201010839 九、發明說明： 【發明所屬之技術領域】 ^ 本發明係關於一種模具之製造方法，特別是關於利用 熱壓轉印技術縮小模具之表面結構之尺寸，進而製作用於 製造增亮膜之模具的製造方法。 【先前技術】201010839 IX. Description of the invention: [Technical field to which the invention pertains] ^ The present invention relates to a method for manufacturing a mold, and more particularly to reducing the size of a surface structure of a mold by using a hot press transfer technique, thereby producing a brightness enhancing film. The method of manufacturing the mold. [Prior Art]
液晶顯不器面板〔Liquid Crystal Display Panel，LCD ❹ Panel〕之液晶本身並不會發光，其面板光源是由液晶顯示 器中的背光模組〔Backlight modules〕所供應，且背光模組 設有光學膜片及其增亮膜，促使輝度充分、分佈均勻與高 亮度之光源透過有效光機構而轉化成亮度高且均一的面光 源。 目前習知光學膜片之增亮膜係可採用射出成型的方 式製成。首先必須先製備所需之成型模具，其係利用光刻 模造〔Lithographic GalVanoformung Abformung，LIGA〕 © 製程於一基材上製作出稜鏡結構，再用電鑄方式脫膜出所 需之稜鏡結構模具，將此稜鏡結構模具裝置於射出成型機 臺上，接著注入熔融高分子材料且待其凝固後再做修整動 作，即可製作出所需之增亮膜。 然而’上述以光刻模造製作模具具有尺寸上之限制， 其無法製作出極小之稜鏡微結構。另_方面，利用射出成 型製作增亮膜時’必須先製作所需模具以及預先高溫加熱 溶融該高分子材料，才能進行後續之缚模作業，如此不僅 造成習用增亮膜之製程複雜，且加熱熔融該高分子材料亦 201010839 增加製程所耗費之能量及時間，加上射出成型所用之機台 需處於極高溫及高壓的工作環境，導致其本身設備成本昂 、 貴，進而造成該增亮膜的製作成本亦相對提高。另外，等 待高分子材料於模具中冷卻凝固後才能進行下一個增亮膜 之製作程序，造成無法持續製作增亮膜而降低其製造效率 ，再者，僅能在單一模具下射出成型該增亮膜，使所製成 之増亮膜仍與模具之微結構有所差異，降低了製程之精密 Q 度。 另外，亦可採用銑削技術預先製作出上述射出成型所 用之模具。然而，-般而言傳統銳削技術係利用一刀具銑 射出該模具所需之形狀，但受限於刀具尺寸，使得所製作 出之模具的表面結構〔特別是凹槽結構〕尺寸最小也只能 相同於該刀具之刀鼻半徑，導致在講求尺寸微小化的現今 科技產業，該模具的加工方式已無法滿足目前的產業需求 。基於上述原因，有必要進一步改良上述習用用於製造增 ® 亮膜之模具的製造方法。 【發明内容】 為改善前述習知用於製造增亮膜之模具的製造方法 存在模具表面結構之尺寸限制等缺點，本發明係提供一種 用於製造增亮膜之模具的製造方法，其主要之發明目的係 為有效且精確的減小用於製造增亮膜之模具的表面結構尺 寸’以供後續成形增亮膜之用。 為達到前述發明目的，本發明所運用之技術手段及藉 由該技術手段所能達到之功效包含有·· —6 — 201010839 一種用於製造增亮膜之模具的製造方法，其步驟包含 :於一第一基材上加工形成微透鏡陣列結構，以製備一第 、 一模具，且該第一模具具有一微透鏡間距；加熱一金屬玻 璃基材至其玻璃轉換溫度以上，並將該第一模具上之微透 鏡陣列結構經由數次熱壓而轉印於該金屬玻璃基材之一表 面上，接著冷卻該金屬玻璃基材至玻璃轉換溫度以下，以 • 作為一第二模具，且該第二模具之微透鏡間距小於該第一 ❹ 模具之微透鏡間距。藉此，可以精確的於該第二模具之表 面獲得小的表面結構尺寸，且藉由該第二模具作為該增亮 膜之成形模具，不僅可以降低其製備成本，亦可達到連續 製作該増亮膜以提升製作效率之目的。 【實施方式】 為了讓本發明之上述和其他目的、特徵和優點能更明 確被了解，下文將特舉本發明較佳實施例，並配合所附圖 式，作詳細說明如下。 © ，請參照第1及2圖所示，本發明較佳實施例之用於製 造增亮膜之模具的製造方法的第-步驟si係··於-第-基 材上加工形成-三面角錐狀微透鏡陣列結構，以製備一第 模具1更詳s之，因為機械加工技術所需之機台設備 及其維護費用低，且製作過程簡單，因此，於此第-步驟 S1中係利用機械加卫技術〔例如··精_石磨削加工技術 〕於該第基材之—表面上加卫出該三面角錐狀微透鏡陣 列結構，且其具有—微透鏡間距”a”及-角錐高度”H”，該 微透鏡間距”a”係相 押的兩個二面角錐之尖端的間距，其約 201010839 為180微米〔从m〕，該角錐高度” H”係相鄰的兩個三面角 錐之間之最低點至該三面角錐之尖端的距離，其中該第一 基材較佳係選自鋼鐵類之金屬材料。藉此，如第2圖所示 以加工後之第一基材作為該第一模具1，且該第一模具1 具有二面角錐狀微透鏡陣列結構，以進行後續作業步驟。 请參照第1至6圖所示，本發明較佳實施例之用於製 造增亮膜之模具的製造方法的第二步驟S2係：將該第一模 〇 具1上之三面角錐狀微透鏡陣列結構熱壓印於一金屬玻璃 基材2上，以製備一第二模具2’，且該第二模具2,之微連 鏡間距係小於該第一模具丨之微透鏡間距。更詳言之，金 屬玻璃〔Bulk metallic glasses，BMGs〕材料，於其玻璃轉 換溫度點〔Tg〕以上時係非結晶的半溶融狀態，因而具有 低黏度、高流動率的熱塑性㈣，易於將所f之圖案轉印 成型於金屬玻璃材料上；另外，若將該金屬玻璃材料冷卻 至過冷區域〔Tx〕下可快速固化成型且具有一定硬度。本 ❹ ㈣較佳係選擇具有義轉換溫度點介於絕對溫度370Κ 至450Κ之間的合金作為本發明之該金屬玻璃基材2,以進 行熱壓印作業’因此，其較佳係選自含有金、鑛或敍等元 权合金。於此第二步驟S2 t ,如第2圖所示，將該第一 模具1及該金屬玻璃基材2分別熱性連接且固定於一熱磨 ' 印機3之上、下加熱平纟31、32，利用該下加熱平台32 控制該金屬玻璃基材2之溫度介於37〇κ至45〇κ之間，將 該上加熱平台31往該下加熱平台32之方向移動且加歷 叠合於該下加熱平台32，使該第一模具i具有三面角錐狀 201010839The LCD of the Liquid Crystal Display Panel (LCD Panel) does not emit light itself. The panel light source is supplied by a backlight module in the liquid crystal display, and the backlight module is provided with an optical film. The film and its brightness enhancing film promote a light source with sufficient brightness, uniform distribution and high brightness to be converted into a high brightness and uniform surface light source through an effective optical mechanism. At present, the brightness enhancement film of the conventional optical film can be made by injection molding. First, the required molding die must be prepared by using a Lithographic GalVanoformung Abformung (LIGA) © process to fabricate a crucible structure on the substrate, and then electroforming the desired crucible structure. The mold, the 稜鏡 structure mold is placed on the injection molding machine, and then the molten polymer material is injected and then solidified and then trimmed to produce the desired brightness enhancement film. However, the above-mentioned photolithographic molding of the mold has a size limitation, which makes it impossible to produce a very small crucible microstructure. On the other hand, when using the injection molding to make the brightness enhancement film, it is necessary to first make the required mold and preheat the polymer material at a high temperature to carry out the subsequent binding operation, which not only causes the complicated process of the conventional brightness enhancement film to be complicated, but also heats up. Melting the polymer material also increases the energy and time required for the process, and the machine used for injection molding needs to be in an extremely high temperature and high pressure working environment, which causes the cost of the device itself to be expensive and expensive, thereby causing the brightness enhancement film. Production costs have also increased. In addition, after waiting for the polymer material to be cooled and solidified in the mold, the next brightness-increasing film can be produced, which makes it impossible to continuously produce the brightness-increasing film and reduce the manufacturing efficiency. Furthermore, the brightness can be formed only under a single mold. The film makes the formed bright film still different from the microstructure of the mold, which reduces the precision Q degree of the process. Alternatively, the mold for injection molding described above may be prepared in advance by milling. However, in general, the traditional sharpening technique uses a tool to mill out the shape required for the mold, but is limited by the size of the tool, so that the surface structure of the mold (especially the groove structure) is minimized. The same radius of the nose of the tool can lead to the current technological industry in which the size is miniaturized. The processing method of the mold can no longer meet the current industrial needs. For the above reasons, it is necessary to further improve the above-described manufacturing method for manufacturing a mold for adding a bright film. SUMMARY OF THE INVENTION In order to improve the manufacturing method of the above-mentioned conventional mold for manufacturing a brightness enhancement film, there are disadvantages such as size limitation of the surface structure of the mold, and the present invention provides a method for manufacturing a mold for manufacturing a brightness enhancement film, which is mainly The object of the invention is to effectively and accurately reduce the surface structure size of the mold used to make the brightness enhancing film for subsequent shaping of the brightness enhancing film. In order to achieve the foregoing object, the technical means utilized by the present invention and the effects achievable by the technical means include a method for manufacturing a mold for manufacturing a brightness enhancement film, the steps of which include: Forming a microlens array structure on a first substrate to prepare a first mold, and the first mold has a microlens pitch; heating a metal glass substrate to a glass transition temperature thereof, and the first The microlens array structure on the mold is transferred onto one surface of the metal glass substrate by several hot pressing, and then the metal glass substrate is cooled to below the glass transition temperature to serve as a second mold, and the first The microlens pitch of the two molds is smaller than the microlens pitch of the first mold. Thereby, a small surface structure size can be obtained accurately on the surface of the second mold, and by using the second mold as the forming mold of the brightness enhancement film, not only the manufacturing cost thereof can be reduced, but also the continuous production of the crucible can be achieved. Bright film to enhance the efficiency of production. The above and other objects, features and advantages of the present invention will become more fully understood, © , please refer to the first and second figures, the first step of the manufacturing method of the mold for manufacturing the brightness enhancement film according to the preferred embodiment of the present invention is formed on the -substrate - trihedral pyramid The microlens array structure is used to prepare a first mold 1 because the machine equipment required for the machining technology and the maintenance cost thereof are low, and the manufacturing process is simple. Therefore, in the first step S1, the machine is utilized. A garnishing technique (for example, a fine stone grinding technique) affixes the trihedral pyramidal microlens array structure on the surface of the first substrate, and has a microlens pitch "a" and a pyramid height "H", the spacing of the microlens spacing "a" is the pitch of the tips of the two dihedral pyramids, which is about 18010 microns [from m], which is adjacent to the two trihedral pyramids. The distance from the lowest point to the tip of the trihedral pyramid, wherein the first substrate is preferably selected from the group consisting of steel-based metal materials. Thereby, as shown in Fig. 2, the processed first substrate is used as the first mold 1, and the first mold 1 has a dihedral pyramidal microlens array structure for performing a subsequent work step. Referring to FIGS. 1 to 6, a second step S2 of the manufacturing method of the mold for manufacturing a brightness enhancement film according to a preferred embodiment of the present invention is a three-sided pyramidal microlens on the first mold member 1. The array structure is hot-embossed on a metal glass substrate 2 to prepare a second mold 2', and the second mold 2 has a micro-mirror spacing smaller than the micro-lens spacing of the first mold. More specifically, the material of Bulk metallic glasses (BMGs) is a non-crystalline semi-melt state at the glass transition temperature point [Tg] or higher, and thus has a low viscosity, high flow rate thermoplastic (IV), which is easy to be The pattern of f is transferred onto the metallic glass material; in addition, if the metallic glass material is cooled to the supercooled region [Tx], it can be rapidly solidified and has a certain hardness. (4) Preferably, an alloy having a temperature difference between 370 Å and 450 Å in absolute temperature is selected as the metal glass substrate 2 of the present invention for performing a hot embossing operation. Therefore, it is preferably selected from the group consisting of Gold, mineral or Syrian alloys. In the second step S2 t , as shown in FIG. 2 , the first mold 1 and the metal glass substrate 2 are respectively thermally connected and fixed on a hot-grinding machine 3, and the lower heating flat 31, 32, using the lower heating platform 32 to control the temperature of the metal glass substrate 2 between 37 〇 κ to 45 〇 κ, moving the upper heating platform 31 toward the lower heating platform 32 and superimposing The lower heating platform 32 is such that the first mold i has a triangular pyramid shape 201010839
微透鏡陣列結構的表面疊合於該金屬玻璃基材2，進 該第-模具1之三面肖綠微透鏡_結構的三角錐尖 部分轉印至該金;1破壤基材2之_表面上〔如第3圖所示 〕’又’如第4及5圖所示’將該上加熱平台31復位 行橫向移動，再重複上述壓印作業，以便於該金屬破璃基 ，材2之表面上壓印出具有_微透鏡間距”b，，及—角雜高度 的三面肖軸料鏡_結構，且雜透制距”b”約 為2至50_之間’該角錐高度，，h，，小於該第一模具！之 角錐面度’Ή’’。當此三面角錐狀微透鏡陣列結構佈滿在整 個該金屬玻璃基材2之表面時，即形成該第二模具2，〔如 第5及6圖所示〕。相較於該第—模具！之微透鏡間距” ’該第二模具2’係具有較小之微透鏡間距”b，，，以便藉由該 第二模具2’製作成形所需之增亮膜。 請參照第7及8圖所示，當利用本發明之第二模具2, 來製作增亮膜時，係將該第二模具2,及—高分子基材4分 別熱性連接且固定於該熱壓印機3之上、下加熱平台31、 32;利用該下加熱平台32控制該高分子基材4之溫度介於 370K至470K之間’其較佳係介於39〇K至41〇κ之間，以 使該高分子基材4處於半熔融狀態；接著，將該第二模具 2’具有三面角錐狀微透鏡陣列結構的表面加壓疊合於該高 分子基材4之一表面，使該第二模具2’之三面角錐狀微透 鏡陣列微結構藉由熱壓印技術而轉印形成在該高分子基材 4之表面上，如此即可形成一增亮膜5〔如第8圖所示〕。 再者，當該高分子基材4所受熱壓印的表面大於該第二模 201010839 具2’形成有該三面角錐狀微透鏡陣列結構之表面時，亦僅 需藉由該上加熱平台31移動該第二模具2’來對該高分子 基材4尚未加工之表面進行壓印作業。其中，該高分子基 材4較佳係選自聚曱基丙稀酸曱酯〔p〇lymethylThe surface of the microlens array structure is superposed on the metal glass substrate 2, and the triangular pyramid tip portion of the structure of the three sides of the first mold 1 is transferred to the gold; 1 the surface of the grounding substrate 2 [As shown in Fig. 3] 'again' as shown in Figs. 4 and 5', the upper heating platform 31 is moved laterally, and the above-mentioned imprinting operation is repeated to facilitate the metal breaking base. a three-sided Mirror structure having a _microlens pitch "b", and a horn height is embossed on the surface, and the pitch "b" is about 2 to 50 Å, which is the height of the pyramid. h, is smaller than the first taper of the first mold! 'Ή''. When the three-sided pyramidal microlens array structure is covered on the surface of the entire metallic glass substrate 2, the second mold 2 is formed, As shown in Figures 5 and 6], the second mold 2' has a smaller microlens pitch "b" compared to the first mold +" to be used by the second mold 2' Preparation of a brightness enhancement film required for molding. Referring to Figures 7 and 8, when the second mold 2 of the present invention is used to produce a brightness enhancement film The second mold 2 and the polymer substrate 4 are respectively thermally connected and fixed to the hot stamping machine 3 and the lower heating platform 31, 32; the polymer substrate 4 is controlled by the lower heating platform 32. The temperature is between 370K and 470K, which is preferably between 39〇K and 41〇κ, so that the polymer substrate 4 is in a semi-molten state; then, the second mold 2' has three sides. The surface of the pyramidal microlens array structure is pressure-bonded to one surface of the polymer substrate 4, so that the trigonal pyramidal microlens array microstructure of the second mold 2' is transferred by thermal imprinting technology. On the surface of the polymer substrate 4, a brightness enhancement film 5 can be formed (as shown in Fig. 8). Further, when the surface of the polymer substrate 4 is hot-embossed is larger than the second mode 201010839 When the surface of the three-sided pyramidal microlens array structure is formed by 2', the surface of the polymer substrate 4 is not embossed by moving the second mold 2' by the upper heating platform 31. The polymer substrate 4 is preferably selected from the group consisting of polydecyl methacrylate [p〇lymethy] l
Methacrylate ’ PMMA〕、紫外光硬化樹脂〔UV curable resin〕或聚乙烯對苯二甲酸酯〔P〇lyethylene Terephthalate ，PET〕等尚分子材料。 除藉由熱壓印技術以形成該增亮膜5之外，亦可選擇 藉由旋轉塗佈之方式，於該該第二模具2,具有三面角錐狀 微透鏡陣列結構的表面上，均勻塗佈紫外光固化樹脂，其 中該紫外光固化樹脂較佳係選自UV膠；待旋轉塗佈作業 完成後，該紫外光固化樹脂經由紫外光照射一預定時間， 以固化該紫外光固化樹脂；最後，將該固化後之紫外光固 化樹脂剝離該第二模具2,即可獲得一增亮膜。 如上所述，本發明藉由該金屬玻璃基材2之物化特性 ，利用預先製備之該第一模具1於該金屬玻璃基材2上進 行熱壓印，以有效且精確地製備出具有微透鏡間距小至2 至50/zm的三面角錐狀微透鏡陣列結構的該第二模具2, ，以供後續快速且持續的製作成形該增亮膜。 雖然本發明已利用上述較佳實施例揭示，然其並非用 以限定本發明’任何熟習此技藝者在不脫離本發明之精神 和範圍之内，相對上述實施例進行各種更動與修改仍屬本 發明所保護之技術範疇，因此本發明之保護範圍當視後附 之申請專利範圍所界定者為準。 201010839 【圈式簡單說明】 第1圖：本發明較佳實施例之用於製造增亮膜之模具 v 的製造方法之流程圖。 第2圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之一第一模具與一金屬玻璃基材設置於一熱壓 印機之示意圖。 第3圖：本發明較佳實施例之用於製造增亮膜之模具 ❹的製造方法之第一模具壓印於該金屬玻璃基材之示意圖。 第4圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之第一模具橫向移動後再壓印於該金屬玻璃基 材之示意圖。 第5圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之第二模具之製作完成示意圖。 第6圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之第二模具之俯視圖。 ❹ 第7圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之第二模具壓印於一高分子基材之示意圖。 第8圖：本發明較佳實施例之用於製造增亮膜之模具 的製造方法之一增亮膜之剖視圖。 η 【主要元件符號說明】 第一模具 2’第二模具 31 上加熱平台 2 金屬玻璃基材 3 熱壓機 32下加熱平台 201010839 4 高分子基材 5 S1 第一步驟 S2 增亮膜 第二步驟 ❹ ❹ —12 —Mthacrylate ‘PMMA〕, UV curable resin, or polyethylene terephthalate (PET). In addition to forming the brightness enhancement film 5 by hot stamping technology, it is also possible to uniformly coat the second mold 2 on the surface having a triangular pyramidal microlens array structure by spin coating. The ultraviolet curing resin, wherein the ultraviolet curing resin is preferably selected from the group consisting of UV glue; after the spin coating operation is completed, the ultraviolet curing resin is irradiated by ultraviolet light for a predetermined time to cure the ultraviolet curing resin; The cured UV curable resin is peeled off from the second mold 2 to obtain a brightness enhancement film. As described above, the present invention utilizes the physicochemical properties of the metallic glass substrate 2 to perform hot stamping on the metallic glass substrate 2 by using the first mold 1 prepared in advance to efficiently and accurately prepare the microlens. The second mold 2 of the trihedral pyramidal microlens array structure having a pitch as small as 2 to 50/zm is used for subsequent rapid and continuous formation of the brightness enhancing film. The present invention has been disclosed in the above-described preferred embodiments, and it is not intended to limit the invention. It is intended that the present invention may be practiced without departing from the spirit and scope of the invention. The technical scope of the invention is protected, and therefore the scope of the invention is defined by the scope of the appended claims. 201010839 [Brief Description] FIG. 1 is a flow chart showing a manufacturing method of a mold v for manufacturing a brightness enhancement film according to a preferred embodiment of the present invention. Fig. 2 is a view showing a manufacturing method of a mold for producing a brightness enhancement film according to a preferred embodiment of the present invention. A first mold and a metal glass substrate are disposed on a hot stamping machine. Fig. 3 is a schematic view showing the first mold of the manufacturing method for producing a brightness enhancement film according to a preferred embodiment of the present invention, which is imprinted on the metal glass substrate. Fig. 4 is a view showing the first mold of the manufacturing method of the mold for producing a brightness enhancement film according to a preferred embodiment of the present invention, which is laterally moved and then imprinted on the metallic glass substrate. Fig. 5 is a view showing the completion of the second mold of the method for producing a mold for producing a brightness enhancement film according to a preferred embodiment of the present invention. Fig. 6 is a plan view showing a second mold for a method of manufacturing a mold for producing a brightness enhancement film according to a preferred embodiment of the present invention. ❹ Figure 7 is a schematic view showing the second mold of the manufacturing method of the mold for producing a brightness enhancement film according to a preferred embodiment of the present invention, which is imprinted on a polymer substrate. Fig. 8 is a cross-sectional view showing a brightness enhancing film of a method for producing a mold for producing a brightness enhancing film according to a preferred embodiment of the present invention. η [Description of main component symbols] First mold 2' second mold 31 Upper heating platform 2 Metal glass substrate 3 Hot press 32 heating platform 201010839 4 Polymer substrate 5 S1 First step S2 Brightening film second step ❹ ❹ —12 —