pss-3000 sheet - optical filters ltd · pss-3000 sheet is a thermoset, cell cast transparent...

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.

PSS-3000 Sheet Technical Design Guide Page | 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 ..................................................................................................................... 11

Physical Properties ...................................................................................................................... 12

Packaging and Handling ................................................................................................................... 13

Cleaning Specifications .................................................................................................................... 13

Cutting Instructions ......................................................................................................................... 14


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.


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) Brown

Neutral Gray Red

Blue Laser Red (650 nm)

Aqua (Blue-Green) Laser Red (670 nm)

Amber Green

Yellow 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 +/- 0.10

0.7 +/- 0.10

1.0 +/- 0.10

1.5 +/- 0.15

2.0 +/- 0.20

3.0 +/- 0.30

4.0 +/- 0.40

5.0 +/- 0.50

6.0 +/- 0.60

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-0-13830A 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

OBSERVER

40cm 30cm

PSS-3000 SHEET OPAQUE MASK

STRIP LIGHT


Inspection Criteria – Level I

Dimension > 360x360 mm

Defect Size criteria Number criteria

Circular defect Dig, dots, inclusion,

bubble etc.

Size < 0.10mm No limited but not agglomerate

0.10mm ≤ Size < 0.40mm

Max = 3 defects

Minimum distance between defect > 20 mm

0.40mm ≤Size< 0.70mm Max = 1 defect


Size ≥ 0.70mm none

Linear defect

Scratch, inclusion, fiber

inclusion etc

Size < 0.040mm No limit but not agglomerate

0.040mm≤Size<0.080mm 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


Total number of linear defects Max= 3 defects

Edge Chip For laser cut or scored

edges

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


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 No limit but not agglomerate

0.20mm ≤ Size < 0.50mm Max = 1 defect

Size< 0.70mm None

Minimum distance between defects > 20 mm

Linear defect

Scratch, inclusion, fiber

inclusion etc

Size < 0.030mm No limit

0.030mm≤Size<0.100mm,

Length ≤ 20mm

No limit

Size ≥ 0.160mm None

Minimum distance between defects > 20 mm

Spread defect Dirty, Ink, Wave,

combination

Not acceptable None

Edge Chip For laser cut or scored

edges

W ≤ 0.25 mm No requirement

0.25 < W ≤ 0.5 mm No requirement

W > 0.5 mm No requirement

Total defects acceptable No Maximum


Properties

Optical Performance

Precision optics, low haze and high light transmission are key performance attribute of PSS-3000

sheet.

UNITS STANDARD

PSS-3000 sheet

SMOOTH 135 GLOSS

UNITS

85 GLOSS

UNITS

Luminous Transmittance % 92.0 92.0 91.9

Haze % 0.03 0.87 2.00

Yellowness Index ASTM E313 0.77 0.77 0.80

Refractive Index, ηe 1.50 1.50 1.50

Abbe Value 57 57 57

* Gloss Measured at a 60 ° angle

Typical Light Transmission Spectra of PSS-3000 sheet - Clear (Colorless) grades:


Typical Light Transmission of PSS-3000 Sheet Colors:


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 D1003-07 is only 9.8%.

TEST

CONDITIONS UNITS STANDARDS PSS-3000

MECHANICAL Tests conducted on 1.0 mm thick sheet

Taber

Abrasion

500 g, 100 Cycles

(3mm thick) % ASTM D1044 9.66

Steel Wool

Abrasion 200 Cycles, #0000 % 2

Photo: PSS-3000 after 100 cycles Taber Abrasion


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 D638-08 51

Tensile Elongation at Break 50% RH / 23°C % ASTM D638-08 14

Tensile Modulus 50% RH / 23°C MPa ASTM D638-08 1,582

Tensile Yield Stress 50% RH / 23°C MPa ASTM D638-08 44

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 D790-07 30

Flexural Stress 50% RH / 23°C MPa ASTM D790-07 91

Flexural Modulus 50% RH / 23°C MPa ASTM D790-07 2,724

Martens Hardness (HM) N/mm2

ISO 14577 103

Rockwell Hardness 50% RH / 23° C ASTM D785 88

Pencil Hardness 7.5 N Force ISO 15184 H

Taber Abrasion 500 g, 100 Cycles

(3mm thick) % ASTM D1044 9.66

Steel Wool Abrasion 200 Cycles, #0000 % 2

Izod Impact – Notched 25°C Ft lb/inch ASTM D256 0.2-0.4

Izod Impact – Unnotched 25°C Ft lb/inch ASTM D256 2-3

THERMAL Tests conducted on 3.0 mm thick sheet

Specific Heat 25°C J / g / °C ASTM E1269 1.30

Thermal Expansion

Coefficient μm / (m °C) ASTM E831 100

Heat Distortion

Temperature 264 psi °C ASTM D648 55

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 /

D635-06 HB

Flash Ignition Temperature °C ASTM D1929 376

Self Ignition Temperature °C ASTM D1929 382

ELECTRICAL Tests conducted on 1.0 mm thick sheet

Surface Resistivity 50% RH / 23°C, 500 V Ohms ASTM D257-99 28 x 1015

Volume Resistivity 50% RH / 23°C, 500 V Ohms ASTM D257-99 15 x 1015

Dielectric Constant At 100 Hz ASTM D150 4.4

BASIC Tests conducted on 1.0 mm thick sheet

Specific Gravity g / cm3

1.31

Water Absorption 7 days / 25°C % 0.7

Oxygen Permeability 0% RH / 23°C cm3

/ (100 in2

*

day) ASTM D3801 0.1

Water Vapor Transmission

Rate 100% RH / 38°C g / (100 in

2

* day) ASTM F1249 0.27


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.


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

12.150D with two 50W laser tubes and air assist.

Laser Settings

Sheet thickness

(in)

Cutting Speed (%)

0.030 27

0.040 25

0.060 18

0.080 12

0.118 7.5

0.195 4.8

0.240 4

*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).


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

(cutter in-out)

1250 mm/min 450 mm/min

FA – linear speed on X and Y axis

2500 mm/min 675 mm/min

S – cutter spinning speed

28000 rpm 38500 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 - optical filters ltd · pss-3000 sheet is a thermoset, cell cast transparent...

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