高光效防眩光阻燃擴(kuò)散板——2019神燈獎申報技術(shù)

項目名稱：  高光效防眩光阻燃擴(kuò)散板

High Light Efficiency Flame Retardant Diffusion Plate

申報單位：  江西盛匯光學(xué)科技協(xié)同創(chuàng)新有限公司

綜合介紹或申報理由：

隨著生活品質(zhì)的提高，人們越來越追求更加舒適的、友好型生活，照明行業(yè)同樣面臨著從之前關(guān)注亮度到現(xiàn)在越遠(yuǎn)越關(guān)注照明的舒適性，UGR擴(kuò)散板就是在這種背景下應(yīng)運而生。我司不斷摸索，采用原材料PC作為主材料，定制蜂巢狀透鏡或者四棱錐體模具，最后通過熱成型將結(jié)構(gòu)復(fù)制到PC板片材表面，符合市場未來的需求。

主要技術(shù)參數(shù)：

1、UGR＜19 

2、TP(a) 阻燃等級；

TP(a) flame retardant   

3、透光率：大于90%,

 Light transmission more than 90% 

4、霧度：＞94, 

haze degree more than 94%

與國內(nèi)外同類產(chǎn)品或同類技術(shù)的比較情況：

1、與國外產(chǎn)品對比：國外UGR加工工藝屬于UV成型，在PET膜上成型環(huán)柱形結(jié)構(gòu)，成型的PET膜很軟，需要覆蓋在透明板上使用；UGR效果良好，但是生產(chǎn)和使用工藝煩雜，不良率高，UV加工過程有環(huán)境污染。 

2、與國內(nèi)產(chǎn)品對比;國內(nèi)UGR加工主要是采用PS材料在表面成型規(guī)則的四棱錐，俗稱棱晶板，結(jié)構(gòu)精確度低，棱鏡平面尺寸2-4mm，光學(xué)均勻性、成型良率及美觀度差；并且PS材料使用壽命短，一般6-12個月光學(xué)特性就會不達(dá)標(biāo) 

3、我司產(chǎn)品相對于國外產(chǎn)品加工工藝簡單，一次成型，成本低，而且不會對環(huán)境造成污染，相對于國內(nèi)產(chǎn)品，結(jié)構(gòu)精確度高，結(jié)構(gòu)精平面尺寸0.15-0.4mm，使用壽命3-5年，同時賦予產(chǎn)品阻燃性能，外觀視覺效果也更美觀。近年來歐盟出臺的LED健康照明標(biāo)準(zhǔn)，照明行業(yè)已經(jīng)從對光效、節(jié)能的追求提升到對光品質(zhì)、光健康和光環(huán)境的需求，我司的UGR擴(kuò)散板，符合目前健康照明的行業(yè)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.

經(jīng)濟(jì)評價分析：

我司的UGR擴(kuò)散板加工工藝簡單，成本低，環(huán)境污染小，目前市場上至少有2-3億人民幣的潛在價值需求。

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

技術(shù)及工藝創(chuàng)新要點：

高光效防眩光阻燃擴(kuò)散板就是輔助控制UGR＜19以及燃燒等級滿足TP（a）的一種擴(kuò)散板，區(qū)別于傳統(tǒng)的擴(kuò)散板，，其低光澤度處理和更加科學(xué)的配方工藝，使其擴(kuò)散性能更佳，增強了擴(kuò)散板的勻光性能和阻燃性能。

1.高光效防眩光阻燃擴(kuò)散板區(qū)別于現(xiàn)有技術(shù)中的采用PMMA、PS作為原材料，我司采用光學(xué)性能優(yōu)異、尺寸穩(wěn)定性更好的聚碳酸酯（PC）作為原材料；

2.本產(chǎn)品的很好地解決了阻燃問題：一是使用阻燃性能更加優(yōu)異的聚碳酸酯PC作為主材料，二是添加阻燃劑制成色母粒通過共混工藝對PC阻燃進(jìn)行改良解決了產(chǎn)品的阻燃問題；

3.本產(chǎn)品需要設(shè)計加工具備UGR功能的模具，UGR功能的模具有兩種結(jié)構(gòu)，透鏡結(jié)構(gòu)和四棱錐結(jié)構(gòu)，兩者加工難度不一樣，目前透鏡結(jié)構(gòu)能加工60-700目的結(jié)構(gòu)，而四棱錐結(jié)構(gòu)受設(shè)備工藝影響，只能加工30-200目的結(jié)構(gòu)，因此生產(chǎn)不同板片材厚度對應(yīng)加工模具的結(jié)構(gòu)選擇是不同的；最終使壓延對輥壓制擴(kuò)散板的過程中將擴(kuò)散板表面形成凸形蜂巢狀或者凸形四棱錐體形狀；

4、本產(chǎn)品解決了擴(kuò)散與防眩光矛盾問題：防眩光是聚光，擴(kuò)散是散光，兩者互為矛盾，添加阻燃劑會提高擴(kuò)散效果，阻燃劑添加量越多，擴(kuò)散效果越好，防眩光效果就越差，因此選取進(jìn)口高效阻燃劑，少量的含量就能使PC板片材達(dá)到TP（a）的阻燃等級，提高防眩光效果；

5.本產(chǎn)品工藝通過熱成型或紫外成型將模具上的微結(jié)構(gòu)90%復(fù)制到板片材：發(fā)明工藝中對擠出機(jī)工藝（流道溫度、輥溫以及模具采用機(jī)械限位等）調(diào)整，將壓延對輥表面上的結(jié)構(gòu)深度90%復(fù)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.

實際運用案例和用戶評價意見：

如圖
   

申報單位介紹：

江西盛匯光學(xué)科技協(xié)同創(chuàng)新有限公司是經(jīng)江西省科技廳批準(zhǔn)，注冊資金八千萬，目前已投資1.5億元，以研究世界前沿的光學(xué)應(yīng)用技術(shù)為核心業(yè)務(wù)的科技協(xié)同創(chuàng)新體承辦單位。 公司研發(fā)、生產(chǎn)、銷售的“明月牌”PC光學(xué)擴(kuò)散板&膜、廣泛應(yīng)用于LED筒燈、面板燈、高棚燈、廣告燈箱、LCD背光模組等光學(xué)領(lǐng)域，被譽為高品質(zhì)健康照明的“伴侶”，多次榮獲照明行業(yè)優(yōu)秀技術(shù)獎。 

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.

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