CN117092730A

CN117092730A - Optical structure and manufacturing method thereof

Info

Publication number: CN117092730A
Application number: CN202310561453.0A
Authority: CN
Inventors: 杨景安; 辛隆宾; 陈辉勇; 赖建智; 阮幼梅; 谬佳烨; 林格蔚; 黄明德; 邱政杰; 吴文仁
Original assignee: Ubright Optronics Corp
Current assignee: Ubright Optronics Corp
Priority date: 2022-05-18
Filing date: 2023-05-18
Publication date: 2023-11-21
Also published as: KR20230161367A; TW202346989A

Abstract

The invention discloses an optical structure and a manufacturing method thereof, wherein the optical structure comprises an optical film with a substrate, a plurality of multi-surface concave parts are formed on the upper surface of the substrate, and a prism module is arranged above the first optical film, wherein the prism module comprises a plurality of prism sheets which are stacked and adhered to each other.

Description

Optical structure and manufacturing method thereof

Technical Field

The present invention relates to an optical film, and more particularly, to a composite optical film.

Background

High brightness, color saturation, light splitting effect, "light and thin" is a development direction of liquid crystal displays. However, in order to achieve the above object, the overall thickness of the backlight module is too high by the conventional method.

Furthermore, conventional methods do not enable true roll-to-roll manufacturing processes for mass production.

The present invention therefore proposes a new solution to overcome the above drawbacks.

Disclosure of Invention

The present invention provides an optical structure and a method for manufacturing the same, wherein a plurality of continuous seamless multi-faceted concave structures are formed on an optical film through a plurality of multi-faceted structures protruding from a roller, so as to be suitable for batch production in a roll-to-roll manner, and can generate a good light splitting effect to reduce the MURA effect and avoid forming shadows of light.

The present invention provides an optical structure comprising: a first composite optical film comprising a substrate, wherein a first material comprising a first photo-curable resin is coated on a first surface of the substrate, wherein a first plurality of multi-faceted recesses are formed in the first photo-curable resin, wherein the first plurality of multi-faceted recesses are distributed side-by-side along a length and a width of the first substrate to form a first multi-faceted recess matrix, wherein the first multi-faceted recess matrix comprises a first plurality of rows of multi-faceted recesses and a first plurality of columns of multi-faceted recesses, wherein at least two multi-faceted recesses are in each of the first plurality of rows of multi-faceted recesses, and at least two multi-faceted recesses are in each of the first plurality of columns of multi-faceted recesses, wherein there is no gap between each two adjacent multi-faceted recesses; and a prism module disposed above the first composite optical film, wherein the prism module includes a plurality of prism sheets stacked one on another, wherein each prism sheet includes a plurality of prisms disposed on an upper side of the prism sheet, wherein for each two adjacent prism sheets, a first plurality of prisms on an upper side of a lower prism sheet of the two adjacent prism sheets are bonded to a lower surface of an upper prism sheet of the two adjacent prism sheets.

In an embodiment, a first diffusion layer is attached to a lower surface of a prism sheet at a bottommost layer of the plurality of prism sheets, and a plurality of beads are disposed in the first diffusion layer, wherein the first diffusion layer is disposed above the first composite optical film.

In one embodiment, the first diffusion layer is disposed on a lower surface of a bottom-most prism sheet of the plurality of prism sheets, wherein the lower surface of the first diffusion layer comprises an embossed surface, wherein the first diffusion layer is disposed above the first composite optical film.

In an embodiment, a second diffusion layer is attached to the lower surface of the first composite optical film, wherein a plurality of beads are disposed in the second diffusion layer.

In an embodiment, the second diffusion layer is bonded to a lower surface of the first composite optical film, wherein the lower surface of the second diffusion layer comprises an embossed surface.

In one embodiment, a second diffusion layer is bonded to the lower surface of the first composite optical film, wherein the lower surface of the second diffusion layer comprises an embossed surface.

In an embodiment, the material of the first substrate is PET.

In one embodiment, the first photo-curable resin is a UV resin.

In an embodiment, the first photocurable resin comprises at least one of the following materials: epoxy resins, acrylates, polyamides, polyimides, and polyisoprene.

In one embodiment, polymethyl methacrylate is coated on an upper surface of the substrate, wherein the plurality of first multi-faceted recesses are formed in the polymethyl methacrylate.

In an embodiment, each of the plurality of first multi-faceted recesses is a cone groove.

In an embodiment, each of the plurality of first multi-faceted recesses has an inverted pyramid shape.

In one embodiment, a second photo-curable resin is coated on a lower surface of the substrate, wherein a plurality of second multi-faceted recesses are formed in the second photo-curable resin.

In an embodiment, the second photocurable resin comprises at least one of the following materials: epoxy resins, acrylates, polyamides, polyimides, and polyisoprene.

In one embodiment, a second material comprising a second photo-curable resin is coated on a second surface of the substrate, wherein a second plurality of multi-faceted recesses are formed in the second photo-curable resin, wherein the second plurality of multi-faceted recesses are distributed side-by-side along a length and a width of the substrate to form a second multi-faceted recess matrix, wherein the second multi-faceted recess matrix comprises a second plurality of rows of multi-faceted recesses and a second plurality of columns of multi-faceted recesses, wherein at least two multi-faceted recesses are in each of the second plurality of rows of multi-faceted recesses, and at least two multi-faceted recesses are in each of the second plurality of columns of multi-faceted recesses, wherein there is no gap between each two adjacent multi-faceted recesses.

In one embodiment, the first diffusion layer comprises a third photocurable resin, wherein the plurality of beads are disposed in the third photocurable resin.

In one embodiment, the first diffusion layer comprises a third photocurable resin, wherein the embossed surface is disposed in the third photocurable resin.

In one embodiment, the second diffusion layer comprises a fourth photocurable resin, wherein the plurality of beads are disposed in the fourth photocurable resin.

In one embodiment, the second diffusion layer comprises a fourth photocurable resin, wherein the embossed surface is disposed in the fourth photocurable resin.

In one embodiment, the second surface of the substrate has a microstructure having an uneven appearance to enhance optical haze.

The present invention provides a method of forming an optical film, the method comprising: providing a substrate; coating a material containing a first resin on an upper surface of the substrate; forming a first plurality of multi-faceted recesses in the first resin; coating a material containing a second resin on a lower surface of the substrate; a second plurality of multi-faceted recesses is formed in the second resin, wherein the plurality of multi-faceted recesses are capable of scattering light entering the substrate.

In one embodiment, the step of forming a plurality of multi-faceted recesses in the resin comprises: forming a plurality of multi-surface protrusions by scribing on a mold; forming the first plurality of multi-faceted recesses in the first resin on the upper surface of the substrate by using a plurality of multi-faceted protrusions on the mold; the second plurality of multi-faceted recesses are formed in the second resin on the lower surface of the substrate by using a plurality of multi-faceted protrusions on the mold.

In one embodiment, the resin is made of a photo-curable resin.

In one embodiment, the resin is made of polymethyl methacrylate.

In one embodiment, the substrate is made of PET.

In one embodiment, each groove of the plurality of multi-faceted recesses is a cone groove.

In an embodiment, each groove of the plurality of multi-sided recesses has an inverted pyramid shape.

Those skilled in the art will appreciate the features and embodiments of the invention described in the following paragraphs and in the detailed description of the invention with reference to the drawings.

Drawings

FIG. 1A shows a schematic top view of an optical film according to an embodiment of the present invention.

FIG. 1B shows a schematic top view of an optical film according to an embodiment of the present invention.

Fig. 2A shows a pyramidal structure on a substrate.

Fig. 2B shows another pyramidal structure on a substrate.

Fig. 2C shows another pyramidal structure on a substrate.

Fig. 2D shows a cross-sectional view in which the upper surface of the substrate has a plurality of first multi-faceted recesses and the lower surface of the substrate has a plurality of second multi-faceted recesses.

Fig. 3 shows a schematic top view of a prism module according to an embodiment of the present invention.

Fig. 4 shows a schematic top view of a prism module according to an embodiment of the present invention.

FIG. 5 shows a schematic top view of a composite optical film according to an embodiment of the invention.

FIG. 6A shows a schematic top view of a composite optical film according to an embodiment of the invention.

FIG. 6B is a schematic top view of a composite optical film according to an embodiment of the invention.

Fig. 6C is a schematic top view of a backlight module according to an embodiment of the invention.

FIG. 7 shows a schematic top view of an optical structure according to an embodiment of the invention.

FIG. 8 shows a schematic top view of an optical structure according to an embodiment of the invention.

FIG. 9 shows a schematic top view of an optical structure according to an embodiment of the invention.

FIG. 10 shows a schematic top view of an optical structure according to an embodiment of the invention.

FIG. 11A is a schematic top view of an optical structure according to an embodiment of the invention.

Fig. 11B is a schematic top view of a backlight module according to an embodiment of the invention.

FIG. 12 shows a schematic top view of an optical structure according to an embodiment of the invention.

FIG. 13 shows a schematic top view of an optical structure according to an embodiment of the invention.

Fig. 14 illustrates a method of forming a composite optical film according to one embodiment of the invention.

FIG. 15 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention.

FIG. 16 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention.

FIG. 17 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention.

Reference numerals illustrate: 100-optical film; 101 to a substrate; 103a, 103b, 104a, 104b to multi-faceted recesses; 203a, 203b, 204a, 204b to multi-faceted recesses; 150-light; 101a to a first surface; 101b to a second surface; 102 to a first material; 202-second material; l-length; w-width; 280-a plurality of first multi-surface concave parts; 281 to a plurality of second multi-sided depressions; p1-space; p2-space; t1, T2 and T3-thickness; 300-composite optical film; 205. 206 to prism sheets; 205a, 206a to a substrate; 205b, 206b to a plurality of prisms; 207a to an adhesive layer; 600-optical structure; 900-optical structure; 700. 800-diffusion layer; 700a, 800a to an embossed surface; 700b, 800 b-bead; 650. 950 to a backlight module; 401 to a light source; 402-mini-LEDs.

Detailed Description

Detailed description of the inventionin the following description, the preferred embodiments are described herein for purposes of illustration and description, but are not intended to limit the scope of the invention.

Fig. 1A shows a top view of an optical film 100 according to one embodiment of the invention, wherein the optical film 100 comprises a substrate 101, wherein a plurality of first multi-faceted recesses 103a, 103b, 104a, 104b are formed on a first surface 101A of the substrate 101, wherein the plurality of first multi-faceted recesses 103a, 103b, 104a, 104b are capable of scattering light 150 entering a second surface 101b of the substrate 101, wherein the first surface 101A and the second surface 101b are opposite surfaces of the substrate 101.

In one embodiment, the multi-faceted recess includes at least three side surfaces.

In one embodiment, the plurality of multi-faceted recesses 104a, 104b are distributed along the length L of the substrate.

In one embodiment, the plurality of multi-faceted recesses 103a, 103b are distributed along the width W of the substrate 101.

In one embodiment, the plurality of multi-faceted recesses 104a, 104b are distributed along the length L of the substrate, wherein there is no gap between two adjacent multi-faceted recesses 104a, 104 b.

In one embodiment, the plurality of multi-faceted recesses 103a, 103b are distributed along the width W of the substrate, wherein there is no gap between two adjacent multi-faceted recesses 103a, 103 b.

In one embodiment, the plurality of multi-faceted recesses 104a, 104b are distributed along the length L of the substrate and the plurality of multi-faceted recesses 103a, 103b are distributed along the width W of the substrate, wherein there is no gap between two adjacent multi-faceted recesses 104a, 104b and no gap between two adjacent multi-faceted recesses 103a, 103 b.

Fig. 1B shows a top view of an optical film 100 according to an embodiment of the invention, wherein the optical film 100 comprises a substrate 101, wherein a first surface 101a of the substrate 101 is coated with a resin-comprising material 102, wherein a plurality of multi-faceted recesses 103a, 103B, 104a, 104B are formed in the resin-comprising material 102, wherein the plurality of multi-faceted recesses 103a, 103B, 104a, 104B are capable of scattering light 150 entering a second surface 101B of the substrate, wherein the first surface 101a and the second surface 101B are opposite surfaces of the substrate 101.

In one embodiment, the resin-containing material 102 comprises a photocurable resin.

In one embodiment, the resin-containing material 102 includes polymethyl methacrylate (PMMA).

In one embodiment, the resin-containing material 102 includes a photocurable resin, such as: epoxy resins, acrylates, polyamides, polyimides, and polyisoprene.

In one embodiment, in fig. 1A and 1B, a plurality of multi-faceted recesses 104a, 104B are distributed along the length L of the substrate 101.

In one embodiment, in fig. 1A and 1B, a plurality of multi-faceted recesses 103a, 103B are distributed along the width W of the substrate 101.

In one embodiment, in fig. 1A and 1B, a plurality of multi-faceted recesses 104a, 104B are distributed along the length L of the substrate, with no gaps between two adjacent multi-faceted recesses 104a, 104B.

In one embodiment, in fig. 1A and 1B, a plurality of multi-faceted recesses 104a, 104B are distributed along the length L of the substrate and a plurality of multi-faceted recesses 103a, 103B are distributed along the width W of the substrate, wherein there is no gap between two adjacent multi-faceted recesses 104a, 104B and no gap between two adjacent multi-faceted recesses 103a, 103B.

In one embodiment, in fig. 1A and 1B, each groove in the plurality of multi-faceted recesses 103a, 103B, 104a, 104B is a cone groove.

In one embodiment, in fig. 1A and 1B, each of the plurality of multi-faceted recesses 103a, 103B, 104a, 104B is an inverted pyramidal recess.

In one embodiment, in fig. 1A and 1B, each groove in the plurality of multi-faceted recesses includes at least three sloped side surfaces, wherein each sloped side surface is sloped inwardly.

In one embodiment, in fig. 1A and 1B, each groove in the plurality of multi-faceted recesses includes four sloped side surfaces, wherein each sloped side surface is sloped inwardly.

In one embodiment, in fig. 1A and 1B, the second surface of the substrate 101 includes a microstructure having non-uniformity to enhance optical haze.

In one embodiment, in fig. 1A and 1B, the heterogeneous microstructure is formed by coating an organic polymer having a plurality of particles embedded therein.

Fig. 2A shows a cone structure protruding over a mold 250, e.g. the cone is a square cone.

Fig. 2B shows a cone structure protruding over the mold 250, for example, the cone is a triangular cone.

Fig. 2C shows a cone structure protruding over the mold 250, for example, the cone is a pyramid.

Fig. 2D shows a cross-sectional view wherein the upper surface of the substrate 101 has a first structure having a plurality of first multi-faceted recesses 280. The lower surface of the substrate 101 has a second structure having a plurality of second multi-faceted recesses 281. In one embodiment, the pitch P1 between each two adjacent multi-faceted recesses of the plurality of first multi-faceted recesses 280 is the same as the pitch P2 between each two adjacent multi-faceted recesses of the plurality of second multi-faceted recesses 281. In one embodiment, the pitch P1 between each two adjacent multi-faceted recesses of the plurality of first multi-faceted recesses 280 is different than the pitch P2 between each two adjacent multi-faceted recesses of the plurality of second multi-faceted recesses 281. In one embodiment, the pitch P1 is in the range of 56-60 μm. In one embodiment, the pitch P2 is in the range of 59-63 μm. In one embodiment, the thickness T1 of one of the plurality of first multi-faceted recesses 280 is in the range of 10-30 μm; the substrate may be PET and the thickness T2 of the substrate may be in the range of 30-300 μm. In one embodiment, the thickness T3 of one multi-faceted recess of the plurality of second multi-faceted recesses 281 is in the range of 5-50 μm. In one embodiment, the total thickness of T1, T2, T3 is in the range of 40-400 μm.

In one embodiment, each of the plurality of multi-faceted recesses is a cone groove.

In one embodiment, each of the plurality of multi-faceted recesses has an inverted pyramid shape.

Fig. 3 shows a schematic top view of a prism module 300 according to an embodiment of the present invention, wherein the prism module 300 comprises a plurality of prism sheets 205, 206 stacked on top of each other, wherein each prism sheet 205, 206 comprises a plurality of prisms 205b, 206b on the upper side of the prism sheet 205, 206, wherein for each two adjacent prism sheets 205, 206a first plurality of prisms 205b on the upper side of the lower prism sheet 205 is attached to the lower surface of the upper prism sheet 206.

In one embodiment, as shown in fig. 3, the prism sheet 205 includes a substrate 205a, wherein a plurality of prisms 205b are disposed on the substrate 205 a.

In one embodiment, as shown in fig. 3, the prism sheet 206 includes a substrate 206a, wherein a plurality of prisms 206b are disposed on the substrate 206 a.

In one embodiment, as shown in fig. 3, the prism module 300 further includes an adhesive layer 207a, wherein the prism sheet 205 is attached to the prism sheet 206 by the adhesive layer 207a disposed between the prism sheet 205 and the prism sheet 206.

In one embodiment, the tops of the first plurality of prisms 205a are embedded in the adhesive layer 207 a.

In one embodiment, as shown in fig. 3, a diffusion layer 700 is disposed on the lower surface of the bottommost prism sheet 205.

In one embodiment, as shown in fig. 3, the lower surface of the diffusion layer 700 includes an embossed surface 700a.

In one embodiment, after the UV resin is coated on the lower surface of the bottom-most prism sheet 205, the lower surface of the UV resin is embossed to form the embossed surface 700a.

In one embodiment, as shown in FIG. 4, a plurality of beads 700b are disposed in the diffusion layer 700.

In one embodiment, the back of one prism film is coated with UV resin and the prism tip of the other prism film is immersed, and the prism film with the immersed prism tip is embossed after the back is coated with UV resin, and finally the whole is formed into a double prism film module after being irradiated with UV light.

Fig. 5 shows a schematic top view of a composite optical film 200 according to an embodiment of the present invention, wherein the composite optical film 200 comprises a first substrate 101, wherein an upper surface of the first substrate 101 is coated with a first material comprising a first photo-curable resin 102, wherein a first plurality of multi-faceted recesses 103a, 103b, 104a, 104b are formed in the first photo-curable resin 102, wherein the first plurality of multi-faceted recesses 103a, 103b, 104a, 104b are distributed side-by-side along a length L and a width W of the first substrate 101 to form a first multi-faceted recess matrix, wherein the first multi-faceted recess matrix comprises a first plurality of multi-faceted recess rows and a first plurality of multi-faceted recess columns, wherein each of the first plurality of multi-faceted recess rows has at least two multi-faceted recesses, each of the first plurality of multi-faceted recess columns has at least two multi-faceted recesses, wherein each two adjacent multi-sided recesses of the first plurality of multi-sided recesses 103a, 103b, 104a, 104b have no gaps therebetween, wherein a second material comprising a second photo-curable resin 202 is coated on the lower surface of the first substrate 101, wherein a second plurality of multi-sided recesses 203a, 203b, 204a, 204b are formed in a second photo-curable resin 202, wherein the plurality of second multi-sided recesses 203a, 203b, 204a, 204b are distributed side by side along the length L and the width W of the first substrate 101 to form a second multi-sided recess matrix, wherein the second multi-sided recess matrix comprises a second plurality of multi-sided recess rows and a second plurality of multi-sided recess columns, wherein each of the second plurality of multi-sided recess rows has at least two multi-sided recesses, each of the second plurality of multi-sided recess columns has at least two multi-sided recesses, wherein the second plurality of multi-sided recesses 203a, 204b are arranged side by side along the length L and the width W of the first substrate 101, 203b, 204a, 204b, there is no gap between every two adjacent multi-faceted recesses.

In one embodiment, the first plurality of multi-faceted recesses 103a, 103b, 104a, 104b and the second plurality of multi-faceted recesses 203a, 203b, 204a, 204b are mirror images of each other.

In one embodiment, the first substrate 101 comprises PET.

In one embodiment, the first photocurable resin 102 comprises a UV resin.

In one embodiment, the second photocurable resin 202 includes at least one of the following materials: epoxy resins, acrylates, polyamides, polyimides, and polyisoprene.

In one embodiment, the first material comprises PMMA (polymethyl methacrylate) coated on a top surface of the substrate, wherein the first plurality of multi-faceted recesses are formed in the PMMA.

In one embodiment, the second material comprises PMMA (polymethyl methacrylate) coated on the top surface of the substrate, wherein the second plurality of multi-faceted recesses are formed in the PMMA.

In one embodiment, each of the plurality of multi-faceted recesses is a conical recess.

Fig. 6A shows a schematic top view of an optical structure 600 according to an embodiment of the invention, wherein the optical structure 600 comprises: a first composite optical film 100, as shown in fig. 1B, wherein the first composite optical film 100 comprises a substrate 101, wherein a first material comprising a first photo-curable resin 102 is coated on a first surface of the substrate 101, wherein a first plurality of multi-faceted recesses 103a, 103B are formed in the first photo-curable resin 102, as shown in fig. 1B, wherein the first plurality of multi-faceted recesses 103a, 103B, 104a, 104B are distributed side-by-side along a length L and a width W of the substrate 101 to form a first multi-faceted recess matrix, wherein the first multi-faceted recess matrix comprises a first plurality of rows of multi-faceted recesses and a first plurality of columns of multi-faceted recesses, wherein each of the first plurality of rows of multi-faceted recesses has at least two multi-faceted recesses, wherein each of the first plurality of columns of multi-faceted recesses 103a, 103B, 104a, 104B has no gaps between each two adjacent multi-faceted recesses of the first plurality of multi-faceted recesses; a prism module disposed above the first optical film, wherein the prism module 300 includes a plurality of prism sheets 205, 206 stacked one on top of the other, wherein each prism sheet 205, 206 includes a plurality of prisms 205b, 206b on an upper side of the prism sheet 205, 206, wherein for each two adjacent prism sheets 205, 206, a first plurality of prisms 205b on an upper side of a lower prism sheet 205 is attached to a lower surface of the upper prism sheet 206.

In one embodiment, as shown in fig. 6A, wherein the prism sheet 205 is attached to the prism sheet 206 by an adhesive layer 207a disposed between the prism sheet 205 and the prism sheet 206.

In one embodiment, as shown in fig. 6A, the first composite optical film 100 is attached to the prism sheet 205 by an adhesive layer 208a provided between the prism sheet 205 and the first composite optical film 100.

In one embodiment, as shown in fig. 6B, a first diffusion layer 700 is disposed on the lower surface of the lowermost prism sheet 205 of the plurality of prism sheets 205, 206, and a second diffusion layer 800 is disposed on the lower surface of the substrate 101.

Fig. 6C is a schematic top view of a backlight module 900 according to an embodiment of the invention, wherein the backlight module 900 includes the composite optical structure 600 shown in fig. 6C. As shown in fig. 6B, the light source 401 is located below the optical structure 600. In one embodiment, the light source 401 comprises a plurality of mini-LEDs 402, wherein the plurality of mini-LEDs 402 emit light into the substrate 101 through the lower surface of the substrate 101.

In one embodiment, as shown in fig. 7, a first diffusion layer 700 is disposed on a lower surface of a bottom-most prism sheet 205 of the plurality of prism sheets 205, 206, wherein the lower surface of the first diffusion layer 700 includes a first embossed surface 700a, wherein the first diffusion layer 700 is disposed on the first optical film 100, wherein a second diffusion layer 800 is disposed on the lower surface of the first composite optical film 100, wherein the lower surface of the second diffusion layer 800 includes a second embossed surface 800a.

In one embodiment, after the UV resin is coated on the lower surface of the first composite optical film 100, the lower surface of the UV resin is embossed to form the embossed surface 800a.

In one embodiment, as shown in fig. 8, a first diffusion layer 700 is disposed on a lower surface of a bottommost prism sheet 205 of the plurality of prism sheets 205, 206, wherein the lower surface of the first diffusion layer 700 comprises a first embossed surface 700a, wherein the first diffusion layer 700 is disposed on the first optical film 100, wherein a second diffusion layer 800 is disposed on a lower surface of the first composite optical film 100, wherein a plurality of beads 800b are disposed in the second diffusion layer 800.

In one embodiment, as shown in fig. 9, a first diffusion layer 700 is disposed on the lower surface of the bottommost prism sheet 205 of the plurality of prism sheets 205, 206, wherein a plurality of beads 700b are disposed in the first diffusion layer 700, wherein a second diffusion layer 800 is disposed on the lower surface of the first composite optical film 100, wherein a plurality of beads 800b are disposed in the second diffusion layer 800.

In one embodiment, as shown in fig. 10, a first diffusion layer 700 is disposed on a lower surface of a lowermost prism sheet 205 of the plurality of prism sheets 205, 206, wherein a plurality of beads 700b are disposed in the first diffusion layer 700, wherein a second diffusion layer 800 is disposed on a lower surface of the first composite optical film 100, wherein the lower surface of the second diffusion layer 800 comprises a second embossed surface 800a.

FIG. 11A shows a schematic top view of an optical structure 650 according to an embodiment of the present invention, wherein the optical structure 650 comprises: a first composite optical film 200, as shown in FIG. 5, wherein the first composite optical film 200 comprises a substrate 101, wherein an upper surface of the substrate 101 is coated with a first material comprising a first photo-curable resin 102, wherein a first plurality of multi-faceted recesses 103a, 103b, 104a, 104b are formed in the first photo-curable resin 102, wherein the first plurality of multi-faceted recesses 103a, 103b, 104a, 104b are distributed side-by-side along a length L and a width W of the first substrate 101 to form a first multi-faceted recess matrix, wherein the first multi-faceted recess matrix comprises a first plurality of rows of multi-faceted recesses and a first plurality of columns of multi-faceted recesses, wherein each of the first plurality of rows of multi-faceted recesses has at least two multi-faceted recesses, each of the first plurality of columns of multi-faceted recesses has at least two multi-faceted recesses, wherein each two adjacent multi-sided recesses of the first plurality of multi-sided recesses 103a, 103b, 104a, 104b have no gaps therebetween, wherein a second material comprising a second photo-curable resin 202 is coated on the lower surface of the substrate 101, wherein a second plurality of multi-sided recesses 203a, 203b, 204a, 204b are formed in a second photo-curable resin 202, wherein the plurality of second multi-sided recesses 203a, 203b, 204a, 204b are distributed side by side along the length L and the width W of the substrate 101 to form a second multi-sided recess matrix, wherein the second multi-sided recess matrix comprises a second plurality of multi-sided recess rows and a second plurality of multi-sided recess columns, wherein each row of the second plurality of multi-sided recess rows has at least two multi-sided recesses, each column of the second plurality of multi-sided recess columns has at least two multi-sided recesses, wherein the first plurality of second multi-sided recesses 203a, 203b, 204a, 204b have no gaps between every two adjacent multi-faceted recesses; a prism module disposed above the first optical film, wherein the prism module 300 includes a plurality of prism sheets 205, 206 stacked one on top of the other, wherein each prism sheet 205, 206 includes a plurality of prisms 205b, 206b on an upper side of the prism sheet 205, 206, wherein for each two adjacent prism sheets 205, 206, a first plurality of prisms 205b on an upper side of a lower prism sheet 205 is attached to a lower surface of the upper prism sheet 206.

In one embodiment, as shown in fig. 11A, a first diffusion layer 700 is disposed on the lower surface of the bottommost prism sheet 205 of the plurality of prism sheets 205, 206.

Fig. 11B shows a schematic top view of a backlight module 950 according to an embodiment of the invention, wherein the backlight module 950 includes the optical structure 650 shown in fig. 11A, and the light source 401 is located under the first composite optical film 200. In one embodiment, the light source 401 includes a plurality of micro LEDs 402.

In one embodiment, as shown in fig. 12, a first diffusion layer 700 is disposed on a lower surface of a lowermost prism sheet 205 of the plurality of prism sheets 205, 206, wherein the lower surface of the first diffusion layer 700 includes a first embossed surface 700a, wherein the first diffusion layer 700 is disposed above the first composite optical film 200.

In one embodiment, as shown in fig. 13, a first diffusion layer 700 is disposed on the lower surface of the bottommost prism sheet 205 of the plurality of prism sheets 205, 206, wherein a plurality of beads 700b are disposed in the first diffusion layer 700, wherein the first diffusion layer 700 is disposed above the composite optical film 200.

In one embodiment, the first diffusion layer 700 comprises a photocurable resin, wherein the plurality of beads are disposed in the photocurable resin.

In one embodiment, the first diffusion layer 700 comprises a photo-curable resin, wherein the embossed surface is disposed in the photo-curable resin.

In one embodiment, the second diffusion layer 800 comprises a photocurable resin, wherein the plurality of beads are disposed in the photocurable resin.

In one embodiment, the second diffusion layer 800 comprises a fourth photo-curable resin, wherein the embossed surface is disposed in the fourth photo-curable resin.

Fig. 14 illustrates a method of forming a composite optical film according to one embodiment of the invention, wherein the method comprises: step 601S: providing a substrate; step 602S: a first material including a first photo-curing resin is coated on a first surface of the substrate. Step 603S: forming a first plurality of multi-faceted recesses in the first material, wherein each recess is formed by a corresponding shape protruding over the roller; step 604S: coating a second material comprising a first photocurable resin on a second surface of the substrate, wherein the first surface and the second surface are opposing surfaces of the substrate; step 605S: a second plurality of multi-faceted depressions are formed in the second material, wherein each depression is formed by a corresponding shape protruding over the roller.

In one embodiment, a prism module, as shown in fig. 3 or 4, may be disposed above the composite optical film.

FIG. 15 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention, wherein the method comprises: step 701S: providing a sheet; step 702S: a first material including a first photo-curable resin is coated on a first surface of the sheet. Step 703S: forming a first plurality of multi-faceted recesses in the first material, wherein each recess is formed by a corresponding shape protruding over the roller; step 704S: coating a second material comprising a first photocurable resin on a second surface of the sheet, wherein the first surface and the second surface are opposing surfaces of the sheet; step 705S: embossing the second material including the photo-curable resin to form a diffusion layer; step 706S: the sheet is cut into a plurality of individual pieces to form a plurality of composite optical films.

FIG. 16 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention, wherein the method comprises: step 801S: providing a sheet; step 802S: a first material including a first photo-curable resin is coated on a first surface of the sheet. Step 803S: forming a first plurality of multi-faceted recesses in the first material, wherein each recess is formed by a corresponding shape protruding over the roller; step 804S: coating a second material comprising a first photocurable resin on a second surface of the sheet, wherein the first surface and the second surface are opposing surfaces of the sheet; step 805S: forming a second plurality of multi-faceted depressions in the second material, wherein each depression is formed by a corresponding shape protruding over the roller; step 806S: the sheet is cut into a plurality of individual pieces to form a plurality of composite optical films.

FIG. 17 illustrates a method of forming a plurality of composite optical films according to one embodiment of the invention, wherein the method comprises: step 901S: providing a sheet; step 902S: a first material including a first photo-curable resin is coated on a first surface of the sheet. Step 903S: forming a first plurality of multi-faceted recesses in the first material, wherein each recess is formed by a corresponding shape protruding over the roller; step 904S: coating a second material comprising a first photocurable resin on a second surface of the sheet, wherein a plurality of beads are disposed in the second material comprising the first photocurable resin, wherein the first surface and the second surface are opposite surfaces of the sheet; step 905S: the sheet is cut into a plurality of individual pieces to form a plurality of composite optical films.

In one embodiment, the sheet is a PET sheet.

In one embodiment, the method further comprises disposing a prism module above the composite optical film, wherein the prism module comprises a plurality of prism sheets stacked on each other.

In one embodiment, the first plurality of multi-faceted recesses and the second plurality of multi-faceted recesses are mirror images of each other.

In one embodiment, the substrate comprises PET.

In one embodiment, the prism sheet is disposed on a composite optical film.

In one embodiment, the second brightness enhancing film is disposed on the prism sheet.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-face convex structures, such as a plurality of multi-face pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of diffusion films with inverted pyramid groove structures, on the PET sheet with the first surface coated with the UV resin in a roller embossing mode and simultaneously irradiating UV rays, wherein the inverted pyramid groove structures are formed in the UV resin; coating the second surface of the PET sheet with UV resin, embossing and forming, and collecting a coiled material; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, simultaneously coating UV resin on the back surface of the prism film immersed by the prism tip, embossing, and finally forming a double prism film module after the whole is irradiated with UV rays; the invention is completed by cutting the coiled material into single sheets and then placing the double prism sheet module on the single sheets. The invention can reduce the total thickness of the backlight module framework, and can also shield the light and shadow of the Mini-LED and increase the whole luminance, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-face convex structures, such as a plurality of multi-face pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of inverted pyramid groove structures, on the PET sheet with the first surface coated with the UV resin in a roller embossing mode and simultaneously irradiating UV rays, wherein the inverted pyramid groove structures are formed in the UV resin; coating diffusion particles on the second surface of the PET sheet, and then irradiating UV rays to form and collect a coiled material; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, simultaneously coating UV resin on the back surface of the prism film immersed by the prism tip, embossing, and finally forming a double prism film module after the whole is irradiated with UV rays; the invention is completed by cutting the coiled material into single sheets and then placing the double prism sheet module on the single sheets. The invention can reduce the total thickness of the backlight module framework, and can also shield the light and shadow of the Mini-LED and increase the whole luminance, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-face convex structures, such as a plurality of multi-face pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of diffusion films with inverted pyramid groove structures, on the PET sheet with the first surface coated with the UV resin in a roller embossing mode and simultaneously irradiating UV rays, wherein the inverted pyramid groove structures are formed in the UV resin; coating diffusion particles on the second surface of the PET sheet, and then irradiating UV rays to form and collect a coiled material; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, coating diffusion particles on the back surface of the prism film immersed by the prism tip, and finally forming the whole after irradiating UV rays into a double prism film module; the invention is completed by cutting the coiled material into single sheets and then placing the double prism sheet module on the single sheets. The invention can reduce the total thickness of the backlight module framework, and can also shield the light and shadow of the Mini-LED and increase the whole luminance, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-face convex structures, such as a plurality of multi-face pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of diffusion films with inverted pyramid groove structures, on the PET sheet with the first surface coated with the UV resin in a roller embossing mode and simultaneously irradiating UV rays, wherein the inverted pyramid groove structures are formed in the UV resin; coating diffusion particles on the second surface of the PET sheet, and then irradiating UV rays to form and collect a coiled material; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, simultaneously coating UV resin on the back surface of the prism film immersed by the prism tip, embossing, and finally forming a double prism film module after the whole is irradiated with UV rays; the invention is completed by cutting the coiled material into single sheets and placing the double prism sheet module on the coiled material, and the backlight module structure not only reduces the total thickness, but also can shield the light shadow of Mini-LEDs and increase the overall brightness, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-surface convex structures, such as multi-surface pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of inverted pyramid groove structures, on a PET sheet with double sides (upper surface and lower surface) coated with UV resin in a roller embossing mode and simultaneously irradiating UV light, and then collecting a coiled material, wherein the plurality of inverted pyramid groove structures are formed in the UV resin; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, coating diffusion particles on the back surface of the prism film immersed by the prism tip, and finally forming the whole after irradiating UV rays into a double prism film module; the invention is completed by cutting the coiled material into single sheets and then placing the double prism sheet module on the single sheets. The invention can reduce the total thickness of the backlight module framework, and can also shield the light and shadow of the Mini-LED and increase the whole luminance, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

The present invention provides a method of forming an optical structure, wherein the method comprises: firstly, a plurality of multi-face convex structures, such as a plurality of multi-face pyramid convex structures, are manufactured on a roller; manufacturing a plurality of multi-surface concave parts, such as a plurality of inverted pyramid groove structures, on a PET sheet with double sides (upper surface and lower surface) coated with UV resin in a roller embossing mode and simultaneously irradiating UV light, and then collecting a coiled material, wherein the plurality of inverted pyramid groove structures are formed in the UV resin; coating UV resin on the back surface of one prism film and immersing the prism tip of the other prism film, simultaneously coating UV resin on the back surface of the prism film immersed by the prism tip, embossing, and finally forming a double prism film module after the whole is irradiated with UV rays; the invention can reduce the total thickness of the backlight module framework, and can shield the light shadow of Mini-LED and increase the whole brightness, thereby achieving the purposes of uniformity and improving the brightness of LCD pictures.

Although the invention has been described with reference to the preferred embodiments, it should be understood that the invention is not limited thereto, but may be embodied with other specific forms and modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. While these possible modifications and alternatives are not fully provided in the foregoing description, the claims that follow are to encompass virtually all such aspects.

Claims

1. An optical structure, comprising:

a first composite optical film comprising a substrate, wherein a first material comprising a first photo-curable resin is coated on a first surface of the substrate, wherein a first plurality of multi-faceted recesses are formed in the first photo-curable resin, wherein the first plurality of multi-faceted recesses are distributed side-by-side along a length and a width of the substrate to form a first multi-faceted recess matrix, wherein the first multi-faceted recess matrix comprises a first plurality of rows of multi-faceted recesses and a first plurality of columns of multi-faceted recesses, wherein at least two multi-faceted recesses are in each of the first plurality of rows of multi-faceted recesses, and at least two multi-faceted recesses are in each of the first plurality of columns of multi-faceted recesses, wherein there is no gap between each two adjacent multi-faceted recesses; and

and a prism module disposed above the first composite optical film, wherein the prism module includes a plurality of prism sheets stacked one on another, wherein each prism sheet includes a plurality of prisms disposed on an upper side of the prism sheet, wherein for each two adjacent prism sheets, a plurality of prisms on a lower prism sheet of the two adjacent prism sheets are attached to a lower surface of an upper prism sheet of the two adjacent prism sheets.

2. The optical structure of claim 1, wherein a first diffusion layer is disposed on a lower surface of a bottom-most prism sheet of the plurality of prism sheets, the first diffusion layer having a plurality of beads disposed therein, wherein the first diffusion layer is disposed above the first composite optical film.

3. The optical structure of claim 1, wherein a first diffusion layer is disposed on a lower surface of a bottom-most prism sheet of the plurality of prism sheets, wherein the lower surface of the first diffusion layer comprises an embossed surface, wherein the first diffusion layer is disposed above the first composite optical film.

4. The optical structure of claim 2, wherein a second diffusion layer is disposed on a lower surface of the first composite optical film, wherein a plurality of beads are disposed within the second diffusion layer.

5. The optical structure of claim 2, wherein a second diffusion layer is disposed on the lower surface of the first composite optical film, wherein the lower surface of the second diffusion layer comprises an embossed surface.

6. The optical structure of claim 3, wherein a second diffusion layer is disposed on a lower surface of the first composite optical film, wherein a plurality of beads are disposed within the second diffusion layer.

7. The optical structure of claim 3, wherein a second diffusion layer is disposed on the lower surface of the first composite optical film, wherein the lower surface of the second diffusion layer comprises an embossed surface.

8. The optical structure of claim 1 wherein the substrate is PET.

9. The optical structure of claim 1 wherein the first photocurable resin is a UV resin.

10. The optical structure of claim 1, wherein each of the plurality of first multi-faceted depressions is a pyramid recess.

11. The optical structure of claim 1, wherein each of the plurality of first multi-faceted depressions has an inverted pyramid shape.