JPH04334801A - Lamp reflector - Google Patents
Lamp reflectorInfo
- Publication number
- JPH04334801A JPH04334801A JP3106005A JP10600591A JPH04334801A JP H04334801 A JPH04334801 A JP H04334801A JP 3106005 A JP3106005 A JP 3106005A JP 10600591 A JP10600591 A JP 10600591A JP H04334801 A JPH04334801 A JP H04334801A
- Authority
- JP
- Japan
- Prior art keywords
- inorganic filler
- weight
- lamp reflector
- fibrous inorganic
- heat resistance
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000011256 inorganic filler Substances 0.000 claims abstract description 37
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 37
- 239000004734 Polyphenylene sulfide Substances 0.000 claims abstract description 26
- 229920000069 polyphenylene sulfide Polymers 0.000 claims abstract description 26
- 229920005989 resin Polymers 0.000 claims abstract description 24
- 239000011347 resin Substances 0.000 claims abstract description 24
- 238000001746 injection moulding Methods 0.000 claims abstract description 13
- 239000000835 fiber Substances 0.000 claims abstract description 10
- 239000011342 resin composition Substances 0.000 claims description 16
- 238000000465 moulding Methods 0.000 abstract description 2
- 239000000126 substance Substances 0.000 abstract 2
- 239000000805 composite resin Substances 0.000 abstract 1
- 230000004927 fusion Effects 0.000 abstract 1
- 238000000034 method Methods 0.000 description 12
- 238000002156 mixing Methods 0.000 description 7
- 239000000945 filler Substances 0.000 description 6
- 230000005484 gravity Effects 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 229920000642 polymer Polymers 0.000 description 6
- 239000011521 glass Substances 0.000 description 5
- 230000001771 impaired effect Effects 0.000 description 5
- 238000006116 polymerization reaction Methods 0.000 description 5
- 239000000047 product Substances 0.000 description 5
- 229920005992 thermoplastic resin Polymers 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 238000004898 kneading Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- SECXISVLQFMRJM-UHFFFAOYSA-N N-Methylpyrrolidone Chemical compound CN1CCCC1=O SECXISVLQFMRJM-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000007822 coupling agent Substances 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 239000013585 weight reducing agent Substances 0.000 description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 150000004645 aluminates Chemical class 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- -1 sericite Chemical compound 0.000 description 2
- 229910000077 silane Inorganic materials 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 238000001771 vacuum deposition Methods 0.000 description 2
- 238000007738 vacuum evaporation Methods 0.000 description 2
- OCJBOOLMMGQPQU-UHFFFAOYSA-N 1,4-dichlorobenzene Chemical compound ClC1=CC=C(Cl)C=C1 OCJBOOLMMGQPQU-UHFFFAOYSA-N 0.000 description 1
- BDKLKNJTMLIAFE-UHFFFAOYSA-N 2-(3-fluorophenyl)-1,3-oxazole-4-carbaldehyde Chemical compound FC1=CC=CC(C=2OC=C(C=O)N=2)=C1 BDKLKNJTMLIAFE-UHFFFAOYSA-N 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- KLSJWNVTNUYHDU-UHFFFAOYSA-N Amitrole Chemical compound NC1=NC=NN1 KLSJWNVTNUYHDU-UHFFFAOYSA-N 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 238000010306 acid treatment Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 230000009172 bursting Effects 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 1
- 238000011549 displacement method Methods 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 229920006158 high molecular weight polymer Polymers 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- FDNAPBUWERUEDA-UHFFFAOYSA-N silicon tetrachloride Chemical compound Cl[Si](Cl)(Cl)Cl FDNAPBUWERUEDA-UHFFFAOYSA-N 0.000 description 1
- 235000017281 sodium acetate Nutrition 0.000 description 1
- 229940087562 sodium acetate trihydrate Drugs 0.000 description 1
- 229910052979 sodium sulfide Inorganic materials 0.000 description 1
- GRVFOGOEDUUMBP-UHFFFAOYSA-N sodium sulfide (anhydrous) Chemical compound [Na+].[Na+].[S-2] GRVFOGOEDUUMBP-UHFFFAOYSA-N 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Abstract
Description
【０００１】0001
【産業上の利用分野】本発明は、熱可塑性樹脂組成物を
基体とする、たとえば自動車のヘッドライト等に用いる
ランプリフレクターに関するものであり、更に詳しくは
ポリフェニレンスルフィド樹脂、特定の繊維径を有する
繊維状充填材および無機質中空状充填材を必須成分とす
る樹脂組成物を基体とする、耐熱性、耐久性および生産
性にすぐれ、且つ軽量のランプリフレクターに関するも
のである。[Industrial Field of Application] The present invention relates to a lamp reflector based on a thermoplastic resin composition and used for example in automobile headlights. The present invention relates to a light-weight lamp reflector that has excellent heat resistance, durability, and productivity and is based on a resin composition containing a hollow filler and an inorganic hollow filler as essential components.
【０００２】0002
【従来の技術】近年の自動車工業分野における金属部品
のプラスチック化は一段とその速度を増しており、しか
も代替すべきプラスチック材料に対する要求も単なる軽
量化やデザインの自由度増加にとどまらず、部品の複合
化による部品点数の削減によってもたらされるトータル
生産コストの抑制およびプラスチック部品自体の生産性
向上へと高度化している。その中でも自動車用ランプリ
フレクターは比較的大型の部品であることから、軽量化
や生産性向上による低コスト化が強く求められる部品で
ある。[Background Art] In recent years, the use of plastic for metal parts in the automobile industry has been rapidly increasing, and the demand for alternative plastic materials is not limited to simple weight reduction and increased freedom of design, but also composite materials for parts. This has led to a reduction in the number of parts, resulting in lower total production costs and improved productivity of the plastic parts themselves. Among these, automotive lamp reflectors are relatively large parts, and therefore there is a strong demand for lower costs by reducing weight and improving productivity.
【０００３】そして、従来ランプリフレクターのプラス
チック化は主としてフェノール樹脂や不飽和ポリエステ
ルなどの熱硬化性樹脂をベースとするコンパウンドによ
ってなされていた。[0003] Conventionally, lamp reflectors have been made of plastics mainly using compounds based on thermosetting resins such as phenolic resins and unsaturated polyesters.
【０００４】0004
【発明が解決しようとする課題】しかしながら、熱硬化
性樹脂からなるランプリフレクターは、軽量および材料
コストの低減という目的は一応達成することができるも
のの、成形サイクルが長い、金型汚れが多発しクリーニ
ングが頻繁に必要となる、或いは成形品にバリが発生し
易いためこれを除去する工程が必要になるなど生産性の
点では多くの問題があり、これらの改良が望まれていた
。[Problems to be Solved by the Invention] However, although lamp reflectors made of thermosetting resin can achieve the goals of being lightweight and reducing material costs, they require a long molding cycle, frequently stain the mold, and are difficult to clean. There are many problems in terms of productivity, such as the frequent need for burrs and the need for a process to remove burrs, which tend to occur on molded products, and improvements in these have been desired.
【０００５】このような生産性の問題を解決するための
方法としては、射出成形可能な熱可塑樹脂の使用が考え
られ、一部ではナイロン樹脂やＰＢＴ、ＰＥＴなどのポ
リエステル樹脂を用いた検討もなされているが、ランプ
リフレクターは強い光源の近傍で用いられることから高
い耐熱性が要求され、しかも真空蒸着などの方法で表面
を金属化された際、平滑な金属表面を与えるための高度
な表面平滑性や温度、湿度などの異なる環境下でも焦点
に ”ブレ” を生じさせないための高い寸法安定性お
よび高い機械強度なども同時に要求されるため、未だこ
れらの諸要求を全て満足できる熱可塑性樹脂材料は見出
されていないのが実情である。そして、更に最近の軽量
化要求の高度化にともなって、熱硬化樹脂系コンパウン
ド品よりも更に低比重化の要求も出ているのである。[0005] As a method to solve such productivity problems, the use of thermoplastic resins that can be injection molded is considered, and some studies are also considering the use of nylon resins, polyester resins such as PBT, and PET. However, since lamp reflectors are used near strong light sources, high heat resistance is required, and when the surface is metallized using methods such as vacuum evaporation, an advanced surface is required to give a smooth metal surface. High dimensional stability and high mechanical strength are also required to prevent the focal point from wobbling even under different environments such as smoothness, temperature, and humidity, and there are still thermoplastic resins that can satisfy all of these requirements. The reality is that no material has been found. Furthermore, as the recent demands for weight reduction have become more sophisticated, there has also been a demand for lower specific gravity than thermosetting resin compound products.
【０００６】本発明者らは、ポリフェニレンスルフィド
樹脂 （以下ＰＰＳ樹脂と略す） をマトリクス樹脂と
して選択し、更に無機充填材と特定の中空状無機質充填
材を特定の割合で組み合わせて得られる樹脂組成物を射
出成形することにより、耐熱性、表面平滑性、寸法安定
性および強度などの諸要求特性を満足し、且つ軽量で生
産性の高い熱可塑性樹脂製ランプリフレクターが得られ
ることを見出した。[0006] The present inventors selected a polyphenylene sulfide resin (hereinafter abbreviated as PPS resin) as a matrix resin, and created a resin composition obtained by combining an inorganic filler and a specific hollow inorganic filler in a specific ratio. It has been found that by injection molding, it is possible to obtain a thermoplastic resin lamp reflector that satisfies various required properties such as heat resistance, surface smoothness, dimensional stability, and strength, and is lightweight and highly productive.
【０００７】しかし、最近ランプリフレクターを小型化
する傾向があり、同じ光源に対して反射面積が小さくな
るのでリフレクターは従来以上に高い温度に曝され、さ
らに高い耐熱性を要求される。一方、リフレクターの耐
熱性を高めるため樹脂組成物に繊維状無機質充填材を添
加することが知られているが、この場合の繊維状無機質
充填材としては繊維径９〜１５ミクロンのガラスファイ
バーが用いられる。[0007] However, recently there has been a trend to downsize lamp reflectors, and as a result, the reflection area becomes smaller for the same light source, so reflectors are exposed to higher temperatures than before and are required to have even higher heat resistance. On the other hand, it is known that a fibrous inorganic filler is added to the resin composition in order to improve the heat resistance of the reflector, but in this case, glass fiber with a fiber diameter of 9 to 15 microns is used as the fibrous inorganic filler. It will be done.
【０００８】ところがこのようなガラスファイバーの如
き繊維径が９ミクロン以上の繊維状無機質充填材を配合
したＰＰＳ樹脂組成物を溶融射出成形することにより得
られるランプリフレクターは表面に繊維状無機質充填材
に起因する凹凸が発生し、表面を金属化処理しても平滑
な金属表面を得ることができない。そこで本発明者らは
上記耐熱性、表面平滑性に加えて寸法安定性、強度、軽
量性および生産性などの諸要求全てを満足するすぐれた
熱可塑性樹脂製ランプリフレクターを得ることを課題と
して鋭意検討した結果、ＰＰＳ樹脂をマトリクス樹脂と
して選択し、更に特定の繊維径を有する繊維状無機質充
填材、中空状無機質充填材および必要に応じて非繊維状
無機質充填材を特定の割合で組み合わせて得られる樹脂
組成物を溶融射出成形することにより、従来の問題点が
一挙に解決でき、上記要求特性を全て満足するランプリ
フレクターが得られることを見出し、本発明に到達した
。However, a lamp reflector obtained by melt injection molding a PPS resin composition containing a fibrous inorganic filler having a fiber diameter of 9 microns or more, such as glass fiber, has a fibrous inorganic filler on the surface. As a result, unevenness occurs, and even if the surface is metallized, a smooth metal surface cannot be obtained. Therefore, the inventors of the present invention have worked diligently to obtain an excellent thermoplastic resin lamp reflector that satisfies all the requirements such as dimensional stability, strength, lightness, and productivity in addition to the heat resistance and surface smoothness mentioned above. As a result of the study, PPS resin was selected as the matrix resin, and a fibrous inorganic filler having a specific fiber diameter, a hollow inorganic filler, and, if necessary, a non-fibrous inorganic filler were combined in a specific ratio. The present inventors have discovered that by melt-injection molding a resin composition, all of the conventional problems can be solved at once, and a lamp reflector that satisfies all of the above-mentioned required characteristics can be obtained, and the present invention has been achieved.
【０００９】[0009]
【課題を解決するための手段】すなわち本発明はＰＰＳ
樹脂３０〜７０重量％、繊維径が０．１〜９ミクロンの
繊維状無機質充填材５〜３０重量％、非繊維状無機質充
填材０〜３０重量％および中空状無機質充填材１５〜５
０重量％からなるポリフェニレンスルフィド樹脂組成物
を溶融射出成形することにより得られる成形体を基体と
するランプリフレクターを提供するものである。[Means for solving the problems] That is, the present invention
30-70% by weight of resin, 5-30% by weight of fibrous inorganic filler with a fiber diameter of 0.1-9 microns, 0-30% by weight of non-fibrous inorganic filler, and 15-5% by weight of hollow inorganic filler.
The present invention provides a lamp reflector having a molded body obtained by melt injection molding a polyphenylene sulfide resin composition containing 0% by weight as a base.
【００１０】本発明で使用するＰＰＳ樹脂とは、構造式
[0010] The PPS resin used in the present invention has the structural formula
【００１１】で示される繰返し単位を７０モル％以上、
より好ましくは９０モル％以上含む重合体であり、上記
繰返し単位が７０モル％未満では耐熱性が損われるため
好ましくない。ＰＰＳ樹脂は一般に、特公昭４５−３３
６８号公報で代表される製造法により得られる比較的分
子量の小さい重合体と、特公昭５２−１２２４０号公報
で代表される製造法により得られる本質的に線状で比較
的高分子量の重合体等があるが、前記特公昭４５−３３
６８号公報記載の方法で得られた重合体においては、重
合後酸素雰囲気下において加熱することにより、あるい
は過酸化物等の架橋剤を添加して加熱することにより高
重合度化して用いるのが一般的である。本発明において
はいかなる方法により得られたＰＰＳ樹脂を用いること
も可能であるが、線状で比較的高分子量の重合体がより
好ましく使用される。70 mol% or more of the repeating unit represented by
More preferably, it is a polymer containing 90 mol% or more, and if the repeating unit is less than 70 mol%, heat resistance will be impaired, which is not preferable. PPS resin is generally manufactured under the
A relatively low molecular weight polymer obtained by the production method typified by Japanese Patent Publication No. 68, and an essentially linear and relatively high molecular weight polymer obtained by the production method typified by Japanese Patent Publication No. 52-12240. etc., but the above-mentioned special public interest public
In the polymer obtained by the method described in Publication No. 68, it is possible to increase the degree of polymerization by heating in an oxygen atmosphere after polymerization, or by adding a crosslinking agent such as a peroxide and heating. Common. In the present invention, it is possible to use PPS resin obtained by any method, but a linear polymer having a relatively high molecular weight is more preferably used.
【００１２】また、ＰＰＳ樹脂はその繰返し単位の３０
モル％未満を下記の構造式を有する繰返し単位等で構成
することが可能である。[0012] PPS resin also has 30 repeating units.
It is possible for less than mol % to be composed of repeating units having the following structural formula, etc.
【００１３】[0013]
【００１４】本発明で使用されるＰＰＳ樹脂は、上記重
合工程を経て生成した後、酸処理、熱水処理または有機
溶媒による洗浄など従来公知の後処理を施されたもので
あってもよい。またその重合度については特に制限はな
く、通常３００℃、ずり速度２００秒−１の条件下にお
ける溶融粘度が１００〜１００００ポイズのものを任意
に用いることができる。The PPS resin used in the present invention may be produced through the above polymerization step and then subjected to conventionally known post-treatments such as acid treatment, hot water treatment, or washing with an organic solvent. There is no particular restriction on the degree of polymerization, and any polymer having a melt viscosity of 100 to 10,000 poise under the conditions of 300 DEG C. and a shear rate of 200 sec-1 can be used.
【００１５】本発明において特定の繊維径を有する繊維
状無機質充填材を選択することが極めて重要である。繊
維状無機質充填材の添加はリフレクターが必要とする耐
熱性および強度を発現する上で不可欠であるが、一般的
に用いられるような繊維径が９ミクロンを越える繊維状
無機質充填材を添加すると表面平滑性が損われて好まし
くない。また、リフレクターに要求される高い耐熱性お
よび強度を発現するためには繊維状無機質充填材のアス
ペクト比が少なくとも１００を越えることが望ましい。
本発明で使用される繊維径が０．１〜９ミクロンの繊維
状無機質充填材の具体例としては、上記形状になるよう
に製造または選別されたガラス繊維、チタン酸カリウム
ウィスカーなどを挙げることができる。上記充填材は必
要に応じてシラン系あるいはチタネート系、アルミネー
ト系などのカップリング剤で予備処理して使用すること
ができる。上記充填材の配合量はＰＰＳ樹脂組成物全体
に対して５〜３０重量％、好ましくは１０〜２０重量％
の範囲である。配合量が５重量％に満たないと最終製品
の耐熱性および強度が不足するため好ましくなく、一方
３０重量％を越えると表面平滑性、流動性などが損われ
るので好ましくない。In the present invention, it is extremely important to select a fibrous inorganic filler having a specific fiber diameter. Addition of fibrous inorganic filler is essential for achieving the heat resistance and strength required by the reflector, but adding fibrous inorganic filler with a fiber diameter of more than 9 microns, which is commonly used, causes the surface This is undesirable because smoothness is impaired. Further, in order to exhibit the high heat resistance and strength required for the reflector, it is desirable that the aspect ratio of the fibrous inorganic filler exceeds at least 100. Specific examples of the fibrous inorganic filler with a fiber diameter of 0.1 to 9 microns used in the present invention include glass fibers manufactured or selected to have the above shape, potassium titanate whiskers, etc. can. The above filler can be used after being pretreated with a silane-based, titanate-based, or aluminate-based coupling agent, if necessary. The blending amount of the filler is 5 to 30% by weight, preferably 10 to 20% by weight based on the entire PPS resin composition.
is within the range of If the amount is less than 5% by weight, the final product will lack heat resistance and strength, which is undesirable, while if it exceeds 30% by weight, surface smoothness, fluidity, etc. will be impaired.
【００１６】本発明で用いられる他の配合成分である中
空状無機質充填材の代表例としてはガラスバルーン、シ
ラスバルーン、アルミナシリケートバルーンおよびシリ
カバルーンなどを挙げることができる。これら中空状無
機質充填材には各々その比重の異なるいくつかの種類が
存在するが、本発明においては最終製品の強度、比重、
寸法安定性などの要求に合わせて適宜選択することがで
き、また前記繊維状無機質充填材と同様、必要に応じて
カップリング剤で予備処理して使用することもできる。
なかでもガラスバルーンは破裂強度が高く、また平滑な
表面を付与することができるため好適に用いられる。こ
れら中空無機質充填材の配合量は全樹脂組成物に対し１
５〜５０重量％の範囲内であり、更に好ましくは２０〜
４０重量％である。配合量が１５重量％に満たないと軽
量化効果が不十分であり好ましくなく、一方５０重量％
を越えると機械強度の損失が著しくなるため好ましくな
い。Typical examples of hollow inorganic fillers which are other compounding components used in the present invention include glass balloons, shirasu balloons, alumina silicate balloons, and silica balloons. There are several types of hollow inorganic fillers with different specific gravity, but in the present invention, the strength, specific gravity,
It can be selected as appropriate depending on requirements such as dimensional stability, and like the fibrous inorganic filler, it can be used after being pretreated with a coupling agent if necessary. Among them, glass balloons are preferably used because they have high bursting strength and can provide a smooth surface. The amount of these hollow inorganic fillers is 1% to the total resin composition.
It is within the range of 5 to 50% by weight, more preferably 20 to 50% by weight.
It is 40% by weight. If the blending amount is less than 15% by weight, the weight reduction effect will be insufficient and undesirable;
Exceeding this is not preferable because the loss of mechanical strength becomes significant.
【００１７】本発明で必要に応じて使用される非繊維状
無機質充填材とは、繊維状でもなく、中空状でもない無
機質充填材のことを意味し、具体例としては、ワラステ
ナイト、シリカ、セリサイト、カオリン、マイカ、クレ
ー、ベントナイト、アスベスト、タルク、アルミナシリ
ケートなどの珪酸塩、アルミナ、塩化珪素、酸化マグネ
シウム、酸化ジルコニウム、酸化チタンなどの金属酸化
物、炭酸カルシウム、炭酸マグネシウム、ドロマイトな
どの炭酸塩、硫酸カルシウム、硫酸バリウム等の硫酸塩
、ガラス・ビーズ、窒化ホウ素および炭化珪素などを挙
げることができる。これら無機質充填材のうちから強度
、寸法安定性、表面平滑性などの要求に適合したものを
単独或いは２種以上の混合物の形で任意に選択すること
が可能であるが、好ましく用いられるものとしてはワラ
ステナイト、炭酸カルシウムなどの強度と寸法安定性を
同時に付与できる充填材が挙げられる。これら充填材は
必要に応じてシラン系あるいはチタネート系、アルミネ
ート系などのカップリング剤で予備処理して使用するこ
とができる。これら非繊維状無機質充填材の配合量は全
樹脂組成物に対し０〜３０重量％、好ましくは０〜１０
重量％の範囲である。配合量が３０重量％を越えると低
比重性が損われるので好ましくない。[0017] The non-fibrous inorganic filler used as necessary in the present invention means an inorganic filler that is neither fibrous nor hollow, and specific examples include wollastenite, silica, Silicates such as sericite, kaolin, mica, clay, bentonite, asbestos, talc, alumina silicate, metal oxides such as alumina, silicon chloride, magnesium oxide, zirconium oxide, titanium oxide, calcium carbonate, magnesium carbonate, dolomite, etc. Mention may be made of carbonates, sulfates such as calcium sulfate and barium sulfate, glass beads, boron nitride and silicon carbide. Among these inorganic fillers, it is possible to arbitrarily select one that meets the requirements for strength, dimensional stability, surface smoothness, etc., either alone or in the form of a mixture of two or more types. Examples include fillers that can provide strength and dimensional stability at the same time, such as wollastenite and calcium carbonate. These fillers can be used after being pretreated with a silane-based, titanate-based, or aluminate-based coupling agent, if necessary. The blending amount of these non-fibrous inorganic fillers is 0 to 30% by weight, preferably 0 to 10% by weight based on the total resin composition.
% by weight. If the blending amount exceeds 30% by weight, low specific gravity will be impaired, which is not preferable.
【００１８】本発明におけるＰＰＳ樹脂組成物の調製方
法は特に制限がなく、ＰＰＳ樹脂、繊維状または非繊維
状無機質充填材および中空状無機質充填材をリボンブレ
ンダー、ヘンシェルミキサー、Ｖブレンダーなどを用い
てドライブレンドした後、バンバリーミキサー、ミキシ
ングロール、単軸又は２軸の押出機、ニーダーなどを用
いて溶融混練する方法などを挙げることができる。中で
も単軸又は２軸の押出機を用いて溶融混練する方法が簡
便且つ効率的であることから好ましい。The method for preparing the PPS resin composition in the present invention is not particularly limited, and the PPS resin, fibrous or non-fibrous inorganic filler, and hollow inorganic filler are mixed using a ribbon blender, Henschel mixer, V blender, etc. Examples include a method of dry blending and then melt-kneading using a Banbury mixer, mixing roll, single-screw or twin-screw extruder, kneader, or the like. Among these, a method of melt-kneading using a single-screw or twin-screw extruder is preferred because it is simple and efficient.
【００１９】また本発明で用いるＰＰＳ樹脂組成物には
、本発明の効果を損わない範囲で、酸化防止剤、熱安定
剤、滑剤、結晶核剤、紫外線吸収剤、着色剤、難燃剤な
どの通常の添加剤および少量の他種ポリマを添加するこ
とができ、更に、ＰＰＳ樹脂の架橋度を制御する目的で
、通常の過酸化剤および、特開昭５９−１３１６５０号
公報に記載されているチオホスフィン酸金属塩等の架橋
促進剤または特開昭５８−２０４０４５号公報、特開昭
５８−２０４０４６号公報等に記載されているジアルキ
ル錫ジカルボキシレート、アミノトリアゾール等の架橋
防止剤を配合することも可能である。The PPS resin composition used in the present invention may also contain antioxidants, heat stabilizers, lubricants, crystal nucleating agents, ultraviolet absorbers, colorants, flame retardants, etc., to the extent that the effects of the present invention are not impaired. In addition, for the purpose of controlling the degree of crosslinking of the PPS resin, conventional additives and small amounts of other polymers can be added. A crosslinking accelerator such as a metal salt of thiophosphinic acid, or a crosslinking inhibitor such as dialkyltin dicarboxylate or aminotriazole described in JP-A-58-204045, JP-A-58-204046, etc. It is also possible to do so.
【００２０】このようして得られたＰＰＳ樹脂組成物を
十分な容量および型締力を有する射出成形機を用いて、
通常シリンダー温度 ２８０〜３５０ ℃、金型温度５
０〜１６０ ℃の条件で所望の形状に射出成形し、得ら
れた成形体 （基体） の表面に真空蒸着などの方法を
用いてアルミニウム、亜鉛などの金属コーティングを施
すことにより、ランプリフレクターが形成される。この
金属コーティングの際には予め成形体表面をプライマー
処理することも可能である。[0020] The thus obtained PPS resin composition is molded using an injection molding machine having sufficient capacity and mold clamping force.
Normal cylinder temperature 280-350℃, mold temperature 5
A lamp reflector is formed by injection molding into a desired shape at a temperature of 0 to 160°C, and applying a metal coating such as aluminum or zinc to the surface of the resulting molded body (substrate) using a method such as vacuum deposition. be done. At the time of this metal coating, it is also possible to pre-treat the surface of the molded body with a primer.
【００２１】本発明のランプリフレクターは射出成形に
より製造されるため生産性が高く、また強度、表面平滑
性、寸法安定性および耐熱性にすぐれ、しかも軽量であ
るというすぐれた特徴を有するものである。[0021] The lamp reflector of the present invention is manufactured by injection molding, so it has high productivity, and has the excellent characteristics of being excellent in strength, surface smoothness, dimensional stability, and heat resistance, and being lightweight. .
【００２２】[0022]
【実施例】以下に実施例を挙げて本発明を更に詳しく説
明する。なお実施例および比較例に記された特性は次の
方法で測定した。
（１） 成形品の比重：水中置換法
（２） 引張り強度 ：ＡＳＴＭ Ｄ６３８（３）
曲げ強度 ：ＡＳＴＭ Ｄ７９０（４） 衝撃強
度 ：ＡＳＴＭ Ｄ２５６（５） 表面平滑性
：射出成形で成形基体表面に真空蒸着法でアルミニウ
ムを蒸着せしめ、その鏡面に蛍光灯を反射させ、その反
射像のゆがみの有無を目視判定した。
優れたものから順に◎、○、△、×で示す。[Examples] The present invention will be explained in more detail with reference to Examples below. Note that the characteristics described in Examples and Comparative Examples were measured by the following method. (1) Specific gravity of molded product: Underwater displacement method (2) Tensile strength: ASTM D638 (3)
Bending strength: ASTM D790 (4) Impact strength: ASTM D256 (5) Surface smoothness
: Aluminum was deposited by vacuum evaporation on the surface of a molded substrate by injection molding, a fluorescent lamp was reflected on the mirror surface, and the presence or absence of distortion in the reflected image was visually determined. The results are indicated by ◎, ○, △, and × in descending order of excellence.
【００２３】（６） 熱変形温度 ：ＡＳＴＭ Ｄ６
４８荷重 １８．６（ｋｇ／ｃｍ２）
参考例 （ＰＰＳ樹脂の重合）
オートクレーブに硫化ナトリウム３．２６ｋｇ （２５
モル、結晶水４０％を含む） 、水酸化ナトリウム４ｇ
、酢酸ナトリウム三水和物１．３６ｋｇ （約１０モル
） およびＮ−メチル−２−ピロリドン （以下ＮＭＰ
と略称する） ７．９ｋｇを仕込み、攪拌しながら徐々
に ２０５℃まで昇温し、水１．３６ｋｇを含む留出水
約１．５Ｌを除去した。残留混合物に１，４−ジクロル
ベンゼン３．７５ｋｇ （２５．５モル） およびＮＭ
Ｐ２ｋｇを加え、 ２６５℃で３時間加熱した。反応生
成物を７０℃の温水で５回洗浄し、８０℃で２４時間減
圧乾燥して、溶融粘度約１０００ポアズ （３００℃、
剪断速度２００秒−１） の粉末状ＰＰＳ樹脂約２ｋｇ
を得た。(6) Heat distortion temperature: ASTM D6
48 load 18.6 (kg/cm2) Reference example (Polymerization of PPS resin) 3.26 kg of sodium sulfide (25
mol, containing 40% water of crystallization), 4 g of sodium hydroxide
, 1.36 kg (approximately 10 mol) of sodium acetate trihydrate, and N-methyl-2-pyrrolidone (hereinafter NMP).
(abbreviated as ) was charged, and the temperature was gradually raised to 205° C. while stirring, and about 1.5 L of distilled water containing 1.36 kg of water was removed. 3.75 kg (25.5 mol) of 1,4-dichlorobenzene and NM
2 kg of P was added and heated at 265°C for 3 hours. The reaction product was washed 5 times with hot water at 70°C and dried under reduced pressure at 80°C for 24 hours to give a melt viscosity of about 1000 poise (300°C,
Approximately 2 kg of powdered PPS resin with a shear rate of 200 seconds-1)
I got it.
【００２４】同様の操作を繰返し、以下に記載の実施例
に供した。
〔実施例１〕参考例に記載のＰＰＳ樹脂４５重量％、繊
維系６ミクロンでアスペクト比が５００のガラスファイ
バー１５重量％およびガラスバルーン （スリーエム
（株） 社製 ”グラスバブルス” ＳＳＸ） ４０重
量％からなる混合物をＶブレンダーを用いて均一ブレン
ドした後、６５ｍｍφ、Ｌ／Ｄ＝３０の単軸押出機のホ
ッパーに供給し、シリンダー温度 ３２０℃、８０ｒｐ
ｍ の条件で溶融混練を行い、吐出ガットを冷却後ペレ
タイザーでペレット化した。[0024] The same operation was repeated to provide the following examples. [Example 1] 45% by weight of the PPS resin described in the reference example, 15% by weight of glass fiber with a fiber system of 6 microns and an aspect ratio of 500, and a glass balloon (3M
After homogeneously blending a mixture of 40% by weight of "Glass Bubbles" (SSX) manufactured by Co., Ltd. using a V blender, it was supplied to the hopper of a single screw extruder with a diameter of 65 mm and L/D = 30, and the cylinder temperature was 320°C. ,80rp
Melt-kneading was performed under the conditions of m, and the discharge gut was cooled and pelletized using a pelletizer.
【００２５】次に、このペレットを １４０℃で５時間
熱風乾燥した後、シリンダー温度 ３２０℃、金型温度
１３０℃での射出成形に供し、特性評価試験片および
乗用車ヘッドライト用ランプリフレクター基体成形品を
得た。ランプリフレクター基体成形品については更に真
空蒸着法によりアルミニウム蒸着を行い、その表面平滑
性を評価した。結果は表１に示す通りであり、ここで得
られたＰＰＳ樹脂組成物は、高い耐熱性、低比重性およ
び良好な機械物性を有していた。またこれをベースに調
製されたランプリフレクターは良好な表面平滑性と密着
性を有する極めて実用価値の高いものであることが判明
した。
〔実施例１〜３， 比較例１〜３〕繊維状無機質充填材
、中空無機質充填材および非繊維状無機質充填材の種類
と配合量を代えて、実施例１で記したのと同様の手順で
溶融混練、射出成形を行い、それらの特性を表１にまと
めて記載した。この結果から明らかなように、本発明に
よれば軽量かつ十分な耐熱性および強度を持ち、しかも
表面平滑性の良好なすぐれたランプリフレクターが得ら
れる。Next, the pellets were dried with hot air at 140°C for 5 hours and then subjected to injection molding at a cylinder temperature of 320°C and a mold temperature of 130°C to obtain characteristic evaluation test pieces and lamp reflector base molded products for passenger car headlights. I got it. For the lamp reflector base molded product, aluminum was further deposited using a vacuum deposition method, and its surface smoothness was evaluated. The results are shown in Table 1, and the PPS resin composition obtained here had high heat resistance, low specific gravity, and good mechanical properties. It has also been found that a lamp reflector prepared based on this has excellent surface smoothness and adhesion and is of extremely high practical value. [Examples 1 to 3, Comparative Examples 1 to 3] The same procedure as described in Example 1 was carried out by changing the types and amounts of the fibrous inorganic filler, hollow inorganic filler, and non-fibrous inorganic filler. Melt-kneading and injection molding were carried out, and their properties are summarized in Table 1. As is clear from these results, according to the present invention, an excellent lamp reflector that is lightweight, has sufficient heat resistance and strength, and has good surface smoothness can be obtained.
【００２６】[0026]
【００２７】[0027]
【発明の効果】以上説明したように、本発明によれば、
ＰＰＳ樹脂をマトリクス樹脂として使用し、特定の繊維
状無機質充填材と中空無機質充填材を組み合わせて得ら
れるＰＰＳ樹脂組成物を射出成形することにより、軽量
、耐熱性、強度、寸法安定性および表面平滑性などの諸
特性を満足するランプリフレクターを生産性良く製造す
ることが可能である。[Effects of the Invention] As explained above, according to the present invention,
By using PPS resin as a matrix resin and injection molding a PPS resin composition obtained by combining a specific fibrous inorganic filler and hollow inorganic filler, it is possible to achieve lightweight, heat resistance, strength, dimensional stability, and surface smoothness. It is possible to manufacture lamp reflectors with high productivity that satisfy various characteristics such as performance.
Claims (1)
７０重量％、繊維径が０．１〜９ミクロンの繊維状無機
質充填材５〜３０重量％、非繊維状無機質充填材０〜３
０重量％および中空状無機質充填材１５〜５０重量％か
らなるポリフェニレンスルフィド樹脂組成物を溶融射出
成形することにより得られる成形体を基体とするランプ
リフレクター。[Claim 1] Polyphenylene sulfide resin 30~
70% by weight, 5-30% by weight of fibrous inorganic filler with a fiber diameter of 0.1-9 microns, 0-3% of non-fibrous inorganic filler
A lamp reflector having as a base a molded article obtained by melt injection molding a polyphenylene sulfide resin composition comprising 0% by weight and 15 to 50% by weight of a hollow inorganic filler.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3106005A JPH04334801A (en) | 1991-05-10 | 1991-05-10 | Lamp reflector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3106005A JPH04334801A (en) | 1991-05-10 | 1991-05-10 | Lamp reflector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH04334801A true JPH04334801A (en) | 1992-11-20 |
Family
ID=14422571
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3106005A Pending JPH04334801A (en) | 1991-05-10 | 1991-05-10 | Lamp reflector |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH04334801A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09251806A (en) * | 1996-03-14 | 1997-09-22 | Koito Mfg Co Ltd | Lamp reflecting mirror and manufacture thereof |
| JP2005171242A (en) * | 2003-11-21 | 2005-06-30 | Toray Ind Inc | Polyphenylene sulfide resin composition |
| WO2013168313A1 (en) * | 2012-05-11 | 2013-11-14 | ポリプラスチックス株式会社 | Resin composition for light-reflective component |
| WO2014002305A1 (en) * | 2012-06-26 | 2014-01-03 | ポリプラスチックス株式会社 | Light-reflecting component and method for producing same |
-
1991
- 1991-05-10 JP JP3106005A patent/JPH04334801A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09251806A (en) * | 1996-03-14 | 1997-09-22 | Koito Mfg Co Ltd | Lamp reflecting mirror and manufacture thereof |
| JP2005171242A (en) * | 2003-11-21 | 2005-06-30 | Toray Ind Inc | Polyphenylene sulfide resin composition |
| WO2013168313A1 (en) * | 2012-05-11 | 2013-11-14 | ポリプラスチックス株式会社 | Resin composition for light-reflective component |
| WO2014002305A1 (en) * | 2012-06-26 | 2014-01-03 | ポリプラスチックス株式会社 | Light-reflecting component and method for producing same |
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