PC diffusion plate with surface microstructure

Abstract

The utility model discloses a kind of PC diffusion plate with surface microstructure, it is related to diffusion plate technical field.The utility model includes abrasion-resistant surface layer, diffusion function layer and substrate layer by from top to bottom sequentially composite;The outer surface of abrasion-resistant surface layer is equipped with regularly arranged microstructure unit, microstructure unit is dome-shaped boss, the top of dome-shaped boss is arc surface, arc radius R is 0.05~0.08mm;The bottom of dome-shaped boss is square, bottom surface side length a is 0.25~0.35mm, height h is 0.08~0.1mm;The spacing d between adjacent two dome-shaped bosses is 0.02~0.03mm, and it is diagonal 45 rectangular array arrangement;The thickness of abrasion-resistant surface layer is 0.15~0.3mm.The utility model is set by setting dome-shaped boss structure, its top is arc surface instead of sharp corner shape, reduce the stress concentration point when contact with hard object, realize the promotion of microstructure wear resistance, scratch resistance, avoid the optical performance attenuation caused by tip or edge wear.

Description

Technical Field

[0001] This utility model belongs to the field of diffusion plate technology, specifically, it relates to a PC diffusion plate with surface microstructure. Background Technology

[0002] As a key component in LED lighting and flat panel display, the surface microstructure of the diffuser plate plays a decisive role in its optical performance.

[0003] Chinese patent CN222979818U discloses a PC diffuser plate with surface microstructures, including a diffuser plate body, comprising a top layer, a foam layer, and a bottom layer stacked together in sequence. The outer surface of the top layer is provided with obliquely rectangular arranged quadrangular pyramidal microstructures. The quadrangular pyramidal microstructures are regular square pyramids and are spaced apart. By setting the quadrangular pyramidal microstructures, the diffuser plate significantly improves the brightness and uniformity of the surrounding area, reduces the spacing between the quadrangular pyramidal microstructures, and significantly improves the bright and dark stripes generated when the diffuser plate is backlit. The foam layer in the diffuser plate has small and uniformly distributed pores, which improves the diffusion of the plate. The three-layer co-extrusion process and the structure of the quadrangular pyramidal microstructures can ensure the scratch resistance of the diffuser plate surface and the uniform optical effect of secondary diffusion. However, the quadrangular pyramidal microstructures are convex in shape and small in size. During daily use or installation, if they come into contact with hard objects, the tips or edges of the microstructures are easily worn or scratched.

[0004] In view of this, this utility model is proposed. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a PC diffusion plate with surface microstructure, which solves the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by this utility model is as follows: A PC diffusion plate with surface microstructure includes a wear-resistant surface layer, a diffusion functional layer, and a substrate layer, which are sequentially composited from top to bottom. The outer surface of the wear-resistant surface layer is provided with regularly arranged microstructure units, each of which is a dome-shaped boss. The top of each dome-shaped boss is an arc surface with a radius R of 0.05–0.08 mm. The bottom of each dome-shaped boss is square, with a side length a of 0.25–0.35 mm and a height h of 0.08–0.1 mm. The spacing d between two adjacent dome-shaped bosses is 0.02–0.03 mm, and they are arranged in a 45° oblique rectangular array. The wear-resistant surface layer has a thickness of 0.15–0.3 mm and is made of PC composite material with 0.5–1.5 wt% nano-alumina added. The diffusion functional layer contains closed pores with an average diameter of 100–200 μm and a pore density of 300–500 pores / cm³.

[0007] Optionally, the top arc radius R of the dome-shaped boss is 0.06 to 0.07 mm.

[0008] Optionally, the particle size of the nano-alumina in the wear-resistant surface layer is 20-50 nm.

[0009] Optionally, the surface hardness of the wear-resistant surface layer is ≥2H (pencil hardness test).

[0010] Optionally, the thickness of the substrate layer is 1 to 3 mm, and it is made of flame-retardant PC material.

[0011] Optionally, the wear-resistant surface layer, diffusion functional layer, and substrate layer are integrally formed by a three-layer co-extrusion process.

[0012] Optionally, the bottom of the dome-shaped boss is provided with a rounded transition at the connection between it and the wear-resistant surface layer, and the radius of the transition rounded corner r is 0.01 to 0.02 mm.

[0013] By adopting the above technical solution, this utility model has the following beneficial effects compared with the prior art. Of course, any product implementing this utility model does not necessarily need to achieve all of the following advantages at the same time: 1. By setting a dome-shaped boss structure with a rounded top rather than a sharp corner, the stress concentration points when in contact with hard objects are reduced, thereby improving the wear and scratch resistance of the microstructure and avoiding the degradation of optical performance caused by wear of the tip or edge. 2. By setting a rounded transition structure at the connection between the bottom of the dome-shaped boss and the wear-resistant surface (the transition radius r is 0.01~0.02mm), the stress under external impact is dispersed, avoiding the problem of easy cracking at the edge of similar four-corner pyramid microstructures, thereby enhancing the overall structural stability of the microstructure and ensuring the stability of optical performance during long-term use. 3. By adding 0.5-1.5wt% nano-alumina (particle size 20-50nm) to the wear-resistant surface structure, its surface hardness is increased to ≥2H, which is much higher than the HB level of traditional diffuser plates, thus achieving effective protection of the microstructure and resisting friction and minor collision damage during daily installation and use.

[0014] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. Attached Figure Description

[0015] The accompanying drawings described below are merely some embodiments. Those skilled in the art can obtain other drawings based on these drawings without any creative effort. In the drawings: Figure 1 This is a schematic diagram of the overall structure; Figure 2 for Figure 1 Enlarged structural diagram at point A; Figure 3 This is an exploded structural diagram of the wear-resistant surface layer, diffusion functional layer, and substrate layer. Figure 4 This is a schematic diagram of the diffusion functional layer structure; Figure 5 This is a schematic diagram of the overall and partial cross-sectional structure; Figure 6 This is a schematic diagram of the overall structure from another perspective.

[0016] The attached diagram lists the components represented by each number as follows: 1. Substrate layer; 2. Diffusion functional layer; 3. Wear-resistant surface layer; 4. Dome-shaped boss; 5. Closed cell.

[0017] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the present invention in any way, but rather to illustrate the concept of the present invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings.

[0019] Example 1 Please see Figure 1-6 As shown, this embodiment provides a PC diffusion plate with surface microstructure, including a wear-resistant surface layer 3, a diffusion functional layer 2, and a substrate layer 1 sequentially composited from top to bottom; the outer surface of the wear-resistant surface layer 3 is provided with regularly arranged microstructure units, each microstructure unit being a dome-shaped protrusion 4, the top of the dome-shaped protrusion 4 being an arc surface with an arc radius R of 0.05–0.08 mm; the bottom of the dome-shaped protrusion 4 being a square with a side length a of 0.25–0.35 mm and a height h of 0.08–0.1 mm; the spacing d between two adjacent dome-shaped protrusions 4 is 0.02–0.03 mm, and they are arranged in a 45° oblique rectangular array; the thickness of the wear-resistant surface layer 3 is 0.15–0.3 mm, and it is made of PC composite material with 0.5–1.5 wt% nano-alumina added; the diffusion functional layer 2 contains closed pores 5 with an average diameter of 100–200 μm and a pore density of 300–500 pores / cm³.

[0020] The wear-resistant surface layer 3 focuses on surface protection and primary optical control, the diffusion layer 2 undertakes the main task of light homogenization, and the substrate layer 1 provides structural support and stability. The three layers work together to ensure optical performance and enhance physical properties. The rounded top design of the dome-shaped protrusion 4 reduces sharp contact points. Combined with the wear-resistant surface layer 3 reinforced with nano-alumina (hardness ≥2H), it can withstand friction and minor impacts during daily installation and cleaning, solving the problem of optical performance degradation caused by easy wear of traditional microstructures. The rounded corners further reduce stress concentration and improve structural durability. The oblique array arrangement and size optimization of the surface microstructure can achieve uniform light scattering and avoid bright and dark stripes. The pore structure of the diffusion layer 2 and the surface microstructure form a double diffusion effect, with a light transmittance of over 90%, while ensuring brightness consistency over a wide viewing angle. Even if the surface is slightly scratched, the dome-shaped design has less impact on the light path than traditional sharp-corner structures, resulting in slower optical performance degradation.

[0021] Example 2 Please see Figure 1-6As shown, in this embodiment, the radius R of the top arc of the dome-shaped protrusion 4 is 0.06-0.07 mm. This radius ensures that light is scattered from multiple angles when it comes into contact with the protrusion (avoiding uneven brightness caused by reflection in a single direction), while also reducing the sharpness of the protrusion's top. Compared to a smaller radius (e.g., 0.05 mm), this range reduces stress concentration during impacts; compared to a larger radius (e.g., 0.08 mm), it avoids a decrease in scattering efficiency due to an overly flat top. This improves scratch resistance while maintaining the uniformity of optical diffusion, ensuring that light effectively diffuses after passing through the protrusion without creating local bright spots or dark areas due to an unreasonable arc. The nano-alumina particles in the wear-resistant surface layer 3 have a particle size of 20-50 nm. A particle size of 20-50 nm is considered "submicron," which allows light to pass through... The small size effect uniformly fills the gaps between PC molecules (avoiding agglomeration) and enhances the hardness of the surface material through interfacial interaction. When the particle size is less than 20nm, the nanoparticles are prone to agglomeration due to excessive surface energy, which reduces the uniformity of the material. When the particle size is greater than 50nm, the interfacial bonding force between the particles and the PC matrix decreases, and the strengthening effect weakens. This ensures that the nano-alumina is uniformly distributed in the wear-resistant surface layer 3, which can not only stably improve the surface hardness to above 2H, but also avoid the increase in local brittleness caused by particle agglomeration, so that the surface layer has both high wear resistance and good toughness. The surface hardness of the wear-resistant surface layer 3 is ≥2H (pencil hardness test). In the pencil hardness test, 2H hardness means that the surface layer can withstand a pencil with a hardness of 2H being scratched under certain pressure without producing a scratch, which is much higher than the HB level of traditional PC diffusion plates (easily scratched by hard objects). This hardness index is achieved through the synergistic effect of the dispersion reinforcement of nano-alumina and the inherent properties of the PC substrate. It meets the friction requirements during daily installation and cleaning, without causing surface embrittlement due to excessive hardness (such as when the hardness reaches 4H or above, the material is prone to cracking). It significantly improves the scratch resistance of the diffuser plate, reduces surface damage during transportation, installation and use, and extends the optical performance stability period of the product. It is especially suitable for scenarios with high-frequency contact or that require regular cleaning (such as shopping mall light boxes and classroom panel lights).

[0022] Example 3 Please see Figure 1-6As shown, in this embodiment, the thickness of the substrate layer 1 is 1-3mm, made of flame-retardant PC material. The substrate layer 1 provides stable support for the overall structure (avoiding warping caused by the three-layer composite) and expands its application scenarios through its flame-retardant properties (such as homes and offices with high fire safety requirements). Simultaneously, the 1-3mm thickness makes the product lighter while maintaining strength, reducing installation difficulty. The wear-resistant surface layer 3, the diffusion functional layer 2, and the substrate layer 1 are integrally formed through a three-layer co-extrusion process. The three-layer structure is tightly bonded, eliminating the risk of interlayer delamination and improving the overall structural stability of the diffusion plate. Integrated molding reduces production steps and minimizes errors caused by multi-step processing (such as interlayer alignment deviations), balancing product quality and production efficiency. The bottom of the dome-shaped boss 4 connects to the wear-resistant surface layer 3 with a rounded transition radius r of 0.01–0.02 mm. This connection point is a critical area of ​​stress concentration; right angles or excessively small rounded corners (<0.01 mm) are prone to cracking under external forces (such as impacts or compression), while excessively large rounded corners (>0.02 mm) reduce the connection area between the boss bottom and the surface, decreasing the boss's structural stability. The 0.01–0.02 mm rounded corner disperses external forces through the arc surface, ensuring the connection strength between the boss and the surface layer, preventing the boss from breaking at the root or cracking due to external impacts, further improving the durability of the surface microstructure, and ensuring that optical performance does not degrade after long-term use.

[0023] Working principle: Optical control and protection are achieved through multi-layer synergy. The light first undergoes primary diffusion through the dome-shaped protrusions 4 of the wear-resistant surface layer 3, then undergoes secondary scattering through the pores of the diffusion functional layer 2, and finally is stably output through the substrate layer 1 to ensure uniform light. The nano-alumina reinforcing material and the arc-shaped structure of the protrusions in the wear-resistant surface layer 3 enhance scratch resistance, and the three-layer co-extrusion process enhances overall stability, achieving a synergy between high uniformity and high durability.

[0024] This utility model is not limited to the above-described embodiments. Anyone should know that structural changes made under the guidance of this utility model, and any technical solutions that are the same as or similar to this utility model, fall within the protection scope of this utility model. Technical aspects, shapes, and structures not described in detail in this utility model are all publicly known technologies.

Claims

1. A PC diffusion plate with surface microstructures, characterized in that, It includes a wear-resistant surface layer (3), a diffusion functional layer (2) and a substrate layer (1) that are sequentially composited from top to bottom; The outer surface of the wear-resistant surface layer (3) is provided with regularly arranged microstructure units, each of which is a dome-shaped boss (4). The top of the dome-shaped boss (4) is an arc surface with a radius R of 0.05 to 0.08 mm. The bottom of the dome-shaped boss (4) is a square with a side length a of 0.25 to 0.35 mm and a height h of 0.08 to 0.1 mm. The spacing d between two adjacent dome-shaped protrusions (4) is 0.02-0.03 mm, and they are arranged in a rectangular array at an angle of 45°. The wear-resistant surface layer (3) has a thickness of 0.15-0.3 mm and is made of PC composite material with 0.5-1.5 wt% nano-alumina added. The diffusion functional layer (2) has closed pores (5) with an average diameter of 100-200 μm and a pore density of 300-500 pores / cm³.

2. The PC diffusion plate with surface microstructure according to claim 1, characterized in that: The top arc radius R of the dome-shaped boss (4) is 0.06 to 0.07 mm.

3. The PC diffusion plate with surface microstructure according to claim 1, characterized in that: The alumina nanoparticles in the wear-resistant surface layer (3) have a particle size of 20-50 nm.

4. A PC diffusion plate with surface microstructure according to claim 1, characterized in that: The surface hardness of the wear-resistant surface layer (3) is ≥2H.

5. A PC diffusion plate with surface microstructure according to claim 1, characterized in that: The thickness of the substrate layer (1) is 1-3 mm, and it is made of flame-retardant PC material.

6. A PC diffusion plate with surface microstructure according to claim 1, characterized in that: The wear-resistant surface layer (3), diffusion functional layer (2) and substrate layer (1) are integrally formed by a three-layer co-extrusion process.

7. A PC diffusion plate with surface microstructure according to claim 1, characterized in that: The bottom of the dome-shaped boss (4) and the wear-resistant surface layer (3) are provided with a rounded transition, and the radius of the transition rounded corner r is 0.01 to 0.02 mm.

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