Product Specifications
|
Specification |
Data |
|
Optical Material |
Optical PC, PMMA, or dedicated light-diffusing resin |
|
Wall Thickness |
1-4 mm |
|
Clear PC Luminous Transmittance |
89-90% at 1-4 mm thickness |
|
Clear PC Haze |
Below 1% |
|
Low-Diffusion PC Grade |
76-87% transmittance; 10-30 degree half-power angle at 1-4 mm |
|
High-Diffusion PC Grade |
45-69% transmittance; 44-58 degree half-power angle at 1-4 mm |
|
Reference LED-To-diffuser Distance |
15-50 mm |
|
Reference LED Pitch |
20-60 mm |
|
Optical Surface |
Frosted, matte, microtextured, or prismatic |
|
Heat Performance |
HDT 121-136 degrees C for selected diffuser-grade PC |
|
PC Material Drying |
120 degrees C for 2-4 hours; residual moisture at or below 0.01-0.02% |
|
PC Molding Temperature |
Melt temperature 260-310 degrees C; mold temperature 80-120 degrees C |
|
Optical Test Methods |
ISO 13468-2 for luminous transmittance; ASTM D1003 or ISO 14782 for haze |
|
Dimensional Tolerance |
+/-0.20-0.50 mm according to part size and mounting geometry |
Key Advantages
● Specified Diffusion Across The Illuminated Area
The optical surface and wall section are set across the LED field. At the approved LED pitch and diffuser distance, the cover blends individual points into a continuous illuminated area. The result is based on the specified geometry rather than random frosting or visual appearance alone.
● Uniform Optical Wall And Gate Layout
Wall thickness and gate position are balanced so density changes, weld lines, and flow marks stay away from the main illuminated zone. When the lamp is on, this helps reduce visible bands and shadow areas across the cover.
● Integrated Mounting Geometry
Locating and fastening features are molded into the optical cover. They hold the diffuser at a fixed distance from the LED board during assembly, helping maintain the same fixture fit and illuminated result from one unit to another.
Customization Options
For transparent LED-grade PC, a common material benchmark is approximately 89-90% luminous transmittance at a thickness of 1-4 mm with haze below 1%. Diffuser grades are specified separately because transmission must be considered together with haze, LED hiding, and the approved illuminated result.
Optical PC, PMMA, or a dedicated diffuser resin is selected according to fixture temperature, impact requirement, and the required surface. Wall thickness, curvature, microtexture, prismatic geometry, and the mounting interface are developed from the LED layout and the available distance between the board and cover.
UV-stabilized, flame-retardant, or heat-aging-resistant material can be specified for outdoor, enclosed, or continuously illuminated fixtures. Part marking, protective film, and optical-surface packing are defined to protect the approved appearance during assembly and shipment.
Customization Process
Requirement Confirmation
Provide the target product, required dimensions, customization scope, and order quantity.
Product Solution
Review the supplied data to select the optical material, wall and surface structure, mounting interface, and tooling approach.
Quotation Confirmation
Confirm the final specification, project cost, MOQ, and delivery schedule before development starts.
Sample Development
Prepare the sample with existing tooling or a new mold and apply the approved optical surface, finish, and markings.
Sample Approval
Check the dimensions, appearance, fit, and function. The approved sample becomes the production reference.
Production And Delivery
Complete production, protective packing, and shipment under the agreed terms, with the required delivery documents supplied.
Quality Control
The resin batch, drying condition, and traceability are verified before molding. Optical performance is compared with the approved illuminated sample using the specified LED module. Mounting fit and the lit surface are also checked for dimensional or visual deviation. Parts with unacceptable hotspots, flow marks, warpage, contamination, or surface damage are removed before 100% pre-packing inspection. Third-party inspection is accepted.
FAQ
Q1: Can an optical sample be supplied before production?
A1: Yes. A new diffuser sample is developed after the fixture data, LED layout, drawing, material target, and mold fee have been confirmed.
Q2: What payment terms apply to custom diffusers?
A2: The mold fee and order advance payment are paid before tooling and production. The balance is paid under the agreed EXW, FOB, or CIF term.
Q3: Can light transmission alone define a diffuser?
A3: No. Transmission must be assessed together with haze, LED pitch, LED-to-diffuser distance, wall thickness, and hotspot-hiding performance.
Q4: Which optical test methods should be stated on the drawing?
A4: Use ISO 13468-2 for luminous transmittance and ASTM D1003 or ISO 14782 for haze. The same thickness and specimen condition should be used for approval and batch comparison.
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