PSS-3000 Sheet. Technical Design Guide. Revision Written By Date of Release. 01 Chuck Clontz March 23, 2012

Transcription

1 PSS-3000 Sheet Technical Design Guide Revision Written By Date of Release 01 Chuck Clontz March 23, 2012 CR-39 is a registered trademark of PPG Industries Ohio, Inc.

2 Table of Contents Product Definition... 3 General Information... 4 Material... 4 Surface Finishes... 4 Colors... 4 Available Sizes and Thickness... 4 Cosmetic Specifications... 5 Properties... 8 Optical Performance... 8 Abrasion Properties Physical Properties Packaging and Handling Cleaning Specifications Cutting Instructions PSS-3000 Sheet Technical Design Guide Page 2

3 Product Definition PSS-3000 optical sheet is produced using a technologically advanced thermoset resin and offers excellent optical properties, rugged durability and lightweight performance. PSS-3000 sheet, produced from CR-39 monomer, was developed as a substitute for glass. PSS-3000 sheet also offers outstanding chemical resistance, mechanical properties and thermal stability. PSS-3000 sheet combines the optical quality and chemical resistance of glass with the lightweight performance of plastics. PSS-3000 Sheet Technical Design Guide Page 3

4 General Information Material PSS-3000 sheet is a thermoset, cell cast transparent optical polymer which has a unique combination of properties and advantages over other plastics for a multitude of optical displays and bar code scanner exit window applications. PSS-3000 sheet is based on allyl diglycol carbonate (ADC) chemistry. Surface Finishes Four Surface Finishes Available, One or Two Sides Smooth / no Matte finish Light Glare Reduction / 135 Gloss Units Medium Glare Reduction / 110 Gloss Units Heavy Glare Reduction / 85 Gloss Units Colors Clear (Colorless) Neutral Gray Blue Aqua (Blue-Green) Amber Yellow Brown Red Laser Red (650 nm) Laser Red (670 nm) Green IR Transmitting Only Custom Colors available on request Available Sizes and Thickness Custom Sizes up to 960 mm x 480 mm (37.8 x 18.9 ) Dimensional Tolerances: +/- 10 mm. of nominal dimension Standard Thicknesses: mm Tolerance (mm) 0.5 +/ / / / / / / / / PSS-3000 Sheet Technical Design Guide Page 4

5 Cosmetic Specifications The following visual inspection for PSS-3000 optical sheet products is performed. The size of defects refers to the Scratch and Dig Paddle specifications (MIL A standard). PSS-3000 sheet samples are observed facing a strip light in a room with an ambient light. Ambient light: 250 <Ev < 500 Lux as measured 10 cm above the PSS-3000 sheet with Minolta CL-200 chromameter Strip light: PHILIPS tubes : model TLD 10W 30cm or TLD18/54 56cm (or equivalent model) Ambient light DARK BACKGROUND STRIP LIGHT OPAQUE MASK PSS-3000 SHEET OBSERVER 30cm 40cm

6 Circular defect Inspection Criteria Level I Dimension > 360x360 mm Defect Size criteria Number criteria Dig, dots, inclusion, bubble etc. Size < 0.10mm 0.10mm Size < 0.40mm No limited but not agglomerate Max = 3 defects Minimum distance between defect > 20 mm 0.40mm Size< 0.70mm Size 0.70mm Max = 1 defect Minimum distance between defect > 100 mm none Linear defect Scratch, inclusion, fiber inclusion etc Size < 0.040mm 0.040mm Size<0.080mm No limit but not agglomerate L 20 mm Max= 2 defects 20 <L<35 mm Max= 1 defect 0.080mm Size<0.160mm L 20 mm Max= 1 defect 20 <L<35 mm Max= 1 defect Size 0.160mm none Edge Chip For laser cut or scored edges Minimum distance between defect > 20 mm Total number of linear defects Max= 3 defects W 0.25 mm No limit 0.25 < W 0.5 mm Max= 3 defects/ edge Depth 50% sheet thickness W > 0.5 mm none Crack Crack Not acceptable none Total defects acceptable N = 5 defects PSS-3000 Sheet Technical Design Guide Page 6

7 Inspection Criteria Level II PSS-3000 Dimension > 455 x 480 mm (or equivalent surface area) Defect Size criteria Number criteria Circular defect Dig, dots, inclusion, bubbles, stains, delamination, etc. Size < 0.20mm 0.20mm Size < 0.50mm Size< 0.70mm No limit but not agglomerate Max = 1 defect None Minimum distance between defects > 20 mm Linear defect Scratch, inclusion, fiber inclusion etc Size < 0.030mm 0.030mm Size<0.100mm, Length 20mm No limit No limit Size 0.160mm None Spread defect Edge Chip Dirty, Ink, Wave, combination For laser cut or scored edges Minimum distance between defects > 20 mm Not acceptable None W 0.25 mm No requirement 0.25 < W 0.5 mm No requirement Total defects acceptable W > 0.5 mm No requirement No Maximum PSS-3000 Sheet Technical Design Guide Page 7

8 Properties Optical Performance Precision optics, low haze and high light transmission are key performance attribute of PSS-3000 sheet. PSS-3000 sheet UNITS STANDARD SMOOTH 135 GLOSS UNITS 85 GLOSS UNITS Luminous Transmittance % Haze % Yellowness Index ASTM E Refractive Index, η e Abbe Value * Gloss Measured at a 60 angle Typical Light Transmission Spectra of PSS-3000 sheet - Clear (Colorless) grades: PSS-3000 Sheet Technical Design Guide Page 8

9 Typical Light Transmission of PSS-3000 Sheet Colors: PSS-3000 Sheet Technical Design Guide Page 9

10 PSS-3000 Sheet Technical Design Guide Page 10

11 Abrasion Properties Uncoated PSS-3000 is inherently scratch resistant. The increase in haze on 3.0 mm thick uncoated sheets after 100 cycles using a CS-10 wheel with a 500 gram weight at 72 rpm per ASTM D1044 and ASTM D is only 9.8%. MECHANICAL Taber Abrasion TEST CONDITIONS UNITS STANDARDS PSS-3000 Tests conducted on 1.0 mm thick sheet 500 g, 100 Cycles (3mm thick) % ASTM D Steel Wool Abrasion 200 Cycles, #0000 % 2 Photo: PSS-3000 after 100 cycles Taber Abrasion PSS-3000 Sheet Technical Design Guide Page 11

12 Physical Properties TEST CONDITIONS UNITS STANDARDS PSS-3000 MECHANICAL Tests conducted on 1.0 mm thick sheet Tensile Stress at Break 50% RH / 23 C MPa ASTM D Tensile Elongation at Break 50% RH / 23 C % ASTM D Tensile Modulus 50% RH / 23 C MPa ASTM D ,582 Tensile Yield Stress 50% RH / 23 C MPa ASTM D Compressive Stress 50% RH / 23 C MPa ASTM D695-02a 58 Compressive Modulus 50% RH / 23 C MPa ASTM D695-02a 1,088 Compressive Yield 50% RH / 23 C MPa ASTM D695-02a 42 Maximum Load 50% RH / 23 C N ASTM D Flexural Stress 50% RH / 23 C MPa ASTM D Flexural Modulus 50% RH / 23 C MPa ASTM D ,724 Martens Hardness (HM) N/mm 2 ISO Rockwell Hardness 50% RH / 23 C ASTM D Pencil Hardness 7.5 N Force ISO H Taber Abrasion 500 g, 100 Cycles (3mm thick) % ASTM D Steel Wool Abrasion 200 Cycles, #0000 % 2 Izod Impact Notched 25 C Ft lb/inch ASTM D Izod Impact Unnotched 25 C Ft lb/inch ASTM D THERMAL Tests conducted on 3.0 mm thick sheet Specific Heat 25 C J / g / C ASTM E Thermal Expansion Coefficient μm /(m C) ASTM E Heat Distortion Temperature 264 psi C ASTM D Softening Temperature C ASTM E1545 >200 FLAMMABILITY Tests conducted on 1.0 mm thick sheet UL 94 Flammability Class 50% RH / 23 C ASTM D3801 / D HB Flash Ignition Temperature C ASTM D Self Ignition Temperature C ASTM D ELECTRICAL Tests conducted on 1.0 mm thick sheet Surface Resistivity 50% RH / 23 C, 500 V Ohms ASTM D x Volume Resistivity 50% RH / 23 C, 500 V Ohms ASTM D x Dielectric Constant At 100 Hz ASTM D BASIC Tests conducted on 1.0 mm thick sheet Specific Gravity g / cm Water Absorption 7 days / 25 C % 0.7 Oxygen Permeability 0% RH / 23 C Water Vapor Transmission Rate cm 3 / (100 in 2 * day) ASTM D % RH / 38 C g / (100 in 2 * day) ASTM F PSS-3000 Sheet Technical Design Guide Page 12

13 Packaging and Handling Packaging description All PSS-3000 sheets are covered with a clear low tack protective film on both sides then placed in double walled corrugated cardboard boxes. Handling procedures Although PSS-3000 sheets are durable and abrasion resistant, precautions should be taken to insure materials are carefully handled by trained persons. Inspection should only be carried out in a clean environment. Place sheets not protected by plastic film on a clean lint free cloth. Removing the protective plastic film may generate static charge. Deionized dry clean compressed air will help to reduce it. Additionally: 1. Use clean lint free wipes or dry clean compressed air to remove dust from the surface. 2. Handle parts by the edges only if and when the protective foil is removed, if necessary wear clean protective gloves. 3. Remove half the protective film on both sides whilst holding the filter on the protective half, complete the evaluation of this area and replace the protective foil. Repeat this on the opposite side to inspect the total area with the minimal risk of damage. 4. Do not slide or drag parts across any surface. 5. Never place the filter down without placing it back into its packaging or clean lint free cloth protection. Cleaning Specifications PSS 3000 sheets have great chemical resistance and permit cleaning with several detergents and solvents like alcohol, thinner, acetone. Adhesive residue, dust and dirt may be removed by glass cleaner or above mentioned solvents and soft clean cloth. PSS-3000 Sheet Technical Design Guide Page 13

14 Cutting Instructions I. Using a Laser Cutting Tool All PSS-3000 sheets can be cut to any shape or size using a computer controlled laser with general tolerance of ± 0.1 mm. See table below for laser settings using a Universal Laser Systems ILS D with two 50W laser tubes and air assist. Laser Settings Sheet thickness Cutting Speed (%) (in) *All vector cutting performed at 100% power. II. Using a Computer Numerically Controlled (CNC) Cutting Tool Customers that are used to processing plastic material that is softer than PSS-3000 sheet may have to increase the RPM of their milling machine and adjust milling linear speed depending on the thickness of the sheet. Otherwise, the risk of breaking or chipping the PSS-3000 sheet increases. Specific details are below: 1. CUTTER SPINNING SPEED The cutter spinning speed can be set as high as possible. In general: 5 mm diameter cutter: 25,000 rpm 1 mm diameter cutter: 40,000 rpm 2. CUTTER ROTATION DIRECTION For best results, the cutter tool should move in the same direction as rotation of tool. 3. CUTTER LINEAR DIRECTIONAL SPEED The X, Y and Z linear speeds will depend on how much material is going to be removed (thickness and size reduction). PSS-3000 Sheet Technical Design Guide Page 14

15 4. CUTTING SQUARE ANGLES 90 tool movement is suggested for cutting square angles and to continue the cutter past the end of the sheet as shown to the right. 5. COOLING REQUIREMENTS Cooling by liquid is not needed. Air flow to cool the cutter and remove the cut material is recommended. 6. EXAMPLE OF PARAMETERS FOR A 1.0 MM THICK SHEET USING CNC MACHINE Cutting Diameter 5.5 mm 1.0 mm FZ linear speed on Z axis 1250 mm/min 450 mm/min (cutter in-out) FA linear speed on X and Y axis 2500 mm/min 675 mm/min S cutter spinning speed rpm rpm III. Using a Knife-Blade to Score PSS-3000 Sheet A Tantung or Widia blade can be used to score PSS-3000 sheet. Note that thinner sheets (<1.0mm) may chip or crack when attempting to break the sheets apart. PSS-3000 Sheet Technical Design Guide Page 15