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

14 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 1

All Science Journal Classification (ASJC) codes

Mechanical Engineering
Electrical and Electronic Engineering

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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.",

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