TW201829587A - Light reflector, substrate, light emitting device and method of manufacturing substrate - Google Patents

Abstract

An object of the present invention is to provide a light reflector which can produce high strength and high toughness even in the absence of glass fiber content or glass fiber, and which is excellent in heat discoloration resistance and light reflectivity. The light reflector of the present invention includes a peripheral wall and a recess surrounded by the peripheral wall. The peripheral wall includes a portion having a thickness of 100 μm or less. The light reflector 1 contains a cured product of a molding material for a light reflector. The molding material for a light reflector contains a thermosetting resin and a white fiber material.

Description

Light reflector, substrate, light emitting device and method of manufacturing substrate

The present invention generally relates to a light reflector, a substrate, a light emitting device, and a method of manufacturing a substrate. More particularly, the present invention relates to a method of fabricating a light reflector, a substrate, a light-emitting device, and a substrate that are particularly suitable for use in fabricating a side-view type of light-emitting device.

BACKGROUND OF THE INVENTION In recent years, the use of light-emitting diodes as an alternative source of fluorescent and incandescent lamps has rapidly expanded. For example, a light-emitting device including a light-emitting element such as a light-emitting diode and a resin-made light reflector (reflector) that can reflect light emitted from the light-emitting element can be used for illumination purposes. The current problem is how to make such a light-emitting device with a light-emitting diode long-lasting to maintain the initial brightness.

One of the main causes of the decrease in the brightness of the light-emitting device is that the light reflector is discolored by heat, resulting in a decrease in light reflectance. Therefore, we believe that if the light reflector can be manufactured with less thermal discoloration, the life of the light-emitting device can be extended.

For example, Zhouzhi Ceramics is a material with good heat and discoloration properties. However, ceramics have their limits in processing precision, are easy to be brittle, and are expensive, so they lack versatility and are not suitable as materials for light reflectors.

In contrast, polyamide resin, generally referred to as nylon, has excellent chemical resistance, heat resistance, abrasion resistance, and toughness, and is inexpensiver than ceramics, and is therefore widely used for lighting applications. However, the nylon light-reflecting body is highly discolored and cannot sustain the life of the light-emitting device as expected.

In view of the above, it has been proposed to produce a light-reflecting body by using a thermosetting resin such as an unsaturated polyester resin or an epoxy resin (for example, Japanese Patent No. 4844699, Japanese Patent No. 5153952, and Japanese Patent Laid-Open No. 2014-019747 Bulletin). The light reflector made of a thermosetting resin has an advantage of being excellent in heat discoloration resistance.

However, it is difficult to obtain high toughness and high strength comparable to nylon with a thermosetting resin such as an unsaturated polyester resin or an epoxy resin. Generally, the light reflector contains glass fibers to impart high strength to the light reflector, but it is extremely difficult to impart high toughness.

Moreover, in recent years, as the distance between the light-emitting element and the light reflector is shortened and the light-emitting device is downsized, the thickness of the light reflector is gradually reduced. For example, a side view type light reflector has a portion having 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 cited is that the glass fibers are arranged to cross the light reflecting body, and the glass fibers form a light passage that allows light to pass through the light reflecting body, so that the light easily penetrates the light reflecting body. For other reasons, 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 or the like. Therefore, especially small light reflectors are difficult to have high light reflectance. On the other hand, if the light reflector does not contain glass fibers, it is difficult for the light reflector to have sufficient strength.

SUMMARY OF THE INVENTION An object of the present invention is to provide a light reflector which has high strength and high toughness, and has excellent heat discoloration resistance and light reflectivity, even if it has a small thickness portion, has a small glass fiber content or contains no glass fiber, and has excellent heat resistance and light reflectivity. Method and illuminating device.

The light reflector of one aspect of the present invention contains a cured product of a molding material for a light reflector. The light reflector has a peripheral wall and a recess surrounded by the peripheral wall. The peripheral wall includes a portion having a thickness of 100 μm or less. The molding material for a light reflector contains a thermosetting resin and a white fiber material.

A substrate according to an aspect of the present invention includes the light reflector and a lead buried in the light reflector. The lead wire 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.

A light-emitting device according to an aspect of the invention includes the substrate and the light-emitting element. The light-emitting element is electrically connected to the internal terminal of the lead wire and mounted inside the recess of the light reflector.

A method for producing a substrate according to an aspect of the present invention includes a process of forming a light reflector by molding a light reflector, and forming the light reflector so that the lead portion protrudes from the light reflector The light reflector is integrated with the lead.

MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described. In the present specification and the drawings, the same components are denoted by the same reference numerals, and the description thereof will not be repeated.

Molding material for light reflector The molding material for a light reflector of the present embodiment is suitably used for producing a light reflector 1 (reflector). The molding material for a light reflector contains a thermosetting resin and a white fiber material. For example, the molding material for a light reflector contains a thermosetting resin, a polymerization initiator, a filler, a release agent, and a white fiber material. The molding material for a light reflector preferably further contains rubber particles 13. The molding material for a light reflector is preferably a solid at 30 ° C or lower. The molding material for a light reflector can be processed into a pellet by pulverization processing or extrusion processing.

In the present embodiment, by the additive effect of the components constituting the molding material for a light reflector, it is possible to produce a light reflector having high strength and high toughness even if the glass fiber content is small or glass fiber is not contained, and the heat discoloration resistance is good. .

In other words, since the molding material for the light reflector contains the white fiber material, the curing shrinkage can be suppressed at the time of molding, and the light reflector 1 can have high strength and high dimensional stability. Further, since the white fiber material is less likely to transmit light, even if the light reflector 1 has a small thickness portion, the white fiber material does not easily hinder the light reflectivity of the light reflector 1. Therefore, even if the light reflector 1 is small or thin, the high intensity and high light reflectivity of the light reflector 1 can be ensured.

Further, when the molding material for a light reflector contains the core-shell type rubber particles 13, the portion having a small thickness of the light reflector 1 can be made soft, and the brittleness can be suppressed, thereby ensuring high toughness.

Moreover, since the molding material for a light reflector contains a thermosetting resin, the heat reflection property of the light reflector 1 is favorable.

The molding material for a light reflector includes a peripheral wall 10 and a recess 11 surrounded by the peripheral wall 10. The peripheral wall 10 is suitable for producing a light reflector 1 having a thickness of 100 μm or less (refer to Figs. 1, 2A and 2B). The detailed configuration of the light reflector 1 will be described later. When the light-reflecting body 1 having such a shape and size contains the cured product of the molding material for a light-reflecting body of the present embodiment, even if it has a small thickness portion, it has high strength even if it has a small glass fiber content or contains no glass fiber. It has high toughness and good heat discoloration and light reflectivity.

In addition, a light reflector other than the light reflector 1 described above can be produced from the molding material for a light reflector of the present embodiment. Regardless of the size and shape, the light reflector containing the cured product of the molding material for a light reflector has high strength and high toughness even when the glass fiber content is small or contains no glass fiber, and is excellent in heat discoloration resistance and light reflectivity.

Hereinafter, the constituent components of the molding material for a light reflector will be described first. (thermosetting resin)

The component contained in the thermosetting resin may be any of a monomer and an oligomer (prepolymer). The thermosetting resin preferably has at least one functional group selected from the group consisting of a vinyl group, an acryl group, a carboxyl group, a hydroxyl group, and an epoxy group. This functional group involves a reaction such as a crosslinking reaction when forming a molding material for a light reflector.

However, as shown in FIG. 2A and FIG. 2B described later, the light-emitting device 6 includes the light reflector 1 and the light-emitting element 3. It is assumed that the light reflector 1 is formed of a thermoplastic resin, and when the light-emitting element 3 generates heat, the light reflector 1 is deformed by heat. However, the light reflector 1 is produced by using a molding material for a light reflector containing a thermosetting resin, and even if the light-emitting element 3 generates heat, the light reflector 1 can be prevented from being deformed by heat.

The thermosetting resin preferably contains one or more components selected from the group consisting of unsaturated polyester resins, epoxy resins, and phenol resins. At this time, the moldability of the molding material for a light reflector is good. Further, in this case, the light reflector can also have high heat discoloration resistance and high strength.

In particular, the thermosetting resin preferably contains either or both of an unsaturated polyester resin and an epoxy resin. Compared with the phenol resin, the unsaturated polyester resin and the epoxy resin can impart high heat discoloration resistance to the light reflector 1, and the light reflector 1 is less likely to be discolored even at a high temperature.

Further, the thermosetting resin preferably contains an unsaturated polyester resin. The unsaturated polyester resin imparts higher heat discoloration resistance to the light reflector 1 than the epoxy resin. The reason for this is that if the molding material for a light reflector contains an unsaturated polyester resin, the unreacted functional group which is a cause of discoloration does not easily remain inside the light reflector 1 . That is, since the polymerization speed of the unsaturated polyester resin is fast, even if the molding cycle when the light reflector 1 is produced is short, unreacted functional groups are hardly left.

The unsaturated polyester resin contains, for example, an unsaturated alkyd resin and a crosslinking agent (copolymerizable compound). The unsaturated alkyd resin will start to soften at, for example, 30 ° C or higher and preferably 50 ° C or higher.

The unsaturated alkyd resin can be obtained by dehydrating and condensing polybasic acids and glycols. The polybasic acid preferably contains an unsaturated polybasic acid. The polybasic acid may further contain a saturated polybasic acid.

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.

The saturated polybasic acid is, for example, selected from the group consisting of phthalic anhydride, isophthalic acid, p-citric acid, adipic acid, sebacic acid, 1,4-cyclohexanedicarboxylic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride And one or more selected from the group consisting of tetramethylene phthalic anhydride, HET acid, and tetrabromophthalic anhydride.

The glycols are, for example, selected from the group consisting of ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butylene glycol, 1,6-hexanediol, and 1,4-cyclohexane. One or more of the group consisting of alkane dimethanol, hydrogenated bisphenol A, bisphenol A propylene oxide compound, and dibromo neopentyl glycol.

The melt viscosity of the unsaturated alkyd resin is preferably in 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 unsaturated alkyd resin and a p-citric acid unsaturated alkyd resin. When the unsaturated alkyd resin has the above-mentioned melt viscosity, the molding material for a light reflector can have high formability, and the light reflector 1 can have high heat discoloration resistance.

The crosslinking agent contains, for example, one or more kinds of vinyl copolymerization 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, from diallyl phthalate, triallyl cyanurate, diallyl tetrabromide, phenoxyethyl acrylate, 2-hydroxyethyl acrylate and 1 One or more kinds of 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 above-exemplified monomers. In particular, the crosslinking agent preferably contains one or more components selected from the group consisting of diallyl phthalate prepolymers, diallyl phthalate monomers, and styrene monomers.

The mass ratio of the unsaturated alkyd resin to the crosslinking agent in the unsaturated polyester resin is preferably in the range of 99:1 to 50:50. When the crosslinking agent contains a monomer, the more the monomer content, the more difficult the molding material for the light reflector becomes solid at room temperature, so the monomer content is preferably 10 parts by mass or less based on 100 parts by mass of the unsaturated polyester resin.

The epoxy resin is not particularly limited as long as it is a resin having two or more epoxy groups (ethylene oxide rings) in one molecule. The epoxy resin may be selected from the group consisting of polyphenol type epoxy resins, epoxy propyl ether type epoxy resins, epoxy propyl ester type epoxy resins, epoxy propyl amine type epoxy resins, and alicyclic rings. One or more components selected from the group consisting of oxygen resins. Epoxy resin can also contain three bismuth Skeleton epoxy resin. With three Specific examples of the epoxy resin of the skeleton include tris-propyl isocyanate.

The phenol resin is a thermosetting resin synthesized from phenols and formaldehyde. The phenol resin contains either or both of a novolac type phenol resin and a resol type phenol resin. The phenolic phenol resin can be obtained by condensing a phenol with formaldehyde by an acidic catalyst. The phenolic phenol resin is added with hexamethylenetetramine and heated to harden it. On the other hand, a resol type phenol resin can be obtained by condensing a phenol with formaldehyde by a basic catalyst. When the resol type phenol resin is heated, it can be dehydrated and crosslinked to be hardened.

The content of the thermosetting resin is preferably in the range of 14% by mass or more and 40% by mass or less, more preferably 16% by mass or more and 34% by mass or less, and more preferably 20% by mass or more, based on the total amount of the molding material for the light reflector. More preferably, it is in the range of 28% by mass or less. When the content of the thermosetting resin is 14% by mass or more, the light reflectance of the light reflector 1 can be suppressed from being lowered. When the content of the thermosetting resin is 40% by mass or less, the decrease in strength of the light reflector 1 can be suppressed. (polymerization initiator)

The molding material for a light reflector may contain a polymerization initiator. When the thermosetting resin has radical polymerization reactivity, the molding material for a light reflector preferably contains a thermal radical polymerization initiator as a polymerization initiator. The polymerization initiator is not particularly limited, and examples thereof include a heat-decomposable organic peroxide. The organic peroxide contains, for example, selected from the group consisting of tert-butylperoxy-2-ethylhexylmonocarbonate, 1,1-di(tri-hexylperoxy)cyclohexane, 1,1-di ( Tertiary butylperoxy)-3,3,5-trimethylcyclohexane, butyl peroxyoctanoate, benzammonium peroxide, methyl ethyl ketone peroxide, acetamidine peroxide, One or more components selected from 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 prevention of fire and explosion, the polymerization initiator can also be masterbatch to further improve safety.

The molding material for the light reflector may also contain a curing agent. A hardener may be added to promote hardening of the thermosetting resin. For example, when the thermosetting resin contains an epoxy resin, the molding material for a light reflector 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)

The molding material for a light reflector may contain a filler. The filling material contains either or both of an inorganic filler and a white pigment. That is, the molding material for the light reflector may contain an inorganic filler. Further, the molding material for the light reflector may contain a white pigment.

The inorganic filler material contains either or both of cerium oxide and aluminum hydroxide. In particular, the inorganic filler material preferably contains cerium oxide. The cerium oxide contains, for example, one or more components selected from the group consisting of molten cerium oxide powder, spherical cerium oxide powder, crushed cerium oxide powder, and crystalline cerium oxide powder. The inorganic filler may contain hollow oxides, hydrates, inorganic foaming particles, cerium oxide hollow spheres or the like other than the above-mentioned materials, as long as the effect of the molding material for a light reflector of the present embodiment is not impaired. particle.

The average particle diameter of the inorganic filler is preferably 250 μm or less, more preferably 0.05 μm or more and 100 μm or less, and more preferably 0.1 μm or more and 10 μm or less. When the inorganic filler having such an average particle diameter is contained in the molding material for a light reflector, the moldability of the molding material for a light reflector can be improved, and the light reflectivity and moisture resistance of the light reflector 1 can be improved. In the light-emitting device 6 shown in FIG. 2A and FIG. 2B, the light L emitted from the light-emitting element 3 is reflected by the reflection surface 23 (the inner circumferential surface 12 or the like) and enters the peripheral wall 10 (the upper wall portion 18 and the lower wall portion). In the 19 and 2 side wall portions 20), the number of refractions of the light L can be increased by the fine inorganic filler as described above. As a result, it is possible to suppress the light L from penetrating the peripheral wall 10, thereby improving light concealability. Further, the average particle diameter in the present specification means a particle diameter (median diameter (D50)) of 50% of the cumulative value in the particle size distribution obtained by the laser diffraction scattering method. The laser diffraction scattering method can utilize Mie scattering or not. The shape of the particle size distribution at this time is not particularly limited.

The content of the inorganic filler is preferably 32 parts by mass or more, and more preferably 50 parts by mass or more and 250 parts by mass or less with respect to 100 parts by mass of the thermosetting resin. In this case, the moldability of the molding material for the light reflector can be improved, the heat discoloration resistance of the light reflector 1 can be improved, and the light reflectance can be improved. Further, at this time, in the light-emitting device 6 shown in FIG. 2A and FIG. 2B, which will be described later, the number of times of refraction of the light L can be increased inside the peripheral wall 10 by a large amount of the inorganic filler. As a result, it is possible to suppress the light L from penetrating the peripheral wall 10, so that the light concealing property of the peripheral wall 10 can be improved.

The white pigment contains, for example, one or more components selected from the group consisting of titanium oxide, barium titanate, barium titanate, alumina, magnesia, 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. The 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-type titanium oxide excellent in thermal stability.

The average particle diameter of the white pigment is preferably 2 μm or less, more preferably 0.1 μm or more and 1 μm or less, more preferably 0.2 μm or more and 0.7 μm or less. At this time, similarly to the case of the inorganic filler, in the light-emitting device 6 shown in FIG. 2A and FIG. 2B, which will be described later, the number of refractions of the light L can be increased by the white pigment which is smaller than the inorganic filler in the peripheral wall 10 as described above. . As a result, it is possible to suppress the light L from penetrating the peripheral wall 10, thereby improving light concealability.

The white pigment content is preferably 100 parts by mass or more, and more preferably 100 parts by mass or more and 300 parts by mass or less, based on 100 parts by mass of the thermosetting resin. When the content of the white pigment is 100 parts by mass or more, the light reflectance of the light reflector 1 can be improved. Further, at this time, in the light-emitting device 6 shown in FIGS. 2A and 2B described later, the number of times of refraction of the light L can be increased by the presence of a larger amount of white pigment than the inorganic filler in the peripheral wall 10 as described above. As a result, it is possible to suppress the light L from penetrating the peripheral wall 10, so that the light concealing property of the peripheral wall 10 can be improved. When the content of the white pigment is 300 parts by mass or less, the thin-wall filling property of the molding material for a light reflector can be improved, and the bending strength of the light reflector 1 can be further improved.

The total content of the inorganic filler and the white pigment is preferably in the range of 33% by mass or more and 74% by mass or less, and more preferably in the range of 50% by mass or more and 72% by mass or less, based on the total amount of the molding material for the light reflector. .

The total content of the inorganic filler and the white pigment is preferably 500 parts by mass or less, and more preferably 100 parts by mass or more and 400 parts by mass or less based on 100 parts by mass of the thermosetting resin. In this case, the fluidity of the molding material for a light reflector can be improved at the time of molding, and the moldability can be improved.

The smaller the particle size of the inorganic filler and the white pigment, the more likely the aggregation or oil absorption phenomenon occurs, and it is not easy to be uniformly dispersed in the molding material for the light reflector. Accordingly, in order to improve the dispersibility of the inorganic filler and the white pigment in the molding material for a light reflector, the inorganic filler and the white pigment are preferably subjected to a surface treatment by either or both of a fatty acid and a coupling agent. (release agent)

The molding material for a light reflector may contain a mold release agent. The release agent contains, for example, one or more selected from the group consisting of a fatty acid wax, a fatty acid metal salt wax, and a mineral wax. In particular, the release agent preferably contains either or both of a fatty acid wax and a fatty acid metal salt wax which are excellent in heat discoloration resistance. More specifically, the release agent contains, for example, one or more selected from the group consisting of stearic acid, zinc stearate, aluminum stearate, and calcium stearate.

The content of the releasing agent is preferably in the range of 4 parts by mass or more and 15 parts by mass or less based on 100 parts by mass of the thermosetting resin. At this time, the light reflector 1 has a good mold release property from the mold, and also has an excellent appearance and can have particularly high light reflectivity. (rubber particles)

The molding material for a light reflector may contain rubber particles 13. As schematically shown in Fig. 8, the rubber particles 13 have a core outer shell structure. That is, the rubber particles 13 include the core portion 14 and the outer shell portion 15. Either or both of the core portion 14 and the outer casing portion 15 may have elasticity. In other words, both the core portion 14 and the outer casing portion 15 may be formed of an elastically deformable resin, or the core portion 14 may be formed of an elastically deformable resin and the outer casing portion 15 may be formed of a plastically deformable resin, or may be a core portion. 14 is formed of a plastically deformable resin and the outer casing portion 15 is formed of an elastically deformable resin. When the light reflector 1 is made of the molding material for the light reflector containing the core-shell type rubber particles 13, the light reflector 1 can be made low in elasticity and can have high toughness.

It is also possible that the core portion 14 is formed of a plastically deformable resin and the outer casing portion 15 is formed of an elastically deformable resin. The ideal core portion 14 is formed of an elastically deformable resin. Thereby, the impact resistance and toughness of the light reflector 1 can be further improved, and cracks in the light reflector 1 can be suppressed. Specific examples of the elastically deformable resin include a resin having a three-dimensional crosslinked structure or a two-dimensional crosslinked structure. Specific examples of the resin having a three-dimensional crosslinked structure include a polymer obtained by adding a crosslinking agent to a thermosetting resin and crosslinking reaction according to a desired filling material. Specific examples of the resin having a two-dimensional crosslinked structure include a polymer obtained by adding a nucleating agent to a thermoplastic resin and crosslinking reaction according to a desired filler. More preferably, both the core portion 14 and the outer casing portion 15 are flexible.

The ideal core portion 14 is a granular rubber. The core portion 14 preferably contains one or more components selected from the group consisting of polyoxyxene rubber, acrylic rubber, and butadiene rubber. In particular, when the core portion 14 contains polyoxyxene rubber, the weather resistance and impact resistance of the light reflector 1 are also improved. Further, when the core portion 14 contains acrylic rubber, the fluidity of the molding material for a light reflector can be improved at the time of molding, and the chemical resistance of the light reflector 1 can be improved. Further, when the core portion 14 contains butadiene rubber, the impact resistance of the light reflector 1 is also improved.

The outer casing portion 15 covers the inner core portion 14. The outer casing portion 15 preferably has a functional group. The outer casing portion 15 is preferably composed of a plurality of graft chains 16 having functional groups. One end portion of each of the graft chains 16 is bonded to the surface of the core portion 14. The functional group is preferably located at the end of the graft chain 16 that is not bonded to the side of the core portion 14. The outer shell portion 15 is preferably reactive with a thermosetting resin. That is, the outer casing portion 15 is preferably reactive with the thermosetting resin for chemical bonding. At this time, when the light reflector is cured by the molding material to form the light reflector 1, the outer shell portion 15 reacts with the thermosetting resin to perform chemical bonding. When the light reflector is cured by the molding material, the outer shell portion 15 has high affinity with the thermosetting resin even if the outer shell portion 15 does not react with the thermosetting resin. Therefore, the rubber particles 13 are chemically bonded to the resin formed by curing the thermosetting resin in the light reflecting body 1 or adhered to the resin phase with high affinity. Therefore, the stress between the resin phase and the rubber particles 13 is easily dispersed, and peeling at the interface between the resin phase and the rubber particles 13 is less likely to occur. Therefore, the impact resistance of the light reflector 1 can be improved. Since the outer shell portion 15 is reactive with the thermosetting resin, the functional group of the outer shell portion 15 is preferably reactive with the thermosetting resin, that is, it is preferably reactive with the thermosetting resin for chemical bonding. The functional group may contain, for example, a group selected from the group consisting of methacryloyl fluorenyl, acryl fluorenyl, vinyl, epoxy, amine, carbamide, ureide, sulfhydryl, isocyanate, and carboxyl groups. One or more groups in the group. When the thermosetting resin is an unsaturated polyester resin, the functional group is preferably reactive with an unsaturated double bond in the unsaturated polyester resin, and particularly preferably contains either or both of a methacryl fluorenyl group and an acryl fluorenyl group. By. When the thermosetting resin is an epoxy resin, the functional group is preferably reactive with an epoxy group, and it is particularly preferred to contain either or both of a carboxyl group and an amine group.

The average particle diameter of the rubber particles 13 is preferably in the range of 0.1 μm or more and 1 mm or less. When the average particle diameter of the rubber particles 13 is 0.1 μm or more, the impact resistance of the light reflector 1 can be further improved. When the average particle diameter of the rubber particles 13 is 1 mm or less, the rubber particles 13 can be easily and uniformly dispersed in the molding material for a light reflector, and the light reflector 1 can be easily dispersed uniformly.

The content of the rubber particles 13 is preferably in the range of 0.1% by mass or more and 30% by mass or less, and more preferably 0.1% by mass or more and less than 22% by mass, based on the total amount of the molding material for the light reflector. Thereby, even if the light reflector 1 has a small thickness portion, it is difficult to cause a defect due to the unfilling at the time of molding. That is, the thin wall filling property of the molding material for a light reflector can be improved. Further, by the content of the rubber particles 13 being in the above range, the light reflector 1 having excellent heat discoloration resistance and high toughness can be obtained.

The elastic modulus of the ideal rubber particles 13 at 25 ° C is 1 GPa or less. Thereby, the toughness of the light reflector 1 can be further improved. Further, the elastic modulus of the rubber particles 13 at 25 ° C can be measured by the method specified in JIS K 6254.

Further, the presence or absence of the rubber particles 13 in the light reflector 1 may be performed by any one of gas chromatography mass spectrometry (GC/MS) and Fourier transform infrared spectroscopy (FT-IR) or a combination of the methods. confirm. When the core portion 14 of the rubber particles 13 contains polyoxyxene rubber, qualitative and quantitative analysis using a thermally desorbed cyclic siloxane is effective. That is, for example, after heating the sample of the light reflector 1 at 250 ° C for 3 minutes and injecting the generated gas into the gas chromatography mass spectrometer, the qualitative analysis of the detected cyclic oxirane and the conversion to toluene are performed. Semiquantitative. Thereby, it can be easily confirmed whether or not the core portion 14 has the rubber particles 13 containing the polyoxyethylene rubber. When the core portion 14 contains acrylic rubber or butadiene rubber, the presence or absence of the rubber particles 13 can be confirmed by infrared spectroscopy (IR). (white fiber)

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 does not selectively absorb or reflect light of a specific wavelength region in the range of 400 nm or more and 700 nm or less in the visible light wavelength region. Specifically, the rate of change 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 preferably 10% or less. The rate of change of the spectral reflectance is the value of the highest reflectance "A (%)" and the minimum reflectance "B (%)" of the spectral reflectance from 400 nm to 700 nm in the wavelength region, and {(AB)/ A} × 100 (%) Calculated value. In addition, the white fiber material is preferably a natural product or mineral such as ash stone, not an artificial product such as glass fiber. Such natural materials and minerals are more likely to cause incident light to spread randomly on the surface (i.e., appear whiter than glass fibers) because of its complex surface and finer concavities and convexities than glass fibers.

By using an artificial material formed of a fibrous glass fiber by an artificial method, by using a fibrous material composed of a natural material or a mineral, light leakage of the light reflecting body 1 can be greatly reduced. This is because the surface of the natural or mineral has a complex concave and convex shape, so the light is not easily caused by the natural or mineral interior.

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, and preferably 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, and preferably in the range of 50 μm or more and 150 μm or less. The average fiber length of the white fiber material affects the strength of the light reflector 1, so that it is more suitable for the size of the light reflector 1. That is, the ideal range of the average fiber length of the white fiber material is such that the size of the first forming portion 101 of the light reflecting body 1 can be accommodated as shown in FIG. 2A and FIG. 2B as X ₁₀₁ (0.3 to 0.4 mm) × Y ₁ The degree of the space in (2.8~3.2mm) × Z ₁ (0.25~0.40mm) is particularly effective. Further, the average fiber diameter and the average fiber length of the white fiber material are the arithmetic mean values of the fiber diameter and the fiber length obtained by subjecting the electron microscope photograph of the white fiber material to image processing.

The aspect ratio of the white fiber material is defined by the ratio of the average fiber length to the average fiber diameter. The aspect ratio of the white fiber material is preferably in the range of 3 or more and 500 or less, and more preferably in the range of 3 or more and 20 or less. At this time, the strength of the light reflector 1 can be effectively improved, and the surface roughness of the light reflector 1 after the burring treatment can be effectively suppressed.

The white fiber material preferably contains limestone. At this time, the light reflectivity and strength of the light reflector 1 are extremely high. The ash stone is represented by the chemical formula CaSiO ₃ , also known as calcium metasilicate. The average fiber diameter of the limestone is preferably in the range of 1 μm or more and 125 μm or less. The average fiber length of the limestone is preferably in the range of 20 μm or more and 500 μm or less. The aspect ratio of the limestone is preferably in the range of 3 or more and 20 or less.

The white fiber material may also contain components other than the limestone. The components other than the ash stone include inorganic or electrically insulating fibers and whiskers other than ash. Such fibers and whiskers can effectively increase the strength of the light reflector 1 even when the amount of addition is small.

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, and 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, and more preferably in the range of 10 μm or more and 20 μm or less. When the average fiber diameter of potassium titanate is in the range of 0.3 μm or more and 0.6 μm or less and the average fiber length is in the range of 10 μm or more and 20 μm or less, the molding material for a light reflector can have particularly excellent formability.

The white fibrous material may also contain an alumina-based filler. The alumina-based filler contains acicular boehmite. The average fiber diameter of the acicular boehmite is preferably in the range of 0.1 μm or more and 10 μm or less, and more preferably in the range of 0.4 μm or more and 2 μm or less. The average fiber length of the acicular boehmite is preferably in the range of 1 μm or more and 20 μm or less, and more preferably in the range of 2 μm or more and 10 μm or less. The aspect ratio of the acicular boehmite is preferably 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 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 a light reflector can have particularly excellent moldability.

The white fiber material may also contain strontium carbide whiskers. When the light reflector 1 contains strontium carbide whiskers, it has high thermal conductivity and heat dissipation. The average fiber diameter of the niobium carbide whisker is preferably in the range of 0.2 μm or more and 2 μm or less. The average fiber length of the strontium carbide whiskers is preferably in the range of 2 μm or more and 200 μm or less. In particular, when the average fiber diameter of the cerium carbide whisker is in the range of 0.45 μm or more and 0.6 μm or less and the aspect ratio is in the range of 30 or more and 50 or less, the forming material for the light reflecting body can have particularly good formability. .

The fibrous material may also be selected from the group consisting of cerium 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 of the groups formed. The average fiber diameter of the tantalum nitride whisker is preferably in the range of 0.1 μm or more and 1.6 μm or less. The average fiber length of the tantalum nitride whisker is preferably in the range of 5 μm or more and 200 μm or less. The average fiber diameter of the mullite is preferably in the range of 0.1 μm or more and 10 μm or less. The average fiber length of the mullite is preferably in the range of 10 μm or more and 100 μm or less. The average fiber diameter of the mullite and the δ alumina is preferably in the range of 2 μm or more and 10 μm or less. The average fiber length of the mullite and the δ alumina is preferably in the range of 10 μm or more and 100 μm or less. The average fiber diameter of α·δ alumina is preferably in the range of 2 μm or more and 10 μm or less. The average fiber length of the α·δ alumina is preferably in the range of 10 μm or more and 100 μm or less.

The white fibrous material may also contain at least one of basic magnesium sulfate and calcium carbonate. In particular, calcium carbonate has good alkali resistance and can be obtained at low cost. The average fiber diameter of the alkaline magnesium sulfate is preferably in the range of 0.5 μm or more and 1 μm or less. The average fiber length of the alkaline magnesium sulfate is preferably in the range of 10 μm or more and 30 μm or less. The average fiber diameter of the calcium carbonate is preferably in the range of 0.5 μm or more and 1 μm or less. The average fiber length of the calcium carbonate is preferably in the range of 10 μm or more and 30 μm or less.

The white fiber material may also contain a Tetrapod (four-legged, registered trademark)-like zinc oxide called Pana-Tetra (registered trademark) manufactured by AMTEC Co., Ltd. The average fiber length of the acicular portion of the Tetrapod (four-legged, registered trademark)-like zinc oxide is preferably in the range of 10 μm or more and 20 μm or less.

The white fiber material may also contain various ceramic fibers such as hydrated magnesium silicate or potassium titanate fiber.

The white fiber material may contain only one of the above-exemplified components, and may contain two or more components. When the white fiber material contains two or more kinds of components, the characteristics of the components can be combined well.

The white fiber material is treated with a decane coupling agent. Specific examples of the method of treating the surface of the white fibrous material with a decane coupling agent include a dry method and a wet method. According to the dry method, a large amount of white fiber material treated with a decane coupling agent can be obtained in a short time, and productivity is high. According to the wet method, the surface of the white fiber material can be uniformly treated with a decane coupling agent.

Specific examples of the decane coupling agent will be described in the case where the thermosetting resin contains an unsaturated polyester resin and the case where the thermosetting resin contains an epoxy resin.

When the thermosetting resin contains an unsaturated polyester resin, the decane coupling agent preferably contains a solvent selected from the group consisting of epoxy decane, vinyl decane, methacryl decyl decane, trimethyl decane, acryl decyl decane and amino decane. One or more components in the group. Among these, the decane coupling agent particularly preferably contains at least one of methacryl decyl decane and acryl decyl decane. More specifically, the decane coupling agent preferably contains at least one of 3-methacryloxypropyltrimethoxydecane and 3-propenyloxypropyltrimethoxydecane. At this time, the light reflector 1 can have a particularly high strength.

When the thermosetting resin contains an epoxy resin, the decane coupling agent preferably contains one or more components selected from the group consisting of epoxy decane, amino decane, isocyanate, and decyl decane. The decane coupling agent particularly preferably contains 3-aminopropyltrimethoxydecane. At this time, the light reflector 1 can have a particularly high strength.

The content of the white fiber material in the molding material for a light reflector is preferably in the range of 10 parts by mass or more and 240 parts by mass or less based on 100 parts by mass of the thermosetting resin. When the content of the white fiber material is 10 parts by mass or more, the light reflector 1 can have a particularly high strength. In particular, when the unsaturated polyester resin is contained in the molding material for the light reflector, the unsaturated polyester resin contains 10 parts by mass or more of the white fiber material, whereby the hardening shrinkage can be suppressed. When the content of the white fiber material is 240 parts by mass or less, the decrease in the thin wall filling property of the molded article can be suppressed. The content of the white fiber material is preferably in the range of 50 parts by mass or more and 100 parts by mass or less.

Whether the white fiber material is treated with a decane coupling agent can be confirmed by infrared spectroscopy (IR). Further, after the sample of the light reflector 1 is cut off, the fracture surface can be observed by a scanning electron microscope (SEM) or the like to confirm whether or not the white fiber material is treated with a decane coupling agent. (other ingredients)

The molding material for a light reflector may contain a fibrous filler (reinforcing material) other than a white fiber material, or may not contain a reinforcing material. In addition, the reinforcing material is not contained in the above filler. When the molding material for a 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 based on 100 parts by mass of the thermosetting resin.

The average fiber diameter of the reinforcing material is preferably in the range of 5 μm or more and 15 μm or less, and preferably in the range of 6 μm or more and 13 μm or less. At this time, the intensity of the light reflector 1 becomes extremely high. The smaller the average fiber length of the reinforcing material, the better, such as 0.5 mm or less, 0.2 mm or less, 0.1 mm or less, and 0.05 mm or less. The reinforcing material having a long average fiber length has excellent handleability. Therefore, for the starting material, for example, a reinforcing material having an average fiber length of 0.5 mm or more and 3 mm or less may be used. In this case, even if the reinforcing material has an average fiber length of 0.5 mm or more and 3 mm or less, the average fiber length can be shortened to 0.5 mm or less, 0.2 mm or less, or 0.1 by cutting in a kneading step (described later). Any of mm or less and 0.05 mm or less. Further, in the kneading step, the thermosetting resin can be used to wet the cut surface of the reinforcing material to improve the adhesion strength between the reinforcing material and the thermosetting resin. In this way, in the kneading step, the average fiber length of the fibrous filler is as short as 0.5 mm or less, whereby the strength of the light reflector 1 can be particularly enhanced, and the light reflectance of the light reflector 1 can be particularly enhanced. The average fiber diameter and the average fiber length of the reinforcing material are the arithmetic mean values of the fiber diameter and the fiber length obtained by image processing the electron micrograph of the reinforcing material.

The reinforcing material may also contain materials for the manufacture of fiber reinforced plastic (FRP). Specific examples of the fiber-reinforced plastics include a bulk molding compound (BMC) and a sheet molding material (SMC). For example, the reinforcing material contains one or more components selected from the group consisting of glass fibers, vinylon fibers, linalyl fibers, and polyester fibers.

The forming material for the light reflector is particularly preferably free of glass fibers. Even if the molding material for a light reflector contains glass fibers, the glass fiber content is preferably 10% by mass or less based on the total amount of the molding materials for the light reflector. In this case, the light reflectivity of the light reflector 1 can be particularly improved by greatly reducing the light path that the glass fiber may form. Therefore, even if the light reflector 1 has a small thickness portion, the light reflector 1 can have a high degree of light. Reflective.

In addition to the above components, the molding material for a light reflector may contain a suitable additive such as a polymerization inhibitor, a colorant, a tackifier, a flame retardant, and a flexibility imparting agent. (Bending characteristics of a molding material for a light reflector)

The cured product of the molding material for a light reflector preferably has a bending strength at 25 ° C of 70 MPa or more. It is easier to obtain such a large bending strength by using a white fiber material and using a white fiber material which is treated with a decane coupling agent. Thereby, the strength of the light reflector 1 can be further improved.

The cured elastic modulus of the molded material for a light reflector at 25 ° C is preferably in the range of 4 GPa or more and 15 GPa or less. When the molding material for a light reflector contains the rubber particles 13 including the core portion 14 and the outer shell portion 15, the bending elastic modulus in the above range can be easily obtained. Thereby, the toughness of the light reflector 1 can be further improved.

It is preferable that the cured product of the molding material for a light reflector has a bending strength at 25 ° C of 70 MPa or more, and the cured product of the molded material for a light reflector has a bending elastic modulus at 25 ° C of 4 GPa or more and 15 GPa or less. Inside. When the molding material for a light reflector contains a white fiber material (preferably a white fiber material treated with a decane coupling agent) and rubber particles 13 having the core portion 14 and the outer shell portion 15, a large bending strength and the above can be easily obtained. The flexural modulus of elasticity in the range. Thereby, the strength and toughness of the light reflector 1 can be further improved.

Method for Producing a Forming Material for a Light Reflector A method for producing a material for a light reflector includes, for example, a process in which a mixture containing a thermosetting resin and rubber particles 13 is heated at a temperature in a range of 60 ° C or more and 160 ° C or less. At the same time, it is kneaded and processed into powder, granules or granules.

More specifically, the manufacturing method of the molding material for a light reflector includes, for example, the following steps A1 to C1.

In the step A1, the thermosetting resin, the white fiber material, and the polymerization initiator, the filler, the release agent, the rubber particles 13, and the like are required to be mixed at a predetermined ratio to obtain a mixture. As described above, the rubber particles 13 include the core portion 14 and the outer shell portion 15 that covers the core portion 14. The mixing can be carried out, for example, using a mixer such as a mixer or a mixer.

In the step B1, the mixture obtained in the step A1 is heated at a temperature in the range of 60 ° C or more and 160 ° C or less while kneading. When the heating temperature is lower than 60 ° C, the mixture obtained in the step A1 becomes a solid or a liquid having a very high viscosity, which may adversely affect the kneading property. If the heating temperature exceeds 160 ° C, the mixture obtained in the step A1 may cause thermal polymerization in the kneading step. The kneading can be carried out, for example, using a kneading machine such as a pressure kneader, a heating roll machine, or an extruder.

In the step C1, the heat-kneaded mixture obtained in the 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 or the like.

Light Reflector The light reflector 1 contains a cured product of a molded material for a light reflector. The light reflector 1 includes a peripheral wall 10 and a recess 11 surrounded by the peripheral wall 10. The peripheral wall 10 includes a portion having a thickness of 100 μm or less. As described above, the molding material for a light reflector contains a thermosetting resin and a white fiber material. As described above, the light reflector 1 contains a cured product of a molding material for a light reflector, and the molding material for the light reflector contains a thermosetting resin and a white fiber material. Therefore, even if the light reflector 1 has a portion having a small thickness, it has high strength and high toughness despite a small amount of glass fiber or no glass fiber. Further, the light reflector 1 has good heat discoloration resistance and light reflectivity.

An example of the light reflector 1 is shown in Figs. 1, 2A and 2B. In FIGS. 1, 2A, and 2B, the directions indicated by the X, Y, and Z arrows refer to directions orthogonal to each other. Hereinafter, the direction indicated by the X arrow is referred to as the X-axis direction, the direction indicated by the Y arrow is referred to as the Y-axis direction, and the direction indicated by the Z-arrow is referred to as the Z-axis direction.

The light reflector 1 is, for example, an LED reflector, a laser reflector, or the like. As shown in FIG. 2A and FIG. 2B, the light reflector 1 can be accommodated in a space of X ₁ (0.8~1.2 mm)×Y ₁ (2.8~3.2 mm)×Z ₁ (0.25~0.40 mm), that is, a square body. In the space, the size X _{1 of} the square body in the X-axis direction is in the range of 0.8 mm or more and 1.2 mm or less, and the dimension Y ₁ in the Y-axis direction is in the range of 2.8 mm or more and 3.2 mm or less and the Z-axis The dimension Z _{1 of the} direction is in the range of 0.25 mm or more and 0.40 mm or less, but is not limited to this size. The light reflector 1 contains a cured product of the above-described molding material for a light reflector. The light reflector 1 is obtained by curing the above-mentioned light reflector with a molding material. Ideally, the light reflector 1 is formed by compression molding, transfer molding, or injection molding, and the light reflector is molded and cured.

The base 40 includes a light reflector 1 and a lead 2 . The lead 2 is buried in the light reflector 1. The lead 2 has internal terminals 211, 221 and external terminals 212, 222.

The lead 2 is electrically conductive. The lead 2 is usually made of metal. The lead wire 2 can be obtained by processing a copper plate having a thickness of, for example, 10 cm or more and 50 cm or less and a thickness of 0.05 mm or more and 1.00 mm or less into a predetermined shape, followed by surface treatment such as tin plating, nickel plating, or silver plating. The inner terminals 211, 221 are exposed in the inner surface 8 of the recess 11 of the light reflector 1 (refer to Fig. 2A). The external terminals 212 and 222 are in a state of protruding from the outer surface 9 of the light reflecting body 1 (refer to FIG. 1).

As shown in FIGS. 2A and 2B, the light reflector 1 is provided with a peripheral wall 10 and a recess 11. The peripheral wall 10 is a cylindrical wall. The recess 11 is surrounded by the peripheral wall 10. In detail, the light reflector 1 has the first molded portion 101 and the second molded portion 102. In the above, the first molded portion 101 includes the peripheral wall 10 and the recess 11 . The second molding portion 102 and the first molding portion 101 are laminated and integrated in the X-axis direction, and the lead wires 2 are interposed between the second molding portion 102 and the first molding portion 101. As described above, the first molded portion 101 of the light reflector 1 has the recess 11. The recess 11 is opened in the X-axis direction. In other words, the direction in which the recess 11 opens is the X-axis direction. The peripheral wall 10 is composed of the upper wall portion 18 and the lower wall portion 19 facing the Z-axis direction and the two side wall portions 20 facing the Y-axis direction. The thickness Y ₂ of the front end portion of the peripheral wall 10 (the portion farther from the bottom surface 17 of the recess 11) is preferably 25 μm or more and preferably 100 μm or less. The peripheral wall 10 includes, for example, a portion having a thickness of 100 μm or less. In the present embodiment, in particular, the front end portion of the upper wall portion 18 and the lower wall portion 19 is a thin portion having a thickness of 100 μm or less. As shown in FIG. 3A, the recess 11 is surrounded by the upper wall portion 18 and the lower wall portion 19 and the two side wall portions 20. As shown in FIG. 3A and the like, the opening shape of the recess 11 is convex when viewed from the direction opposite to the X-axis direction, but is not limited to this shape. As shown in Fig. 2A, the lead 2 is exposed in the inner face 8 (especially the bottom face 17) of the recess 11. The inner surface 8 of the recess 11 is composed of a bottom surface 17 and an inner circumferential surface 12. The inner surface 8 of the recess 11 includes a reflecting surface 23, and at least the inner peripheral surface 12 includes a reflecting surface 23. The depth of the recess 11 is the distance X ₁₀₁ from the bottom surface 17 of the recess 11 to the X-axis direction between the openings. X _{101 is, for} example, in the range of 0.3 mm or more and 0.4 mm or less. The lead 2 is provided with a first lead 21 and a second lead 22. The first lead 21 includes an internal terminal 211 that is exposed at the bottom surface 17 of the recess 11 and an external terminal 212 that protrudes from the outer surface 9 of the light reflector 1 toward the outside of the light reflector 1 . The second lead 22 also includes an internal terminal 221 that is exposed at the bottom surface 17 of the recess 11 and an external terminal 222 that protrudes from the outer surface 9 of the light reflector 1 toward the outside of the light reflector 1 . As shown in FIG. 3A, the two external terminals 212, 222 protrude in the same direction (Z-axis direction). The two external terminals 212 and 222 may protrude in a direction orthogonal to the direction in which the opening of the recess 11 faces (the X-axis direction), or may protrude obliquely in a direction (X-axis direction) in which the opening of the recess 11 faces.

In the light reflector 1 described above, the volume of the first molded portion 101 (excluding the volume of the recess 11) is smaller than the volume of the second molded portion 102. Further, in the first molded portion 101, the volume of the upper wall portion 18 and the lower wall portion 19 is smaller than the volume of the side wall portion 20. In particular, since the upper wall portion 18 and the lower wall portion 19 are portions having a small thickness, the white fiber material contained in the molding material for a light reflector at the time of molding tends to be aligned in the X-axis direction to cause anisotropy. The viscosity of the molding material for a light reflector containing a thermosetting resin at the time of molding is extremely low compared to a molding material containing a thermoplastic resin. Therefore, the white fiber material is easily aligned in a portion having a small thickness. Since the anisotropy is generated as described above, even a portion having a small thickness such as the upper wall portion 18 and the lower wall portion 19 (for example, a portion having a thickness of 100 μm or less or even 50 μm or less) can have high strength. Although the side wall portion 20 is less likely to generate anisotropy than the upper wall portion 18 and the lower wall portion 19, since the side wall portion 20 has a large volume, it can have high strength even if it is isotropic. Further, although the second molded portion 102 is less likely to generate anisotropy than the first molded portion 101, the second molded portion 102 has a large volume, so that it can have high strength even if it is isotropic.

The presence or absence of anisotropy can be confirmed by thermomechanical analysis (TMA) by measuring the flow direction of the molding material for the light reflector during molding and the linear expansion coefficient of the cured product in the direction perpendicular thereto. For example, in FIG. 2B, the flow direction is the X-axis direction, and the vertical direction is the Y-axis direction.

Method for Producing Light Reflector and Substrate The method for producing the light reflector 1 and the substrate 40 includes, for example, a process of forming a light reflector 1 by molding a light reflector. The forming method is, for example, compression molding, transfer molding or injection molding. When the light reflector 1 is produced, the light reflector 1 and the lead 2 are integrated such that one of the leads 2 protrudes from the light reflector 1.

The manufacturing method of the present embodiment may include a process in which the lead frame 200 including the lead wires 2 of the frame 170 and the connection frame 170 is used in the production of the light reflector 1, and the lead 2 is formed after the light reflector 1 is fabricated. Block 170 is cut away. The configuration of the lead frame 200 will be described in detail later.

The manufacturing method of this embodiment may include a process of bending the lead 2 after fabricating the light reflector.

In the present embodiment, even if the light reflector 1 has a portion having a small thickness as described above, it has high strength and high toughness although the glass fiber content is small or glass fiber is not contained. Therefore, the method of manufacturing the light reflector 1 and the substrate 40 includes a process of cutting the lead 2 from the frame 170 and bending the lead 2, so that even if pressure is applied to the light reflector 1, the light reflector 1 is not easily cracked. Breakage, etc.

Specifically, the method of manufacturing the light reflector 1 includes, for example, the following steps A2 and B2. In the following, a method of manufacturing the light reflector 1 shown in Figs. 1, 2A, and 2B will be specifically described, but the light reflector 1 is not limited to the one shown in Figs. 1, 2A, and 2B.

In the step A2, the above-mentioned molding material for a light reflector is prepared. The molding material for the light reflector can be produced in the above manner.

Step B2 is a method of compression molding, transfer molding, or injection molding, whereby the light reflector prepared in the step A2 is cured by the molding material to be integrated with the lead 2, and a part of the lead 2 is cured from the molding material for the light reflector. protruding.

An example of the lead frame 200 is shown in FIG. 5A. The lead frame 200 can be used to manufacture the light reflector 1 and the substrate 40. The lead frame 200 is electrically conductive and is usually made of metal. The lead frame 200 shown in FIG. 5A is used for a multi-cavity, and has a frame 170 having a plurality of lattices and leads 2 of a plurality of connection frames 170. In Figure 5A, block 170 has 20 grids. One grid is the smallest unit. Each grid is provided with a lead 2. Each lead 2 has a first lead 21 and a second lead 22. The first lead 21 has an internal terminal 211 and an external terminal 212. The second lead 22 has an internal terminal 221 and an external terminal 222.

In the compression molding, the lead frame 200 and the light-reflecting body molding material are placed in a mold that has been heated to a suitable temperature, and the mold is closed and then heated and pressurized.

In the transfer molding system, the lead frame 200 is placed in a mold that has been heated to a suitable temperature, and a light reflector that has been fed into a portion called a pot is pressurized with a molding material and flows into the mold through the injection port, and is heated. Pressurized forming method.

In the injection molding system, the lead frame 200 is first placed in a mold that has been heated to a suitable temperature, and the optical reflector is pressed into the mold by a molding material using an injection molding machine. The molding conditions at this time are, for example, a drum temperature of 70 ° C or more and 90 ° C or less, an injection pressure of 5 MPa or more and 70 MPa or less, and a mold temperature of 150 ° C or more and 170 ° C or less. It can also be post-hardened according to the demand.

In addition, the injection molding system JIS industrial terminology dictionary (third edition) is described. One of the methods of injection molding into a thermoplastic resin and a thermosetting resin is a method in which a molding material is heated and melted in an injection drum, and a fluidized molding material is pressure-injected into a mold which is closed by an injection plunger or a screw. The technology used to form the mold. (JIS K 6900).

Then, the light reflector is molded and hardened by compression molding, transfer molding or injection molding in a mold, and a plurality of light reflectors 1 and a plurality of leads in the lead frame 200 can be respectively manufactured as shown in FIG. 5B. 2 Each is in an integrated state. In the grid of the frame 170 of each of the lead frames 200, a light reflector 1 containing a cured product of a molding material for a light reflector is formed, and the external terminals 212, 222 of one portion of the leads 2 are from the light reflector 1 protruding. The conventional molding material is likely to cause burrs, cracks, and breakage in the light reflector 1. However, in the case of the molding material for a light reflector of the present embodiment, generation of burrs, cracks, and breakage of the light reflector 1 can be suppressed.

After the light reflector is molded and cured by the molding material, the light reflector 1 and the lead frame 200 are taken out from the mold, and the lead frame 200 is cut at the position shown by a broken line in FIG. 5B, whereby the lead 2 can be cut away from the frame 170. Thereby, a plurality of light reflectors 1 combined with the lead wires 2 before the bending process as shown in Fig. 3A can be obtained.

It is preferable to perform deburring treatment on the light reflector 1. The deburring treatment includes, for example, one or more treatments selected from the group consisting of wet blasting, alkaline electrolysis, and alkaline solution treatment. The wet blasting treatment can be carried out by a known method using a wet blasting device. The alkaline electrolytic treatment can be carried out by a known method using an electrolytic deburring machine. The alkaline solution treatment can be carried out by, for example, treating the surface of the light reflector 1 with an alkaline solution such as an aqueous potassium hydroxide solution or an aqueous sodium hydroxide solution.

When the white fiber material is treated with a decane coupling agent, even if the glazing treatment is performed on the light reflector 1, the white fiber material is less likely to scatter from the surface of the light reflector 1 and is less likely to fall off, so that the surface roughness of the light reflector 1 can be suppressed. Therefore, the surface of the light reflector 1 can be easily kept smooth, so that the light reflectivity of the light reflector 1 can be highly maintained.

FIG. 6A shows a lead frame 200 according to another embodiment and a light reflector 1 integrally formed with the lead frame 200. The lead frame 200 has a frame 170, a lead 2 of the connecting frame 170, and a strut 180 of the pair of connecting frames 170.

Each of the stays 180 protrudes toward the side wall portion 20 of the light reflector 1. Each of the stays 180 slightly penetrates the light reflector 1 in the vicinity of the boundary between the first molded portion 101 and the second molded portion 102 (refer to FIG. 6B). The enlargement of the α portion of Fig. 6A is shown in Fig. 6F. As shown in Fig. 6F, the length 180 of the strut 180 that penetrates the portion of the light reflector 1 in the strut 180 in the protruding direction is, for example, in the range of 70 μm or more and 80 μm or less.

In addition, FIG. 7A shows an example of the relationship between the light reflector 1 and the strut 180 when the light reflector 1 of FIG. 1 is manufactured using the lead frame 200 having the strut 180, and the same pattern as that of FIG. 6F is shown. However, the illustration of the external terminal 222 is omitted in FIG. 7A. Further, when the light reflector 1 similar to that of FIG. 1 is manufactured by the lead frame 200 including the support bar 180 as described above, a hole portion is formed in the light reflector 1 at a position where the stay 180 penetrates. 1, 2A, 3A to 3C, and 4A to 4C each show a light reflector 1 made using a lead frame 200 having no struts 180, so that the hole formed by the struts 180 is not marked. .

The distance D3 between the side surface of the strut 180 and the side surface of the light reflector 1 (refer to FIGS. 6F and 7B) is, for example, in the range of 30 μm or more and 40 μm or less. In addition, FIG. 7B corresponds to the light reflector 1 of FIG. 1, and shows the same appearance as that of FIG. 6F.

When the light reflector 1 is formed of a conventional molding material, when the struts 180 are removed, the γ portion in FIG. 7B is likely to be cracked or the like.

When the light reflector 1 is fabricated using the lead frame 200 having the struts 180, the light reflector 1 is suspended by a pair of struts 180. The light reflector 1 can be subjected to deburring in this state. After the burr processing, the lead frame 200 is cut away from the frame 170 by the position of the broken line shown in FIGS. 6A and 6C, and the struts 180 can be removed from the light reflector 1. Thereby, the light reflector 1 combined with the lead 2 before the bending process can be obtained. The conventional molding material is likely to cause cracks and breakage of the light reflector 1 when the struts 180 are removed. However, in the case of the molding material for a light reflector of the present embodiment, cracks and breakage of the light reflector 1 can be suppressed. In addition, in Fig. 6C, reference numeral 30 is a gate mark. The gate mark 30 is a protrusion formed on the light reflector 1 by a gate mark, and the gate is an injection port into which the resin is injected into the mold cavity.

The method of manufacturing the light reflector 1 may further include the following step C2.

In step C2, one of the leads 2 protruding from the light reflector 1 of the cured product of the molding material is cut or bent. The lead frame 200 including the cutting of the plurality of cavities is cut. The bending step of step C2, that is, the terminal bending step, will be described below.

As shown in FIG. 3A, the external terminals 212, 222 which are a part of the lead 2 protrude from the light reflecting body 1. The external terminals 212, 222 are bent so as to be opposed to the surface of the light reflector 1 in a manner as shown in FIGS. 3B and 3C. The arrows in Figures 3B and 3C indicate the direction in which the external terminals 212, 222 of the lead 2 are bent. In this manner, by bending the external terminals 212 and 222 of the lead 2, the lead 2 after the bending process and the light reflector 1 combined therewith can be obtained. Further, in the bending process, the outer terminals 212, 222 of the lead 2 may be bent as shown in Figs. 4A to 4C.

When the lead frame 200 that is integrated with the light reflector 1 is cut as described above, or the lead 2 that is integrated with the light reflector 1 is bent, the light reflector 1 is given a large amount. Load. On the other hand, when the light reflector 1 is made of a conventional molding material, it is easy to cause damage to the light reflector 1 such as burrs, cracks, and breakage during the cutting or bending of the lead frame 200. It is particularly easy to generate cracks and the like in the ? portion in Fig. 3B. In contrast, when the light reflector 1 is formed from the molding material for a light reflector of the present embodiment, the light reflector 1 has high toughness and high strength, so that the lead frame 200 can be cut or bent. The light reflector 1 is suppressed from being damaged by burrs, cracks, breaks, and the like. In particular, even if the light reflector 1 has a small thickness portion, since the light reflector 1 has moderate elasticity and high strength, the light reflector 1 is less likely to be broken when the lead frame 200 is cut or the terminal is bent. The light-emitting device 6 can be manufactured using such a light reflector 1.

The method of manufacturing the light reflector 1 may also include the following step C3 instead of the step C2.

In the step C3, the lead 2 protruding from the light reflector 1 of the cured product of the light-reflecting material is cut and bent. The lead frame 200 including the cutting of the plurality of cavities is cut. At the same time as the cutting, the external terminals 212 and 222 protruding from the light reflecting body 1 are bent so as to be opposed to the surface of the light reflecting body 1 as shown by the arrows in FIGS. 3B and 3C. In this way, by bending the outer terminals 212 and 222 of the lead 2, the light reflector 1 combined with the lead 2 after the bending process can be obtained.

When the lead frame 200 that is integrated with the light reflector 1 is cut as described above, the lead wire 2 that is integrated with the light reflector 1 is subjected to bending processing, and the light reflector 1 is given a large amount. Load. On the other hand, if the light reflector 1 is formed of a conventional molding material, the cutting and bending are performed at the same time, and the light reflector 1 is likely to be damaged by burrs, cracks, breakage, or the like. In contrast, when the light reflector 1 is formed of the molding material for a light reflector of the present embodiment, the light reflector 1 has high toughness and high strength, so that damage to the light reflector 1 such as burrs, cracks, and breakage can be suppressed. . In particular, even if the light reflector 1 has a small thickness portion, since the light reflector 1 has moderate elasticity and high strength, the light reflector 1 is less likely to be broken when the lead frame 200 is cut and the terminal is bent at the same time. The light-emitting device 6 can be manufactured using such a light reflector 1.

Light Emitting Device The light emitting device 6 includes a light reflecting body 1 and a light emitting element 3. An example of the light-emitting device 6 including the light reflector 1 is shown in Figs. 1, 2A and 2B. The light-emitting device 6 includes a light reflector 1, a light-emitting element 3, and a lead 2. In this example, the light reflector 1 and the lead 2 are combined such that the lead 2 is buried in the light reflector 1. The configuration of the light reflector 1, the base 40, and the light-emitting device 6 manufactured by the molding material for a light reflector of the present embodiment is not limited to this example.

The light-emitting element 3 is, for example, a light-emitting diode (LED) or a laser diode (LD), but is not limited thereto. As shown in FIGS. 2A and 2B, the light-emitting element 3 is electrically connected to the internal terminal 221 exposed at the bottom surface 17 of the recess 11 and is mounted inside the recess 11 of the light reflector 1. Specifically, the light-emitting element 3 is electrically connected to the internal terminal 211 of the first lead 21 by the metal wire 41.

That is, the light-emitting device 6 includes the base 40 and the light-emitting element 3, and the light-emitting element 3 is electrically connected to the internal terminal 221 of the lead 2 and mounted inside the recess 11 of the light reflector 1. The light reflector 1 shown in Figs. 2A and 2B is of a side view type (sidelight type), and has a shorter distance D1 from the light-emitting element 3 to the inner peripheral surface 12 of the recess 11 than the plan view type (upper light-emitting type). a lot of. For example, the distance D1 is in the range of 0.01 mm or more and 0.15 mm or less (10 μm or more and 150 μm or less). As described above, if the distance D1 is short, for example, when the peripheral wall 10 is formed of a conventional molding material, it is likely to be deteriorated by the light L emitted from the light-emitting element 3. Further, when the thickness of the peripheral wall 10 is small, the light L emitted from the light-emitting element 3 easily penetrates the peripheral wall 10 and leaks to the outside. In the present embodiment, the problem that the light reflector 1 is deteriorated by light L and light leakage is solved is solved.

In other words, in the present embodiment, since the molding material for a light reflector contains a thermosetting resin, the shortest distance between the light-emitting element 3 and the inner peripheral surface 12 of the recess 11 is 0.15 as long as the distance D1 is as described above. Below mm, it is also possible to suppress deterioration of the peripheral wall 10 due to the light L. In other words, the shortest distance between the light-emitting elements 3 to the inner peripheral surface 12 of the recess 11 is preferably 0.15 mm or less. In this case, the light reflector 1 can be downsized, and even if it is miniaturized in this manner, the light reflector 1 can be prevented from being deteriorated by the light L in the present embodiment. Further, when the molding material for a light reflector contains a thermosetting resin, the content of the filler material can be relatively increased to reduce the content of the thermosetting resin. Therefore, deterioration of the peripheral wall 10 by the light L can be further suppressed. Further, when the glass fiber content is 0% by mass or more and 10% by mass or less based on the total amount of the molding material for the light reflector, the light passage which the glass fiber can form can be greatly reduced, whereby the light reflector 1 has a small thickness. The portion of the light reflector 1 can also suppress light leakage, and the light reflector 1 can have high light reflectivity.

As shown in FIGS. 2A and 2B, at least one portion of the inner peripheral surface 12 of the recess 11 is inclined toward the bottom surface 17 of the recess 11 so as to face the opening side of the recess 11. That is, a part or all of the inner peripheral surface 12 of the recess 11 can function as the reflecting surface 23, that is, the light L emitted from the light-emitting element 3 is reflected toward the opening side of the recess 11. Therefore, the light L emitted from the light-emitting element 3 is easily reflected on the inner peripheral surface 12 of the recess 11 of the light reflector 1. As a result, the extraction efficiency of the light L from the light-emitting device 6 can be improved. Further, the bottom surface 17 of the recess 11 can also function as the reflecting surface 23.

The light-emitting element 3 can also be sealed with the sealing material 5 by filling the sealing material 5 in the recess 11 of the light-emitting device 6. At this time, the sealing member 5 can protect the light-emitting element 3 from external gas or the like.

The sealing material 5 can be produced, for example, from a resin composition for sealing. The resin composition for sealing may, for example, contain one selected from the group consisting of epoxy resins, modified epoxy resins, polyoxyxylene resins, modified polyoxyxylene resins, acrylate resins, and urethane resins. The above resins are used as thermosetting resins.

The sealing material 5 may also contain a fluorescent substance as needed. That is, the resin composition for sealing may also contain a fluorescent substance. At this time, the hue of the light L emitted from the light-emitting device 6 can be controlled by the fluorescent substance.

As shown in FIG. 1, the light reflector 1 of the present embodiment can be mounted on a substrate 7, for example. At this time, for example, the external terminals 212, 222 of the light reflector 1 may be soldered or the like to be connected to the terminals 71, 72 located on one surface 73 of the substrate 7. Thereby, the light reflector 1 can be supported by the substrate 7 while being electrically connected to the substrate 7. The light reflector 1 shown in Fig. 1 is of a side view type (sidelight type). That is, when the light reflector 1 is mounted on the substrate 7, the opening of the recess 11 of the light reflector 1 faces the direction of the surface 73 supporting the light reflector 1 along the substrate 7, from the light reflector 1 toward The direction of the face 73 is illuminated.

Here, the inventors obtained the following findings. The light reflectance is determined by the thickness of the light reflecting body 1 where the light reaches. When the thickness is increased, the light reflectance is increased, and when the thickness is small, the light reflectance is lowered. In fact, the inventors conducted experiments using the molding materials for light reflectors of the present embodiment and known molding materials (nylon or the like) to prepare samples having various thicknesses. As a result, it was found that the thickness of the sample was reduced to about 400 μm, and the light reflectance of the sample made of the conventional molding material was drastically lowered. On the other hand, the sample made of the molding material for a light reflector of the present embodiment can maintain the light reflectance at a high level. In addition, the scratches caused by the glass fibers were also found to be the cause of the decrease in light reflectance. The scratch is a stain generated when the glass fiber comes into contact with the mold. From this point of view, it is preferable that the molding material for the light reflector does not contain glass fibers. Even if the molding material for a light reflector contains glass fibers, the glass fiber content is preferably 10% by mass or less based on the total amount of the molding materials for the light reflector. At this time, not only the light passage which the glass fiber may form can be reduced, but also the generation of scratches due to the glass fiber (especially the stain of the reflecting surface 23) can be suppressed, and the light reflectivity of the light reflector 1 can be improved. Therefore, even if the light reflector 1 has a portion having a small thickness, the light reflector 1 can have a high degree of light reflectivity.

In particular, the side view type light reflector 1 shown in FIGS. 1 , 2A, and 2B is reduced in size and thickness. For example, in the vicinity of the opening of the recess 11 of the light reflector 1, the thickness of the upper wall portion 18 and the lower wall portion 19 is extremely small. In this manner, although the light reflector 1 is small and has a small thickness portion, in the present embodiment, since the light reflector 1 contains a white fiber material (preferably a white fiber material treated with a decane coupling agent), the white The fibrous material can suppress light penetration and simultaneously increase the strength of the light reflector 1. Further, especially when the light reflector 1 contains the core outer shell type rubber particles 13, the rubber particles 13 greatly contribute to low elasticity, and the toughness of the light reflector 1 can be further improved.

For example, the minimum thickness of the peripheral wall 10 surrounding the recess 11 in the light reflector 1 may be in the range of 30 μm or more and 200 μm or less, or may be 100 μm or less. In particular, the thickness of the front end portion of the upper wall portion 18 and the lower wall portion 19 of the peripheral wall 10 (the portion farther from the bottom surface 17 of the recess 11) may be in the range of 20 μm or more and 60 μm or less, and more preferably 25 μm or more and 50 μm or less. The thickness of the root portion of the upper wall portion 18 and the lower wall portion 19 (the portion closer to the bottom surface 17 of the recess 11) may be in the range of 40 μm or more and 70 μm or less, and may be in the range of 45 μm or more and 60 μm or less. . As described above, even if the light reflector 1 has a small thickness portion, the light reflector 1 can have high toughness and high strength and high light reflectivity at the same time.

EXAMPLES Hereinafter, the present invention will be specifically described by way of examples. However, the invention is not limited by the following examples. <Molding Material for Manufacturing Light Reflector> The following materials were used as constituent components of the molding material for a light reflector.

(1) Thermosetting Resin (1-1) Unsaturated Polyester Resin (1-1-1) Unsaturated Alkyd Resin and p-Toluene-Based Unsaturated Alkyd Resin (manufactured by Japan U-Pica Co., Ltd.) "U-Pica 8552") (1-1-2) Crosslinking agent and diallyl citrate prepolymer ("DAP Polymer" manufactured by OSAKA SODA CO., LTD.) (1-2) Epoxy resin Tripolyglycidyl isocyanate ("TEPIC-S" manufactured by Nissan Chemical Industries, Ltd., epoxy equivalent 100 g/eq) (1-3) Phenol resin / phenolic phenol resin ("Manufactured by Panasonic Co., Ltd." PDR"), weight average molecular weight 4000 to 5000 The above thermosetting resins all have double bonds.

(2) Polymerization initiator ・Polymerization initiator 1: Dicumyl peroxide (Percumyl D-40, manufactured by Nippon Oil Co., Ltd., 40% masterbatch) ・Polymerization initiator 2: hexahydrophthalic anhydride (new "RIKACID HH" manufactured by Nippon Chemical and Chemical Co., Ltd.) ・Polymerization initiator 3: hexamethylenetetramine (manufactured by MITSUBISHI GAS CHEMICAL COMPANY, INC.)

(3) Filling material (3-1) Inorganic filler and cerium oxide ("FB-820" manufactured by Denka Co., Ltd., fused cerium oxide, average particle size 25 μm) (3-2) White pigment, oxidation Titanium (Tioxide R-TC30, rutile type titanium oxide, average particle size 0.4 μm made by Tioxide Japan KK)

(4) Release agent Zinc stearate ("SZ-P" manufactured by Suga Chemical Industry Co., Ltd.)

(5) Rubber particles and rubber particles 1: "S2001" manufactured by Mitsubishi Rayon Co., Ltd., core portion: polyoxyxene rubber, outer shell portion: acrylic rubber, average particle diameter 200 μm, elastic modulus at 25 ° C 0.1 GPa・Rubber particle 2: "S2200" manufactured by Mitsubishi Rayon Co., Ltd., core part: polyoxyxene rubber, outer shell: epoxy resin, average particle diameter of 200 μm, elastic modulus at 25 ° C, 0.5 GPa, rubber particle 3 : "C-223A" manufactured by Mitsubishi Rayon Co., Ltd., core portion: butadiene rubber, outer shell portion: acrylic rubber, average particle diameter: 200 μm, elastic modulus at 25 ° C, 0.2 GPa, rubber particle 4: Mitsubishi Rayon "W-377" manufactured by Co., Ltd., core portion: acrylic rubber, outer casing: acrylic rubber, average particle diameter: 200 μm, elastic modulus at 25 ° C, 0.8 GPa, rubber particle 5: "EXL, The Dow Chemical Company" -2311", core portion: acrylic rubber, outer shell portion: styrene, average particle diameter 200 μm, elastic modulus at 25 ° C 1.0 GPa The above rubber particles all have a core outer shell structure.

(6) Fibrous material and fiber material 1: 矽 矽 ( (“SH800” manufactured by KINSEI MATEC CO., LTD., average fiber length 130 μm, average fiber diameter 6.5 μm, aspect ratio 20) The fiber material and the fiber material 2 obtained by the surface treatment of decane: 矽 矽 ( (SH800, manufactured by KINSEI MATEC CO., LTD., average fiber length 130 μm, average fiber diameter 6.5 μm, aspect ratio 20) The fiber material and the fiber material 3 obtained by the surface treatment of the decyl hydride. The ash stone (the FPW #800, manufactured by KINSEI MATEC CO., LTD.) having an average surface length of 12 μm and an average Fiber diameter: 4 μm, length to width ratio 3) ・Fiber material 4: Whisker which is surface-treated with methacrylonitrile-based decane (Tismo N, manufactured by Otsuka Chemical Co., Ltd., average fiber length 20 μm, average fiber diameter) 0.6 μm, aspect ratio 33) ・Fiber material 5: Needle-shaped alumina without surface treatment (Serra-sur BMI, manufactured by Hohhot Lime Industry Co., Ltd.), average fiber length 6 μm, average fiber diameter 1 μm, length and width Than 6) ・Fiber 6: Benzene decyl decane Needle-shaped alumina (Serra-sur BMI, manufactured by Hohhot Lime Industry Co., Ltd., average fiber length 6 μm, average fiber diameter 1 μm, aspect ratio 6) ・Fiber material 7: methacrylic acid-based A scaly alumina treated with decane ("Serra-sur BMT" manufactured by Kahe Lime Industrial Co., Ltd., average fiber length 9 μm, average fiber diameter 0.3 μm, aspect ratio 30)

(7) Reinforcing material and glass fiber ("CS 3J-261S" manufactured by Nitto Bose Co., Ltd.) The materials shown in the column of Tables 1 to 4 are mixed using a mixer, and the amounts are as shown in Tables 1 to 4. Mix to obtain a mixture.

Next, the mixture was heated at a temperature of 60 ° C or more and 160 ° C or less using a pressure kneader while kneading.

Next, the mixture obtained by heating and kneading was processed into pellets using a granulator to obtain a molding material for a light reflector. <Evaluation method> (bending strength and flexural modulus)

A test piece according to JIS K 6911 was produced by injection molding using a molding material for a light reflector. The molding conditions were a drum temperature of 80 ° C, an injection pressure of 40 MPa, a mold temperature of 160 ° C, and a holding time of 180 seconds. The bending strength and flexural modulus of the obtained test piece at 25 ° C were measured in accordance with JIS K 6911. (initial light reflectance)

The light-reflecting body molding material 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 prepare a test piece having a thickness of 1 mm. The initial light reflectance of the obtained test piece at a wavelength of 460 nm was measured by a reflectance measuring instrument (a spectrophotometer manufactured by Nippon Denshoku Industries Co., Ltd.). (heat resistant discoloration)

After the test piece in which the initial light reflectance was measured was heated at 150 ° C for 1,000 hours, the light reflectance of the test piece was measured again by a reflectance measuring instrument (Spectrophotometer manufactured by Nippon Denshoku Industries Co., Ltd.). The measurement results were judged on the basis of the following criteria. "◎": light reflectance is 85% or more "○": light reflectance is 80% or more and less than 85% "△": light reflectance is 75% or more and less than 80% "×": light reflectance Less than 75% (light concealment)

The light-reflecting body molding material 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 prepare a test piece having a thickness of 100 μm. The light transmittance of the obtained test piece at a wavelength of 460 nm was measured by a reflectance measuring instrument (a spectrophotometer manufactured by Nippon Denshoku Industries Co., Ltd.). The measurement results were judged on the basis of the following criteria. Further, the lower the light transmittance, the more the light is penetrated into the portion having a small thickness when the light reflector is formed from the molding material for the light reflector, so that the light reflectance is less likely to be smaller and thinner with the light reflector. And lower. "◎": 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)

The lead frame shown in FIG. 5A was prepared, and the light-reflecting body molding material was 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 while the lead frame was mounted on a mold. Thereby, the light reflector can be manufactured as shown in FIG. 5B while the light reflector is integrated with the lead frame. The light reflector and the lead frame are taken out from the mold, and the lead frame is cut at a position shown by a broken line in Fig. 5B, and the lead is cut away from the frame of the lead frame. The thickness of the smallest portion of the light reflector is 30 μm. Confirm whether or not the light reflector is not filled. From the results, the thin wall filling property was evaluated in the following manner.

"◎": No light reflector was found to be filled.

"○": The portion of the light reflector having a thickness of 40 μm or less was found to be unfilled, and the portion having a thickness of more than 40 μm was not found to be unfilled.

"△": The portion where the thickness of the light reflector is larger than 40 μm and 60 μm or less is not filled, and the portion having a thickness of more than 60 μm is not found to be unfilled.

"X": The portion where the thickness of the light reflector is larger than 60 μm and 0.1 mm or less is not filled, and the portion having a thickness of more than 0.1 mm is not found to be unfilled. (fiber alignment)

The light reflector was cut along the surface in which the light reflector was flowed in the direction in which the light reflector was formed, and the formed cross section was observed by a scanning electron microscope. Further, when the light reflector is produced, the light reflector is cut on the surface orthogonal to the flow direction of the light reflector for the molding material, and the formed cross section is observed by a scanning electron microscope. Based on these results, it was confirmed whether or not the fiber material in the light reflector was aligned. As a result, the fiber alignment was evaluated as "having" when the alignment was found, and "none" was found when the alignment was not found. (lead bending resistance)

A 480 sample having a light reflector and a lead was produced using a lead frame having 480 grids. For each sample, the lead was bent in a state where the light reflector was fixed, as shown in FIGS. 3A to 3C, and the light reflector was observed under a microscope to confirm the presence or absence of cracks. From the results, the lead bending resistance was evaluated in the following manner.

"◎": All samples were not found to have cracks in the light reflector.

"○": One or more and five or less samples were found to have cracks in the light reflector.

"△": Six or more and ten or less samples were found to have cracks in the light reflector.

"X": More than 11 samples were found to have cracks in the light reflector.

[Table 1]

[Table 2]

[table 3]

[Table 4]

1‧‧‧Light reflector

2‧‧‧ lead

3‧‧‧Lighting elements

5‧‧‧ Sealing material

6‧‧‧Lighting device

7‧‧‧Substrate

8‧‧‧ inside

9‧‧‧ outside

10‧‧‧Wall

11‧‧‧ recess

12‧‧‧ inner circumference

13‧‧‧ rubber particles

14‧‧‧ Kernel Department

15‧‧‧ Shell Department

16‧‧‧Graft chain

17‧‧‧ bottom

18‧‧‧Upper wall

19‧‧‧ Lower Wall

20‧‧‧ Sidewall

21‧‧‧First lead

22‧‧‧second lead

23‧‧‧reflecting surface

30‧‧‧Spot mark

40‧‧‧ base

41‧‧‧Metal wire

71, 72‧‧‧ terminals

73‧‧‧ Face

101‧‧‧1st forming department

102‧‧‧2nd forming department

170‧‧‧ box

180‧‧‧ pole

200‧‧‧ lead frame

211‧‧‧Internal terminals

212‧‧‧External terminals

221‧‧‧Internal terminals

222‧‧‧External terminals

D1, D3‧‧‧ distance

D2‧‧‧ size

L‧‧‧Light

X101‧‧‧ distance

X1‧‧‧ size

Y1‧‧‧ size

Z1‧‧‧ size

Fig. 1 is a perspective view showing a light-emitting device and a substrate including a light reflector according to an embodiment of the present invention. In Fig. 1, the X-axis, the Y-axis, and the Z-axis indicate directions orthogonal to each other. 2, FIG. 2A is a cross-sectional view taken along line A-A of the light-emitting device of FIG. 1. 2B is a cross-sectional view taken along line B-B of the light-emitting device of FIG. 1. In FIGS. 2A and 2B, the X axis, the Y axis, and the 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 a bending process of a lead wire combined with a light reflector. In FIGS. 3A to 3C, the X axis, the Y axis, and the 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 of a lead which has been combined with a light reflector. In FIGS. 4A to 4C, the X-axis, the Y-axis, and the 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 plan view showing the lead frame of Fig. 5A and a light reflector integrally formed with the lead frame. Fig. 6 is a plan view showing a lead frame and a light reflector integrally formed with the lead frame according to another embodiment of the present invention. Figure 6B is a cross-sectional view taken along line C-C of Figure 6A. Figure 6C is a bottom view of Figure 6A. Figure 6D is a side view of Figure 6A. Figure 6E is a cross-sectional view taken along line D-D of Figure 6A. Fig. 6F is an enlarged view of the α portion in Fig. 6A. In Fig. 7, Fig. 7A is a plan view showing a light reflector suspended by a strut. Fig. 7B is a perspective view showing a light reflector suspended by a strut. Fig. 8 is a schematic cross-sectional view of rubber particles.

Claims (22)

A light reflector comprising a cured product of a molding material for a light reflector, and includes a peripheral wall and a recess surrounded by the peripheral wall; the peripheral wall includes a portion having a thickness of 100 μm or less, and the molding material for the light reflector contains a thermosetting resin And white fiber. The light reflector of claim 1, wherein the white fiber material comprises a limestone. The light reflector of claim 1 or 2, wherein the white fiber material has an aspect ratio in the range of 3 or more and 500 or less. The light reflector of claim 1 or 2, wherein the content of the white fiber material in the molding material for a light reflector is 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. Inside. The light reflector of claim 1 or 2, wherein the forming material for the light reflector does not contain glass fibers or contains glass fibers and the total amount of the glass fibers is 10 masses with respect to the total amount of the forming materials for the light reflectors. %the following. A light reflector according to claim 1 or 2, wherein the aforementioned white fiber material is treated with a decane coupling agent. The light reflector of claim 1 or 2, wherein the light reflector molding material further contains rubber particles, and the rubber particles have an inner core portion and an outer shell portion covering the inner core portion. The light reflector of claim 7, wherein the outer shell portion is reactive with the thermosetting resin. The light reflector of claim 7, wherein the content of the rubber particles in the molding material for a light reflector is in a range of 0.1% by mass or more and 30% by mass or less based on the total amount of the molding material for the light reflector. The light reflector of claim 7, wherein the rubber particles have an average particle diameter in a range of 0.1 μm or more and 1 mm or less. The light reflector of claim 7, wherein the core portion contains one or more components selected from the group consisting of polyoxyxene rubber, acrylic rubber, and butadiene rubber. The light reflector of claim 7, wherein the rubber particles have an elastic modulus of 1 GPa or less at 25 °C. The light reflector of claim 1 or 2, wherein the cured product of the molding material for the light reflector has a bending strength at 25 ° C of 70 MPa or more. The light reflector of claim 1 or 2, wherein the cured product of the shaped material for the light reflector has a flexural modulus at 25 ° C in the range of 4 to 15 GPa. The light-reflecting body of claim 1 or 2, wherein the thermosetting resin contains one or more components selected from the group consisting of unsaturated polyester resins, epoxy resins, and phenol resins. The light reflector of claim 1 or 2, wherein the depth of the recess is in a range of 0.3 mm or more and 0.4 mm or less. A substrate comprising: a light reflector according to any one of claims 1 to 16; and a lead embedded in the light reflector; wherein the lead has an internal terminal exposed on an inner surface of the recess and the light reflector External terminals protruding outside. A light-emitting device comprising the substrate of claim 17 and a light-emitting element, wherein the light-emitting element is electrically connected to the internal terminal of the lead and mounted inside the recess of the light reflector. The light-emitting device of claim 18, wherein the shortest distance between the light-emitting elements and the inner peripheral surface of the peripheral wall is 0.15 mm or less. A method for producing a substrate, comprising the method for producing a substrate according to claim 17, comprising the steps of: forming a light reflector by forming a light reflector, and forming the light reflector, and forming the light reflector The light reflector is partially integrated with the lead wire so as to protrude from the light reflector. A method of manufacturing a substrate according to claim 20, comprising: a lead frame used in the production of the light reflector, wherein the lead frame has a frame and the lead connected to the frame, and after the light reflector is fabricated The aforementioned lead wires are cut away from the aforementioned frame. The method for producing a substrate according to claim 20 or 21, further comprising the step of bending the lead wire after the light reflector is fabricated.