LGP For LED

High-transmittance materials such as optical-grade PMMA and PC are preferred. For some high-end products, special materials such as MS resin and COC are used. Batch testing of raw materials ensures that their transmittance, color difference, and dimensional stability meet standards. They are then cleaned and dried to remove impurities and moisture, preventing them from affecting subsequent processing accuracy and optical performance.

The dimensions and thickness of the LGP are determined using CAD design software. Microstructure patterns (dots, prisms, etc.) are designed using optical simulation software (such as 3D optical simulation), and a 48-hour optical analysis is performed to generate uniformity and brightness distribution maps, verifying the design's rationality. Prototype samples are then manufactured (completed in 5-7 days) for actual optical testing, optimizing the design until it meets standards.

Select the appropriate forming process based on product requirements-Injection molding is suitable for mass production, complex shapes, or ultra-thin LGPs. Molten optical material is injected into a high-precision mold and cooled to form the final shape. Extrusion molding is suitable for large-volume production of flat LGPs with uniform thickness. The material is heated and softened before being extruded through a mold to form a continuous sheet. After forming, the substrate is cut to ensure dimensional accuracy (error ≤ ±0.01mm).

This is the core process, mainly divided into three methods: Laser engraving (highest precision, capable of achieving <10µm microstructures, suitable for high-end products), UV printing (high efficiency, moderate cost, suitable for mid-to-low-end products), and screen printing (low cost, suitable for large-size products). These processes create precise microstructures on or inside the substrate, achieving uniform light guidance. After processing, the surface is cleaned to remove residual impurities.

Depending on application requirements, a reflective layer (silver reflective film or white PET substrate) is laminated to the back of the LGP to improve light recovery efficiency; a diffusion layer is laminated to the front to further optimize light softness and eliminate light spots caused by microstructures. Some products may include a brightness enhancement film to improve front brightness.

100% comprehensive inspection of finished products is conducted, including light transmittance, brightness uniformity, dimensional accuracy, and appearance defects (scratches, bubbles, dot defects, etc.). AOI automated inspection equipment ensures product qualification. After passing inspection, products are packaged in a cleanroom to prevent damage during transportation and finally stored for delivery (mass production delivery cycle 10-15 days).