CN110684331A - Anti-dazzle diffusion plate and preparation process thereof - Google Patents
Anti-dazzle diffusion plate and preparation process thereof Download PDFInfo
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- CN110684331A CN110684331A CN201910949257.4A CN201910949257A CN110684331A CN 110684331 A CN110684331 A CN 110684331A CN 201910949257 A CN201910949257 A CN 201910949257A CN 110684331 A CN110684331 A CN 110684331A
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- C—CHEMISTRY; METALLURGY
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/24—Calendering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/002—Combinations of extrusion moulding with other shaping operations combined with surface shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/20—Compounding polymers with additives, e.g. colouring
- C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
- C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2469/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2201/00—Properties
- C08L2201/02—Flame or fire retardant/resistant
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
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Abstract
The anti-glare diffusion plate comprises the following components in percentage by mass: polycarbonate (C): 99.7% -99.95%; potassium perfluorobutylsulfonate flame retardant: 0.05% -0.3%, wherein the polycarbonate is polycarbonate with B1 grade flame retardant property; the surface of the anti-dazzle diffusion plate consists of a plurality of convex semicircles or convex regular pyramids which are continuously arranged. The preparation process of the anti-glare diffusion plate comprises the following steps: mixing a flame retardant with part of polycarbonate resin raw materials, and melting at high temperature in a masterbatch machine to prepare masterbatch; then, uniformly mixing the color master batch and the other part of polycarbonate raw material by a V-shaped mixer and then melting; and then, flowing the molten material into a calender roll group with a concave semicircular or concave quadrangular pyramid on the surface, pressing the molten material into a diffusion plate with uniform thickness, and finally carrying out conventional treatment such as cooling and the like to obtain the anti-glare diffusion plate.
Description
Technical Field
The invention belongs to the technical field of optical diffusion plates, and particularly relates to an anti-dazzle diffusion plate and a forming process thereof.
Background
The UGR (Unified Glare Rating, also known as Unified Glare value, is a psychological parameter for measuring the subjective reaction of discomfort caused by light emitted by a lighting device in an indoor visual environment to eyes) diffusion plate is an anti-Glare diffusion plate for assisting in controlling UGR < 19, is different from the traditional diffusion plate, has better diffusion performance due to the low-gloss processing mode and the formula process, enhances the light uniformity of the diffusion plate, and is an ideal solution for effectively preventing Glare.
In the application of the UGR in lamp illumination, the UGR values are different, the difference of the illumination effect is obvious, and the difference of vision and psychology is large. With the improvement of life quality, people seek more comfortable and environment-friendly life, the illumination industry is also confronted with the comfort of illumination from the prior attention on brightness to the present far and far attention, and the UGR diffusion plate is produced under the background.
At present, most of UGR diffusion plate main materials in the market are mostly made of PMMA and PS, the flame retardant effect is poor, and the market prospect is not good.
Disclosure of Invention
In order to overcome the defects that the anti-glare diffusion plate in the prior art is poor in optical performance, poor in dimensional stability and incapable of meeting the requirements in flame retardant property, the invention provides the anti-glare diffusion plate, the raw material of Polycarbonate (PC) with B1-grade flame retardant property is adopted, efficient flame retardant is added for modification, the anti-glare (UGR) diffusion plate meeting the TP (a) flame retardant requirement is produced through processes of high-temperature melting, extrusion and the like, and the preparation process of the anti-glare diffusion plate is provided.
The technical scheme of the invention is that the anti-glare diffusion plate comprises the following components in percentage by mass: polycarbonate (C): 99.7% -99.95%; potassium perfluorobutylsulfonate flame retardant: 0.05% -0.3%, wherein the polycarbonate is polycarbonate with B1-grade flame retardant property, and the polycarbonate and the flame retardant are treated by a blending process to reach the standard of combustion TP (a); the surface of the anti-dazzle diffusion plate is composed of a plurality of optical microstructures which are continuously arranged, and the optical microstructures are in a convex semicircular shape or a convex quadrangular pyramid shape.
The invention also provides a process for preparing the anti-glare diffusion plate, which comprises the following steps:
(1) preparing color master batch: fully mixing a flame retardant with part of polycarbonate resin, feeding the mixture into a color master machine, melting the mixture at a high temperature, extruding and cooling the mixture through a melting pipeline, and cutting the mixture into color master batches serving as auxiliary raw materials for manufacturing the diffusion plate;
(2) blending: uniformly mixing the color master batch obtained in the step (1) with the rest of polycarbonate raw material through a V-shaped mixer;
(3) melting: adding the mixture obtained in the step (2) into a melting cavity of equipment at a preset speed, and melting;
(4) casting: extruding the melted raw materials along an extrusion die channel according to a certain amount, and enabling the raw materials to flow out through a die lip with a regulated thickness, wherein the die lip is used for obtaining fluid with a certain thickness;
(5) rolling: making the molten raw material flowing out of the die lip flow into a calendering roller set, and pressing the molten raw material into a diffusion plate with uniform thickness by the calendering roller with the adjusted gap; the surface of the molten raw material forms a convex honeycomb or convex quadrangular pyramid corresponding to the preset structure on the surface of the calendering roller pair in the calendering process by a thermoforming or ultraviolet forming process;
(6) and (3) cooling: cooling the diffusion plate with undegraded temperature to normal temperature by a cooling roller;
(7) coating a protective film: in order to ensure the cleanliness of the diffusion plate, a protective film is compounded;
(8) trimming: trimming the product according to the specified width;
(9) and (4) checking: carrying out product quality inspection;
(10) packaging: packaging the qualified product into finished products according to the requirements of users;
(11) and (7) warehousing.
Further, a portion of the polycarbonate resin in the above step (1) is in the range of 5.55% to 33.23% by weight based on the total weight of the polycarbonate resin in the anti-glare diffuser plate.
Further, the temperature of the high-temperature melting in the above step (1) is about 275 ℃.
Further, the melting in the above step (3) is carried out at about 265 ℃.
The anti-dazzle diffusion plate uses Polycarbonate (PC) with excellent optical performance and better dimensional stability as a main material, and the polycarbonate PC is modified by adopting a potassium perfluorobutylsulfonate flame retardant, so that the obtained anti-dazzle diffusion plate has anti-dazzle performance, and the surface of the extruded anti-dazzle diffusion plate presents numerous convex semicircular honeycomb shapes and convex quadrangular pyramid shapes with consistent structures by using rollers with honeycomb concave semicircles and cone structures in the preparation process, so that light entering the diffusion plate and radiating at an angle of more than 120 degrees is weakened, glare generated by a lamp is reduced, and the anti-dazzle effect is achieved; in the process of manufacturing the anti-glare diffuser plate, the optical structure of the roll surface is maximally transferred to the diffuser plate by setting the extruder process (runner temperature, roll temperature, etc.).
The invention has the advantages that:
1. the anti-glare diffusion plate is different from the anti-glare diffusion plate in the prior art which adopts PMMA and PS as raw materials, and the anti-glare diffusion plate adopts Polycarbonate (PC) with excellent optical performance and better dimensional stability as a raw material;
2. the invention well solves the flame-retardant problem: firstly, polycarbonate PC with more excellent flame retardant property is used as a main material, secondly, a perfluorobutyl potassium sulfonate flame retardant is added to prepare a color master batch, and the flame retardance of the PC is improved again through a blending process so that the combustion grade of the product reaches TP (a);
3. the mold with the UGR function is designed and processed, the mold with the UGR function has two structures, namely a concave semicircular structure and a rectangular pyramid structure, the processing difficulty of the concave semicircular structure and the rectangular pyramid structure is different, the concave semicircular structure can process a 60-700-mesh structure at present, the rectangular pyramid structure is influenced by equipment and technology and can only process a 30-200-mesh structure, and therefore, the structure selection of the processing mold corresponding to the thickness of different sheet plates is different; finally, in the process of pressing the diffusion plate by the calendering pair rollers, the surface of the diffusion plate is formed into a convex semicircular honeycomb shape or a convex quadrangular pyramid shape;
4. the invention solves the problem of contradiction between diffusion and anti-glare: the anti-dazzle light is condensation light, the diffusion light is diffusion light, the two are contradictory, the diffusion effect can be improved by adding the flame retardant, the more the addition amount of the flame retardant is, the better the diffusion effect is, and the worse the anti-dazzle effect is, so that the PC plate can reach the combustion grade of TP (a) by selecting the flame retardant potassium perfluorobutylsulfonate with a small content, and the anti-dazzle effect is improved;
5. the process of the invention copies the microstructure on the die to a sheet material through thermal forming or ultraviolet forming: in the invention process, the extruder process, namely the calendering process (the temperature of a flow channel, the temperature of a roller, a mould and the like adopt mechanical limit) is adjusted, and the structure on the surface of a calendering roller pair is copied to a plate sheet.
Drawings
These and/or other aspects and advantages of the present invention will become more apparent and more readily appreciated from the following detailed description of the embodiments of the invention, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic view showing a lens structure shape structure of a surface of an anti-glare diffuser plate according to an embodiment of the present invention;
fig. 2 is a schematic structural view of a regular rectangular pyramid structure on the surface of an anti-glare diffuser plate according to an embodiment of the present invention.
Fig. 3 is a schematic process flow diagram of the preparation of the anti-glare diffuser plate according to the embodiment of the invention.
Detailed Description
In order that those skilled in the art will better understand the present invention, the following detailed description of the invention is provided in conjunction with the accompanying drawings and the detailed description of the invention.
Example 1
A process for preparing an anti-glare diffuser plate with a continuous convex semicircle surface, which comprises the following steps according to the process flow diagram shown in fig. 3:
(1) preparing color master batch: fully mixing a flame retardant potassium perfluorobutyl sulfonate accounting for 0.3 percent of the total mass of the raw materials with a polycarbonate resin accounting for 33.23 percent of the total mass of the polycarbonate resin, putting the mixture into a color master batch machine, melting the mixture at a high temperature of 275 ℃, extruding and cooling the mixture through a melting pipeline, and cutting the mixture into color master batches serving as auxiliary raw materials for manufacturing the diffusion plate;
(2) blending: uniformly mixing the color master batch obtained in the step (1) with the rest polycarbonate raw material through a V-shaped mixer;
(3) melting: adding the mixture obtained in the step (2) into a melting cavity of equipment at a preset speed, and melting at 265 ℃;
(4) casting: extruding the melted raw materials along an extrusion die channel according to a certain amount, and enabling the raw materials to flow out through a die lip with a regulated thickness, wherein the die lip is used for obtaining fluid with a certain thickness;
(5) rolling: making the molten raw material flowing out of the die lip flow into a calendering roller set, and pressing the molten raw material into a diffusion plate with uniform thickness by the calendering roller with the adjusted gap; the surface of the rolling double-roll is provided with a preset microstructure, the preset microstructure is a concave semicircular honeycomb shape, the diameter of each concave semicircle is 254 micrometers, the depth is 127 micrometers, and a convex semicircular honeycomb shape corresponding to the preset structure on the surface of the rolling double-roll is formed on the surface of the molten raw material in the rolling process through a thermal forming or ultraviolet forming process in the rolling process; the diameter of the convex semicircle of the formed structure is 254 micrometers, and the height is 63.5-127 micrometers;
(6) and (3) cooling: cooling the diffusion plate with undegraded temperature to normal temperature by a cooling roller;
(7) coating a protective film: in order to ensure the cleanliness of the diffusion plate, a protective film is compounded;
(8) trimming: trimming the product according to the specified width;
(9) and (4) checking: carrying out product quality inspection;
(10) packaging: packaging the qualified product into finished products according to the requirements of users;
(11) and (7) warehousing.
The schematic structural diagram of the anti-glare diffusion plate obtained by the process method is shown in fig. 1, and it can be seen that the surface of the diffusion plate is a convex semicircle with a diameter of 254 microns and a height of 63.5-127 microns.
Example 2
A process for preparing an anti-glare diffuser plate with a surface consisting of continuous convex regular rectangular pyramids, which comprises the following steps according to a process flow diagram shown in fig. 3:
(1) preparing color master batch: fully mixing a flame retardant potassium perfluorobutyl sulfonate accounting for 0.05 percent of the total mass of the raw materials with a polycarbonate resin accounting for 5.56 percent of the total mass of the polycarbonate resin, putting the mixture into a color master batch machine, melting the mixture at a high temperature of 275 ℃, extruding and cooling the mixture through a melting pipeline, and cutting the mixture into color master batches serving as auxiliary raw materials for manufacturing the diffusion plate;
(2) blending: uniformly mixing the color master batch obtained in the step (1) with the rest of polycarbonate raw material through a V-shaped mixer;
(3) melting: adding the mixture obtained in the step (2) into a melting cavity of equipment at a preset speed, and melting at a preset temperature of 265 ℃;
(4) casting: extruding the melted raw materials along an extrusion die channel according to a certain amount, and enabling the raw materials to flow out through a die lip with a regulated thickness, wherein the die lip is used for obtaining fluid with a certain thickness;
(5) rolling: making the molten raw material flowing out of the die lip flow into a calendering roller set, and pressing the molten raw material into a diffusion plate with uniform thickness by the calendering roller with the adjusted gap; the surface of the molten raw material forms a convex quadrangular pyramid corresponding to the predetermined structure on the surface of the rolling pair roller in the rolling process by a thermal forming or ultraviolet forming process;
(6) and (3) cooling: cooling the diffusion plate with undegraded temperature to normal temperature by a cooling roller;
(7) coating a protective film: in order to ensure the cleanliness of the diffusion plate, a protective film is compounded;
(8) trimming: trimming the product according to the specified width;
(9) and (4) checking: carrying out product quality inspection;
(10) packaging: packaging the qualified product into finished products according to the requirements of users;
(11) and (7) warehousing.
The schematic structural diagram of the anti-glare diffuser plate obtained by the process method is shown in fig. 2, and it can be seen that the surface of the diffuser plate is composed of continuous convex regular rectangular pyramids.
Having described embodiments of the present invention, the foregoing description is intended to be exemplary, not exhaustive, and not limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (5)
1. An anti-glare diffusion plate is characterized by comprising the following components in percentage by mass:
polycarbonate (C): 99.7% -99.95%;
potassium perfluorobutylsulfonate flame retardant: 0.05 to 0.3 percent of the total weight of the mixture,
the polycarbonate is polycarbonate with B1 grade flame retardant property;
the surface of the anti-dazzle diffusion plate is composed of a plurality of optical microstructures which are continuously arranged, and the optical microstructures are convex honeycomb-shaped or convex quadrangular pyramid-shaped.
2. A process for preparing an anti-glare diffuser plate according to claim 1, comprising the steps of:
(1) preparing color master batch: fully mixing a flame retardant with part of polycarbonate resin, feeding the mixture into a masterbatch machine, melting the mixture at high temperature, extruding and cooling the mixture through a melting pipeline, and cutting the mixture into masterbatch which is used as an auxiliary raw material for manufacturing a diffusion plate;
(2) blending: uniformly mixing the color master batch obtained in the step (1) with the rest of polycarbonate raw material through a V-shaped mixer;
(3) melting: adding the mixture obtained in the step (2) into a melting cavity of equipment at a preset speed, and melting;
(4) casting: extruding the melted raw materials along an extrusion die channel according to a certain amount, and flowing out through a die lip with adjusted thickness;
(5) rolling: making the molten raw material flowing out of the die lip flow into a calendering roller set, and pressing the molten raw material into a diffusion plate with uniform thickness by the calendering roller with the adjusted gap; the surface of the molten raw material forms a convex honeycomb or convex quadrangular pyramid corresponding to the predetermined structure on the surface of the calendering roller pair in the calendering process by a thermoforming or ultraviolet forming process in the calendering process;
(6) and (3) cooling: cooling the diffusion plate with undegraded temperature to normal temperature by a cooling roller;
(7) coating a protective film: in order to ensure the cleanliness of the diffusion plate, a protective film is compounded;
(8) trimming: trimming the product according to the specified width;
(9) and (4) checking: carrying out product quality inspection;
(10) packaging: packaging the qualified product into finished products according to the requirements of users;
(11) and (7) warehousing.
3. The process for preparing an anti-glare diffuser plate according to claim 2, wherein the portion of the polycarbonate resin in the step (1) is in the range of 5.55 to 33.23 wt% based on the total weight of the polycarbonate resin in the anti-glare diffuser plate.
4. The process for preparing an anti-glare diffuser plate according to claim 2, wherein the temperature of the high-temperature melting in the step (1) is about 275 ℃.
5. The process for preparing an anti-glare diffuser plate according to claim 2, wherein the melting in the step (3) is performed at about 265 ℃.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113504591A (en) * | 2021-07-08 | 2021-10-15 | 江西盛汇光学科技协同创新有限公司 | Diffusion brightening composite optical membrane and preparation method thereof |
| CN113504592A (en) * | 2021-07-08 | 2021-10-15 | 江西盛汇光学科技协同创新有限公司 | Diffusion film for printing display and preparation method thereof |
| CN113801405A (en) * | 2021-10-11 | 2021-12-17 | 绍兴明优光电科技有限公司 | Light guide plate and preparation process thereof |
| CN115307107A (en) * | 2022-08-15 | 2022-11-08 | 昆山市诚泰电气股份有限公司 | Optical grade plastic microcrystal plate with microstructure adjusting glare index value and production process thereof |
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| CN113504591A (en) * | 2021-07-08 | 2021-10-15 | 江西盛汇光学科技协同创新有限公司 | Diffusion brightening composite optical membrane and preparation method thereof |
| CN113504592A (en) * | 2021-07-08 | 2021-10-15 | 江西盛汇光学科技协同创新有限公司 | Diffusion film for printing display and preparation method thereof |
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