TW201205896A - Method for producing light-emitting device, light-emitting device, and reflector - Google Patents

Abstract

A reflector having a smooth surface and a method for producing said reflector by using a liquid crystal resin composition obtained by mixing an inorganic filler with a liquid crystal resin are provided. The reflector is produced in such a manner that the difference (ΔRa) between the surface roughness (Ra) of the reflector and the surface roughness (Ra) of the inner wall surface of a mold for producing the reflector is not more than 0.1 mm. The mean primary particle diameter of the inorganic filler that is used is ideally not more than 15 μm. Furthermore, the content of the inorganic filler is ideally between 5 parts by mass and 70 parts by mass per 100 parts by mass for the liquid crystal resin.

Description

201205896 VI. Description of the Invention: TECHNICAL FIELD The present invention relates to a method of manufacturing a light-emitting device, a light-emitting device, and a reflector. [Prior Art] A light-emitting device in which a light-emitting element is mounted has been known [for example, refer to Patent Document 1). The light-emitting device described in Patent Document 1 includes a circuit board on which an LED (Light Emitting Diode) element (light-emitting element) as a light source is mounted, and a reflector (reflector). Reflecting light from LED elements provided on a printed circuit board. In the light-emitting device described in Patent Document i, the reflection system is made of a metal material and is fixed to the circuit board by a resin adhesive. However, in recent years, the light-emitting device has been required to be thinner and smaller. That is, the reflector is also required to be small and lightweight. However, as described above, the current reflective system is made of a metal material, and it is not easy to reduce the size and weight. Therefore, as described in Patent Document 2, it is conceivable to manufacture a reflector composed of a resin material. Since the resin material has characteristics such as easy molding, it is considered that it is easier to manufacture a compact and lightweight reflector. Patent Document 2' describes the production of a reflector using a thermosetting resin as a raw material. However, the reflector described in Patent Document 2 has a problem of shrinkage due to hardening and dimensional instability. Further, even when a thermoplastic resin is used, since the resin shrinks after cooling after molding, there is a tendency that a problem of a dimensionally stable reflector cannot be obtained as in the case of using a thermosetting resin. [Patent Document 1] Japanese Laid-Open Patent Publication No. 2001-24233 [Patent Document 2] [Problems to be Solved by the Invention] A resin having a small shrinkage ratio after molding, A liquid crystalline resin is known. It is considered that the reflector is formed by using a liquid resin as a raw material. By forming a metal layer on the surface of the molded body, a stable reflector having a size can be obtained. However, in the manufacturing steps of the light-emitting device, the reflector is exposed to the same gamma. Therefore, when a liquid crystalline resin is used as a raw material of a reflector, it is necessary to add an inorganic filler to the liquid crystalline resin to improve heat resistance. However, in order to improve the heat resistance, when a resin composition obtained by blending an inorganic filler with a liquid crystalline resin is used as a raw material to produce a reflector, the surface of the reflector is rough. If the surface of the reflector is rough, the metal layer reflected by the light of the lED element cannot be smoothly formed on the reflector. As a result, the reflector cannot effectively reflect the light from the led element. The present invention has been made to solve the problems as described above, and the object thereof is to provide a reflector having a smooth surface and a method for producing the reflector using a liquid crystalline resin composition in which an inorganic filler is blended with a liquid crystalline resin. [Means for Solving the Problem] The inventors of the present invention have focused on the above-mentioned problems. As a result, it was found that the difference between the surface roughness Ra of the reflector and the surface roughness of the inner wall surface of the mold for producing the reflector was 0.1 mm or less, and the above problem was solved. More specifically, the present invention 4 201205896 provides the following. (1) A method of manufacturing a light-emitting device, wherein the light-emitting device includes a circuit board 'I-light element' mounted on a circuit board and a reflector. The light-emitting element is disposed on the circuit board, and the reflector has an inclined surface that reflects light of the light-emitting TL in a desired direction. The method of manufacturing the light-emitting device includes a reflector manufacturing step of liquid helium The invention relates to a reflector for producing a reflector; a metal layer forming step of forming a metal layer on the inclined surface of the reflector obtained in the reflector manufacturing step, and a step of loading the light beam 7L, which is mounted on the circuit substrate to mount the light And a reflector arrangement step of disposing a reflector on the circuit board, wherein the reflector manufacturing step is to roughen the surface roughness Ra of the reflector and the surface of the inner wall surface of the mold for manufacturing the reflector. The step of producing a reflector is such that the difference (ΔRa) of the degree Ra is 0.1 mm or less. (2) The method of manufacturing a light-emitting device according to the above aspect, wherein the difference (ΔRa) is 0.03 mm or less. (3) A light-emitting device comprising: a circuit board; a light-emitting element mounted on the circuit board; and a reflector disposed on the circuit board surrounding the light-emitting element, wherein the reflector includes liquid crystal The resin; and the inorganic filler have an average primary particle diameter of 15 # m or less; and a metal layer is disposed on the surface of the reflector. (4) The light-emitting device according to (3), wherein the inorganic filler is a plate-like filler and/or a powder filler. (5) The light-emitting device according to (3), wherein the inorganic filler has an average primary particle diameter of 0·7 &quot; m or less. The light-emitting device according to any one of the aspects of the present invention, wherein the content of the inorganic filler is 5 parts by mass or more and 70 parts by mass or less with respect to the mass portion of the liquid crystalline resin (10). A liquid crystalline resin; and an inorganic filler having a metal layer on the surface. (7) A reflector having an average primary particle diameter of 15/m or less. [Effect of the invention] According to the present invention, a surface can be obtained by using a liquid crystalline resin composition in which an inorganic filler is blended with a liquid crystalline resin. Smooth reflector. As a result of the smoothing of the inclined surface formed on the surface of the reflector, the metal layer formed on the inclined surface also becomes smooth, and the light from the light-emitting layer can be efficiently reflected. Further, the surface of the reflector according to the present invention is hardly fibrillated. As a result, the metal layer formed on the surface of the reflector does not peel off due to fibrillation of the surface of the reflector. Therefore, the adhesion between the metal layer and the surface of the reflector is very high. [Embodiment] Hereinafter, embodiments of the present invention will be described in detail, but the present invention is not limited to the following embodiments. <Light-emitting device> Fig. 1 is a perspective view schematically showing a light-emitting device 1 of the present invention. Fig. 2 is a view showing the reflector 12 of the present invention, (a) is a perspective view of the reflector 12, and (b) is a cross-sectional view taken along line XX of (a). The light-emitting device 1 of the present invention includes a circuit board 1 〇, a light-emitting element i i , and a reflector 12 . In the light-emitting device 1 shown in Fig. 1, a light-emitting element u, a body 12, is disposed on a surface of a circuit board i 〇6 201205896. A plurality of electrode layers are formed to surround the light-emitting element 11 so as to form a reflective oxygen resin or a liquid crystal resin (the circuit board 10 is not shown on the surface and the back surface of the insulating substrate made of the glass ring). The light emitting element U is disposed on one surface of the circuit board 10. The number of the light-emitting elements 11 is not particularly limited, and one or a plurality of light-emitting elements may be disposed on one surface of the circuit board. The light-emitting 7G member 11 includes an electrode portion (not shown) that is electrically connected to the electrode layer of the circuit substrate 10. When a voltage is applied to the electrode layer, current is passed through the light-emitting element U by the electrical connection, and the light-emitting element 丨丨 emits the light-reflecting body 12, and the bottom surface and the circuit board 10 are formed by using a plate-shaped member formed by a mold. The joint is disposed on the circuit board 1A. Further, the reflector 12 has an opening portion 贯通2〇 penetrating the bottom surface and the surface, an inclined surface 121 for reflecting light by the light-emitting element, and a metal layer 122 formed on the surface. Further, the metal layer 122 may be provided on at least the inclined surface 121, and may be provided on a portion other than the inclined surface 211 of the surface of the reflector. The opening portion 1 2 0 ' is circular in plan view, and is tapered upward from the bottom surface. The inclined surface 121' is an inner side surface of the opening portion 120. As described above, since the opening portion 120 is formed to be tapered in a tapered shape from the bottom surface, the inclined surface 121 is inclined toward one surface of the circuit board 10. Since the inclined surface is inclined, the light of the light-emitting element can be efficiently reflected upward by 201205896 by the metal layer 122' formed on the inclined surface 121. Here, the direction in which the desired progress direction of the reflected light is upward (the direction perpendicular to the surface of the circuit board ίο) is adjusted so that the direction of the reflected light is adjusted by adjusting the tilt angle. In the present invention, the difference between the surface roughness of the reflector and the surface roughness Ra of the inner wall surface of the mold for producing the reflector is Δ. The difference in surface roughness Ra (ARa) becomes smaller as described above, indicating that the surface of the reflector 12 is smooth. When the surface of the reflector 12 is smooth, the inclined surface i 2丨 of a part of the surface of the reflector is also smooth. Then, the surface of the metal layer 122 formed on the smooth inclined surface 121 is also smooth. When the surface of the metal layer 122 is smoothed, the reflectance can be increased to effectively reflect the light from the light-emitting element. As described above, the present invention is characterized by the reflector 12. Hereinafter, the material used for the reflector 12 will be described in more detail. The reflector 丨2 used in the light-emitting device 1 of the present invention is composed of a liquid crystalline resin composition containing a liquid crystalline resin and an inorganic filler. Hereinafter, the description will be given in the order of the liquid crystalline resin and the inorganic filler. [Liquid Crystal Resin] Since the liquid crystalline resin has high dimensional stability, the size 12 of the reflector 12 can be obtained by using a liquid crystalline resin. Further, since the liquid crystal resin has high fluidity, the reflector 12 can be easily reduced in size and thickness. The liquid crystalline resin used in the present invention means a melt-processable polymer having a property of forming an optically anisotropic molten phase. The nature of the anisotropic melt phase can be confirmed by conventional polarizing inspection using a crossed polarizer. Further, it was confirmed that the molten phase of the molten film placed on the Leitz heating stage was observed under a nitrogen atmosphere at a magnification of 4 Torr using a Leitz polarizing microscope. When the liquid crystalline resin to be used in the present invention is inspected between orthogonal polarizations, the polarized light is normally transmitted even when it is in a molten stationary state, and optical anisotropy is exhibited. The liquid crystalline resin as described above is not particularly limited to an aromatic polyester or an aromatic polyamine; the amine is preferably a part of the same molecular chain containing aromatic polyyttrium or aramid polyglycolamine. Lipid is also in this range. When such a solution is dissolved in pentafluorophenol at a concentration of 〇·1% by weight at 60 ° C, it has a logarithmic viscosity (丨.ν·) of at least about dl/g of 2·0 to 10. 〇dl/g. By.芳香族Aromatic polyester or aromatic: lipotein which is applicable to the liquid crystalline resin of the present invention has at least one selected from the group consisting of aromatic hydroxycarboxylic acid, aromatic hydroxylamine, and *-amine As a constituent component, the aromatic I amide is particularly preferable. More specifically, there are two types of polyesters which are (1) mainly composed of an aromatic hydroxycarboxylic acid and a derivative thereof; or one or two (2) mainly of (a) aromatic species The above, the race of the carboxylic acid and its derivatives, or the two (b) the above-mentioned aromatic carboxylic acid, the alicyclic dicarboxylic acid and the derivative thereof, and the aromatic diol and the alicyclic diol Polyester composed of one or more of aliphatic eves; diol and its derivatives to (3) mainly of (4) aromatic (tetra)yl (tetra) and its derivatives i or 201205896 or more, (b) aromatic One or two kinds of aromatic hydroxylamines and derivatives thereof, (c) aromatic dicarboxylic acid, polyaliphatic amine composed of alicyclic or higher; dicarboxylic acid and its derivatives 1 or 2 (4) mainly one or two or two kinds of (a) aromatic species or more, a group of hydroxycarboxylic acids and derivatives thereof, (8) aromatic transamines, aromatic diamines and derivatives thereof (A kind or more than two kinds, and (4) an aromatic-alcohol, an alicyclic diol, an aliphatic diol, and at least one of the compounds of the genus 1 or 2 Further, a polyester resin or the like may be used. Further, a molecular weight modifier may be used in combination with the above-mentioned constituent components as needed. A preferred example of a specific compound which can be applied to the liquid crystal resin of the present invention may be mentioned. An aromatic hydroxycarboxylic acid such as benzoic acid, 6-trans-based _ 2 _naphthoic acid; 2,6-dihydroxy1,4-dihydroxynaphthalene, 4,4,-dihydroxybiphenyl, hydroquinone, Resorcinol, an aromatic diol such as a compound represented by the following formula (1) and the following formula (Η); terephthalic acid, isophthalic acid, 4,4-diphenyldicarboxylic acid, 2, 6-dicarboxylic acid, an aromatic dicarboxylic acid such as a compound represented by the following formula (π丨); an aromatic amine such as an aminophenol or p-phenylenediamine; (I) 201205896

(x ' is selected from the group consisting of alkylene (Cl~C4), alkenylene, -ο-, -S〇_-S〇2-, -s-, -CO-)

ΌΗ

(II

HOOC

COOH (i (Y_ is selected as -(CH2)n~(n=l 〜4), -0(CH2)n〇-(n =Bu4).) [Inorganic filler] Inorganic filler' is for lifting The liquid crystal resin composition is added with a material having a heat resistance of $ and a metal layer having a good adhesion. The helmet and the filler can also impart physical properties such as properties to the reflector (1) type of inorganic sputum. There is no particular limitation on the surface of the molded body, and there is a tendency that the metal layer on the surface of the molded body is insufficiently adhered to the surface of the molded body. However, when the two metal layers and the surface of the molded body* form a metal layer on the surface of the formed body, the molded body which is not hairy has a strong strength. That is, as long as the surface of the reflector and the surface of the molded body are $

The surface of the formed body is strongly adhered to the opposite side, and the metal layer J W body is obtained. Therefore, the surface roughness Ra of the female projectile is 0.1 mm or less with respect to the difference (ARa) between the surface roughness Ra of the inner wall a 201205896 of the mold which is necessary to make the reflector. The inorganic filler is appropriately selected in accordance with the type of the liquid crystalline resin and the size of the inorganic filler, so that the difference (? Ra) of the surface roughness Ra is 0.1 mm or less. Specifically, it is selected from general inorganic fillers such as a fibrous filler, a particulate filler, and a plate-like filler. In order to adjust the difference (?Ra) of the surface roughness Ra to 〇1 mm or less, it is preferable to use a granular filler or a plate-shaped filler in the inorganic filler. Granular fillers, such as cerium oxide, quartz powder, glass beads, ground glass fiber, glass balloons, glass powder, calcium silicate, aluminum silicate, kaolin 'talc, talc, diatomaceous earth, ash Metal oxides such as citrate, iron oxide, titanium oxide, oxidized, trioxide, oxidized, etc., metal carbonates such as calcium carbonate and magnesium carbonate, such as calcium sulfate and barium sulfate, Other ferrites, tantalum carbide, tantalum nitride, boron nitride, various 2 gene powders, etc. Further, the "plate-like filler" may, for example, be a mica or a tablet. Among these, the use of cerium oxide talc powder *Qing / 々 々 left, Δ Ra) is adjusted to 妗: the following 'use of the average primary particle size of the smaller granular filler and flat-secondary particle size Small plate fillers are preferred. The average-secondary particle size is less than 15 (four). When the average-secondary particle diameter is the following:: The inert resin composition has an average decrease in fluidity due to a decrease in fluidity of the inorganic filler, and when cerium oxide is used as the inorganic filler, t is 0. 7 or less is particularly good. 12 201205896 In the above description, an inorganic filler which is likely to be less than or equal to 1 mm or less in relation to the difference in surface roughness Ra (Δ Ra) will be described. Next, when the difference (? Ra) between the surface roughness Ra is 〇 _ lmm or less, how the inorganic filler exists on the surface of the reflector 12 will be described. The difference between the above-mentioned surface roughness is 0.1 mm or less, and the surface characteristics of the reflector are greatly improved. As a result of the surface characteristics being greatly improved, the surface of the reflector 12 is smooth, and the inclined surface 121 which is a part of the surface of the reflector 12 is also smooth, and the metal layer 122 formed on the reflector 12 is also flat. Therefore, the light-emitting device 1 of the present invention can effectively reflect the light of the light-emitting element 藉 by forming the surface of the metal layer 122 on the inclined surface 121. Further, even if the reflector 12 is subjected to ultrasonic cleaning, the surface of the reflector 丨 2 is hardly fibrillated. That is, in the reflector 12 described above, the surface of the reflector is not easily raised. As a result, a metal layer having good adhesion can be formed on the surface of the reflector. In particular, if the difference (Δ Ra) between the surface roughness Ra is suppressed to 〇·03ηππ or less, the surface of the reflector 12 becomes very smooth. By making the difference (?" of the surface roughness Ra (?" below 〇.3__, the light from the light-emitting element 11 can be more effectively reflected on the surface of the metal layer 122, and it is easier to suppress the reflection of the reflector. The surface is raised by using a cerium oxide having an average primary particle diameter of 0.7/m or less, or a plate-like filler having an average primary particle diameter of 2 〇 ym or less or a powdery filling having an average primary particle diameter of 2. 〇/zm or less. As the inorganic filler, the difference in the above-mentioned surface roughness Ra (Δ Ra) can be easily adjusted to 〇.3_ or less. Finally, the content of the inorganic filler in the reflector 12 will be described. Counter 13 201205896 The content of the inorganic filler in the liquid crystal resin is preferably 5 parts by mass or more and 70 parts by mass or less, and the content of the inorganic filler is 纟5. At the same time, it is easy to provide desired physical properties (especially heat resistance and fluidity). On the other hand, when the content of the inorganic filler is 7 parts by mass or less, the above advantages of using a liquid crystalline resin are easily obtained (for example, Fluidity, dimensional stability Further, a more preferable inorganic filler is contained in the liquid crystal resin, and the liquid crystal resin composition is not more than or equal to or less than ±6 G f in 15 parts by mass. It is possible to have sufficient fluidity and high heat retention. What is the degree of fluidity of the liquid crystalline resin composition, and it is particularly limited to, for example, the melting viscosity measured by the method described in the examples is 5 Ρ &quot; Further, the following is not particularly limited, and the heat resistance of the liquid crystalline resin composition is not particularly limited. For example, the load bending temperature measured by the method described in the examples is 200. 0 ° C or less is preferable to ? c; n. #物性, / 35〇t or less is better. Furthermore, it can also be adjusted by changing the particle size of the inorganic filler. 卞 3 - person change

[Other components; I liquid crystal resin, Youyou 4 〇 1 I do not know the scope of the effect of the present invention may also be blended with other thermoplastic resins &amp; the object. The thermoplastic tree used in this case曰 'There is no special job, exemplified material; poly-olefin; poly-terephthalic acid r ^ 嗽 propylene 4 poly T acid ethyl alcohol ester, polybutylene terephthalate aromatic dicarboxylic acid sterol Ss, etc. Aromatic polyester composed of mono- or hydroxycarboxylic acid; poly 14 201205896 acetal resin (monomer or copolymer); polystyrene, polystyrene, polyamine, polycarbonate, ABS, poly Oxyphenylene oxide, polyoxyphenylene sulfide, fluorinated resin, etc. Further, these thermoplastic resins may be used in combination of two or more kinds. In addition, these resins are used to improve mechanical, electrical, chemical properties or flame retardancy. It is known that various additives, reinforcing agents, stabilizers, oxidation inhibitors, pigments, and the like are added as needed. <Method for Producing Light-Emitting Device> A method for manufacturing a light-emitting device according to the present invention includes: manufacturing a circuit Substrate 10, 70 pieces of light 11' a substrate 10; and a reflector 12, which is disposed on the circuit board i surrounding the light-emitting element u. The method of the light-emitting device 1 includes a reflector manufacturing step, a metal layer forming step, a light-emitting TL device loading step, and a reflection The step of disposing the body. The steps of manufacturing the substrate and the liquid crystal resin composition to produce the reflector 1 2 reflector 1 2 are not particularly limited as long as they are formed by using a mold. A method of forming a mold by a general method. For example, the reflector 12 can be produced by an injection molding method. The metal layer 122 is formed on the surface of the reflector obtained in the reflector manufacturing step in the metal layer forming step. Aluminium, silver, grade, and μ, various metals such as nickel, palladium, platinum, and gold are used as the metal layer 122. The method is not limited. The process represented by metal plating, and the dry process of vacuum evaporation, sputtering, and ion can be used. The formation of the metal layer 122 is made into the metal layer 122. Want The type of the metal of the raw material of 1々 is suitable for use and can be used. 201205896 The step of forming the metal layer is performed on the surface of the reflector 12 obtained by the step of manufacturing the reflector, and the layer 122 is formed. For example, various metals such as aluminum, silver, chromium, nickel, silver, and gold are used as raw materials. The method for forming the metal layer 122 is not particularly limited, and is represented by metal plating. The formula can be used, and the dry process represented by the vacuum vapor deposition method, the sputtering method, and the ion plating method can be used. The method for forming the metal (4) 2 is as long as the metal of the material of the metal f 122 is suitable. In the light-emitting element carrying step, the light-emitting element 11 is disposed in the vicinity of the center of the surface of the circuit board 10 on which the electrode layer is formed. Specifically, the light-emitting element 11 is fixed to the surface of the circuit board 10 by a relay or the like, and the electrode portion of the light-emitting element 11 is electrically connected to the electrode layer, and the light-emitting element U is mounted on the circuit board 10. In the reflector arrangement step, the reflector 12 is placed on the circuit board 10. The end surface on the bottom surface side of the reflector 12 is in contact with the surface of the circuit board 1'. The light-emitting element is surrounded by the inclined surface! The reflector 12 is disposed on the circuit board around the electrode layer. The reflector 12 is fixed to one side of the circuit board with an adhesive or the like. [Examples] Hereinafter, the present invention will be specifically described by way of examples and comparative examples, but the present invention is not limited to the examples. <Materials> Liquid crystal resin: Vectra E950iSX (manufactured by Polyplastics Co., Ltd.) Glass fiber: ECS03T-786IK, manufactured by Nippon Electric Glass Co., Ltd.), fiber diameter: 10.5# m (fiber length of glass fiber to be described later) is squeezed The condition (screw ^ 201205896 rotation number, tube temperature) is adjusted.) True spherical cerium oxide 1: AMAFINE S0-C2 (made by ADMATECHS), average primary particle size 〇. 5# m True spherical cerium oxide 2 : DENKA fused cerium oxide FB-5S DC (manufactured by Electric Chemical Industry Co., Ltd.), average primary particle size 4.0//m Glass beads: EGB731 (manufactured by Potters-Ballotini), average primary particle size 18 // m talc: Crown Talc PP (made by Matsumura Industry Co., Ltd.) average primary particle size 11 M m Neuburg Siliceous Earth: Sillikolloid P87 (manufactured by Hoffman Minerals Co., Ltd.) average primary particle diameter κ m <for manufacturing examples Preparation of the composition of the comparative example and the addition of the inorganic fillers shown in Tables 1 and 2 to the amount of the inorganic filler shown in Tables 1 and 2 (mass portion) to prepare a liquid crystalline resin combination. <Fluidity Evaluation> In order to confirm the fluidity of the liquid crystalline resin compositions of the examples and the comparative examples, the melt viscosity of the resin compositions was used, and the resin compositions were used to obtain L = 20 mm. , d = lmm capillary rheometer (Toyo Seiki Capillograph 1B type) 'measured melt viscosity according to I SO 11443' at a temperature of 350 ° C, a shear rate of 1000 / s. The measurement results are shown in Tables 1 and 2. <temperature at which the load was bent (DTUL)&gt; The liquid crystal resin composition used in the production of the examples and the comparative examples was used as a raw material to obtain an injection-molded sheet of 10 mm x 4 nim x 80 nm. The load bending temperature of the injection-molded test pieces was measured in accordance with IS075-1, 17 201205896 2 '. The measurement results are shown in Tables 1 and 2. <Production of Reflector> The resin composition described in Tables 1 and 2 was molded to produce a reflector as shown in Fig. 2 in which each resin composition was molded. It was confirmed that the smoothness of the surface of all the reflectors produced was the same. <Evaluation of Surface Roughness Ra> The center portion of the reflector that is cut in half in the direction of the through-hole portion is measured by an ultra-deep color 3D shape measurement microscope νκ_95 (manufactured by Keyence), and the surface roughness Ra of the inclined surface is measured. . Further, the surface roughness Ra of the mold was also measured in the same manner as the molded body. Tables 1 and 2 show the surface roughness of the inclined surface of the reflector of the examples and the comparative examples. Further, the surface roughness of the inner wall surface of the mold corresponding to the inclined surface was 〇·25_, and the difference (Δ Ra) between the surface roughness of the examples and the comparative examples is also shown in Tables 1 and 2. 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 Next, the current value was set to 15 mA. Finally, a reflector attached to a substrate set at a position of 3 离 mm from the target was sputtered using a platinum-palladium target to form a platinum palladium film. As a result, a reflector in which the metal layer is formed on the entire surface is obtained. With respect to all of the examples and comparative examples, a reflector of a metal layer formed on the surface was known by the above method. Furthermore, the smoothness of the surface of the metal layer is the same. The reflectance of the surface of the metal layer formed on the reflector is difficult to measure because the reflector is too small. Therefore, the injection molding test piece of the liquid crystal resin composition used in the production of the examples and the comparative examples was used as a raw material to form a metal &amp; n # rate formed on the injection-molded test piece. The method of forming the metal layer is formed in the same manner as the method of forming on the reflector. The mold for producing the test piece was the same as the above-described embodiment, and the surface roughness Ra of the inner wall surface was 0.25 mm. Further, the smoothness of the surface of the obtained injection-molded test piece was the same. Therefore, regarding the central portion of the surface of the injection-molded test piece, the surface roughness Ra was measured by the above method. As a result of the measurement, the same results were obtained for all the injection-molded test pieces, and the surface roughness of the reflectors of the examples and the comparative examples obtained by using the same composition. For each of the injection-molded test pieces, a surface of the metal layer side on the upper surface of the center portion of the injection-molded test piece in which the metal layer was formed was used, and a wavelength of 47 〇 nm was used by a UV-ray spectrophotometer (manufactured by JASCO Corporation). The light is measured for reflectance. The measurement results are shown in Tables 1 and 2. [Table 1] Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 True spherical ceria 1 10 25 45 65 True spherical ceria 2 45 Glass beads 45 Talc 45 Neuburger ruthenium oxide 45 Melt viscosity (Pa-s) 22 26 33 ] 42 --- 270 28 77 37 41 DTULCC) 257 262 266 264 258 267 276 Shape roughness of the formed body Ra(&quot;m) 0.227 0.232 0.223 0.222 0.312 0.325 0.258 0.223 Difference (ARa) 〇m) 0.023 0.018 0.027 0.028 0.062 0.072 0.054 0.029 Reflectance (3⁄4) 86 85 84 84 82 81 83 84 19 201205896 [Table 2] Comparative Example 1 Comparative Example 2 Comparative Example 3 Glass fiber 45 45 45 (woven length / Mm) (500) (390) (280) Glass bead melt viscosity (Pa.s) 54 52 49 DTUL (°C) 297 294 292 Shaped surface roughness Ra (jtnn) 0.383 0. 374 0.335 Difference (ARa) (/zm) 0.133 0.124 0.105 Reflectance (3⁄4) 74 77 78 It is apparent from the results of Tables 1 and 2 that the surface of the reflector is thick and the surface of the inner wall of the mold is made thick. The difference in the roughness (ARa) is 0.1 mm or less, and it is confirmed that it is formed on the reflector. Metal layer, can effectively reflect light. Then, it was confirmed by Examples 1 to 8, that the effect was not dependent on the type of the inorganic filler. Further, it was confirmed from Examples 1 to 4 and Example 5 that the effect was not dependent on the size of the inorganic filler. Further, from the results of the examples and the comparative examples, it was confirmed that the use of the plate-like filler or the particulate filler as the inorganic filler can easily adjust the difference in surface roughness (ARa) to 0.1 mm or less. As a result of the results of Examples 1 to 4, it was confirmed that the smaller the content of the inorganic filler, the smaller the difference in surface roughness Ra (ΔRa), and the higher the reflectance of the surface of the metal layer. Further, it was confirmed that the smaller the content of the inorganic filler, the smaller the smelting viscosity. In other words, it has been confirmed that the content of the inorganic filler is small, the fluidity is high, and it is easy to form a product having a small thickness and a light weight. In addition, it has been confirmed that the content of the inorganic filler is not more than 10% by mass, and the heat resistance is sufficient. 20 201205896 From the results of Examples 3 and 5 to 8, it was confirmed that the average primary particle diameter of the inorganic filler was more than about 18, and the fluidity was greatly lowered (the melting point was greatly increased), if the inorganic filler was used. The average primary particle size of about 11 or less 'can be adjusted to be above about 3 〇 Pa.s -&quot; below the low melting: degree. <Check whether the inclined surface is raised or not.> The reflector before the formation of the metal layer of Example 5 was applied for 1 minute in a room temperature water = ultrasonic cleaner. Thereafter, the reflectors applied with the ultrasonic cleaning machine were compared to visually evaluate the fuzzing of the surface of the reflector. The evaluation was evaluated by the following 4 yang slaves, and the results of the evaluation are shown in Table 3. ◎ 〇 Δ No fluffing at all. Visually confirm that the surface is barely raised. The fuzzing can be visually confirmed. x. Visually confirm most of the fuzz of the surface. [table 3]

m: two using an oxidized stone with an average primary particle diameter of 5·5";; hair 'confirming the use of the average-secondary particle size of the second emulsified stone eve, the occurrence of awn; such as &lt; The body and the metal layer are pilgrimages. The less the fluffing is, the better the forming genus is. The result is that the above surface 21 201205896 βρ can significantly improve the difference in inverse roughness (Δ Ra). The adhesion between the surface of the emitter and the metal layer is below 0. 〇3aun. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view schematically showing a light-emitting device of the present invention. Fig. 2 is a view schematically showing a reflector 12 of the present invention. (a) is a perspective view of the reflector 12, and (b) is a cross-sectional view of the line (a) 2XX. [Description of main components] 1 to a light-emitting device; 10 to a circuit substrate; 11 to a light-emitting element; 12 to a reflector; 12 0 ~ opening; 121 ~ inclined surface; 122 ~ metal layer. 22

Claims (1)

201205896 VII. Patent application scope: 1) A method for manufacturing a light-emitting device, wherein the light-emitting device includes: a circuit substrate; the light-emitting device is mounted on the circuit substrate; and the reflector is disposed on the circuit substrate surrounding the light-emitting device The reflector has an inclined surface that reflects light from the light-emitting element in a desired direction, and the method of manufacturing the light-emitting device includes: a reflector manufacturing step of manufacturing a reflector from a liquid crystalline resin composition; and a metal layer forming step; a step of forming a metal layer on the inclined surface of the reflector obtained in the reflector manufacturing step; a step of loading the light-emitting 7L; mounting the light-emitting element on the circuit board; and a step of disposing the reflector on the circuit board In the reflector, the reflector manufacturing step 'produces a reflector by making a difference (ΔRa) between the surface roughness of the reflector and the surface roughness Ra of the inner wall surface of the mold for producing the reflector to 0.1 mm or less. The steps. 2. The method of manufacturing a light-emitting device according to claim 1, wherein the difference (Δ Ra) is 〇. 〇 3 mm or less. 3. A light-emitting device comprising: a circuit board; a light-emitting element 'mounted on a circuit board; and a reflector' disposed on the circuit board surrounding the light-emitting element, 23 201205896 The reflector includes · liquid crystal Resin; and inorganic filler, average - a metal layer is disposed on the surface of the reflector at a distance of 15 // m or less. 4. The luminescent filler inorganic filler according to claim 3, which is a platy filler and/or a pulverulent filler. 5. The illuminating device according to claim 3: the inorganic filler is an average 6. The primary particle size is 〇.7#^ or less. 6. If the content of the above-mentioned inorganic filler is the content of the above-mentioned inorganic filler, the above liquid 曰e • 'where the above' 'Oxide crushed. The luminescent resin 100 described above is a mass portion of 5 mass parts or more and 7 〇 mass parts or less. 7. The type of reflector includes: a liquid crystalline resin; an inorganic filler, an average primary particle diameter of 1 芍 15 # m or less It has a metal layer on the surface. twenty four