Wear-resistant Prism Plate
Product Name: Wear-resistant Prism Plate
Material: PS, PMMA, PC
Thickness: Customizable
Size: Customizable
Advantages: Diffuses light,
Anti-glare,
High surface hardness,
Scratch-resistant,
Extends product lifespan
- Fast Delievery
- Quality Assurance
- 24/7 Customer Service
Product Introduction
Rina Technology Co., Ltd. is one of the leading manufacturers and suppliers of wear-resistant prism plate in China. Welcome to wholesale durable products in stock here and get quotation from our factory. All customized products are with high quality and low price.
Products Description
Custom Prism Plate Product Introduction
Wear-resistant Prism Plate Product Introduction
Wear-resistant prism plates are functional optical components that combine a special optical structure with a high-strength wear-resistant coating. Their core is a precision-machined prism array structure, combined with surface strengthening technology, which achieves efficient light refraction
The prism units can be designed in various forms, such as triangular prisms, square prisms, or irregularly shaped prisms, depending on the application requirements. Sizes range from micro-components of a few millimeters to large plates of several meters, and they are widely used in LCD backlight modules, road lighting reflectors
Compared to ordinary prism plates, the biggest advantage of wear-resistant prism plates lies in their "dual balance of functionality and durability." Ordinary prism plates are often prone to scratches during installation, use, and maintenance due to their fragile surface,
leading to a decline in optical performance. Wear-resistant prism plates, through special material combinations and processing, can maintain stable optical performance under harsh conditions for a long time, significantly extending product lifespan and reducing later maintenance costs.
Wear-Resistant Prism Plate Production Process
1. Raw Material Selection and Pre-treatment: First, select high-quality substrates with a light transmittance ≥92%, such as polymethyl methacrylate (PMMA), polycarbonate (PC), or optical glass. The substrate thickness is determined according to the product application (usually 0.5-5mm). The substrate is then cleaned, degreased, and dried to remove surface impurities and stains, avoiding any impact on subsequent processing accuracy.
2. Prism Structure Mold Preparation: A master mold for the prism array is fabricated using precision CNC machining technology. The dimensional error of the prism units on the master mold surface must be controlled within ±0.001mm. For mass production, sub-molds are replicated from the master mold to ensure mold consistency and stability. The mold material is typically high-strength alloy steel or ceramic to ensure wear resistance.
3. Substrate Molding and Prism Structure Pressing: The appropriate molding process is selected based on the substrate type-plastic substrates are often injection molded or calendered, where molten plastic is injected into the mold and cooled to form a sheet with a prism structure; glass substrates are processed using precision grinding and polishing to create the prism array on the surface. This step requires strict control of temperature, pressure, and cooling rate to ensure the integrity of the prism structure and its optical accuracy.
4. Surface Abrasion-Resistant Coating: This is the core step in achieving the "abrasion-resistant" characteristic. A high-hardness abrasion-resistant coating is applied to the surface of the formed prism plate using processes such as vacuum deposition, roller coating, or spraying. Commonly used coating materials include silicon dioxide (SiO₂), silicon nitride (Si₃N₄), or special organic abrasion-resistant resins.
5. Curing and Post-Treatment: After coating, the prism plate is placed in a curing oven. Ultraviolet irradiation or thermal curing ensures a tight bond between the coating and the substrate, improving adhesion and stability. Subsequently, edge trimming and burr removal are performed, and the prism is processed into specific sizes and shapes according to customer requirements. A secondary cleaning of the product surface is also conducted.
6. Quality Inspection and Shipment: The inspection process covers two major dimensions: optical performance and physical performance. Optically, it tests transmittance, refractive index, and light uniformity. Physically, it tests surface hardness (typically requiring a Mohs hardness ≥ 6H), abrasion resistance (tested by steel wool friction, with no obvious scratches after 500 cycles), and impact resistance.
Wear-Resistant Prism Plate Parameter Details
| Parameter Category | Specific Parameter | Description |
|---|---|---|
| Basic Dimensions | Standard Thickness | 1.5mm, 2.0mm, 2.5mm, 3.0mm, 4.0mm; Customization from 0.8mm to 10mm supported |
| Standard Width | 1220mm, 1500mm; Adjustable according to production requirements | |
| Standard Length | 2440mm; Custom cutting supported, minimum cutting size 50mm × 50mm | |
| Optical Performance | Light Transmittance | 85% - 95% (Varies slightly depending on thickness and prism structure; 92% for standard 3.0mm type) |
| Light Uniformity | ≥90%, effectively eliminates LED shadowing and avoids "hotspot" issues | |
| Beam Angle Control Range | 30° ~ 120°, customizable for directional or wide-area lighting effects via prism density and angle design |
Comparison of the advantages of materials used in Wear-Resistant Prism Plate
| Dimension | PMMA-based Prism Panel | PC-based Prism Panel | PS-based Prism Panel |
|---|---|---|---|
| Light Transmission | Optimal, 93%-95% transmittance, pure and neutral light, excellent optical effect | Good, 88%-92% transmittance, soft light, better anti-aging performance than PMMA | Average, 80%-85% transmittance, prone to decrease over time |
| Physical Strength | Moderate, average impact resistance, easily scratched by sharp objects, but lightweight | Optimal, 6-8 times the impact strength of PMMA, drop and impact resistant, suitable for outdoor and industrial use | Poor, brittle, prone to breaking, low impact resistance, only for low-risk scenarios |
| Weather Resistance | Good, can be used in semi-outdoor scenarios with UV inhibitors, prone to yellowing outdoors without them | Optimal, inherently UV resistant, withstands high and low temperatures, suitable for outdoor and harsh environments | Poor,Not resistant to high and low temperatures, prone to aging and brittleness, only for indoor, room temperature environments |
| Processability | Optimal, easy to cut, bend, bond, high precision prism structure formation, suitable for complex customization | Good, can be cut and bent, but requires higher forming temperature, slightly higher cost for complex structures | Moderate, easy to cut but difficult to bend, average precision in prism structure formation |
| Cost | Moderate, cost-effective, mainstream choice for indoor lighting | Higher, cost is 1.5-2 times that of PMMA, suitable for high-performance requirements | Lowest, price only 50%-70% of PMMA, suitable for low-cost, temporary lighting needs |
| Applicable Scenarios | Indoor commercial lighting, home lighting, flat lights, panel lights, etc. | Outdoor lighting, industrial lighting, explosion-proof lights, children's room lighting, etc. | Temporary lighting, low-cost fixtures, disposable lighting products, etc. |
Application Scenarios of Wear-Resistant Prism Plate
RINA TECHNOLOGY
is a high-tech enterprise specializing in research, development, production ,sales of Optical LED products and provide the one step optical lighting solution for customers.Established in 2011, Hong Kong, after years of rapid development, Rina Tech has settled office and factory in Shenzhen,and has professional senior technicians and qualified managers,has a talented team for product research and designing.
Nowadays, we have laser cutting machines, printers, film cutting machines, injection molding equipments,high-standard assembly workshops, BM-7 clean machines and other advanced equipments.
Our factory daily output is more than 80000pcs. to cater for the market at home and abroad.With years of unremitting effort,RINA TECH has passed get the Registration Certificate ofCustoms Declaration Unit of the People's Republic of China , National Credit Cultivation Certificate and Get our own Brand already.
We has made many breakthroughs in researching and manufacturing and has
obtained lots of good reputation from oversea customers.
Now we has cooperated with and become strategic partner of some famous enterprises such as LG, Samsung, Lenovo etc."Living on Sincerity, following with Market, Advancing by Specialty" is our eternal philosophy,and the company motto is "Good at Production, Good for Society".
We look forward to cooperating with you to make the world better and future brighter!
FAQ
1. What is the surface hardness level of the Wear-resistant Prism Plate? Does it require special protection in daily use?
The surface Mohs hardness is 6H-8H, close to that of ordinary glass. No special protection is needed for daily wiping and minor friction; simply avoid direct scratching with sharp, hard objects (such as blades).
2. Is the Wear-resistant Prism Plate suitable for strong outdoor light environments? Will it age due to UV exposure?
Suitable for outdoor use. With UV-resistant treatment, the light transmittance decreases by ≤3% after 5 years of outdoor use, and it is not prone to yellowing or embrittlement.
3. Will there be differences in optical performance between Wear-resistant Prism Plates of different thicknesses? How to choose the appropriate thickness?
The difference in optical performance is minimal (light transmittance difference ≤1%). Thickness mainly affects strength: 0.5-1.5mm for precision electronics, 2-5mm for outdoor/impact-resistant applications.
4. Can the Wear-resistant Prism Plate be cut, drilled, or otherwise processed? Will processing affect its performance?
It can be further processed (cutting, drilling, etc.), and diamond tools are recommended. After proper processing, the optical and wear-resistant properties of non-processed areas are unaffected.
5. How to judge the quality of Wear-resistant Prism Plate? Are there any simple identification methods?
Three identification methods: ① Check if the light is uniform and without dark areas when held up to the light; ② Rub it with steel wool 50 times without scratches; ③ The surface is free of bubbles, impurities, and structural defects.
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