Fast fabrication of integrated surface-relief and particle-diffusing plastic diffuser by use of a hybrid extrusion roller embossing process.
Most plastic diffusers are either of surface-relief or particle-diffusing types, based on different principles and fabrication methods. This paper reports an innovative extrusion roller embossing process, which enables the fabrication of diffusers with both surface-relief and particle-diffusing functions. An extruder with die is employed to fabricate the thin film of PC/bead composite; the roller micro-embossing process is used to replicate the microstructure onto the surface of PC composite film. A metallic roller mold with microstructures is fabricated using turning process. During the extrusion rolling embossing process, the extruded film of PC with diffusion beads is immediately pressed against the surface of the roller mold. Under the proper processing parameters, the plastic diffusers integrating surface-relief and particle-diffusing functions have been successfully fabricated. The shape, uniformity, and optical properties of fabricated diffuser have been verified. This method shows the great potential for continuous fabrication of high-performance plastic diffusers integrating surface-relief and particle-diffusing functions with high throughput.
Huang
Tzu-Chien
TC
Department of Mechanical Engineering, National Taiwan University, Taipei 106, Taiwan.
Ciou
Jian-Ren
JR
Huang
Po-Hsun
PH
Hsieh
Kuo-Huang
KH
Yang
Sen-Yeu
SY
D004867:Equipment Design; D019544:Equipment Failure Analysis; D005336:Fiber Optic Technology / Q000295:instrumentation*; D008904:Miniaturization; D010969:Plastics / Q000737:chemistry*; D012542:Scattering, Radiation; D013499:Surface Properties; D018511:Systems Integration
D010969:Plastics