TWI582475B - Method of making lightguide - Google Patents
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- TWI582475B TWI582475B TW103141953A TW103141953A TWI582475B TW I582475 B TWI582475 B TW I582475B TW 103141953 A TW103141953 A TW 103141953A TW 103141953 A TW103141953 A TW 103141953A TW I582475 B TWI582475 B TW I582475B
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Description
本發明係關於一種製造光導膜的方法。 This invention relates to a method of making a light directing film.
光導(lightguide)是一種膜，在其上下表面之間提供對於光的實質全內反射。光係自一或多個光源而入射於該膜的邊緣(該邊緣係垂直於該膜的上下表面)。光導膜在該上下表面包括有經織構的輪廓(textured profile)時能用作為背光單元，以便使光自光導膜散射出。經織構的表面藉由折射及/或全反射而將光重新導出於光導膜之外。 A light guide is a film that provides substantial total internal reflection of light between its upper and lower surfaces. The light system is incident on the edge of the film from one or more light sources (the edge is perpendicular to the upper and lower surfaces of the film). The light guiding film can be used as a backlight unit when the upper and lower surfaces include a textured profile to scatter light from the light guiding film. The textured surface re-exports light out of the lightguide film by refraction and/or total reflection.
光導膜通常配置在顯示系統中的背光單元之中，該顯示系統係諸如液晶顯示(liquid crystal display，LCD)面板；廣告面板；一般照明應用；或資訊顯示器，例如：汽車儀表板、家電控制面板及機器狀態指示燈。在一些情況中，背光單元的大多數面積需要有照明，而其他情況中只有背光單元的特定面積需要照明。 The light guiding film is usually disposed in a backlight unit in a display system, such as a liquid crystal display (LCD) panel; an advertising panel; a general lighting application; or an information display, such as a car dashboard, a home appliance control panel And machine status indicator. In some cases, most of the area of the backlight unit requires illumination, while in other cases only a particular area of the backlight unit requires illumination.
如美國專利案號US4630895A與US5673128A所揭示，已知的一種光導膜製造方法係將白散射光點(dot)予以網印於光導膜表面。其方式並無散射角度的控制(即光落點(drop)為具有低接觸角度的平坦狀，其原因在於光學基板以及形成白光點的樹脂之間為具有有限的表面能量差異)並且使用於增加散射的顆粒添加劑擁有在可見光範圍內顯著的光吸收係數，而導致光隨著與光源間的距離增加而逐漸變黃。 A known method of fabricating a light directing film is to screen a white scattered light spot on the surface of a light directing film, as disclosed in U.S. Patent Nos. 4,630,895, issued to U.S. Pat. There is no control of the scattering angle (ie, the drop is flat with a low contact angle due to the limited surface energy difference between the optical substrate and the resin forming the white spot) and is used to increase The scattered particulate additive possesses a significant light absorption coefficient in the visible range, causing the light to gradually turn yellow as the distance from the source increases.
另一種先前技術的製造方法如美國專利案號US6480307B1與US6623667B2所揭示，係為射出成型(injection moulding)光導。該成型係使用快速切削(flycutting)、車削(turning)、銑削(milling)、研磨(grinding)、(蝕刻)或相似加工處理。該材料為經熔融、添入至 模型、使之凝固(或潛在性固化)，然後脫出。成型加工處理不適合散射(即，加工)面積小於光導膜面積相當多的情況，且特別是對於散射面積的形狀為複雜且本質為具有選擇性的情況，像是用於資訊顯示器的情況。再者，射出成型係不適合快速製造，及因少量製造故經濟規模低。 Another prior art manufacturing method is disclosed in U.S. Patent Nos. 6,480,307 B1 and 6,623,667 B2, which are injection molding light guides. The forming system uses fly cutting, turning, milling, grinding, etching or the like. The material is melted and added to Model, make it solidify (or potentially cure), and then detach. The forming process is not suitable for the case where the scattering (i.e., processing) area is considerably larger than the area of the light guiding film, and particularly the case where the shape of the scattering area is complicated and selective in nature, as in the case of an information display. Furthermore, the injection molding system is not suitable for rapid manufacturing, and the economic scale is low due to a small amount of manufacturing.
再另一種已知的製造方法如美國專利案號US7252428B2及US7543974B2所揭示，係為微結構的熱或紫外線(UV)凸印(embossing)。熱或UV固化之光導膜凸印係為典型的捲對式(reel-to-reel)處理並且凸印的圖案係成形於滾輪(drum)上的織構或表面輪廓。該表面輪廓藉鑽石車削或類似處理而產生，並且該輪廓能夠沿該滾輪的長度而變化。在UV固化凸印中，典型地，光導膜的整個下表面係以未固化樹脂塗覆。這會在散射區域為總光導膜面積的一小部分時造成相當大的材料浪費。再者，散射區域以外的光導膜的面積必須是光學平滑且共面於光導膜表面，以避免不需要的光提取。捲對式凸印的另外壞處在於當表面輪廓需要沿滾輪的周緣而變化時，該光導膜的尺寸則會被該滾輪的周緣所限制。在該表面輪廓需要沿滾輪的周緣變化的方面，凹版印刷技術是可利用的，但此種處理有射出成型之成型製造上的相同壞處。而當藉由沖壓而凸印時，同樣有射出成型的缺點。 A further known method of manufacture is disclosed in U.S. Patent No. 7,252, 428 B2 and U.S. Patent No. 7,543, 974 B2, which is incorporated herein by reference. Thermal or UV-cured light-guide film embossing is a typical reel-to-reel process and the embossed pattern is formed into a texture or surface profile on a drum. The surface profile is produced by diamond turning or the like and the profile can vary along the length of the roller. In UV curing embossing, typically the entire lower surface of the light directing film is coated with an uncured resin. This can result in considerable material waste when the scattering region is a small fraction of the total photoconductive film area. Furthermore, the area of the light directing film outside the scattering region must be optically smooth and coplanar to the surface of the light directing film to avoid unwanted light extraction. An additional disadvantage of roll-to-face embossing is that the size of the light-guide film is limited by the circumference of the roller as the surface profile needs to vary along the circumference of the roller. Gravure printing techniques are available in that the surface profile needs to vary along the circumference of the roller, but such treatment has the same disadvantages in injection molding. When embossing by stamping, there is also the disadvantage of injection molding.
本發明的目的在於提供一種光導膜製造處理，供材料的有效使用，適合於快速少量至大量的製造，以得到薄型、明亮且高效的背光單元。 SUMMARY OF THE INVENTION It is an object of the present invention to provide a photoconductive film manufacturing process for efficient use of materials, which is suitable for rapid small to large manufacturing to obtain a thin, bright and efficient backlight unit.
本發明提供一種製造光導膜的方法，包含：(a)提供一光導膜，具有一上表面及一下表面，而供光在該上表面與該下表面之間為實質全內反射；(b)施加一可流動性且可固化的材料於至少該下表面而成一圖案；(c)施加一表面織構於該材料；以及(d)固化該材料，而使於位在該光導膜上所得到經表面織構的圖案得以自該光導膜提取出光。 The invention provides a method for manufacturing a light guiding film, comprising: (a) providing a light guiding film having an upper surface and a lower surface, wherein the light supply is substantially total internal reflection between the upper surface and the lower surface; (b) Applying a flowable and curable material to at least the lower surface to form a pattern; (c) applying a surface texture to the material; and (d) curing the material to obtain a position on the light guiding film The surface textured pattern is capable of extracting light from the light directing film.
在步驟(b)中所施加的該材料可包括一可固化樹脂。其可包 括散射奈米顆粒(例，TiO2)，以促進散射。其可包括紫外光調降浸灰添加劑，諸如：UV吸收劑或是磷光劑之類的活性成分。其可應用於高解析度印刷處理，例如：噴墨印刷或網版印刷。該材料的用量可隨著整個該表面而改變。特別是，該材料可僅施加於該光導膜提取出光的部分。 The material applied in step (b) may comprise a curable resin. It may include scattering nanoparticle (eg, TiO 2 ) to promote scattering. It may include an ultraviolet light immersion liming additive such as a UV absorber or an active ingredient such as a phosphor. It can be applied to high resolution printing processes such as inkjet printing or screen printing. The amount of the material can vary with the entire surface. In particular, the material may be applied only to the portion of the light directing film that extracts light.
在步驟(b)之前，可於該表面施加一表面改質劑，例，聚合物或低聚物。此種表面改質的作用可為平坦化、表面能改變、或修改或匹配折射率。 Prior to step (b), a surface modifying agent, such as a polymer or oligomer, can be applied to the surface. The effect of such surface modification can be planarization, surface energy change, or modification or matching of the refractive index.
步驟(c)中所施加的織構可經配置而配合該材料之圖案以增進光散射。該織構可為均佈於整個該表面、或是隨著整個該表面而改變，以有效地產生均勻照明或產生照明會變化的圖案。該織構可包括一隨機粗糙化的輪廓或是週期性幾何微結構，例如：角柱形、角錐形、圓錐形及/或微透鏡形。 The texture applied in step (c) can be configured to match the pattern of the material to enhance light scattering. The texture may be uniform throughout the surface or may change throughout the surface to effectively produce uniform illumination or to produce a pattern that will vary in illumination. The texture may comprise a randomly roughened profile or a periodic geometric microstructure, such as a corner cylinder, a pyramid, a cone, and/or a microlens.
步驟(c)可包括例如捲對式凸印(reel-to-reel embossing)或沖壓凸印(stamping embossing)。 Step (c) may include, for example, reel-to-reel embossing or stamping embossing.
為了提供具有兩個相對的織構表面，步驟(b)、(c)及(d)中能夠對該光導膜之上表面與下表面予以執行上述的可選特徵。 In order to provide two opposing textured surfaces, the optional features described above can be performed on the upper and lower surfaces of the light directing film in steps (b), (c) and (d).
本發明將藉由以下之附呈圖式而僅以例示方式作詳細之說明。 The invention will be described in detail by way of illustration only by the accompanying drawings.
1‧‧‧光導 1‧‧‧Light Guide
2‧‧‧背光單元 2‧‧‧Backlight unit
3‧‧‧反射件 3‧‧‧reflector
4‧‧‧擴散膜 4‧‧‧Diffuser film
5‧‧‧增亮膜 5‧‧‧Brightening film
6‧‧‧光源 6‧‧‧Light source
7‧‧‧上表面 7‧‧‧ upper surface
8‧‧‧下表面 8‧‧‧ Lower surface
9‧‧‧樹脂 9‧‧‧Resin
10‧‧‧印模 10‧‧‧ impression
11‧‧‧表面織構 11‧‧‧ Surface texture
12‧‧‧表面織構 12‧‧‧ Surface texture
13‧‧‧樹脂 13‧‧‧Resin
14‧‧‧圖像 14‧‧‧ Images
15‧‧‧圖像 15‧‧‧ Images
16‧‧‧幾何形狀 16‧‧‧Geometry
17‧‧‧文字 17‧‧‧ text
18‧‧‧小滴 18‧‧‧ droplets
19‧‧‧滾輪 19‧‧‧Roller
20‧‧‧表面織構 20‧‧‧ Surface texture
21‧‧‧微結構表面 21‧‧‧Microstructured surface
22‧‧‧樹脂 22‧‧‧Resin
23‧‧‧表面織構 23‧‧‧ Surface texture
24‧‧‧背光單元 24‧‧‧Backlight unit
25‧‧‧光導 25‧‧‧Light Guide
26‧‧‧反射件 26‧‧‧Reflecting parts
27‧‧‧擴散膜 27‧‧‧Diffuser film
28‧‧‧增亮膜 28‧‧‧Brightening film
29‧‧‧表板 29‧‧‧Table
30‧‧‧透光窗 30‧‧‧Light window
31‧‧‧孔洞 31‧‧‧ hole
32‧‧‧孔洞 32‧‧‧ holes
33‧‧‧微結構面積 33‧‧‧Microstructural area
34‧‧‧光源 34‧‧‧Light source
35‧‧‧光束 35‧‧‧ Beam
36‧‧‧光束 36‧‧‧ Beam
37‧‧‧微結構面積 37‧‧‧Microstructure area
38‧‧‧光束 38‧‧‧ Beam
39‧‧‧光束 39‧‧‧ Beam
40‧‧‧光束 40‧‧‧ Beam
圖1係結合有根據本發明所製造的一光導膜的一背光單元的***示意圖；圖2a至2c係顯示根據本發明的一實施例的一方法的示意圖；圖3a至3c係顯示根據本發明製造的樹脂圖像；圖4a及4b顯示本發明方法的改變樹脂分佈實施例；圖5a及5b顯示另一實施例；圖6係根據本發明的一實施例的一背光單元的***圖； 圖7a及7b係該背光單元的各別實施例的側視圖。 1 is a schematic exploded view of a backlight unit incorporating a light guide film manufactured in accordance with the present invention; FIGS. 2a to 2c are schematic views showing a method according to an embodiment of the present invention; and FIGS. 3a to 3c are diagrams showing the present invention. Figure 4a and 4b show an embodiment of a modified resin distribution of the method of the present invention; Figures 5a and 5b show another embodiment; Figure 6 is an exploded view of a backlight unit in accordance with an embodiment of the present invention; 7a and 7b are side views of respective embodiments of the backlight unit.
圖1係顯示與本發明一致的背光單元範例佈局之***圖。該背光單元2包括一光導膜1，具有一上表面及一下表面，能夠藉由全內反射來導引光；一選配光學反射件3，位在該光導膜之下表面之下；一選配擴散膜4，位在該光導膜1的上表面之上；以及一選配增亮膜5，位在該選配擴散膜4之上。該光導膜1包括多個光源6，光學耦合於該膜而將光入射於該膜。該光源6根據使用者條件需要分佈於該光導膜1側邊。光源的例子包括任何種類的發光二極體(light-emitting diode，LED)：頂光、側光LED、有機LED(OLED)、或其他點光源，像是通過光纖傳遞的光源或雷射。下表面上的經織構輪廓使得自光導膜出來的光朝選配擴散膜4散射。朝著底部反射件3散射的光穿透過光導膜而朝著選配擴散膜4反射。該選配擴散膜4作用以改善來自該光導膜1的照明均勻性。該選配增亮膜5改善來自該光導膜1的在正向軸向(出光方向)照明亮度。以此方式，背光單元2用於顯示系統之照明，諸如：液晶顯示面板中；廣告看板中；或是一般照明應用中；或資訊顯示器中，例如：汽車儀表板、家電控制或狀態面板或工業機器。在一些情況中，背光單元的大多數面積需要有照明，而其他情況中只有背光單元的特定面積需要照明。 1 is an exploded view showing an example layout of a backlight unit consistent with the present invention. The backlight unit 2 includes a light guiding film 1 having an upper surface and a lower surface for guiding light by total internal reflection; an optional optical reflecting member 3 positioned below the lower surface of the light guiding film; A diffusion film 4 is disposed on the upper surface of the light guiding film 1; and an optional brightness enhancing film 5 is disposed on the optional diffusion film 4. The light guiding film 1 includes a plurality of light sources 6 optically coupled to the film to inject light into the film. The light source 6 is distributed on the side of the light guiding film 1 according to user conditions. Examples of light sources include any type of light-emitting diode (LED): top light, side light LED, organic LED (OLED), or other point source, such as a light source or laser that is transmitted through an optical fiber. The textured profile on the lower surface causes light emerging from the photoconductive film to scatter toward the optional diffusion film 4. Light scattered toward the bottom reflector 3 penetrates the light guide film and is reflected toward the optional diffusion film 4. The optional diffusion film 4 acts to improve illumination uniformity from the light guiding film 1. The optional brightness enhancement film 5 improves the illumination brightness in the forward axial direction (light exit direction) from the light guide film 1. In this way, the backlight unit 2 is used for illumination of a display system, such as in a liquid crystal display panel; in an advertising billboard; or in a general lighting application; or in an information display, such as a car dashboard, a home appliance control or status panel, or an industrial machine. In some cases, most of the area of the backlight unit requires illumination, while in other cases only a particular area of the backlight unit requires illumination.
圖2係製造光導膜的方法的示意圖。圖2a中，該光導膜1具有實質平行的一上表面7及一下表面8(在另外的實施例中，該上表面7與該下表面8之間則有一角度而形成一楔形光導膜)且在該上表面7與該下表面8之間提供光的全內反射。適合的光導膜材料例如包括聚碳酸酯(polycarbonate，PC)、聚對苯二甲酸乙二酯(polyethylene terephthalate，PET)、聚甲基丙烯酸甲酯(polymethyl methacrylate，PMMA)環烯共聚物(cyclic olefin copolymer，COC)環烯烴聚合物(cyclic olefin polymers，COP)。整體而言，該光導膜為光學透光於可見光譜的材料，其厚度大致在0.050mm與50mm之間，具體數字為0.125 mm與5mm之間。 2 is a schematic view of a method of manufacturing a light guiding film. In Fig. 2a, the light guiding film 1 has a substantially parallel upper surface 7 and a lower surface 8 (in another embodiment, the upper surface 7 and the lower surface 8 are angled to form a wedge-shaped light guiding film) and Total internal reflection of light is provided between the upper surface 7 and the lower surface 8. Suitable light-guiding film materials include, for example, polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA) cycloolefin copolymer (cyclic olefin). Copolymer, COC) cyclic olefin polymers (COP). Generally, the light guiding film is a material that optically transmits light to the visible spectrum, and the thickness thereof is substantially between 0.050 mm and 50 mm, and the specific number is 0.125. Between mm and 5mm.
圖2b中，該光導膜1之下表面8係以可流動性且可固化的聚合樹脂9披覆。該披覆處理最好為一高解析度印刷處理，例如噴墨印刷及網版印刷，但也可為任何與該聚合樹脂相容的沉積處理而且能夠達到在印刷面上的圓點尺寸(drop size)在0.01mm到500mm的範圍中，特別是0.01mm至200mm的範圍。再者該高解析度印刷處理允許沉積樹脂的高度控制。圖2b顯示樹脂分佈9，其有樹脂高度上的改變。圖2b亦包括一表面織構印模10，該印模10具有一週期性微結構表面織構11，其係轉換成樹脂分佈9。該固化的聚合樹脂具有一折射係數，其較佳地為近似或略高於該光導膜1。圖2c中，該凸印處理在該光導膜1上形成一可變高度的微結構表面織構12。該微結構表面織構12較佳地係於整個光導膜面積均勻地提取光，但亦可採任何期望型式的光分佈。 In Fig. 2b, the lower surface 8 of the light guiding film 1 is coated with a flowable and curable polymer resin 9. Preferably, the coating treatment is a high resolution printing process, such as ink jet printing and screen printing, but can also be any deposition process compatible with the polymeric resin and can achieve a dot size on the printing surface (drop Size) is in the range of 0.01 mm to 500 mm, especially in the range of 0.01 mm to 200 mm. Again, this high resolution printing process allows for a high degree of control of the deposited resin. Figure 2b shows a resin distribution 9, which has a change in resin height. Figure 2b also includes a surface texture stamp 10 having a periodic microstructured surface texture 11 that is converted into a resin distribution 9. The cured polymeric resin has a refractive index which is preferably approximately or slightly higher than the light guiding film 1. In Figure 2c, the embossing process forms a variable height microstructured surface texture 12 on the light directing film 1. The microstructured surface texture 12 preferably extracts light uniformly over the entire area of the light directing film, but may also take any desired type of light distribution.
該印刷樹脂分佈無法有效地單獨自光導膜提取光。該基板材料及沉積樹脂具有相似的材料性質並且該最小表面能輪廓係不適合光提取。該印刷樹脂分佈係配合表面材質以確保藉由該光導膜產生所需的照明輪廓。光學設計軟體(例如：LightTools)能夠用於樹脂分佈與表面材質兩者的最佳化以達成整個光導膜面積上的均勻照明、或是更為複雜的照明分佈。 The printing resin distribution cannot effectively extract light from the light guiding film alone. The substrate material and the deposited resin have similar material properties and the minimum surface energy profile is not suitable for light extraction. The printed resin distribution is matched to the surface material to ensure that the desired illumination profile is produced by the light directing film. Optical design software (eg, LightTools) can be used to optimize both resin distribution and surface material to achieve uniform illumination over the entire photoconductive film area, or a more complex illumination distribution.
能夠圖案化該光導膜的印刷技術包括噴墨印刷及網版印刷。一般而言，該印刷處理控制所沉積的樹脂量以及移動平台控制二維分佈。。熟習本領域技術者當知能夠印刷出不同的空間上改變的樹脂分佈。圖3的例子中包括灰階及半色調圖像。圖3a中，該光導膜1上的樹脂分佈13為一灰階圖像。在此例子中，樹脂厚度為連續性改變(如圖2b的分佈9所示)且藉由印刷處理與材料性質所控制。再者，作為設計軟體與印刷機之間介面的光柵圖像處理器軟體的配置導致如圖3b所示的半色調圖像14。在此例子中，樹脂分佈大部分為固定高度並利用軟體改變圖像的填充密度。在圖3c中，一更複雜的樹脂圖像15包括幾何形狀16與文字 17的灰階印刷，諸如可能為照明一公司標識、電腦圖像、或其他圖案所須。幾何形狀16與文字17中的漸層圖案(自亮而暗)為以圖例示漸增的樹脂沉積量(面積或高度)並據以進一步使來自光源6的光散射提升。 Printing techniques capable of patterning the light directing film include ink jet printing and screen printing. In general, the printing process controls the amount of resin deposited and the mobile platform controls the two-dimensional distribution. . It is known to those skilled in the art that it is possible to print different spatially varying resin distributions. The grayscale and halftone images are included in the example of FIG. In Fig. 3a, the resin distribution 13 on the light guiding film 1 is a gray scale image. In this example, the resin thickness is a continuous change (as shown by the distribution 9 of Figure 2b) and is controlled by the printing process and material properties. Furthermore, the configuration of the raster image processor software as the interface between the design software and the printer results in a halftone image 14 as shown in Figure 3b. In this example, the resin distribution is mostly at a fixed height and the soft body is used to change the packing density of the image. In Figure 3c, a more complex resin image 15 includes geometric shapes 16 and text. Grayscale printing of 17, such as may be required for lighting a company logo, computer image, or other graphics. The gradation pattern (self-illuminating and dark) in the geometric shape 16 and the text 17 is an illustration of an increasing amount of resin deposition (area or height) and further scatters light from the light source 6 accordingly.
如圖4a所示，該樹脂分佈能夠藉由改變相似小滴18的二維陣列的密度分佈而形成，諸如可藉由網版印刷、或藉由以壓電供需式噴墨印刷直接控制印刷而形成。為了產生均勻照明，小滴18的密度依照隨著對該光源6的距離的公式的控制方式而增加。圖4a中亦包括凸印滾輪19的範例。該滾輪19具有一表面織構20，在此範例為一週期性微結構，其係轉換成樹脂小滴18的分佈9。圖4b中，採用表面織構處理，創造出密度變化的微結構表面21。 As shown in Figure 4a, the resin distribution can be formed by varying the density distribution of a two-dimensional array of similar droplets 18, such as by screen printing, or by direct control of printing by piezoelectric supply-demand inkjet printing. form. To produce uniform illumination, the density of the droplets 18 increases in accordance with the manner in which the formula for the distance to the source 6 is controlled. An example of a embossing roller 19 is also included in Figure 4a. The roller 19 has a surface texture 20, here an example of a periodic microstructure that is converted into a distribution 9 of resin droplets 18. In Figure 4b, a surface texture treatment is used to create a microstructured surface 21 of varying density.
在另一實施例中，如圖5a所示，該光導膜1之上表面7與下表面8皆為一可流動性且可固化聚合樹脂22所披覆。該披覆處理較佳為一高解析度印刷處理，例如包括噴墨印刷及網版印刷，但也可為任何與該聚合樹脂相容之沉積處理而且能夠達到在印刷面上的圓點尺寸在0.01mm到500mm的範圍中，特別是0.01mm至200mm的範圍。再者該高解析度印刷處理允許沉積樹脂的高度控制。圖5a顯示樹脂分佈22，其有樹脂高度上的改變。該表面織構11在此範例中為一週期性微結構(位於印模10中)，其係轉換成樹脂分佈22。圖5b中，表面織構處理於該上表面7與下表面8上創造出一多變高度微結構表面23。該多變高度微結構表面23較佳地係於整個光導膜面積均勻地提取光，但亦可採任何期望型式的光分佈。在此一實施例中，該微結構表面織構23能夠透過該上表面7與下表面8而提取光，或是藉由將一選配光學反射件3配置在光導膜1的下表面8之下而使該微結構表面織構23僅能夠透過該上表面7提取光。該二種織構處理能夠同時性或接續性實行。 In another embodiment, as shown in FIG. 5a, the upper surface 7 and the lower surface 8 of the light guiding film 1 are both flowable and coated by the curable polymer resin 22. The coating treatment is preferably a high-resolution printing process, for example, including inkjet printing and screen printing, but can also be any deposition process compatible with the polymer resin and can achieve a dot size on the printing surface. In the range of 0.01 mm to 500 mm, particularly in the range of 0.01 mm to 200 mm. Again, this high resolution printing process allows for a high degree of control of the deposited resin. Figure 5a shows a resin distribution 22 with a change in resin height. The surface texture 11 is in this example a periodic microstructure (located in the stamp 10) that is converted into a resin distribution 22. In Figure 5b, the surface texture treatment creates a variable height microstructured surface 23 on the upper surface 7 and the lower surface 8. The variable height microstructured surface 23 preferably extracts light uniformly over the entire area of the light directing film, but may also take any desired type of light distribution. In this embodiment, the microstructured surface texture 23 can extract light through the upper surface 7 and the lower surface 8, or can be disposed on the lower surface 8 of the light guiding film 1 by arranging an optional optical reflecting member 3. The microstructure surface texture 23 is only capable of extracting light through the upper surface 7. The two texture processes can be performed simultaneously or in succession.
在該樹脂的高度改變處，該光導膜不同部位的照度係取決於用了多少樹脂填充於經施加的表面織構。表面織構的形狀能夠為隨機且非重複，像是當噴砂或化學蝕刻一金屬凸印母版時所可能形成者。當該表 面織構為一週期性圖案時，重複性微結構的形狀能夠但不限於為角柱形、角錐形、圓錐形、或微透鏡形。在週期性微結構的情況中，該微結構的幾何能夠最佳化以配合該光源的分佈而將照度最大化。可選地，隨機或周期性或其他微結構的空間分佈能夠是一致的或變化的。在一個實施例中，平金屬(或其他適合材料)片係經圖案化且包繞於一凸印滾輪。或者，該滾輪本身能夠使用任何所屬領域的已知方法而選擇性圖案化。這些或其他技術當為熟習本領域技術者所知。藉此，光提取的程度係由藉高解析度印刷處理所沉積的樹脂的分佈與施加於該圖案化樹脂的表面織構的分佈(及形狀)所決定。 At the height change of the resin, the illuminance of the different portions of the light guiding film depends on how much resin is used to fill the applied surface texture. The shape of the surface texture can be random and non-repeating, as may be the case when sandblasting or chemical etching a metal relief master. When the table When the face texture is a periodic pattern, the shape of the repeating microstructure can be, but is not limited to, a prismatic shape, a pyramidal shape, a conical shape, or a microlens shape. In the case of periodic microstructures, the geometry of the microstructure can be optimized to match the distribution of the source to maximize illumination. Alternatively, the spatial distribution of random or periodic or other microstructures can be uniform or varied. In one embodiment, a flat metal (or other suitable material) sheet is patterned and wrapped around a embossing roller. Alternatively, the roller itself can be selectively patterned using any method known in the art. These or other techniques are known to those skilled in the art. Thereby, the degree of light extraction is determined by the distribution of the resin deposited by the high-resolution printing process and the distribution (and shape) of the surface texture applied to the patterned resin.
該表面織構亦能夠最佳化以配合任何額外的光學膜(諸如但不限於擴散膜及增亮膜)而將照度最大化。該擴散膜4擴散光。通常，該擴散膜具有小於1mm的厚度，特別是小於或等於0.5mm。在此所使用的用詞「擴散(diffuse/diffusing)」係意在包括藉由來自表面織構及/或顆粒等的反射(reflection)、折射(refraction)或繞射(diffraction)的散射或擴散。該增亮膜5提供一高光準直性能以給予高亮度表現。該增亮膜典型地為一棱柱膜，能夠包括一聚合物基底且帶有一具有棱柱織構的披覆層。在進一步的實施例中，該背光單元2包括結合單一膜的一擴散膜4及一增亮膜5，例如多功能膜。 The surface texture can also be optimized to maximize illumination with any additional optical film such as, but not limited to, a diffuser film and a brightness enhancing film. The diffusion film 4 diffuses light. Typically, the diffusing film has a thickness of less than 1 mm, in particular less than or equal to 0.5 mm. As used herein, the term "diffuse/diffusing" is intended to include scattering or diffusion by reflection, refraction, or diffraction from surface textures and/or particles, and the like. . The brightness enhancement film 5 provides a high light collimation performance to impart high brightness performance. The brightness enhancing film is typically a prismatic film that can comprise a polymeric substrate with a coating having a prismatic texture. In a further embodiment, the backlight unit 2 comprises a diffusion film 4 incorporating a single film and a brightness enhancement film 5, such as a multifunctional film.
在另一實施例中，該光導膜的散射效率透過在樹脂基質中引進奈米及微米顆粒而進一步提升；顆粒添加劑例如包括但不限於鈦氧化物(TiO2)、氧化鋁(Al2O3)、二氧化矽(SiO2)、ITO/ATO或是如PMMA、聚酰亞胺及聚碳酸酯之類的聚合物顆粒，以及前述材料的結合。在此一實施例中，較佳地係以網版印刷處理該樹脂，但通常亦可使用與相容微粒樹脂的高解析度印刷處理而進行沉積。高散射效率能使散射處理為輪廓的結構與該輪廓的量的光學擴散所共用而減少材料。在替代性實施例中，分散於樹脂中的奈米及微米顆粒能夠包括發出可見光光譜的光學磷光劑。這類的磷光劑能夠經配置而對於所發之光添加色偏，或是將UV LED的UV 光透過UV吸收與UV再發射而轉換為可見(例如，黃)光。再者，該樹脂中亦可包含有這類型的UV吸收劑(諸如UVA’s及HALS)，以避免光導膜的變黃。奈米及微米顆粒對於樹脂基質之引進係藉由本發明的製造處理予以促進，但不相容於依靠建造塊材的處理，諸如射出成型及熱凸印。 In another embodiment, the scattering efficiency of the light guiding film is further enhanced by introducing nano and micro particles into the resin matrix; the particle additives include, for example, but not limited to, titanium oxide (TiO 2 ), aluminum oxide (Al 2 O 3 ) ), cerium oxide (SiO 2 ), ITO/ATO or polymer particles such as PMMA, polyimide and polycarbonate, and combinations of the foregoing. In this embodiment, the resin is preferably treated by screen printing, but it is generally also possible to deposit using a high resolution printing process with a compatible particulate resin. The high scattering efficiency enables the structure of the scattering process to be contoured to be shared with the optical diffusion of the amount of the profile to reduce the material. In an alternative embodiment, the nanoparticles and microparticles dispersed in the resin can comprise an optical phosphor that emits a spectrum of visible light. Phosphors of this type can be configured to add color shift to the emitted light, or to convert UV light from the UV LED into visible (eg, yellow) light by UV absorption and UV re-emission. Further, this type of UV absorber (such as UVA's and HALS) may be included in the resin to avoid yellowing of the light guiding film. The introduction of nano and microparticles to the resin matrix is facilitated by the manufacturing process of the present invention, but is incompatible with processing by building blocks, such as injection molding and hot embossing.
該光導膜之散射效率係為光源、光導膜材質、樹脂及表面織構的函數。樹脂的分佈量能夠藉由基板表面與樹脂的性質而選擇性控制。樹脂的黏度與表面能可調適以增進解析度、最大沉積高度及印刷便利。在進一步的實施例中，在樹脂應用之前施加於該基板的聚合物或寡聚體層的形式的表面處理亦可透過黏度與表面張力的控制而用以增進解析度、最大沉積高度及印刷便利。這類的表面處理能夠使用捲對式處理而施加，藉由噴塗或其他本技術領域已知的方法。為了改變表面能，能夠使用改質劑來修改樹脂組成(像是上述用於披覆應用者)，像是使用有機矽聚丙烯酸酯樹脂或是脂肪族聚氨酯四丙烯酸酯寡聚物以及選擇性配以一般的有機溶劑。。 The scattering efficiency of the light guiding film is a function of the light source, the material of the light guiding film, the resin, and the surface texture. The amount of distribution of the resin can be selectively controlled by the properties of the substrate surface and the resin. The viscosity and surface energy of the resin can be adjusted to improve resolution, maximum deposition height and printing convenience. In a further embodiment, the surface treatment in the form of a polymer or oligomer layer applied to the substrate prior to resin application can also be used to enhance resolution, maximum deposition height, and ease of printing by controlling viscosity and surface tension. Such surface treatments can be applied using roll-to-roll processing by spraying or other methods known in the art. In order to change the surface energy, modifiers can be used to modify the resin composition (such as those mentioned above for coating applications), such as the use of organic bismuth polyacrylate resins or aliphatic urethane tetraacrylate oligomers and optional Take a general organic solvent. .
在已知光導膜中，微結構特徵覆蓋該光導膜的主要部分。本發明的目的係為使用上述處理製造且配置於背光單元的光導膜，其中由微結構織構所覆蓋的面積小於該光導膜之面積相當多。在這些情況中，僅於光導的特定區域需要有照明。例如，該微結構織構能夠為一小的電腦圖像或一片段文字，其中該文字的面積係相當地小於該光導的面積。上述處理的特別優點在於能夠以高解析度且有效地在該光導面積的特定小部分形成對於密度、高度或其他幾何參數上要求有變化的微結構織構。上述處理的進一步優點在於該微結構織構的高解析度圖形化，特別是文字，允許有效散射線寬小於500mm且特別是小於250mm的形狀。 In known light directing films, microstructure features cover a major portion of the light directing film. The object of the present invention is a light guiding film manufactured using the above process and disposed in a backlight unit, wherein an area covered by the microstructure texture is considerably smaller than an area of the light guiding film. In these cases, illumination is only required in certain areas of the light guide. For example, the microstructure texture can be a small computer image or a segment of text, wherein the area of the text is substantially smaller than the area of the light guide. A particular advantage of the above described process is the ability to form microstructure textures that require variations in density, height or other geometrical parameters at a particular fraction of the area of the light guide with high resolution and efficiency. A further advantage of the above treatment is that the high resolution patterning of the microstructure texture, particularly text, allows for effective scattering of lines having a line width of less than 500 mm and in particular less than 250 mm.
根據本發明的背光單元包括：本發明的一光導；一光學反射件，位在該光導的下表面之下；一選配擴散膜，位在該光導的上表面之上；一選配增亮膜，位在該選配擴散膜之上；以及在本實施例中還有一具有多個透光窗的不透明表板，位於該選配增亮膜之上。該光導包括多個光源， 光學耦合於該膜而將光入射於該膜。該些微結構特徵將來自光導的光朝該表板散射。朝著底部反射件3散射的光係朝著該表板反射。該選配擴散膜作用以改善來自該光導的照明均勻性。該選配增亮膜改善來自該光導的在軸照明亮度。在此例子中，該表板係為不透明且包括數個孔洞(空隙或光學透光面積)，該些孔洞部分對應於該光導的微結構面積。在此實施例中，該光導透過該不透明表面中的孔洞提供照明，該不透明表板除此之外避免漫射光到達觀看者。該表板的透光面積可為電腦圖像、標識、文字、或其他圖案型式或其他幾何形狀。或者，在另外的實施例中，該背光單元不包括有一表板，且來自該光導的照明為直接可視。在其他另外的實施例中，該背光單元不包括有一表板，且來自該光導的照明可直接提供照明於觀看者、或於顯示系統，像是位於該背光單元之上的一個或多個液晶顯示(LCD)面板。 A backlight unit according to the present invention comprises: a light guide of the present invention; an optical reflector located below the lower surface of the light guide; an optional diffusion film positioned above the upper surface of the light guide; The film is positioned over the optional diffusion film; and in this embodiment there is also an opaque surface having a plurality of light transmissive windows over the optional brightness enhancing film. The light guide includes a plurality of light sources, Optically coupled to the film, light is incident on the film. The microstructure features scatter light from the light guide toward the surface. The light scattered toward the bottom reflector 3 is reflected toward the surface. The optional diffusion film acts to improve illumination uniformity from the light guide. The optional brightness enhancing film improves the on-axis illumination brightness from the light guide. In this example, the panel is opaque and includes a plurality of holes (voids or optically transmissive areas) that correspond to the microstructure area of the light guide. In this embodiment, the light guide provides illumination through holes in the opaque surface, which in addition prevents diffused light from reaching the viewer. The light transmissive area of the panel can be a computer image, logo, text, or other pattern or other geometric shape. Alternatively, in a further embodiment, the backlight unit does not include a watch panel and illumination from the light guide is directly visible. In still other embodiments, the backlight unit does not include a watch panel, and illumination from the light guide can directly provide illumination to a viewer, or to a display system, such as one or more liquid crystals located above the backlight unit. Display (LCD) panel.
圖6顯示根據本發明的一態樣的一背光單元24的***圖。該背光單元包括：一光導膜25，形成為上下表面能夠以全內反射而導引光；一光學反射件26，位於光導的下表面之下；一選配擴散膜27，位於光導之下表面之上；一選配增亮膜28，位於該選配擴散膜27之上；以及一不透明表板29，位於該選配增亮膜28之上。該表板29於此例子中係為光學不透明且包括多個孔洞(空隙或光學透光面積)30，該些孔洞係對應於該光導的微結構面積33。該透光面積30可為電腦圖像、文字、標識、或其他圖案型式或其他幾何形狀。該表板29亦可包括多個孔洞31，該些孔洞不對應該光導25的微結構面積。這些孔洞31可於該背光單元24中以各種膜型式呈現且可例如供背光單元組裝期間的對準輔助。該表板29可進一步包括多個孔洞32，該些孔洞不對應該光導25的微結構面積。這些孔洞32可於該背光單元24中以各種膜型式呈現且照明該背光單元24中未被該光導25所照明的一些面積。圖6的例圖中，這些孔洞32藉由進一步的該光學反射件26之下的照明光源(圖未示)而照明。從而該背光單元表板29可含有不同用途的多數個孔洞，僅有一些被照明，且僅有一 些是由該光導25所照明。在其他的實施例中，不需要該選配表板，且對應於該光導之微結構面積33的該些孔洞30可對於觀看者提供直接照明或是照明一顯示系統，像是位於該背光單元之上的一個或多個液晶顯示(LCD)面板。 Figure 6 shows an exploded view of a backlight unit 24 in accordance with an aspect of the present invention. The backlight unit comprises: a light guiding film 25 formed such that upper and lower surfaces can guide light by total internal reflection; an optical reflecting member 26 is located below the lower surface of the light guide; and an optional diffusion film 27 is located under the light guiding surface Above; an optional brightness enhancing film 28 is disposed over the optional diffusion film 27; and an opaque surface plate 29 is disposed over the optional brightness enhancing film 28. The skin 29 is optically opaque in this example and includes a plurality of voids (voids or optically transmissive areas) 30 that correspond to the microstructure area 33 of the light guide. The light transmissive area 30 can be a computer image, text, logo, or other pattern or other geometric shape. The watch panel 29 can also include a plurality of apertures 31 that do not correspond to the microstructure area of the light guide 25. These holes 31 can be presented in various film patterns in the backlight unit 24 and can be used, for example, for alignment assistance during assembly of the backlight unit. The surface plate 29 can further include a plurality of holes 32 that do not correspond to the microstructure area of the light guide 25. These holes 32 may be present in the backlight unit 24 in various film types and illuminate some of the area of the backlight unit 24 that is not illuminated by the light guide 25. In the example of FIG. 6, the holes 32 are illuminated by further illumination sources (not shown) beneath the optical reflector 26. Thus, the backlight unit bezel 29 can contain a plurality of holes for different purposes, only some are illuminated, and only one These are illuminated by the light guide 25. In other embodiments, the optional surface plate is not required, and the holes 30 corresponding to the microstructure area 33 of the light guide can provide direct illumination or illumination to the viewer, such as in the backlight unit. One or more liquid crystal display (LCD) panels above.
此例子中的光導25具有複雜且非矩形形狀，並且包括多個光源34，該些光源光學耦合於該膜而將光入射於該膜。該些光源34根據使用者條件及該表板孔洞的佈局(無論是否被此光導照明)而應需要分佈於該光導1側邊。光源的例子包括發光二極體(LED)：頂光、側光LED、有機LED(OLED)、或其他點光源，包括通過光纖傳遞的光源或雷射。微結構特徵33僅覆蓋該全部光導面積的一小部分，其將來自光導的光朝該表板29散射，朝該底部反射件26散射的光則朝該表板29反射。該選配擴散膜27作用以改善來自該光導25的照明均勻性。該選配增亮膜28作用以改善來自該光導25的在正向軸向照明亮度。 The light guide 25 in this example has a complex and non-rectangular shape and includes a plurality of light sources 34 that are optically coupled to the film to inject light into the film. The light sources 34 should be distributed on the side of the light guide 1 according to user conditions and the layout of the plate holes (whether or not illuminated by the light guide). Examples of light sources include light emitting diodes (LEDs): top light, side light LEDs, organic LEDs (OLEDs), or other point sources, including light sources or lasers that are transmitted through optical fibers. The microstructure feature 33 covers only a small portion of the total light guide area that scatters light from the light guide toward the surface plate 29, and light scattered toward the bottom reflector 26 is reflected toward the surface plate 29. The optional diffusion film 27 acts to improve illumination uniformity from the light guide 25. The optional brightness enhancing film 28 acts to improve the brightness in the forward axial illumination from the light guide 25.
圖7顯示根據圖6中實施例的該背光單元24的側視圖。圖7a中，該背光單元包括：一光導膜25、一光學反射件26及一不透明表板29，及選擇性地在該光導25的微結構面積37之上有多個透光孔洞30。該光導包括多個光源34，光學耦合於該膜而將光入射於該膜。圖7中，一示意光束35透過全內反射而於該光導內受引導。另一示意光束36係顯示投射於該微結構面積37。在此例子中，該光束36係顯示透過反射而由該光導25散射出。該光束36通過該不透明表板29的光學透光孔洞30。又一光束38係顯示投射於微結構面積37。在此例子中，該光束38係顯示透過反射而由該光導25散射出並且投射於該光學反射件26。反射後，該光束36投射於該表板29並且被吸收。圖7b中，該背光單元包括一光導膜25、一光學反射件26、一選配擴散膜27、位於該選配擴散膜27之上的一選配增亮膜28、位於該選配增亮膜28之上且具有多個光學透光窗30的一不透明表板29。該光導包括多個光源34，光學耦合於該膜而將光入射於該膜。一示意光束39係顯示透射於該微結構面積37。在此例子中， 該光束39係顯示透過反射而由該光導25散射出。該光束39通過該擴散膜27且根據該擴散膜的擴散強度而隨機朝該增亮膜28散射。該增亮膜28作用以準直該光。該光束39通過該不透明表板29的光學透光孔洞30。為了闡明該擴散膜27的優點，又一光束40係顯示投射於該微結構面積37。在此例子中，該光束40係顯示透過反射而由該光導25散射出並且投射於該擴散膜27。圖7a中，在缺乏擴散膜27的情況下，該光束38係投射於該表板29。圖7b中，該光束40通過該擴散膜27且根據該擴散膜的擴散強度而隨機朝該增亮膜28散射。該增亮膜28作用以準直該光。該光束40通過該不透明表板29的光學透光孔洞30。 Figure 7 shows a side view of the backlight unit 24 in accordance with the embodiment of Figure 6. In FIG. 7a, the backlight unit includes a light guiding film 25, an optical reflecting member 26 and an opaque surface plate 29, and selectively has a plurality of light transmitting holes 30 above the microstructure area 37 of the light guide 25. The light guide includes a plurality of light sources 34 that are optically coupled to the film to inject light into the film. In Figure 7, a schematic light beam 35 is guided within the light guide by total internal reflection. Another schematic beam 36 is shown projected onto the microstructure area 37. In this example, the beam 36 is shown to be scattered by the light guide 25 by reflection. The beam 36 passes through the optically transparent aperture 30 of the opaque surface plate 29. A further beam 38 is shown projected onto the microstructure area 37. In this example, the beam 38 is shown to be reflected by the light guide 25 and reflected by the light guide 25 and projected onto the optical reflector 26. After reflection, the beam 36 is projected onto the surface plate 29 and absorbed. In FIG. 7b, the backlight unit includes a light guiding film 25, an optical reflecting member 26, an optional diffusion film 27, and an optional brightness enhancing film 28 on the optional diffusion film 27, which is located in the optional brightening film. An opaque surface 29 above the film 28 and having a plurality of optically transparent windows 30. The light guide includes a plurality of light sources 34 that are optically coupled to the film to inject light into the film. A schematic beam 39 is shown to be transmitted through the microstructure area 37. In this example, The light beam 39 is shown to be transmitted by reflection and scattered by the light guide 25. The light beam 39 passes through the diffusion film 27 and is randomly scattered toward the brightness enhancement film 28 in accordance with the diffusion intensity of the diffusion film. The brightness enhancing film 28 acts to collimate the light. The beam 39 passes through the optically transparent aperture 30 of the opaque surface plate 29. To clarify the advantages of the diffuser film 27, a further beam 40 is shown projected onto the microstructure area 37. In this example, the beam 40 is shown to be diffused by the light guide 25 and projected onto the diffuser film 27 by reflection. In Fig. 7a, in the absence of the diffusion film 27, the beam 38 is projected onto the surface plate 29. In Figure 7b, the beam 40 passes through the diffuser film 27 and is randomly scattered toward the brightness enhancing film 28 in accordance with the diffusion intensity of the diffusing film. The brightness enhancing film 28 acts to collimate the light. The beam 40 passes through the optically transparent aperture 30 of the opaque panel 29.
1‧‧‧光導膜 1‧‧‧Light film
7‧‧‧上表面 7‧‧‧ upper surface
8‧‧‧下表面 8‧‧‧ Lower surface
9‧‧‧聚合樹脂 9‧‧‧Polymerized resin
10‧‧‧印模 10‧‧‧ impression
11‧‧‧表面織構 11‧‧‧ Surface texture
12‧‧‧表面織構 12‧‧‧ Surface texture
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| CN101131446A (en) * | 2006-08-22 | 2008-02-27 | 株式会社西铁城电子 | Sidelight type light guide panel, method of manufacturing the same, and back lamp device |
| TW201239389A (en) * | 2011-02-02 | 2012-10-01 | Sumitomo Chemical Co | Light guide plate, surface light source device, transmission-type image display device, method of manufacturing light guide plate, and ultraviolet curing type ink-jet ink for light guide plate |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101131446A (en) * | 2006-08-22 | 2008-02-27 | 株式会社西铁城电子 | Sidelight type light guide panel, method of manufacturing the same, and back lamp device |
| TW201239389A (en) * | 2011-02-02 | 2012-10-01 | Sumitomo Chemical Co | Light guide plate, surface light source device, transmission-type image display device, method of manufacturing light guide plate, and ultraviolet curing type ink-jet ink for light guide plate |
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