composition for lamp reflector and molded product thereof | |
| CN1167897A (en) | Lamp reflector molding composition, process for producing lamp reflector, and lamp reflector | |
| CN111201280A (en) | Unsaturated polyester resin composition, molded article containing cured product thereof, and lamp reflector containing the molded article | |
| JP6454639B2 (en) | Polyester resin composition for reflector and reflector including the same | |
| JP6140484B2 (en) | Unsaturated polyester resin composition for lamp reflector and molded product thereof, and lamp reflector | |
| JP4002746B2 (en) | Unsaturated polyester resin composition and cured product thereof, and lamp reflector substrate | |
| KR20010051060A (en) | Unsaturated polyester resin and composition for molding compound | |
| JP7186602B2 (en) | Thermosetting resin composition, molding and lamp reflector | |
| JP2011162748A (en) | Bulk molding compound, lamp reflector and method for producing the same | |
| JP5919071B2 (en) | Thermoplastic resin for reflector and reflector | |
| JP2011073322A (en) | Lamp reflector molding | |
| WO2021065217A1 (en) | Thermally curable resin composition, molded object, and lamp reflector | |
| CN116745330A (en) | Unsaturated polyester resin composition and molded article | |
| JPS63268722A (en) | Unsaturated polyester resin composition | |
| CN104334595B (en) | Unsaturated polyester resin compositions and article shaped thereof and lamp reflector | |
| JP2018103446A (en) | Film insert molding and film insert molding production method | |
| JPH1045892A (en) | Unsaturated polyester for molding material and molding material using the same | |
| JPH08333426A (en) | Thermosetting molding material and method for molding the same | |
| JP2001294636A (en) | Resin composition | |
| MXPA97010391A (en) | Powder coatings with double, thermal and ultraviol curing |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| RJ01 | Rejection of invention patent application after publication |
Application publication date: 20200526 |
|
| RJ01 | Rejection of invention patent application after publication |