Fabrication of seamless roller mold for continuous roller imprinting of microlens array films

Yung Chun Lee; Hong Wei Chen; Fei Bin Hsiao

doi:10.1109/JMEMS.2011.2178115

Fabrication of seamless roller mold for continuous roller imprinting of microlens array films

Yung Chun Lee, Hong Wei Chen, Fei Bin Hsiao

Department of Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

16 Citations (Scopus)

Abstract

This paper describes an innovative approach for fabricating a seamless roller mold based on cylindrical photolithography, isotropic chemical etching, and electropolishing. Hexagonally arrayed concave microstructures with a near-semispherical profile are directly and seamlessly fabricated on a metal roller. The fabricated roller mold is then used for continuous roller imprinting of microlens array (MLA) on a thin polyethylene terephthalate (PET) substrate. The fabricated ball-shape microlenses have a footprint diameter of 54 μ m and a sag height of 20.5 μ m and are hexagonally close packed with a filling ratio larger than 91%. This MLA/PET optical film can serve as a brightness enhancement film in flat panel backlighting, and its optical performance is experimentally verified. A 30% increase in the forward on-axis luminance is observed.

Original language	English
Article number	6119182
Pages (from-to)	316-323
Number of pages	8
Journal	Journal of Microelectromechanical Systems
Volume	21
Issue number	2
DOIs	https://doi.org/10.1109/JMEMS.2011.2178115
Publication status	Published - 2012 Apr

All Science Journal Classification (ASJC) codes

Mechanical Engineering
Electrical and Electronic Engineering

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10.1109/JMEMS.2011.2178115

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title = "Fabrication of seamless roller mold for continuous roller imprinting of microlens array films",

abstract = "This paper describes an innovative approach for fabricating a seamless roller mold based on cylindrical photolithography, isotropic chemical etching, and electropolishing. Hexagonally arrayed concave microstructures with a near-semispherical profile are directly and seamlessly fabricated on a metal roller. The fabricated roller mold is then used for continuous roller imprinting of microlens array (MLA) on a thin polyethylene terephthalate (PET) substrate. The fabricated ball-shape microlenses have a footprint diameter of 54 μ m and a sag height of 20.5 μ m and are hexagonally close packed with a filling ratio larger than 91%. This MLA/PET optical film can serve as a brightness enhancement film in flat panel backlighting, and its optical performance is experimentally verified. A 30% increase in the forward on-axis luminance is observed.",

author = "Lee, {Yung Chun} and Chen, {Hong Wei} and Hsiao, {Fei Bin}",

note = "Funding Information: Manuscript received May 21, 2011; revised October 6, 2011; accepted October 20, 2011. Date of publication December 30, 2011; date of current version April 4, 2012. This work was supported by the National Science Council (NSC) of Taiwan through Project NSC 99-2120-M-006-001. Subject Editor O. Solgaard.",

year = "2012",

month = apr,

doi = "10.1109/JMEMS.2011.2178115",

language = "English",

volume = "21",

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journal = "Journal of Microelectromechanical Systems",

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AU - Lee, Yung Chun

AU - Chen, Hong Wei

AU - Hsiao, Fei Bin

N1 - Funding Information: Manuscript received May 21, 2011; revised October 6, 2011; accepted October 20, 2011. Date of publication December 30, 2011; date of current version April 4, 2012. This work was supported by the National Science Council (NSC) of Taiwan through Project NSC 99-2120-M-006-001. Subject Editor O. Solgaard.

PY - 2012/4

Y1 - 2012/4

N2 - This paper describes an innovative approach for fabricating a seamless roller mold based on cylindrical photolithography, isotropic chemical etching, and electropolishing. Hexagonally arrayed concave microstructures with a near-semispherical profile are directly and seamlessly fabricated on a metal roller. The fabricated roller mold is then used for continuous roller imprinting of microlens array (MLA) on a thin polyethylene terephthalate (PET) substrate. The fabricated ball-shape microlenses have a footprint diameter of 54 μ m and a sag height of 20.5 μ m and are hexagonally close packed with a filling ratio larger than 91%. This MLA/PET optical film can serve as a brightness enhancement film in flat panel backlighting, and its optical performance is experimentally verified. A 30% increase in the forward on-axis luminance is observed.

AB - This paper describes an innovative approach for fabricating a seamless roller mold based on cylindrical photolithography, isotropic chemical etching, and electropolishing. Hexagonally arrayed concave microstructures with a near-semispherical profile are directly and seamlessly fabricated on a metal roller. The fabricated roller mold is then used for continuous roller imprinting of microlens array (MLA) on a thin polyethylene terephthalate (PET) substrate. The fabricated ball-shape microlenses have a footprint diameter of 54 μ m and a sag height of 20.5 μ m and are hexagonally close packed with a filling ratio larger than 91%. This MLA/PET optical film can serve as a brightness enhancement film in flat panel backlighting, and its optical performance is experimentally verified. A 30% increase in the forward on-axis luminance is observed.

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ER -

Fabrication of seamless roller mold for continuous roller imprinting of microlens array films

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