JPS5999402A - Reflection mirror - Google Patents

Abstract

PURPOSE:To obtain a reflection mirror causing no cracking in the protective oxide film even at high temp. by successively forming a heat resistant resin underlayer made of a specified heat resistant resin, a bright metallic film and a protective oxide film on a substrate in a contact state. CONSTITUTION:A heat resistant resin underlayer, a bright metallic film and a protective oxide film are successively formed on a substrate in a contact state to obtain a reflection mirror. The heat resistant resin of the heat resistant resin underlayer has 20-50kg/mm.<2> Young's modulus and <1.5X10<-4>/ deg.C expansion coefft. The substrate is formed by finishing a platelike material made of Al, an Al alloy, Fe or an Fe alloy to the prescribed shape of a reflection mirror by press forming, spinning or other method. SiO2 is used most practically as the bright metal of the bright metallic film from the viewpoint of transparency, safety and economical efficiency.

Description

[Detailed description of the invention] The present invention relates to a reflecting mirror for a lighting device.

In general, reflectors for HID light source lighting equipment such as outdoor sports lighting, factory lighting, road lighting, and plaza lighting must have high specularity (reflectance) and the ability to withstand high temperatures of nearly 200°C (due to radiant heat from lamps). It is also required to have good resistance to moisture and corrosive gases. In order to meet these demands, heat-resistant resin is baked on the 7 surfaces of the metal base material,
A reflector on which A1 and SiO2 were sequentially deposited was considered.

However, this reflective mirror has the disadvantage that the underlying heat-resistant resin has a large coefficient of expansion, and therefore cracks occur in the SiO□ protective film on the surface due to the expansion of the heat-resistant resin, especially at high temperatures of 150 to 200°C. was.

As a result of repeated research to eliminate these drawbacks, the inventors have increased the expansion coefficient of the base heat-resistant resin to 1.5
The inventors have discovered that the desired objective can be achieved by setting the Young's modulus to less than 10-'/'C and setting the Young's modulus to 20 to 50 kg/mrrr, and have thus arrived at this invention.

That is, in this invention, a heat-resistant resin base layer is formed in close contact with a base material, a bright metal film is closely formed on this heat-resistant resin base layer, and an oxide protective film is further formed in close contact with the heat-resistant resin base layer. The gist of the reflector is a reflector whose heat-resistant resin base layer has a Young's modulus of 20 to 50 kg/m g and an expansion coefficient of less than 1.5 x 10-'/''c. It is something to do.

Next, this invention will be explained in detail.

The base material used for the reflecting mirror of this invention is ΔI.

Press-forming plate materials made of AI alloy, Fe, and Fe alloy.

A reflector shaped into a predetermined shape by a forming method such as spatula drawing is used.

Heat-resistant resins (paints) used for the base layer include heat-resistant resins of 180°C or higher, such as acrylic resins, silicone resins, alkyd melamine resins, phenol resins, polyamide resins, polyimide resins, polyether sulfon resins, polysulfone resins, and polyphenylene sulfide resins. A heat-resistant resin with a Young's modulus of 20 to 5 Qkg/mm and an expansion coefficient of less than 1.5 x 10-4/''C is used. The resin can be obtained by, for example, containing 5 to 35% by weight (hereinafter abbreviated as "%") of extender pigments such as calcium carbonate, talc, silica sand, alumina, and white pigments such as titanium oxide, either alone or in combination. can. The content of the above pigment is 5
%, the expansion coefficient will not be less than 1.5 x 104/'c. Moreover, when it exceeds 35%, specularity deteriorates. Therefore, the pigment content needs to be set at 5 to 35%. If a heat-resistant resin having a puffer ratio and an expansion coefficient outside the ranges described above is used, cracks will occur in the oxide protective film made of Si02 or the like at high temperatures of 150 to 200°C.

Therefore, it is necessary to use a heat-resistant resin having the puffer index and expansion coefficient as described above.

As the bright metal used for the bright metal film, AI is used.

Examples include Δg, Cr, Ni, etc. However, from the viewpoint of reflectance, cost, ease of vapor deposition, etc., it is most practical to use 81.

The oxide used for the oxide protective film is SiO.

Examples include 5iO7, TiO□, Al□03, etc. However, from the viewpoints of transparency, stability, and economy, Si02
It is most practical to use

The reflecting mirror of the present invention is manufactured using the above-mentioned raw materials, for example, in the following manner. That is, a metal base material is degreased and dried in advance, and a heat-resistant resin is applied thereto by a method such as a spray method, an electrostatic coating method, or a dipping method. In this case, it is preferable to set the coating film thickness to 5 to 15 μm. Coating thickness is 5
When it is less than μ, specularity becomes insufficient if the surface of the base material is rough.

Moreover, if it exceeds 15 μm, gas may remain in the coating film depending on the degree of baking when the coating film is baked in a subsequent step, causing inconvenience (occurrence of clouding) in the next step of vapor deposition, and also being disadvantageous in terms of cost. Next, the heat-resistant resin coating film is baked to form a heat-resistant resin base layer. Then, a bright metal is vapor-deposited on this heat-resistant resin base layer. Vapor deposition may be performed by a normal method. That is, the bright metal is evaporated by resistance heating or electron beam heating under a vacuum of 10-4 to 10-5 T'orr to form a metal film on the base layer. This film thickness is 300 to 1000
It is preferable to set it within the human range. When the film thickness is less than 300 mm, the base layer becomes transparent and the reflectance becomes low. On the other hand, if the number of participants exceeds 1,000, no further increase in effectiveness can be expected and it becomes uneconomical in terms of cost. In addition, if necessary, in order to improve the adhesion between the base layer and the metal film,
Bombardment treatment may be performed immediately before vapor deposition.

Next, an oxide is deposited on the metal film. That is, (2) the oxide is evaporated by electron beam heating under a vacuum of 4 to 10 Torr to form a predetermined film. This film thickness is 0
．． It is preferable to set it in the range of 3 to 2μ. Film thickness is 0
．． If it is less than 3μ, there will be many pinholes in the oxide protection film and the corrosion resistance will deteriorate. On the other hand, if the thickness exceeds 2μ, no further increase in effectiveness can be expected, and the deposition process becomes time consuming and uneconomical.

Note that when forming this oxide protective film, if necessary, bombardment treatment may be performed before vapor deposition of the oxide to improve the adhesion between the oxide protective film and the metal film.

A reflecting mirror is manufactured in this way. The configuration of this reflecting mirror is shown in FIG. In the figure, 1 is a metal base material, 2 is a base layer, 3 is a metal film, and 4 is an oxide protective coating. This reflective mirror does not cause cracks in the oxide protective coating even at high temperatures (150 to 200°C), and is therefore ideal as a reflective mirror for HID light source outdoor sports lighting, factory lighting, road lighting, and the like.

Next, examples will be described together with comparative examples.

[Example 1] Aluminum base material with a thickness of 1111 mm (15 cm x 15 cm + n
) was spray-coated with a heat-resistant silicone paint (containing 20% barium sulfate) to a thickness of 10 μm and baked at 180 tons for 20 minutes to form a base layer. Separately, a film of this heat-resistant silicone paint was exploded and the Young's modulus and expansion coefficient were measured, and the Young's modulus was 25 kg/mm, and the expansion coefficient was 1°2 x 10-4/°C. Set the aluminum plate with this base layer on the vapor deposition equipment, 5×1 leaf 5T
High purity aluminum (99,99%) in vacuum of orr
was vapor-deposited by resistance heating to form an aluminum film with a thickness of 100 OA. Next, install a vapor deposition device of 5 x 1O-5T.
A 5000-layer 5i02 protective film was formed by depositing quartz (SiO□) by electron beam heating while maintaining the orr. The reflector thus obtained has excellent specularity with a total reflectance of 89% and a diffuse reflectance of 1.8%, and shows no discoloration or cracks even after being left in an atmosphere at 200°C for 48 hours. No change was observed. Also, JIS H-86
No particular change was observed even after carrying out 10 cycles of the salt water spray test based on No. 17 (1 cycle = 8 hours of spraying + 16 hours of rest). Furthermore, -10℃~+60℃, 90~
No change was observed even when a 10-day humidity test was conducted in an atmosphere of 98% R)l. Moreover, the adhesion when peeled off the tape was good not only at the initial stage but also after the heat resistance test, the salt spray test, and the moisture resistance test.

[Example 2] An aluminum base material (15QIIX15C) was prepared in the same manner as in Example 1.
Spray heat-resistant acrylic paint (containing 20% barium sulfate) to a thickness of 10 μm on
A base layer was formed by baking at ℃ for 40 minutes. This heat-resistant acrylic resin had a Young's modulus of 23 kg/mm and an expansion coefficient of 1.3 xlQ"/"C. From this point on, the same procedure as in Example 1 was carried out, with 900 AIs and 5i02s.
000 people were deposited to obtain a reflecting mirror. This product has a total reflectance of 88%, a diffuse reflectance of 2.0%, and a heat resistance test (200%
There was no change in appearance or generation of cracks at 4811rC), and no abnormalities were found in the salt spray test (10 cycles). In addition, moisture resistance test (-10"c ~ +6
0”C.

There was no abnormality in 90-98%R)l (10 days), and the adhesion (tape peel test) was good both at the initial stage and in each test.

[Example 3] An aluminum base material (15 cm x 15 cm) was prepared in the same manner as in Example 1.
x 1 m), was spray-painted to a thickness of lOμ with a paint obtained by adding 20 parts of titanium oxide to 100 parts of resin to the heat-resistant acrylic paint (containing 20% barium sulfate) used in Example 2. Baked at 20 (1"C) for 40 minutes to form a base layer (Young's modulus of 30 + r/mm, expansion coefficient of 1°1
10-4/"C) was formed. From here on, the same procedure as in Example 1 was carried out, and 7AI was used for 1000 people and 5i02 was used for 550OA.
A reflecting mirror was obtained by vapor deposition. This one has a total reflectance of 87%.
Diffuse reflectance is 3.2%, heat resistance (200℃ x 48H)
In R), there was no abnormality in appearance and no cracks were generated.
There were no abnormalities in the salt spray test (10 cycles). In addition, moisture resistance test (-10℃~+60℃, 90~98℃
%R) for 1.10 days), and the adhesion (tape peel test) was good both at the initial stage and after each test.

[Example 4] Parabolic shaped Al (580 fl in diameter and 300 fl in depth)
After degreasing and drying the molded base material, the same paint as in Example 3 was applied to a thickness of 15 μm and baked at 200° C. for 40 minutes.

From this point on, the same procedure as in Example 1 was carried out, and 81 was used at 100 OA.

A reflector was obtained by depositing 5,700 SiO2 layers. This product has a total reflectance of 88% and a diffuse reflectance of 3.5%, and has a heat resistance, salt spray test, moisture resistance test, and adhesion test of Example 3.
Similarly, there was no abnormality.

[Comparative example]

Young's modulus was 23 kg/mrl in the same manner as in Example 1.

Expansion coefficient 2. A silicone paint of Ox 10-4/''c was spray applied to a thickness of 10 μm to form a base layer.

From this point on, the same procedure as in Example 1 was carried out to prepare AI for 900 people and S
The reflector obtained by vapor-depositing 25,000 particles had good specularity and adhesion, but in a heat resistance test, cracks occurred in the SiO□ layer over the entire surface after 30 minutes at 200°C. Poor heat resistance;
In the salt spray test and the humidity test, the surface became partially cloudy after 5 cycles and the corrosion resistance was also poor.

[Brief explanation of drawings]

FIG. 1 is a block diagram of the present invention. I...Metal base material 2...Underlying layer 3...Metal film
4...Oxide protective film agent Patent attorney Takehiko Matsumoto] Voluntary amendment to Figure 1 procedure) January 22, 1980 To the Commissioner of the Japan Patent Office 1, 1 ■ Cow's Sacrifice 209811 No. 2, Name of Invention Reflector 36 Relationship with the case of the person making the amendment Patent Applicant Address 1048 Kadoma, Kadoma City, Osaka Name (583) Matsushita Electric Works Co., Ltd. Representative Iku Yaku Kobayashi 4, Agent No person 7. Contents of the amendment (1) In the 8th page, line 12 of the specification, the word [Arryl] has been changed to “
Acrylic,” he corrected. (2) On page 8, page 12 of the specification, “(barium sulfate 20
barium sulfate 20%
"instead of," he corrected.

Claims (1)

[Claims] (11) A heat-resistant resin base layer is formed in close contact with the base material, a bright metal film is formed in close contact with the heat-resistant resin base layer, and an oxide protective film is further formed in close contact with the heat-resistant resin base layer. is a reflective mirror in which the Young's modulus of the heat-resistant resin of the heat-resistant resin base layer is 20.
~50 kg/mrrl, expansion coefficient 1.5 Xl0-
4/''C. (2) The heat-resistant resin base layer is formed by applying a heat-resistant resin containing 5 to 35% by weight of a pigment onto a base material and baking it. 2. The reflecting mirror according to claim 1, which is