TWI723193B - Reflector, base body, light emitting device and method of manufacturing the base body - Google Patents
Reflector, base body, light emitting device and method of manufacturing the base body Download PDFInfo
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- TWI723193B TWI723193B TW106122349A TW106122349A TWI723193B TW I723193 B TWI723193 B TW I723193B TW 106122349 A TW106122349 A TW 106122349A TW 106122349 A TW106122349 A TW 106122349A TW I723193 B TWI723193 B TW I723193B
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- light reflector
- light
- molding material
- reflector
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Abstract
本發明課題在於提供一種可製造儘管玻璃纖維含量少或不含玻璃纖維也具高強度且高韌性，而且耐熱變色性及光反射性良好的光反射體。本發明之光反射體具備周壁及被周壁包圍之凹處。周壁包含厚度100μm以下之部分。光反射體1含有光反射體用成形材料之硬化物。光反射體用成形材料含有熱硬化性樹脂及白色纖維材。The subject of the present invention is to provide a light reflector that can be manufactured with high strength and high toughness even though the content of glass fiber is small or without glass fiber, and which has good heat discoloration resistance and light reflectivity. The light reflector of the present invention has a peripheral wall and a recess surrounded by the peripheral wall. The peripheral wall includes a portion with a thickness of 100 μm or less. The light reflector 1 contains a cured product of a molding material for the light reflector. The molding material for the light reflector contains a thermosetting resin and a white fiber material.
Description
本發明一般而言涉及光反射體、基體、發光裝置及基體之製造方法。較詳細來說，本發明涉及一種尤其適合用來製造側視型發光裝置之光反射體、基體、發光裝置及基體之製造方法。The present invention generally relates to a manufacturing method of a light reflector, a substrate, a light-emitting device, and a substrate. In more detail, the present invention relates to a manufacturing method of a light reflector, a base, a light-emitting device, and a base, which are particularly suitable for manufacturing a side-view light-emitting device.
發明背景 近年，快速擴大運用發光二極體作為螢光燈及白熾燈的替代光源。舉例來說，譬如有將具備發光二極體等發光元件及構成為可反射從發光元件發出之光之樹脂製光反射體(反光件)的發光裝置用於照明用途等。而現在的課題在於，如何才能使這種安裝有發光二極體的發光裝置長效維持初始亮度。Background of the Invention In recent years, the use of light-emitting diodes as alternative light sources for fluorescent lamps and incandescent lamps has been rapidly expanded. For example, there is a light-emitting device provided with a light-emitting element such as a light-emitting diode and a resin light reflector (reflector) configured to reflect light emitted from the light-emitting element for lighting purposes. The current problem is how to maintain the initial brightness of such a light-emitting device equipped with a light-emitting diode for a long time.
發光裝置之亮度降低的主因之一為光反射體因熱而變色，造成光反射率降低。所以，吾等認為，如能以熱變色較少之素材來製造光反射體，便可延長發光裝置的壽命。One of the main reasons for the decrease in the brightness of the light-emitting device is that the light reflector changes color due to heat, which causes the light reflectivity to decrease. Therefore, we believe that if the light reflector can be made of materials with less thermal discoloration, the life of the light-emitting device can be prolonged.
譬如，周知陶瓷係耐熱變色性良好的素材。然而，陶瓷於加工精度有其極限，容易脆性裂斷且價格高，所以缺乏通用性，不適合作為光反射體的素材。For example, well-known ceramics are materials with good heat-resistance to discoloration. However, ceramics have their limits in terms of processing accuracy, are prone to brittle fracture and are expensive, so they lack versatility and are not suitable as materials for light reflectors.
相對地，一般稱為尼龍的聚醯胺樹脂具優異的耐藥性、耐熱性、耐摩耗性及韌性，且比陶瓷低廉，所以常廣泛運用在照明用途上。然而，尼龍製的光反射體熱變色嚴重，無法如預期延續發光裝置的壽命。In contrast, polyamide resins generally called nylon have excellent chemical resistance, heat resistance, abrasion resistance, and toughness, and are cheaper than ceramics, so they are often widely used in lighting applications. However, the light reflector made of nylon has severe thermal discoloration and cannot extend the life of the light emitting device as expected.
爰此，有研究提議以不飽和聚酯樹脂及環氧樹脂等熱硬化性樹脂來製造光反射體(譬如可參照日本專利第4844699號公報、日本專利第5153952號公報及日本特開2014-019747號公報)。以熱硬化性樹脂做成的光反射體具有耐熱變色性良好的優點。In this regard, there are research proposals to produce light reflectors from thermosetting resins such as unsaturated polyester resins and epoxy resins (for example, refer to Japanese Patent No. 4844699, Japanese Patent No. 5153952 and Japanese Patent Laid-Open No. 2014-019747 No. Bulletin). The light reflector made of thermosetting resin has the advantage of good heat discoloration resistance.
然而，以不飽和聚酯樹脂及環氧樹脂等熱硬化性樹脂很難取得足以匹敵尼龍的高韌性及高強度。一般會使光反射體含有玻璃纖維以賦予光反射體高強度，但要賦予高韌性極難。However, thermosetting resins such as unsaturated polyester resins and epoxy resins are difficult to achieve high toughness and high strength that are comparable to nylon. Generally, the light reflector contains glass fibers to impart high strength to the light reflector, but it is extremely difficult to impart high toughness.
又，近年隨著發光元件與光反射體間之距離縮短、發光裝置小型化，也逐漸縮小光反射體的厚度。譬如，側視型光反射體具有厚度非常小的部分。光反射體含有玻璃纖維時，光反射體若具有厚度小的部分，到達光反射體之光可能無法被充分反射。列舉其原因之一，係因玻璃纖維被配置成橫切光反射體內，而玻璃纖維會形成可使光通過光反射體內的光通道，以致光容易穿透光反射體。再舉其他原因，則是進入光反射體內之光直接被密封在光反射體內。吾等認為，實際上係光被光反射體吸收等而衰減。所以，尤其是小型的光反射體很難具有高光反射率。另一方面，光反射體若不含玻璃纖維，光反射體便很難具有充分的強度。In addition, in recent years, as the distance between the light-emitting element and the light-reflecting body has been shortened and the light-emitting device has been miniaturized, the thickness of the light-reflecting body has been gradually reduced. For example, the side-view type light reflector has a portion with a very small thickness. When the light reflector contains glass fibers, if the light reflector has a small thickness, the light reaching the light reflector may not be sufficiently reflected. One of the reasons for this is that the glass fibers are arranged to cross the light reflector, and the glass fibers form a light channel that allows light to pass through the light reflector, so that light easily penetrates the light reflector. To cite another reason, the light entering the light reflector is directly sealed in the light reflector. We believe that the light is actually attenuated by absorption by the light reflector. Therefore, it is difficult for a small-sized light reflector to have high light reflectivity. On the other hand, if the light reflector does not contain glass fibers, it is difficult for the light reflector to have sufficient strength.
發明概要 本發明目的在於提供一種即使具有厚度較小的部分，儘管玻璃纖維含量少或不含玻璃纖維也具高強度且高韌性，而且耐熱變色性及光反射性良好的光反射體及其製造方法以及發光裝置。SUMMARY OF THE INVENTION The object of the present invention is to provide a light reflector that has high strength and high toughness, and has good heat-resistant discoloration and light reflectivity, and its manufacture, even if it has a portion with a small thickness, despite the low glass fiber content or no glass fiber. Method and light emitting device.
本發明一態樣之光反射體含有光反射體用成形材料之硬化物。前述光反射體具備周壁及被前述周壁包圍之凹處。前述周壁含有厚度100μm以下之部分。前述光反射體用成形材料含有熱硬化性樹脂及白色纖維材。One aspect of the light reflector of the present invention includes a hardened product of a molding material for the light reflector. The light reflector includes a peripheral wall and a recess surrounded by the peripheral wall. The aforementioned peripheral wall includes a portion with a thickness of 100 μm or less. The aforementioned molding material for a light reflector contains a thermosetting resin and a white fiber material.
本發明一態樣之基體具備前述光反射體及埋入前述光反射體的引線。前述引線具有在前述凹處之內面露出的內部端子及從前述光反射體之外面突出的外部端子。A base of one aspect of the present invention includes the light reflector and a lead embedded in the light reflector. The lead has an internal terminal exposed on the inner surface of the recess and an external terminal protruding from the outer surface of the light reflector.
本發明一態樣之發光裝置具備前述基體及發光元件。前述發光元件與前述引線之前述內部端子電連接且搭載在前述光反射體之前述凹處的內部。A light-emitting device of one aspect of the present invention includes the aforementioned substrate and a light-emitting element. The light emitting element is electrically connected to the internal terminal of the lead, and is mounted in the recess of the light reflector.
本發明一態樣之基體之製造方法包含下述製程：將光反射體用成形材料成形製作光反射體，並於製作前述光反射體時，以前述引線部分從前述光反射體突出的方式使前述光反射體與引線一體化。A method of manufacturing a substrate according to one aspect of the present invention includes the following process: forming a light-reflecting body using a molding material to produce a light-reflecting body, and when the light-reflecting body is produced, the lead part is made to protrude from the light-reflecting body The aforementioned light reflector is integrated with the lead.
用以實施發明之形態 以下說明本發明之實施形態。另，在本說明書及圖式中，針對實質上相同的構成要素係賦予同一符號以省略重複說明。Modes for Carrying Out the Invention The mode for carrying out the invention will be described below. In addition, in this specification and the drawings, the same reference numerals are given to substantially the same constituent elements to omit overlapping descriptions.
光反射體用成形材料 本實施形態之光反射體用成形材料很適合用來製造光反射體1(反光件)。光反射體用成形材料含有熱硬化性樹脂及白色纖維材。譬如，光反射體用成形材料含有熱硬化性樹脂、聚合引發劑、充填材、脫模劑及白色纖維材。光反射體用成形材料宜更含有橡膠粒子13。光反射體用成形材料在30℃以下宜為固體。光反射體用成形材料可藉由粉碎加工或擠製造粒加工而加工成粒狀。Molding material for light reflector The molding material for light reflector of this embodiment is very suitable for manufacturing the light reflector 1 (reflector). The molding material for the light reflector contains a thermosetting resin and a white fiber material. For example, the molding material for the light reflector contains a thermosetting resin, a polymerization initiator, a filler, a mold release agent, and a white fiber material. The molding material for the light reflector preferably further contains
本實施形態中，藉由構成光反射體用成形材料之成分的加乘效果，可製造即使玻璃纖維含量少或不含玻璃纖維也具高強度且高韌性，而且耐熱變色性良好的光反射體。In this embodiment, due to the additive effect of the components constituting the molding material for the light reflector, it is possible to produce a light reflector with high strength and high toughness even if the content of glass fiber is small or without glass fiber, and with good heat discoloration resistance. .
亦即，因為光反射體用成形材料含有白色纖維材，所以成形時可抑制硬化收縮，同時光反射體1可具有高強度及高度的尺寸穩定性。此外，由於白色纖維材不易透光，所以即使光反射體1具有厚度較小的部分，白色纖維材也不易阻礙光反射體1的光反射性。因此，光反射體1就算是小型或薄型，也能確保光反射體1的高強度及高光反射性。That is, since the molding material for the light reflector contains a white fiber material, it is possible to suppress curing shrinkage during molding, and the
又，光反射體用成形材料含有內核外殼型的橡膠粒子13時，可使光反射體1厚度較小的部分變柔軟，以抑制其變脆，從而可確保高韌性。In addition, when the molding material for the light reflector contains the core-shell
又，光反射體用成形材料含有熱硬化性樹脂，所以光反射體1之耐熱變色性良好。In addition, the molding material for the light reflector contains a thermosetting resin, so the
該光反射體用成形材料具備周壁10及被周壁10包圍之凹處11，周壁10對於用來製造包含厚度100μm以下部分的光反射體1(對照圖1、圖2A及圖2B)相當適宜。關於該光反射體1的詳細構成容後說明。具有這種形狀及尺寸的光反射體1若含有本實施形態之光反射體用成形材料之硬化物，則即使具有厚度較小的部分，儘管玻璃纖維含量少或不含玻璃纖維也具高強度且高韌性，而且耐熱變色性及光反射性良好。This molding material for a light reflector includes a
另，亦可從本實施形態之光反射體用成形材料製作上述光反射體1以外的光反射體。不論尺寸及形狀，含有光反射體用成形材料之硬化物的光反射體儘管玻璃纖維含量少或不含玻璃纖維也具高強度且高韌性，而且耐熱變色性及光反射性良好。In addition, light reflection bodies other than the above-mentioned
以下首先說明光反射體用成形材料之構成成分。 (熱硬化性樹脂)First, the constituent components of the molding material for light reflectors will be described below. (Thermosetting resin)
熱硬化性樹脂中所含成分可為單體及寡聚物(預聚物)中之任一者。熱硬化性樹脂宜具有選自於由乙烯基、丙烯醯基、羧基、羥基及環氧基所構成群組中之至少1種官能基。該官能基在成形光反射體用成形材料時會涉及交聯反應等反應。The components contained in the thermosetting resin may be any of monomers and oligomers (prepolymers). The thermosetting resin preferably has at least one functional group selected from the group consisting of a vinyl group, an acrylic group, a carboxyl group, a hydroxyl group, and an epoxy group. This functional group involves a reaction such as a crosslinking reaction when molding a molding material for a light reflector.
然而，如後述圖2A及圖2B所示，發光裝置6具備光反射體1及發光元件3。假設，光反射體1係由熱可塑性樹脂所形成，當發光元件3發熱時，光反射體1有因熱而變形之虞。但，光反射體1若以含有熱硬化性樹脂之光反射體用成形材料來製作，即使發光元件3發熱，也能抑制光反射體1因熱而變形的情況。However, as shown in FIGS. 2A and 2B described later, the light-
熱硬化性樹脂宜含有選自於由不飽和聚酯樹脂、環氧樹脂及苯酚樹脂所構成群組中之1種以上成分。此時，光反射體用成形材料的成形性良好。此外，在此情況下，光反射體也能具有高耐熱變色性及高強度。The thermosetting resin preferably contains one or more components selected from the group consisting of unsaturated polyester resin, epoxy resin, and phenol resin. In this case, the moldability of the molding material for the light reflector is good. In addition, in this case, the light reflector can also have high heat discoloration resistance and high strength.
尤其，熱硬化性樹脂宜含有不飽和聚酯樹脂及環氧樹脂中之任一者或兩者。比起苯酚樹脂，不飽和聚酯樹脂及環氧樹脂能賦予光反射體1較高的耐熱變色性，即使在高溫下，光反射體1也不易變色。In particular, the thermosetting resin preferably contains either or both of unsaturated polyester resin and epoxy resin. Compared with phenol resins, unsaturated polyester resins and epoxy resins can impart higher heat-resistant discoloration resistance to the
此外，熱硬化性樹脂宜含有不飽和聚酯樹脂。比起環氧樹脂，不飽和聚酯樹脂能賦予光反射體1更高的耐熱變色性。其理由是因為光反射體用成形材料若含有不飽和聚酯樹脂，為變色原因之未反應的官能基就不易殘留在光反射體1內部。亦即，不飽和聚酯樹脂的聚合速度快，所以即使製造光反射體1時的成形週期短，也不易殘留未反應的官能基。In addition, the thermosetting resin preferably contains an unsaturated polyester resin. Compared with epoxy resin, unsaturated polyester resin can impart higher heat discoloration resistance to
不飽和聚酯樹脂含有譬如不飽和醇酸樹脂及交聯劑(共聚性化合物)。不飽和醇酸樹脂會在譬如30℃以上且宜為50℃以上開始軟化。The unsaturated polyester resin contains, for example, an unsaturated alkyd resin and a crosslinking agent (copolymerizable compound). Unsaturated alkyd resins will begin to soften, for example, above 30°C and preferably above 50°C.
不飽和醇酸樹脂可使多元酸類及甘醇類脫水縮合而獲得。多元酸類宜含有不飽和多元酸類。多元酸類更可含有飽和多元酸類。Unsaturated alkyd resin can be obtained by dehydration condensation of polybasic acids and glycols. The polybasic acids preferably contain unsaturated polybasic acids. The polybasic acids may further contain saturated polybasic acids.
不飽和多元酸類含有譬如選自於由馬來酸酐、延胡索酸、伊康酸、檸康酸所構成群組中之1種以上成分。The unsaturated polybasic acid contains, for example, one or more components selected from the group consisting of maleic anhydride, fumaric acid, itaconic acid, and citraconic acid.
飽和多元酸類含有譬如選自於由酞酸酐、異酞酸、對酞酸、己二酸、癸二酸、1,4-環己烷二羧酸、四氫酞酸酐、甲基四氫酞酸酐、內亞甲四氫酞酐、氯橋酸(HET acid)及四溴酞酸酐所構成群組中之1種以上。Saturated polybasic acids contain, for example, selected from phthalic anhydride, isophthalic acid, terephthalic acid, adipic acid, sebacic acid, 1,4-cyclohexanedicarboxylic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride , Methylenetetrahydrophthalic anhydride, HET acid and tetrabromophthalic anhydride constitute more than one species in the group.
甘醇類含有譬如選自於由乙二醇、丙二醇、二乙二醇、二丙二醇、新戊二醇、1,3-丁二醇、1,6-己二醇、1,4-環己烷二甲醇、氫化雙酚A、雙酚A環氧丙烷化合物及二溴新戊二醇所構成群組中之1種以上。Glycols contain, for example, selected from ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butanediol, 1,6-hexanediol, 1,4-cyclohexane One or more of the group consisting of alkane dimethanol, hydrogenated bisphenol A, bisphenol A propylene oxide compound, and dibromoneopentyl glycol.
不飽和醇酸樹脂之熔融黏度宜在0.1Pa・s以上且10Pa・s以下之範圍內。為此，不飽和醇酸樹脂宜為異酞酸系不飽和醇酸樹脂及對酞酸系不飽和醇酸樹脂中之任一者或兩者。不飽和醇酸樹脂若具有上述熔融黏度，光反射體用成形材料便能具有高成形性，且光反射體1能具有高耐熱變色性。The melt viscosity of unsaturated alkyd resin should be within the range of 0.1 Pa·s or more and 10 Pa·s or less. For this reason, the unsaturated alkyd resin is preferably either or both of an isophthalic acid-based unsaturated alkyd resin and a terephthalic acid-based unsaturated alkyd resin. If the unsaturated alkyd resin has the above-mentioned melt viscosity, the light reflector molding material can have high moldability, and the
交聯劑含有譬如選自於由苯乙烯、乙烯基甲苯、二乙烯苯、α-甲基苯乙烯、甲基丙烯酸甲酯及乙酸乙烯酯所構成群組中之1種以上乙烯基系共聚性單體。交聯劑亦可含有譬如選自於由酞酸二烯丙酯、三聚氰酸三烯丙酯、四溴酞酸二烯丙酯、丙烯酸苯氧乙酯、丙烯酸2-羥乙酯及1,6-己二醇二丙烯酸酯所構成群組中之1種以上共聚性單體。交聯劑亦可含有上述所列舉之單體中至少1種以上聚合而成的預聚物。尤其，交聯劑宜含有選自於由酞酸二烯丙酯預聚物、酞酸二烯丙酯單體及苯乙烯單體所構成群組中之1種以上成分。The crosslinking agent contains, for example, one or more vinyl copolymers selected from the group consisting of styrene, vinyl toluene, divinylbenzene, α-methylstyrene, methyl methacrylate, and vinyl acetate monomer. The crosslinking agent may also contain, for example, selected from diallyl phthalate, triallyl cyanurate, diallyl tetrabromophthalate, phenoxyethyl acrylate, 2-hydroxyethyl acrylate and 1 One or more copolymerizable monomers in the group consisting of ,6-hexanediol diacrylate. The crosslinking agent may also contain a prepolymer obtained by polymerizing at least one of the monomers listed above. In particular, the crosslinking agent preferably contains one or more components selected from the group consisting of a diallyl phthalate prepolymer, a diallyl phthalate monomer, and a styrene monomer.
不飽和聚酯樹脂中不飽和醇酸樹脂與交聯劑之質量比宜在99：1~50：50之範圍內。交聯劑含有單體時，單體含量愈多，光反射體用成形材料愈不易在常溫下變固體，所以相對於不飽和聚酯樹脂100質量份，單體含量宜在10質量份以下。The mass ratio of unsaturated alkyd resin to crosslinking agent in unsaturated polyester resin should be within the range of 99:1-50:50. When the crosslinking agent contains a monomer, the higher the monomer content, the less likely the light reflector molding material to become solid at room temperature. Therefore, the monomer content is preferably 10 parts by mass or less relative to 100 parts by mass of the unsaturated polyester resin.
環氧樹脂只要是1分子中具有2個以上環氧基(環氧乙烷環)之樹脂即無特別限定。環氧樹脂可含有選自於由多酚型環氧樹脂、環氧丙基醚型環氧樹脂、環氧丙基酯型環氧樹脂、環氧丙基胺型環氧樹脂及脂環式環氧樹脂所構成群組中之1種以上成分。環氧樹脂亦可含有具有三吖
苯酚樹脂係由酚類及甲醛合成之熱硬化性樹脂。苯酚樹脂含有譬如酚醛型苯酚樹脂及可熔酚醛型苯酚樹脂中之任一者或兩者。酚醛型苯酚樹脂可以酸性觸媒使酚類與甲醛縮合而獲得。於酚醛型苯酚樹脂加入六亞甲四胺並予以加熱使其硬化。另一方面，可熔酚醛型苯酚樹脂可以鹼性觸媒使酚類與甲醛縮合而獲得。將可熔酚醛型苯酚樹脂加熱便可使其脫水交聯而硬化。Phenol resin is a thermosetting resin synthesized from phenols and formaldehyde. The phenol resin contains, for example, one or both of a novolac type phenol resin and a resol type phenol resin. Phenolic phenol resin can be obtained by condensing phenols and formaldehyde with an acid catalyst. Add hexamethylenetetramine to the phenolic phenol resin and heat it to harden it. On the other hand, the resol-type phenol resin can be obtained by condensing phenols and formaldehyde with an alkaline catalyst. The resol-type phenol resin can be dehydrated, cross-linked and hardened by heating.
相對於光反射體用成形材料整體量，熱硬化性樹脂含量宜在14質量%以上且40質量%以下之範圍內，16質量%以上且34質量%以下之範圍內較佳，20質量%以上且28質量%以下之範圍內更佳。熱硬化性樹脂含量若在14質量%以上，可抑制光反射體1的光反射性降低。熱硬化性樹脂含量若在40質量%以下，可抑制光反射體1的強度降低。 (聚合引發劑)The content of the thermosetting resin is preferably within the range of 14% by mass to 40% by mass relative to the total amount of the molding material for the light reflector, preferably within the range of 16% by mass to 34% by mass, and 20% by mass or more. And the range of 28 mass% or less is more preferable. If the content of the thermosetting resin is 14% by mass or more, the decrease in the light reflectivity of the
光反射體用成形材料可含有聚合引發劑。熱硬化性樹脂具有自由基聚合反應性時，光反射體用成形材料宜含有熱自由基聚合引發劑作為聚合引發劑。聚合引發劑並無特別限定，可舉如加熱分解型的有機過氧化物。有機過氧化物含有譬如選自於由三級丁基過氧基-2-乙基己基單碳酸酯、1,1-二(三級己基過氧基)環己烷、1,1-二(三級丁基過氧基)-3,3,5-三甲基環己烷、過氧辛酸三級丁酯、過氧化苯甲醯、過氧化甲基乙基酮、過氧化乙醯丙酮、過氧苯甲酸三級丁酯及過氧化二異丙苯基所構成群組中之1種以上成分。尤其，聚合引發劑宜含有像過氧化二異丙苯基，10小時半衰期溫度為100℃以上的有機過氧化物。基於預防火災及***觀點，聚合引發劑亦可業經母粒(masterbatch)化以進一步提高安全性。The molding material for light reflectors may contain a polymerization initiator. When the thermosetting resin has radical polymerization reactivity, the molding material for the light reflector preferably contains a thermal radical polymerization initiator as the polymerization initiator. The polymerization initiator is not particularly limited, and includes, for example, heat-decomposable organic peroxides. The organic peroxide contains, for example, selected from the group consisting of tertiary butylperoxy-2-ethylhexyl monocarbonate, 1,1-bis(tertiary hexylperoxy)cyclohexane, 1,1-bis( Tertiary butyl peroxy)-3,3,5-trimethylcyclohexane, tertiary butyl peroxyoctanoate, benzyl peroxide, methyl ethyl ketone peroxide, acetone peroxide, One or more components in the group consisting of tertiary butyl peroxybenzoate and dicumyl peroxide. In particular, the polymerization initiator preferably contains an organic peroxide having a 10-hour half-life temperature of 100°C or higher, such as dicumyl peroxide. Based on the viewpoint of preventing fire and explosion, the polymerization initiator can also be masterbatched to further improve safety.
光反射體用成形材料亦可含有硬化劑。可添加硬化劑來促進熱硬化性樹脂硬化。譬如，熱硬化性樹脂含有環氧樹脂時，光反射體用成形材料含有譬如六氫酞酸酐作為硬化劑。熱硬化性樹脂含有苯酚樹脂時，光反射體用成形材料含有譬如六亞甲四胺作為硬化劑。 (充填材)The molding material for a light reflector may contain a hardening agent. A hardener can be added to promote the hardening of the thermosetting resin. For example, when the thermosetting resin contains epoxy resin, the molding material for light reflectors contains, for example, hexahydrophthalic anhydride as a curing agent. When the thermosetting resin contains a phenol resin, the molding material for a light reflector contains, for example, hexamethylenetetramine as a curing agent. (Filling material)
光反射體用成形材料可含有充填材。充填材含有譬如無機充填材及白色顏料中之任一者或兩者。亦即，光反射體用成形材料可含有無機充填材。又，光反射體用成形材料可含有白色顏料。The molding material for the light reflector may contain a filler. The filling material contains, for example, either or both of an inorganic filling material and a white pigment. That is, the molding material for a light reflector may contain an inorganic filler. In addition, the molding material for a light reflector may contain a white pigment.
無機充填材含有譬如二氧化矽及氫氧化鋁中之任一者或兩者。尤其，無機充填材宜含有二氧化矽。二氧化矽含有譬如選自於由熔融二氧化矽粉末、球狀二氧化矽粉末、破碎二氧化矽粉末、結晶二氧化矽粉末所構成群組中之1種以上成分。只要不損及本實施形態之光反射體用成形材料所致之效果，無機充填材亦可含有上述所舉之物以外的氧化物、水合物、無機發泡粒子、二氧化矽中空球體等中空粒子。The inorganic filler contains, for example, one or both of silicon dioxide and aluminum hydroxide. In particular, the inorganic filling material preferably contains silicon dioxide. The silicon dioxide contains, for example, one or more components selected from the group consisting of molten silicon dioxide powder, spherical silicon dioxide powder, crushed silicon dioxide powder, and crystalline silicon dioxide powder. As long as the effect of the molding material for the light reflector of this embodiment is not impaired, the inorganic filler may also contain oxides, hydrates, inorganic foamed particles, hollow silica spheres, etc. other than the above-mentioned ones. particle.
無機充填材之平均粒徑宜為250μm以下，較宜在0.05μm以上且100μm以下之範圍內，更宜在0.1μm以上且10μm以下之範圍內。光反射體用成形材料中若含有這類平均粒徑的無機充填材，便可提升光反射體用成形材料之成形性，此外也能提升光反射體1之光反射性及耐濕性。另，在後述圖2A及圖2B所示發光裝置6，從發光元件3發出之光L即使未被反射面23(內周面12等)反射而進入周壁10(上壁部18、下壁部19及2邊側壁部20)內，於該等內部依舊可如上述藉由微小的無機充填材來增加光L的折射次數。其結果可抑制光L穿透周壁10，從而可提高光隱蔽性。另，本說明書中平均粒徑意指利用雷射繞射散射法求得之粒度分布中累積值50%的粒徑(中值粒徑(D50))。雷射繞射散射法可利用米氏(Mie)散射，亦可不利用。此時的粒度分布形狀無特別限定。The average particle size of the inorganic filler is preferably 250 μm or less, more preferably in the range of 0.05 μm or more and 100 μm or less, and more preferably in the range of 0.1 μm or more and 10 μm or less. If the molding material for the light reflector contains such an inorganic filler having an average particle diameter, the moldability of the molding material for the light reflector can be improved, and the light reflectivity and moisture resistance of the
相對於熱硬化性樹脂100質量份，無機充填材含量宜為32質量份以上，較宜在50質量份以上且250質量份以下之範圍內。在此情況下，可提升光反射體用成形材料之成形性，更能提升光反射體1之耐熱變色性，也能提高光反射率。此外，此時在後述圖2A及圖2B所示發光裝置6，於周壁10內部可如上述藉由多量存在的無機充填材來增加光L的折射次數。其結果可抑制光L穿透周壁10，從而可提高周壁10之光隱蔽性。The content of the inorganic filler is preferably 32 parts by mass or more with respect to 100 parts by mass of the thermosetting resin, and more preferably in the range of 50 parts by mass or more and 250 parts by mass or less. In this case, the moldability of the molding material for the light reflector can be improved, the heat discoloration resistance of the
白色顏料含有譬如選自於由氧化鈦、鈦酸鋇、鈦酸鍶、氧化鋁、氧化鎂、氧化鋅及碳酸鋇所構成群組中之1種以上成分。尤其，白色顏料宜含有選自於由氧化鈦、氧化鋁及鈦酸鋇所構成群組中之1種以上成分。氧化鈦可含有譬如選自於由銳鈦礦型氧化鈦、金紅石型氧化鈦及板鈦礦型氧化鈦所構成群組中之1種以上成分。氧化鈦宜含有熱穩定性優異的金紅石型氧化鈦。The white pigment contains, for example, one or more components selected from the group consisting of titanium oxide, barium titanate, strontium titanate, aluminum oxide, magnesium oxide, zinc oxide, and barium carbonate. In particular, the white pigment preferably contains one or more components selected from the group consisting of titanium oxide, aluminum oxide, and barium titanate. Titanium oxide may contain, for example, one or more components selected from the group consisting of anatase-type titanium oxide, rutile-type titanium oxide, and brookite-type titanium oxide. The titanium oxide preferably contains rutile titanium oxide having excellent thermal stability.
白色顏料之平均粒徑宜為2μm以下，較宜在0.1μm以上且1μm以下之範圍內、更宜在0.2μm以上且0.7μm以下之範圍內。此時亦與無機充填材之情況同樣地，在後述圖2A及圖2B所示發光裝置6中，可如上述於周壁10內部藉由比無機充填材更微小的白色顏料來增加光L的折射次數。其結果可抑制光L穿透周壁10，從而可提高光隱蔽性。The average particle size of the white pigment is preferably 2 μm or less, more preferably in the range of 0.1 μm or more and 1 μm or less, and more preferably in the range of 0.2 μm or more and 0.7 μm or less. At this time, as in the case of the inorganic filler, in the light-emitting
相對於熱硬化性樹脂100質量份，白色顏料含量宜為100質量份以上，較宜在100質量份以上且300質量份以下之範圍內。白色顏料含量若在100質量份以上，即可提高光反射體1之光反射率。此外，此時在後述圖2A及圖2B所示發光裝置6中，也能如上述於周壁10內部藉由存在比無機充填材更多量的白色顏料來增加光L的折射次數。其結果可抑制光L穿透周壁10，從而可提高周壁10之光隱蔽性。白色顏料含量若在300質量份以下，即可提高光反射體用成形材料的薄壁充填性，更能提高光反射體1之彎曲強度。The content of the white pigment is preferably 100 parts by mass or more with respect to 100 parts by mass of the thermosetting resin, and more preferably in the range of 100 parts by mass or more and 300 parts by mass or less. If the content of the white pigment is more than 100 parts by mass, the light reflectance of the
相對於光反射體用成形材料整體量，無機充填材及白色顏料的含量合計宜在33質量%以上且74質量%以下之範圍內，較宜在50質量%以上且72質量%以下之範圍內。The total content of the inorganic filler and the white pigment relative to the total amount of the molding material for the light reflector should be in the range of 33% by mass to 74% by mass, and more preferably in the range of 50% by mass to 72% by mass. .
相對於熱硬化性樹脂100質量份，無機充填材及白色顏料的含量合計宜為500質量份以下，較宜在100質量份以上且400質量份以下之範圍內。此時，可提高光反射體用成形材料於成形時的流動性，提升成形性。The total content of the inorganic filler and the white pigment relative to 100 parts by mass of the thermosetting resin is preferably 500 parts by mass or less, and more preferably within the range of 100 parts by mass or more and 400 parts by mass or less. In this case, the fluidity of the molding material for the light reflector during molding can be improved, and the moldability can be improved.
無機充填材及白色顏料的粒徑愈小，愈容易產生凝聚或吸油現象，而不易在光反射體用成形材料中均勻分散。爰此，為了提升無機充填材及白色顏料在光反射體用成形材料中的分散性，無機充填材及白色顏料宜業經脂肪酸及耦合劑中之任一者或兩者施行表面處理。 (脫模劑)The smaller the particle size of the inorganic filler and the white pigment, the more likely it is to cause aggregation or oil absorption, and it is difficult to uniformly disperse in the molding material for the light reflector. In this regard, in order to improve the dispersibility of the inorganic filler and the white pigment in the molding material for the light reflector, the inorganic filler and the white pigment should be surface treated with either or both of the fatty acid and the coupling agent. (Release agent)
光反射體用成形材料可含有脫模劑。脫模劑含有譬如選自於由脂肪酸系蠟、脂肪酸金屬鹽系蠟及礦物系蠟所構成群組中之1種以上之蠟。尤其，脫模劑宜含有耐熱變色性優異的脂肪酸系蠟及脂肪酸金屬鹽系蠟中之任一者或兩者。較具體而言，脫模劑含有譬如選自於由硬脂酸、硬脂酸鋅、硬脂酸鋁及硬脂酸鈣所構成群組中之1種以上之蠟。The molding material for light reflectors may contain a mold release agent. The mold release agent contains, for example, one or more waxes selected from the group consisting of fatty acid waxes, fatty acid metal salt waxes, and mineral waxes. In particular, the mold release agent preferably contains one or both of fatty acid wax and fatty acid metal salt wax having excellent heat discoloration resistance. More specifically, the mold release agent contains, for example, one or more waxes selected from the group consisting of stearic acid, zinc stearate, aluminum stearate, and calcium stearate.
相對於熱硬化性樹脂100質量份，脫模劑含量宜在4質量份以上且15質量份以下之範圍內。此時，光反射體1具有從模具脫模的良好脫模性，也具有優異的外觀，並可具有特別高的光反射性。 (橡膠粒子)The content of the release agent is preferably in the range of 4 parts by mass or more and 15 parts by mass or less with respect to 100 parts by mass of the thermosetting resin. At this time, the
光反射體用成形材料可含有橡膠粒子13。如圖8示意顯示，橡膠粒子13具有內核外殼結構。亦即，橡膠粒子13具備內核部14及外殼部15。內核部14及外殼部15中之任一者或兩者具有彈性即可。換言之，可以是內核部14及外殼部15兩者由可彈性變形之樹脂形成，也可以是內核部14由可彈性變形之樹脂形成且外殼部15由可塑性變形之樹脂形成，或可以是內核部14由可塑性變形之樹脂形成且外殼部15由可彈性變形之樹脂形成。光反射體1若是以這種含有內核外殼型橡膠粒子13之光反射體用成形材料製作而成，光反射體1便可被低彈性化，從而可具有高韌性。The molding material for the light reflector may contain
亦可以是內核部14由可塑性變形之樹脂形成且外殼部15由可彈性變形之樹脂形成。理想係內核部14由可彈性變形之樹脂形成。藉此可進一步提高光反射體1之抗衝擊性及韌性，進而可抑制光反射體1上產生裂痕。可彈性變形之樹脂的具體例可舉如具有三維交聯結構或二維交聯結構之樹脂。具有三維交聯結構之樹脂的具體例可舉如：於熱硬化性樹脂加入交聯劑及因應需求之充填材進行交聯反應而成的聚合物。具有二維交聯結構之樹脂的具體例可舉如：於熱可塑性樹脂加入成核劑及因應需求之充填材進行交聯反應而成的聚合物。較理想係內核部14及外殼部15兩者皆具彈性。It is also possible that the
理想係內核部14為粒狀橡膠。內核部14宜含有選自於由聚矽氧橡膠、丙烯酸橡膠及丁二烯橡膠所構成群組中之1種以上成分。尤其，內核部14含有聚矽氧橡膠時，也會提高光反射體1之耐候性及抗衝擊性。又，內核部14含有丙烯酸橡膠時，可提高光反射體用成形材料於成形時之流動性，又能提高光反射體1之耐藥性。另，內核部14含有丁二烯橡膠時，也會提高光反射體1的抗衝擊性。Ideally, the
外殼部15覆蓋著內核部14。外殼部15宜具有官能基。外殼部15宜由多個具有官能基之接枝鏈16構成。各接枝鏈16之其一端部鍵結於內核部14表面。官能基宜位於接枝鏈16中之未鍵結於內核部14之側的端部。外殼部15宜對熱硬化性樹脂具有反應性。亦即，外殼部15宜可與熱硬化性樹脂起反應進行化學鍵結。此時，若使光反射體用成形材料硬化來製作光反射體1，外殼部15會和熱硬化性樹脂起反應而進行化學鍵結。使光反射體用成形材料硬化時，即使外殼部15不與熱硬化性樹脂起反應，外殼部15也和熱硬化性樹脂具有高親和性。所以，橡膠粒子13在光反射體1內會透過與熱硬化性樹脂硬化所形成之樹脂相行化學鍵結或是與該樹脂相之高親和性而密著。因此，樹脂相與橡膠粒子13間之應力容易被分散，且不易在樹脂相與橡膠粒子13之界面發生剝離。因此可提高光反射體1之抗衝擊性。因為外殼部15對熱硬化性樹脂具有反應性，所以外殼部15具有之官能基宜對熱硬化性樹脂具有反應性，也就是宜能與熱硬化性樹脂起反應進行化學鍵結。官能基可含有譬如選自於由甲基丙烯醯基、丙烯醯基、乙烯基、環氧基、胺基、脲基(carbamide)、脲基(ureide)、巰基、異氰酸酯基及羧基所構成群組中之1種以上之基。熱硬化性樹脂為不飽和聚酯樹脂時，官能基宜對不飽和聚酯樹脂中之不飽和雙鍵具有反應性，尤其宜含有甲基丙烯醯基及丙烯醯基中之任一者或兩者。熱硬化性樹脂為環氧樹脂時，官能基宜對環氧基具有反應性，尤其宜含有羧基及胺基中之任一者或兩者。The
橡膠粒子13之平均粒徑宜在0.1μm以上且1mm以下之範圍內。橡膠粒子13之平均粒徑若為0.1μm以上，便能進一步提高光反射體1之抗衝擊性。橡膠粒子13之平均粒徑若為1mm以下，橡膠粒子13在光反射體用成形材料中便可輕易地均勻分散，在光反射體1中也容易均勻分散。The average particle diameter of the
相對於光反射體用成形材料總量，橡膠粒子13含量宜在0.1質量%以上且30質量%以下之範圍內，較宜在0.1質量%以上且低於22質量%之範圍內。藉此，即使光反射體1有厚度較小的部分，也不易在成形時因未充填而發生不良情況。亦即，可提高光反射體用成形材料之薄壁充填性。此外，藉由橡膠粒子13含量在上述範圍內，可獲得耐熱變色性良好且高韌性的光反射體1。The content of the
理想係橡膠粒子13在25℃下之彈性模數為1GPa以下。藉此可進一步提高光反射體1之韌性。另，橡膠粒子13在25℃下之彈性模數可利用JIS K 6254中規定之方法來測定。The elastic modulus of the
此外，光反射體1中有無橡膠粒子13譬如可以氣相層析質量分析法(GC/MS)及傅立葉轉換紅外光譜法(FT-IR)中之任一方法或將該等方法加以組合來進行確認。橡膠粒子13之內核部14含有聚矽氧橡膠時，利用熱脫附之環狀矽氧烷的定性及定量分析較為有效。亦即，譬如在250℃下將光反射體1之試料加熱3分鐘並將所產生之氣體注入氣相層析質量分析裝置後，分析所檢測之環狀矽氧烷的定性及進行甲苯換算的半定量。藉此可輕易確認內核部14有無含有聚矽氧橡膠的橡膠粒子13。內核部14含有丙烯酸橡膠或丁二烯橡膠時，則可利用紅外線光譜法(IR)確認橡膠粒子13之有無。 (白色纖維材)In addition, the presence or absence of
如上述，光反射體用成形材料含有白色纖維材。纖維材為白色意指纖維材不會在可見光波長區域之400nm以上且700nm以下之範圍內，選擇性地吸收或反射特定波長區域之光。具體上，白色纖維材在波長區域400nm以上且700nm以下之分光反射率的變化率宜為20%以下，10%以下較佳。分光反射率的變化率係從波長區域400nm以上且700nm以下之分光反射率的最高反射率之值「A(%)」及最低反射率之值「B(%)」，利用{(A-B)/A}×100(%)算式算出之值。另，白色纖維材宜為矽灰石等天然物或礦物，而非玻璃纖維等人工製品。這類的天然物及礦物因其表面複雜，而比起玻璃纖維形成有較細微的凹凸，所以更容易使入射光在其表面無規擴散(也就是看起來比玻璃纖維更白)。As described above, the molding material for a light reflector contains a white fiber material. The fact that the fiber material is white means that the fiber material will not selectively absorb or reflect light in a specific wavelength region within the range of 400 nm or more and 700 nm or less of the visible light wavelength region. Specifically, the change rate of the spectral reflectance of the white fiber material in the wavelength region of 400 nm or more and 700 nm or less is preferably 20% or less, and more preferably 10% or less. The change rate of the spectral reflectance is the highest reflectance value "A(%)" and the lowest reflectance value "B(%)" of the spectral reflectance in the wavelength range from 400nm to 700nm, using {(AB)/ A}×100(%) The value calculated by the formula. In addition, the white fiber material should be natural materials or minerals such as wollastonite, rather than artificial products such as glass fiber. Because of their complex surface, these natural substances and minerals have finer unevenness than glass fiber, so it is easier for incident light to diffuse randomly on its surface (that is, it looks whiter than glass fiber).
比起以人為方法形成為纖維狀之玻璃纖維的人工製品，藉由使用由天然物或礦物所構成之纖維狀材料，可大幅減低光反射體1的漏光現象。此乃因為天然物或礦物表面具有複雜的凹凸形狀，所以光不易通過天然物或礦物內部所致。Compared with artificial products formed into fibrous glass fibers by artificial methods, by using fibrous materials composed of natural substances or minerals, the light leakage phenomenon of the
白色纖維材之平均纖維徑長宜在0.1μm以上且30μm以下之範圍內，0.3μm以上且20μm以下之範圍內較佳。白色纖維材之平均纖維長度宜在5μm以上且400μm以下之範圍內，50μm以上且150μm以下之範圍內較佳。白色纖維材之平均纖維長度會影響光反射體1的強度，所以與光反射體1尺寸相符者更佳。亦即，白色纖維材之平均纖維長度的理想範圍，以光反射體1之第1成形部101大小為可容置於如圖2A及圖2B所示X101
(0.3~0.4mm)×Y1
(2.8~3.2mm)×Z1
(0.25~0.40mm)之空間內之程度大小的情況特別有效。另，白色纖維材的平均纖維徑長及平均纖維長度分別係將白色纖維材之電子顯微鏡照片進行影像處理所得纖維徑長及纖維長度的算術平均值。The average fiber diameter of the white fiber material is preferably in the range of 0.1 μm or more and 30 μm or less, preferably in the range of 0.3 μm or more and 20 μm or less. The average fiber length of the white fiber material is preferably in the range of 5 μm or more and 400 μm or less, preferably in the range of 50 μm or more and 150 μm or less. The average fiber length of the white fiber material will affect the strength of the
白色纖維材之長寬比係以平均纖維長度相對於平均纖維徑長之比值為定義。白色纖維材之長寬比宜在3以上且500以下之範圍內，較宜在3以上且20以下之範圍內。此時，可有效提升光反射體1的強度，且能有效抑制去毛邊處理後之光反射體1的表面粗糙。The aspect ratio of the white fiber material is defined by the ratio of the average fiber length to the average fiber diameter length. The aspect ratio of the white fiber material should be within the range of 3 or more and 500 or less, more preferably within the range of 3 or more and 20 or less. At this time, the strength of the
白色纖維材宜含有矽灰石。此時，光反射體1的光反射性及強度會變得特別高。矽灰石係以化學式CaSiO3
表示，亦稱偏矽酸鈣。矽灰石之平均纖維徑長宜在1μm以上且125μm以下之範圍內。矽灰石之平均纖維長度宜在20μm以上且500μm以下之範圍內。矽灰石之長寬比宜在3以上且20以下之範圍內。The white fiber material should contain wollastonite. At this time, the light reflectivity and intensity of the
白色纖維材亦可含有矽灰石以外之成分。矽灰石以外之成分包含矽灰石以外之無機系或電絕緣性的纖維及晶鬚。這類的纖維及晶鬚即使添加量少，也能有效提高光反射體1的強度。The white fiber material may also contain ingredients other than wollastonite. Components other than wollastonite include inorganic or electrically insulating fibers and whiskers other than wollastonite. Such fibers and whiskers can effectively increase the strength of the
譬如，白色纖維材可含有鈦酸鉀。鈦酸鉀之平均纖維徑長宜在0.1μm以上且1μm以下之範圍內，較宜在0.3μm以上且0.6μm以下之範圍內。鈦酸鉀之平均纖維長度宜在5μm以上且100μm以下之範圍內，較宜在10μm以上且20μm以下之範圍內。鈦酸鉀之平均纖維徑長在0.3μm以上且0.6μm以下之範圍內且平均纖維長度在10μm以上且20μm以下之範圍內時，光反射體用成形材料可具有特別良好的成形性。For example, the white fiber material may contain potassium titanate. The average fiber diameter of potassium titanate is preferably in the range of 0.1 μm or more and 1 μm or less, more preferably in the range of 0.3 μm or more and 0.6 μm or less. The average fiber length of potassium titanate is preferably in the range of 5 μm or more and 100 μm or less, more preferably in the range of 10 μm or more and 20 μm or less. When the average fiber diameter length of potassium titanate is within the range of 0.3 μm or more and 0.6 μm or less and the average fiber length is within the range of 10 μm or more and 20 μm or less, the molding material for light reflectors can have particularly good moldability.
白色纖維材亦可含有氧化鋁系填料。氧化鋁系填料含針狀軟水鋁石。針狀軟水鋁石之平均纖維徑長宜在0.1μm以上且10μm以下之範圍內，較宜在0.4μm以上且2μm以下之範圍內。針狀軟水鋁石之平均纖維長度宜在1μm以上且20μm以下之範圍內，較宜在2μm以上且10μm以下之範圍內。針狀軟水鋁石之長寬比宜在10以上且100以下之範圍內，較宜在30以上且50以下之範圍內。針狀軟水鋁石之平均纖維徑長在0.4μm以上且2μm以下之範圍內且長寬比在30以上且50以下之範圍內時，光反射體用成形材料可具有特別良好的成形性。The white fiber material may also contain alumina-based fillers. The alumina-based filler contains acicular boehmite. The average fiber diameter of acicular boehmite should preferably be in the range of 0.1 μm or more and 10 μm or less, more preferably in the range of 0.4 μm or more and 2 μm or less. The average fiber length of acicular boehmite should preferably be in the range of 1 μm or more and 20 μm or less, more preferably in the range of 2 μm or more and 10 μm or less. The aspect ratio of acicular boehmite should be in the range of 10 or more and 100 or less, more preferably in the range of 30 or more and 50 or less. When the average fiber diameter length of the acicular boehmite is in the range of 0.4 μm or more and 2 μm or less and the aspect ratio is in the range of 30 or more and 50 or less, the molding material for light reflectors can have particularly good moldability.
白色纖維材亦可含有碳化矽晶鬚。光反射體1若含有碳化矽晶鬚，即可具有高導熱性及放熱性。碳化矽晶鬚之平均纖維徑長宜在0.2μm以上且2μm以下之範圍內。碳化矽晶鬚之平均纖維長度宜在2μm以上且200μm以下之範圍內。尤其當碳化矽晶鬚之平均纖維徑長在0.45μm以上且0.6μm以下之範圍內且長寬比在30以上且50以下之範圍內時，光反射體用成形材料可具有特別良好的成形性。The white fiber material may also contain silicon carbide whiskers. If the
纖維材亦可含有選自於由氮化矽晶鬚、高鋁紅柱石、高鋁紅柱石・δ氧化鋁(Al2 O3 ：SiO2 =72：28)及α・δ氧化鋁(Al2 O3 ：SiO2 =95：5)所構成群組中之1種以上。氮化矽晶鬚之平均纖維徑長宜在0.1μm以上且1.6μm以下之範圍內。氮化矽晶鬚之平均纖維長度宜在5μm以上且200μm以下之範圍內。高鋁紅柱石之平均纖維徑長宜在0.1μm以上且10μm以下之範圍內。高鋁紅柱石之平均纖維長度宜在10μm以上且100μm以下之範圍內。高鋁紅柱石・δ氧化鋁之平均纖維徑長宜在2μm以上且10μm以下之範圍內。高鋁紅柱石・δ氧化鋁之平均纖維長度宜在10μm以上且100μm以下之範圍內。α・δ氧化鋁之平均纖維徑長宜在2μm以上且10μm以下之範圍內。α・δ氧化鋁之平均纖維長度宜在10μm以上且100μm以下之範圍內。The fiber material may also contain selected from silicon nitride whiskers, mullite, mullite, δ alumina (Al 2 O 3 : SiO 2 =72:28) and α・δ alumina (Al 2 O 3 : SiO 2 =95: 5) One or more types in the group. The average fiber diameter of silicon nitride whiskers should preferably be in the range of 0.1 μm or more and 1.6 μm or less. The average fiber length of silicon nitride whiskers should preferably be in the range of 5 μm or more and 200 μm or less. The average fiber diameter of mullite should be within the range of 0.1 μm or more and 10 μm or less. The average fiber length of mullite should be within the range of 10 μm or more and 100 μm or less. The average fiber diameter of mullite and δ alumina should be within the range of 2μm or more and 10μm or less. The average fiber length of mullite and δ alumina should be within the range of 10μm or more and 100μm or less. The average fiber diameter of α・δ alumina should be within the range of 2μm or more and 10μm or less. The average fiber length of α・δ alumina should be within the range of 10μm or more and 100μm or less.
白色纖維材亦可含有鹼性硫酸鎂及碳酸鈣中之至少一者。尤其是碳酸鈣具有良好的耐鹼性，且可以低成本取得。鹼性硫酸鎂之平均纖維徑長宜在0.5μm以上且1μm以下之範圍內。鹼性硫酸鎂之平均纖維長度宜在10μm以上且30μm以下之範圍內。碳酸鈣之平均纖維徑長宜在0.5μm以上且1μm以下之範圍內。碳酸鈣之平均纖維長度宜在10μm以上且30μm以下之範圍內。The white fiber material may also contain at least one of alkaline magnesium sulfate and calcium carbonate. Especially calcium carbonate has good alkali resistance and can be obtained at low cost. The average fiber diameter of alkaline magnesium sulfate is preferably in the range of 0.5 μm or more and 1 μm or less. The average fiber length of alkaline magnesium sulfate is preferably in the range of 10 μm or more and 30 μm or less. The average fiber diameter of calcium carbonate is preferably within the range of 0.5 μm or more and 1 μm or less. The average fiber length of calcium carbonate is preferably within the range of 10 μm or more and 30 μm or less.
白色纖維材亦可含有AMTEC Co.,Ltd.製造稱為Pana-Tetra(註冊商標)的Tetrapod(四腳，註冊商標)狀氧化鋅。該Tetrapod(四腳，註冊商標)狀氧化鋅之針狀部分的平均纖維長度宜在10μm以上且20μm以下之範圍內。The white fiber material may also contain Tetrapod (four-legged, registered trademark) zinc oxide called Pana-Tetra (registered trademark) manufactured by AMTEC Co., Ltd.. The average fiber length of the needle-shaped portion of the Tetrapod (four-legged, registered trademark) zinc oxide is preferably within the range of 10 μm or more and 20 μm or less.
白色纖維材亦可含有水合矽酸鎂、鈦酸鉀纖維等各種陶瓷纖維。The white fiber material can also contain various ceramic fibers such as hydrated magnesium silicate and potassium titanate fibers.
白色纖維材可僅含有上述列舉之多種成分中之1種成分，亦可含有2種以上成分。白色纖維材若含有2種以上成分，可善加組合成分彼此的特性。The white fiber material may contain only one component among the multiple components listed above, or two or more components. If the white fiber material contains two or more components, the characteristics of the combined components can be improved.
白色纖維材宜業經矽烷耦合劑處理。以矽烷耦合劑處理白色纖維材表面之方法具體例可舉如乾式法、濕式法。根據乾式法，可在短時間內大量獲得業經矽烷耦合劑處理的白色纖維材，生產性變高。根據濕式法，則可以矽烷耦合劑均勻地處理白色纖維材表面。The white fiber material should be treated with silane coupling agent. Specific examples of the method of treating the surface of the white fiber material with a silane coupling agent include a dry method and a wet method. According to the dry method, a large amount of white fiber materials treated with a silane coupling agent can be obtained in a short time, and the productivity is improved. According to the wet method, the surface of the white fiber material can be treated uniformly with silane coupling agent.
針對矽烷耦合劑之具體例，分成熱硬化性樹脂含有不飽和聚酯樹脂之情況及熱硬化性樹脂含有環氧樹脂之情況來加以說明。Specific examples of the silane coupling agent are divided into a case where the thermosetting resin contains an unsaturated polyester resin and a case where the thermosetting resin contains an epoxy resin.
熱硬化性樹脂含有不飽和聚酯樹脂時，矽烷耦合劑宜含有選自於由環氧基矽烷、乙烯基矽烷、甲基丙烯醯基矽烷、三甲基矽烷、丙烯醯基矽烷及胺基矽烷所構成群組中之1種以上成分。該等中，矽烷耦合劑尤宜含有甲基丙烯醯基矽烷及丙烯醯基矽烷中之至少一者。較具體而言，矽烷耦合劑宜含有3-甲基丙烯醯氧基丙基三甲氧基矽烷及3-丙烯醯氧基丙基三甲氧基矽烷中之至少一者。此時，光反射體1可具有特別高的強度。When the thermosetting resin contains unsaturated polyester resin, the silane coupling agent is preferably selected from epoxy silane, vinyl silane, methacryl silane, trimethyl silane, acryl silane and amino silane One or more components in the group. Among these, the silane coupling agent particularly preferably contains at least one of methacryloxysilane and acryloxysilane. More specifically, the silane coupling agent preferably contains at least one of 3-methacryloxypropyltrimethoxysilane and 3-acryloxypropyltrimethoxysilane. At this time, the
熱硬化性樹脂含有環氧樹脂時，矽烷耦合劑宜含有選自於由環氧基矽烷、胺基矽烷、異氰酸酯及巰基矽烷所構成群組中之1種以上成分。矽烷耦合劑尤宜含有3-胺丙基三甲氧基矽烷。此時，光反射體1可具有特別高的強度。When the thermosetting resin contains an epoxy resin, the silane coupling agent preferably contains one or more components selected from the group consisting of epoxy silane, amino silane, isocyanate, and mercapto silane. The silane coupling agent particularly preferably contains 3-aminopropyltrimethoxysilane. At this time, the
相對於熱硬化性樹脂100質量份，光反射體用成形材料中之白色纖維材含量宜在10質量份以上且240質量份以下之範圍內。白色纖維材含量若在10質量份以上，光反射體1即可具有特別高的強度。尤其，不飽和聚酯樹脂於硬化時的收縮很大，所以光反射體用成形材料中含有不飽和聚酯樹脂時，藉由含有10質量份以上之白色纖維材，可抑制硬化收縮。白色纖維材含量若在240質量份以下，可抑制成形品之薄壁充填性降低。白色纖維材含量在50質量份以上且100質量份以下之範圍內較佳。The content of the white fiber material in the molding material for light reflectors is preferably in the range of 10 parts by mass or more and 240 parts by mass or less with respect to 100 parts by mass of the thermosetting resin. If the content of the white fiber material is 10 parts by mass or more, the
白色纖維材有無業經矽烷耦合劑處理可利用紅外線光譜法(IR)確認。此外，截斷光反射體1之試料後，可利用掃描型電子顯微鏡(SEM)等觀察斷裂面來確認白色纖維材有無業經矽烷耦合劑處理。 (其他成分)Whether the white fiber material has been treated with silane coupling agent can be confirmed by infrared spectroscopy (IR). In addition, after the sample of the
光反射體用成形材料可含有白色纖維材以外之纖維狀充填材(補強材)，亦可不含補強材。另，補強材係不含於上述充填材中之成分。光反射體用成形材料含有補強材時，相對於熱硬化性樹脂100質量份，補強材含量宜在3質量份以上且50質量份以下之範圍內。The molding material for the light reflector may contain a fibrous filler (reinforcing material) other than the white fiber material, or may not contain a reinforcing material. In addition, the reinforcing material is a component not contained in the above-mentioned filling material. When the molding material for the light reflector contains a reinforcing material, the content of the reinforcing material is preferably in the range of 3 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the thermosetting resin.
補強材之平均纖維徑長宜在5μm以上且15μm以下之範圍內，6μm以上且13μm以下之範圍內較佳。此時，光反射體1之強度會變得特別高。補強材之平均纖維長度愈小愈佳，如0.5mm以下、0.2mm以下、0.1mm以下、0.05mm以下。平均纖維長度較長的補強材具優異的處置性，所以譬如就起始原料而言，亦可使用平均纖維長度在0.5mm以上且3mm以下之補強材。此時，即使是平均纖維長度為0.5mm以上且3mm以下之補強材，亦可藉由在捏合步驟(後述)中予以切斷，而將平均纖維長度縮短至0.5mm以下、0.2mm以下、0.1mm以下、0.05mm以下中之任一者。而且，在捏合步驟中可利用熱硬化性樹脂來濕濡補強材之切斷面，來提高補強材與熱硬化性樹脂之密著強度。如此一來，在捏合步驟中藉由纖維狀充填材之平均纖維長度短至0.5mm以下，可特別提高光反射體1之強度，且可特別提升光反射體1之光反射率。補強材之平均纖維徑長及平均纖維長度皆係將補強材之電子顯微鏡照片進行影像處理而取得的纖維徑長及纖維長度之算術平均值。The average fiber diameter of the reinforcing material is preferably in the range of 5 μm or more and 15 μm or less, preferably in the range of 6 μm or more and 13 μm or less. At this time, the intensity of the
補強材亦可含有用於製造纖維強化塑膠(FRP)的材料。纖維強化塑膠之具體例可舉如塊狀模料(BMC)及片狀模料(SMC)。譬如，補強材含有選自於由玻璃纖維、維尼綸纖維、芳醯胺纖維及聚酯纖維所構成群組中之1種以上成分。Reinforcing materials can also contain materials used to make fiber reinforced plastics (FRP). Specific examples of fiber-reinforced plastics include block molding materials (BMC) and sheet molding materials (SMC). For example, the reinforcing material contains one or more components selected from the group consisting of glass fiber, vinylon fiber, aramid fiber, and polyester fiber.
光反射體用成形材料尤宜不含玻璃纖維。即使光反射體用成形材料含有玻璃纖維，相對於光反射體用成形材料總量，玻璃纖維含量也宜在10質量%以下。此時，藉由大幅減少玻璃纖維可能形成之光通道，可特別提升光反射體1之光反射性，所以即使光反射體1具有厚度較小的部分，光反射體1也能具有高度的光反射性。The forming material for the light reflector preferably does not contain glass fiber. Even if the forming material for the light reflector contains glass fibers, the content of the glass fiber is preferably 10% by mass or less with respect to the total amount of the forming material for the light reflector. At this time, by greatly reducing the optical channels that may be formed by the glass fiber, the light reflectivity of the
除了上述成分以外，光反射體用成形材料亦可含有聚合抑制劑、著色劑、增黏劑、阻燃劑、可撓性賦予劑等適宜的添加劑。 (光反射體用成形材料之彎曲特性)In addition to the above-mentioned components, the molding material for light reflectors may contain suitable additives such as polymerization inhibitors, colorants, tackifiers, flame retardants, and flexibility imparting agents. (Bending characteristics of molding materials for light reflectors)
光反射體用成形材料之硬化物在25℃下之彎曲強度宜為70MPa以上。利用白色纖維材且宜利用業經矽烷耦合劑處理的白色纖維材，較容易獲得這麼大的彎曲強度。藉此，可進一步提高光反射體1之強度。The bending strength of the hardened product of the molding material for the light reflector at 25°C is preferably 70 MPa or more. The use of white fiber materials and preferably white fiber materials treated with silane coupling agent, it is easier to obtain such a large bending strength. Thereby, the strength of the
光反射體用成形材料之硬化物在25℃下之彎曲彈性模數宜在4GPa以上且15GPa以下之範圍內。光反射體用成形材料含有具備內核部14及外殼部15之橡膠粒子13時，藉其可輕易獲得上述範圍內之彎曲彈性模數。藉此，可進一步提高光反射體1之韌性。The flexural modulus of the hardened product of the molding material for the light reflector should be within the range of 4GPa or more and 15GPa or less at 25°C. When the molding material for the light reflector contains the
較宜係光反射體用成形材料之硬化物在25℃下之彎曲強度為70MPa以上，且光反射體用成形材料之硬化物在25℃下之彎曲彈性模數在4GPa以上且15GPa以下之範圍內。光反射體用成形材料同時含有白色纖維材(宜為業經矽烷耦合劑處理之白色纖維材)及具備內核部14及外殼部15之橡膠粒子13時，藉此可輕易獲得大的彎曲強度及上述範圍內之彎曲彈性模數。藉此，可進一步提高光反射體1之強度及韌性。Preferably, the bending strength of the hardened product of the light reflector molding material at 25°C is 70 MPa or more, and the bending elastic modulus of the hardened product of the light reflector molding material at 25°C is in the range of 4 GPa or more and 15 GPa or less Inside. When the molding material for the light reflector contains both white fiber material (preferably white fiber material treated with silane coupling agent) and
光反射體用成形材料之製造方法 光反射體用成形材料之製造方法譬如包含下述製程：將含有熱硬化性樹脂及橡膠粒子13之混合物，在60℃以上且160℃以下範圍內之溫度加熱並同時予以捏合後，加工成粉狀、粒狀或顆粒狀。Manufacturing method of molding material for light reflector The manufacturing method of molding material for light reflector includes, for example, the following process: heating a mixture containing thermosetting resin and
較具體上，光反射體用成形材料之製造方法包含譬如以下步驟A1~步驟C1。More specifically, the manufacturing method of the molding material for the light reflector includes, for example, the following steps A1 to C1.
步驟A1係將上述熱硬化性樹脂及白色纖維材以及因應需求之聚合引發劑、充填材、脫模劑、橡膠粒子13等，分別以預定比率加以混合而獲得混合物。如上述，橡膠粒子13具備內核部14及覆蓋內核部14之外殼部15。混合譬如可使用混合器及攪拌機等混合機來進行。Step A1 is to mix the above-mentioned thermosetting resin, white fiber material, polymerization initiator, filler, mold release agent,
步驟B1係將步驟A1中所得混合物在60℃以上且160℃以下範圍內之溫度下加熱並同時予以捏合。加熱溫度若低於60℃，步驟A1中所得混合物就會變固體狀或黏度非常高的液狀，恐對捏合作業性帶來不良影響。加熱溫度若超過160℃，步驟A1中所得混合物恐在捏合步驟中即引發熱聚合反應。捏合譬如可使用加壓捏揉機、加熱輥機、擠壓機等捏合機來進行。In step B1, the mixture obtained in step A1 is heated and kneaded at a temperature in the range of 60°C or more and 160°C or less. If the heating temperature is lower than 60° C., the mixture obtained in step A1 will become solid or liquid with very high viscosity, which may adversely affect the kneading performance. If the heating temperature exceeds 160°C, the mixture obtained in step A1 may initiate a thermal polymerization reaction in the kneading step. The kneading can be performed using a kneader such as a pressure kneader, a heated roll machine, or an extruder, for example.
在步驟C1係將步驟B1中製得之加熱捏合後的混合物，加工成選自於由粉狀、粒狀及顆粒狀所構成群組中之1種以上形狀。該加工可使用適宜的造粒機、整粒機、製粒機等來進行。In step C1, the heated and kneaded mixture prepared in step B1 is processed into one or more shapes selected from the group consisting of powder, granules and granules. This processing can be carried out using a suitable granulator, granulator, granulator, etc.
光反射體 光反射體1含有光反射體用成形材料之硬化物。光反射體1具備周壁10及被周壁10包圍之凹處11。周壁10包含厚度100μm以下之部分。如上述，光反射體用成形材料含有熱硬化性樹脂及白色纖維材。如上述，光反射體1含有光反射體用成形材料之硬化物，且該光反射體用成形材料含有熱硬化性樹脂及白色纖維材。所以，即使光反射體1具有厚度較小的部分，儘管玻璃纖維含量少或不含玻璃纖維，也具高強度且高韌性。此外，光反射體1之耐熱變色性及光反射性良好。Light reflector The
圖1、圖2A及圖2B中展示光反射體1之例。圖1、圖2A及圖2B中，以X、Y及Z箭頭表示之方向指相互正交之方向。以下，X箭頭表示之方向稱作X軸方向，Y箭頭表示之方向稱作Y軸方向，Z箭頭表示之方向稱作Z軸方向。Examples of the
光反射體1譬如為LED反光件、雷射反光件等。光反射體1譬如圖2A及圖2B所示，係可容置在X1
(0.8~1.2mm)×Y1
(2.8~3.2mm)×Z1
(0.25~0.40mm)之空間亦即一方形體之空間內的大小，該方形體於X軸方向之尺寸X1
在0.8mm以上且1.2mm以下之範圍內、Y軸方向之尺寸Y1
在2.8mm以上且3.2mm以下之範圍內並且Z軸方向之尺寸Z1
在0.25mm以上且0.40mm以下之範圍內，惟不限於此大小。光反射體1含有上述光反射體用成形材料之硬化物。光反射體1係使上述光反射體用成形材料硬化而製得。理想係利用壓縮成形、轉注成形或射出成形，將光反射體用成形材料成形硬化來製作光反射體1。The
基體40具備光反射體1及引線2。引線2係埋入光反射體1中。引線2具有內部端子211、221及外部端子212、222。The
引線2為導電性。引線2通常為金屬製。引線2譬如可將一邊10cm以上且50cm以下之範圍內且厚度0.05mm以上且1.00mm以下之範圍內的銅板加工成預定形狀後，進行鍍錫、鍍鎳、鍍銀等表面處理而製得。內部端子211、221在光反射體1之凹處11之內面8呈露出狀態(對照圖2A)。外部端子212、222則呈現從光反射體1之外面9突出的狀態(對照圖1)。
如圖2A及圖2B所示，光反射體1具備周壁10及凹處11。周壁10為筒狀壁。凹處11被周壁10包圍。詳而言之，光反射體1具有第1成形部101及第2成形部102。該等中，第1成形部101包含周壁10及凹處11。第2成形部102及第1成形部101係依序於X軸方向層疊而一體化，且於第2成形部102及第1成形部101之間夾有引線2。如上述，光反射體1之第1成形部101具有凹處11。凹處11係朝X軸方向開口。換言之，凹處11開口之方向即X軸方向。周壁10係由與Z軸方向相對向之上壁部18及下壁部19、及與Y軸方向相對向之2邊側壁部20所構成。周壁10之前端部分(距離凹處11之底面17較遠的部分)之厚度Y2
譬如宜為25μm以上且宜為100μm以下。周壁10包含譬如厚度100μm以下之部分。本實施形態中，尤其包含上壁部18及下壁部19之前端部分為厚度100μm以下的薄壁部分。如圖3A所示，凹處11被上壁部18及下壁部19以及2邊側壁部20包圍。如圖3A等所示，從與X軸方向相反之方向觀看時，凹處11之開口形狀呈凸形，惟不限於該形狀。如圖2A所示，引線2在凹處11之內面8(尤其是底面17)呈露出狀態。凹處11之內面8係由底面17及內周面12構成。凹處11之內面8含反射面23，且至少內周面12含有反射面23。凹處11之深度係從凹處11之底面17起至開口間之X軸方向的距離X101
。X101
譬如在0.3mm以上且0.4mm以下之範圍內。引線2具備第一引線21及第二引線22。第一引線21具備在凹處11之底面17露出之內部端子211及從光反射體1之外面9朝光反射體1外部突出之外部端子212。第二引線22亦具備在凹處11之底面17露出之內部端子221及從光反射體1之外面9朝光反射體1外部突出之外部端子222。如圖3A所示，二個外部端子212、222朝同方向(Z軸方向)突出。二個外部端子212、222可朝與凹處11開口朝向之方向(X軸方向)正交的方向突出，亦可朝與凹處11開口朝向之方向(X軸方向)斜向突出。As shown in FIGS. 2A and 2B, the
上述光反射體1中，第1成形部101之體積(凹處11之容積除外)比第2成形部102之體積小。又，第1成形部101中，上壁部18及下壁部19之體積比側壁部20之體積小。尤其，上壁部18及下壁部19為厚度較小的部分，所以成形時光反射體用成形材料中所含白色纖維材便容易朝X軸方向配向而產生各向異性。比起含有熱可塑性樹脂之成形材料，含有熱硬化性樹脂之光反射體用成形材料於成形時的黏度會變得非常低，所以在厚度較小的部分白色纖維材即容易配向。如上述因為產生各向異性，所以即使像上壁部18及下壁部19等厚度較小的部分(譬如，厚度100μm以下、甚至50μm以下的部分)也能具有高強度。雖然比起上壁部18及下壁部19，側壁部20較不易產生各向異性，但因為側壁部20之體積較大，所以即使為各向同性也能具有高強度。又，雖然比起第1成形部101，第2成形部102較不易產生各向異性，但因為第2成形部102之體積較大，所以即使為各向同性也能具有高強度。In the
各向異性之有無譬如可藉由熱機械分析(TMA)測定成形時光反射體用成形材料的流動方向及與其呈垂直之方向上的硬化物之線膨脹係數來確認。譬如，圖2B中流動方向為X軸方向，垂直方向為Y軸方向。The presence or absence of anisotropy can be confirmed by, for example, thermomechanical analysis (TMA) measuring the flow direction of the molded material for the photoreflector and the linear expansion coefficient of the hardened product in the direction perpendicular to it. For example, the flow direction in Figure 2B is the X-axis direction, and the vertical direction is the Y-axis direction.
光反射體及基體之製造方法 光反射體1及基體40之製造方法包含譬如將光反射體用成形材料成形來製作光反射體1的製程。成形方法譬如為壓縮成形、轉注成形或射出成形。製作該光反射體1時，以引線2之一部分從光反射體1突出的方式使光反射體1與引線2一體化。The manufacturing method of the light reflection body and the base body The manufacturing method of the
本實施形態之製造方法亦可包含下述製程：在製作光反射體1時，係使用具備框170及連結框170之引線2的引線框架200，並於製作光反射體1後將引線2從框170切離。關於引線框架200之構成容後詳細說明。The manufacturing method of this embodiment may also include the following process: when manufacturing the
本實施形態之製造方法亦可包含在製作光反射體後將引線2彎折之製程。The manufacturing method of this embodiment may also include a process of bending the
本實施型態中，即使光反射體1如上述具有厚度較小的部分，儘管玻璃纖維含量少或不含玻璃纖維，也具高強度且高韌性。因此，光反射體1及基體40之製造方法藉由包含從框170切離引線2及將引線2彎折等製程，則即使對光反射體1施加壓力，也不易於光反射體1產生裂痕、斷裂等破損。In this embodiment, even if the
具體上，光反射體1之製造方法包含譬如以下步驟A2及步驟B2。另，以下將針對圖1、圖2A及圖2B所示光反射體1之製造方法具體說明，惟光反射體1不限於圖1、圖2A及圖2B所示之物。Specifically, the manufacturing method of the
步驟A2係準備上述光反射體用成形材料。光反射體用成形材料可以上述方式製造。Step A2 is to prepare the above-mentioned molding material for the light reflector. The molding material for the light reflector can be manufactured in the above-mentioned manner.
步驟B2係利用壓縮成形、轉注成形或射出成形，使步驟A2中所準備之光反射體用成形材料硬化而與引線2一體化，且使引線2之一部分從光反射體用成形材料之硬化物突出。Step B2 is to use compression molding, transfer molding or injection molding to harden the molding material for the light reflector prepared in Step A2 to be integrated with the
於圖5A展示引線框架200之一例。引線框架200可用來製造光反射體1及基體40。引線框架200為導電性，通常為金屬製。圖5A所示引線框架200係多腔用，具有具備多個格子之框170及多個連結框170之引線2。圖5A中，框170具有20個格子。1個格子為最小單位。每一格子設有一引線2。各引線2具有第一引線21及第二引線22。第一引線21具有內部端子211及外部端子212。第二引線22具有內部端子221及外部端子222。An example of the
壓縮成形係將引線框架200及光反射體用成形材料設置於已加熱至適溫之模具中，合閉模具後進行加熱、加壓的成形方法。Compression molding is a molding method in which the
轉注成形係將引線框架200設置於已加熱至適溫之模具中，將已饋入稱為坩堝(pot)之部分的光反射體用成形材料加壓並透過注入口流入模具內，並予以加熱、加壓的成形方法。In transfer molding, the
射出成形係先將引線框架200設置於已加熱至適溫之模具中，再使用射出成形機將光反射體用成形材料加壓注入模具內的成形方法。這時的成形條件譬如滾筒溫度在70℃以上且90℃以下之範圍內，射出壓力在5MPa以上且70MPa以下之範圍內，且模具溫度在150℃以上且170℃以下之範圍內。亦可因應需求施行後硬化處理。The injection molding is a molding method in which the
另，射出成形係JIS工業用語大辭典(第3版)中所記述。射出成形為成形熱可塑性樹脂及熱硬化性樹脂之方法之一，係使成形材料在射出滾筒中加熱熔融後，將呈流動化之成形材料以壓力注入經射出柱塞或螺桿而緊閉之模具中來進行成形的技術。(JIS K 6900)。In addition, injection molding is described in the JIS Dictionary of Industrial Terms (3rd Edition). Injection molding is one of the methods of molding thermoplastic resins and thermosetting resins. After the molding material is heated and melted in the injection roller, the fluidized molding material is injected under pressure into the mold closed by the injection plunger or screw. The technology of forming in the future. (JIS K 6900).
然後，藉由壓縮成形、轉注成形或射出成形在模具內使光反射體用成形材料成形硬化，即可如圖5B所示製造出多個光反射體1分別與引線框架200中之多個引線2各自呈一體化之狀態。於每一個引線框架200之框170所具有之格子中，製作含有光反射體用成形材料之硬化物的光反射體1，且引線2之一部分的外部端子212、222係從該光反射體1突出。習知之成形材料容易於光反射體1產生毛邊、裂痕、斷裂，但若為本實施形態之光反射體用成形材料，則可抑制光反射體1之毛邊、裂痕及斷裂產生。Then, by compression molding, transfer molding or injection molding, the molding material for the light reflector is molded and hardened in the mold, and a plurality of
光反射體用成形材料成形硬化後，將光反射體1及引線框架200從模具中取出，並在圖5B所示虛線位置切斷引線框架200，即可將引線2從框170切離。藉此可製得如圖3A所示多個與彎折加工前之引線2組合的光反射體1。After the molding material for the light reflector is molded and hardened, the
宜對光反射體1施行去毛邊處理。去毛邊處理包含譬如選自於由濕式噴砂處理、鹼性電解處理及鹼性溶液處理所構成群組中之1種以上處理。濕式噴砂處理可使用濕式噴砂裝置以公知方法進行。鹼性電解處理可使用電解去毛邊機以公知方法進行。鹼性溶液處理譬如可以氫氧化鉀水溶液、氫氧化鈉水溶液等鹼性溶液處理光反射體1表面來進行。The
白色纖維材業經矽烷耦合劑處理時，則即使對光反射體1施行去毛邊處理，白色纖維材也不易從光反射體1表面飛散且不易脫落，所以可抑制光反射體1的表面粗糙。所以，可輕易保持光反射體1表面平滑，故而可高度維持光反射體1的光反射性。When the white fiber material is treated with a silane coupling agent, even if the
圖6A展示另一實施形態之引線框架200及與該引線框架200一體形成的光反射體1。該引線框架200具有框170、連結框170之引線2及一對連結框170之支桿180。FIG. 6A shows a
各支桿180皆朝光反射體1之側壁部20突出。各支桿180在第1成形部101與第2成形部102之邊界附近，有稍微穿入光反射體1(對照圖6B)。將圖6A之α部分擴大顯示於圖6F。如圖6F所示，支桿180中穿入光反射體1之部分的支桿180沿突出方向之尺寸D2譬如在70μm以上且80μm以下之範圍內。Each
另，圖7A係顯示使用具備支桿180之引線框架200來製造圖1之光反射體1時，光反射體1與支桿180之關係的一例，展示與圖6F相同之模樣。惟，在圖7A中省略了外部端子222之圖示。又，像這樣以具備支桿180之引線框架200來製造與圖1同樣之光反射體1時，於光反射體1上在支桿180穿入的位置會形成孔部。圖1、圖2A、圖3A~圖3C、圖4A~圖4C皆展示使用不具支桿180之引線框架200而製成的光反射體1，所以未標示出支桿180穿入所形成的孔部。In addition, FIG. 7A shows an example of the relationship between the
支桿180之側面與光反射體1之側面間的距離D3(對照圖6F及圖7B)譬如在30μm以上且40μm以下之範圍內。另，圖7B係與圖1之光反射體1相對應，展示與圖6F相同之模樣。The distance D3 between the side surface of the
光反射體1若係以習知的成形材料形成，則在拔去支桿180時，圖7B中之γ部分容易產生裂痕等。If the
若是使用具備支桿180之引線框架200來製作光反射體1，光反射體1便係由一對支桿180懸吊。可在此狀態下對光反射體1施行去毛邊處理。去毛邊處理後，藉由在圖6A及圖6C所示虛線之位置切斷引線框架200，即可將引線2從框170切離，從光反射體1拔去支桿180。藉此可製得與彎折加工前之引線2組合的光反射體1。習知之成形材料在拔去支桿180時容易於光反射體1產生裂痕、斷裂，但若為本實施形態之光反射體用成形材料，則可抑制光反射體1之裂痕、斷裂產生。另，圖6C中，符號30為澆口痕(gate mark)。澆口痕30係以澆口痕跡形成於光反射體1的突起，該澆口即為樹脂注入模具模槽內的注入口。If the
光反射體1之製造方法更可包含下述步驟C2。The manufacturing method of the
步驟C2係將從光反射體用成形材料之硬化物的光反射體1突出的引線2之一部分切斷或彎折。切斷包含切斷為上述多腔時的引線框架200。以下針對步驟C2之彎折步驟亦即端子彎曲步驟加以說明。Step C2 is to cut or bend a part of the
如圖3A所示，為引線2一部分的外部端子212、222係從光反射體1突出。以如圖3B及圖3C所示方式將該外部端子212、222彎折使其配置成與光反射體1表面相對向。圖3B及圖3C中之箭頭表示彎折引線2之外部端子212、222的方向。如此一來，藉由對引線2之外部端子212、222施行彎折加工，可獲得彎折加工後之引線2及與其組合的光反射體1。另，於彎折加工時，亦可以如圖4A~圖4C所示方式對引線2之外部端子212、222施行彎折加工。As shown in FIG. 3A, the
若如上述將與光反射體1呈一體化狀態的引線框架200切斷、或是對與光反射體1呈一體化狀態之引線2施行彎折加工，會對光反射體1施予巨大的荷重。而如果光反射體1係以習知成形材料製作，則在引線框架200之切斷或彎折加工時，容易於光反射體1產生毛邊、裂痕、斷裂等破損。尤其容易在圖3B中之β部分產生裂痕等。相對地，如果光反射體1係從本實施形態之光反射體用成形材料製作而成，因為光反射體1具有高韌性及高強度，所以能在引線框架200之切斷或彎折加工時抑制於光反射體1產生毛邊、裂痕、斷裂等破損。尤其即使光反射體1具有厚度較小的部分，也因為光反射體1具有適度的彈性及高強度，所以引線框架200之切斷或端子彎曲時，光反射體1不易破損。可使用這種光反射體1來製造發光裝置6。If the
光反射體1之製造方法亦可包含下述步驟C3來替代步驟C2。The manufacturing method of the
步驟C3係同時將從光反射體用成形材料之硬化物的光反射體1突出的引線2進行切斷及彎折。切斷包含切斷為上述多腔時的引線框架200。並且在與此切斷之同時，以如圖3B及圖3C之箭頭所示方式，將從光反射體1突出之外部端子212、222彎折使其配置成與光反射體1表面相對向。如此一來，藉由對引線2之外部端子212、222施行彎折加工，可獲得與彎折加工後之引線2組合成的光反射體1。Step C3 is to cut and bend the
若如上述將與光反射體1呈一體化狀態之引線框架200切斷的同時，對與光反射體1呈一體化狀態之引線2施行彎折加工，會對光反射體1施予巨大的荷重。而如果光反射體1係以習知成形材料形成，切斷及彎折若同時進行，便容易於光反射體1產生毛邊、裂痕、斷裂等破損。相對地，如果光反射體1係以本實施形態之光反射體用成形材料形成，因為光反射體1具有高韌性及高強度，所以能抑制於光反射體1產生毛邊、裂痕、斷裂等破損。尤其即使光反射體1具有厚度較小的部分，也因為光反射體1具有適度的彈性及高強度，所以在同時進行引線框架200之切斷及端子彎曲時，光反射體1不易破損。可使用這種光反射體1來製造發光裝置6。If the
發光裝置 發光裝置6具備光反射體1及發光元件3。圖1、圖2A及圖2B中展示具備光反射體1之發光裝置6之例。該發光裝置6具備光反射體1、發光元件3以及引線2。本例中，係以引線2埋入在光反射體1中的方式組合光反射體1及引線2。由本實施形態之光反射體用成形材料製造之光反射體1、基體40及發光裝置6的結構不侷限於本例。Light-emitting device The light-emitting
發光元件3譬如為發光二極體(LED)或雷射二極體(LD)，惟不受此限。如圖2A及圖2B所示，發光元件3係與在凹處11之底面17露出之內部端子221電連接且搭載於光反射體1之凹處11的內部。具體上，發光元件3係以金屬線41與第一引線21之內部端子211電連接。The
亦即，發光裝置6具備基體40及發光元件3，且發光元件3與引線2之內部端子221電連接並搭載於光反射體1之凹處11內部。圖2A及圖2B所示光反射體1為側視型(側面發光型)，比起俯視型(上面發光型)，其從發光元件3到凹處11之內周面12間之距離D1短很多。譬如，距離D1在0.01mm以上且0.15mm以下(10μm以上且150μm以下)之範圍內。如所述若距離D1很短，譬如周壁10係以習知成形材料形成時，便容易因發光元件3發出之光L而劣化。再加上周壁10之厚度一小，發光元件3發出之光L便容易穿透周壁10而洩漏至外部。在本實施形態得以解決這種光反射體1因光L而劣化及漏光等課題。That is, the light-emitting
亦即，在本實施形態因為光反射體用成形材料含有熱硬化性樹脂，所以即使距離D1如上述非常短如具體上從發光元件3至凹處11之內周面12間之最短距離為0.15mm以下，也能抑制周壁10因光L而劣化。換言之，發光元件3至凹處11之內周面12間的最短距離宜為0.15mm以下。此時可將光反射體1小型化，而且即使像這樣將之小型化，在本實施形態中依舊可抑制光反射體1因光L而劣化。此外，光反射體用成形材料含有熱硬化性樹脂時，相對地增加充填材含量即可減少熱硬化性樹脂含量，所以更能抑制周壁10因光L而劣化。又，相對於光反射體用成形材料總量，玻璃纖維含量在0質量%以上且10質量%以下時，可大幅減少玻璃纖維可能形成之光通道，藉此即使光反射體1具有厚度較小的部分，也能抑制漏光，光反射體1便可具有高光反射性。That is, in this embodiment, since the molding material for the light reflector contains thermosetting resin, even if the distance D1 is very short as described above, the shortest distance from the light-emitting
如圖2A及圖2B所示，凹處11之內周面12至少一部係以朝向凹處11之開口側的方式對凹處11之底面17呈傾斜。亦即，凹處11之內周面12的一部分或全部可作為反射面23發揮功能，也就是使從發光元件3發出之光L朝凹處11之開口側反射。所以，從發光元件3發出之光L容易在光反射體1之凹處11的內周面12反射。其結果可提高來自發光裝置6之光L的擷取效率。另，凹處11之底面17亦能作為反射面23發揮功能。As shown in FIGS. 2A and 2B, at least a part of the inner
亦可藉由於發光裝置6之凹處11內充填密封材5，以密封材5來密封發光元件3。此時，可以密封材5保護發光元件3免受外部氣體等。It is also possible to seal the light-emitting
密封材5可從譬如密封用樹脂組成物製作。密封用樹脂組成物譬如可含有選自於由環氧樹脂、改質環氧樹脂、聚矽氧樹脂、改質聚矽氧樹脂、丙烯酸酯樹脂及胺甲酸乙酯樹脂所構成群組中之1種以上樹脂作為熱硬化性樹脂。The sealing
密封材5亦可視需求含有螢光物質。亦即，密封用樹脂組成物亦可含有螢光物質。此時，可以螢光物質控制從發光裝置6發出之光L的色調。The sealing
本實施形態之光反射體1如圖1所示，可搭載於譬如基板7上。此時，譬如光反射體1之外部端子212、222可以焊接等連接於位在基板7之一面73上的端子71、72。藉此，光反射體1可被基板7支撐，且同時能與基板7電連接。圖1所示光反射體1為側視型(側面發光型)。亦即，光反射體1若搭載於基板7上，光反射體1之凹處11的開口便會朝向沿著基板7支撐光反射體1之面73的方向，從光反射體1朝沿著面73之方向發光。As shown in FIG. 1, the
在此，本發明人等獲得下述見解。光反射率係視光反射體1中光到達處之厚度而定。該厚度變大時，光反射率即增高；該厚度變小時，光反射率則降低。實際上，發明人等使用本實施形態之光反射體用成形材料及習知的成形材料(尼龍等)製作成各種厚度的試料來進行實驗。結果查明，厚度變小時，以400μm左右為界，以習知成形材料做成的試料光反射率會急遽降低。相對地，以本實施形態之光反射體用成形材料做成的試料則可高度維持光反射率。此外亦查明玻璃纖維所造成之擦痕為光反射率降低之原因。擦痕係玻璃纖維與模具接觸時產生的汙痕。由此觀點來看，同樣以光反射體用成形材料不含玻璃纖維為宜。即使光反射體用成形材料含有玻璃纖維，相對於光反射體用成形材料總量，玻璃纖維含量也宜在10質量%以下。此時，不僅能減少玻璃纖維可能形成之光通道，也能抑制玻璃纖維所致之擦痕(尤其是反射面23的汙痕)生成，從而可提升光反射體1之光反射性。所以，即使光反射體1具有厚度較小的部分，光反射體1也能具有高度的光反射性。Here, the inventors of the present invention obtained the following findings. The light reflectivity depends on the thickness of the
尤其，如圖1、圖2A及圖2B所示之側視型光反射體1講求小型化、薄型化。譬如，在光反射體1之凹處11的開口附近，上壁部18及下壁部19之厚度非常小。如此一來，儘管光反射體1為小型且具有厚度較小的部分，在本實施形態中因為光反射體1含有白色纖維材(宜為業經矽烷耦合劑處理的白色纖維材)，所以該白色纖維材可抑制光穿透並可同時提升光反射體1的強度。此外，尤其當光反射體1含有內核外殼型橡膠粒子13時，該橡膠粒子13大大地有利於低彈性化，可進一步提升光反射體1之韌性。In particular, the side-view type
譬如，光反射體1中包圍凹處11之周壁10的最小厚度可在30μm以上且200μm以下之範圍內，甚至可在100μm以下。尤其，周壁10中之上壁部18及下壁部19的前端部分(距離凹處11之底面17較遠的部分)厚度可在20μm以上60μm以下之範圍內，更可在25μm以上且50μm以下之範圍內；上壁部18及下壁部19的根部(距離凹處11之底面17較近的部分)厚度可在40μm以上且70μm以下之範圍內，更可在45μm以上60μm以下之範圍內。像這般即使光反射體1具有厚度較小的部分，在本實施形態中光反射體1也能具有高韌性及高強度並同時具有高光反射性。For example, the minimum thickness of the
實施例 以下藉由實施例來具體說明本發明。惟，本發明不受以下實施例限定。 ＜製造光反射體用成形材料＞ 作為光反射體用成形材料之構成成分使用下列物質。Examples The following examples illustrate the present invention in detail. However, the present invention is not limited by the following examples. <Production of molding materials for light reflectors> The following substances are used as constituent components of the molding materials for light reflectors.
(1)熱硬化性樹脂 (1-1)不飽和聚酯樹脂 (1-1-1)不飽和醇酸樹脂 ・對酞酸系不飽和醇酸樹脂(Japan U-Pica Co., Ltd.製「U-Pica 8552」) (1-1-2)交聯劑 ・酞酸二烯丙酯預聚物(OSAKA SODA CO., LTD.製「DAP Polymer」) (1-2)環氧樹脂 ・三聚異氰酸三環氧丙酯(日產化學工業股份有限公司製「TEPIC-S」、環氧當量100g/eq) (1-3)苯酚樹脂 ・酚醛型苯酚樹脂(Panasonic股份有限公司製「PDR」)、重量平均分子量4000~5000 上述熱硬化性樹脂皆具有雙鍵。(1) Thermosetting resin (1-1) Unsaturated polyester resin (1-1-1) Unsaturated alkyd resin and terephthalic acid unsaturated alkyd resin (manufactured by Japan U-Pica Co., Ltd.) "U-Pica 8552") (1-1-2) Crosslinking agent・Diallyl phthalate prepolymer (“DAP Polymer” manufactured by OSAKA SODA CO., LTD.) (1-2) Epoxy resin・Triglycidyl isocyanate ("TEPIC-S" manufactured by Nissan Chemical Industry Co., Ltd., epoxy equivalent 100g/eq) (1-3) Phenolic resin and phenolic resin (manufactured by Panasonic Co., Ltd.) PDR"), weight average molecular weight 4000~5000 The above thermosetting resins all have double bonds.
(2)聚合引發劑 ・聚合引發劑1：過氧化二異丙苯基(日油股份有限公司製「Percumyl D-40」、40%母粒) ・聚合引發劑2：六氫酞酸酐(新日本理化股份有限公司製「RIKACID HH」) ・聚合引發劑3：六亞甲四胺(MITSUBISHI GAS CHEMICAL COMPANY, INC.製)(2) Polymerization initiator ・Polymerization initiator 1: Dicumyl peroxide ("Percumyl D-40" manufactured by NOF Corporation, 40% masterbatch) ・Polymerization initiator 2: Hexahydrophthalic anhydride (new "RIKACID HH" manufactured by RIKA Co., Ltd.) ・Polymerization initiator 3: hexamethylenetetramine (manufactured by MITSUBISHI GAS CHEMICAL COMPANY, INC.)
(3)充填材 (3-1)無機充填材 ・二氧化矽(Denka Co., Ltd.製「FB-820」、熔融二氧化矽、平均粒徑25μm) (3-2)白色顏料 ・氧化鈦(Tioxide Japan K.K.製「Tioxide R-TC30」、金紅石型氧化鈦、平均粒徑0.4μm)(3) Filling material (3-1) Inorganic filling material・Silica ("FB-820" manufactured by Denka Co., Ltd., fused silica, average particle size 25μm) (3-2) White pigment, oxidation Titanium (Tioxide R-TC30 manufactured by Tioxide Japan KK, rutile titanium oxide, average particle size 0.4μm)
(4)脫模劑 硬脂酸鋅(堺化學工業股份有限公司製「SZ-P」)(4) Mold release agent Zinc stearate ("SZ-P" manufactured by Sakai Chemical Industry Co., Ltd.)
(5)橡膠粒子 ・橡膠粒子1：Mitsubishi Rayon Co., Ltd.製「S2001」、內核部：聚矽氧橡膠、外殼部：丙烯酸橡膠、平均粒徑200μm、25℃下之彈性模數0.1GPa ・橡膠粒子2：Mitsubishi Rayon Co., Ltd.製「S2200」、內核部：聚矽氧橡膠、外殼部：環氧樹脂、平均粒徑200μm、25℃下之彈性模數0.5GPa ・橡膠粒子3：Mitsubishi Rayon Co., Ltd.製「C-223A」、內核部：丁二烯橡膠、外殼部：丙烯酸橡膠、平均粒徑200μm、25℃下之彈性模數0.2GPa ・橡膠粒子4：Mitsubishi Rayon Co., Ltd.製「W-377」、內核部：丙烯酸橡膠、外殼部：丙烯酸橡膠、平均粒徑200μm、25℃下之彈性模數0.8GPa ・橡膠粒子5：The Dow Chemical Company製「EXL-2311」、內核部：丙烯酸橡膠、外殼部：苯乙烯、平均粒徑200μm、25℃下之彈性模數1.0GPa 上述橡膠粒子皆具有內核外殼結構。(5) Rubber particles and rubber particles 1: "S2001" manufactured by Mitsubishi Rayon Co., Ltd., inner core: silicone rubber, outer shell: acrylic rubber, average particle size 200μm, elastic modulus at 25°C: 0.1GPa・Rubber particles 2: "S2200" manufactured by Mitsubishi Rayon Co., Ltd., inner core: silicone rubber, outer shell: epoxy resin, average particle size 200μm, modulus of elasticity at 25°C: 0.5GPa ・Rubber particles 3 : "C-223A" manufactured by Mitsubishi Rayon Co., Ltd., inner core: butadiene rubber, outer shell: acrylic rubber, average particle size 200μm, modulus of elasticity at 25°C 0.2GPa ・Rubber particles 4: Mitsubishi Rayon "W-377" manufactured by Co., Ltd., core part: acrylic rubber, shell part: acrylic rubber, average particle size 200μm, modulus of elasticity at 25°C 0.8GPa ・Rubber particles 5: EXL manufactured by The Dow Chemical Company -2311", the inner core part: acrylic rubber, the outer part: styrene, the average particle size is 200μm, and the elastic modulus at 25°C is 1.0GPa. The above-mentioned rubber particles all have a core-shell structure.
(6)纖維材 ・纖維材1：對矽灰石(KINSEI MATEC CO.,LTD.製「SH800」、平均纖維長度130μm、平均纖維徑長6.5μm、長寬比20)以甲基丙烯醯基矽烷施行表面處理所得的纖維材 ・纖維材2：對矽灰石(KINSEI MATEC CO.,LTD.製「SH800」、平均纖維長度130μm、平均纖維徑長6.5μm、長寬比20)以丙烯醯基矽烷施行表面處理所得的纖維材 ・纖維材3：業以甲基丙烯醯基矽烷施行表面處理的矽灰石(KINSEI MATEC CO.,LTD.製「FPW #800」、平均纖維長度12μm、平均纖維徑長4μm、長寬比3) ・纖維材4：業以甲基丙烯醯基矽烷施行表面處理的晶鬚(大塚化學股份有限公司製「Tismo N」、平均纖維長度20μm、平均纖維徑長0.6μm、長寬比33) ・纖維材5：未經表面處理的針狀氧化鋁(河合石灰工業股份有限公司製「Serra-sur BMI」、平均纖維長度6μm、平均纖維徑長1μm、長寬比6) ・纖維材6：業以甲基丙烯醯基矽烷施行表面處理的針狀氧化鋁(河合石灰工業股份有限公司製「Serra-sur BMI」、平均纖維長度6μm、平均纖維徑長1μm、長寬比6) ・纖維材7：業以甲基丙烯醯基矽烷進行處理的鱗片狀氧化鋁(河合石灰工業股份有限公司製「Serra-sur BMT」、平均纖維長度9μm、平均纖維徑長0.3μm、長寬比30)(6) Fiber material and fiber material 1: Wollastonite ("SH800" manufactured by KINSEI MATEC CO., LTD., average fiber length 130μm, average fiber diameter length 6.5μm, aspect ratio 20) based on methacrylic acid Fiber material and fiber material obtained by surface treatment of silane 2: Acrylic acid is used for wollastonite ("SH800" manufactured by KINSEI MATEC CO., LTD., average fiber length 130μm, average fiber diameter length 6.5μm, aspect ratio 20) Fibrous materials and fiber materials obtained by surface treatment with silane-based silane 3: Wollastonite ("FPW #800" manufactured by KINSEI MATEC CO., LTD., manufactured by KINSEI MATEC CO., LTD.), with an average fiber length of 12 μm, average Fiber diameter length 4μm, aspect ratio 3) ・Fiber material 4: Whiskers surface-treated with methacrylic silane (Tismo N manufactured by Otsuka Chemical Co., Ltd., average fiber length 20μm, average fiber diameter length 0.6μm, aspect ratio 33) ・Fiber material 5: Untreated acicular alumina ("Serra-sur BMI" manufactured by Kahe Lime Industry Co., Ltd., average fiber length 6μm, average fiber diameter length 1μm, length and width Ratio 6) ・Fiber material 6: Acicular alumina ("Serra-sur BMI" manufactured by Kahe Lime Industry Co., Ltd., with an average fiber length of 6μm, an average fiber diameter of 1μm, Aspect ratio 6) ・Fiber material 7: Scale-like alumina treated with methacrylic silane ("Serra-sur BMT" manufactured by Kahe Lime Industry Co., Ltd., average fiber length 9μm, average fiber diameter length 0.3 μm, aspect ratio 30)
(7)補強材 ・玻璃纖維(日東紡績股份有限公司製「CS 3J-261S」) 使用混合器將表1~表4之組成欄所示原料，按該表1~表4所示摻合量予以混合而獲得混合物。(7) Reinforcing material and glass fiber ("CS 3J-261S" manufactured by Nittobo Co., Ltd.) Use a mixer to mix the raw materials shown in the composition column of Table 1 to Table 4, and the blending amount is shown in Table 1 to Table 4 It is mixed to obtain a mixture.
接著使用加壓捏揉機將混合物在60℃以上且160℃以下範圍內之溫度下加熱並同時進行捏合。Next, a pressure kneader is used to heat the mixture at a temperature in the range of 60°C or higher and 160°C or lower while simultaneously kneading.
接下來，使用製粒機將加熱捏合後之混合物加工成顆粒狀而獲得光反射體用成形材料。 ＜評估方法＞ (彎曲強度及彎曲彈性模數)Next, a pelletizer is used to process the heated and kneaded mixture into pellets to obtain a molding material for a light reflector. <Evaluation method> (Bending strength and bending elastic modulus)
使用光反射體用成形材料，利用射出成形製作遵照JIS K 6911之試驗片。成形條件係設為滾筒溫度80℃、射出壓力40MPa、模具溫度160℃、保持時間180秒。遵照JIS K 6911，測定所得試驗片在25℃下之彎曲強度及彎曲彈性模數。 (初始光反射率)Using the molding material for the light reflector, a test piece conforming to JIS K 6911 was produced by injection molding. The molding conditions were as follows: the drum temperature was 80°C, the injection pressure was 40 MPa, the mold temperature was 160°C, and the holding time was 180 seconds. According to JIS K 6911, the bending strength and bending elastic modulus of the obtained test piece at 25°C were measured. (Initial light reflectivity)
利用射出成形在射出壓力20MPa、模具溫度150℃、保持時間120秒之條件下將光反射體用成形材料成形，製作出厚度1mm之試驗片。以反射率測定器(日本電色工業股份有限公司製分光色彩計)測定所得試驗片在波長460nm下的初始光反射率。 (耐熱變色性)The molding material for the light reflector was molded by injection molding under the conditions of an injection pressure of 20 MPa, a mold temperature of 150° C., and a holding time of 120 seconds to produce a test piece with a thickness of 1 mm. The initial light reflectance of the obtained test piece at a wavelength of 460 nm was measured with a reflectance meter (Spectrocolorimeter manufactured by Nippon Denshoku Industries Co., Ltd.). (Heat discoloration resistance)
將測出上述初始光反射率之試驗片在150℃下加熱1000小時後，再次以反射率測定器(日本電色工業股份有限公司製分光色彩計)測定該試驗片之光反射率。測定結果按以下基準做判定。 「◎」：光反射率為85%以上 「○」：光反射率為80%以上且低於85% 「△」：光反射率為75%以上且低於80% 「×」：光反射率低於75% (光隱蔽性)After the test piece with the initial light reflectance measured above was heated at 150°C for 1000 hours, the light reflectance of the test piece was measured again with a reflectance measuring device (Spectrocolorimeter manufactured by Nippon Denshoku Industries Co., Ltd.). The measurement result is judged according to the following criteria. "◎": Light reflectance is over 85% "○": Light reflectance is over 80% and less than 85% "△": Light reflectance is over 75% and less than 80% "×": Light reflectance Less than 75% (light concealment)
利用射出成形在射出壓力30MPa、模具溫度150℃、保持時間90秒之條件下將光反射體用成形材料成形，製作出厚度100μm之試驗片。以反射率測定器(日本電色工業股份有限公司製分光色彩計)測定所得試驗片在波長460nm下的透光率。測定結果按以下基準做判定。另，透光率愈低，以光反射體用成形材料製造出光反射體時，光就愈不易在厚度較小之部分穿透，於是可判斷光反射性愈不易隨光反射體小型・薄型化而降低。 「◎」：透光率低於1.5% 「○」：透光率為1.5%以上且低於2.0% 「△」：透光率為2.0%以上且低於3.0% 「×」：透光率為3.0%以上 (薄壁充填性)The molding material for the light reflector was molded by injection molding under the conditions of an injection pressure of 30 MPa, a mold temperature of 150° C., and a holding time of 90 seconds to produce a test piece with a thickness of 100 μm. The light transmittance of the obtained test piece at a wavelength of 460 nm was measured with a reflectance meter (Spectrocolorimeter manufactured by Nippon Denshoku Industries Co., Ltd.). The measurement result is judged according to the following criteria. In addition, the lower the light transmittance, when the light reflector is manufactured from the molding material for the light reflector, the light is less likely to penetrate the part with a small thickness, so it can be judged that the light reflectivity is less likely to follow the miniaturization and thinning of the light reflector. And reduce. "◎": Light transmittance is less than 1.5% "○": Light transmittance is 1.5% or more and less than 2.0% "△": Light transmittance is 2.0% or more and less than 3.0% "×": Light transmittance 3.0% or more (thin wall filling)
準備圖5A所示引線框架，並在該引線框架裝設於模具之狀態下，利用射出成形在射出壓力10MPa、模具溫度150℃、保持時間120秒之條件下將光反射體用成形材料成形。藉此，可如圖5B所示製造出光反射體的同時使光反射體與引線框架一體化。將光反射體及引線框架從模具取出，並在圖5B所示虛線位置切斷引線框架，將引線從引線框架之框切離。光反射體中厚度最小部分的厚度為30μm。確認該光反射體有無未充填。從其結果以下述方式評估薄壁充填性。The lead frame shown in FIG. 5A is prepared, and with the lead frame installed in the mold, the light reflector molding material is molded by injection molding under the conditions of an injection pressure of 10 MPa, a mold temperature of 150° C., and a holding time of 120 seconds. Thereby, the light reflector can be integrated with the lead frame while manufacturing the light reflector as shown in FIG. 5B. The light reflector and the lead frame are taken out of the mold, and the lead frame is cut at the dotted line shown in FIG. 5B, and the lead is cut away from the frame of the lead frame. The thickness of the smallest part of the light reflector is 30 μm. Check whether the light reflector is not filled. From the results, the thin-wall filling properties were evaluated in the following manner.
「◎」：未發現光反射體未充填。"◎": The light reflector was not found to be unfilled.
「○」：在光反射體之厚度40μm以下的部分發現未充填，厚度大於40μm的部分則未發現未充填。"○": No filling is found in the part of the light reflector with a thickness of 40 μm or less, and no filling is found in the part with a thickness greater than 40 μm.
「△」：在光反射體之厚度大於40μm且60μm以下的部分發現未充填，厚度大於60μm的部分則未發現未充填。"△": No filling was found in the part where the thickness of the light reflector was greater than 40 μm and 60 μm or less, and the part where the thickness was greater than 60 μm was not found unfilled.
「×」：在光反射體之厚度大於60μm且0.1mm以下的部分發現未充填，厚度大於0.1mm的部分則未發現未充填。 (纖維配向性)"×": The part of the light reflector whose thickness is greater than 60μm and less than 0.1mm is found to be unfilled, and the part whose thickness is greater than 0.1mm is not found to be unfilled. (Fiber Orientation)
在沿著製作光反射體時光反射體用成形材料流動方向之面切斷光反射體後，以掃描型電子顯微鏡觀察所形成之截面。並且，亦在製作光反射體時與光反射體用成形材料流動方向正交之面切斷光反射體後，以掃描型電子顯微鏡觀察所形成之截面。根據該等結果確認光反射體中之纖維材有無配向。其結果，纖維配向性在發現有配向之情況評估為「有」，未發現配向之情況則評估為「無」。 (引線彎曲耐性)After the light reflector was cut along the flow direction of the molding material for the light reflector, the cross section formed was observed with a scanning electron microscope. In addition, when the light reflector was produced, the light reflector was cut at a plane orthogonal to the flow direction of the molding material for the light reflector, and the formed cross section was observed with a scanning electron microscope. According to these results, it is confirmed whether the fiber material in the light reflector is aligned or not. As a result, the fiber orientation is evaluated as "Yes" when the orientation is found, and "No" when the orientation is not found. (Lead bending resistance)
使用具有480個格子之引線框架，來製作具備光反射體及引線的480個試樣。針對各試樣，在光反射體已固定之狀態下以如圖3A~圖3C所示方式對引線施行彎折加工後，以顯微鏡觀察光反射體，確認有無裂痕。從其結果以下述方式評估引線彎曲耐性。A lead frame with 480 grids was used to produce 480 samples with light reflectors and leads. For each sample, after bending the lead wire in the manner shown in Figs. 3A to 3C with the light reflector fixed, observe the light reflector with a microscope to confirm whether there are cracks. From the results, the lead bending resistance was evaluated in the following manner.
「◎」：所有試樣皆未於光反射體發現裂痕。"◎": No cracks were found in the light reflector for all samples.
「○」：有1個以上且5個以下之試樣於光反射體發現裂痕。"○": 1 or more and 5 or less samples have cracks in the light reflector.
「△」：有6個以上且10個以下之試樣於光反射體發現裂痕。"△": There are more than 6 samples and less than 10 samples found cracks in the light reflector.
「×」：有11個以上試樣於光反射體發現裂痕。"×": There are more than 11 samples found cracks in the light reflector.
[表1]
[表2]
[表3]
[表4]
1‧‧‧光反射體2‧‧‧引線3‧‧‧發光元件5‧‧‧密封材6‧‧‧發光裝置7‧‧‧基板8‧‧‧內面9‧‧‧外面10‧‧‧周壁11‧‧‧凹處12‧‧‧內周面13‧‧‧橡膠粒子14‧‧‧內核部15‧‧‧外殼部16‧‧‧接枝鏈17‧‧‧底面18‧‧‧上壁部19‧‧‧下壁部20‧‧‧側壁部21‧‧‧第一引線22‧‧‧第二引線23‧‧‧反射面30‧‧‧澆口痕40‧‧‧基體41‧‧‧金屬線71、72‧‧‧端子73‧‧‧面101‧‧‧第1成形部102‧‧‧第2成形部170‧‧‧框180‧‧‧支桿200‧‧‧引線框架211‧‧‧內部端子212‧‧‧外部端子221‧‧‧內部端子222‧‧‧外部端子D1、D3‧‧‧距離D2‧‧‧尺寸L‧‧‧光X101‧‧‧距離X1‧‧‧尺寸Y1‧‧‧尺寸Z1‧‧‧尺寸1‧‧‧Light reflector2‧‧‧Lead wire3‧‧‧Light-emitting element5‧‧‧Sealing material6‧‧‧Light-emitting device7‧‧‧Substrate 8‧‧‧Inside 9‧‧‧Outside 10‧‧‧ Peripheral wall 11‧‧‧Concavity 12‧‧‧Inner circumferential surface 13‧‧‧Rubber particles 14‧‧‧Inner core part 15‧‧‧Outer part 16‧‧‧Graft chain 17‧‧‧Bottom surface 18‧‧‧Upper wall Part 19‧‧‧Bottom wall part 20‧‧‧Side wall part 21‧‧‧First lead 22‧‧‧Second lead 23‧‧‧Reflective surface 30‧‧‧Gate mark 40‧‧‧Base 41‧‧‧ Wire 71, 72‧‧‧Terminal 73‧‧‧Surface 101‧‧‧The first forming part 102‧‧‧The second forming part 170‧‧‧Frame 180‧‧‧Pole 200‧‧‧Lead frame 211‧‧ ‧Internal terminal 212‧‧‧External terminal 221‧‧‧Internal terminal 222‧‧‧External terminal D1, D3‧‧‧Distance D2‧‧‧Dimension L‧‧‧Light X101‧‧‧Distance X1‧‧‧Dimension Y1‧ ‧‧Size Z1‧‧‧Size
圖1係顯示本發明一實施形態中具備光反射體之發光裝置及基板的立體圖。圖1中，X軸、Y軸及Z軸表示相互正交之方向。 圖2中，圖2A為圖1之發光裝置的A-A截面圖。圖2B為圖1之發光裝置的B-B截面圖。圖2A及圖2B中，X軸、Y軸及Z軸表示相互正交之方向。 圖3中，圖3A~圖3B係顯示對已與光反射體組合之引線施行彎折加工之一連串樣貌一例的立體圖。圖3A~圖3C中，X軸、Y軸及Z軸表示相互正交之方向。 圖4中，圖4A~圖4B係顯示對已與光反射體組合之引線施行彎折加工之一連串樣貌之另一例的立體圖。圖4A~圖4C中，X軸、Y軸及Z軸表示相互正交之方向。 圖5中，圖5A係顯示引線框架一例的俯視圖。圖5B係顯示圖5A之引線框架及與該引線框架一體形成之光反射體的俯視圖。 圖6中，圖6A係顯示本發明之另一實施形態中引線框架及與該引線框架一體形成之光反射體的俯視圖。圖6B係圖6A之C-C截面圖。圖6C係圖6A之仰視圖。圖6D係圖6A之側視圖。圖6E係圖6A之D-D截面圖。圖6F係圖6A中之α部分的擴大圖。 圖7中，圖7A係顯示被支桿垂吊之光反射體的俯視圖。圖7B係顯示被支桿垂吊之光反射體的立體圖。 圖8係橡膠粒子的示意截面圖。FIG. 1 is a perspective view showing a light emitting device and a substrate provided with a light reflector in an embodiment of the present invention. In Fig. 1, the X-axis, Y-axis, and Z-axis indicate directions orthogonal to each other. In FIG. 2, FIG. 2A is an A-A cross-sectional view of the light-emitting device of FIG. 1. Fig. 2B is a B-B cross-sectional view of the light-emitting device of Fig. 1. In FIGS. 2A and 2B, the X-axis, Y-axis, and Z-axis indicate directions orthogonal to each other. In Fig. 3, Figs. 3A to 3B are perspective views showing an example of a series of appearances of bending processing on the lead combined with the light reflector. In FIGS. 3A to 3C, the X-axis, Y-axis, and Z-axis indicate directions orthogonal to each other. In FIG. 4, FIGS. 4A to 4B are perspective views showing another example of a series of appearances of bending processing on the lead combined with the light reflector. In FIGS. 4A to 4C, the X-axis, Y-axis, and Z-axis indicate directions orthogonal to each other. In FIG. 5, FIG. 5A is a plan view showing an example of a lead frame. FIG. 5B is a top view showing the lead frame of FIG. 5A and the light reflector integrally formed with the lead frame. In FIG. 6, FIG. 6A is a top view of a lead frame and a light reflector integrally formed with the lead frame in another embodiment of the present invention. Fig. 6B is a cross-sectional view taken along line C-C in Fig. 6A. Fig. 6C is a bottom view of Fig. 6A. Fig. 6D is a side view of Fig. 6A. Fig. 6E is a D-D cross-sectional view of Fig. 6A. Fig. 6F is an enlarged view of part α in Fig. 6A. In Fig. 7, Fig. 7A shows a top view of a light reflector suspended by a support rod. Fig. 7B is a perspective view showing the light reflector suspended by the support rod. Fig. 8 is a schematic cross-sectional view of rubber particles.
1‧‧‧光反射體 1‧‧‧Light reflector
2‧‧‧引線 2‧‧‧Lead
5‧‧‧密封材 5‧‧‧Sealing material
6‧‧‧發光裝置 6‧‧‧Light-emitting device
7‧‧‧基板 7‧‧‧Substrate
9‧‧‧外面 9‧‧‧outside
10‧‧‧周壁 10‧‧‧ Zhoubi
11‧‧‧凹處 11‧‧‧Recess
18‧‧‧上壁部 18‧‧‧Upper wall
19‧‧‧下壁部 19‧‧‧Lower Wall
20‧‧‧側壁部 20‧‧‧Sidewall
21‧‧‧第一引線 21‧‧‧First lead
22‧‧‧第二引線 22‧‧‧Second lead
40‧‧‧基體 40‧‧‧Matrix
71、72‧‧‧端子 71, 72‧‧‧Terminal
73‧‧‧面 73‧‧‧Noodles
101‧‧‧第1成形部 101‧‧‧The first forming part
102‧‧‧第2成形部 102‧‧‧The second forming part
212、222‧‧‧外部端子 212, 222‧‧‧External terminal
Claims (21)
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| JP2016-141592 | 2016-07-19 | ||
| JP2016141592 | 2016-07-19 | ||
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| JP2016196004 | 2016-10-03 | ||
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| JP2017072687 | 2017-03-31 | ||
| JP2017-072700 | 2017-03-31 | ||
| JP2017-072687 | 2017-03-31 | ||
| JP2017072700 | 2017-03-31 |
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| TW201829587A TW201829587A (en) | 2018-08-16 |
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| TW106122349A TWI723193B (en) | 2016-07-19 | 2017-07-04 | Reflector, base body, light emitting device and method of manufacturing the base body |
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| KR102624113B1 (en) * | 2018-06-08 | 2024-01-12 | 서울바이오시스 주식회사 | Light emitting device package and manufacturing method thereof |
| JP7291507B2 (en) * | 2019-03-22 | 2023-06-15 | 日本特殊陶業株式会社 | dust core |
| WO2021025125A1 (en) * | 2019-08-08 | 2021-02-11 | 住友ベークライト株式会社 | Thermosetting resin composition |
| JP2022047423A (en) * | 2020-09-11 | 2022-03-24 | 味の素株式会社 | Resin composition |
| WO2022064986A1 (en) * | 2020-09-25 | 2022-03-31 | 旭有機材株式会社 | Thermosetting resin composition |
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| JP7065381B2 (en) | 2022-05-12 |
| KR20180009721A (en) | 2018-01-29 |
| JP2018160655A (en) | 2018-10-11 |
| KR20180009720A (en) | 2018-01-29 |
| JP7065382B2 (en) | 2022-05-12 |
| TWI737758B (en) | 2021-09-01 |
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| TW201829593A (en) | 2018-08-16 |
| JP2018160654A (en) | 2018-10-11 |
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