CN106154367B - Light diffusion sheet - Google Patents
Light diffusion sheet Download PDFInfo
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- CN106154367B CN106154367B CN201610707423.6A CN201610707423A CN106154367B CN 106154367 B CN106154367 B CN 106154367B CN 201610707423 A CN201610707423 A CN 201610707423A CN 106154367 B CN106154367 B CN 106154367B
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
- G02B5/0226—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures having particles on the surface
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
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Abstract
The invention discloses a light diffusion sheet and a manufacturing method thereof. The light diffusion sheet is structurally characterized in that a micro-structural layer is arranged on the surface of one side of the transparent substrate layer, and diffusion particles are filled in a concave structure of the micro-structural layer. In order to realize the diffusion sheet, the manufacturing method is characterized in that a mold with a topologically arranged pattern convex structure is used for duplicating the mold structure on a transparent substrate in an imprinting mode to obtain a concave structure complementary with the mold structure; and (3) coating the diffusion particles into the sunken microstructures by a blade coating technology to form a patterned diffusion particle arrangement. The invention solves the problem that the traditional random structure can not be manually optimized by arranging the graphical diffusion particles, generates light diffusion effect under the combined action of the graphical structure and the diffusion particles, and is used for shaping the backlight source and the light beam.
Description
Technical Field
The invention relates to a light diffusion sheet, which is characterized in that light diffusion particles are filled in grooves of a patterned microstructure. Under the combined action of the patterned structure and the diffusion particles, a light diffusion effect is generated and is used for the backlight source and the beam shaping direction.
Background
Light diffusers are indispensable components in the field of display and illumination. Its main function is to diffuse light and uniformly convert point/line light source into line/surface light source. In the traditional diffusion sheet, chemical particles are added into a transparent plastic material to form a diffusion layer, and incident light rays are transmitted in two or more media with different refractive indexes in the diffusion layer and are refracted, reflected and scattered to form the effect of diffusing light.
Currently, there are three main processing methods for light diffusion sheets: embossing, heat treatment injection molding and coating processes. The embossing process melts the polymer on the surface of the film and utilizes a plurality of rollers with fine structures to process the film, the method is simple and convenient, but the main defect of the embossing process is that the density of the diffusion film material is uneven. The main materials of the injection molding method by heat treatment comprise methyl methacrylate, azodiisobutyronitrile, diffusion powder, dye and the like. Fully stirring and mixing, injecting the mixture into a mould, and baking and curing the mixture by using an oven for at least 4-8 hours, wherein the production period is long. The most common method for producing a diffusion film is a coating method, and a diffusion layer is formed on the surface of a transparent substrate by electrostatic coating. This method is technically mature, but uses many kinds of polymer materials, such as thermoplastic polymer resin (monomer or polymer of methacrylate, polyester, polycarbonate, polystyrene, polymethylpentene) as adhesive material, and further requires olefinic acid esters, photoinitiator, diffusion powder, dye, toughening agent, wetting agent, defoaming agent, etc. In addition, the diffusion layer is added on the substrate to increase the thickness of the diffusion sheet, so that the use of various polymers causes greater light energy absorption loss, and organic pollutants are generated in production, which is not favorable for environmental protection.
With the wide use of the novel solid light sources such as the light emitting diode, the light diffusion sheet matched with the light emitting diode is required to have high transmittance and easily adjustable haze, and special optical effects such as soft light without hot spots and directional diffusion are also required to be realized, so that new technical challenges are provided for the research and development and the manufacture of the light diffusion sheet.
The continuous advanced micro-nano manufacturing technology makes the mass manufacturing of large-breadth micro-nano structures possible. The micro-nano structure with certain topological arrangement is processed on the surface of the plastic substrate to be used as a light diffusion sheet, so that the requirements of lightness, thinness, flexibility, functionalization, high light energy utilization rate, low cost and low energy consumption in the production process of the optical functional film are met, and the optical functional film becomes a favorite of a new generation of optical functional films. Light diffusers based on surface microstructures can also be subdivided into two categories: one type is a completely random structure. Such as a random microlens array structure. Although it can well diffuse and soften light, it can only meet the requirements of a certain kind of optical film, such as a light diffusion sheet used in a liquid crystal television, due to the randomness of the arrangement of the scattering units. The other type is a regularly arranged structure, and by designing topological arrangement of the micro-nano structure, optical effects such as optimized directional scattering and soft light are realized, and functions which are difficult to realize by random arrangement are obtained. The optimally designed microstructure diffusion sheet has higher flexibility and wide adaptability, and plays an important role in the aspects of light modulation of new-generation organic light-emitting diodes, solar cells and the like and improvement of the light energy utilization rate of devices.
The microstructure diffuser with optimized topological arrangement studied at present is reported in documents [1] s.m. Mahpeykar, et al. linear hexagonal diffusion gratings as optical diffusers for embedded structured waveguide photo management, adv. opt. mater.4(7): 1106-) 1114, 2016), and self-assembled honeycomb dense Polystyrene (PS) microspheres are self-assembled on Polydimethylsiloxane (PDMS), and the optical field with adjustable diffraction angle is realized by using the stretchability of PDMS. Documents [2] c.l. Lai, j.s. Lin, t. Yoshimi, and w.h. Fan, a micro structure diffusion plate for LED lighting, proc. SPIE 6758, 2007 report that light diffusion sheets made of regular microlens arrays are used to prevent LED glare, also using a self-organizing method to densely arrange polystyrene microspheres on a substrate in a honeycomb. The self-organizing method is not suitable for making large-area structural templates. Documents [3] T.C. Huang1, J.R. Ciou1, P.H. Huang1, K.H. Hsieh, and Sen-you Yang Fast surface of integrated surface-relief and particle-dispersion planar user by a hybrid extrusion roller encapsulation process, Optics Express 16(1), 440-447, 2008 report a light diffuser that mixes a microstructure and doped particles and a method for making the same. The technical route is that a melt extruder is utilized to lead polycarbonate mixed with PMMA diffusion particles to pass through a roller with a microstructure, and the integrated light diffusion sheet is obtained after cooling and solidification. The melt extrusion process is complicated and requires expensive equipment.
Disclosure of Invention
The invention aims to provide a light diffusion sheet with diffusion particles arranged in a patterned mode and a manufacturing method thereof. The light diffusion sheet of the invention has the conception that the concave structures are manufactured on the base material, and the preset concave structures are in topological arrangement, such as square, hexagonal, strip, annular and the like. The concave structure is filled with organic or inorganic diffusion particles, the diffusion particles can be spherical, ellipsoidal, cylindrical, cuboid or other special-shaped bodies, and the refractive index of the diffusion particles is different from that of the base material, the micro-nano structure layer and the protective layer. When an incident light beam passes through the surface of the diffusion sheet, optical phenomena such as refraction, scattering, diffraction and the like occur under the influence of the diffusion particles arranged in a pattern, and the diffusion effect on the light is formed.
A light diffusing sheet characterized in that: the light-emitting diode is characterized by comprising a transparent substrate layer, wherein a microstructure layer is arranged on the surface of one side of the transparent substrate layer, the microstructure layer is provided with a microstructure, the microstructure is of a recessed structure, and diffusion particles are filled in the recessed structure of the microstructure layer.
In one embodiment, the microstructures in the microstructure layer are recessed and used for inducing the arrangement of the diffusion particles, and the arrangement mode can be linear grating, rectangular, annular and hexagonal arrangement, or symmetrical axis arrangement in a plane or asymmetrical axis arrangement in the plane; the diffusion particle arrangement may be continuous or discrete.
In one embodiment, the material of the microstructure layer may be the same as or different from the material of the substrate layer.
In one embodiment, the width of the recessed structure is greater than 1 micron, and the aspect ratio is greater than 0.3.
In one embodiment, the recessed structure of the microstructure layer is filled with diffusion particles distributed according to the topological arrangement of the recessed structure; the diffusion particles may be larger, smaller, or equal to the characteristic size of the recessed features, and may be spherical, ellipsoidal, cylindrical, rectangular, or other shapes.
In one embodiment, a transparent protective layer may be disposed outside the microstructure layer, and the protective layer completely or partially covers the diffusion particles.
In one embodiment, the absolute value of the difference between the optical refractive index of the diffusion particles filled in the recessed structure of the microstructure layer and the refractive index of the transparent substrate layer, the microstructure layer, the protective layer material, or one of them is not less than 0.01.
A method for manufacturing a light diffusion sheet, comprising the steps of:
s1, manufacturing a structure on the transparent substrate by using a mold with a convex structure in a hot-pressing or ultraviolet-pressing mode, and obtaining a concave structure complementary with the convex structure of the mold in the microstructure layer;
s2 using a doctor blade technique to doctor blade the diffusing particles into the recessed structures fabricated in the above step to form a patterned diffusing particle arrangement.
In one embodiment, the method further comprises step S3, coating a protective layer on the surface of the microstructure layer.
In one embodiment, the absolute value of the difference between the optical refractive index of the diffusion particles filled in the recessed structure of the microstructure layer and the refractive index of the transparent substrate layer, the microstructure layer, the protective layer material, or one of them is not less than 0.01.
The invention provides a novel light diffusion sheet structure and a manufacturing method thereof. The diffusion sheet is manufactured by a micro-nano imprinting and blade coating technology, and the functions of directional scattering and light spot homogenization are realized by the refraction and diffraction of a micro-nano topological structure to light and the scattering effect of diffusion particles to light. The micro-nano imprinting technology is a technology which can be used for preparing large-area graphical micro-nano structures in a large scale, the processing resolution of the micro-nano imprinting technology is only related to the size of a template pattern, and the micro-nano imprinting technology is not limited by the physical limitation of the shortest exposure wavelength of optical lithography, and has the advantages of high resolution, high yield and low cost. The blade coating technology realizes the filling of the diffusion particles, the method is convenient and fast, the process is simple, and the batch production is easy to realize.
Due to the application of the technical scheme, the structure-induced patterned diffusion particle scattering sheet has the following two advantages compared with the prior art:
1. manually-interoperable diffusing particles and scattered light fields are implemented in multiple dimensions. The invention utilizes the induction of the patterned structure to realize the patterned arrangement of the diffusion particles, thereby being capable of artificially optimizing and designing the scattering characteristics of a large number of the diffusion particles, such as directional scattering and obtaining flexible soft light (soft light), more flexibly regulating and controlling the light field and having wider adaptability.
The process is convenient and reliable: the whole process flow is smooth and convenient, batch and large-breadth manufacturing is easy to realize, the method is suitable for plates and coiled materials, required equipment is cheaper than extrusion hot melting equipment, and the operation cost is lower.
Drawings
Fig. 1 is a schematic view of a light diffusion sheet structure with light diffusion particles arranged in a pattern according to a first embodiment of the present invention;
wherein: 11. diffusing the particles; 12. a substrate; 13. a micro-nano structure layer; 14. micro-nano structure
FIGS. 2a-2d are flow charts of a light diffusion sheet with light diffusion particles arranged in a pattern according to the first embodiment; FIG. 2a is a schematic view of an imprint mold according to a first embodiment; FIG. 2b is a schematic diagram illustrating a complementary recess structure on a substrate by an imprint mold according to one embodiment; FIG. 2c is a schematic diagram of the filling of the diffusion particles by the knife coating technique in the first embodiment; FIG. 2d shows a surface with a passivation layer according to the first embodiment.
Wherein: 21. a micro-nano structure layer; 22. a substrate; 23. diffusing the particles; 24. protective layer
FIG. 3 is a schematic structural diagram of a mold for implementing imprint of a recessed structure according to an embodiment;
FIG. 4 is a schematic structural diagram of another mold for implementing the imprinting of the concave structure in the first embodiment;
FIG. 5 is a schematic structural diagram of another mold for implementing the imprinting of the concave structure in the first embodiment;
FIG. 6 is a schematic structural diagram of another mold for implementing the imprinting of the concave structure in the first embodiment;
FIG. 7 is a view showing a case where the diffusion particles are arranged in a multi-layered stack in the recess structure according to the third embodiment;
FIG. 8 is a schematic view showing a topology of a recess structure filled with diffusion particles according to the fourth embodiment;
FIG. 9 is another topology of the recess structure filled with diffusion particles according to the fourth embodiment;
FIG. 10 is another topology of the recess structure filled with diffusion particles according to the fourth embodiment;
FIG. 11 is a case that the micro-nano structure layer completely covers the protection layer in the fifth embodiment;
wherein 111, protective layer
Fig. 12 shows a case that the micro-nano structure layer partially covers the protection layer in the fifth embodiment.
Wherein 121, a protective layer
Detailed Description
The invention is further described with reference to the following figures and examples:
the first embodiment is as follows: referring to fig. 1, a light diffusion sheet is schematically shown, in which light diffusion particles are arranged in a patterned manner. The substrate 12 is fabricated with recessed structures 14, the recessed structures 14 are in a predetermined topological arrangement, such as a square, a hexagon, a stripe, a ring, etc., the width of the recessed structures is greater than 1 μm, and the aspect ratio is greater than 0.3. The recessed structures 14 are filled with diffusion particles 11 made of organic or inorganic materials, the diffusion particles 11 can be spherical, ellipsoidal, cylindrical, cuboid or other special-shaped bodies, the refractive index of the diffusion particles 11 is different from that of the base material 12, the micro-nano structure layer 13 and the protective layer, and the absolute value of the difference between the optical refractive index of the diffusion particles and the refractive index of one of the transparent base material layer, the micro-nano structure layer and the protective layer is not less than 0.01. When an incident light beam passes through the surface of the diffusion sheet, optical phenomena such as refraction, scattering, diffraction and the like occur under the influence of the diffusion particles 11 arranged in a pattern, and the diffusion effect on the light is formed. The diffusion particles 11 have a characteristic size of 1 to 10 μm. The absolute value of the refractive index difference between the diffusion particles and one of the base material 12, the micro-nano structure layer material 13 and the protective layer material is more than 0.01; or the absolute value of the difference in refractive index between two of them is greater than 0.05.
Example two: referring to fig. 2a-2d, the present invention provides a process for manufacturing a light diffusion sheet. Firstly, a mould with a protruding structure of a topological arrangement pattern is manufactured. The patterned raised structure mold of fig. 2a can be implemented by various methods, such as mask lithography exposure, laser direct writing, chemical etching or mechanical scribing. The material of the mould can be a metal material, such as nickel, stainless steel, copper or a metal alloy material, and an organic material, such as polycarbonate, polyvinyl chloride, polyester, perfluoropolyether alkene, tetrafluoroethylene copolymer and acrylic acid; is inorganic non-metallic material, such as silicon dioxide, silicon, carbon steel, and silicon carbide. Next, fig. 2b is a schematic diagram of a concave structure formed on the transparent substrate 22 by imprinting using a mold. Thermal embossing or ultraviolet embossing may be used. Hot stamping is to use a hard blank of a stamping die to form the stamping die, then soften the polymer substrate 21 by high temperature, or coat the polymer substrate with a high molecular polymer material 21 with hot soft melting property, put the polymer substrate into a stamping machine to be heated, press the stamping die on the polymer substrate with a certain pressure, then reduce the temperature to the vicinity of the freezing point of the polymer, and separate the stamping die and the polymer layer, so that the surface of the substrate has a structure complementary to the structure on the stamping die. The process of ultraviolet imprinting is basically the same as that of hot imprinting, and a polymer which can be cured under ultraviolet irradiation is required to be used as an imprinting layer material, a high-temperature and high-pressure mode is not required, but a pressing mold material (or a substrate material) is required to be transparent to an ultraviolet band. Again, fig. 2c is a schematic diagram of the recessed structure in the microstructure layer filled with diffusion particles 23. And scraping the diffusion particles into the concave microstructure by using a scraper through a scraping technology to form the diffusion particles in a patterned arrangement. Finally, the outer surface of the micro-nano structure layer can be covered by a transparent material to be used as a protective layer 24, and the appearance of smooth surface can be realized. Because the refractive index of the diffusion particles is different from that of the base material, the micro-nano structure layer and the protective layer, the diffusion particles arranged in a graphical mode scatter incident light.
Example three: referring to fig. 3 to 4, in a light diffusion sheet according to the present invention, the shape of the concave structures filled with diffusion particles depends on the shape of the microstructures of the mold. The microstructure shape such as sphere, ellipsoid, triangular pyramid, rectangular pyramid, etc., the cross section is a circle, ellipse, triangle, quadrangle or other irregular polygon, and the shape capable of filling diffusion particles is within the protection scope of the present invention. The diffusion particles are filled in the processed recess structure, and the state is shown in fig. 5-6. When the structures on the mold have a high aspect ratio, the recessed structures of the microstructure layer will also have a large aspect ratio, and the diffusing particles will be arranged in a multi-layer stack within the recessed structures, as shown in fig. 7. This provides an additional spatial dimension for designing the light modulation of the diffuser.
Example four: referring to fig. 8 to 10, in a light diffusion sheet according to the present invention, the distribution of the central positions of light diffusion spots is determined by the topology of the concave structures filled with diffusion particles. The topological structure can be a linear grating, such as a square, a hexagon, a strip, a ring and the like.
In example five, referring to fig. 11 to 12, in the light diffusion sheet provided by the present invention, the micro-nano structure layer may be covered with a protection layer 111 or 112, and the protection layer may completely cover the diffusion particles or partially cover the diffusion particles.
Claims (9)
1. A light diffusing sheet characterized in that: the microstructure comprises a transparent substrate layer, wherein a microstructure layer is arranged on the surface of one side of the transparent substrate layer, microstructures are arranged on the microstructure layer in an embossing mode, the microstructures are of a concave structure, the concave structure is in preset topological arrangement, diffusion particles are filled in the concave structure of the microstructure layer, the diffusion particles are continuously arranged in the concave structure, and the absolute value of the difference between the optical refractive index of the diffusion particles filled in the concave structure of the microstructure layer and the refractive index of the microstructure layer is not less than 0.01; wherein the width of the concave structure is more than 1 micron, and the aspect ratio is more than 0.3; wherein the topological arrangement is one of square, hexagonal or circular.
2. A light diffusing sheet according to claim 1, wherein the microstructures in the microstructure layer are recessed to induce an arrangement of diffusing particles, an arrangement of symmetric axes in a plane, or an arrangement of asymmetric axes in a plane.
3. A light diffusing sheet according to claim 2, wherein the material of the micro-structure layer is the same as or different from the material of the base material.
4. A light diffusing sheet according to claim 1, wherein the diffusing particles are smaller than or equal to the characteristic size of the concave structures, and have a shape of a sphere, an ellipsoid, a cylinder, a rectangular parallelepiped, or other shapes.
5. A light diffusing sheet according to claim 1, wherein a transparent protective layer is provided outside the microstructured layer, the protective layer completely or partially covering the diffusing particles.
6. The light diffusion sheet according to claim 4, wherein the absolute value of the difference between the optical refractive index of the diffusion particles filled in the recessed structures of the microstructure layer and the refractive indices of the transparent substrate layer and the protective layer is not less than 0.01.
7. A method for manufacturing a light diffusion sheet, comprising the steps of:
s1, manufacturing a structure on the transparent substrate by using a mold with a convex structure in a hot-pressing or ultraviolet-pressing mode, and obtaining a concave structure which is complementary with the convex structure of the mold in the microstructure layer, wherein the concave structures are arranged in a preset topology;
s2, coating diffusion particles into the concave structures manufactured in the previous step by a blade coating technology to form patterned diffusion particle arrangement, wherein the diffusion particles are continuously arranged in the concave structures;
wherein the width of the concave structure is more than 1 micron, and the aspect ratio is more than 0.3; the absolute value of the difference between the optical refractive index of the diffusion particles filled in the concave structure of the microstructure layer and the refractive index of the microstructure layer is not less than 0.01; wherein the topological arrangement is one of square, hexagonal or circular.
8. A method for making a light diffusing sheet according to claim 7, further comprising step S3 of coating a protective layer on the surface of the microstructure layer.
9. A light diffusing sheet according to claim 8, wherein the diffusing particles filled in the recessed structures of the microstructure layer have an absolute value of a difference between an optical refractive index and a refractive index of the transparent substrate layer, the protective layer material, or one of them of not less than 0.01.
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CN108614315A (en) * | 2018-07-06 | 2018-10-02 | 深圳市光科全息技术有限公司 | A kind of optical diffusion film |
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CN114077000A (en) * | 2020-08-13 | 2022-02-22 | 苏州维旺科技有限公司 | Diffusion sheet, preparation method thereof and backlight module |
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