WO2021065767A1 - Lamp member resin composition, lamp member, and method for producing lamp member resin composition - Google Patents

Abstract

A lamp member resin composition according to the present invention comprises: as component (P), an aromatic polysulfone; and, as component (M), at least one type of substance selected from the group consisting of oxides, peroxides, multiple oxides, and carbonates of metals belonging to groups 1 and 2 of the long-form periodic table. The present invention also pertains to a lamp member molded from the lamp member resin composition.

Description

A method for producing a resin composition for a lamp member, a lamp member, and a resin composition for a lamp member.

The present invention relates to a resin composition for a lamp member that is suitably used as a molding material for a lamp member, a lamp member produced by using the resin composition for a lamp member, and a method for producing a resin composition for a lamp member.
The present application claims priority based on Japanese Patent Application No. 2019-182112 filed in Japan on October 2, 2019, the contents of which are incorporated herein by reference.

At present, polyetherimide is the mainstream as a material used for lamp members of automobiles and the like.
For example, in Patent Document 1, the reflective surface is made of a polyetherimide-based resin containing 0 to 10 parts by weight of glass fiber or an inorganic filler as a reflector for various floodlights such as headlamps of automobiles and the like. The reflector is disclosed.

Japanese Unexamined Patent Publication No. 2004-45883

However, even polyetherimide does not have sufficient heat resistance, and there is a demand for the development of a material having excellent heat resistance that can be applied to lamp members in place of polyetherimide.
As a result of the studies by the present inventors, it has been found that aromatic polysulfone, which has a higher glass transition temperature than polyetherimide and has excellent heat resistance, is a useful material for lamp members.

However, when the above aromatic polysulfone is applied to a lamp member exposed to high heat emitted from a light source, there is a problem that the lamp becomes cloudy.

The present invention has been made to solve the above-mentioned problems, and can be suitably used for a lamp member having excellent heat resistance characteristics and reducing the occurrence of fogging of the lamp, and for molding the lamp member. An object of the present invention is to provide a resin composition for a lamp member.

As a result of diligent studies to solve the above problems, the present inventors, together with aromatic polysulfones, oxides, peroxides, compound oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table. It has been found that the fogging of the lamp can be reduced by using at least one selected from the group consisting of, and the present invention has been completed.
That is, the present invention has the following aspects.

(1) Ingredients (P): Aromatic polysulfone and
Component (M): At least one selected from the group consisting of oxides, peroxides, double oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table.
A resin composition for a lamp member containing.
(2) The resin composition for a lamp member according to (1) above, wherein the reduced viscosity of the component (P) is more than 0.36 (dL / g) and 0.50 (dL / g) or less.
(3) The resin composition for a lamp member according to (1) or (2) above, wherein the component (M) is an oxide of a metal belonging to Group 1 or Group 2 in the long periodic table.
(4) The resin composition for a lamp member according to (3) above, wherein the component (M) is magnesium oxide.
(5) The above-mentioned (1) to (4), wherein the content of the component (M) is 0.5 to 10 parts by mass with respect to 100 parts by mass of the component (P). Resin composition for lamp members.
(6) A lamp member molded from the resin composition for a lamp member according to any one of (1) to (5) above.
(7) Ingredients (P): Aromatic polysulfone and
Component (M): At least one selected from the group consisting of oxides, peroxides, double oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table.
A method for producing a resin composition for a lamp member, which comprises a step of mixing.

According to the present invention, it is possible to provide a lamp member having excellent heat resistance characteristics and reducing the occurrence of fogging of the lamp, and a resin composition for the lamp member which can be suitably used for molding the lamp member.

It is a schematic diagram which shows an example of the structure of the lamp member of an embodiment. It is a graph which shows the result of having measured the apparent melt viscosity about the resin composition for a lamp member acquired in an Example.

Hereinafter, embodiments of the method for producing the resin composition for lamp members, the lamp member, and the resin composition for lamp members of the present invention will be described.

<< Resin composition for lamp members >>
The resin composition for a lamp member of the embodiment contains (P) component: aromatic polysulfone and (M) component: oxides, peroxides, and compound oxidations of metals belonging to Group 1 or Group 2 in the long periodic table. It contains at least one selected from the group consisting of substances and carbon oxides.

<Lamp member>
The lamp member of the embodiment can be molded from the resin composition for the lamp member.
Examples of the lamp including the lamp member of the embodiment include a lamp including a light source that emits light and heat at the time of lighting and a lamp member that surrounds the light source.

Examples of the type of the light source include a light emitting diode (LED), a halogen lamp, a HID lamp, and the like.

As the lamp including the lamp member of the embodiment, for example, it can be mounted on a vehicle such as an automobile, a motorcycle, a bicycle, or a train and can be used. Examples of the type of lamp include a headlamp.
The current headlamps are roughly classified into two types, a projector type and a reflector type, and the resin composition for a lamp member of the embodiment can be applied to either type.

For example, as a projector type lamp having the above configuration, as shown in FIG. 1, a lamp 1 including a light source 12 and a lamp member 3 can be exemplified. Examples of the lamp member 3 include a lens 14 that collects light emitted from a light source, a reflector 10 that reflects light emitted from a light source 12, and a lens holder 20 that fixes the lens 14.

The lamp member of the embodiment may further include a housing for accommodating a light source, a reflector, a lens, etc., a lens cover that covers the front surface of the lens and transmits light emitted from the light source, and the like.

The lamp member can be produced by using the resin composition for the lamp member of the embodiment as a molding material. The problematic fogging of the lamp is considered to be derived from the volatile components released from the lamp member in a high temperature environment, and it is presumed that a substance causing fogging adheres to the lens and the lens cover. Lenses and lens covers are often made of transparent resin materials, glass, and other materials that are prone to fogging in order to enhance light transmission, and glass lenses tend to be particularly prone to fogging.
The lamp member molded from the resin composition for the lamp member of the embodiment has excellent heat resistance characteristics and is unlikely to cause fogging of the lamp. Therefore, the lamp member is suitable as a member for surrounding a light source that emits light and heat when lit. ..

The lamp member of the present embodiment is molded from the resin composition for the lamp member. The lamp member of the present embodiment may be a molded body of the resin composition for the lamp member.

Examples of the method for manufacturing the lamp member include a method having a step of molding the resin composition for the lamp member of the embodiment into a shape corresponding to the lamp member.

As the molding method, melt molding is preferable, extruding molding, T-die molding, blow molding, injection molding and the like can be exemplified, and a molding method according to the shape of the member and the like can be selected to obtain a resin composition for a lamp member. It can be molded into a shape corresponding to the lamp member.
The shape corresponding to the lamp member refers to the shape of the lamp member, the shape of a part of the portion constituting the lamp member, the shape of the lamp member or a part thereof, or a shape to which an arbitrary structure is added.

The lamp member of the present embodiment is preferably an injection molded product using the above-mentioned resin composition as a forming material.

Examples of the method for manufacturing the lamp member include a method having a step of injection molding the resin composition for the lamp member of the embodiment into a shape corresponding to the lamp member.
For the lamp member, which is an injection-molded product, the resin composition for the lamp member is used, for example, at a mold temperature of 120 to 180 ° C. and a resin melting temperature of 330 to 400 ° C., using a general injection molding machine. It can be manufactured by injection molding. Since the lamp member of the embodiment uses the resin composition for the lamp member as the forming material, it has excellent heat resistance characteristics and can make the lamp less likely to be fogged.

<(P) component>
Hereinafter, the component (P): aromatic polysulfone contained in the resin composition for a lamp member will be described. Component (P): As the aromatic polysulfone, _{a structural unit containing at least a structure in which a sulfonyl group (-SO 2-} ), an arylene group (-Ar-) and an ether bond (-O-) are bonded in this order. Examples thereof include resins having.

Examples of the resin include a compound represented by the following general formula (I) and a compound represented by the following general formula (II).

(In the formula, R ¹ independently represents an alkyl group having 1 to 10 carbon atoms, an alkenyl group having 2 to 10 carbon atoms, an aryl group having 6 to 20 carbon atoms, or a halogen atom, and n1 is 0 to 4 of an integer, each R ¹ identical or different phenylene groups may be the same or different, each n1 identical or different phenylene groups may be the same or different from each other.)

(In the formula, R ² independently represents an alkyl group having 1 to 10 carbon atoms, an alkenyl group having 2 to 10 carbon atoms, an aryl group having 6 to 20 carbon atoms, or a halogen atom, and n2 is 0 to 4 ^{Each R 2} of the same or different phenylene groups may be the same or different from each other, and each n 2 of the same or different phenylene groups may be the same or different from each other.)

The alkyl group having 1 to 10 carbon atoms in R ¹ and R ² may be linear or branched, and may be, for example, a methyl group, an ethyl group, an n-propyl group, an isopropyl group or an n-butyl group. , Isobutyl group, s-butyl group, t-butyl group, n-hexyl group, 2-ethylhexyl group, n-octyl group, n-decyl group and the like.
The alkyl group in R ¹ and R ² is preferably an alkyl group having 1 to 6 carbon atoms.

In R ¹ and ^{R 2,} the alkenyl group having 2 to 10 carbon atoms, in the alkyl group exemplified in ^{R 1} and ^{R 2,} single bond between any one of the carbon atoms (C-C) is a double The one substituted with the bond (C = C) can be exemplified, and the position of the double bond is not limited.
Examples of the aryl group having 6 to 20 carbon atoms in R ¹ and R ² include a phenyl group, an o-tolyl group, an m-tolyl group, a p-tolyl group, a 1-naphthyl group, a 2-naphthyl group and the like. Be done.
Examples of the halogen atom in R ¹ and R ² include a fluorine atom, a chlorine atom, a bromine atom, an iodine atom and the like.
n1 and n2 are independently integers of 0 to 4, preferably 0 to 2, and more preferably 0 to 1.

Examples of commercially available products of the compound represented by the general formula (I) include Sumitomo Chemical Co., Ltd.'s trade name Sumika Excel PES 3600P, 4100P and 4800P. The terminal structure of the aromatic polysulfone resin is determined according to the production method of each resin, and examples thereof include, but are not limited to, Cl, OH, and OR (R is an alkyl group).

The ratio of the content of the component (P) to the total mass (100% by mass) of the resin composition for a lamp member may be, for example, 50% by mass or more, and may be 50 to 99.9% by mass. It may be 70 to 99.5% by mass, and may be 80 to 99.0% by mass.

The reduced viscosity of the component (P) is preferably more than 0.36 (dL / g) and 0.50 (dL / g) or less, and is 0.38 (dL / g) or more and 0.48 (dL / g) or more. ) Or less, and more preferably 0.40 (dL / g) or more and 0.45 (dL / g) or less.
When the reducing viscosity of the component (P) exceeds or exceeds the above lower limit value, the occurrence of fogging of the lamp is further prevented and the heat resistance of the resin composition for the lamp member is also improved. When the reducing viscosity of the component (P) is not more than the above upper limit value, the handling and moldability of the resin composition for a lamp member can be improved.

The reduced viscosity of the component (P) can be measured by the following method.
The viscosity (η) of 1 dL of a solution prepared by dissolving 1 g of the component (P) in N, N-dimethylformamide is measured at 25 ° C. using an Ostwald type viscosity tube.
Further, the viscosity (η0) of N, N-dimethylformamide, which is a solvent, is measured at 25 ° C. using an Ostwald type viscosity tube.
The specific viscosity ratio ((η-η0) / η0) is obtained from the viscosity (η) of the solution and the viscosity (η0) of the solvent. The reduced viscosity (dL / g) is determined by dividing this specific viscosity by the concentration of the solution (about 1 g / dL).

By containing the component (P), the resin composition for a lamp member of the embodiment is imparted with strength applicable to the lamp member exposed to high heat, and can exhibit excellent heat resistance characteristics.

As an index showing the heat resistance characteristics of the resin composition for lamp members of the embodiment, the 180 ° C. bending strength of the cured product of the resin composition for lamp members can be adopted. The 180 ° C. bending strength is preferably 35 MPa or more, more preferably 40 MPa or more, further preferably 50 MPa or more, and particularly preferably 55 MPa or more.
The upper limit of the bending strength at 180 ° C. is not particularly limited, but may be 70 MPa or less, 65 MPa or less, and 60 MPa or less.
The numerical range of the above numerical values may be, for example, 35 MPa or more and 70 MPa or less, 40 MPa or more and 65 MPa or less, 50 MPa or more and 65 MPa or less, and 55 MPa or more and 60 MPa or less.
The value of the bending strength at 180 ° C. shall be the value obtained by the method and measurement conditions shown below.

(Measurement of bending strength at 180 ° C)
Using an injection molding machine using a resin composition for a lamp member as a molding material, a rod-shaped test piece having a width of 12.7 mm, a length of 127 mm, and a thickness of 6.4 mm is molded at a cylinder temperature of 360 ° C. and a mold temperature of 150 ° C. , ASTM D790, the bending strength at 180 ° C. is measured by performing the bending test at a test speed of 2 mm / min, a distance between fulcrums of 100 mm, and a radius of 5 mm at the tip of the indenter. For the value of bending strength, the average value of the results for the three test pieces is adopted.

The glass transition temperature (° C.) of the aromatic polysulfone of the embodiment is preferably 200 ° C. or higher, and more preferably 215 ° C. or higher. The glass transition temperature (° C.) is an index for determining the degree of heat resistance of aromatic polysulfone, and it can be said that the higher the temperature, the better the heat resistance. The glass transition temperature can be calculated by a differential scanning calorimetry device according to JIS-K7121.

<(M) component>
Hereinafter, the component (M) contained in the resin composition for lamp members: selected from the group consisting of oxides, peroxides, compound oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table. At least one kind to be described will be described.

As the oxide of the metal belonging to Group 1 or Group 2 in the long periodic table, the general formula M ₂ O or M'O (in these formulas, M is Group 1 and M'is a metal element belonging to Group 2. ) Can be exemplified.
As the peroxide of the metal belonging to Group 1 or Group 2 in the long periodic table, the general formula M'O ₂ (in these formulas, M is Group 1 and M'is a metal element belonging to Group 2. ) Can be exemplified.
In the above oxides and peroxides, M is preferably at least one selected from the group consisting of Na and K. M'is preferably at least one selected from the group consisting of Mg, Ca, and Ba, more preferably at least one selected from the group consisting of Mg, and Ca, and even more preferably Mg.

The compound oxide containing a metal belonging to Group 1 or Group 2 in the long periodic table is the general formula M ₂ O · mM ″ O ₂ · xH ₂ O, M'O · mM'' O ₂ · xH _2. O, M ₂ O · pM'''' ₂ O ₃ · mM _{'' O 2} · xH ₂ O or M ₂ O · pM'O mM'''' ₂ O ₃ · nM''O ₂ · xH ₂ O (these In the formula, M is a metal element belonging to Group 1, M'is a metal element belonging to Group 2, M'' is a tetravalent metal element, M'''is a trivalent metal element, and p, m, n are 1. Examples of the above positive numbers and x being 0 or more positive numbers) can be exemplified.
In the above-mentioned compound oxide, M is preferably K, and M'is preferably at least one selected from the group consisting of Mg, Ca, and Ba. Examples of this include, but are not limited to, wollastonite, attapulsite, sericite, mica, potassium titanate, barium titanate and the like.

Carbonates containing metals belonging to Group 1 or Group 2 in the Long Periodic Table are the general formulas M ₂ CO ₃ , M'CO ₃ or M'・ M'' (CO ₃ ) ₂ (in the formula, M is Group 1 and M'and M'' can be exemplified by those represented by metal elements belonging to Group 2.
In the above carbonate, M is preferably K, and M'and M'is preferably at least one selected from the group consisting of Mg, Ca, and Ba. Examples of this include, but are not limited to, potassium carbonate, calcium carbonate, dolomite and the like.
Further, as a carbonate containing a metal belonging to Group 1 or Group 2 in the long periodic table, layered double hydroxide can be exemplified. Examples of the layered double hydroxide include hydrotalcite. These can be used alone or in combination of two or more. Of these, hydrotalcite is preferred. The formula for hydrotalcite is:
_{Mg 1-y Al y (OH} ) 2 (CO 3) y / 2 · qH 2 O
[Representing numerical values of 0 <y ≦ 0.5 and 0 ≦ q in the formula]
It is represented by.
The hydrotalcite may be a natural product or a synthetic product, and can be used regardless of its crystal structure, crystal particle size, and the like.

As the oxides, peroxides, double oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table, a mixture or solid solution thereof may be used. Examples of the mixture or solid solution of the metal oxide include calcined dolomite (mixture containing calcium oxide and magnesium oxide), calcined hydrotalcite (solid solution of calcium oxide and aluminum oxide) and the like. Examples on the market include calcined dolomite ("KT" manufactured by Yoshizawa Lime Industry Co., Ltd.), calcium oxide ("Moistop # 10" manufactured by Sankyo Seiko Co., Ltd., etc.), magnesium oxide ("Kyowa Chemical Industry Co., Ltd." Kyowa Mag MF-150 "," Kyowa Mag MF-30 "," Pure Mag FNMG "manufactured by Tateho Chemical Industries, Ltd., etc.), Lightly baked magnesium oxide ("# 500", "# 1000", "# 5000" manufactured by Tateho Chemical Industries, Ltd. Etc.), calcined hydrotalcite (“N41S” manufactured by Toda Kogyo Co., Ltd., “KW-2100”, “KW-2200” manufactured by Kyowa Chemical Industries Co., Ltd.), semi-firing hydrotalcite (“DHT-4C” manufactured by Kyowa Chemical Industries Co., Ltd.) , "DHT-4A-2", etc.) and the like.

As the component (M), those exhibiting alkalinity are preferable from the viewpoint of neutralization with acid gas (sulfite gas), and for example, magnesium oxide, calcium oxide, barium oxide, barium peroxide, wollastonite, attapulsite, and seri. Cyto, mica, potassium titanate, barium titanate, potassium carbonate, calcium carbonate, dolomite, hydrotalcite, calcined hydrotalcite and the like are preferable.

As the component (M), one type may be contained alone, or two or more types may be contained in combination.

Among those exemplified above, from the viewpoint that the occurrence of fog of the lamp can be reduced more effectively, the component (M) is an oxide of a metal belonging to Group 1 or Group 2 in the long periodic table. It is preferable that the component (M) is magnesium oxide.

The content of the component (M) is preferably 0.5 to 10 parts by mass, preferably 0.7 to 10 parts by mass, and 1 to 1 to 10 parts by mass with respect to 100 parts by mass of the component (P). It is more preferably 7 parts by mass, further preferably 1 to 5 parts by mass, and particularly preferably 1.5 to 4 parts by mass. The upper limit value and the lower limit value of the numerical range of the content of the component (M) exemplified above can be freely combined.
The resin composition for a lamp member containing the component (M) at the above lower limit value or more can more effectively reduce the occurrence of fogging of the lamp. Further, when the component (M) is contained below the above upper limit value, the heat resistance of the composition for the lamp member is good, and the addition of the component (M) causes an increase in the melt viscosity of the resin composition for the lamp member. It is difficult to stabilize the quality of the resin composition for lamp members.

As the melt viscosity of the resin composition for a lamp member, the melt viscosity at 380 ° C. measured using a capillary rheometer can be adopted, and the melt viscosity can be measured by the measurement method described below.

(Measurement of apparent melt viscosity of resin composition for lamp members)
As the melt viscosity of the resin composition for a lamp member at 380 ° C., the melt viscosity at 380 ° C. measured using a capillary rheometer is measured. A capillary having a diameter of 1.0 mm and a length of 10 mm was used, and 20 g of a pellet-shaped resin composition for a lamp member dried at 150 ° C. for 4 hours was placed in a cylinder set at 380 ° C. and conformed to ISO 11443. It is assumed that the melt viscosity at a shear rate of 12000s- ^{1 has been measured.}

The inventors have found that the suppression of the increase in melt viscosity is more pronounced as the content of chlorine (Cl) contained in the resin composition for lamp members is higher, and the chlorine (Cl) is more pronounced. In an aromatic polysulfone composition having a content of more than 2000% by mass, preferably 3000% by mass or more and 5000% by mass or less, the content of the component (M) is 0 with respect to 100 parts by mass of the component (P). .5 to 10 parts by mass, preferably 0.7 to 10 parts by mass, more preferably 1 to 7 parts by mass, further preferably 1 to 5 parts by mass, 1 It is particularly preferably .5 to 4 parts by mass. The upper limit value and the lower limit value of the numerical range of the content of the component (M) exemplified above can be freely combined.

Alternatively, from the viewpoint that the increase in melt viscosity is unlikely to occur, the content of chlorine (Cl) contained in the resin composition for lamp members is preferably 2000 mass ppm or less, and preferably 1700 mass ppm or less. Is more preferable, and 1500 mass ppm or less is further preferable. Here, the lower limit of the content of chlorine (Cl) contained in the resin composition for lamp members may be, for example, 100 ppm by mass or more, or 500 ppm or more. Here, the preferable range of the content of chlorine (Cl) contained in the resin composition for lamp members is, for example, 100 mass ppm or more and 2000 mass ppm or less, and 100 mass ppm or more and 1700 mass ppm or less. It may be 500 ppm or more and 1500 mass ppm or less.

Chlorine (Cl) contained in the above resin composition for lamp members may correspond to the Cl atom of the aromatic polysulfone at its terminal.

Aromatic polysulfone is usually produced by polycondensation reaction of an aromatic dihalogenosulfone compound and an aromatic dihydroxy compound in the coexistence of a base and a reaction solvent (see, for example, Japanese Patent Application Laid-Open No. 2012-509375). .. That is, the aromatic polysulfone obtained by the polycondensation reaction of the aromatic dihalogenosulfone compound and the aromatic dihydroxy compound has a halogen atom or a phenolic hydroxyl group at the terminal thereof.

The content of chlorine (Cl) contained in the resin composition for lamp members can be adjusted by, for example, adopting the method disclosed in Japanese Patent Application Laid-Open No. 2018-070698.

More specifically, in a method for producing aromatic polysulfone by a polycondensation reaction of an aromatic dihalogenosulfone compound and an aromatic dihydroxy compound, the polycondensation reaction is carried out in the presence of at least one aromatic end cap agent. Can be mentioned in.

Examples of the aromatic terminal cap agent include those disclosed in Japanese Patent Application Laid-Open No. 2018-070698. For example, it does not contain a structure that is reactive to halogen atoms or easily generates radicals, and is easily available. From the viewpoint, 4-phenylphenol, 1-naphthol, 2-naphthol, and 4-phenoxyphenol are preferable.

The polycondensation reaction is carried out in the coexistence of at least one aromatic terminal cap agent to obtain aromatic polysulfone, and then the solvent is removed, and the precipitate containing aromatic polysulfone is repeatedly washed with a poor solvent. By doing so, chlorine (Cl) can be efficiently removed.

The inventors have found that the above-mentioned increase in melt viscosity is unlikely to occur by using magnesium oxide as the component (M), as shown in Examples described later.
This is probably because the addition of a metal oxide may cause the polymerization reaction of aromatic polysulfone having a Cl atom at the end to proceed, but the use of magnesium oxide makes it difficult for such a polymerization reaction to proceed. Inferred.

Therefore, it is particularly preferable that the component (M) is magnesium oxide from the viewpoint that the occurrence of fogging of the lamp can be reduced particularly effectively and the above-mentioned increase in melt viscosity is unlikely to occur.
Many of the lamp members are relatively large, and in their molding, appropriate fluidity of the composition is often required. It can be said that the fact that the melt viscosity of the resin composition for a lamp member of the embodiment is unlikely to increase is a suitable feature as a composition used for manufacturing a lamp member.
Further, from the viewpoint of suppressing an increase in the melt viscosity, it is preferable that the content of the component (M) is in the range exemplified above.

In the resin composition for a lamp member of the embodiment, the reduced viscosity of the component (P) is more than 0.36 (dL / g) and 0.50 (dL / g) or less, and the component (M) is magnesium oxide. It is preferable that the heat resistance of the resin composition for the lamp member and the reduction of the occurrence of fogging of the lamp are further satisfactorily achieved.

In the resin composition for a lamp member of the embodiment, the reduced viscosity of the component (P) is more than 0.36 (dL / g) and 0.50 (dL / g) or less, and the component (M) is magnesium oxide. The content of the component (M) is 1 to 10 parts by mass with respect to 100 parts by mass of the component (P), which improves the heat resistance of the resin composition for lamp members and reduces the occurrence of fogging of the lamp. , Even better achieved, especially preferred.

(Other ingredients)
In the present embodiment, the resin composition for a lamp member may contain other components that do not correspond to any of the components (P) and (M) as long as the effects of the present invention are not impaired.

Examples of other components include fillers, additives, resins other than the component (P) (hereinafter, may be referred to as “other resins”) and the like.
These other components may be contained alone or in combination of two or more.

The filler may be a fibrous filler or a granular filler.
Further, the filler may be an inorganic filler or an organic filler.

Examples of the fibrous inorganic filler include glass fibers; carbon fibers such as pan-based carbon fibers and pitch-based carbon fibers; ceramic fibers such as silica fibers, alumina fibers and silica-alumina fibers; and metal fibers such as stainless steel fibers. Be done. Further, whiskers such as potassium titanate whiskers, barium titanate whiskers, wollast night whiskers, aluminum borate whiskers, silicon nitride whiskers, and silicon carbide whiskers can also be mentioned.

Examples of glass fibers include those manufactured by various methods such as chopped glass fibers and milled glass fibers.

Examples of carbon fibers include pan-based carbon fibers made from polyacrylonitrile, pitch-based carbon fibers made from coal tar and petroleum pitch, cellulose-based carbon fibers made from viscose rayon and cellulose acetate, and hydrocarbons. Examples thereof include vapor-phase growth-based carbon fibers made from rayon and the like. The carbon fiber may be chopped carbon fiber or milled carbon fiber.

Examples of granular inorganic fillers include silica, alumina, titanium oxide, boron nitride, silicon carbide, calcium carbonate and the like.

Examples of additives include metering stabilizers, mold release agents, antioxidants, heat stabilizers, UV absorbers, antistatic agents, surfactants, flame retardants and colorants.

Examples of other resins include thermoplastic resins other than liquid crystal polymers such as polypropylene, polyamide, polyester, polyphenylene sulfide, polyetherketone, polycarbonate, polyphenylene ether, polyetherimide, and fluororesin; phenolic resin, epoxy resin, and polyimide resin. , Thermoplastic resins such as cyanate resin.

<< Manufacturing method of resin composition for lamp members >>
The resin composition for a lamp member of the present embodiment can be produced by mixing the component (P), the component (M) and other components used as necessary in a batch or in an appropriate order.
The method for producing a resin composition for a lamp member of the present embodiment includes a step of mixing the component (P) and the component (M).

Examples of the component (P) and the component (M) include those described in the above << Resin composition for lamp member >>.

The amount of the component (M) used is preferably 0.5 to 10 parts by mass with respect to 100 parts by mass of the component (P), and more preferably 1 to 7 parts by mass. It is preferable to mix in a ratio of 1.5 to 4 parts by mass, more preferably. The resin composition for a lamp member obtained by mixing the component (M) at a ratio of the lower limit value or more can more effectively reduce the occurrence of fogging of the lamp. Further, the resin composition for lamp members obtained by mixing the component (M) at a ratio of not more than the above upper limit has good heat resistance of the composition for lamp members, and the melt viscosity due to the addition of the component (M). Is unlikely to increase, and it is easy to stabilize the quality of the resin composition for lamp members.

As the mixing, melt kneading is preferable. The resin composition for a lamp member of the present embodiment is provided as pelletized by melting and kneading the component (P), the component (M) and other components used as necessary using an extruder. It is possible.

The resin composition for lamp members of the embodiment is selected from the group consisting of (M) component: oxides, peroxides, compound oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table. By containing at least one of these, the effect of reducing the fogging of the lamp is exhibited.

The effect of reducing fogging of the lamp in the resin composition for the lamp member can be confirmed without actually manufacturing the lamp. For example, as in the method specifically described in the examples, a test device imitating a lamp can be used, and the resin composition for a lamp member is cured in a container assuming a space volume of a housing for accommodating a light source. After storing the object, the inside of the container is heated, and the comparison result of the amount of components adhering to the inside of the container before and after heating and the comparison result of the actual degree of cloudiness can be obtained. Then, as compared with the resin composition containing the component (P), the resin composition according to the embodiment obtained by further adding the component (M) to the resin composition adhered to the inside of the container after heating. It can be determined that the effect of reducing the fogging of the lamp is achieved when the amount of the component is reduced, the degree of fogging is low, or the heating time until the occurrence of fogging is short.

The mechanism by which the component (M) exerts the effect of reducing the fogging of the lamp is inferred as follows. When the component (P) contained in the resin composition for a lamp member is heated, sulfurous acid (SO ₂ ) gas is generated, and it is considered that, for example, sodium sulfate that has reacted with Na contained in the glass lens of the lamp adheres to the glass lens. .. It is considered that by adding the above component (M), the component (M) reacts with sulfur dioxide gas and the generation of sulfur dioxide gas can be suppressed.

As described above, since the resin composition for the lamp member of the embodiment contains the component (P), the molded product molded from the composition for the lamp of the embodiment exhibits excellent heat resistance characteristics. Further, when the resin composition for the lamp member of the embodiment contains the component (M), it is possible to reduce the occurrence of fogging of the lamp formed from the composition.
Further, when the reduced viscosity of the component (P) is more than 0.36 (dL / g), the effect of reducing the occurrence of fogging of the lamp is further enhanced, and further, more suitable heat resistance characteristics as a lamp member are exhibited. When the reduced viscosity of the component (P) is 0.50 (dL / g) or less, the molding characteristics for molding the lamp member become better.
Further, when the component (M) is magnesium oxide, the effect of reducing the occurrence of fogging of the lamp is further enhanced, and the molding characteristics for molding the lamp member are also improved.
As described above, the composition for a lamp of the embodiment has very excellent properties as a composition used for molding a lamp member.

Next, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the following Examples.

≪Evaluation≫
<Measurement of reducing viscosity of aromatic polysulfone>
1 g of aromatic polysulfone to be measured was dissolved in N, N-dimethylformamide to make the volume 1 dL, and the viscosity (η) of this solution was measured at 25 ° C. using an Ostwald-type viscosity tube. _{The viscosity (η 0} ) of N, N-dimethylformamide, which is a solvent, was measured at 25 ° C. using an Ostwald-type viscosity tube. The specific viscosity ((η-η ₀ ) / η ₀ ) was obtained from the viscosity (η) of the solution and the viscosity (η ₀ ) of the solvent, and this specific viscosity was calculated as the concentration of the solution (about 1 g / dL). ) To determine the reduced viscosity (dL / g) of the resin.

<Cloud test>
Pellets of the resin composition for lamp members are made into a flat plate with a width of 64 mm, a length of 64 mm, and a thickness of 1 mm at a cylinder temperature of 360 ° C and a mold temperature of 150 ° C using an injection molding machine (PS40E5ASE, Nissei Resin Industry Co., Ltd.). The test piece was molded and cut into 10 mm squares, which was used as the test piece. 2 g of the test piece was placed in a petri dish having a diameter of 32 mm and a height of 15 mm, soda-lime glass was placed on the petri dish, heated on a hot plate set at 260 ° C., and the time until fogging occurred on the glass was measured. .. The longer this time is, the less fogging is.

<Measurement of bending strength at 180 ° C>
Using an injection molding machine (PS40E5ASE, Nissei Resin Industry Co., Ltd.), pellets of the resin composition for lamp members were subjected to a cylinder temperature of 360 ° C. and a mold temperature of 150 ° C., a width of 12.7 mm, a length of 127 mm, and a thickness of 6. A 4 mm rod-shaped test piece is formed, and a bending test is performed at a test speed of 2 mm / min, a distance between fulcrums of 100 mm, and an indenter tip radius of 5 mm in accordance with ASTM D790. Was measured. For the value of bending strength, the average value of the results for the three test pieces was adopted.

<Measurement of apparent melt viscosity of resin composition for lamp members>
As the melt viscosity of the resin composition for a lamp member, the melt viscosity at 380 ° C. measured using a capillary rheometer was measured. A capillary of 1.0 mmΦ × 10 mm was used, and 20 g of pellets of a resin composition for a lamp member dried at 150 ° C. for 4 hours was placed in a cylinder set at 380 ° C., and melted ^{at a shear rate of 12000s -1 in accordance with ISO 11443.} The viscosity was measured.

<Measurement of glass transition temperature of aromatic polysulfone>
The glass transition temperature was calculated by a method according to JIS-K7121 using a differential scanning calorimetry device (DSC-50 manufactured by Shimadzu Corporation). About 10 mg of the sample was weighed and raised to 400 ° C. at a heating rate of 10 ° C./min, cooled to 50 ° C., and again raised to 400 ° C. at a heating rate of 10 ° C./min. From the DSC chart obtained by the second temperature rise, the glass transition temperature was calculated by a method according to JIS-K7121.

≪Manufacturing of resin composition for lamp member≫
(Example 1)
As a component (P), 100 parts by mass of Sumika Excel PES4100P (polyether sulfone (PES), manufactured by Sumitomo Chemical Industry Co., Ltd., glass transition temperature: 225 ° C., reducing viscosity: 0.41 dL / g), and oxidation as a component (M). Magnesium (Kyowa Mag 150 manufactured by Kyowa Chemical Industry Co., Ltd.). After mixing with 5 parts by mass, pellets of a resin composition for a lamp member were produced by melt-kneading using a twin-screw extruder (PCM-30, manufactured by Ikegai Iron Works Co., Ltd.). As the melt-kneading conditions, the cylinder set temperature of the twin-screw extruder was set to 340 ° C., and the screw rotation speed was set to 150 rpm.

(Examples 2 to 12, Comparative Examples 1 to 2)
In Example 1, pellets of the resin composition for lamp members were produced in the same manner as in Example 1 except that the type of PES, the type of metal oxide, and the blending amount thereof were changed as shown in Table 1. "-" In the table means that the component is not included. As calcium oxide, Inoue Lime Industry Co., Ltd. (VESTA-PP) was used. As the Sumika Excel PES3600P, a polyether sulfone (PES) manufactured by Sumitomo Chemical Co., Ltd., a glass transition temperature of 225 ° C., and a reduction viscosity of 0.36 dL / g were used.

The above-mentioned fogging test and measurement of 180 ° C. bending strength were carried out for each of the manufactured test pieces (molded parts) of the resin composition for lamp members. The results are also shown in Table 1.

Further, the above-mentioned apparent melt viscosity was measured for the resin compositions for lamp members of Comparative Example 1, Example 1, Example 2, Example 5, and Example 6. The results are shown in FIG.

Referring to Table 1, the resin compositions for lamp members of Examples 1 to 10 containing the components (P) and (M) are the resin compositions for lamp members of Comparative Examples 1 and 2 not containing the component (M). In comparison, the occurrence of fogging in the fogging test was suppressed.

Further, in the resin compositions for lamp members of Examples 1 to 7 in which the reduced viscosity of PES of the component (P) exceeds 0.36 (dL / g), the value of bending strength at 180 ° C. is high, and particularly excellent heat resistance characteristics are obtained. Had.

Further, comparison between Example 2 and Example 8, comparison between Example 4 and Example 9, comparison between Example 5 and Example 10, comparison between Example 6 and Example 11, and Example 7 and According to the comparison with Example 12, the higher the reduced viscosity of PES of the component (P), the more the occurrence of fogging in the fogging test was suppressed.

Further, according to the comparison between Example 2 and Example 6 and the comparison between Example 4 and Example 7, the case where MgO is used as the component (M) is the case where CaO is used as the component (M). Rather, the occurrence of fogging in the fogging test was suppressed.

In Examples 2 to 4 in which the reduced viscosity of PES of the component (P) exceeded 0.36 (dL / g) and MgO was used as the component (M), the occurrence of fogging in the fogging test was particularly suppressed. ..

Further referring to FIG. 2, in Examples 1 and 2 in which MgO was used as the component (M), the melt viscosity of the composition was less likely to increase than in Examples 5 to 6 in which CaO was used as the component (M). It turned out that.

Each configuration in each embodiment and a combination thereof are examples, and the configuration can be added, omitted, replaced, and other changes are possible without departing from the spirit of the present invention. Moreover, the present invention is not limited to each embodiment, but is limited only to the scope of claims.

1 ... Lamp, 3 ... Lamp member, 10 ... Reflector, 12 ... Light source, 14 ... Lens, 20 ... Lens holder

Claims (7)

(P) Ingredients: Aromatic polysulfone and
Component (M): At least one selected from the group consisting of oxides, peroxides, double oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table.
A resin composition for a lamp member containing. The resin composition for a lamp member according to claim 1, wherein the reduced viscosity of the component (P) is more than 0.36 (dL / g) and 0.50 (dL / g) or less. The resin composition for a lamp member according to claim 1 or 2, wherein the component (M) is an oxide of a metal belonging to Group 1 or Group 2 in the long periodic table. The resin composition for a lamp member according to claim 3, wherein the component (M) is magnesium oxide. The resin composition for a lamp member according to any one of claims 1 to 4, wherein the content of the component (M) is 0.5 to 10 parts by mass with respect to 100 parts by mass of the component (P). .. A lamp member molded from the resin composition for a lamp member according to any one of claims 1 to 5. (P) Ingredients: Aromatic polysulfone and
Component (M): At least one selected from the group consisting of oxides, peroxides, double oxides and carbon oxides of metals belonging to Group 1 or Group 2 in the long periodic table.
A method for producing a resin composition for a lamp member, which comprises a step of mixing.

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