CN1914033A - Base material for light reflector and light reflector - Google Patents

Base material for light reflector and light reflector Download PDF

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Publication number
CN1914033A
CN1914033A CNA200580003331XA CN200580003331A CN1914033A CN 1914033 A CN1914033 A CN 1914033A CN A200580003331X A CNA200580003331X A CN A200580003331XA CN 200580003331 A CN200580003331 A CN 200580003331A CN 1914033 A CN1914033 A CN 1914033A
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China
Prior art keywords
base material
light reflector
layer
polymeric membrane
aluminium
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Chinese (zh)
Inventor
永田贤一
和气进
田边胜
樱井雅浩
冲村裕伸
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Mitsui Chemicals Inc
Mitsui Chemical Industry Co Ltd
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Mitsui Chemical Industry Co Ltd
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Publication of CN1914033A publication Critical patent/CN1914033A/en
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/08—Mirrors
    • G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
    • G02B5/085—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal
    • G02B5/0858—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising a single metallic layer with one or more dielectric layers
    • G02B5/0866—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising a single metallic layer with one or more dielectric layers incorporating one or more organic, e.g. polymeric layers
    • 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
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/08—Mirrors
    • G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
    • G02B5/0825—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only
    • G02B5/0833—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only comprising inorganic materials only
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/08—Mirrors
    • G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
    • G02B5/0825—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only
    • G02B5/0841—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only comprising organic materials, e.g. polymers
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/08—Mirrors
    • G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
    • G02B5/085—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal
    • G02B5/0858—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising a single metallic layer with one or more dielectric layers

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Optical Elements Other Than Lenses (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention provides a base material for light reflector that has a high light reflectance, thermal stability, resistance to high temperature high humidity and geometrical stability, being thin; and a relevant light reflector. There is provided a base material for light reflector comprising a polymer membrane (A), inorganic substance layer (B), adhesive layer (C) and base (D), these components arranged in the order of (A)/(B)/(C)/(D), wherein the inorganic substance layer (B) is a layer containing at least a metal, a metal oxide or a mixture thereof. It has been found that this base material for light reflector has strikingly high thermal stability, resistance to high temperature high humidity and geometrical stability as compared with those of the prior art. A light reflector exhibiting high reflectance and excelling in durability can be obtained by superimposing metal layer (E) containing silver or aluminum on the polymer film (A) of the base material for light reflector.

Description

Base material for light reflector and refractive body
Technical field
The present invention relates to the base material for light reflector that constitutes by polymeric membrane, inorganic layer, bond layer, base material and use their refractive body.Relate to the OA machine that is used for LCD, facsimile machine, duplicator, projector, flash lamp, DPE machine, exposure device, light aging device etc., the base material for light reflector and the refractive body of industrial machine in more detail.
Background technology
Recently, along with the high pixelation of LCD, to the requirement raising of backlight illumination.One of method that improves backlight illumination is, uses the high refractive body of reflecting rate as lamp box, makes the method for being fully used from the light of illuminator.This refractive body, owing to also absorb from the heat of illuminator radiation, thereby not only require to have high reflectance, and require to have high-fire resistance.
In addition, particularly the component parts of portable machine such as notebook requires its volume little in light weight.Volume is little, in light weight, thin thickness, can keep stable shaped material to be suitable for using as the refractive body of LCD backlight with lamp box.The more important thing is especially to have high-temp resisting high-humidity resisting character, can in various environment, using.
Be used for the refractive body of the lamp reflector of LCD backlight part and the reflecting umbrella of fluorescent lamp etc. in the past, constituted by reflector layer, polymeric membrane, bond layer, base material successively, and used metallic films such as silver or aluminium as reflector layer.
Put down in writing a kind of duplexer in the Te Kaiping 8-118536 communique with metal film layer, polymeric membrane, bond layer, base material, and with the refractive body of metal film layer as reflector layer.The bonding of polymeric membrane and base material is according to behind a coating adhesive that does not form reflector layer of polymeric membrane, drying, again with itself and base material lamination in sequence with roller.
In order to improve the cementability of polymeric membrane and base material, various processing are carried out on known surface at polymeric membrane.For example, for the method for the adhesive strength that improves polymeric membrane and bonding agent has, carry out the method that blasting treatment strengthens its surface roughness on the polymeric membrane surface, carry out the glow discharge processing on the polymeric membrane surface and wait the method that the surface that changes the polymeric membrane surface can state, polymeric membrane surface coating surface can be big the method for other resins.For example, the spy opens in the 2003-341000 communique and puts down in writing, and the copolyester that forms with water-soluble or water dispersible in polyester film surface is that resin and/or polyurethane series resin are the optics polyester film of the material layer of main component.
Specially permit in No. 2553187 communiques and put down in writing, carry out sandblast processing back on the polymeric membrane surface and further have the metallic film 0.5nm～10nm of surface active and thermoplasticity adhesive linkage, the polymeric membrane of easy bonding processing in the compacting.Pasted among the embodiment of chlorotrifluoroethylene polymer film and nylon film and put down in writing, if suppress metallic film under the situation of not carrying out sandblast processing, adhesive strength just reduces when the thickness of metallic film is big.
In the processing method in the past, the adhesive strength of polymeric membrane and base material is not necessarily abundant, particularly under high temperature or hot and humid condition, has the problem of the adhesive strength reduction of polymeric membrane and base material.Particularly the adhesive strength of polymeric membrane and metal system base material is not enough.
And the surface treatment method of polymeric membranes such as sandblast influences the surface configuration of the non-treated side of polymeric membrane, thereby may cause that the surface configuration of reflector layer changes, and causes reflecting rate to reduce.
Patent documentation 1: the spy opens flat 8-118536 communique
Patent documentation 2: the spy opens the 2003-341000 communique
Patent documentation 3: specially permit No. 2553187 communique
Summary of the invention
The purpose of this invention is to provide have high reflecting rate, hear resistance, high-temp resisting high-humidity resisting, shape stability, and the refractive body of thin thickness.
The inventor finds, by the base material side at polymeric membrane inorganic layer is set, and can improve the cementability of polymeric membrane and base material, can access the base material for light reflector with high-temp resisting high-humidity resisting, hear resistance, shape stability, thereby finish the present invention.
Promptly, first invention of the present invention is a kind of base material for light reflector, it is characterized by, has the stepped construction that comprises polymeric membrane (A), inorganic layer (B), bond layer (C), base material (D), (A), (B), (C), (D) be the sequential cascade according to (A)/(B)/(C)/(D), inorganic layer (B) is for comprising the layer of metal, metallic compound or their mixture at least.
Consider that from the humidity resistance angle peel strength of the polymeric membrane (A) of above-mentioned base material for light reflector after placing 500 hours under the environment of 60 ℃ of relative humidity 90% of temperature and base material (D) is preferably 0.10kN/m or more than it.
And, consider that from the hear resistance angle peel strength of the polymeric membrane (A) of above-mentioned base material for light reflector in 100 ℃ of environment and base material (D) is preferably 0.10kN/m or more than it.
In addition, consider that from the high angle of processability, mechanical strength base material (D) is preferably the plate that contains metal.
And, consider that from the cementability and the high angle of polymeric membrane pliability of polymeric membrane and base material the thickness of inorganic layer (B) is preferably 10nm～100nm.
In addition, second invention is a kind of refractive body, it is characterized by, and forms the metal level (E) that contains silver or aluminium on above-mentioned base material for light reflector, constitutes the stepped construction of (E)/(A)/(B)/(C)/(D).
Consider that from the angle that can obtain high reflecting rate metal level (E) is preferably silver or contains the alloy of silver.
Description of drawings
Fig. 1 is the sectional view of the example of expression base material for light reflector of the present invention.
Fig. 2 is the sectional view of the example of expression refractive body of the present invention.
The specific embodiment
Below, the present invention is described in detail.
Base material for light reflector of the present invention has the stepped construction that comprises polymeric membrane (A), inorganic layer (B), bond layer (C), base material (D), (A), (B), (C), (D) be the sequential cascade according to (A)/(B)/(C)/(D).
Below, describe in detail about each constituent material.
(polymeric membrane (A))
Polymeric membrane among the present invention (A) then is not particularly limited so long as can tolerate the stable on heating material of the object of the invention degree.For example can be, polyesters such as PETG (PET), PEN, bisphenol-A is that Merlon etc. is polycarbonate-based, TPOs such as polyethylene, polypropylene, cellulose derivative classes such as primary cellulose acetate, vinylites such as Vingon, polyimide, polyamide-based, polyether sulfone, polysulfones are resin, polyacrylate is a resin, the film that various plastics such as fluorine resin are made.The preferred PETG that uses.Owing to used the high material of hear resistance, can obtain the refractive body that can at high temperature use.And, can contain additives such as other heat-resisting stabilizing agents, antioxidant in these polymeric membranes.
Because the free degree height of membrane forming polymer processability, and suitable rolling produces manufacture methods such as (roll toroll) technology continuously, and therefore the productivity ratio height is preferred.
The thickness of polymeric membrane (A) is not particularly limited, but preferred 1～200 μ m, more preferably 5～100 μ m, further preferred 10 μ m～50 μ m.Under the situation of thickness in above-mentioned scope of polymeric membrane (A), the suffered stress of polymeric membrane is little when carrying out bending process, can prevent that it from peeling off from base material.And, simple to operate during manufacturing, therefore the sheet metal handling ease is preferred.Blocked up, the suffered stress of polymeric membrane becomes big when carrying out bending process, may peel off from base material.And owing to increase with the refractive body gross thickness of its manufacturing, the refractive body little with gross thickness compares, even be processed into onesize lamp box, the space between lamp and the refractive body is also narrow, causes reflecting rate and hear resistance to reduce, and is not preferred therefore.In addition, thin excessively, it is difficult that the operation during manufacturing may become.
(inorganic layer (B))
Among the present invention,, paste polymeric membrane and base material across this inorganic layer at the one side formation inorganic layer of polymeric membrane.If do not form inorganic layer, particularly under the situation of the metal system of use base material,, need the sufficiently high bonding agent of adhesive strength in order to paste polymeric membrane and metal system base material.Bonding agent also needs to have hear resistance, the high-temp resisting high-humidity resisting degree, is very difficult and select such bonding agent.By inorganic layer is set, even use known bonding agent, the adhesive strength of polymeric membrane and base material is also very high, is preferred therefore.
Inorganic layer is the layer that comprises metal, metallic compound or their mixture.Specifically, can use the monomer of metals such as gold, silver, aluminium, copper, nickel, iron, cobalt, tungsten, molybdenum, tantalum, chromium, indium, manganese, titanium, palladium, zirconium, bismuth, tin, zinc, antimony, cerium, neodymium, lanthanum, thorium, magnesium, gallium as metal, or by two or more alloy that constitutes or mixture in them.Can use the oxide of indium, titanium, zirconium, bismuth, tin, zinc, antimony, tantalum, cerium, neodymium, lanthanum, thorium, magnesium, gallium, silicon, aluminium etc., zinc sulphide sulfides etc. as metallic compound.Also can use the mixture of metallic compound and the mixture of metallide.The monomer of wherein preferred gold, silver, aluminium, copper, nickel, iron, cobalt, tungsten, molybdenum, tantalum, chromium, indium, manganese, titanium, palladium or by two or more alloy that constitutes in them or mixture, zinc oxide, indium oxide, tin oxide, silica especially preferably uses nichrome, zinc oxide, inconel.The further preferred nichrome that uses.
Inorganic layer can be any color, is not particularly limited coloured or colourless.When making refractive body, outermost is the metal level of reflecting surface.Because inorganic layer is between polymeric membrane and bond layer, its color is to not influence of reflecting surface.Therefore, do not limit color, the transparency of inorganic layer.
Preferred 10nm～the 100nm of the thickness of inorganic layer, more preferably 10nm～50nm, further preferred 10nm～25nm.When the thickness of inorganic layer is thinner than above-mentioned scope, can make the effect reduction that improves polymeric membrane and the adhesive strength of base material.When thicker than above-mentioned scope, though compare with the situation of thickness in scope, the adhesive strength of polymeric membrane and base material does not change, the easy variation of the pliability of inorganic layer.In addition, owing to increased manufacturing cost, therefore tend to not preferred.
(the formation method of inorganic layer (B))
The formation method of inorganic layer (B) has wet method and dry method.
Wet method is the general name of galvanoplastic, is precipitating metal and form the method for film from solution.The object lesson that can enumerate has silver mirror reaction etc.On the other hand, dry method is the general name of vacuum film formation method, and the object lesson that can enumerate has vacuum vapour deposition, ion plating method, ion beam-assisted vacuum vapour deposition, sputtering method etc.Preferably use among the present invention, can adopt the vacuum film formation method of rolling continuous production processes that can continuous film forming, wherein preferably use electron beam heated type vacuum vapour deposition, sputtering method.
In the vacuum vapour deposition, will be by usefulness electronic beam method, electrical resistance heating, induction heating etc. as raw-material metal, metallic compound or their mixture fusion, vapour pressure is risen, metal or metallic compound attached on the polymeric membrane surface, are formed layer.
At this moment, can import gases such as oxygen, make it and the raw material reaction of evaporating; Also can import gases such as argon, apply voltage, produce plasma, make it evaporation in plasma.
Sputtering method has, and DC magnetron sputtering method, RF magnetron sputtering method, ion beam sputtering, ECR sputtering method, conventional RF sputtering method, conventional DC sputtering method etc. all can use.In the sputtering method, use metal, metal alloy, metallic compound or their mixture as target.Sputter gas can use inert gases such as helium, neon, argon, krypton, xenon, preferably uses argon gas.The purity of gas is preferably more than and equals 99%, more preferably greater than equaling 99.5%.Also can in reaction, add the gas (reactant gas) that needs and carry out sputter.Reactant gas can be selected known gas on demand for use.Reactant gas, specifiable representational example has oxygen, hydrogen etc.
The assay method of layer thickness has, and uses the method for contact pin type surfagauge, interreflection interferometer, little balancing method, quartz crystal method etc.When particularly utilizing the quartz crystal method, because thickness can be measured, be suitable for being used for the thickness that obtains to expect in film forming procedure.Also have on the basis that concerns between research film formation time and the thickness, according to the method for film formation time control thickness.Among the present invention, use method according to film formation time control thickness.
When on polymeric membrane, inorganic layer being set, can carry out Corona discharge Treatment, glow discharge processing etc. on this polymeric membrane surface.These processing have and improve institute and form layer effect with the cementability of polymeric membrane.Can in the scope of those skilled in the art's technology general knowledge, suitably adopt the processing method except that above-mentioned processing method in addition.But, must under the degree of the surface configuration that does not form the inorganic layer side that does not influence polymeric membrane, carry out.Carry out excess processes, the surface configuration that does not form the inorganic layer side is changed, when making refractive body, reflectivity descends.
(bond layer (C))
The bonding agent that is used for bond layer then is not particularly limited so long as at high temperature can keep the material of adhesive strength, can use known material.Preferred silicone-based bonding agent, the ethene of using is that bonding agent, polyester are that bonding agent, urethane adhesive, epoxy are that bonding agent, cyanoacrylate are bonding agent etc.More preferably using polyester is bonding agent, urethane adhesive.
According to the difference of adhering method, these bonding agents roughly are divided into heat curing-type, heat molten type, 2 liquid mixed types, but preferably use quantity-produced heat curing-type or heat molten type.Wherein polyester is the heat molten type bonding agent, polyurethane series heat molten type bonding agent can be bonding at short notice, and therefore low price is particularly preferred.
As one of index of the bonding agent of selecting at high temperature to keep adhesive strength, can enumerate glass transition temperature (Tg).Tg can measure or measure with the DSC (differential scanning calorimetry) that meets the JIS-K-7121 standard by the viscoplasticity temperature dispersion.Obtain Tg by viscoplasticity temperature dispersion mensuration among the present invention.Can at high temperature keep the Tg of the bonding agent of adhesive strength, normally 30～90 ℃, preferred 40～90 ℃, more preferably 60～90 ℃.
The thickness of bond layer is 0.5 μ m～50 μ m normally, preferred 3～25 μ m, more preferably 5～15 μ m.When bond layer is in this scope, can make the attenuation of refractive body thickness, be preferred therefore.When thinner than this scope, adhesive strength may die down.When thicker than this scope, it is big that refractive body thickness becomes, and dissolvent residual can make adhesive strength descend in bond layer.
When forming bond layer, preferably use rubbing method.According to the polymeric membrane of coating and the kind of bonding agent, multiple coating process is arranged.Being widely used is intaglio plate rubbing method and reverse rubbing method, and these can use.In the intaglio plate rubbing method, the gravure roll rotation that allows part immerse bonding agent makes the gravure roll of adhering to bonding agent contact with the film that transmits by backing roll, is coated with.Coating weight is adjusted by the rotating speed of control roll and the viscosity of bonding agent.It is similar with the intaglio plate rubbing method to reverse rubbing method, just by with the join measuring roller of setting of applicator roll the amount of the bonding agent that adheres on the applicator roll being adjusted.The baking temperature of the bonding agent that is coated with and stacked temperature, different according to the kind of bonding agent.For example, when using the above-mentioned common bonding agent of mentioning, temperature is about 100 ℃.
(base material (D))
Base material is mainly used in the purpose that keeps the refractive body dimensionally stable.So long as can satisfy the material of this purpose, then be not particularly limited.Preferably easy to process, have heat-resisting quantity, high-temp resisting high-humidity resisting, the material that volume in light weight is little.Preferable alloy or resin especially preferably use metal.Specifically can use aluminium, aluminium alloy, stainless steel, ormolu, steel etc.These metals have the following advantages separately, can select for use respectively according to the difference of refractive body application target.Because the in light weight and processability of aluminium is good, and its thermal conductivity height can make its suffered heat be dispersed in the air effectively, so be applicable to and make LCD that refractive body is heated with backlight because of lamp is luminous.Aluminium alloy is in light weight and mechanical strength is big.Stainless steel has the mechanical strength of appropriateness, and good corrosion resistance.Ormolu is a brass, and mechanical strength is big and welding is easy, therefore is convenient to make electric terminal.The low price of steel preferably uses in the time of therefore need controlling cost.
The example of resin can be enumerated polyolefin and various resins such as derivative, polyacrylate and derivative thereof, polyester and derivative thereof, polystyrene and derivative thereof, nylon and derivative thereof, polyimides and derivative thereof, PEN and derivative thereof thereof.Wherein, can use Tg to be higher than the resin of bonding agent aptly.
Can carry out surface treatment to the face of bonding agent one side of base material, cementability is improved.
The thickness of base material can be according to the material that uses, the application target of refractive body, and the operability during with reference to the shape of refractive body, processability, weight, manufacturing determines, is not particularly limited, but is preferably 0.05mm～5mm.0.1mm～0.8mm more preferably.
(metal level (E) that contains silver or aluminium)
Containing the metal level (E) of silver or aluminium, if be formed on the one side that does not form inorganic layer of polymeric membrane, then can obtain very high reflecting rate, is preferred therefore.This layer (E) forms in order to have catoptrical function.The metal of metal level preferably uses the monomer of silver or aluminium or contains silver or the alloy of aluminium.
The monomer of silver or aluminium, preferred silver or aluminium are 100 weight %, but in fact often contain hetero atom or other metals such as aerobic or sulphur.Therefore said silver or aluminium monomer are defined as among the present invention, and silver or aluminium are more than or equal to the material of 99 weight %.The silver in the metal level or the containing ratio of aluminium are preferably 99.9 weight % or more than it, more preferably 99.99 weight % or more than it.
As the alloy that contains silver or aluminium, can enumerate the silver or the aluminium of metals such as for example containing gold, copper, nickel, iron, cobalt, tungsten, molybdenum, tantalum, chromium, indium, manganese, titanium, palladium, neodymium, cadmium, antimony, tin, zinc, niobium, bismuth.The kind of institute's containing metal can be multiple.Amount is not particularly limited, but considers reflecting rate, preferred 0.01 weight %～20.0 weight %.The situation of silver alloy, according to the combination of the metal of metalized ag, can improve durability.When being a kind with the metal of silver combination, preferred gold, copper, neodymium, indium, tin, tungsten, titanium, chromium, palladium, bismuth, silver be during with 2 kinds of metallic combinations, preferably palladium and copper, palladium and gold, neodymium and gold, neodymium and copper, indium and tin.
Contain silver or aluminium metal level (E) the preferred 50nm of thickness or more than, more preferably 80nm or more than, further preferred 100nm or more than.During less than 50nm, light will see through the metal level (E) that contains silver or aluminium, makes reflecting rate reduce.The thickness of this layer is that 100nm or its can obtain sufficient reflecting rate when above, does not have special upper thickness limit value.But,, just exist polymeric membrane to curl easily and problem such as manufacturing cost increase if surpass the thick-layer of 1000nm.
Can protective layer be set in the polymeric membrane side of the metal level that contains silver or aluminium (E) and/or the opposition side of polymeric membrane side.That is to say, when protective layer being set, become polymeric membrane (A)/protective layer/contain metal level (E)/such structure of protective layer of silver or aluminium in the both sides of the metal level that contains silver or aluminium (E).
By polymeric membrane side protective layer is set, can controls the state on polymeric membrane surface, can improve polymeric membrane and the adhesive strength that contains the metal level of silver or aluminium at the metal level that contains silver or aluminium (E).In addition, can also improve the environment resistant of the metal level that contains silver or aluminium.So long as have the material of above-mentioned functions, the material and the thickness that are used for protective layer just are not particularly limited.Can be that individual layer also can be a multilayer.Since this protective layer polymeric membrane and contain silver or the metal level of aluminium (E) between, its use and light reflectance and color had nothing to do.For example can use metal monomer, compounds such as aluminium, copper, nickel, iron, cobalt, tungsten, molybdenum, tantalum, chromium, indium, manganese, titanium, palladium, zirconium, bismuth, tin, zinc, antimony, cerium, neodymium, lanthanum, thorium, magnesium, gallium, by two or more alloy that constitutes, the mixture in them.Especially preferably use the zinc oxide of zinc oxide, interpolation aluminium.
By opposition side protective layer is set, can obtains to contain the effect of the environment resistant enhancing of metal level of silver or aluminium and the effect that reflecting rate further improves at the polymeric membrane of the metal level that contains silver or aluminium (E).Material and thickness thereof that protective layer uses only otherwise the metal level reflecting rate that contains silver or aluminium is significantly reduced to get final product, are not particularly limited.Protective layer can be that individual layer also can be a multilayer.Specifically can enumerate transparent metal oxides such as zinc oxide, the zinc oxide that adds aluminium, silica, titanium oxide.These materials can obtain above-mentioned effect, and form continuously with the metal level that contains silver or aluminium easily, so are preferred.More preferably use the zinc oxide of zinc oxide, interpolation aluminium.
Metal level of argentiferous or aluminium (E) and protective layer can adopt the method identical with inorganic layer (B) to form.When use can not make the simultaneously cambial device in polymeric membrane two sides, metal level of argentiferous or aluminium (E) (and protective layer) and inorganic layer, forming which layer earlier can.
Can adopt methods such as Corona discharge Treatment, glow discharge processing to handle on the polymeric membrane surface that formation contains the metal level (E) of silver or aluminium and protective layer.These processing methods have and improve institute and form layer effect with the cementability of polymeric membrane.Can in the scope of those skilled in the art's technology general knowledge, suitably adopt the processing method beyond the above-mentioned processing method in addition.But, must under the degree that does not influence the polymeric membrane surface configuration, carry out.Carry out excess processes, the polymeric membrane surface configuration is changed, can't obtain minute surface.
Below describe in detail for the base material for light reflector and the refractive body that use above-mentioned parts.
(base material for light reflector and refractive body)
The example of base material for light reflector of the present invention as shown in Figure 1, the example of refractive body is as shown in Figure 2.Base material for light reflector is a stacked inorganic layer 20, bond layer 30, base material 40 and make on polymeric membrane 10 among Fig. 1.In addition, refractive body is stacked inorganic layer 20, bond layer 30, a base material 40 on polymeric membrane 10 among Fig. 2, and forms in the one side that does not form inorganic layer 20 of polymeric membrane and to contain the metal level 50 of silver or aluminium and make.The metal level side that contains silver or aluminium is a light reflection surface.
The gross thickness of refractive body is so long as can stably keep the thickness of shape then to be not particularly limited.Preferred 0.1mm～0.8mm.Blocked up, not only making volume increase weight increases, even and be processed into lamp box with the thin identical size of refractive body of gross thickness, the interval of lamp and refractive body also narrows down, and may reduce reflecting rate, hear resistance.
The reflecting rate of the refractive body of measuring as light entrance face with the metal level that contains silver or aluminium, when being standard sample with the aluminium oxide, for the light of 550nm wavelength, preferred 90% or more than, more preferably 92% or more than, further preferred 94% or more than.
Among the present invention, high-temp resisting high-humidity resisting is, places 500 hours under the environment of 60 ℃ of temperature, relative humidity 90%, is fetched in 23 ℃, the environment of humidity 50%, after specimen temperature drops to 23 ℃, estimates with the peel strength of polymeric membrane and base material.
Preferred peel strength is 0.10kN/m or more than it, more preferably 0.60kN/m or more than it.When peel strength during less than 0.10kN/m, polymeric membrane is easy to peel off from base material.Particularly carry out under the situation of the lamp reflector after the bending process, the polymeric membrane that peels off may contact with lamp, is not preferred therefore.
Among the present invention, hear resistance is to estimate with the polymeric membrane under 100 ℃ of conditions and the peel strength of base material.The preferred 0.10kN/m of peel strength or more than it, more preferably 0.20kN/m or more than it.Peel strength is during less than 0.10kN/m, and polymeric membrane is easy to peel off from base material.Particularly carry out under the situation of the lamp reflector after the bending process, the polymeric membrane that peels off may contact with lamp, is not preferred therefore.
Embodiment
The mensuration of rerum natura and hear resistance, heat-resisting moistly estimate by following method.
1, the mensuration of peel strength
Refractive body is cut into the long 100mm of wide 10mm, polymeric membrane is torn 20mm from base material.Then, using Compression and Expansion testing machine (the modern field of Co., Ltd. makes made SV-55-0-20L), make polymeric membrane and base material keep 90 °, lift polymeric membrane with the speed of 50mm/min, is that peel strength is measured with masterpiece at this moment.
2, heat-resisting moist evaluation
In ヤ マ ト science Co., Ltd. system IG46M, after placing 500 hours under the condition of 60 ℃ of relative humidity 90% of temperature, be fetched into 23 ℃, humidity 50% indoor, after specimen temperature drops to room temperature, measure peel strength.
3, hear resistance evaluation
Hot air generator (Co., Ltd.'s bamboo steel is done made) is installed in cupping machine (Co., Ltd. modern field make made SDW200S), and making in the chamber of hot air generator becomes 100 ℃ of environment, sample is positioned in the chamber after 5 minutes the mensuration peel strength.
4, the mensuration of glass transition temperature
Bonding agent is dried at 40 ℃ does not have solvent odor, and drying under reduced pressure is 24 hours then.This test film is cut into the about 7.9mm of diameter, the about 2mm of thickness.Use the rotary flow graph RMS-800 of Rheometorics society's system, use the 7.9mm parallel-plate, with strain rate smaller or equal to 20%, the condition of rate of straining 10rad/sec, carry out temperature dispersion from 0 ℃ to 150 ℃ and measure.With the peak value of the tan δ that obtains glass transition temperature as bonding agent.
(embodiment 1)
Utilize the DC magnetron sputtering method, with the zinc oxide (purity 99.9%) that adds 2 weight % aluminium oxide is target, argon gas with purity 99.5% is a sputter gas, goes up the zinc oxide of the interpolation aluminium oxide that forms thickness 5nm at PETG film (the system テ イ ジ of Supreme Being people Dupont Kabushiki Kaisha Application テ ト ロ Application film SG, thickness 25 μ m).
Then, not taking out this film from injection apparatus, use the DC magnetron sputtering method, is target with the silver of purity 99.9%, is sputter gas with the argon of purity 99.5%, the silver of formation thickness 130nm.
Then, not taking out this film from injection apparatus, use the DC magnetron sputtering method, is target with the zinc oxide (purity 99.9%) of the aluminium oxide that adds 2 weight %, is sputter gas with the argon of purity 99.5%, the zinc oxide of the interpolation aluminium oxide of formation thickness 5nm.
Then, from injection apparatus, take out film, make the opposition side of above-mentioned sputter face become sputter face, prepare the system film.Using the DC magnetron sputtering method, is target with the nichrome of purity 99.9%, make the film of thickness 20nm after, from sputter equipment, take out.
On the face of the formation nicr layer of this film, be heat molten type bonding agent (the system SP7029 of ダ イ ヤ ボ Application De Industrial Co., Ltd, Tg75 ℃) with intaglio plate rubbing method coated polyester, form the adhesive linkage of thickness 7 μ m.With the film of this stacked adhesive linkage and brass sheet (thick 200 μ m), under the condition of 100 ℃ of roller surface temperature, add the hot pressing layer as base material.It was stopped 100 seconds in 192 ℃ of heating furnaces, heat-treat, bonding, obtain refractive body.By said method, measure peel strength, carry out synthetic determination.
Evaluation result is as shown in table 1.In table, when the peel strength measurement result is used to estimate heat-resisting moist, hear resistance, be good more than or equal to 0.10kN/m, be bad less than 0.10kN/m.
(embodiment 2)
As inorganic layer, use the DC magnetron sputtering method, be target with the zinc oxide (purity 99.9%) that adds 2 weight % aluminium oxide, argon with purity 99.5% is a sputter gas, form the zinc oxide of the interpolation aluminium oxide of thickness 20nm, identical with embodiment 1 method in addition, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 1.
(embodiment 3)
As inorganic layer, use the DC magnetron sputtering method, be target with titanium (purity 99.9%), be sputter gas with the argon of purity 99.5%, make the film of thickness 20nm, identical with embodiment 1 method in addition, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 1.
(embodiment 4)
Except that using stainless steel (SUS304) plate (thickness 0.1mm) as the base material, identical with embodiment 1 method, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 1.
(embodiment 5)
Remove to use polyester be heat molten type bonding agent (Toyo Boseki K.K's system, the solvable type bonding agent of amorphous polyester organic solvent バ イ ロ Application GK640, Tg79 ℃) as outside the bond layer, identical with embodiment 1 method, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 2.
(embodiment 6)
Remove to use polyester be heat molten type bonding agent (Toyo Boseki K.K's system, amorphous polyester are heat molten type bonding agent バ イ ロ Application 29SS, Tg72 ℃) as outside the bond layer, identical with embodiment 1 method, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 2.
(embodiment 7)
Remove and use polyurethane series heat molten type bonding agent (the big system AG946HV of Japanese ink Industrial Co., Ltd, Tg58 ℃) as outside the bond layer, identical with embodiment 1 method, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 2.
(comparative example 1)
As inorganic layer, do not form nicr layer, in addition make refractive body according to the method identical with embodiment 1.
Evaluation method is with embodiment 1.The result is as shown in table 3.
(comparative example 2)
As inorganic layer, do not form nicr layer, in addition make refractive body according to the method identical with embodiment 5.
Evaluation method is with embodiment 1.The result is as shown in table 3.
(comparative example 3)
As inorganic layer, do not form nicr layer, in addition make refractive body according to the method identical with embodiment 6.
Evaluation method is with embodiment 1.The result is as shown in table 3.
(comparative example 4)
As inorganic layer, do not form nicr layer, in addition make refractive body according to the method identical with embodiment 7.
Evaluation method is with embodiment 1.The result is as shown in table 3.
(comparative example 5)
Be formed with the PETG film of water-soluble polyester resin (the system A1511 of Toyo Boseki K.K, thickness 38 μ m) not formation water-soluble polyester resin one side, the zinc oxide film of the zinc oxide film of the identical interpolation of formation successively aluminium oxide, silver layer, interpolation aluminium oxide with embodiment 1 method.Being formed with water-soluble polyester resin one side, with embodiment 1 method same coated bonding agent, paste with brass sheet, make refractive body.
Evaluation method is with embodiment 1.The result is as shown in table 4.
(comparative example 6)
Bonding agent in using embodiment 5 is as the bond layer, the identical refractive body made from comparative example 5 methods.
Evaluation method is with embodiment 1.The result is as shown in table 4.
(comparative example 7)
Bonding agent in using embodiment 6 is as the bond layer, the identical refractive body made from comparative example 5 methods.
Evaluation method is with embodiment 1.The result is as shown in table 4.
Table 1
Embodiment 1 Embodiment 2 Embodiment 3 Embodiment 4
Base material (D) Brass sheet Brass sheet Brass sheet Stainless steel (SUS304)
Bond layer (C) SP7029 SP7029 SP7029 SP7029
Bonding agent Tg (℃) 75 75 75 75
Inorganic layer (B) NiCr ZnO Ti NiCr
Polymeric membrane (A) PET PET PET PET
The metal level (E) (protective layer/metal level (E)/protective layer) that contains silver or aluminium Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO
Peel strength (firm bonding back) (kN/m) 0.60 0.60 0.60 0.60
Peel strength (behind the damp heat test) (kN/m) 0.60 0.60 0.60 0.60
Peel strength (under 100 ℃ of conditions) (kN/m) 0.20 0.18 0.22 0.19
Synthetic determination Well Well Well Well
Table 2
Embodiment 5 Embodiment 6 Embodiment 7
Base material (D) Brass sheet Brass sheet Brass sheet
Bond layer (C) GK640 29SS AG946HV (polyurethane series)
Bonding agent Tg (℃) 79 72 58
Inorganic layer (B) NiCr NiCr NiCr
Polymeric membrane (A) PET PET PET
The metal level (E) (protective layer/metal level (E)/protective layer) that contains silver or aluminium Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO
Peel strength (firm bonding back) (kN/m) 0.49 0.60 0.45
Peel strength (behind the damp heat test) (kN/m) 0.45 0.55 0.42
Peel strength (under 100 ℃ of conditions) (kN/m) 0.21 0.25 0.11
Synthetic determination Well Well Well
Table 3
Comparative example 1 Comparative example 2 Comparative example 3 Comparative example 4
Base material (D) Brass sheet Brass sheet Brass sheet Brass sheet
Bond layer (C) SP7029 GK640 29SS AG946HV (polyurethane series)
Bonding agent Tg (℃) 75 79 72 58
Inorganic layer (B) - - - -
Polymeric membrane (A) PET PET PET PET
The metal level (E) (protective layer/metal level (E)/protective layer) that contains silver or aluminium Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO
Peel strength (firm bonding back) (kN/m) 0.02 0.01 0.02 0.01
Peel strength (behind the damp heat test) (kN/m) 0.01 0.02 0.01 0.02
Peel strength (under 100 ℃ of conditions) (kN/m) 0.01 0.03 0.02 0.03
Synthetic determination Bad Bad Bad Bad
Table 4
Comparative example 5 Comparative example 6 Comparative example 7
Base material (D) Brass sheet Brass sheet Brass sheet
Bond layer (C) SP7029 GK640 29SS
Bonding agent Tg (℃) 75 79 72
Inorganic layer (B) Water-soluble coating Water-soluble coating Water-soluble coating
Polymeric membrane (A) PET PET PET
The metal level (E) (protective layer/metal level (E)/protective layer) that contains silver or aluminium Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO Add Al 2O 3ZnO/Ag/ add Al 2O 3ZnO
Peel strength (firm bonding back) (kN/m) 0.60 0.56 0.60
Peel strength (behind the damp heat test) (kN/m) 0.01 0.01 0.03
Peel strength (under 100 ℃ of conditions) (kN/m) 0.20 0.20 0.25
Synthetic determination Bad Bad Bad
Can know according to The above results,, can produce refractive body with heat-resisting quantity, high-temp resisting high-humidity resisting by inorganic layer is set.
The possibility of using on the industry
Such as above detailed description, according to the present invention, can provide to have high reflecting rate, heat resistance, high-temp resisting high-humidity resisting, shape stability, and the refractive body of thin thickness. Thereby, needing to be suitable for the purposes of highlight illumination, during for example as lamp reflector backlight in the liquid crystal display, can realize the raising of backlight illumination.

Claims (7)

1. base material for light reflector, it is characterized by, has the stepped construction that comprises macromolecule membrane (A), inorganic layer (B), bond layer (C), base material (D), (A), (B), (C), (D) be the sequential cascade according to (A)/(B)/(C)/(D), inorganic layer (B) is for comprising the layer of metal, metallic compound or their mixture at least.
2. base material for light reflector according to claim 1 is characterized by, and the macromolecule membrane (A) after placing 500 hours under the condition of 60 ℃ of relative humidity 90% of temperature and the peel strength of base material (D) are more than or equal to 0.10kN/m.
3. base material for light reflector according to claim 1 is characterized by, and under 100 ℃ of conditions, the peel strength of macromolecule membrane (A) and base material (D) is more than or equal to 0.10kN/m.
4. base material for light reflector according to claim 1 is characterized by, and base material (D) is for containing the plate of metal.
5. base material for light reflector according to claim 1 is characterized by, and the thickness of inorganic layer (B) is 10nm～100nm.
6. refractive body is characterized by, and forms the metal level (E) that contains silver or aluminium on the described base material for light reflector of claim 1, becomes the stepped construction of (E)/(A)/(B)/(C)/(D).
7. refractive body according to claim 6 is characterized by, and metal level (E) is for silver or contain silver-colored alloy.
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JP2010128087A (en) * 2008-11-26 2010-06-10 Mitsubishi Plastics Inc Optical film and optical film laminated metallic body
JP5481282B2 (en) * 2010-06-07 2014-04-23 神鋼リードミック株式会社 Electronic component materials
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