Reflector and preparation method therefor

Abstract

Embodiments of the present disclosure relate to the technical field of optics, and provide a reflector and a preparation method therefor. A prepared reflector is used for an automobile lamp, and can meet temperature resistance conditions; and while it is ensured that the surface contour meets the requirements of an optical surface, a metal reflective layer can be plated and the requirements of reflectivity are met, without performing a primer treatment in advance during process preparation.

Description

A reflector and a method for manufacturing the same TECHNICAL FIELD

[0001] The present disclosure relates to the field of optical technology, and in particular, to a reflector and a method for manufacturing the same. BACKGROUND

[0002] In a vehicle lamp module, a reflector is an extremely important component. The light beams emitted by the LED light source are reflected by the reflector and modulated by the light beams, and finally converge on the focal point of the lens. The heat dissipation capacity of the vehicle lamp module is an important indicator affecting the stability of the vehicle lamp module. If the heat dissipation is not effective and the local temperature of the optical element is too high, not only will it have an adverse effect on the service life of the optical element, but also it will affect the stability of the working performance of the entire vehicle lamp module. With the increasing requirements for the light source power of the vehicle lamp module in the market, the reflective element in the vehicle lamp module needs to meet higher heat resistance requirements.

[0003] In the reflector of the prior art vehicle lamp module, polycarbonate (PC) and high-temperature-resistant polycarbonate (PCHT) cannot meet the current temperature resistance requirements, although the preparation process is simple, but cannot be widely used. Polyetherimide (PEI) has a high temperature resistance level and can be directly plated with aluminum without primer treatment, but PEI has a high cost and is not suitable for mass production and product cost control. Polyphenylene sulfide (PPS), bulk molding compound (BMC), and aluminum alloy (ADC12) also have high temperature resistance levels, but the surface profile of these materials does not meet the requirements of the optical surface of the reflector, and the reflectivity can only meet the requirements of optical design after the primer treatment and aluminum plating in the process preparation. When the primer treatment is performed on such materials, the primer may accumulate and affect the flatness of the optical surface of the prepared reflector, thereby significantly increasing the rejection rate of the prepared reflector. In addition, the primer usually contains organic solvents, and the volatile organic compounds (VOC) released during the primer spraying and drying will have a negative impact on the environment. Primer treatment also increases the complexity of the production process, increases the production cost, and increases the cost of waste treatment.

[0004] SUMMARY

[0005] The purpose of the present disclosure is to provide a reflector and a method for manufacturing the same. The prepared reflector is used in an automotive vehicle lamp, and the reflector can meet the temperature resistance conditions, ensure that the surface profile meets the requirements of the optical surface, and does not need to be treated with primer in advance during the process preparation process to meet the requirements of the reflectivity of the metal reflective layer.

[0006] Embodiments of the present disclosure are implemented as follows:

[0007] In an aspect of the embodiments of the present disclosure, a mirror is provided, the mirror comprising a substrate layer and a metal reflective layer plated on one side of the substrate layer, the material of the substrate layer comprising a polyphenylene sulfide base material, 15-25% of glass fiber by mass fraction, 15-25% of mineral powder by mass fraction, and 1-3% of glycidyl ester-maleic anhydride-ethylene copolymer by mass fraction.

[0008] Optionally, the metal reflective layer comprises an aluminum layer or a silver layer.

[0009] Optionally, the diameter of the glass fiber is between 4-8 microns.

[0010] Optionally, the particle size of the mineral powder is between 4-8 microns.

[0011] Optionally, the substrate layer is integrally formed by using an injection molding process.

[0012] In another aspect of the embodiments of the present disclosure, a preparation method of a mirror is provided, comprising: providing a polyphenylene sulfide base material, and adding glass fiber, mineral powder, and glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide base material respectively to form a modified polyphenylene sulfide material by extrusion; performing pre-drying treatment on the modified polyphenylene sulfide material; injection molding the modified polyphenylene sulfide material after the pre-drying treatment at a mold temperature greater than 140°C to form a substrate layer; and plating a metal reflective layer on one side surface of the substrate layer, the metal reflective layer comprising an aluminum layer or a silver layer.

[0013] Optionally, the adding of the glass fiber, the mineral powder, and the glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide base material to form the modified polyphenylene sulfide material by extrusion comprises: adding the glass fiber in a mass fraction of 15-25%, adding the mineral powder in a mass fraction of 15-25%, and adding the glycidyl ester-maleic anhydride-ethylene copolymer in a mass fraction of 1-3%.

[0014] Optionally, the injection molding of the modified polyphenylene sulfide material after the pre-drying treatment at a mold temperature greater than 140°C to form the substrate layer comprises: a barrel temperature of 290-320°C, an injection speed of 32-64 mm / s, a holding pressure of 40-70 MPa, a holding time of 2 s, a cooling time of 55 s, a screw rotation speed of 80-150 rpm, and a back pressure of 0.2-1 MPa.

[0015] Optionally, the pre-drying treatment on the modified polyphenylene sulfide material comprises: baking the modified polyphenylene sulfide material at 140°C for 3 hours.

[0016] Optionally, before the providing of the polyphenylene sulfide base material, the method further comprises: mixing xylene and sodium sulfide to synthesize the polyphenylene sulfide base material.

[0017] The beneficial effects of the present disclosure include that the reflector provided by the embodiments of the present disclosure comprises a substrate layer and a metal reflection layer plated on one side of the substrate layer, the preparation material of the substrate layer comprises a polyphenylene sulfide base material, and 15-25% by mass fraction of glass fiber, 15-25% by mass fraction of mineral powder, and 1-3% by mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer. The substrate layer thus formed and the plated metal reflection layer are two completely different types of materials. Taking the metal reflection layer as an aluminum layer as an example, there is no hydrogen bond and intermolecular force between the two materials, but the 1-3% by mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer added forms an activation layer on the surface of the polyphenylene sulfide base material of the substrate layer, the activation layer improves the bonding force between the substrate layer and the metal reflection layer, so that the substrate layer of the prepared reflector does not need to be previously subjected to primer treatment, and the substrate layer and the plated metal reflection layer are not easy to separate or fall off, and moreover, the 15-25% by mass fraction of glass fiber and the 15-25% by mass fraction of mineral powder improve the polyphenylene sulfide base material, so that the surface profile of the substrate layer can meet the optical surface requirement and the high temperature resistance requirement. In this way, the reflector provided by the embodiments of the present disclosure can meet the temperature resistance requirement when used as a vehicle lamp reflector and the optical surface requirement as a reflector, and can effectively improve the bonding capacity between the substrate layer and the metal reflection layer on the premise that the process step of primer treatment of the substrate layer is omitted, thereby avoiding the problem of falling off. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present disclosure, the following will briefly introduce the drawings needed to be used in the embodiments. It should be understood that the following drawings only show some of the embodiments of the present disclosure, and therefore should not be regarded as a limitation on the scope, and for those skilled in the art, other related drawings can also be obtained without creative labor on the basis of these drawings.

[0019] FIG. 1 is a structural schematic diagram of a reflector provided by an embodiment of the present disclosure;

[0020] FIG. 2 is a first comparative example effect diagram of a substrate layer of a reflector provided by an embodiment of the present disclosure;

[0021] FIG. 3 is an embodiment effect diagram of a substrate layer of a reflector provided by an embodiment of the present disclosure;

[0022] FIG. 4 is a second comparative example effect diagram of a substrate layer of a reflector provided by an embodiment of the present disclosure;

[0023] FIG. 5 is one of flowcharts of a preparation method of a reflector of an embodiment of the present disclosure;

[0024] FIG. 6 is another of flowcharts of a preparation method of a reflector of an embodiment of the present disclosure;

[0025] Fig. 7 is a flow chart III of a method for preparing a mirror according to an embodiment of the present disclosure;

[0026] Fig. 8 is a flow chart IV of a method for preparing a mirror according to an embodiment of the present disclosure;

[0027] Fig. 9 is a flow chart V of a method for preparing a mirror according to an embodiment of the present disclosure.

[0028] Fig. 10 is a schematic view of a mirror according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0029] In order to make the objectives, technical solutions and advantages of the embodiments of the present disclosure clearer, the technical solutions in the embodiments of the present disclosure will be described clearly and completely below with reference to the drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, and the detailed description of the embodiments is not intended to limit the scope of the claimed present disclosure, but only represents selected embodiments of the present disclosure. The components of the embodiments of the present disclosure generally described and shown in the drawings herein can be arranged and designed in various different configurations, and all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present disclosure.

[0030] It should be noted that similar reference numerals and letters in the following drawings represent similar items, and therefore, once an item is defined in one drawing, it need not be further defined and explained in subsequent drawings.

[0031] In the description of the present disclosure, it should be noted that if the terms "upper", "lower", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the present disclosure is usually placed, and are only for the convenience of describing the present disclosure and simplifying the description, and therefore cannot be understood as indicating or implying that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present disclosure.

[0032] In addition, if the terms "first", "second" and the like appear, they are only for differentiation description and cannot be understood as indicating or implying relative importance. It should be noted that the features in the embodiments of the present disclosure can be combined with each other without conflict.

[0033] Please refer to Figs. 1-9, the embodiments of the present disclosure provide a mirror and a method for preparing the same. The mirror according to the embodiments of the present disclosure can be applied in the optical structure of a car lamp, or can also be applied in various large, medium and small devices in other fields such as vehicle-mounted and engineering equipment.

[0034] Fig. 1 is a structural schematic diagram of the reflector 10 provided in the embodiments of the present disclosure, Figs. 2-4 are effect schematic diagrams of the embodiments and the comparative examples with different adding proportions after adding glycidyl ester-maleic anhydride-ethylene copolymer in the polyphenylene sulfide substrate of the base layer 11 provided in the embodiments of the present disclosure, and Figs. 5-9 are flowcharts of the preparation method of the reflector 10 provided in the embodiments of the present disclosure.

[0035] The reflector 10 used in the vehicle lamp module brings a high temperature while emitting light, and therefore, the reflector 10 used in the vehicle lamp module needs to have a long-time high-temperature resistance. In the base substrate of the reflector commonly used in the prior art, polycarbonate (PC) and high-temperature-resistant polycarbonate (PCHT) cannot meet the current temperature resistance requirement, and polyphenylene sulfide (PPS), bulk molding compound (BMC) and aluminum alloy (ADC12) have a high temperature resistance level and can meet the temperature resistance requirement of the vehicle lamp, but the surface profile of the reflector prepared by using these materials does not meet the requirement of preparing the optical surface of the reflector, and moreover, when these materials are used as the base, to ensure stable plating of the metal reflecting layer, a primer treatment needs to be performed in advance before plating of the metal reflecting layer, which not only increases the process steps of preparation, but also increases the rejection rate of the prepared reflector.

[0036] To solve the above problems, the embodiments of the present disclosure provide a reflector 10, please refer to Fig. 1, the reflector 10 includes a base layer 11 and a metal reflecting layer 12 plated on one side of the base layer 11, the preparation material of the base layer 11 includes a polyphenylene sulfide substrate, and 15%-25% mass fraction of glass fiber, 15%-25% mass fraction of mineral powder and 1%-3% mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer.

[0037] By adding 1%-3% mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer, 15%-25% mass fraction of glass fiber and 15%-25% mass fraction of mineral powder in the polyphenylene sulfide substrate of the base layer 11, a modified polyphenylene sulfide material is obtained. The modified polyphenylene sulfide material used as the base layer 11 can be directly plated with the metal reflecting layer 12 without the need for primer treatment in advance, and can also ensure a better interlayer bonding force, avoid peeling of the metal reflecting layer 12, and meet the functional requirements and optical design requirements of high-temperature resistance, optical surface profile and reflectivity. In order to facilitate specific description and experimental data showing, the following, the metal reflecting layer 12 is taken as an example of aluminum layer for description.

[0038] The glycidyl ester-maleic anhydride-ethylene copolymer is added to the polyphenylene sulfide substrate of the base layer 11 in a mass fraction of 1% to 3%, and the glycidyl ester-maleic anhydride-ethylene copolymer is used as a surface activator. The addition of the glycidyl ester-maleic anhydride-ethylene copolymer to the polyphenylene sulfide substrate can improve the surface energy of the polyphenylene sulfide substrate and improve the adhesion of the polyphenylene sulfide substrate, thereby improving the bonding force between the modified polyphenylene sulfide material as the base layer 11 and the metal reflective layer 12 after the metal reflective layer 12 is plated. Moreover, according to the test results, when the mass fraction of the glycidyl ester-maleic anhydride-ethylene copolymer is less than 1%, the surface energy of the polyphenylene sulfide substrate is reduced, thereby reducing the bonding force between the metal reflective layer 12 and the polyphenylene sulfide substrate. If the mass fraction of the glycidyl ester-maleic anhydride-ethylene copolymer is greater than 3%, the waterproof performance of the polyphenylene sulfide substrate is poor, which may cause the metal reflective layer 12 to fall off due to moisture absorption, vapor, and other external environmental reasons after the mirror 10 plated with the metal reflective layer 12 is shipped, installed, or used, thereby affecting the service life of the mirror 10. Therefore, in the embodiment of the present disclosure, the mass fraction of the glycidyl ester-maleic anhydride-ethylene copolymer added to the polyphenylene sulfide substrate of the base layer 11 is 1% to 3%.

[0039] Moreover, 15% to 25% of glass fibers and 15% to 25% of mineral powder are added to the polyphenylene sulfide substrate of the base layer 11. The glass fibers and the mineral powder can improve the surface profile of the polyphenylene sulfide substrate, so that the modified polyphenylene sulfide material as the base layer 11 can meet the optical surface requirements of the mirror plated with the metal reflective layer 12. According to the test results, when the mass fraction of the glass fibers is less than 15% and the mass fraction of the mineral powder is less than 15%, the temperature resistance of the mirror 10 is reduced, which cannot meet the high temperature resistance requirements of the mirror 10 applied to the vehicle lamp module. When the mass fraction of the glass fibers is greater than 25% and the mass fraction of the mineral powder is greater than 25%, the modified polyphenylene sulfide material as the base layer 11 may have the problems of fiber floating and powdering. Therefore, in the embodiment of the present disclosure, the mass fraction of the glass fibers added to the polyphenylene sulfide substrate of the base layer 11 is 15% to 25%, and the mass fraction of the mineral powder added to the polyphenylene sulfide substrate of the base layer 11 is 15% to 25%.

[0040] It should be noted that the structure of the mirror 10 in FIG. 1 is a flat base layer 11 plated with a flat metal reflective layer 12, which is only used to present the connection relationship between the base layer 11 and the metal reflective layer 12. In fact, the mirror 10 in the vehicle lamp module usually needs to meet the requirements of the optical surface and the corresponding optical surface curvature, and is a specific arc surface.

[0041] The beneficial effects of the present disclosure include that the reflector 10 provided by the embodiments of the present disclosure includes a substrate layer 11 and a metal reflection layer 12 plated on one side of the substrate layer 11, and the preparation material of the substrate layer 11 includes a polyphenylene sulfide base material, and 15%-25% mass fraction of glass fiber, 15%-25% mass fraction of mineral powder, and 1%-3% mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer. The substrate layer 11 and the plated metal reflection layer 12 are two completely different types of materials. Taking the metal reflection layer 12 as an aluminum layer as an example, there is no hydrogen bond and intermolecular force between the two materials, but the 1%-3% mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer forms an activation layer on the surface of the polyphenylene sulfide base material of the substrate layer 11, which improves the bonding force between the substrate layer 11 and the metal reflection layer 12, so that the substrate layer 11 of the prepared reflector 10 does not need to be pre-treated with a primer, and the plated metal reflection layer 12 is not easy to separate or fall off. Moreover, the 15%-25% mass fraction of glass fiber and the 15%-25% mass fraction of mineral powder improve the polyphenylene sulfide base material, so that the surface profile of the substrate layer 11 can meet the requirements of the optical surface and the high temperature resistance. In this way, the reflector 10 provided by the embodiments of the present disclosure can meet the temperature resistance requirements when used as a vehicle lamp reflector and the optical surface requirements of the reflector 10, and can effectively improve the bonding ability between the substrate layer 11 and the metal reflection layer 12 without the process step of primer treatment of the substrate layer 11, thereby avoiding the problem of falling off.

[0042] Optionally, the metal reflection layer 12 includes an aluminum layer or a silver layer.

[0043] In an implementation of the embodiment of the present disclosure, the aluminum layer is used as the layer adhered between the base layer 11 and the substrate layer 12 to prepare the reflector 10. The base layer 11 comprises a polyphenylene sulfide substrate, 15%-25% by mass fraction of glass fiber, 15%-25% by mass fraction of mineral powder, and 1%-3% by mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer. The polyphenylene sulfide substrate and the aluminum are two completely different materials, and there is no hydrogen bond and intermolecular force between the two completely different materials. The combination of the polyphenylene sulfide substrate and the aluminum layer is not good, and if only the combination of the polyphenylene sulfide substrate and the aluminum layer is relied on, the aluminum layer is easy to fall off during use. The 1%-3% by mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer added in the polyphenylene sulfide substrate can form an activated layer on the surface of the polyphenylene sulfide substrate, thereby improving the bonding force between the aluminum layer, so that the prepared reflector 10 can ensure that the base layer 11 and the metal reflective layer 12 of the aluminum material do not fall off during use. The 15%-25% by mass fraction of glass fiber and the 15%-25% by mass fraction of mineral powder added in the polyphenylene sulfide substrate also meet the requirements of the surface profile of the reflector 10.

[0044] In addition, in some other application scenarios of the reflector 10 in the embodiment of the present disclosure, the metal reflective layer 12 can also be selected according to actual needs, and silver layer or other metal materials with reflection ability or mixed materials of multiple different metal materials can also be selected, which is not limited in the embodiment of the present disclosure.

[0045] Optionally, the diameter of the glass fiber is between 4-8 μm.

[0046] In the base layer 11, 15%-25% by mass fraction of glass fiber material is added in the polyphenylene sulfide substrate, wherein the diameter of the added glass fiber is between 4-8 μm.

[0047] The glass fiber with a smaller diameter is beneficial to improve the surface profile of the base layer 11, and further improve the reflectivity after the aluminum layer is plated. Considering that the smaller the diameter of the glass fiber is, the higher the cost is, therefore, the diameter of the added glass fiber in the technical scheme of the present application is not less than 4 μm. If the diameter of the glass fiber is set to be too large, the phenomenon of floating fiber is easy to occur in the process, thereby affecting the surface profile of the base layer 11, and further reducing the reflectivity after the aluminum layer is plated. Therefore, the diameter of the added glass fiber in the technical scheme of the present application is not greater than 8 μm.

[0048] Optionally, the particle size of the mineral powder is between 4-8 μm.

[0049] In the base layer 11, 15%-25% by mass fraction of mineral powder material is added in the polyphenylene sulfide substrate, wherein the particle size of the added mineral powder is between 4-8 μm.

[0050] The smaller particle size of the mineral powder is conducive to ensuring that the product prepared has better mechanical properties and surface profile, and improving the reflectivity after the aluminum layer is plated. However, considering that the smaller the particle size of the mineral powder is, the higher the cost is, in the technical scheme of the present application, the particle size of the added mineral powder is not less than 4 μm. If the particle size of the mineral powder is relatively large, the mechanical properties of the product are reduced, the surface profile is affected, and the reflectivity after the aluminum layer is plated is reduced. Therefore, in the technical scheme of the present application, the particle size of the added mineral powder is not more than 8 μm. Therefore, the particle size of the mineral powder is limited to 4-8 μm.

[0051] Optionally, the base layer 11 is integrally formed by using an injection molding process.

[0052] The material of the base layer 11 is a modified polyphenylene sulfide base material in which 15%-25% by mass of glass fiber, 15%-25% by mass of mineral powder, and 1%-3% by mass of glycidyl ester-maleic anhydride-ethylene copolymer are added to a polyphenylene sulfide base material. After the modified polyphenylene sulfide base material is extruded and subjected to a material drying step, the base layer 11 is integrally formed by using an injection molding process. Table 1 is a table of related test parameters of the modified polyphenylene sulfide base material. The related test parameters of the base layer 11 integrally formed by using an injection molding process on the modified polyphenylene sulfide base material are shown in Table 1.

[0053] Table 1: Table of related test parameters of the modified polyphenylene sulfide base material

[0054] According to the related test parameters and experimental data in Table 1, the reflector 10 provided in the present application can meet the requirements of TL207. After being stored at a high temperature of 200℃ for 240 h, the metal reflective layer 12 plated on the base layer 11 of the reflector 10 does not fall off. After being stored in a constant condensation water atmosphere (CH) for 48 h, the metal reflective layer 12 plated on the base layer 11 does not fall off. In the environmental alternating test (PV1200), after 8 cycles, the metal reflective layer 12 plated on the base layer 11 does not fall off.

[0055] Please refer to FIGS. 2-4. FIG. 2 is a photo effect diagram of a first comparative example of the reflector 10 in which less than 1% by mass of glycidyl ester-maleic anhydride-ethylene copolymer is added to the polyphenylene sulfide base material of the base layer 11. FIG. 3 is a photo effect diagram of the reflector 10 of the present application in which 1%-3% by mass of glycidyl ester-maleic anhydride-ethylene copolymer is added to the polyphenylene sulfide base material of the base layer 11. FIG. 4 is a photo effect diagram of a second comparative example of the reflector 10 in which more than 3% by mass of glycidyl ester-maleic anhydride-ethylene copolymer is added to the polyphenylene sulfide base material of the base layer 11.

[0056] According to the comparison of FIG. 2-FIG. 4, it can be seen that the mirror 10 shown in FIG. 3, which is prepared by adding 1%-3% mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer in the polyphenylene sulfide substrate, and then plating the metal reflection layer 12 on the substrate layer 11, has better test results in the related test items of environmental storage, high temperature cycle and condensed water. The comparative examples shown in FIG. 2 and FIG. 4, which are outside the addition range of 1%-3% mass fraction, all have different degrees of defects in the experiment.

[0057] Please refer to Table II for the experimental results of the mirror 10 of the embodiment of the present disclosure for the aluminizing performance evaluation according to the TL 207-2023 standard.

[0058] Table II is a test result table for aluminizing performance evaluation according to the TL 207-2023 standard:

[0059] According to Table II and the comparison of the experimental comparison charts of FIG. 2-FIG. 4, it can be seen that the substrate layer 11 of the mirror 10 provided by the embodiment of the present disclosure does not need to be pre-treated with primer, and can realize that the metal reflection layer 12 plated thereon is not easy to separate or fall off. Moreover, the addition of 15%-25% mass fraction of glass fiber and 15%-25% mass fraction of mineral powder improves the polyphenylene sulfide substrate, so that the surface profile of the substrate layer 11 can meet the requirements of optical surface and high temperature resistance. The mirror 10 provided by the embodiment of the present disclosure can meet the temperature resistance requirement when used as a vehicle lamp reflector and the optical surface requirement of the mirror 10. Moreover, under the premise of omitting the process step of primer treatment of the substrate layer 11, the bonding capacity between the substrate layer 11 and the metal reflection layer 12 can be effectively improved, and the problem of falling off can be avoided.

[0060] For the optical performance test of the mirror 10 provided by the embodiment of the present disclosure, first, as shown in Table III below, different materials are selected to prepare the mirrors for testing, and a test group and a plurality of control groups for optical performance test are formed.

[0061] Table II is a sorting grouping table for preparing mirrors with different materials:

[0062] The test group of the mirrors prepared according to the different materials in Table II is tested for luminous flux and brightness, and the parameter values of luminous flux and brightness of each group are recorded. The comparison table of optical performance test is shown in Table III below.

[0063] Table III is a comparison table of optical performance test

[0064] Another aspect of the embodiment of the present disclosure, as shown in FIG. 5, provides a preparation method of a mirror 10, which comprises:

[0065] S101, provide a polyphenylene sulfide substrate, and add glass fiber, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide substrate respectively, and extrude to form a modified polyphenylene sulfide material.

[0066] The preparation method of the reflector 10 provided by the embodiment of the present disclosure first provides a polyphenylene sulfide substrate. Since the polyphenylene sulfide substrate and the metal material of the metal reflecting layer 12 are two completely different materials, there is no hydrogen bond and intermolecular force between the two completely different materials. The combination effect of the polyphenylene sulfide substrate and the metal material alone is poor. If only the polyphenylene sulfide substrate is used as the combination of the base layer 11 and the metal reflecting layer 12, the metal reflecting layer 12 will easily fall off during use. Therefore, glass fiber, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer are added into the polyphenylene sulfide substrate respectively. After adding the glass fiber, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer in a predetermined proportion respectively, the mixed material is extruded to form a modified polyphenylene sulfide material. Since the glass fiber, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer in a predetermined proportion are added, the glycidyl ester-maleic anhydride-ethylene copolymer can form an activated layer on the surface of the polyphenylene sulfide substrate, thereby improving the bonding force between the aluminum layer. In this way, it can be ensured that the prepared reflector 10 will not have the problem of falling off between the base layer 11 and the metal reflecting layer 12 of the aluminum material during use. Moreover, since the glass fiber and the mineral powder in a predetermined proportion are added respectively, the requirements of the optical design such as the surface profile of the reflector 10 are also met.

[0067] S102, pre-drying treatment is performed on the modified polyphenylene sulfide material.

[0068] After the modified polyphenylene sulfide material is extruded, pre-drying treatment is performed on the modified polyphenylene sulfide material to provide preliminary preparation for the forming effect of the subsequent injection molding process.

[0069] S103, injection molding is performed on the modified polyphenylene sulfide material after the pre-drying treatment at a mold temperature greater than 140℃ to form the base layer 11.

[0070] Then, the modified polyphenylene sulfide material after the pre-drying treatment is injection molded. The injection molding process is performed in a mold, and the mold temperature is ensured to be in a temperature environment greater than 140℃. After the injection molding in the mold, the base layer 11 is formed. The temperature environment greater than 140℃ can effectively improve the effect of injection molding.

[0071] S104, a metal reflecting layer 12 including an aluminum layer or a silver layer is plated on one side surface of the base layer 11.

[0072] The modified polyphenylene sulfide material is used to form the base layer 11 on one side of the surface of the base layer 11 by the injection molding process of S103 step, and the metal reflecting layer 12 is plated to obtain the reflector 10 provided by the embodiment of the present disclosure. The following is illustrated by taking the metal reflecting layer 12 as an aluminum layer as an example. The base layer 11 formed by the injection molding of the modified polyphenylene sulfide material provided by the embodiment of the present disclosure can directly plate the aluminum layer on the surface to prepare the reflector 10, without the process step of primer treatment of the base layer 11 before plating the aluminum layer, so as to effectively improve the bonding capacity between the base layer 11 and the aluminum layer, and avoid the problems such as the peeling of the plated aluminum layer.

[0073] Optionally, as shown in FIG. 6, S101, the polyphenylene sulfide substrate is provided, and glass fibers, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer are added into the polyphenylene sulfide substrate respectively, and extrusion is performed to form the modified polyphenylene sulfide material, which comprises:

[0074] S1011, the mass fraction of the added glass fibers accounts for 15%-25%, the mass fraction of the added mineral powder accounts for 15%-25%, and the mass fraction of the added glycidyl ester-maleic anhydride-ethylene copolymer accounts for 1%-3%.

[0075] In the step of first adding glass fibers, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide substrate, and extrusion is performed to form the modified polyphenylene sulfide material, the mass fraction of the added glycidyl ester-maleic anhydride-ethylene copolymer accounts for 1%-3%. As can be known from the experimental effect diagrams of FIGS. 2-4, when the mass fraction of the added glycidyl ester-maleic anhydride-ethylene copolymer accounts for 1%-3%, the best TL 207 test result can be obtained. The mass fraction of the added glass fibers accounts for 15%-25%, and the mass fraction of the added mineral powder accounts for 15%-25%, which can improve the surface profile of the polyphenylene sulfide substrate, so that the reflector made of the plated metal reflecting layer 12 meets the optical surface requirement, and can meet the high temperature resistance requirement when the reflector 10 is applied to the vehicle lamp module and no powdering phenomenon occurs on the surface of the base layer 11. According to the test results, when the content of the glass fibers is less than 15% and the content of the mineral powder is less than 15% by mass fraction, the temperature resistance of the reflector 10 decreases, which cannot meet the high temperature resistance requirement when the reflector 10 is applied to the vehicle lamp module. When the content of the glass fibers is more than 25% and the content of the mineral powder is more than 25%, the floating fiber problem occurs on the surface of the modified polyphenylene sulfide material as the base layer 11, and even the powdering phenomenon may occur on the surface of the base layer 11.

[0076] Optionally, as shown in FIG. 7, S103, the pre-drying treated modified polyphenylene sulfide material is injection molded at a mold temperature greater than 140°C to form the base layer 11, which comprises:

[0077] S1031, the barrel temperature is between 290-320℃, the injection speed is between 32-64mm / s, the holding pressure is between 40-70MPa, the holding time is 2s, the cooling time is 55s, the screw rotation speed is between 80-150rpm, and the back pressure is between 0.2-1MPa.

[0078] In some embodiments of the present disclosure, in the process of injection molding the mold to form the base layer 11, specifically, the barrel temperature is set between 290-320℃, the injection speed is between 32-64mm / s, the holding pressure is between 40-70MPa, the holding time is 2s, the cooling time is 55s, the screw rotation speed is between 80-150rpm, and the back pressure is between 0.2-1MPa. By limiting the parameters of the barrel temperature, injection speed, holding pressure, holding time, cooling time, and screw rotation speed, back pressure, the completion of the injection molding process can be more effectively guaranteed, so that the base layer 11 formed by injection molding meets the requirements of stable metal reflection layer 12 plating, and the required mirror 10 is obtained.

[0079] Optionally, as shown in FIG. 8, S102, the pre-drying treatment of the modified polyphenylene sulfide material includes:

[0080] S1021, the modified polyphenylene sulfide material is baked at 140℃ for 3 hours.

[0081] The pre-drying treatment of the modified polyphenylene sulfide material before the injection molding process includes baking at 140℃ for 3 hours. Keeping the modified polyphenylene sulfide material at 140℃ for 3 hours can meet the pre-drying treatment requirements of the modified polyphenylene sulfide material, thereby providing a prerequisite for the next high-temperature injection molding.

[0082] Optionally, as shown in FIG. 9, before S101, the method further includes:

[0083] S100, xylene is mixed with sodium sulfide to synthesize polyphenylene sulfide substrate.

[0084] The provided polyphenylene sulfide substrate is synthesized by mixing xylene with sodium sulfide.

[0085] The preparation method of the reflector 10 provided by the embodiments of the present disclosure includes the following steps: providing a polyphenylene sulfide substrate, adding glass fibers, mineral powder and glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide substrate respectively, extruding to form a modified polyphenylene sulfide material; performing pre-drying treatment on the modified polyphenylene sulfide material; injection molding the modified polyphenylene sulfide material after the pre-drying treatment at a mold temperature greater than 140 DEG C to form a base layer 11; and plating a metal reflection layer 12 on one side surface of the base layer, wherein the metal reflection layer 12 includes an aluminum layer or a silver layer. The glass fibers, the mineral powder and the glycidyl ester-maleic anhydride-ethylene copolymer are added into the polyphenylene sulfide substrate respectively, and after the glass fibers, the mineral powder and the glycidyl ester-maleic anhydride-ethylene copolymer in a preset proportion are added, the mixed material is extruded to form the modified polyphenylene sulfide material. Due to the addition of the glass fibers, the mineral powder and the glycidyl ester-maleic anhydride-ethylene copolymer in a preset proportion, the glycidyl ester-maleic anhydride-ethylene copolymer can form an activation layer on the surface of the polyphenylene sulfide substrate, thereby improving the bonding force between the aluminum layer and the base layer 11, so that the prepared reflector 10 can not fall off between the base layer 11 and the metal reflection layer 12 during use. Moreover, due to the addition of the glass fibers and the mineral powder in a preset proportion respectively, the requirements of the optical design such as the surface profile of the reflector 10 are also met. After the pre-drying treatment is completed, the injection molding process is performed, and the mold temperature is ensured to be greater than 140 DEG C, and the injection molding through the mold forms the base layer 11. The temperature environment greater than 140 DEG C can effectively improve the effect of the injection molding. Finally, the metal reflection layer 12 is plated on the surface of the injection molded base layer 11 to prepare the reflector 10, and without the process step of primer treatment on the base layer 11 before plating the metal reflection layer 12, the bonding ability between the base layer 11 and the metal reflection layer 12 can be effectively improved, and the problem of the metal reflection layer 12 falling off can be avoided. Industrial applicability

[0086] In summary, the present disclosure provides a reflector and a preparation method thereof. The reflector is prepared by the preparation method, the modified polyphenylene sulfide material is injection molded at a mold temperature greater than 140 DEG C to form a base layer, and a metal reflection layer is plated directly without primer process to obtain a reflector meeting the requirements of optical surface, temperature resistance and working capacity.

[0087] The reflector has a stable hierarchical structure and a compact structure, can be applied to a vehicle lamp module, is also conducive to flexible adaptation to various other different practical scenarios, and simplifies and optimizes the preparation process and improves the yield.

[0088] The above merely provides the specific implementation of the present disclosure, but the protection scope of the present disclosure is not limited thereto, and any person skilled in the art can easily think of the changes or replacements within the technical range disclosed by the present disclosure, which should be covered in the protection scope of the present disclosure.

Claims

1. A mirror, characterized by The reflector comprises a substrate layer and a metal reflection layer plated on one side of the substrate layer, the material of the substrate layer comprises a polyphenylene sulfide base material, and 15-25% by mass fraction of glass fiber, 15-25% by mass fraction of mineral powder, and 1-3% by mass fraction of glycidyl ester-maleic anhydride-ethylene copolymer.

2. The mirror of claim 1, wherein The metal reflection layer comprises an aluminum layer or a silver layer.

3. The mirror of claim 1, wherein The diameter of the glass fiber is between 4-8 μm.

4. The mirror according to claim 1 or 3, characterized in that The particle size of the mineral powder is between 4-8 μm.

5. The mirror of claim 4, wherein The substrate layer is integrally formed by using an injection molding process.

6. A method for producing a mirror, characterized by The method comprises: providing a polyphenylene sulfide base material, and adding glass fiber, mineral powder, and glycidyl ester-maleic anhydride-ethylene copolymer into the polyphenylene sulfide base material respectively to form a modified polyphenylene sulfide material by extrusion; pre-drying the modified polyphenylene sulfide material; injection molding the modified polyphenylene sulfide material after pre-drying at a mold temperature greater than 140°C to form a substrate layer; plating a metal reflection layer on one side surface of the substrate layer, the metal reflection layer comprising an aluminum layer or a silver layer.

7. The method of claim 6, wherein the mirror is formed by a process selected from the group consisting of sputtering, vacuum deposition, and ion plating. The method comprises: The mass fraction of the added glass fiber is 15-25%, the mass fraction of the added mineral powder is 15-25%, and the mass fraction of the added glycidyl ester-maleic anhydride-ethylene copolymer is 1-3%.

8. The method of claim 6, wherein the mirror is formed by a process selected from the group consisting of sputtering, vacuum deposition, and ion plating. The method comprises: The barrel temperature is between 290-320°C, the injection speed is between 32-64 mm / s, the holding pressure is between 40-70 MPa, the holding time is 2 s, the cooling time is 55 s, the screw rotation speed is between 80-150 rpm, and the back pressure is between 0.2-1 MPa.

9. The method of claim 6, wherein the mirror is prepared by a method comprising: The method comprises: baking the modified polyphenylene sulfide material at 140°C for 3 hours.

10. The method of claim 6, wherein the mirror is prepared by a method comprising: Before providing the polyphenylene sulfide base material, the method further comprises: mixing xylene and sodium sulfide to synthesize the polyphenylene sulfide base material.

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