JP2018013748A - Light reflection body material, light reflection body production method, light reflection body, and lighting fixture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a light reflection body material having excellent moldability.SOLUTION: A light reflection body material contains at least a white pigment, an unsaturated polyester resin, diallyl phthalate and/or diallyl isophthalate, and modified silicone oil, with 50/50(mass ratio)≤(the diallyl phthalate and/or diallyl isophthalate)/(the unsaturated polyester resin)≤80/20(mass ratio).SELECTED DRAWING: Figure 1

Description

  The present invention relates to a light reflector material, a light reflector manufacturing method, a light reflector, and a lighting fixture.

  Various light reflector materials (LED reflector materials) have been proposed. Adoption of a thermosetting resin instead of a thermoplastic resin has been proposed in order to increase the brightness of LEDs.

  For example, “a thermosetting resin and a white pigment are included, and the thermosetting resin includes at least diallyl isophthalate and an unsaturated polyester resin, (diallyl isophthalate)” / (The unsaturated polyester resin) is 40/60 to 80/20 (mass ratio), and a light reflector material in which an inorganic powder is present on the surface of the white pigment is proposed (Japanese Patent No. 5921789). )

  “Unsaturated polyester resin, polymerization initiator, inorganic filler, white pigment, and unsaturated polyester resin composition for LED reflector containing a reinforcing material, wherein the unsaturated polyester resin composition comprises: Unsaturated polyester for LED reflectors containing (meth) acryl-modified silicone alkoxy oligomer having (meth) acryl group, alkyl group, and alkoxy group in an amount of 1 to 15 parts by mass with respect to 100 parts by mass of the unsaturated polyester resin. A “resin composition” has been proposed (Japanese Patent No. 5308601).

Japanese Patent No. 5921789 Patent No. 5308601

Patent Document 1 is composed of diallyl isophthalate and unsaturated polyester resin ((diallyl isophthalate) / (unsaturated polyester resin) = 40/60 to 80/20 (mass ratio)). An LED reflector is proposed.
However, when the said composition was used, the problem was recognized by the moldability of LED reflector. In particular, when the amount of the diallyl isophthalate is large, the problem of moldability becomes large. When an LED reflector was molded from the composition by, for example, transfer molding, the fluidity was poor and a high-quality LED reflector could not be obtained.

The said patent document 2 has proposed the material comprised using unsaturated polyester resin bridge | crosslinked by the siloxane skeleton as resin which comprises a LED reflector.
However, Patent Document 2 discloses that “unsaturated polyester resin and diallyl phthalate and / or diallyl isophthalate are used (50/50 (mass ratio) ≦ (the diallyl phthalate and / or diallyl isophthalate). ) / (The unsaturated polyester resin) ≦ 80/20 (mass ratio)) is not disclosed. There is no description suggesting that moldability is poor when the composition is used.

  The problem to be solved by the present invention is that a thermosetting resin (at least an unsaturated polyester resin and diallyl phthalate and / or diallyl isophthalate is used (50/50 (mass ratio) ≦ (the phthalate When the light reflector is molded using (diallyl acid and / or diallyl isophthalate) / (unsaturated polyester resin) ≦ 80/20 (mass ratio)), the whiteness of the light reflector (light reflection characteristics) Is to improve the problem of formability without sacrificing.

The present invention
A light reflector material,
The material is at least
A white pigment,
An unsaturated polyester resin;
Diallyl phthalate and / or diallyl isophthalate,
Composed of silicone and
50/50 (mass ratio) ≦ (diallyl phthalate and / or diallyl isophthalate) / (unsaturated polyester resin) ≦ 80/20 (mass ratio),
A light reflector material is proposed in which the silicone is a modified silicone oil.

  The present invention is the light reflector material, wherein the modified silicone oil is dimethylpolysiloxane having an organic group (a methyl group is removed) at a side chain and / or a terminal. Suggest materials.

  The present invention is the light reflector material, wherein the modified silicone oil is preferably at least one silicone oil selected from the group of the following formulas (1), (2), (3), and (4). A light reflector material characterized by this is proposed.

  The present invention proposes a light reflector material, wherein the light reflector material is characterized in that the modified silicone oil is preferably a silicone oil represented by the following formula (1).

  The present invention proposes a light reflector material, wherein the light reflector material is characterized in that the modified silicone oil is preferably a silicone oil represented by the following formula (2).

  The present invention proposes a light reflector material, wherein the light reflector material is characterized in that the modified silicone oil is preferably a silicone oil represented by the following formula (3).

  The present invention proposes a light reflector material, wherein the light reflector material is characterized in that the modified silicone oil is preferably a silicone oil represented by the following formula (4).

Formula (1)
[In Formula (1), R is an organic group (a methyl group is excluded), and n is an integer of 1 or more. ]
Formula (2)
[In Formula (2), R is an organic group (a methyl group is excluded), and n is an integer of 1 or more. ]
Formula (3)
[In Formula (3), R is an organic group (a methyl group is excluded), l and m are integers of 1 or more. ]
Formula (4)
[In Formula (4), R is an organic group (a methyl group is excluded), l and m are integers of 1 or more. ]

The present invention proposes a light reflector material which is the light reflector material, wherein the modified silicone oil preferably has a viscosity (25 ° C.) of 10 to 20,000 mm ² / s. .

  The present invention is the light reflector material, wherein the organic group is, for example, in the group of acrylic group, methacryl group, carbinol group, glycidyl group, alkoxy group, diol group, carboxyl group, amino group, phenol group. A light reflector material characterized in that it is at least one selected from:

  The present invention is the light reflector material, wherein (mass of the modified silicone oil) / (total weight of all the light reflector materials) is preferably 0.1 to 5% by mass. A light reflector material is proposed.

  The present invention proposes a light reflector material, wherein the light reflector material is characterized in that the white pigment is preferably a titanium oxide powder.

  The present invention proposes a method of manufacturing a light reflector, wherein the light reflector material is molded.

  The present invention proposes a light reflector characterized in that the light reflector material is used.

  The present invention proposes a luminaire comprising the light reflector.

  When the light reflector material of the present invention is used, the moldability is good.

  The light reflector has little warpage and sink marks and high dimensional accuracy. Excellent heat resistance, light resistance, and weather resistance (less discoloration due to heat and light). Excellent impact resistance.

Schematic sectional view of LED lighting fixture (LED bulb)

  Embodiments of the invention are described.

  The first invention is a light reflector material. The reflector includes a reflector. Although it is described as a reflection “plate”, the shape is not particularly limited as long as it has the ability to reflect light, and is not limited to a “plate” -like planar shape. For example, three-dimensional shapes such as a box shape, a conical shape, and a parabolic shape are also included. The light reflector material is, for example, an LED reflector constituent material. The material includes at least a white pigment, an unsaturated polyester resin, diallyl phthalate and / or diallyl isophthalate, and silicone. The material is composed of a resin composition. The composition contains the white pigment. The composition contains a thermosetting resin. An unsaturated polyester resin is mentioned as a component which comprises the said thermosetting resin. And diallyl phthalate and / or diallyl isophthalate. The ratio of the unsaturated polyester resin to diallyl phthalate and / or diallyl isophthalate is as follows. 50/50 (mass ratio) ≦ (diallyl phthalate and / or diallyl isophthalate) / (unsaturated polyester resin) ≦ 80/20 (mass ratio)

The silicone is a modified silicone oil. The modified silicone oil is preferably dimethylpolysiloxane having an organic group (a methyl group is excluded) in the side chain and / or terminal. The modified silicone oil is preferably at least one silicone oil selected from the group of the formulas (1), (2), (3), and (4). For example, a mixture of the formula (1) and the formula (2) may be used. It may be a mixture of the formula (1) and the formula (3). The mixture of said Formula (1) and Formula (4) may be sufficient. The mixture is not limited to two types. There may be three types or four types. The modified silicone oil is preferably a silicone oil represented by the formula (1). The modified silicone oil is preferably a silicone oil represented by the formula (2). The modified silicone oil is preferably a silicone oil represented by the formula (3). The modified silicone oil is preferably a silicone oil represented by the formula (4). The most preferable silicone oil was a silicone oil represented by the formula (1). The organic groups of the formulas (1), (2), (3), and (4) are organic groups other than Me (methyl group). The silicone oil is preferably a silicone oil that does not have two functional groups, a (meth) acryl group and an alkoxy group at the same time. The organic group is, for example, a functional group that can react with the unsaturated polyester resin. The organic group is, for example, a functional group capable of reacting with a crosslinking agent (diallyl phthalate and / or diallyl isophthalate). The conclusion that all of the modified silicone oil used reacted with the unsaturated polyester resin and the like could not be reached. This is because bleeding of the modified silicone oil was observed. The organic group is at least one selected from the group of, for example, an acryl group, a methacryl group, a carbinol group, a glycidyl group, an alkoxy group, a diol group, a carboxyl group, an amino group, and a phenol group. The organic group is preferably an acrylic group or a methacryl group. The organic group is preferably a carbinol group. The organic group is preferably a glycidyl group. The glycidyl group is, for example, an epoxy group. The organic group is preferably at least one selected from the group consisting of an acryl group, a methacryl group, a carbinol group, and a glycidyl group. The organic group is preferably at least one selected from the group of an acryl group, a methacryl group, and a carbinol group. The modified silicone oil preferably had a viscosity (25 ° C.) of 10 to 20,000 mm ² / s.

  (Mass of the modified silicone oil) / (total mass of all the light reflector materials) was preferably 0.1 to 5 (% by mass).

  The white pigment was preferably a titanium oxide powder.

  The second invention is a method of manufacturing a light reflector. The method is a method of forming the light reflector material by a predetermined forming method. Various methods are used for the forming method. For example, a transfer molding method is used. Alternatively, an injection molding method is used. Alternatively, a compression molding method is used. Other molding methods may be used. The method may be a known method. However, it is not limited to a known method.

  The third invention is a light reflector. The light reflector is constituted by using the light reflector material.

  4th invention is a lighting fixture. The luminaire includes the light reflector.

  Further detailed description will be given below.

[White pigment]
The light reflector material contains the white pigment as an essential component. The white pigment is preferably in a powder form. Examples of the white pigment include titanium oxide. In addition, barium titanate, strontium titanate, aluminum oxide, magnesium oxide, zinc oxide, barium sulfate, magnesium carbonate, barium carbonate, zirconium oxide, and the like can be given. One or two or more of these substances are appropriately used. Of the above, titanium oxide, aluminum oxide, and barium titanate were preferred. In particular, titanium oxide was preferred. Examples of the titanium oxide include anatase type titanium oxide, rutile type titanium oxide, and brucite type titanium oxide. Of these, rutile type titanium oxide having excellent thermal stability was particularly preferred. The white pigment preferably has an average particle size of 2 μm or less. More preferably, the average particle size was 0.1 to 1 μm. More preferably, the average particle size was 0.2 to 0.6 μm. The average particle diameter is a value measured by a laser diffraction scattering method. The titanium oxide powder was preferably surface-treated with an inorganic powder. Preferably, it was surface-treated with at least one selected from the group consisting of silica, alumina, and zirconia. Titanium oxide has a photocatalytic function. When titanium oxide was contained in the light reflector, the light reflector could be damaged by the photocatalytic action of titanium oxide. However, when silica or the like is present (attached) on the surface of the titanium oxide powder, the light reflector is hardly damaged even if the light reflector includes titanium oxide. The reason for this was thought to be that the photocatalytic action of titanium oxide was weakened due to the presence of silica and the like on the surface. The silica or the like adheres to the surface of the white pigment (titanium oxide). Therefore, the size of the silica or the like is preferably smaller than the size of the white pigment (titanium oxide). The magnitude | size of the said silica etc. is 1 micrometer or less, for example. Organic substances for surface treatment of white pigments are silane coupling agents, organic acids, polyols, silicones, and the like. In particular, when titanium oxide is surface-treated with a fatty acid, a silane coupling agent, or the like, even if the titanium oxide is a fine particle, the titanium oxide hardly aggregates. For this reason, a white pigment (titanium oxide) surface-treated with a fatty acid or a silane coupling agent is preferred.

  The white pigment was preferably 80 to 500 parts by mass with respect to 100 parts by mass of the thermosetting resin. More preferably, it was 450 parts by mass or less. When the amount of the white pigment was as described above, the light reflector was particularly excellent in heat resistance and light reflectivity.

[Unsaturated polyester resin]
One essential constituent of the thermosetting resin is an unsaturated polyester resin. Other essential constituents include at least one selected from the group of diallyl phthalate and diallyl isophthalate. The ratio of the said component is as follows. 50/50 (mass ratio) ≦ (total amount of compounds selected from the group of diallyl phthalate and diallyl isophthalate) / (total amount of unsaturated polyester resin) ≦ 80/20 (mass ratio). The reason why the component is an essential component and the amount of the component is as described above is from the viewpoint of characteristics of the light reflector, particularly heat resistance and light resistance.

  The unsaturated polyester resin is obtained, for example, by a dehydration condensation reaction between an unsaturated polybasic acid and a polyhydric alcohol. Examples of the unsaturated polybasic acids include maleic acid, maleic anhydride, fumaric acid, citraconic acid, mesaconic acid, itaconic acid, tetrahydrophthalic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, and glutaconic acid. In order to improve the mechanical properties of the unsaturated polyester resin, saturated polybasic acids are used. Examples of saturated polybasic acids include isophthalic acid, phthalic acid, terephthalic acid, and the like. Examples of the polyhydric alcohol (for example, glycols) include ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, propylene glycol, diethylene glycol, Examples include ethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butanediol, hydrogenated bisphenol A, bisphenol A propylene oxide compound, cyclohexane dimethanol, and dibromoneopentyl glycol.

  The unsaturated polyester resin may be crystalline or amorphous.

[Diallyl phthalate (diallyl isophthalate)]
The diallyl isophthalate is C ₆ H ₄ (COOCH ₂ CHCH ₂ ) ₂ [diallyl 1,3-benzenedicarboxylate]. The diallyl phthalate is C ₆ H ₄ (COOCH ₂ CHCH ₂ ) ₂ [1,2-benzenedicarboxylic acid di-2-propenyl]. The diallyl isophthalate and the diallyl phthalate include a monomer type, an oligomer type, and a mixture type of a monomer and an oligomer. The oligomer may be a mixture of two or more types. Any type may be used in the present invention. The oligomer means a compound obtained by dimerization, trimerization,... By self-polymerization of monomers. Oligomers include dimers, trimers, tetramers, etc. In the present invention, only the diallyl phthalate may be used. Only the diallyl isophthalate may be used. Both may be used.

  In the present invention, (the diallyl phthalate and / or diallyl isophthalate) / (the unsaturated polyester resin) ≧ 50/50 (mass ratio). That is, by increasing the amount of the cross-linking agent (the diallyl phthalate and / or diallyl isophthalate) relative to the amount of the unsaturated polyester resin, the defects in the case of using the unsaturated polyester resin were overcome. . And the characteristic at the time of using the said unsaturated polyester resin was show | played effectively. The (diallyl phthalate and / or diallyl isophthalate) / (unsaturated polyester resin) was preferably 60/40 (mass ratio) or more. The (diallyl phthalate and / or diallyl isophthalate) / (unsaturated polyester resin) was preferably 80/20 (mass ratio) or less. More preferably, it was 70/30 (mass ratio) or less.

  The thermosetting resin has a structure in which the unsaturated polyester resin is crosslinked with a crosslinking agent (diallyl phthalate and / or diallyl isophthalate).

[Modified silicone oil]
The light reflector material contains the thermosetting resin as an essential component. That is, the thermosetting resin is a prerequisite. The reason is from the viewpoint of the characteristics of the light reflector. However, since the thermosetting resin is an essential component, the moldability was inferior. This problem had to be improved. However, whiteness must not be sacrificed. That is, the moldability must be improved while the whiteness of the light reflector is sufficiently maintained. As the improvement method, the present invention proposed the use of modified silicone oil. By using the modified silicone oil, the moldability of the light reflector material (the thermosetting resin) was improved. Moreover, the whiteness of the obtained molded product was high, and it was effective in maintaining the whiteness when exposed to heat and light. The compatibility with the sealant was good and the adhesion was good. The white light of the LED was efficiently reflected.

Silicone oil is a liquid (fluid) liquid at room temperature (25 ° C.) among silicone compounds having a polysiloxane bond as the main skeleton. Contains silicone oil. Specifically, the silicone oil includes a waxy or oily silicone oil having a siloxane bond of less than 2,000 to a gum silicone rubber having a siloxane bond of 2,000 to 10,000.
Silicone oil introduces various organic groups into unmodified silicone oil, such as dimethyl silicone oil, methylphenyl silicone oil, methyl hydrogen silicone (generally called straight silicone oil), and unmodified silicone oil due to differences in structure. Therefore, it is classified as modified silicone oil with a new function added. The silicone oil used in the present invention is a modified silicone oil.
Modified silicone oils include those having an organic group at the side chain of dimethylpolysiloxane, those having an end at the end of the molecular chain, or those having both at the end and the end of the molecular chain. Or those in the side chain are preferred. The organic group is preferably a functional group capable of reacting with a crosslinking agent (diallyl phthalate and / or diallyl isophthalate).
Examples of the modified silicone oil include amino-modified silicone oil, epoxy-modified silicone oil, carbinol-modified silicone oil, phenol-modified silicone oil, carboxy-modified silicone oil, methacryl-modified silicone oil, and acrylic-modified silicone oil. There is at least one selected.
The viscosity (25 ° C.) of the modified silicone oil was 10 to 20,000 mm ² / s. Preferably, 10~2,000mm ² / s, more preferably, was 10~1,000mm ² / s. The viscosity can be measured with a kinematic viscosity measuring device.

  A preferred example of the modified silicone oil is a compound represented by the formula (1). The compound is a silicone oil in which one terminal group is substituted with an organic group. Only one type may be sufficient and two or more types of mixtures may be sufficient.

  A preferred example of the modified silicone oil is a compound represented by the formula (2). The compound is a silicone oil in which both end groups are substituted with organic groups. Only one type may be sufficient and two or more types of mixtures may be sufficient.

  A preferred example of the modified silicone oil is a compound represented by the formula (3). The compound is a silicone oil in which an organic group is bonded to Si in the polymer skeleton. Only one type may be sufficient and two or more types of mixtures may be sufficient.

  A preferred example of the modified silicone oil is a compound represented by the formula (4). The compound is a silicone oil in which both terminal groups are substituted with organic groups and the organic groups are bonded to Si in the polymer skeleton. Only one type may be sufficient and two or more types of mixtures may be sufficient.

  The compound represented by the formula (1) was most preferred. That is, the spiral flow value, which is an index of fluidity, was the highest. This is because the fluidity is high and the filling property at the time of transfer molding is improved.

  The organic group is at least one selected from the group of, for example, an acryl group, a methacryl group, a carbinol group, a glycidyl group, an alkoxy group, a diol group, a carboxyl group, an amino group, and a phenol group. The organic group is preferably at least one selected from the group consisting of an acryl group, a methacryl group, a carbinol group, and a glycidyl group. The organic group is preferably at least one selected from the group of an acryl group, a methacryl group, and a carbinol group. The organic group is preferably an acrylic group or a methacryl group. The organic group is preferably a carbinol group.

  The preferred addition amount of the modified silicone oil was as follows. (Mass of the modified silicone oil) / (total mass of all the light reflector materials) = 0.1 to 5 (mass%). When the amount was less than 0.1% by mass, the effect was lowered. When the content exceeds 5% by mass, the modified silicone oil bleeds out on the surface. When the amount added was, for example, 7% by mass, the modified silicone oil bleeded out during molding. The surface was wet with the oil.

[Polymerization initiator]
For the constitution of the thermosetting resin, a polymerization initiator is preferably used. The polymerization initiator was preferably 1 to 5 parts by mass with respect to 100 parts by mass of the thermosetting resin. More preferably, it was 1.5 parts by mass or more. More preferably, it was 3.5 parts by mass or less.

  As the polymerization initiator, preferably, a thermal decomposition type organic peroxide is used. An example is dicumyl peroxide. Or t-butylperoxy-2-ethylhexyl carbonate, 1,1-di (t-hexylperoxy) cyclohexane, 1,1-di (t-butylperoxy) -3,3,5-trimethylcyclohexane, t -Butyl peroxy octoate, benzoyl peroxide, methyl ethyl ketone peroxide, acetylacetone peroxide, t-butyl peroxybenzoate, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane and the like. Among these, organic peroxides having a 10-hour half-life temperature of 95 ° C. or more are preferable. An example is dicumyl peroxide. The said polymerization initiator may be 1 type (single), or 2 or more types may be used together. Polymerization is performed using a composition containing the above components. Thereby, the thermosetting resin was obtained.

[Inorganic filler]
The light reflector material preferably contains an inorganic filler. The inorganic filler is preferably one or more selected from the group consisting of silica, aluminum hydroxide, aluminum oxide, magnesium oxide, barium sulfate, magnesium carbonate, and barium carbonate. The inorganic filler was preferably 80 to 500 parts by mass with respect to 100 parts by mass of the thermosetting resin.

[Release agent]
The light reflector material preferably contains a release agent. Examples of the mold release agent include waxes used for thermosetting resins (for example, fatty acids, fatty acid metal salts, minerals, and the like). Fatty acid-based and fatty acid metal salt-based waxes were preferred because LED reflectors with excellent heat resistance were obtained. Specific examples include stearic acid and stearates (for example, zinc stearate, aluminum stearate, calcium stearate, etc.). A mold release agent may be used independently and 2 or more types may be used together.

  The release agent was preferably 0.25 to 3.75 parts by mass with respect to 100 parts by mass of the thermosetting resin. More preferably, it was 0.75 mass part or more. More preferably, it was 2.5 parts by mass or less. When the blending amount of the release agent was set as described above, a light reflector excellent in both light release and appearance and excellent in light reflectivity was obtained.

[Reinforcing material]
The light reflector material preferably contains a reinforcing material. Examples of the reinforcing material include glass fiber. Or a vinylon fiber, an aramid fiber, a polyester fiber, a wollastonite, etc. are mentioned. Of these, glass fiber was preferred. Examples of the glass fiber include E glass (electrical alkali-free glass), C glass (chemical alkali-containing glass), A glass (acid-resistant glass), and S glass (high-strength glass) using silicate glass and borosilicate glass as raw materials. ) And the like. What used these as a long fiber (roving) and a short fiber (chopped strand) is used suitably. Surface treatment may be performed on these glass fibers. In particular, there is a method in which E glass fibers having a fiber diameter of 10 to 15 μm are surface-treated with a silane coupling agent, and 200, 400, or 800 monofilaments that have been surface-treated are converged with a converging agent such as vinyl acetate. Adopted.

  When the amount of the reinforcing material increased, the reflectance decreased. Therefore, if the strength as the light reflector can be secured, it is preferable that the reinforcing material is small. That is, the amount of the reinforcing material is preferably 75 parts by mass or less with respect to 100 parts by mass of the thermosetting resin. More preferably, it was 37.5 mass parts or less. More preferably, it was 20 parts by mass or less. The amount of the reinforcing material may be zero. If the lower limit of the amount of the reinforcing material is forced, it was 10 parts by mass.

[Silane coupling agent]
The light reflector material preferably contains a silane coupling agent. The silane coupling agent was preferably 0.25 to 12.5 parts by mass with respect to 100 parts by mass of the thermosetting resin. More preferably, it was 1.25 parts by mass or more. More preferably, it was 7.5 parts by mass or less.

[Antioxidant]
Examples of other additives include phosphorus antioxidants and hindered amine additives. Examples of phosphorus antioxidants include distearyl pentaerythritol diphosphite and tetrakis (2,4-di-t-butyl-5-methylphenyloxy) -4,4′-biphenylenediphosphine. Bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, dibutylamine-1,3,5-triazine-N, N′-bis (2,2,6,6-tetramethyl-4- Piperidyl) butylamine, tetrakis (1,2,2,6,6-pentamethyl-4-piperidyl) -1,2,3,4-butanetetracarboxylate and the like. These are preferably added in an amount of 0.1 to 10 parts by mass with respect to 100 parts by mass of the resin.

[Other additives]
In addition to the above-mentioned blending components, a curing catalyst, a polymerization inhibitor, a thickener, other organic additives and inorganic additives for adjusting the curing conditions of the resin are blended as necessary. .

[Molding]
A composition (light reflector material) containing the unsaturated polyester resin, the diallyl phthalate and / or diallyl isophthalate, the modified silicone oil, the white pigment, and other desired components is mixed with a mixer (for example, a mixer). , Blender, etc.). Then, it knead | mixed with the kneading machine (For example, a pressure kneader, a hot roll, an extruder, etc.). Then, it was pulverized and sized. The composition was molded into a predetermined shape by a melt heating molding method (for example, an injection molding method, an injection compression molding method, a transfer molding method, etc., preferably an injection molding method). As a result, a light reflector (LED reflector) was obtained. The burr generated in the frame of the light reflector could be easily removed by, for example, blasting (shot blasting, sand blasting, glass bead blasting, etc.). Burrs are also removed by machining center processing.

[Light reflector]
The light reflector is attached to a lighting fixture. FIG. 1 is a schematic sectional view of an LED lighting apparatus. The light reflector (LED reflector) 3 efficiently reflects the light from the LED element 2 mounted on the lead frame 1. The shape of the light reflector 3 is appropriately designed in consideration of the light amount, color, directivity, and the like of the LED element 2 to be mounted. The light reflector 3 preferably has a structure for holding the lead frame 1 in consideration of adhesion to the lead frame 1. When the metal lead frame 1 is used, in order to improve the adhesion with the LED reflector 3, it may be possible to perform a metal surface treatment with a triazine compound or the like.

  Hereinafter, the present invention will be specifically described. The following example is only one example of the present invention. The present invention is not limited to the following examples. That is, the present invention includes modifications and applications that do not greatly impair the features of the present invention.

[Unsaturated polyester resin]
A1: Unsaturated polyester resin (Nippon Iupika Co., Ltd .: 8510)
A2: Crystalline polyester resin (Pionear Plastics Co .: P275)
A3: Unsaturated polyester resin (Nippon Iupika Co., Ltd .: 8542)

[Crosslinking agent]
B1: Diallyl isophthalate prepolymer (Daiso Corporation; Isopup)
B2: diallyl isophthalate monomer (Daiso Corporation; monomer 100)
B3: Diallyl phthalate prepolymer (Daiso Corporation; DAP-A)
B4: Diallyl phthalate monomer (Daiso Corporation; DAP-Monomer)

[Polymerization initiator]
C: Dicumyl peroxide (NOF Corporation; Park Mill D40)

[White pigment]
D: Surface-treated titanium oxide Titanium oxide (Ishihara Sangyo Co., Ltd .: UT-771: average particle size 0.25 μm)
Surface treatment: Al ₂ O ₃ , ZrO ₂ , organic matter

[Inorganic filler]
E: Silica (Tosoh Silica Co., Ltd .: Nip Seal VN3)

[Reinforcing material]
F: Wollastonite (Otsuka Chemical Co., Ltd .: Surface treatment product)

[Release agent]
G: Calcium stearate (NOF Corporation: Calcium stearate GP)

[Antioxidant]
I: HALS (ADEKA Corporation: LA-81)

[Silicone oil]
H1: One-end carbinol-modified silicone oil 1: Shin-Etsu Chemical Co., Ltd .: X-22-170BX Viscosity 40mm ² / s (25 ° C)
H2: One-end methacryl-modified silicone oil 2: Shin-Etsu Chemical Co., Ltd .: X-22-2426 Viscosity 200 mm ² / s (25 ° C.)
H3: Carbinol-modified silicone oil at both ends 3: Shin-Etsu Chemical Co., Ltd .: KF-6001 Viscosity 45 mm ² / s (25 ° C.)
H4: Both ends methacryl-modified silicone oil 4: Shin-Etsu Chemical Co., Ltd .: X-22-164A Viscosity 25mm ² / s (25 ° C)
H5: Side chain-modified silicone oil 5: Toray Dow Corning Co., Ltd .: SF8417 Viscosity 1200 mm ² / s (25 ° C.)
H6: Dimethyl silicone oil 6: Shin-Etsu Chemical Co., Ltd .: KF-69 Viscosity 20mm ² / s (25 ° C)

[Example 1]
A1: 30 parts by mass B1: 70 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 100 (spiral flow value: measured using a spiral mold (conditions: molding temperature (160 ° C.), molding pressure (12 MPa), molding time (120 seconds))

[Example 2]
A1: 30 parts by mass B1: 70 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 10 Mass part Spiral flow value: 120

[Example 3]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 130

[Example 4]
A1: 50 parts by mass B1: 50 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 110

[Example 5]
A1: 20 parts by mass B1: 80 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 100

[Example 6]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H2: 5 Mass part Spiral flow value: 110

[Example 7]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H3: 5 Mass part Spiral flow value: 80

[Example 8]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H4: 5 Mass part Spiral flow value: 80

[Example 9]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H5: 5 Mass part Spiral flow value: 85

[Example 10]
A3: 30 parts by mass B1: 70 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 75

[Example 11]
A3: 30 parts by mass B3: 70 parts by mass B4: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 80

[Example 12]
A1: 40 parts by mass B1: 30 parts by mass B2: 1 part by mass B3: 30 parts by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 Parts by mass H1: 5 parts by mass Spiral flow value: 80

[Example 13]
A2: 40 parts by mass B1: 30 parts by mass B2: 1 part by mass B3: 30 parts by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 Parts by mass H1: 5 parts by mass Spiral flow value: 100

[Comparative Example 1]
A1: 40 parts by mass B1: 60 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass Spiral flow value : 40

[Comparative Example 2]
A1: 100 parts by mass C: 3 parts by mass D: 100 parts by mass E: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass Spiral flow value: 50

[Comparative Example 3]
A1: 80 parts by mass B1: 20 parts by mass C: 3 parts by mass D: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass Spiral flow value: 60

[Comparative Example 4]
A1: 30 parts B1: 70 parts B2: 1 parts C: 3 parts D: 200 parts E: 100 parts F: 100 parts G: 2 parts I: 0.5 parts H6: 5 Mass part Spiral flow value: 80

[Comparative Example 5]
A1: 60 parts by mass B1: 40 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 80

[Comparative Example 6]
A1: 15 parts by mass B1: 85 parts by mass B2: 1 part by mass C: 3 parts by mass D: 200 parts by mass E: 100 parts by mass F: 100 parts by mass G: 2 parts by mass I: 0.5 parts by mass H1: 5 Mass part Spiral flow value: 80

  The above materials were blended in the above proportions. Kneading was performed with two rolls heated to 100 ° C. The kneaded material was crushed. This pulverized product was transfer molded. Press molding (180 ° C., 90 seconds, 5 MPa) was performed. A light reflector having a predetermined shape was obtained.

  In the case of Examples 1 to 13, the moldability during molding of the light reflector was good. In particular, in the case of Examples 1, 2, 3, 4, 5, 6, 13 (the modified silicone oil is the formula (1) type), the moldability was particularly good. On the other hand, in the case of Comparative Examples 1 and 2.3 (no addition of the modified silicone oil) having a spiral flow value of 60 or less, the moldability was poor.

  The light reflection characteristics (initial whiteness and whiteness retention) of the light reflectors of Examples 1 to 13 and Comparative Examples 1, 2, 3, 5, and 6 were examined. The results are shown in Table-1.

Table-1
Initial whiteness (W ₁ ) Whiteness retention 1 Whiteness retention 2
Example 1 97 97 96
Example 2 97 97 96
Example 3 97 96 96
Example 4 97 96 96
Example 5 97 96 95
Example 6 97 96 96
Example 7 97 96 96
Example 8 97 96 96
Example 9 97 97 96
Example 10 97 93 92
Example 11 96 92 92
Example 12 96 94 94
Example 13 96 94 94
Comparative Example 1 95 94 94
Comparative Example 2 90 90 85
Comparative Example 3 92 92 88
Comparative Example 5 90 88 85
Comparative Example 6 92 90 90
* Initial whiteness (W ₁ ): The whiteness of the obtained light reflector was measured with a spectrocolorimeter (trade name: CM-5 manufactured by Konica Minolta).
* Whiteness retention ratio 1: The obtained light reflector was held at 150 ° C. for 1000 hours. The whiteness (W ₂ ) at this time was examined with the spectrocolorimeter. The whiteness retention after the heat test (W ₂ / W ₁ × 100) was calculated.
* Whiteness retention ratio 2: Ultraviolet light having a wavelength of 300 nm or more (light source: metal halide lamp, output 16 mW / cm ² ) was irradiated to the light reflector (time: 1000 hours, temperature: 120 ° C.). The whiteness (W ₃ ) after the heat and light resistance test was examined with the spectrocolorimeter. The whiteness retention (W ₃ / W ₁ × 100) after the heat and light resistance test was calculated.

Table 1 shows the following.
The light reflector made of the material of the present invention had high whiteness and excellent durability (heat resistance, heat resistance / light resistance). As described above, the moldability was good. In particular, when the spiral flow value was 100 or more, the moldability was very good.

  When the modified silicone oil of the present invention was used, the initial whiteness was also high.

  In the case of Comparative Example 4, the silicone oil bleeded out on the surface of the molded product. The surface was wet with oil. For this reason, in the first place, it was out of the scope of the whiteness evaluation.

  In Comparative Examples 1, 2, and 3, as described above, the moldability was poor.

  From the comparison between the examples and the comparative examples 1, 2, and 3, the requirement (50/50 (mass ratio) ≦ (diallyl phthalate and / or diallyl isophthalate) // The importance of (unsaturated polyester resin) ≦ 80/20 (mass ratio) is understood.

From the comparison between the examples and the comparative examples 5 and 6, the requirement (50/50 (mass ratio) ≦ (diallyl phthalate and / or diallyl isophthalate) / (unsaturated) also from the characteristics of whiteness. The importance of polyester resin) ≦ 80/20 (mass ratio) is understood.

Claims (12)

A light reflector material,
The material is at least
A white pigment,
An unsaturated polyester resin;
Diallyl phthalate and / or diallyl isophthalate,
Composed of silicone and
50/50 (mass ratio) ≦ (diallyl phthalate and / or diallyl isophthalate) / (unsaturated polyester resin) ≦ 80/20 (mass ratio),
The light reflector material, wherein the silicone is a modified silicone oil. 2. The light reflector material according to claim 1, wherein the modified silicone oil is dimethylpolysiloxane having an organic group (a methyl group is excluded) at a side chain and / or a terminal. 3. The light reflector material according to claim 1, wherein the modified silicone oil is a silicone oil represented by the following formula (1).
Formula (1)
[In Formula (1), R is an organic group (a methyl group is excluded), and n is an integer of 1 or more. ] 3. The light reflector material according to claim 1, wherein the modified silicone oil is a silicone oil represented by the following formula (2).
Formula (2)
[In Formula (2), R is an organic group (a methyl group is excluded), and n is an integer of 1 or more. ] 3. The light reflector material according to claim 1, wherein the modified silicone oil is a silicone oil represented by the following formula (3).
Formula (3)
[In Formula (3), R is an organic group (a methyl group is excluded), l and m are integers of 1 or more. ] 3. The light reflector material according to claim 1, wherein the modified silicone oil is a silicone oil represented by the following formula (4).
Formula (4)
[In Formula (4), R is an organic group (a methyl group is excluded), l and m are integers of 1 or more. ] The organic group is at least one selected from the group consisting of an acryl group, a methacryl group, a carbinol group, a glycidyl group, an alkoxy group, a diol group, a carboxyl group, an amino group, and a phenol group. The light reflector material according to claim 2. The light reflector according to claim 1, wherein (mass of the modified silicone oil) / (total weight of all the light reflector materials) = 0.1 to 5 (mass%). material. 9. The light reflector material according to claim 1, wherein the white pigment is a titanium oxide powder. A method for producing a light reflector, wherein the light reflector material according to any one of claims 1 to 9 is molded. A light reflector comprising the light reflector material according to claim 1. A light fixture comprising the light reflector according to claim 11.