Custom LED Light Diffuser Sheet

The production of custom LED light diffuser sheets is a sophisticated process that requires strict control of various parameters according to customized requirements to ensure stable product performance. The core process mainly includes the following steps:

1. Custom Requirement Analysis and Raw Material Proportioning: Based on customer customization requirements (such as size, light transmittance, light uniformity standards, and operating environment), suitable polymer base materials (such as PVC, PET, TPU, etc.) are selected,

and auxiliary raw materials such as light diffusing agents and functional additives (such as anti-aging agents and antioxidants) are added in precise proportions. All raw materials must be dried to remove moisture and prevent the formation of bubbles during the production process, which could affect product quality.

2. Melt Blending and Extrusion: The pre-treated mixed raw materials are fed into a twin-screw extruder. The heating device in the barrel gradually melts and plasticizes the raw materials, and the rotation of the screw ensures thorough mixing and homogenization of the raw materials, ensuring uniform distribution of light diffusing particles in the base material. Subsequently, the molten material is extruded through a T-die to form a continuous sheet of molten material.

3. Calendering and Forming: The molten sheet extruded from the die enters a calender, where it is rolled by multiple sets of temperature-controlled rollers to adjust the thickness, flatness, and surface gloss of the sheet. Precise control of roller temperature and speed is required during calendering to ensure uniform thickness and prevent defects such as wrinkles and scratches, while further improving the uniform dispersion of light diffusing particles.

4. Cooling and Shaping: After calendering and forming, the sheet enters a cooling device (usually a cooling roller or cooling water tank) to solidify and shape the sheet through rapid cooling, maintaining its shape and size stability. The cooling speed must be strictly controlled; too fast cooling may cause internal stress in the sheet, affecting its flexibility; too slow cooling may lead to surface adhesion or dimensional deviations.

5. Surface Treatment (Optional): Depending on the application requirements, some products require surface treatment, such as coating with anti-scratch coatings, anti-static coatings, or matte coatings. The treatment liquid is uniformly coated onto the sheet surface using specialized coating equipment, followed by curing

5. Cutting and Quality Inspection: The cured sheets are transported to cutting equipment and cut into different sizes according to customer requirements. After cutting, quality control personnel conduct a comprehensive inspection of the product's thickness, light transmittance, uniformity,

6. Packaging and Warehousing: Qualified products are cleaned and then packaged using scratch-resistant and moisture-proof packaging materials to prevent damage during transportation and storage. They are then sorted by specifications and stored in the warehouse.