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高光效防眩光阻燃扩散板——2019神灯奖申报技术

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2019-04-01 作者: 来源:江西盛汇光学科技协同创新有限公司 浏览量: 网友评论: 0

摘要: 高光效防眩光阻燃扩散板,为江西盛汇光学科技协同创新有限公司2019神灯奖申报技术。


项目名称: 高光效防眩光阻燃扩散板

High Light Efficiency Flame Retardant Diffusion Plate

申报单位: 江西盛汇光学科技协同创新有限公司

综合介绍或申报理由:

随着生活品质的提高,人们越来越追求更加舒适的、友好型生活,照明行业同样面临着从之前关注亮度到现在越远越关注照明的舒适性,UGR扩散板就是在这种背景下应运而生。我司不断摸索,采用原材料PC作为主材料,定制蜂巢状透镜或者四棱锥体模具,最后通过热成型将结构复制到PC板片材表面,符合市场未来的需求。

主要技术参数:

1、UGR<19

2、TP(a) 阻燃等级;

TP(a) flame retardant

3、透光率:大于90%,

Light transmission more than 90%

4、雾度:>94,

haze degree more than 94%

与国内外同类产品或同类技术的比较情况:

1、与国外产品对比:国外UGR加工工艺属于UV成型,在PET膜上成型环柱形结构,成型的PET膜很软,需要覆盖在透明板上使用;UGR效果良好,但是生产和使用工艺烦杂,不良率高,UV加工过程有环境污染。

2、与国内产品对比;国内UGR加工主要是采用PS材料在表面成型规则的四棱锥,俗称棱晶板,结构精确度低,棱镜平面尺寸2-4mm,光学均匀性、成型良率及美观度差;并且PS材料使用寿命短,一般6-12个月光学特性就会不达标

3、我司产品相对于国外产品加工工艺简单,一次成型,成本低,而且不会对环境造成污染,相对于国内产品,结构精确度高,结构精平面尺寸0.15-0.4mm,使用寿命3-5年,同时赋予产品阻燃性能,外观视觉效果也更美观。近年来欧盟出台的LED健康照明标准,照明行业已经从对光效、节能的追求提升到对光品质、光健康和光环境的需求,我司的UGR扩散板,符合目前健康照明的行业需求。

1. Compared with foreign products: UGR processing technology belongs to UV forming, forming ring-cylinder structure on PET film, forming PET film is very soft and needs to be covered on transparent board; UGR effect is good, but the production and use process is complicated, bad rate is high, and UV processing process has environmental pollution.

2. Comparing with domestic products, UGR processing in China mainly uses PS material in surface forming rules of quadripyramid, commonly known as prism plate, with low structural accuracy, 2-4mm prism plane size, poor optical uniformity, forming yield and aesthetics; and PS material has short service life, and its optical properties will generally not meet the standards in 6-12 months.

3. Compared with foreign products, our products have simple processing technology, one-time forming, low cost, and no pollution to the environment. Compared with domestic products, our products have high structural accuracy, fine plane size of 0.15-0.4 mm, service life of 3-5 years, at the same time, it gives the product flame retardant performance, and the appearance visual effect is more beautiful. In recent years, the EU issued the LED health lighting standards, the lighting industry has improved from the pursuit of light efficiency and energy saving to the demand for light quality, light health and light environment. Our UGR diffuser meets the current health lighting industry needs.

经济评价分析:

我司的UGR扩散板加工工艺简单,成本低,环境污染小,目前市场上至少有2-3亿人民币的潜在价值需求。

Our companys UGR diffusion plate processing technology is simple, low cost, less environmental pollution, the current market has at least 230 million yuan potential value demand.

技术及工艺创新要点:

高光效防眩光阻燃扩散板就是辅助控制UGR<19以及燃烧等级满足TP(a)的一种扩散板,区别于传统的扩散板,,其低光泽度处理和更加科学的配方工艺,使其扩散性能更佳,增强了扩散板的匀光性能和阻燃性能。

1.高光效防眩光阻燃扩散板区别于现有技术中的采用PMMA、PS作为原材料,我司采用光学性能优异、尺寸稳定性更好的聚碳酸酯(PC)作为原材料;

2.本产品的很好地解决了阻燃问题:一是使用阻燃性能更加优异的聚碳酸酯PC作为主材料,二是添加阻燃剂制成色母粒通过共混工艺对PC阻燃进行改良解决了产品的阻燃问题;

3.本产品需要设计加工具备UGR功能的模具,UGR功能的模具有两种结构,透镜结构和四棱锥结构,两者加工难度不一样,目前透镜结构能加工60-700目的结构,而四棱锥结构受设备工艺影响,只能加工30-200目的结构,因此生产不同板片材厚度对应加工模具的结构选择是不同的;最终使压延对辊压制扩散板的过程中将扩散板表面形成凸形蜂巢状或者凸形四棱锥体形状;

4、本产品解决了扩散与防眩光矛盾问题:防眩光是聚光,扩散是散光,两者互为矛盾,添加阻燃剂会提高扩散效果,阻燃剂添加量越多,扩散效果越好,防眩光效果就越差,因此选取进口高效阻燃剂,少量的含量就能使PC板片材达到TP(a)的阻燃等级,提高防眩光效果;

5.本产品工艺通过热成型或紫外成型将模具上的微结构90%复制到板片材:发明工艺中对挤出机工艺(流道温度、辊温以及模具采用机械限位等)调整,将压延对辊表面上的结构深度90%复制到板片材上。

Highly glossy anti-glare and flame retardant diffuser is a kind of diffuser with auxiliary control UGR < 19 and combustion grade satisfying TP(a). It is different from the traditional diffuser. Its low gloss treatment and more scientific formulation process make its diffusivity better and enhance the uniformity and flame retardancy of the diffuser.

1. High light efficiency anti-glare flame retardant diffuser is different from PMMA and PS as raw materials in the existing technology. Our company uses polycarbonate (PC) with excellent optical properties and better dimensional stability as raw materials.

2. This product solves the flame retardant problem well: first, it uses polycarbonate PC with better flame retardant performance as the main material; second, it adds flame retardant to make color masterbatch, and improves the flame retardant of PC through blending process to solve the flame retardant problem of the product;

3. This product needs to design and process the mould with UGR function. There are two kinds of structure of the mould with UGR function. The lens structure and the quadripyramid structure have different processing difficulty. At present, the lens structure can process 60-700 mesh structure, while the quadripyramid structure can only process 30-200 mesh structure because of the influence of equipment technology. Therefore, the structure selection of the processing die for different sheet thickness is the same. In the process of rolling the diffusion plate, the surface of the diffusion plate will form a convex honeycomb shape or a convex quadripyramid shape.

4. This product solves the contradiction between diffusion and anti-glare: anti-glare is concentration and diffusion is astigmatism. They are contradictory. Adding flame retardant can improve the diffusion effect. The more the flame retardant is added, the better the diffusion effect is, and the worse the anti-glare effect is. Therefore, selecting imported high-efficiency flame retardant, a small amount of content can make PC sheet reach the flame retardant grade of TP(a) and improve the anti-glare effect. Effect;

5. The process of this product duplicates 90% of the micro-structure on the die to the sheet by hot forming or ultraviolet forming. In the invented process, the extruder process (runner temperature, roll temperature and mechanical limit of the die) is adjusted, and 90% of the structure depth on the roll surface is duplicated to the sheet.

实际运用案例和用户评价意见:

如图


申报单位介绍:

江西盛汇光学科技协同创新有限公司是经江西省科技厅批准,注册资金八千万,目前已投资1.5亿元,以研究世界前沿的光学应用技术为核心业务的科技协同创新体承办单位。 公司研发、生产、销售的“明月牌”PC光学扩散板&膜、广泛应用于LED筒灯、面板灯、高棚灯、广告灯箱、LCD背光模组等光学领域,被誉为高品质健康照明的“伴侣”,多次荣获照明行业优秀技术奖。

Jiangxi Shenghui Optical Technology Collaborative Innovation Co.,Ltd, permitted by Jiangxi Science and Technology Department, The registered capital is USD 12 MILLION. Now USD 22 MILLION has been invested at present. It is honored as Science and Technology Collaborative Innovator which specializes in developing optics applications. Our company focuses on developing,producing and selling PC light diffusion sheets and films which are widely applied to LED down lights, panel lights, high bay light, advertising lamp boxes, LCD, backlight modules etc. It is an integral part of Green LED lights with high light efficiency.

产品图片:

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