1233000 玖、發明說明 (發明說明應敘明：發明所屬之技術領域、先前技術、內容、實施方式及圖式簡單說明) 【發明所屬之技術領域】 本發明係與光學元件有關，特別是關於一種光學基材 之製造方法。 5 【先前技術】 習用之直下式背光模組，包含有一框架，其上依序裝 設有一反光片、複數支燈管以及一擴散板，該等燈管部分 之光源直接射向該擴散板，而部分之光源則試射向該反光 片’精由該反光片反射而設向該擴散板。該擴散板將穿過 10 之光源擴散而形成一均勻之面光源。 該擴散板是在一基板上依序貼上擴散薄膜、棱鏡薄膜 與增光膜。這些光學薄膜成本不但昂貴，而且，貼附薄膜 的製程，目前仍有賴人工作業，使工作成本增加。 另外，各層薄膜間必須先塗佈一膠層，使得將該等薄 15 膜依序貼附在該透明基板上。因此，該膠層是否塗佈均勻、 各薄膜是否施壓平均，均是影響該擴散板的光學特性，除 了各薄膜之尺寸與光學特性外，的重要因素。而仰賴人工 作業的貼附工作，造成習用擴散板的良率不佳。 20 【發明内容】 本發明之主要目的在於提供一種光學基材之製造方 法，其製程容易且良率高者。 為達成前述之發明目的，本發明所提供之一種光學基 材之製造方法，包含有下列步驟： 續次頁（發明說明頁不敷使用時，請註記並使用續頁） -4- 1233000 _ 發明說明續頁 加熱一第一材料以及一第二材料至溶融狀態； 將該第一材料與該第二材料堆疊在一起； 加壓該第一材料與該第二材料，使之形成一具有一預 定寬度與一預定厚度之基材，以及 5 在該第二材料之表面成形一預定之表面紋路。 【實施方式】 為了詳細說明本發明之構造及特點所在，茲舉以下之 較佳實施例並配合圖式說明如后，其中： 10 第一圖係本發明第一較佳實施例之流程圖； 第二圖係為依據本發明第一較佳實施例之方法所製造 出之第一種光學基材之剖視圖； 第三圖係為依據本發明第一較佳實施例之方法所製造 出之第二種光學基材之剖視圖； 15 第四圖係為依據本發明第一較佳實施例之方法所製造 出之第三種光學基材之剖視圖； 第五圖係本發明第二較佳實施例之流程圖； 第六圖係為依據本發明第二較佳實施例之方法所製造 出之第一種光學基材之剖視圖，以及 20 第七圖係為依據本發明第二較佳實施例之方法所製造 出之第二種光學基材之剖視圖。 請參閱第一圖所示，本發明第一較佳實施例所提供之 光學基材之製造方法，包含有下列步驟： (A)將一第一材料以及一第二材料加熱至熔融狀態。 -5- 1233000 發明說明$賣胃 该第一材料為内含有擴散粒子的塑膠粒材，可為聚甲 基丙晞酸甲酿(Polymethy 1 methaery· pMMA)、聚碳酸脂 (Polycarbonate，PC)或是或是環埽烴聚合物（Cydic 〇ι^η5 Polymer，COP)等材料。該第二材料為透明塑膠粒材。可為 5聚甲基丙晞酸甲酯(PMMA)、聚峻酸脂(pc)或是環婦煙聚合 物(Cyclic Olefins Polymer，COP)等材料。 (B)將熔融狀之該第一材料與一第二材料注入一連接 器(adapter)中，使第二材料堆疊於該第一材料之上。 孩連接器具有決定該第一材料與該第二材料之厚度比 10 例的作用。 (c)將該第一材料與一第二材料注入一模頭（die head) 中，使其延展為一具有預定寬度之基材。 (D) 利用一壓軋滾輪組(r〇ller caien(Jer)，滾壓由該模頭 流出之基材，使其具有一預定之厚度。該壓軋滾輪上具有 15 一預疋之刻紋，因此當其滾壓該基材之第二材料時，會使 該第二材料之表面形成一預定之表面紋路(surface profile)。 (E) 冷卻經壓軋後之基材，使其固化。 (F) 切割該基材。 依據前述之方法，該基材在一個連續性的製程中完 20成’不需要另外以人工的方式黏貼擴散薄膜與集光薄膜的 步驟’因此產品的良率與製程的的簡易性會提高。依據本 方法所製作出的基材厚度可在〇.5 mm以上，較佳的厚度在 1mm至5mm。而該第二材料所成形的厚度可在1 以 上’較佳的厚度在5〇 # m至200 // m。 _6_ 1233000 _ 發明說明 請參閱第二圖所示，經前述步驟所製造出之光學基材 10具有一第一層12以及一第二層14,其中該第一層12是 由該第一材料所形成，而該第二層14是由該第二材料所形 成。該第一層12中具有擴散粒子16用以擴散光線，而該 5 第二層14之表面具有表面紋路18，可形成棱鏡之作用。 換言之，該光學基材10之第一層12之功能如同習用之擴 散板，而該第二層14之功能如同一棱鏡薄膜，但是該二層 之間並沒有膠層使二者結合在一起。 在前述之製造步騾中，該第一材料之表面亦可在步驟 10 (D)的壓軋過程中印壓出一預定之表面紋路，如此所製造出 之光學基材20，第三圖所示，具有一第一層22以及一第 二層24，其中該第一層22表面具有一第一表面紋路26， 而該第二層24表面具有一第二表面紋路28。該第一表面 紋路26提供擴散之功能，而該第二表面紋路28提供集光 15 之功能。 在第三圖所示之光學基材中，該第一層22内同樣具有 擴散粒子30，可更提高擴散之功能。當然，由於該第一表 面紋路26已具有擴散之功能，該第一層中亦可不具有擴散 粒子。而在製造步驟中，僅需將該第一材料選擇為不具有 20 擴散粒子之一般材料即可。 另外，在步驟（B)中，熔融狀之該第一材料與一第二材 料注入一連接器（adapter)中後，該連接器將該第二材料分別 安排在該第一材料之兩側，如此所形成之光學基材32，如 第四圖所示，具有一第一層34以及二第二層36，分別位 1233000 _ 發明說明®頁 於該第一層34之兩側。而該二第二層36之表面分別具有 一表面紋路38, 40。形成該第二層36之第二材料可為低吸 水性的材料，例如：環晞烴聚合物（Cyclic Olefins Polymer， COP)或是環晞烴共聚合物（Cyclic Olefins Copolymer， 5 COC)。 在此要提出說明的是，本較佳實施例中，在該光學基 材上所形成的表面紋路，是與壓軋步驟，步驟（D)，同時進 行。實務上，在步驟（D)中可僅為壓軋該光學基材至預定厚 度，而待該光學基材冷卻後，再利用習知的壓軋印花製程， 10 網印製程、黃光製程或是其他方法做二次加工完成。 請參閱第五圖所示，本發明第二較佳實施例所提供之 光學基材之製造方法，該光學基材具有三層，包含有下列 步驟： (A) 將一第一材料、一第二材料以及一第三材料加熱至 15 溶融狀態。 (B) 將熔融狀之該第一材料、該第二材料與該第三材料 注入一具有多流道的模頭中，使第三材料與第二材料依序 堆疊於該第一材料之上，並使其延展為一具有預定寬度之 基材。 20 (C)利用一第一壓軋滾輪組，滾壓由該模頭流出之基 材，使其具有一預定之厚度。 (D)利用一第二壓軋滚輪組，該壓軋滾輪上具有一預定 之刻紋，因此當其滾壓該基材之第二材料時，會使該第二 材料之表面形成一表面紋路（surface profile) 〇 1233000 _ 發明說明 (E) 冷卻經壓軋後之基材，使其固化。 (F) 切割該基材。 請參閱第六圖所示，經前述步驟所製造出之光學基材 42具有一第一層44、一第二層46以及一第三層48，其中 5 第三層48位於第一層44與第二層46之間。該第一層44 是由該第一材料所形成，該第二層46是由該第二材料所形 成，而該第三層48是由該第三材料所形成。該第一層44 為透明之基材，第三層48中具有擴散粒子50用以擴散光 線，而該第二層46之表面具有表面紋路52，可形成棱鏡 10 之作用。在前述之光學基材42亦可在該第一層44之表面 成形一表面紋路（圖中未顯示）。 在第二較佳實施例的製造方法中，該第一材料、該第 二材料與該第三材料具有不同的材料特性，例如：具有高 透明度的材料、具有擴散粒子於其中的材料、低吸水性的 15 材料或高反光性的材料等，以使該光學板材可提供較佳的 光學作用。 在步驟(B)中，該第二材料與第三材料可分別被安排在 該第一材料之兩側，請參閱第七圖所示，該光學基材54具 有一第一層56、一第二層58以及一第三層60,其中第一 20 層56位於第二層58與第三層60之間。該第一層56中具 有擴散粒子62，該第二層58之表面具有表面紋路64，該 第三層60是以高反光之材料製成，以形成反光膜之功能。 在步驟（D)中，在該第三層上亦可壓印出一表面紋路， 而形成類似第四圖所示之結構。只不過在該第一層56兩側 -9- 1233000 發明說明m 之第二層58與第三層60為以不同材料所形成。 依據相同的原理，本發明的製造方法中可加入四種（或 四種以上）不同材料，以成形在一起。而所製造出之光學基 材可具有四層（或四層以上），並以預定順序堆疊在一起。 -10 - 1233000 發明說明胃1233000 发明 Description of the invention (The description of the invention should state: the technical field to which the invention belongs, the prior art, the content, the embodiments, and the drawings) [Technical field to which the invention belongs] The present invention relates to optical elements, and more particularly to an optical element. Manufacturing method of optical substrate. 5 [Prior art] The conventional direct type backlight module includes a frame, on which a reflector, a plurality of lamp tubes and a diffuser plate are sequentially installed, and the light sources of these lamp tubes are directed toward the diffuser plate. And some of the light sources are shot toward the reflector, and the light is reflected by the reflector and set to the diffuser. The diffuser diffuses the light source passing through 10 to form a uniform surface light source. The diffusion plate is a substrate in which a diffusion film, a prism film, and a light-increasing film are sequentially attached. These optical films are not only expensive, but the process of attaching the films still requires manual work, which increases the cost of work. In addition, an adhesive layer must be applied between each of the thin films so that the thin 15 films are sequentially attached to the transparent substrate. Therefore, whether the adhesive layer is evenly applied and whether each film is evenly pressed are important factors that affect the optical characteristics of the diffuser, in addition to the size and optical characteristics of each film. And relying on the manual attachment work, the yield of the conventional diffusion plate is not good. [Summary of the Invention] The main object of the present invention is to provide a method for manufacturing an optical substrate, which is easy to manufacture and has a high yield. In order to achieve the aforementioned object of the invention, a method for manufacturing an optical substrate provided by the present invention includes the following steps: Continued page (if the description page of the invention is insufficient, please note and use the continued page) -4- 1233000 _ Invention Description The continuation page heats a first material and a second material to a molten state; stacks the first material and the second material together; presses the first material and the second material to form a predetermined A substrate having a width and a predetermined thickness, and 5 forming a predetermined surface texture on the surface of the second material. [Embodiment] In order to explain the structure and characteristics of the present invention in detail, the following preferred embodiments are described in conjunction with the drawings as follows, wherein: 10 The first diagram is a flowchart of the first preferred embodiment of the present invention; The second figure is a cross-sectional view of a first optical substrate manufactured according to the method of the first preferred embodiment of the present invention; the third figure is the first Sectional view of two optical substrates; 15 The fourth diagram is a cross-sectional view of a third optical substrate manufactured according to the method of the first preferred embodiment of the present invention; the fifth diagram is a second preferred embodiment of the present invention The sixth diagram is a cross-sectional view of a first optical substrate manufactured according to the method of the second preferred embodiment of the present invention, and the seventh diagram is a second preferred embodiment of the present invention. A cross-sectional view of a second optical substrate manufactured by the method. Referring to the first figure, the method for manufacturing an optical substrate provided by the first preferred embodiment of the present invention includes the following steps: (A) heating a first material and a second material to a molten state. -5- 1233000 Description of the invention The first material is plastic granules containing diffusing particles, which can be polymethy 1 methaery · pMMA, polycarbonate (PC) or Cyclocarbon polymer (Cydic 〇ι ^ η5 Polymer, COP) and other materials. The second material is a transparent plastic granule. It can be PMMA, PC or Cyclic Olefins Polymer (COP). (B) The molten first material and a second material are injected into an adapter, so that the second material is stacked on the first material. The connector has the function of determining the thickness ratio of the first material to the second material. (c) Injecting the first material and a second material into a die head to extend it into a substrate having a predetermined width. (D) A rolling roller set (roller caien (Jer)) is used to roll the substrate flowing out of the die to have a predetermined thickness. The rolling roller has 15 pre-etched marks Therefore, when it rolls the second material of the substrate, it will cause the surface of the second material to form a predetermined surface profile. (E) Cool the rolled substrate to make it solidify. (F) Cutting the substrate. According to the method described above, the substrate has completed 20% of the process in a continuous process 'no need to manually attach the diffusion film and the light-collecting film'. Therefore, the product yield and The simplicity of the manufacturing process will be improved. The thickness of the substrate produced according to this method can be greater than 0.5 mm, and the preferred thickness is 1 mm to 5 mm. The thickness of the second material can be greater than 1 ' The best thickness is 5〇 # m to 200 // m. _6_ 1233000 _ Description of the invention Please refer to the second figure. The optical substrate 10 manufactured through the foregoing steps has a first layer 12 and a second layer 14 The first layer 12 is formed of the first material, and the second layer 14 is formed of the first material. The first layer 12 has diffusing particles 16 for diffusing light, and the surface of the second layer 14 has a surface texture 18 to form a prism. In other words, the first layer of the optical substrate 10 The function of 12 is like a conventional diffuser, and the function of the second layer 14 is the same as a prism film, but there is no adhesive layer between the two layers to bring the two together. In the aforementioned manufacturing steps, the first The surface of the material can also be printed with a predetermined surface texture during the rolling process of step 10 (D). The optical substrate 20 thus manufactured, as shown in the third figure, has a first layer 22 and a first layer. Two layers 24, wherein the surface of the first layer 22 has a first surface texture 26, and the surface of the second layer 24 has a second surface texture 28. The first surface texture 26 provides a diffusion function, and the second surface The texture 28 provides the function of collecting light 15. In the optical substrate shown in the third figure, the first layer 22 also has diffusion particles 30, which can further improve the function of diffusion. Of course, since the first surface texture 26 has already With the function of diffusion, the first layer It may not have diffusion particles. In the manufacturing step, it is only necessary to select the first material as a general material without 20 diffusion particles. In addition, in step (B), the molten first material and a first material After the two materials are injected into an adapter, the connector arranges the second material on both sides of the first material. The optical substrate 32 thus formed, as shown in the fourth figure, has a first The first layer 34 and two second layers 36 are respectively 1233000 _ Description of the invention® The pages are on both sides of the first layer 34. The surfaces of the two second layers 36 each have a surface texture 38, 40. The second material forming the second layer 36 may be a material with low water absorption, for example: Cyclic Olefins Polymer (COP) or Cyclic Olefins Copolymer (5 COC). It should be mentioned here that, in the present preferred embodiment, the surface texture formed on the optical substrate is performed simultaneously with the rolling step, step (D). In practice, in step (D), the optical substrate may only be rolled to a predetermined thickness, and after the optical substrate is cooled, the conventional rolling printing process, 10 screen printing process, yellow light process or It is completed by other methods. Please refer to the fifth figure, a method for manufacturing an optical substrate provided by the second preferred embodiment of the present invention. The optical substrate has three layers and includes the following steps: (A) a first material, a first The two materials and a third material are heated to 15 molten states. (B) Injecting the molten first material, the second material, and the third material into a die with multiple flow channels, so that the third material and the second material are sequentially stacked on the first material And extend it into a substrate with a predetermined width. 20 (C) A first rolling roller set is used to roll the substrate flowing out of the die head to a predetermined thickness. (D) using a second rolling roller set, the rolling roller has a predetermined engraving, so when it rolls the second material of the substrate, a surface texture of the second material is formed (Surface profile) 〇1233000 _ Description of the invention (E) The substrate after cooling and rolling is solidified. (F) Cutting the substrate. Please refer to FIG. 6, the optical substrate 42 manufactured through the foregoing steps has a first layer 44, a second layer 46, and a third layer 48, 5 of which the third layer 48 is located on the first layer 44 and The second layer 46. The first layer 44 is formed of the first material, the second layer 46 is formed of the second material, and the third layer 48 is formed of the third material. The first layer 44 is a transparent substrate, the third layer 48 has diffusion particles 50 for diffusing light, and the surface of the second layer 46 has a surface texture 52, which can form the function of the prism 10. A surface texture (not shown) can also be formed on the surface of the first layer 44 on the aforementioned optical substrate 42. In the manufacturing method of the second preferred embodiment, the first material, the second material, and the third material have different material characteristics, for example, a material having high transparency, a material having diffused particles therein, and low water absorption. 15 materials or highly reflective materials, so that the optical sheet can provide better optical effects. In step (B), the second material and the third material may be arranged on both sides of the first material, as shown in FIG. 7. The optical substrate 54 includes a first layer 56 and a first layer. The second layer 58 and a third layer 60, wherein the first 20 layer 56 is located between the second layer 58 and the third layer 60. The first layer 56 has diffusion particles 62, the surface of the second layer 58 has a surface texture 64, and the third layer 60 is made of a highly reflective material to form a reflective film. In step (D), a surface texture can also be embossed on the third layer to form a structure similar to that shown in the fourth figure. It is only on both sides of the first layer 56 that the second layer 58 and the third layer 60 of m are formed of different materials. According to the same principle, four (or more than four) different materials can be added to the manufacturing method of the present invention to form together. The manufactured optical substrate may have four layers (or more than four layers) and be stacked together in a predetermined order. -10-1233000 Invention Description
【圖式簡單說明】 係本發明第-較佳實施例之流程圖； 弟二圖係為依據本發明第一較佳實施例之方法所 出义第一種光學基材之剖视圖； =二圖係為依據本發明第—較佳實施例之方法所 <第二種光學基材之剖视圖； 弟四圖係為依據本發明第一較佳實施例之方法所 出〈第三種光學基材之剖视圖； 10 15 製造 製造 製造 :五圖係本發明第二較佳實施例之流程圖； &圖係為依據本發明第二較佳實施例之方法所製造 出縣學基材之剖视_，以 弟七圖係為依據本發明第二較施例之方法所製 出^弟二種光學基材之剖視圖。[Brief description of the drawings] is a flowchart of the first preferred embodiment of the present invention; the second figure is a cross-sectional view of the first optical substrate according to the method of the first preferred embodiment of the present invention; = The second figure is a sectional view of the second optical substrate according to the method of the first preferred embodiment of the present invention; the fourth figure is the third embodiment of the method according to the first preferred embodiment of the present invention. A cross-sectional view of an optical substrate; 10 15 Manufacturing Manufacturing: Five figures are a flowchart of the second preferred embodiment of the present invention; & Figures are manufactured by the method according to the second preferred embodiment of the present invention The cross-section view of the learning substrate is the cross-sectional view of the two optical substrates manufactured by the method of the second embodiment of the present invention according to the second embodiment of the invention.
-11- 1233000 _ 發明說明-11- 1233000 _ Description of the invention
5 10 【圖式符號說明】 10光學基材 12第一層 14第二層 16擴散粒子 18表面紋路 20光學基材 22第一層 24第二層 26第一表面紋路 28第二表面紋路 30擴散粒子 32光學基材 34第一層 36第二層 38, 40表面紋路 42光學基材 44第一層 46第二層 48第三層 50擴散粒子 52表面紋路 54光學基材 56第一層 58第二層 60第三層 62擴散粒子 64表面紋路 -12-5 10 [Illustration of Symbols] 10 Optical substrate 12 First layer 14 Second layer 16 Diffusion particles 18 Surface texture 20 Optical substrate 22 First layer 24 Second layer 26 First surface texture 28 Second surface texture 30 Diffusion Particles 32 optical substrate 34 first layer 36 second layer 38, 40 surface texture 42 optical substrate 44 first layer 46 second layer 48 third layer 50 diffusion particle 52 surface texture 54 optical substrate 56 first layer 58 first Two layers 60 Third layer 62 Diffusion particles 64 Surface texture -12-