A rapid and precision hot embossing of LGP micro-arch lens array inside core microgrooves: simulation and experiment
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The hot embossing needs the heat preservation for precision micro-forming, thus leading to inefficiency. A hot embossing of polymer micro-arch lens array in half molten is proposed for the application of light guide plate (LGP). It only performs a thermal deformation for micron-scale surface layer to be squeezed into core microgrooves. First, the micro-optic illumination of LGP was analyzed to design the micro-arch lens array; then the micro-grinding was employed to machine smooth microgrooves on ceramic core die; finally, the hot embossing experiments were conducted to adjust the thermal and structural parameters for modeling micro-arch height. It is shown that the micro-arch lens array may be rapidly and precisely formed inside the core microgrooves in half molten. The micro-arch height reaches 22 μm at a loading time of 5 s. The loading temperature and the core microgroove angle greatly influence the micro-arch height. The parameterized model of micro-arch height and radius may be used to optimize the hot embossing variables and the core microgroove parameters. The LGP patterned with the micro-arch lens array increases the irradiance intensity by 16% and its uniformity by 210% compared with smooth one, respectively.
KeywordsHot embossing Microlens array Micro-grinding LGP Die core Micro-optics
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The work was supported by the Natural Science Foundation of China (No. 61475046), the Guangdong Science Foundation of China (No. 2015A030311015), the Guangzhou Science and Technology Project (No. 201508030012), and the Guangdong Science and Technology Project (No. 2014B010104003).
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