Preparation method of PC light diffusion plate

Abstract

The invention relates to the technical field of PC light diffusion plates, and discloses a preparation method of a PC light diffusion plate, which comprises the following steps: preparing a nanoscale light diffusion agent, and uniformly dispersing nano silicon dioxide in polycarbonate resin; producing bio-based PC resin by synthesizing polycarbonate from epoxidized vegetable oil and diol; adding the nano light diffusant into the molten PC resin in a high-shear mixer; extruding the mixture through an automatic continuous production line; a real-time monitoring system is used for monitoring extrusion pressure and temperature; the extruded PC light diffusion plate is subjected to multifunctional coating treatment, and the step of preparing the nanoscale light diffusion agent comprises the step of adding 180-220 mL of ethyl alcohol and 40-60 mL of deionized water into a container. The energy consumption and carbon emission in the production process are obviously reduced by using the bio-based PC resin, and the dependence on fossil fuel is reduced by using the bio-based PC resin, so that the emission of greenhouse gases is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of PC light diffuser plates, in particular to a method for preparing a PC light diffuser plate. Background Art

[0002] PC light diffusers, also known as polycarbonate light diffusers, are widely used in LED lighting and LCD display technologies to improve light uniformity and reduce glare. These sheets diffuse light for a more even distribution, thereby improving the visual performance of lighting or display devices. PC is chosen as the primary material for light diffusers due to its excellent impact resistance, light transmittance, and temperature resistance. They are widely used in commercial and industrial lighting, automotive interior and exterior lighting systems, and various display devices.

[0003] Existing methods for preparing PC light diffuser sheets typically involve mixing a selected PC resin with a light diffuser, such as organic or inorganic particles, and then forming the sheet through extrusion or injection molding. The basic principle of this method is to evenly distribute the light diffuser throughout the PC matrix through physical mixing. The particle size and distribution of the light diffuser directly influence the light scattering efficiency and transmittance of the sheet, thereby improving the light utilization efficiency of lamps and reducing glare caused by direct light sources.

[0004] While existing methods for preparing PC light diffusers can improve the light efficiency of lamps and reduce glare caused by direct light sources, they still have some shortcomings. First, the use of petroleum-based PC resin has a significant impact on the environment, with high energy consumption and the generation of high levels of greenhouse gases during production. Second, the uneven distribution of the light diffuser during physical mixing can lead to unstable optical properties in the finished product, affecting product quality and consistency. Finally, the existing production process is inefficient, with suboptimal energy and material utilization, resulting in high production costs and an increased environmental burden. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention provides a method for preparing PC light diffuser panels. By utilizing bio-based PC resin and high-shear mixing technology, the method effectively reduces energy consumption and greenhouse gas emissions during the production process, while simultaneously improving the optical performance and production efficiency of the panels. The optimization of the automated production line further reduces resource consumption and waste generation, significantly improving production cost-effectiveness.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A method for preparing a PC light diffuser plate, comprising the following steps:

[0007] Prepare nano-scale light diffuser and evenly disperse nano-silicon dioxide in polycarbonate resin;

[0008] Production of bio-based PC resins by synthesizing polycarbonate from epoxidized vegetable oils and diols;

[0009] Add the nano-light diffuser to the molten PC resin in a high shear mixer;

[0010] Extruding the mixture through an automated continuous production line;

[0011] Use real-time monitoring system to monitor extrusion pressure and temperature;

[0012] Multifunctional coating treatment for extruded PC light diffuser sheets.

[0013] Preferably, the preparation of the nanoscale light diffuser comprises:

[0014] Add 180-220 mL of ethanol and 40-60 mL of deionized water to the container;

[0015] Slowly add 8-12 mL of ammonium hydroxide and adjust the pH to 9;

[0016] 8 to 12 mL of ethyl orthosilicate was added, and the mixture was stirred and reacted for 4 to 8 hours to form SiO2 nanoparticles with a particle size of 20 to 50 nm.

[0017] Preferably, the production of bio-based PC resin comprises:

[0018] Heat the epoxidized vegetable oil to 140-160°C;

[0019] Slowly add propylene glycol and react for 3 to 5 hours;

[0020] A polymerization reaction is carried out at a temperature of 200 to 240° C. using a titanium-based catalyst for 5 to 7 hours to obtain a bio-based PC resin.

[0021] Preferably, adding the nano light diffuser to the molten PC resin in the high shear mixer comprises:

[0022] Add nano-SiO2 into the molten PC resin at a ratio of 0.5% to 2%;

[0023] Heat the mixture to 260-300°C;

[0024] Mixing was performed in a high shear mixer for 10-20 minutes to ensure uniform distribution of the nanoparticles.

[0025] Preferably, the extrusion of the mixture through an automated continuous production line comprises:

[0026] Install temperature, speed and pressure sensors at the extruder inlet, outlet and cooling zone;

[0027] Use a PLC system to automatically adjust extrusion temperature and speed based on sensor feedback;

[0028] The extrusion temperature is controlled at 250-270°C, and the cooling speed is adjusted synchronously with the extrusion speed to ensure product quality.

[0029] Preferably, the use of a real-time monitoring system to monitor extrusion pressure and temperature includes:

[0030] Installing high-resolution cameras and pressure sensors in the production line;

[0031] Real-time monitoring of pressure and temperature changes during extrusion and automatic adjustment of production parameters;

[0032] The surface quality of the extruded sheet is automatically detected by image processing software, and an alarm is automatically issued in case of abnormality.

[0033] Preferably, the multifunctional coating treatment includes:

[0034] Formulating an acrylic-based coating containing 3% to 7% TiO2 nanoparticles, 1% to 3% UV stabilizer, and 0.5% to 1.5% antistatic agent;

[0035] The coating is applied using high-precision roller coating equipment, with a coating thickness controlled at 3 to 7 microns;

[0036] Using UV light curing technology, use a UV lamp with a wavelength of 365nm to irradiate for 1 to 3 minutes to complete the curing.

[0037] Preferably, the multifunctional coating treatment further comprises:

[0038] Conduct anti-ultraviolet testing to confirm that the UV blocking rate reaches more than 98%;

[0039] Antistatic performance test was conducted and the static dissipation time was less than 0.5 seconds.

[0040] Preferably, the high shear mixer comprises:

[0041] The shear rate of the high shear mixer was set to 2000–6000 rpm;

[0042] Maintain a constant temperature during mixing to ensure uniform distribution.

[0043] Preferably, the cooling process of the automated continuous production line includes:

[0044] Rapid cooling through cooling rollers and cooling troughs, the cooling temperature range is 15 ~ 30 ° C;

[0045] Air and water are used as cooling media during the cooling process to ensure dimensionally stable and flat products.

[0046] The present invention provides a method for preparing a PC light diffuser plate. It has the following beneficial effects:

[0047] 1. The present invention significantly reduces energy consumption and carbon emissions in the production process by using bio-based PC resin. The application of bio-based PC resin reduces dependence on fossil fuels, thereby helping to reduce greenhouse gas emissions.

[0048] 2. This invention ensures uniform distribution of nanoparticles in the PC resin through a sophisticated high-shear mixing process, significantly improving the light transmittance and light scattering efficiency of the light diffuser. This improvement not only enhances the optical performance of the product but also optimizes its visual effect.

[0049] 3. This invention optimizes the manufacturing process by utilizing an automated production line and its cooling system, effectively controlling resource consumption and waste generation during production, and reducing production costs. Furthermore, by reducing energy consumption and material waste, production efficiency is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 Flow chart of the method of the present invention. DETAILED DESCRIPTION

[0051] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the specification of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0052] Please see the attached Figure 1 The present invention provides a method for preparing a PC light diffuser plate, comprising the following steps:

[0053] Prepare nano-scale light diffusers by evenly dispersing nano-silicon dioxide in polycarbonate resin. Through the dispersion of nano-scale particles, the light diffuser can achieve more uniform light transmission when used, reduce light loss, and improve lighting effects, especially in high-end display devices and lighting systems.

[0054] Producing bio-based PC resins by synthesizing polycarbonate from epoxidized vegetable oils and diols. Using bio-based materials not only reduces dependence on fossil fuels but also enhances the product's environmental profile, which is a key attraction for consumers and businesses increasingly seeking sustainable products.

[0055] The nano-light diffuser is added to the molten PC resin in a high shear mixer. The use of a high shear mixer can effectively avoid uneven distribution of nanoparticles in the high viscosity PC resin, thereby ensuring the consistency and quality of the optical properties of the final product;

[0056] By extruding the mixture through an automated continuous production line, the automated control system can significantly improve production efficiency and product quality, and reduce manual operation errors and material waste;

[0057] Use a real-time monitoring system to monitor extrusion pressure and temperature. Real-time monitoring and automatic adjustment improve the stability and reliability of the production process, reduce production downtime and defective product rate, and ultimately reduce costs;

[0058] The extruded PC light diffuser sheet is treated with a multifunctional coating. The multifunctional coating not only improves the service life and durability of the product, but also enhances its market competitiveness, especially in application scenarios that require long-term use or harsh external environments.

[0059] Please see the attached Figure 1 In a preferred embodiment of the present invention, preparing the nanoscale light diffuser includes:

[0060] Add 180-220 mL of ethanol and 40-60 mL of deionized water to the container. Ethanol, as a solvent, can not only dissolve the silicon source but also stabilize the reaction environment to prevent excessive polymerization. Deionized water is used to adjust the ratio of ethanol to water to optimize solubility and reaction rate.

[0061] Slowly add 8-12 mL of ammonium hydroxide and adjust the pH to 9. Ammonium hydroxide is used to adjust the pH of the solution to 9. Controlling the pH value is crucial for regulating the nucleation and growth rate of silica particles. Too high or too low a pH value will affect the uniformity and size of the particles.

[0062] Add 8 to 12 mL of ethyl orthosilicate and stir the reaction for 4 to 8 hours to form SiO2 nanoparticles with a particle size of 20 to 50 nanometers. Ethyl orthosilicate serves as a silicon source and undergoes hydrolysis and condensation reactions under the action of ethanol and water to generate silicon dioxide. Stirring gradually hydrolyzes the ethyl orthosilicate to generate silicon dioxide particles. This time is conducive to more complete hydrolysis and condensation, thereby generating more uniform particles.

[0063] By precisely controlling the reaction conditions, silica nanoparticles with a particle size of 20 to 50 nanometers are prepared. These small particles can provide better scattering effects in light diffusion applications, thereby enhancing the performance of the light diffuser plate. At the same time, the use of relatively mild chemicals such as ammonium hydroxide and ethyl orthosilicate is more environmentally friendly than using more intense or toxic chemical reagents.

[0064] Please see the attached Figure 1 In a preferred embodiment of the present invention, producing bio-based PC resin comprises:

[0065] Heat the epoxidized vegetable oil to 140-160°C. The heating temperature is controlled within this range to ensure that the oil temperature is sufficient to activate the epoxy groups while avoiding overheating that may cause oil decomposition or unwanted side reactions.

[0066] Slowly add propylene glycol and allow to react for 3 to 5 hours. Propylene glycol, as a multifunctional diol, can react with epoxy groups to form stable carbonate bonds. This reaction time also allows the epoxy groups to react with propylene glycol to form a prepolymer.

[0067] At a temperature of 200-240°C, a polymerization reaction is carried out using a titanium-based catalyst for 5-7 hours to obtain a bio-based PC resin. The titanium-based catalyst can effectively promote the ring-opening and polymerization reaction between the epoxy group and the diol in the synthesis of polycarbonate, thereby improving the selectivity and efficiency of the reaction. At the same time, this reaction time ensures that the polymerization is fully carried out to produce a bio-based PC resin with a higher molecular weight and good performance.

[0068] Using epoxidized vegetable oils from renewable resources instead of traditional petroleum-based raw materials significantly reduces the environmental impact of the production process, while reducing the generation of by-products and waste, lowering production costs, and improving the utilization of raw materials.

[0069] Please see the attached Figure 1 In a preferred embodiment of the present invention, adding the nano light diffuser to the molten PC resin in a high shear mixer comprises:

[0070] Adding nano-SiO2 to the molten PC resin at a ratio of 0.5% to 2% can ensure that it can effectively scatter light without excessively affecting the transparency of the material, thereby optimizing the optical properties of the light diffuser plate, achieving a balance between high transparency and high light diffusion, and adapting to different application requirements;

[0071] The mixture is heated to 260-300°C. This temperature range is set based on the melting point of PC resin and its processing temperature window. It is higher than the melting point of PC to ensure that the resin is completely melted, but not too high to avoid thermal degradation. This not only ensures the full melting of PC resin, but also helps to evenly disperse nano-SiO2, thereby improving the consistency and quality of the final product.

[0072] Mixing in a high-shear mixer for 10 to 20 minutes ensures uniform distribution of the nanoparticles. The high-shear mixer is used to ensure that the nano-SiO2 can be evenly dispersed in the high-viscosity PC resin. The high shear force can break up the agglomeration caused by the mutual attraction between the nanoparticles, ensuring that each particle is individually encapsulated in the resin. This long time can ensure that there is no particle aggregation, while avoiding damage to the particles or degradation of the PC resin due to excessive stirring, thereby greatly improving the optical quality and mechanical properties of the finished product.

[0073] Please see the attached Figure 1 In a preferred embodiment of the present invention, extruding the mixture through an automated continuous production line comprises:

[0074] Temperature, speed, and pressure sensors are installed at the extruder inlet, outlet, and cooling zone. The temperature sensor is used to monitor the temperature of the extruded material to ensure that it is processed within the appropriate temperature range; the speed sensor is used to monitor the extrusion speed to ensure that the material is pushed at a uniform rate; and the pressure sensor is used to detect pressure changes during the extrusion process. The installation of sensors enables real-time monitoring and adjustment of the production line, thereby significantly improving the consistency of product quality and reducing the defective product rate during the production process.

[0075] Use a PLC system to automatically adjust extrusion temperature and speed based on sensor feedback. The PLC system receives and processes sensor data and quickly makes adjustment decisions, such as adjusting the power of the heater or changing the speed of the extrusion screw. The use of the PLC system improves the automation level of the production process, reduces the need for human intervention, improves the accuracy and repeatability of operations, and reduces production costs.

[0076] The extrusion temperature is controlled at 250-270°C, and the cooling rate is adjusted synchronously with the extrusion speed to ensure product quality. This temperature range ensures the full melting of the PC resin while avoiding degradation or color change caused by excessive temperature, thereby ensuring that the extruded sheet has excellent mechanical properties and dimensional stability, making the final product more reliable and durable in use.

[0077] Please see the attached Figure 1 In a preferred embodiment of the present invention, monitoring the extrusion pressure and temperature using a real-time monitoring system includes:

[0078] High-resolution cameras and pressure sensors are installed in the production line. The cameras are used to capture real-time video of the extrusion process, while the pressure sensors are used to measure the pressure throughout the extrusion process to ensure that the pressure is within a safe and optimal operating range. The data from these sensors is transmitted to the central control system in real time to monitor the entire extrusion process and ensure that there are no mechanical failures or material blockages. By promptly detecting any abnormalities in the production process, measures can be taken to quickly resolve the problems and prevent production accidents and quality problems.

[0079] Real-time monitoring of pressure and temperature changes during the extrusion process, automatic adjustment of production parameters, and the use of an automated control system connected to sensors to receive real-time temperature and pressure data. Based on a preset parameter model, the system compares current data with standard data in real time and automatically adjusts the extruder's temperature and pressure. Automated adjustment of production parameters can greatly improve product consistency and quality, reduce human error, and increase production efficiency and material utilization.

[0080] Image processing software automatically inspects the surface quality of extruded sheet materials, generating automatic alarms for any anomalies. Video captured by a high-resolution camera is transmitted in real time to VisionPro, a pre-programmed software program designed to identify any surface defects such as bubbles, cracks, and uneven color. The application of image processing technology improves the speed and accuracy of product inspection, reducing reliance on manual visual inspection. Automatic alarms ensure high quality standards are maintained even in large-scale production, minimizing scrap.

[0081] Please see the attached Figure 1 In a preferred embodiment of the present invention, the multifunctional coating process comprises:

[0082] An acrylic-based coating containing 3% to 7% TiO2 nanoparticles, 1% to 3% UV stabilizer, and 0.5% to 1.5% antistatic agent is formulated. The TiO2 nanoparticles provide excellent optical scattering capabilities, improving the optical properties of the light diffuser. The UV stabilizer is used to resist aging caused by ultraviolet rays, maintaining the product's transparency and strength. The antistatic agent reduces dust absorption, maintaining the cleanliness and gloss of the product surface. These ingredients are uniformly mixed in the acrylic matrix to form a coating premix. The multifunctional properties of this coating make the PC light diffuser have higher durability and better visual effects during use, while also improving long-term environmental stability and user experience.

[0083] The coating is applied using high-precision roller coating equipment, with a controlled coating thickness of 3 to 7 microns. The equipment's adjustment mechanism allows for fine-tuning of the coating pressure and speed to accommodate varying sheet thicknesses and material properties, ensuring uniform coating distribution. High-precision roller coating ensures uniform application, optimizing the coating's functional properties, such as light scattering and UV blocking, while ensuring a beautiful finish.

[0084] UV light curing technology is used, and UV lamps with a wavelength of 365nm are used to irradiate for 1 to 3 minutes to complete the curing. UV light curing is an efficient curing technology that can quickly cure the coating through a photoinitiated reaction in a short time, thereby significantly shortening the production cycle. UV light can excite the photoinitiator in the coating, triggering a polymerization reaction in the acrylic matrix, and quickly forming a stable polymer network structure. UV light curing technology not only speeds up the production process and reduces energy consumption, but also improves the adhesion and chemical resistance of the coating, ensuring the long-term performance and durability of the coating.

[0085] Please see the attached Figure 1 In a preferred embodiment of the present invention, the multifunctional coating process further comprises:

[0086] UV resistance testing is conducted to confirm that the UV blocking rate reaches over 98%. A PC light diffuser coated with a multifunctional coating is placed in a test device and irradiated with 365nm UV light. The intensity of the UV light after passing through the coating is measured, and the UV blocking rate is calculated. Repeated testing ensures consistent and accurate results. The purpose of UV testing is to verify the effectiveness of the UV stabilizer in the coating. UV stabilizers absorb or reflect UV rays, preventing them from penetrating into the PC substrate, thereby extending the material's lifespan and maintaining its mechanical and optical properties. This improves the stability and durability of the product in outdoor or strong light environments, and reduces UV-induced aging and color changes.

[0087] Antistatic performance testing was conducted, with a static dissipation time of less than 0.5 seconds. This test primarily evaluates the effectiveness of antistatic agents in coatings. Antistatic agents reduce static charge accumulation by providing a path for static charge to escape or by increasing surface conductivity. By ensuring a static dissipation time of less than 0.5 seconds, the risk of dust absorption and static discharge is effectively reduced, making the product more suitable for environments requiring high cleanliness.

[0088] Please see the attached Figure 1 In a preferred embodiment of the present invention, the high shear mixer comprises:

[0089] The shear rate of the high shear mixer is set at 2000-6000 rpm. This high shear force is intended to ensure that the nano-silica particles in the mixture are fully and evenly dispersed in the polycarbonate resin. By adjusting the shear rate, the dispersion of the particles can be optimized, and particle agglomeration and sedimentation can be prevented, thereby improving the optical quality and mechanical stability of the final product.

[0090] Maintaining a constant temperature during the mixing process ensures uniform distribution. This constant temperature ensures that the polycarbonate resin maintains appropriate fluidity while avoiding changes in physical properties caused by overheating or overcooling, thereby ensuring that the viscosity of the polymer melt is within an optimal range. By precisely controlling the mixing temperature, degradation or excessive fluidity of the polycarbonate resin can be prevented, ensuring consistency and reproducibility of the coating quality, thereby obtaining a light diffuser with high uniformity and excellent performance.

[0091] Please see the attached Figure 1 In a preferred embodiment of the present invention, the cooling process of the automated continuous production line includes:

[0092] Rapid cooling is achieved through cooling rollers and cooling troughs at a temperature range of 15-30°C. During the cooling process, the thermoplastic resin quickly transitions from a high-temperature molten state to a solidified state. Rapid cooling can effectively reduce the generation of internal stress, avoid the risk of product deformation or internal cracks, and thus improve product quality and consistency.

[0093] Air and water are used as cooling media during the cooling process to ensure the product's dimensional stability and flatness. Combining air and water cooling allows for more efficient thermal management. Air cooling provides a gradual temperature reduction to prevent thermal shock, while water cooling is used to rapidly reduce the temperature. This combination ensures a smooth transition from hot to cold, not only ensuring the dimensional stability and flatness of the PC light diffuser during production, but also improving production efficiency and reducing energy consumption.

[0094] In order to better understand the present invention, the above method is described in detail below with reference to specific examples.

[0095] Example 1: Environmentally friendly PC light diffuser plate

[0096] Material selection and processing:

[0097] Use bio-based PC resins made entirely from renewable resources, such as bio-based polycarbonate derived from corn or sugar beets.

[0098] Uses a solvent-free physical mixing method to reduce volatile organic compound emissions.

[0099] Preparation process:

[0100] 5% environmentally friendly TiO2 nanoparticles are added in a high shear mixer. These particles are synthesized by an environmentally friendly process to ensure low environmental impact.

[0101] Using solar-powered extrusion equipment for PC sheet production further reduces the carbon footprint of the production process.

[0102] Example 2: High optical performance PC light diffuser plate

[0103] Material selection and processing:

[0104] Use PC resin with high optical purity to ensure the transparency and optical performance of the final product.

[0105] A blend of high-refractive-index TiO2 nanoparticles with a specially coated coating, specifically designed to optimize light scattering.

[0106] Preparation process:

[0107] Nanoparticles and PC resin are precisely mixed under controlled temperature and shear conditions, using patented mixing technology to ensure complete dispersion of nanoparticles.

[0108] Advanced roller coating technology is used to evenly coat the surface of PC sheets with anti-scratch and anti-UV layers.

[0109] In the preparation process of PC light diffuser plates, different embodiments can be adopted to adapt to various application requirements and manufacturing conditions. The following are three specific examples that show the impact of different materials, process technologies and equipment configurations on the performance of the final product:

[0110] Example 1: Environmentally friendly PC light diffuser plate

[0111] Material selection and processing:

[0112] Use bio-based PC resins made entirely from renewable resources, such as bio-based polycarbonate derived from corn or sugar beets.

[0113] Uses a solvent-free physical mixing method to reduce volatile organic compound (VOC) emissions.

[0114] Preparation process:

[0115] 5% environmentally friendly TiO2 nanoparticles are added in a high shear mixer. These particles are synthesized by an environmentally friendly process to ensure low environmental impact.

[0116] Using solar-powered extrusion equipment for PC sheet production further reduces the carbon footprint of the production process.

[0117] Beneficial effects:

[0118] This preparation method not only conforms to the trend of sustainable development, but also enhances the competitiveness of the product in the market by using environmentally friendly materials, attracting consumers seeking green products.

[0119] Example 2: High optical performance PC light diffuser plate

[0120] Material selection and processing:

[0121] Use PC resin with high optical purity to ensure the transparency and optical performance of the final product.

[0122] A blend of high-refractive-index TiO2 nanoparticles with a specially coated coating, specifically designed to optimize light scattering.

[0123] Preparation process:

[0124] Nanoparticles and PC resin are precisely mixed under controlled temperature and shear conditions, using patented mixing technology to ensure complete dispersion of nanoparticles.

[0125] Advanced roller coating technology is used to evenly coat the surface of PC sheets with anti-scratch and anti-UV layers.

[0126] Beneficial effects:

[0127] The optimized optical performance makes this PC light diffuser particularly suitable for high-end LED lighting and LCD display backlight modules, improving the brightness and energy efficiency of the equipment.

[0128] Example 3: High-durability PC light diffuser plate

[0129] Material selection and processing:

[0130] Use specially treated PC resin to enhance its UV resistance and heat aging resistance.

[0131] Multifunctional additives such as antioxidants and heat stabilizers are added to extend the service life of the product.

[0132] Preparation process:

[0133] A twin-screw extruder is used to mix PC resin and additives, ensuring efficient and uniform mixing.

[0134] Rapid cooling technology and post-heat treatment process are applied to optimize the mechanical properties and dimensional stability of the products.

[0135] Comparative Experiment 1: Optical Performance Comparison Test

[0136] Experimental purpose: To verify the difference in optical performance between the PC light diffuser plate of the present invention and the traditional PC light diffuser plate, especially the light transmittance and light scattering effect.

[0137] Experimental setup

[0138] Sample preparation:

[0139] Control group A: light diffuser plate made of traditional PC resin.

[0140] Control group B: a light diffuser plate made of conventional PC resin using the high shear mixing process of the present invention.

[0141] Experimental group: a light diffuser plate made using the bio-based PC resin and high shear mixing process proposed in the present invention.

[0142] Optical measuring equipment:

[0143] Use a spectrometer to measure light transmittance;

[0144] The total light scattering efficiency was measured using an integrating sphere;

[0145] Measuring equipment should be calibrated to ensure data accuracy and repeatability.

[0146] Experimental procedures

[0147] Sample preparation:

[0148] Three sets of samples were prepared according to their respective preparation methods, with a uniform size of 200mmx200mm.

[0149] Light transmittance test:

[0150] Place each sample under the spectrometer;

[0151] Record the light intensity passing through the sample and calculate the transmittance.

[0152] Light scattering effect test:

[0153] Place the sample in the integrating sphere;

[0154] Measure and record the intensity of light scattered from multiple angles and calculate the light scattering efficiency.

[0155] Data recording and analysis:

[0156] Collect all test data;

[0157] Statistical software was used to analyze the data and compare the optical properties of the three groups of samples.

[0158] The comparative experimental data are shown in Table 1:

[0159] Table 1 Optical performance comparison test results

[0160] Template Type Test Number Light transmittance (%) Astigmatism angle (degrees) Light scattering efficiency (%) Control group A A1 88.2 25 60.1 Control group A A2 87.9 25 59.8 Control group B B1 90.5 30 63.3 Control group B B2 90.3 30 63.5 Experimental group C1 92.4 35 68.2 Experimental group C2 92.6 35 68.5 Control group A A3 88.0 25 59.9 Control group B B3 90.2 30 63.4 Experimental group C3 92.5 35 68.3

[0161] From the data in Table 1, we can get:

[0162] Light transmittance: The experimental group showed the highest light transmittance, which was significantly higher than that of control group A and control group B, indicating that the materials and processes used in the present invention can significantly improve light transmittance.

[0163] Astigmatism angle: The experimental group also exhibited the largest astigmatism angle, which is an advantage for light diffusers because a larger astigmatism angle helps to distribute light more evenly.

[0164] Light scattering efficiency: The light scattering efficiency of the experimental group is the highest, which indicates that the light diffuser plate of the present invention is more effective in scattering light and is suitable for applications requiring high light scattering performance.

[0165] Comparative Experiment 2: Environmental Impact Test

[0166] Experimental purpose: To evaluate and compare the environmental impact of the production process of light diffuser plates made of bio-based PC resin and traditional petroleum-based PC resin.

[0167] Experimental setup

[0168] Sample preparation:

[0169] Control group: light diffuser using traditional petroleum-based PC resin;

[0170] Experimental group: a light diffuser plate using the bio-based PC resin of the present invention.

[0171] Environmental Impact Assessment Tools:

[0172] Use life cycle assessment software to model and calculate the environmental impact of every step from raw material acquisition to product production, including energy consumption, greenhouse gas emissions, water use, and waste generation.

[0173] Experimental procedures

[0174] Data Collection:

[0175] Collect detailed data on the production and processing of two PC resins, including energy consumption, raw material sources, and chemical use;

[0176] Ensure that the data collected is timely and regionally relevant.

[0177] Life Cycle Assessment Implementation:

[0178] Input all relevant data into the LCA software;

[0179] Analyze the environmental impact of the entire production cycle, paying special attention to key indicators such as carbon footprint and water footprint.

[0180] Result analysis:

[0181] Compare the performance of the two groups of models on key environmental impact indicators;

[0182] Identify which production stages or raw material usage have the greatest environmental impact and explore improvement options.

[0183] The comparative experimental data are shown in Table 2:

[0184] Table 2 Comparative test results of environmental impact

[0185] Template Type Production batch Energy consumption (MJ) CO2 emissions (kg) Water consumption (L) Waste generation (kg) control group 1 150 10 100 2.5 control group 2 152 11 98 2.7 Experimental group 1 130 8 85 2.0 Experimental group 2 128 7.5 88 1.8 control group 3 149 10.5 99 2.6 Experimental group 3 129 7.8 86 2.1

[0186] From the data in Table 2, we can get:

[0187] Energy consumption: The average energy consumption of the experimental group was significantly lower than that of the control group, indicating that the use of bio-based PC resin can effectively reduce energy consumption in the production process.

[0188] CO2 emissions: The CO2 emissions of the experimental group were also significantly lower than those of the control group, which may be related to the fact that the production process of bio-based PC resin is more environmentally friendly and helps reduce greenhouse gas emissions.

[0189] Water consumption: The experimental group consumed less water than the control group, further demonstrating that bio-based PC resin is more water-efficient during the production process.

[0190] Waste Generation: The experimental group also generated less waste than the control group, indicating better environmental performance and resource utilization efficiency.

[0191] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a PC light diffuser plate, characterized in that: The following steps are involved: Prepare nano-scale light diffuser and evenly disperse nano-silicon dioxide in polycarbonate resin; Production of bio-based PC resins by synthesizing polycarbonate from epoxidized vegetable oils and diols; Add the nano-light diffuser to the molten PC resin in a high shear mixer; Extruding the mixture through an automated continuous production line; Use real-time monitoring system to monitor extrusion pressure and temperature; Multifunctional coating treatment for extruded PC light diffuser sheets.

2. The method for preparing a PC light diffuser plate according to claim 1, wherein: The preparation of the nanoscale light diffusing agent comprises: Add 180-220 mL of ethanol and 40-60 mL of deionized water to the container; Slowly add 8-12 mL of ammonium hydroxide and adjust the pH to 9; 8 to 12 mL of ethyl orthosilicate was added, and the mixture was stirred and reacted for 4 to 8 hours to form SiO2 nanoparticles with a particle size of 20 to 50 nm.

3. The method for preparing a PC light diffuser plate according to claim 1, wherein: The production of bio-based PC resin comprises: Heat the epoxidized vegetable oil to 140-160°C; Slowly add propylene glycol and react for 3 to 5 hours; A polymerization reaction is carried out at a temperature of 200 to 240° C. using a titanium-based catalyst for 5 to 7 hours to obtain a bio-based PC resin.

4. The method for preparing a PC light diffuser plate according to claim 1, wherein: Adding the nano light diffuser to the molten PC resin in the high shear mixer comprises: Add nano-SiO2 into the molten PC resin at a ratio of 0.5% to 2%; Heat the mixture to 260-300°C; Mixing was performed in a high shear mixer for 10-20 minutes to ensure uniform distribution of the nanoparticles.

5. The method for preparing a PC light diffuser plate according to claim 1, wherein: The extrusion of the mixture through an automated continuous production line comprises: Install temperature, speed and pressure sensors at the extruder inlet, outlet and cooling zone; Use a PLC system to automatically adjust extrusion temperature and speed based on sensor feedback; The extrusion temperature is controlled at 250-270°C, and the cooling speed is adjusted synchronously with the extrusion speed to ensure product quality.

6. The method for preparing a PC light diffuser plate according to claim 1, wherein: The use of a real-time monitoring system to monitor extrusion pressure and temperature includes: Installing high-resolution cameras and pressure sensors in the production line; Real-time monitoring of pressure and temperature changes during extrusion and automatic adjustment of production parameters; The surface quality of the extruded sheet is automatically detected by image processing software, and an alarm is automatically issued in case of abnormality.

7. The method for preparing a PC light diffuser plate according to claim 1, wherein: The multifunctional coating treatment includes: Formulating an acrylic-based coating containing 3% to 7% TiO2 nanoparticles, 1% to 3% UV stabilizer, and 0.5% to 1.5% antistatic agent; The coating is applied using high-precision roller coating equipment, with a coating thickness controlled at 3 to 7 microns; Using UV light curing technology, use a UV lamp with a wavelength of 365nm to irradiate for 1 to 3 minutes to complete the curing.

8. The method for preparing a PC light diffuser plate according to claim 1, wherein: The multifunctional coating treatment further comprises: Conduct anti-ultraviolet testing to confirm that the UV blocking rate reaches more than 98%; Antistatic performance test was conducted and the static dissipation time was less than 0.5 seconds.

9. The method for preparing a PC light diffuser plate according to claim 1, wherein: The high shear mixer comprises: The shear rate of the high shear mixer was set to 2000–6000 rpm; Maintain a constant temperature during mixing to ensure uniform distribution.

10. The method for preparing a PC light diffuser plate according to claim 1, wherein: The cooling process of the automated continuous production line includes: Rapid cooling through cooling rollers and cooling troughs, the cooling temperature range is 15 ~ 30 ° C; Air and water are used as cooling media during the cooling process to ensure dimensionally stable and flat products.

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