Alexei Volkov
The lighting industry has traditionally used translucent glass and plastics for functional and aesthetic purposes. With the shift to LED-based lighting, the materials used for effective light diffusion have also evolved. LED lights are energy-efficient, long-lasting, and provide control over lighting, but they can cause glare and uneven coverage. To address these issues, lighting specialists have been working to find the best plastics and films for light covers. Acrylic and polycarbonate are two commonly used plastic sheet materials in the lighting industry. They are lightweight, tough, and have excellent optical properties. Polycarbonate is seen as the top choice for LED lighting due to its versatility, strength, and light transmission properties.
| Characteristics | Values |
|---|---|
| Plastic types | Acrylic, Polycarbonate |
| Acrylic properties | Good light transmission, easy to fabricate, inexpensive, UV-resistant, scratch-resistant, good weathering resistance |
| Polycarbonate properties | Good light transmission, impact resistance, heat resistance, flexibility, formability, flame retardant, ignition resistance |
| Applications | Lighting fixtures, lenses, covers, skylights, light diffusers, LED lighting, conventional lighting, aquariums, signage, retail merchandising, menu boards, jewellery cases, mass transit and aerospace lighting |
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What You'll Learn
Acrylic and polycarbonate plastics are used for LEDs
Acrylic and polycarbonate plastics are commonly used for LEDs. Acrylic, also known as plexiglass, is a popular alternative to glass due to its superior resistance to impact, chemicals, and discolouration. It also has excellent optical properties, including good light transmission and diffusion of LED hotspots. Acrylic is easy to fabricate and thermoform into complex shapes, making it a good choice for lighting applications.
Polycarbonate is a tough, lightweight plastic with superior thermal stability compared to acrylic. It can be used for continuous use at temperatures up to 120°C and offers superior ignition resistance for high-powered LED light sources. Polycarbonate is also flexible and formable, making it a versatile choice for lighting designers. It is commonly used in lenses, optics, covers, and light diffusers for LEDs.
Both acrylic and polycarbonate sheets are strong and durable, with excellent visual possibilities, making them suitable for a wide range of lighting applications, including commercial lighting, lenses, and interior LED fixtures. They can be engineered to diffuse LED hotspots while maintaining high light transmission, reducing energy consumption for lighting fixtures.
In terms of specific products, OPTIX® LD acrylic sheet, Plexiglas® Sylk acrylic sheet, and Makrofol® LM polycarbonate film are all known for their excellent LED light-diffusing characteristics. TUFFAK® Lumen XT polycarbonate sheet is also designed for lighting lenses, with a textured surface to enhance light diffusion.
Overall, acrylic and polycarbonate plastics offer unique advantages for LEDs, providing durability, flexibility, and excellent optical properties, while also addressing the challenges of the LED lighting industry with their versatility and customisability.
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Acrylic is a good transmitter of light
Acrylic is often used in commercial lighting fixtures, POS displays, and backlit signs. It is commonly used as an alternative to traditional glass, which can be too fragile or heavy for certain applications. Acrylic is also scratch-resistant and exceptionally resistant to weathering, making it a good choice for outdoor use.
In terms of light transmission, acrylic provides the best light transmission of any plastic. It is also naturally UV-stable, which further enhances its durability in outdoor conditions. Acrylic is also less vulnerable to UV exposure than other plastics, such as polycarbonate, which can yellow and crack over time.
Acrylic is also a good choice for LED lighting due to its ability to be formed into complex shapes. Acrylic sheets can be thermoformed or injection-molded into a variety of shapes and sizes, making it a versatile material for lighting designers.
Overall, acrylic's combination of excellent optical properties, ease of fabrication, durability, and versatility make it a good transmitter of light for a wide range of lighting applications.
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Polycarbonate is highly impact-resistant
Polycarbonate is a type of plastic that is widely used for its impact resistance and transparency. It is a lightweight yet strong material, making it ideal for various applications across multiple industries.
One of the defining characteristics of polycarbonate is its high impact strength. Polycarbonate can withstand up to 900 pounds of impact, making it significantly stronger than other materials such as acrylic and glass. This impact resistance is what makes polycarbonate a common choice for safety equipment such as safety goggles, face shields, and helmets.
In the context of LEDs, polycarbonate is used in light diffusing applications. It helps to hide the "hot spots" of focused light created by LEDs while maintaining high light transmission. Polycarbonate film offers design flexibility, as it can be printed, die-cut, and cold-formed into complex shapes.
Polycarbonate is also known for its durability and ability to withstand extreme temperatures. It has good heat resistance and can operate at higher temperatures than acrylic. Additionally, polycarbonate has superior flammability characteristics, and specific grades of polycarbonate sheets meet fire safety standards.
The impact resistance of polycarbonate makes it suitable for a range of applications beyond lighting. For example, it is used in automotive and aerospace components, medical devices, protective gear, and even bullet-resistant glass. Polycarbonate's strength and durability make it a versatile material that can provide protection and performance in challenging environments.
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Acrylic is easy to fabricate
Acrylic is a type of thermoplastic that is also known as plexiglass or polymethyl methacrylate (PMMA). It is formed through chemical reactions between compounds like methyl methacrylate, acetone, and sodium cyanide. Acrylic is highly versatile and can be fabricated into a practically infinite number of different shapes and sizes.
Acrylic fabrication involves several processes. Firstly, acrylic sheets can be cut into desired sizes and shapes using methods such as saw cutting and routing. Edge finishing and polishing techniques can then be applied to create a clean edge. For more complex shapes, CNC routing can be used to cut curves, corners, and complete shapes.
Another method for shaping acrylic is heat bending, where high temperatures are applied to manipulate the material into specific angles. Drilling, welding, and general assembly techniques can also be used to further customize the fabricated acrylic.
Acrylic is a popular choice for fabrication due to its unique properties. It is stronger and more impact-resistant than glass. Acrylic also has better optical clarity than glass. Acrylic is also available in a variety of colors, textures, and finishes, making it desirable for both translucent and opaque applications. Additionally, its inherent UV resistance makes it durable and versatile for outdoor use.
Acrylic fabrication has a wide range of applications. Basic uses include windows and signs, while more advanced fabrication techniques allow for its use in automobile interiors, watercraft, and architectural glass. Acrylic is also commonly used in lighting applications, particularly LED light diffusion, due to its outstanding optical properties, lightweight, and strength.
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Polycarbonate is flame-retardant
Polycarbonate is a plastic with a range of desirable properties, including strength, durability, heat resistance, and optical clarity. It is commonly used in lighting applications, such as LED light diffusion, due to its ability to transmit light efficiently while diffusing hotspots.
Polycarbonate is also valued for its flame-retardant properties, which make it suitable for various industries and applications. Flame retardancy is a critical characteristic in many contexts, helping to prevent fires and limit damage when they occur. Polycarbonate can be combined with flame retardant materials without significant degradation, and it is often used in electrical devices, aircraft components, and other applications where fire safety is a priority.
Flame retardant polycarbonate sheets are available in different grades, each with specific capabilities to meet the requirements of different industries. For example, some applications require materials that are self-extinguishing, while others need sheeting that meets certain levels of heat release or smoke toxicity when burned. The UL 94 standard, titled "Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances," provides a flammability rating system with six different classifications, including V-0, V-1, and V-2, which indicate the material's ability to self-extinguish and the allowable burning time.
Flame retardant polycarbonate is particularly useful in the transportation, electrical, building and construction, and aerospace industries. In these industries, polycarbonate helps meet local building codes and regulations, such as those outlined by the International Code Council (ICC) and the International Building Code (IBC). For example, in addition to its flame retardancy, polycarbonate is used in aerospace applications because of its lightweight, high-impact strength, formability, and optical clarity.
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Frequently asked questions
Polycarbonate is the most popular plastic used in LEDs. It is a tough, lightweight plastic with excellent optical properties. It is also used in impact-resistant "glass-like" surfaces.
Polycarbonate offers great light transmission, thermal stability, and ignition resistance. It is also flexible and formable, making it a good choice for various LED applications such as lenses, optics, covers, and light diffusers.
Yes, acrylic is another plastic that is commonly used in LEDs. Acrylic has the best optical properties for most uses and is also UV-resistant, making it a popular choice for outdoor use.
