JP2011162748A - Bulk molding compound, lamp reflector and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bulk molding compound giving a formed body of the bulk molding compound excellent in coatability of an undercoat and tight adhesiveness with an undercoated layer, even though a treatment for removing an internal mold release agent is not carried out. <P>SOLUTION: The bulk molding compound comprises an unsaturated polyester resin and/or a vinyl ester resin, a polymerization crosslinking agent and an internal mold release agent, and further contains 1-20 pts.mass polybutadiene based on 100 pts.mass sum total of the unsaturated polyester resin and/or the vinyl ester resin and the polymerization crosslinking agent. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a bulk molding compound (hereinafter referred to as BMC), a lamp reflector, and a method for manufacturing the same. Specifically, the present invention relates to a BMC used for manufacturing a lamp reflector used for a lamp such as a headlamp or a fog lamp in a vehicle such as an automobile or a motorcycle, a lamp reflector manufactured using the BMC, and a manufacture thereof. Regarding the method.

  In lamp reflectors used for headlamps and fog lamps in vehicles such as automobiles and motorcycles, BMC molded bodies (hereinafter referred to as BMC molded bodies) having excellent properties such as moldability, dimensional stability, heat resistance, and mechanical strength. .) Are commonly used as substrates. Here, the BMC is a molding material obtained by blending a fiber reinforcing material or an inorganic filler with a matrix resin such as an unsaturated polyester resin. It is also known to reduce shrinkage of a BMC molded body by adding a styrene-butadiene block copolymer to the BMC (see, for example, Patent Documents 1 to 3).

In the manufacture of the lamp reflector, in order to ensure the smoothness of the reflecting surface, an undercoat agent is applied and cured on the BMC molded body as a base material to form an undercoat layer, and then vapor deposition is performed on the undercoat layer. Using this method, a metal reflection layer made of a metal such as aluminum is formed. For this reason, the BMC molded body is required to have excellent paintability of the undercoat agent and adhesion with the undercoat layer.
However, since an internal mold release agent is generally blended in BMC, when the undercoat agent is applied on the BMC molded body, the internal mold release agent present on the surface of the BMC molded body causes There are problems that “repellency” occurs and the undercoat layer does not sufficiently adhere to the BMC molded body. Therefore, it is necessary to remove the internal mold release agent present on the surface of the BMC molded body, such as heat treatment or frame treatment in which the BMC molded body is placed in a heating furnace for a long time.

Japanese Patent Publication No. 6-53844 Japanese Patent Laid-Open No. 5-140434 International Publication No. 2006/095414

However, the removal treatment of the internal mold release agent present on the surface of the BMC molded body has a problem that the productivity of the lamp reflector is lowered and the manufacturing cost of the lamp reflector is increased.
The present invention has been made to solve the above-described problems, and is excellent in the coating properties of the undercoat agent and the adhesion with the undercoat layer without performing the removal treatment of the internal release agent. It aims at providing BMC which gives a BMC molded object.
It is another object of the present invention to provide a lamp reflector and a method for manufacturing the same that enhance productivity and reduce manufacturing costs.

  As a result of intensive studies to solve the above problems, the present inventors have found that the coating property of the undercoat agent and the adhesion with the undercoat layer in the BMC molded product are reduced on the surface of the BMC molded product. Based on the knowledge that it is closely related to the uneven distribution of the internal mold release agent, a BMC molded body having a phase separation structure can be obtained by blending polybutadienes with BMC at a specific ratio. It has been found that uneven distribution of the internal release agent on the surface of the BMC molded body can be prevented.

That is, the present invention is a BMC including an unsaturated polyester resin and / or vinyl ester resin, a polymerizable crosslinking agent, and an internal mold release agent, and the unsaturated polyester resin and / or the vinyl ester resin and the above The BMC further comprises 1 to 20 parts by mass of a polybutadiene with respect to 100 parts by mass in total with the polymerizable crosslinking agent.
In addition, the present invention is a lamp reflector including the BMC molded body, an undercoat layer formed on the molded body, and a metal reflective layer formed on the undercoat layer. .
Further, the present invention provides a step of forming a molded body by molding the BMC, and applying and curing an undercoat agent on the molded body without performing an internal mold release agent removal treatment to form an undercoat layer. It is a manufacturing method of the lamp reflector characterized by including the process of forming, and the process of forming a metal reflective layer on the undercoat layer.

ADVANTAGE OF THE INVENTION According to this invention, even if it does not perform the removal process of an internal mold release agent, BMC which provides the BMC molded object excellent in the coating property of an undercoat agent and adhesiveness with an undercoat layer can be provided.
In addition, according to the present invention, it is possible to provide a lamp reflector and a method for manufacturing the same that can improve productivity and reduce manufacturing costs.

6 is a cross-sectional view of a lamp including the lamp reflector according to Embodiment 2. It is an expanded sectional view of the aa 'line of FIG.

Embodiment 1 FIG.
The BMC of the present embodiment includes polybutadienes in addition to the unsaturated polyester resin and / or vinyl ester resin, the polymerizable crosslinking agent, and the internal mold release agent.
The unsaturated polyester resin used in the BMC of the present embodiment is generally a condensation product (unsaturated polyester) obtained by esterification reaction of a polyhydric alcohol, an unsaturated polybasic acid and any saturated polybasic acid. , Dissolved in a polymerizable crosslinking agent (also referred to as a reactive diluent). Such unsaturated polyester resins are generally known in the art, and include, for example, “Polyester Resin Handbook” (published by Nikkan Kogyo Shimbun, 1988) and “Paint Glossary of Terms” (Edited by Color Material Association, 1993). ) Etc.

The unsaturated polyester is not particularly limited, and those produced by a known method can be used. The unsaturated polybasic acid (polybasic acid having a polymerizable unsaturated bond) used as a raw material for the unsaturated polyester is not particularly limited. For example, fumaric acid, maleic acid, citraconic acid, itaconic acid or anhydrides thereof. Such as things. The saturated polybasic acid (polybasic acid not having a polymerizable unsaturated bond) used as a raw material for the unsaturated polyester is not particularly limited. For example, phthalic acid, isophthalic acid, het acid, succinic acid, terephthalic acid, Tetrahydrophthalic acid, adipic acid, sebacic acid or their anhydrides can be mentioned. The polyhydric alcohol used as a raw material for the unsaturated polyester is not particularly limited. For example, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, triethylene glycol, pentanediol, hexanediol, neopentanediol. 1,2-butanediol, 1,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2-methyl-1,3-propanediol, 2,2-dimethyl-1,3- Examples include propanediol, cyclohexane-1,4-dimethanol, bisphenol A, hydrogenated bisphenol A, bisphenol A ethylene oxide adduct, bisphenol A propylene oxide adduct, glycerin, and the like. These unsaturated polyester raw materials can be used alone or in combination of two or more.
The synthesis conditions of the unsaturated polyester are not particularly limited, and may be set as appropriate according to the type of raw material used.

The unsaturated polyester may be modified as long as the effects of the present invention are not impaired. For example, it is good also as polyester (meth) acrylate by adding glycidyl (meth) acrylate etc. to the carboxyl group of the terminal of unsaturated polyester. Moreover, in the range which does not inhibit the effect of this invention, radical curable resins, such as polyester (meth) acrylate resin, urethane (meth) acrylate resin, diallyl phthalate resin, can also be used as a part of unsaturated polyester.
The unsaturated polyester preferably has a relatively high degree of unsaturation, and more preferably has an unsaturated group equivalent (molecular weight per unsaturated group) of about 100 to about 800. Those having an unsaturated group equivalent of less than 100 are difficult to synthesize. On the other hand, if the unsaturated group equivalent exceeds 800, a BMC molded article having a desired hardness may not be obtained.

  The polymerizable crosslinking agent used in the unsaturated polyester resin is not particularly limited as long as it has a double bond polymerizable with the unsaturated polyester. For example, styrene monomer, chlorostyrene, vinyl toluene, divinyl. Styrenic crosslinking agents such as benzene; (meth) acrylate crosslinking agents such as methyl (meth) acrylate, ethyl (meth) acrylate, and ethylene glycol di (meth) acrylate; diallyl phthalate monomer; diallyl phthalate prepolymer; triallyl isocyanurate Etc. These can be used alone or in combination of two or more. Among these, a styrene monomer is preferable because the above properties can be obtained with a good balance.

  The acid value of the unsaturated polyester resin in which the unsaturated polyester is dissolved in the polymerizable crosslinking agent is preferably 20 or less, more preferably 15 or less. If the acid value of the unsaturated polyester resin exceeds 20, the BMC molded body may not have a sufficient phase separation structure, and uneven distribution of the internal release agent may not be sufficiently prevented.

  The vinyl ester resin used for the BMC of this embodiment is also called an epoxy acrylate resin, and generally includes a compound having a glycidyl group (epoxy group) and a carboxyl group of a carboxyl compound having a polymerizable unsaturated bond. A compound having a polymerizable unsaturated bond (vinyl ester) produced by a ring-opening reaction is dissolved in a polymerizable crosslinking agent. Such vinyl ester resins are generally known in the technical field. For example, “Polyester Resin Handbook” (published by Nikkan Kogyo Shimbun, published in 1988) and “Paint Glossary of Terms” (edited by Color Material Association, published in 1993). It is described in.

It does not specifically limit as vinyl ester, What was manufactured by the well-known method can be used. The compound having a glycidyl group (epoxy group) used as a raw material for vinyl ester is not particularly limited, and examples thereof include bisphenol A diglycidyl ether and its high molecular weight homologues, novolak glycidyl ethers and the like. The carboxyl compound having a polymerizable unsaturated bond used as a raw material for the vinyl ester is not particularly limited, and examples thereof include unsaturated monobasic acids such as acrylic acid and methacrylic acid; bisphenol (A type and the like), adipic acid, sebacin Examples thereof include dibasic acids such as acids and dimer acids. In particular, if a dibasic acid is used as a raw material, flexibility can be imparted to the vinyl ester. These raw materials for vinyl esters can be used alone or in combination of two or more.
The conditions for synthesizing the vinyl ester are not particularly limited, and may be set as appropriate according to the type of raw material used.

As in the case of the unsaturated polyester, the vinyl ester can be modified or a radical curable resin can be used as part of the vinyl ester as long as the effects of the present invention are not impaired.
The vinyl ester preferably has a relatively high degree of unsaturation, and more preferably has an unsaturated group equivalent (molecular weight per unsaturated group) of about 100 to about 800. Those having an unsaturated group equivalent of less than 100 are difficult to synthesize. On the other hand, if the unsaturated group equivalent exceeds 800, a BMC molded article having a desired hardness may not be obtained.

  The polymerizable crosslinking agent used for the vinyl ester resin is not particularly limited as long as it has a double bond polymerizable with the vinyl ester, and is generally the same as the polymerizable crosslinking agent used for the unsaturated polyester resin. . Specifically, the polymerizable crosslinking agent used in the vinyl ester resin includes styrene-based crosslinking agents such as styrene monomers, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and isobutyl (meth) acrylate. , 2-ethylhexyl (meth) acrylate, isodecyl (meth) acrylate, lauryl (meth) acrylate, tridecyl (meth) acrylate, stearyl (meth) acrylate, cyclohexyl (meth) acrylate, furfuryl (meth) acrylate, tetrahydrofurfuryl (meth) ) Acrylate, benzyl (meth) acrylate, phenoxyethyl (meth) acrylate, isobornyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl ( Acrylate), 2-hydroxybutyl (meth) acrylate, 2-hydroxy-3-acryloyloxypropyl (meth) acrylate, 2-methacryloyloxyethyl 2-hydroxypropyl phthalate, dimethylaminoethyl (meth) acrylate, diethylaminoethyl (Meth) acrylate, glycidyl (meth) acrylate, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6 -Hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, 1,10-decanediol di (meth) acrylate, trimethylolpropane tri (meth) acrylate Glycerin di (meth) acrylate, methoxytriethylene glycol (meth) acrylate, butoxyethyl (meth) acrylate, neopentyl glycol di (meth) acrylate, trifluoroethyl (meth) acrylate, perfluorooctylethyl (meth) Examples include acrylate, allyl (meth) acrylate, dicyclopentenyl (meth) acrylate, and dicyclopentenyloxyethyl (meth) acrylate. These can be used alone or in combination of two or more. Among these, a styrene monomer is preferable because various properties required for a polymerizable crosslinking agent can be obtained in a well-balanced manner.

The polymerizable cross-linking agent used in the BMC of the present embodiment improves kneadability and impregnation of fiber reinforcing materials and inorganic fillers, and improves the hardness, strength, chemical resistance, heat resistance, etc. of the BMC molded body It is a component to be made. The polymerizable crosslinking agent is not particularly limited, and those known in the technical field can be used. The polymerizable crosslinking agent may be the same as the polymerizable crosslinking agent used for the unsaturated polyester resin or vinyl ester resin.
The blending amount of the polymerizable crosslinking agent (including the polymerizable crosslinking agent used in the unsaturated polyester resin or vinyl ester resin) in the BMC of the present embodiment is 10 to 250 parts by mass with respect to 100 parts by mass of the unsaturated polyester, Preferably it is 20-100 mass parts. When the blending amount of the polymerizable crosslinking agent is less than 10 parts by mass, a BMC molded body having desired corrosion resistance can be obtained while the kneading property, impregnation property, and workability of a fiber reinforcing material and an inorganic filler are lowered. There may not be. On the other hand, when the compounding amount of the polymerizable crosslinking agent exceeds 250 parts by mass, a BMC molded body having desired strength and heat resistance may not be obtained.

  It does not specifically limit as an internal mold release agent used for BMC of this Embodiment, A well-known thing can be used in the said technical field. Examples of internal mold release agents include: stearic acid; stearates such as zinc stearate, calcium stearate, aluminum stearate, magnesium stearate; oleic acid; carbana wax; silicone oil; mixture of surfactant and copolymer (BYK-P9050 manufactured by Big Chemie Japan Co., Ltd.). These can be used alone or in combination of two or more. Moreover, the compounding quantity of an internal mold release agent is not specifically limited, What is necessary is just to set suitably according to the kind etc. of the raw material to be used.

The polybutadienes used in the BMC of the present embodiment are also called butadiene rubber, and give a phase separation structure to the BMC molded body, and this phase separation structure prevents uneven distribution of the internal release agent on the surface of the BMC molded body. It is an ingredient to do. Here, the phase separation structure means a structure in which a plurality of phases exist in the resin component.
Examples of polybutadienes include 1,2-polybutadiene; polybutadienes having functional groups such as hydroxyl group-terminated polybutadiene, carboxyl group-terminated polybutadiene, and amino group-terminated polybutadiene; acrylonitrile-butadiene rubbers. Among these, polybutadiene having a functional group at the terminal is preferable, and hydroxyl-terminated polybutadiene is more preferable. Moreover, a commercially available thing can also be used as polybutadienes. Examples of commercially available polybutadienes include R-45HT and R-15HT manufactured by Idemitsu Kosan Co., Ltd., which are hydroxyl-terminated polybutadienes.

  The blending amount of the polybutadienes in the BMC of the present embodiment is 1 to 20 parts by mass, preferably 1 to 18 parts per 100 parts by mass in total of the unsaturated polyester resin and / or vinyl ester resin and the polymerizable crosslinking agent. Part by mass. When the blending amount of the polybutadiene is less than 1 part by mass, the effect of blending the polybutadienes cannot be sufficiently obtained, and the uneven distribution of the internal release agent on the surface of the BMC molded body cannot be sufficiently prevented. On the other hand, when the compounding amount of the polybutadiene exceeds 20 parts by mass, characteristics such as demoldability of the BMC molded body are deteriorated.

The BMC of the present embodiment generally includes a fiber reinforcement and an inorganic filler.
It does not specifically limit as a fiber reinforcement, For example, the chopped strand glass cut | disconnected by fiber length about 1.5-25 mm is mentioned. Further, organic fibers and inorganic fibers such as carbon fibers, pulp fibers, Tetron (registered trademark) fibers, vinylon fibers, aramid fibers, polyethylene terephthalate fibers, and wollastonite can also be used. These can be used alone or in combination of two or more.
The blending amount of the fiber reinforcing material in the BMC of the present embodiment is not particularly limited, and is preferably 3 to 300 with respect to 100 parts by mass in total of the unsaturated polyester resin and / or vinyl ester resin and the polymerizable crosslinking agent. It is 5 mass parts, More preferably, it is 5-200 mass parts. When the blending amount of the fiber reinforcing material is less than 3 parts by mass, a BMC molded body having a desired strength may not be obtained. On the other hand, when the blending amount of the fiber reinforcement exceeds 300 parts by mass, the kneadability or impregnation of the fiber reinforcement and the fluidity of the BMC are deteriorated, and a BMC molded body having desired characteristics cannot be obtained. There is.

The inorganic filler is not particularly limited, and calcium carbonate and aluminum hydroxide are common. Besides these inorganic fillers, known inorganic fillers such as glass powder, glass beads, silica, talc, clay, alumina, barium sulfate, titanium oxide, and hollow filler can be used. These can be used alone or in combination of two or more. Here, it does not specifically limit as a hollow filler, For example, a glass balloon, a silica balloon, an alumina balloon etc. are mentioned. The hollow filler preferably has a pressure strength of at least 2100 × 10 ⁴ N / m ² or more, more preferably 4100 × 10 ⁴ N / m ² or more, and a true specific gravity of preferably 0.3 to 0.8, more preferably. Is in the range of 0.4 to 0.65. When the compressive strength of the hollow filler is less than 2100 × 10 ⁴ N / m ² , the hollow filler is destroyed during BMC preparation or BMC molding, and the effect of blending the hollow filler (reduction in the specific gravity of the molded body) May not be sufficient. In addition, when the true specific gravity of the hollow filler is less than 0.3, the viscosity of the BMC is increased, so that the moldability of the BMC is lowered and the amount of the inorganic filler other than the hollow filler needs to be reduced. As a result, a BMC molded body having desired characteristics may not be obtained. On the other hand, if the true specific gravity of the hollow filler exceeds 0.8, the effect of blending the hollow filler may not be sufficiently obtained.

  The shape of the inorganic filler is not particularly limited. The inorganic filler preferably has an average particle size of 0.5 μm to 50 μm in consideration of kneading properties or impregnation properties. When the average particle size is less than 0.5 μm, the viscosity of BMC increases, and the desired moldability may not be obtained. On the other hand, when the average particle diameter exceeds 50 μm, the fluidity of BMC is lowered, and the desired moldability may not be obtained.

  The blending amount of the inorganic filler in the BMC of the present embodiment is not particularly limited, and is preferably 100 to 500 with respect to a total of 100 parts by mass of the unsaturated polyester resin and / or vinyl ester resin and the polymerizable crosslinking agent. It is 200 mass parts, More preferably, it is 200-450 mass parts. When the blending amount of the inorganic filler is less than 100 parts by mass, the BMC fluidity may be too high and a BMC molded body having desired characteristics may not be obtained. If the blending amount of the inorganic filler exceeds 500 parts by mass, the viscosity of the BMC increases, and the kneadability or impregnation property of the inorganic filler and the fluidity of the BMC decrease, and a BMC molded body having desired characteristics is obtained. It may not be obtained.

  In particular, when a hollow filler is used as the inorganic filler, the amount of the hollow filler in BMC is preferably 100 parts by mass in total of the unsaturated polyester resin and / or vinyl ester resin and the polymerizable crosslinking agent. It is 30-120 mass parts, More preferably, it is 40-75 mass parts. If the blending amount of the hollow filler is less than 30 parts by mass, the effect of blending the hollow filler may not be sufficiently obtained. On the contrary, when the amount of the hollow filler exceeds 120 parts by mass, the viscosity of BMC increases, so that the moldability of BMC decreases and the amount of inorganic filler other than the hollow filler needs to be reduced. As a result, a BMC molded body having desired characteristics may not be obtained.

The BMC of the present embodiment can contain known additives such as a curing agent, a low shrinkage agent, a thickener, a thickener, and a pigment as necessary.
It does not specifically limit as a hardening | curing agent, A well-known thing can be used in the said technical field. Examples of curing agents include ketone peroxides, peroxyketals, hydroperoxides, diallyl peroxides, diacyl peroxides, peroxyesters, peroxydicarbonates, and other organic peroxide catalysts, and azo compounds. It is done. Specifically, as a curing agent, benzoyl peroxide, dicumyl peroxide, diisopropyl peroxide, ditertiary butyl peroxide, t-butyl peroxybenzoate, t-butyl peroxy-2-ethylhexanoate, 1, 1-bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-bis (t-butylperoxy) hexyne-3,3-isopropylhydroperoxide, t -Butyl hydroperoxide, dicumyl peroxide, dicumyl hydroperoxide, acetyl peroxide, bis (4-t-butylcyclohexyl) peroxydicarbonate, diisopropylperoxydicarbonate, isobutyl peroxide, 3, 3, 5 -Trimethyl Kisa noil peroxide, lauryl peroxide, azobisisobutyronitrile, or the like can be used azobis carbonamido. Among these, dicumyl peroxide, ditertiary butyl peroxide, and t-butyl hydroperoxide are preferable from the viewpoint of storage stability. Moreover, these can be used individually or in combination of 2 or more types.
The compounding quantity of the hardening | curing agent in BMC of this Embodiment is not specifically limited, What is necessary is just to adjust suitably according to the kind of hardening | curing agent to be used.

The low shrinkage agent is not particularly limited, and those known in the technical field can be used. Examples of the low shrinkage agent include thermoplastic polymers such as polystyrene, polymethyl methacrylate, polyvinyl acetate, and saturated polyester. These can be used alone or in combination of two or more.
The blending amount of the low shrinkage agent in the BMC of the present embodiment is preferably 15 to 50 parts by mass with respect to a total of 100 parts by mass of the unsaturated polyester resin and / or vinyl ester resin and the polymerizable crosslinking agent. If the blending amount of the low shrinkage agent is less than 15 parts by mass, the effect of blending the low shrinkage agent may not be sufficiently obtained. On the other hand, if the blending amount of the low shrinkage agent exceeds 50 parts by mass, the in-mold fluidity may be lowered during the molding of BMC.

The thickener is not particularly limited, and those known in the technical field can be used. Examples of the thickener include metal oxides and metal hydroxides such as magnesium oxide, magnesium hydroxide, calcium hydroxide, and calcium oxide; isocyanate compounds and the like.
It does not specifically limit as a thickener and a pigment, A well-known thing can be used in the said technical field.
The blending amounts of the thickener, the thickener, and the pigment in the BMC of the present embodiment are not particularly limited, and may be appropriately adjusted according to the types of the thickener, the thickener, and the pigment to be used.

The BMC of the present embodiment can be produced by a method in which the above components are usually performed, for example, by blending the above components and then kneading using a kneader.
In addition, the BMC of the present embodiment can be formed into a desired shape using a known molding method such as compression molding, transfer molding, injection molding or the like.
The BMC molded body thus obtained has a phase separation structure, and this phase separation structure can prevent uneven distribution of the internal release agent on the surface of the BMC molded body. Thereby, when various coatings including an undercoat agent are applied, it is possible to prevent “repellency” of the various coatings, and it is possible to improve the adhesion between the various coatings and the BMC molded body.

Embodiment 2. FIG.
The lamp reflector according to the present embodiment includes a BMC molded body, an undercoat layer formed on the BMC molded body, and a metal reflective layer formed on the undercoat layer.
Hereinafter, a preferred embodiment of a lamp reflector will be described with reference to the drawings.
FIG. 1 a is a cross-sectional view of a lamp provided with the lamp reflector of the present embodiment. 1b is an enlarged cross-sectional view taken along the line aa ′ of FIG. 1a.
In FIG. 1a, a lamp generally includes a lamp reflector, a light source 4 provided at a predetermined position of the lamp reflector, and a front lens 5 provided at an opening of the lamp reflector. Here, the lamp reflector has a BMC molded body 1, an undercoat layer formed on the BMC molded body 1, and a metal reflective layer 3 formed on the undercoat layer 2, as shown in FIG. 1b. . In this lamp, light generated from the light source 4 is reflected by a lamp reflector, more specifically, by the metal reflection layer 3.

The lamp reflector according to the present embodiment having such a configuration can be manufactured as follows.
First, the BMC of Embodiment 1 is molded to obtain the BMC molded body 1. Here, the BMC molded body 1 can be obtained by molding the BMC of Embodiment 1 into a predetermined shape using a known molding method such as compression molding, transfer molding, or injection molding. The BMC molded body 1 has a phase separation structure, and this phase separation structure can prevent uneven distribution of the internal release agent on the surface of the BMC molded body 1.

  Next, the undercoat layer 2 is formed by applying and curing the undercoat agent on the BMC molded body 1 without performing the removal process of the internal release agent. Here, in the conventional manufacturing method of the lamp reflector, it is necessary to remove the internal mold release agent present on the surface of the BMC molded body 1 in order to solve problems such as “repellency” of the undercoat agent. On the other hand, in the present invention, since the internal release agent is prevented from being unevenly distributed on the surface of the BMC molded body 1 by the phase separation structure of the BMC molded body 1, the internal mold release existing on the surface of the BMC molded body 1 is prevented. There is no need to remove the agent. As a result, the productivity of the lamp reflector can be increased and the manufacturing cost of the lamp reflector can be reduced. Moreover, since this BMC molded object 1 has the fine unevenness | corrugation in the surface, it can improve the adhesiveness of the BMC molded object 1 and the undercoat layer 2, and leads also to reliability improvement as a result. .

  It does not specifically limit as an undercoat agent which gives the undercoat layer 2, A well-known thing can be used in the said technical field. This undercoat agent is also called a primer composition, and is generally a resin composition containing a thermosetting resin. Examples of thermosetting resins include polyfunctional monomers such as pentaerythritol triacrylate, pentaerythritol tetraacrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, dipentaerythritol hexaacrylate, and dipentaerythritol pentaacrylate. An acrylic resin obtained by polymerization or copolymerization may be used. The resin composition may also contain a polyester resin such as an unsaturated polyester resin, a vinyl-modified polyester resin, a phenol-modified polyester resin, an oil-modified polyester resin, or a silicone-modified polyester resin, a curing agent, a solvent, and the like. Such an undercoat agent is generally commercially available, and for example, BASF QN11-0107 can be used.

The method for applying the undercoat agent onto the BMC molded body 1 is not particularly limited, and for example, a known method such as an air spray method or an airless spray method can be used. Also, the curing method is not particularly limited, and may be appropriately selected according to the type of the undercoat agent.
The thickness of the undercoat layer 2 may be appropriately set according to the required size of the lamp reflector, but is generally 10 to 50 μm.

Next, the metal reflective layer 3 is formed on the undercoat layer 2. It does not specifically limit as a material of the metal reflective layer 3, A well-known thing can be used in the said technical field. Examples of the material of the metal reflective layer 3 include aluminum, silver, zinc, an alloy mainly composed of silver and zinc, and the like.
The method for forming the metal reflective layer 3 on the undercoat layer 2 is not particularly limited, and for example, a known method such as a vacuum deposition method can be used.
The thickness of the metal reflection layer 3 may be appropriately set according to the required size of the lamp reflector, but is generally 800 to 2,000 mm.

The light source 4 and the front lens 5 provided at predetermined positions of the lamp body are not particularly limited, and those known in the technical field can be used. The method of providing the light source 4 and the front lens 5 is not particularly limited, and can be performed according to a known method.
The lamp reflector according to this embodiment manufactured in this way has high productivity and low manufacturing cost.

EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention in detail, this invention is not limited by these.
(Synthesis of unsaturated polyester resin A)
In a reaction vessel equipped with a stirrer, a reflux condenser, a nitrogen gas inlet tube and a thermometer, 100 mol of propylene glycol, 30 mol of phthalic anhydride, and 70 mol of maleic anhydride are charged, and an acid value of 20 mgKOH / The reaction was continued until g. Next, 0.015 parts by mass of hydroquinone was added to 100 parts by mass of the reaction product and cooled to 160 ° C., and then a styrene monomer was further added to obtain unsaturated polyester resin A. Here, the styrene monomer was added to 35% by mass in the unsaturated polyester resin A. Moreover, the acid value of unsaturated polyester resin was 13 mgKOH / g.

(Synthesis of unsaturated polyester resin B)
In a reaction vessel equipped with a stirrer, a reflux condenser, a nitrogen gas inlet tube, and a thermometer, 1,000 g of unsaturated polyester resin A and 1.2 times equivalent of glycidyl methacrylate of the carboxyl group of unsaturated polyester resin A 24 mol (33.6 g), 0.2 parts by mass of tris (dimethylaminomethyl) phenol, total amount of unsaturated polyester resin A and glycidyl methacrylate with respect to 100 parts by mass of total amount of unsaturated polyester resin A and glycidyl methacrylate An unsaturated polyester resin B was obtained by charging 0.015 parts by mass of hydroquinone with respect to 100 parts by mass and reacting at 110 to 130 ° C. for 3 to 4 hours while blowing air. The acid value of this unsaturated polyester resin B was 0 mgKOH / g. Moreover, content of the styrene monomer in unsaturated polyester resin B was 35 mass%.

(Examples 1-12)
Each component was charged with the composition shown in Table 1, and BMC was obtained by kneading using a double kneader.
The obtained BMC was evaluated for molding shrinkage rate, moldability, and mechanical strength. The test and evaluation methods are as follows.

(1) Mold shrinkage The mold shrinkage is produced by compression-molding a shrink disk specified in JIS K-6911 under conditions of a molding temperature of 150 ° C., a molding pressure of 100 kg / cm ² and a molding time of 3 minutes. The molding shrinkage was calculated according to JIS K-6911.

(2) Formability The formability was evaluated for leveling, gloss, fillability and demoldability.
Leveling, gloss, fillability, and demoldability are: compression molding under conditions of a molding temperature of 150 ° C., a molding pressure of 100 kg / cm ² , and a molding time of 3 minutes to produce a 3 mm × 300 mm × 220 mm flat plate and visually evaluated.
In the evaluation of leveling, filling property and demolding property, ◎ means very good, ○ means good, Δ means somewhat inferior, and × means bad.
In the gloss evaluation, A means gloss and B means no gloss (cloudy).

(3) Mechanical strength Mechanical strength was evaluated with respect to bending strength, bending elastic modulus and Charpy impact strength.
A bending strength and flexural modulus test piece specified in JIS K6911 was produced by compression molding under conditions of a molding temperature of 150 ° C., a molding pressure of 10 MPa, and a molding time of 3 minutes, and the flexural strength based on JIS K6911. And the flexural modulus was measured. Moreover, the Charpy impact strength was measured about the same test piece using the Charpy impact tester.

Next, using the BMC obtained above, compression molding was performed under the conditions of 140 ° C. × 4 minutes to produce a 3 mm × 300 mm × 220 mm flat plate (BMC molded body). Then, a UV curable undercoat agent (QN11-0107 manufactured by BASF) is applied on the flat plate to a thickness of 40 μm by spraying, and then UV is irradiated using a high-pressure mercury lamp to cure the coating. I let you. In UV irradiation, when 600 mJ / cm ² of UV was irradiated per pass, tack was free in the second pass, and stickiness disappeared even when wiped with acetone in the sixth pass.
A sample subjected to 6 passes of UV irradiation was evaluated for adhesion by a cross-cut test. In the cross cut test, the sample was evaluated according to the cross cut tape method (cutting interval: 2 mm) of JIS K 5400 8.5.2 with the evaluation score defined in Table 18 of JIS K 5400 8.5. .

On the other hand, after the BMC obtained above was molded into the shape of a lamp reflector by injection molding, a UV curable undercoat agent (QN11-0107 manufactured by BASF) was applied to the thickness of 40 μm in the same manner as above. It was applied and cured. About this sample, the adhesive evaluation by a cross cut test was performed like the above.
Moreover, when aluminum was vapor-deposited on this sample, it was confirmed that a uniform aluminum layer was formed.

(Comparative Examples 1-5)
Each sample was produced in the same manner as in Examples 1 to 12, and the same evaluation was performed.
Regarding the above evaluation results, the results of Examples 1 to 12 are shown in Table 1, and the results of Comparative Examples 1 to 5 are shown in Table 2, respectively.

As can be seen from the results of Tables 1 and 2, it was found that the BMCs of Examples 1 to 12 blended with polybutadienes at a specific ratio have good moldability and give a BMC molded body excellent in mechanical strength. . Moreover, it turned out that the BMC molded object of Examples 1-12 is excellent in the coating property and adhesiveness of an undercoat agent. This is considered to be due to the fact that the surface of the BMC molded body is cloudy in the gloss evaluation of Examples 1 to 12, and the BMC molded body has a phase separation structure. In other words, this phase separation structure prevents the internal release agent from being unevenly distributed on the surface of the BMC molded body, and improves the coatability and adhesion of the undercoat agent without the need to remove the internal release agent. it is conceivable that.
In contrast, the BMCs of Comparative Examples 1 to 3 in which the compounding amount of the polybutadienes is too large, although the BMC molded body has a phase separation structure, it was excellent in the paintability and adhesion of the undercoat agent. Further, the moldability (particularly, demolding property) and the mechanical strength (particularly hot strength) of the BMC compact were lowered.
In addition, the BMCs of Comparative Examples 4 and 5 in which no polybutadienes were blended gave a BMC molded body having good moldability and good mechanical strength, but the coating properties of the undercoat agent on the BMC molded body and Adhesion was not sufficient. This is presumably because the BMC molded bodies of Comparative Examples 4 and 5 are glossy in evaluation of gloss and do not have a phase separation structure.

  As can be seen from the above results, according to the present invention, it is possible to provide a BMC molded body having excellent paintability of the undercoat agent and adhesion to the undercoat layer without performing the removal treatment of the internal release agent. Can be provided. In addition, according to the present invention, it is possible to provide a lamp reflector and a method for manufacturing the same that can improve productivity and reduce manufacturing costs.

  1 BMC molded body, 2 undercoat layer, 3 metal reflective layer, 4 light source, 5 front lens.

Claims (7)

A bulk molding compound comprising an unsaturated polyester resin and / or vinyl ester resin, a polymerizable crosslinking agent, and an internal mold release agent,
The bulk molding compound characterized by further including 1-20 mass parts of polybutadienes with respect to 100 mass parts in total of the said unsaturated polyester resin and / or the said vinyl ester resin, and the said polymeric crosslinking agent.   The bulk molding compound according to claim 1, wherein a molded body having a phase separation structure is provided.   The bulk molding compound according to claim 1 or 2, wherein an acid value of the unsaturated polyester resin is 20 or less.   The bulk molding compound according to any one of claims 1 to 3, wherein the polybutadiene is a hydroxyl-terminated polybutadiene.   The bulk molding compound according to any one of claims 1 to 4, further comprising at least one selected from the group consisting of a curing agent, a low shrinkage agent, a thickener, a thickener, and a pigment. .   It contains the molded object of the bulk molding compound as described in any one of Claims 1-5, the undercoat layer formed on the said molded object, and the metal reflective layer formed on the said undercoat layer. A lamp reflector characterized by Forming the bulk molding compound according to any one of claims 1 to 5 to obtain a molded body;
A process of forming an undercoat layer by applying and curing an undercoat agent on the molded body without performing an internal mold release agent removal treatment;
And a step of forming a metal reflective layer on the undercoat layer.

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