Optical sheet having a composite structure thereon and method to make the same

Patent metadata

Field	Value
Publication number	US-10429552-B2
Application number	US-201615213420-A
Country	US
Kind code	B2
Filing date	Jul 19, 2016
Priority date	May 16, 2016
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

The present invention discloses a method of forming an optical sheet. The method comprises: providing a mold having a first surface; forming a plurality of first concave shapes on the first surface of the mold such that the first surface of the mold is changed to a second surface of the mold; forming a plurality of second shapes on the plurality of first concave shapes such that the second surface of the mold is changed to a third surface of the mold; and using the third surface of the mold to emboss a film on a substrate to form a composite structure corresponding to the combination of the plurality of first concave shapes and the plurality of second shapes.

First claim

What is claimed is:

1. A method of forming an optical sheet, comprising:
providing a mold having a first surface;
forming a plurality of first concave shapes on the first surface of the mold such that the first surface of the mold is changed to a second surface of the mold, wherein each two adjacent first concave shapes overlap with each other;
forming a plurality of second shapes on the plurality of first concave shapes such that the second surface of the mold is changed to a third surface of the mold, wherein the average size of the plurality of first concave shapes is larger than the average size of the plurality of second shapes; and
using the third surface of the mold to emboss a film on a substrate to form a composite structure corresponding to a combination of the plurality of first concave shapes and the plurality of second shapes, wherein the average roughness (Ra) of the composite structure is in a range from 0.3 μm to 0.8 μm 0.3-0.8 μm.

2. The method according to claim 1 , wherein the plurality of first concave shapes are configured for making corresponding convex regions, wherein the average roughness (Ra) of the corresponding convex regions of the plurality of first concave shapes is symbolized as R 1 and the average roughness (Ra) of the composite structure is symbolized as R 2 , wherein (R 2 −R 1 ) is less than 0.2 μm.

3. The method according to claim 2 , wherein (R 2 −R 1 ) is less than 0.15 μm.

4. The method according to claim 3 , wherein (R 2 −R 1 ) is less than 0.1 μm.

5. The method according to claim 1 , wherein forming the plurality of first concave shapes on the first surface of the mold is performed by using a hard tool to penetrate into the first surface of the mold and forming the plurality of second shapes on the plurality of first concave shapes is performed by a sandblasting process.

6. The method according to claim 5 , wherein the plurality of first concave shapes are configured for making corresponding convex regions, wherein the average roughness (Ra) of the corresponding convex regions of the plurality of first concave shapes is symbolized as R 1 and the average roughness (Ra) of the composite structure is symbolized as R 2 , wherein (R 2 −R 1 ) is less than 0.2 μm.

7. The method according to claim 6 , wherein (R 2 −R 1 ) is less than 0.15 μm.

8. The method according to claim 7 , wherein (R 2 −R 1 ) is less than 0.1 μm.

9. The method according to claim 5 , wherein each of the plurality of second shapes is convex or concave relative to the second surface of the mold.

10. A method of forming an optical sheet, comprising:
providing a mold having a first surface;
forming a plurality of first concave shapes on the first surface of the mold by an FTS (Fast Tool Server) process such that the first surface of the mold is changed to a second surface of the mold, wherein each two adjacent first concave shapes overlap with each other;
forming a plurality of second shapes on the plurality of first concave shapes such that the second surface of the mold is changed to a third surface of the mold, wherein the average size of the plurality of first concave shapes is larger than the average size of the plurality of second shapes; and
using the third surface of the mold to emboss a film on a substrate to form a composite structure corresponding to a combination of the plurality of first concave shapes and the plurality of second shapes, wherein the average roughness (Ra) of the composite structure is in a range from 0.3 μm to 0.8 μm.

11. The method according to claim 10 , wherein forming the plurality of second shapes on the plurality of first concave shapes is performed by a sandblasting process.

12. The method according to claim 10 , wherein each of the plurality of second shapes is convex or concave relative to the second surface of the mold.

13. A method of forming an optical sheet, comprising:
providing a mold having a first surface;
forming a plurality of first concave shapes on the first surface of the mold by an FTS (Fast Tool Server) process such that the first surface of the mold is changed to a second surface of the mold, wherein each two adjacent first concave shapes overlap with each other;
forming a plurality of second shapes on the plurality of first concave shapes such that the second surface of the mold is changed to a third surface of the mold, wherein the average size of the plurality of first concave shapes is larger than the average size of the plurality of second shapes; and
using the third surface of the mold to emboss a film on a substrate to form a composite structure corresponding to a combination of the plurality of first concave shapes and the plurality of second shapes;
wherein the plurality of first concave shapes are configured for making corresponding convex regions having a first average roughness (Ra) R 1 , and the composite structure has a second average roughness (Ra) R 2 , wherein R 2 is in a range from 0.3 μm to 0.8 μm 0.3-0.8 μm and (R 2 −R 1 ) is less than 0.2 μm.

14. The method according to claim 13 , wherein (R 2 −R 1 ) is less than 0.15 μm.

15. The method according to claim 14 , wherein (R 2 −R 1 ) is less than 0.1 μm.

16. The method according to claim 13 , wherein forming the plurality of second shapes on the plurality of first concave shapes is performed by a sandblasting process.

17. The method according to claim 13 , wherein each of the plurality of second shapes is convex or concave relative to the second surface of the mold.

Assignees

• Ubright Optronics Corp

Inventors

• Chen hui-yong
• Hsin Lung-Pin
• Yang Ching-An
• Juan Yu-Mei
• Lai Chien-Chih
• Huang Tzu-Hsiang

Classifications

• G02B5/0231

  the surface having microprismatic or micropyramidal shape (macroscopic prism arrays G02B5/045) · CPC title

• G02B5/0226

  having particles on the surface · CPC title

• G02B5/0215

  the surface having a regular structure · CPC title

• G02B3/0043

  Inhomogeneous or irregular arrays, e.g. varying shape, size, height · CPC title

• B29D11/00278

  Lenticular sheets (B29D11/00269 takes precedence) · CPC title