A mold for resolving an interference prism structure film and a method of manufacturing the same

Abstract

The application provides a mold for resolving interference prism structure film and a preparation method thereof. The surface of the mold is provided with a prism structure layer comprising a plurality of prism structure arrays. The cross section of each prism structure array along the extending direction thereof is a triangle. The first side of the triangle is grown on the surface of the mold. The diagonal vertex connecting line of the first side belonging to the same prism structure array forms a continuous free curve. The free curve is a curve formed by any one or a combination of a simple harmonic wave curve perpendicular to the mold surface and a waveform curve with random and disordered changes in up and down. Before performing the forming cutting, the forming roller for preparing the mold is subjected to surface activation treatment and electroplating treatment. Meanwhile, a release agent is added into the mold. The prism structure of the mold has excellent resolving interference effect, high brightness, shielding property and the effect of widening the visual viewing angle. The mold has superior transfer printing effect, low manufacturing cost and long service life.

Description

Technical Field

[0001] This invention relates to the field of optical thin film technology, and more specifically to a mold for a deinterference prism structure film and its preparation method. Background Technology

[0002] The optical film in the backlight module of the LCD display has the characteristic of high brightness. Existing brightness enhancement optical films are generally composed of single or multiple layers of prism films stacked or bonded together. In order to achieve a higher brightness gain effect, the height of the prisms in the same array is generally the same. Although this achieves a high brightness effect, it is easy to produce moiré interference when assembled into the backlight module, and the viewing angle is relatively low.

[0003] Existing improvement technologies generally involve stacking or bonding a fogging structure layer on top of a single or multiple prism films. This reduces moiré interference and improves the viewing angle by enhancing the overall haze and shielding properties of the bonded film. However, this results in a certain decrease in luminance and an increase in production costs. Summary of the Invention

[0004] To overcome the above-mentioned shortcomings, the present invention aims to provide a mold for a deinterference prism structure film and its preparation method. The optical film transferred through this mold has excellent deinterference effect, high brightness, shielding effect and widened viewing angle. It solves the problem of increased cost and decreased brightness caused by stacking or bonding atomized structural layers on top of single or multiple prism films to reduce moiré interference. At the same time, the preparation method of this mold has the advantages of producing a large number of molds in one processing and low frequency of forming roller remaking, which greatly reduces the production cost of the mold. Moreover, the mold has excellent transfer effect and long service life.

[0005] To achieve the above objectives, the present invention proposes the following technical solution:

[0006] A mold for a deinterference prism structure film, the mold being a substrate film with a first deinterference prism structure layer on its surface, the first deinterference prism structure layer comprising a plurality of first prism structure arrays; each first prism structure array has a triangular cross-section along the array extension direction, and the first side of the triangle grows on the surface of the mold, and the lines connecting the opposite vertices of the first side belonging to the same first prism structure array form a continuous first free curve.

[0007] The first free curve is any one or a combination of two of the following: a simple harmonic wave curve perpendicular to the mold surface and a waveform curve with random and disordered changes.

[0008] As a preferred embodiment of the present invention, the mold is a substrate film on both sides having the first interference prism structure layer and the frosted layer respectively.

[0009] As a preferred embodiment of the present invention, the simple harmonic wave curve is any one or a combination of two of the sine wave curve and the cosine wave curve. When the first free curve follows a sine wave, cosine wave, or a combination of both perpendicular to the mold surface, the first disinterference prism structure layer has excellent disinterference effect and high brightness gain effect; when the first free curve follows a random and disordered change with up-and-down undulations perpendicular to the mold surface, the first disinterference prism structure layer has even better disinterference effect and high shielding effect.

[0010] This invention also proposes a method for preparing a mold for a deinterference prism structure film, comprising the following steps:

[0011] Step 1: Take a cylindrical base roller, level its surface and clean it. Then, activate the surface of the base roller to obtain a surface-activated base roller.

[0012] Step 2: Electroplating the surface-activated base roller to obtain an electroplated roller blank with a metal coating;

[0013] Step 3: The electroplating roller blank is leveled and cut to obtain a shaped roller blank;

[0014] Step 4: The rotating forming roller blank is formed by using a forming cutting tool in a threaded cutting manner. After the forming cutting is completed, a forming roller is obtained. The surface of the forming roller has a second interference prism structure layer that is mirror-symmetrical to the first interference prism structure layer.

[0015] The cutting tool tip is subjected to a voltage of 0.5V-20V. The voltage is continuously changing and is formed by any one or a combination of simple harmonic wave changes and random disordered waveform changes. The frequency of the voltage change is 50Hz-20000Hz.

[0016] Step 5: Take a substrate film, apply a coating liquid to one of the surfaces of the substrate film and let it cure to form a matte layer. The coating liquid contains 0.02%-3% PMMA or PBMA particles with a particle size of 1μm-15μm.

[0017] Step 6: The second interference prism structure layer on the surface of the forming roller is imprinted onto the other surface of the substrate film with the cured matte layer using UV transfer adhesive, thereby obtaining a mold with the first interference prism structure layer. The UV transfer adhesive contains 0.05%-2% of methyl silicone resin release agent, and the main component of the UV transfer adhesive is acrylic resin.

[0018] As a preferred embodiment of the present invention, the activation treatment of the surface of the base roller in step one includes:

[0019] The base roller surface is activated by dilute sulfuric acid to form an oxide layer. This oxide layer enhances the adhesion between the plating layer and the base roller during subsequent electroplating processes and improves the corrosion resistance and stability of the base roller surface.

[0020] As a preferred embodiment of the present invention, step two, which involves electroplating the surface-activated base roller, includes:

[0021] The surface-activated base roller is placed in an electroplating tank containing an electroplating solution at a temperature of 50°C-70°C and a concentration of 100g / L-300g / L. A direct current is applied to form a coating on the surface of the surface-activated base roller. The roller is then cooled at a constant temperature for 20-30 hours to obtain an electroplated roller blank with a single-sided metal coating thickness of 300μm-3000μm.

[0022] The electroplating solution is a copper plating solution or a nickel plating solution. The pH of the copper plating solution is 9-12, and the hardness of the copper plating layer is 200HB-300HB.

[0023] The nickel plating solution has a pH of 3.5-5.0, and the nickel plating layer has a hardness of 550HB-580HB. Copper or nickel plating layers, among other metal plating, have excellent ductility, making them easier to process and shape during machining of the forming roll blank surface, thus reducing the energy consumption of the cutting equipment.

[0024] As a preferred embodiment of the present invention, the coating liquid further contains 0.05%-1% of an antistatic agent. The main component of the antistatic agent is a quaternary ammonium acrylate, which is used to reduce static electricity during mold production and transfer printing.

[0025] As a preferred embodiment of the present invention, step three, which involves leveling and cutting the electroplating roller blank, includes:

[0026] The electroplating roller blank is placed on a precision cutting machine and leveled and cut 2 to 5 times with a leveling cutting tool. The cutting depth of each leveling cut is 10μm-100μm, and the cutting depth of the last leveling cut is 10μm-30μm.

[0027] As a preferred embodiment of the present invention, step four, which involves using a forming cutting tool to perform forming cutting on the rotating forming roll blank using a threaded cutting method, includes:

[0028] The forming roll blank is placed on a precision cutting machine, and the longitudinal speed of the forming roll blank is adjusted to 200rpm-300rpm. The forming cutting tool is used to perform straight thread or oblique thread cutting on the forming roll blank. After the cutting is completed, a forming roll with a second interference prism structure layer is obtained.

[0029] The cutting angle of the cutting head in the horizontal direction of the forming cutting tool is 0°-90°, the transverse cutting distance of the cutting head is 10μm-70μm, and the cutting depth of the cutting head is 5μm-50μm.

[0030] As a preferred embodiment of the present invention, the simple harmonic wave variation is any one or a combination of sine wave variation and cosine wave variation.

[0031] The technical solution of the present invention provides a mold for a deinterference prism structure film and a method for preparing the same, which has at least the following advantages compared with the prior art:

[0032] (1) The cross-section of the prism structure array on the surface of the mold along its extension direction is a triangle, and the first free curve formed by the line connecting the vertices of the triangle follows the simple harmonic wave or random disordered change of up and down undulation perpendicular to the surface of the mold, thereby reducing the overall regularity of the prism structure array, thereby improving the interference resolution effect and shielding of the prism structure, widening the viewing angle, and further improving the versatility of the interference resolution prism structure film, solving the problem of brightness reduction and cost increase caused by the traditional setting of atomization layer bonding.

[0033] (2) The present invention uses a forming roller to prepare a soft film mold with lower cost and a larger quantity, which is used to further produce the required interference-dissolving prism structure film. The main materials of the mold are substrate film, coating liquid and UV transfer adhesive, which have low material cost. Moreover, after a large number of soft film molds are replicated by the forming roller, the frequency of forming roller remaking is low, which reduces the processing cost. At the same time, the acrylic UV transfer adhesive used in the mold to form the interference-dissolving prism structure layer by UV transfer contains methyl silicone resin release agent. This release agent improves the release effect of the mold, which is conducive to better UV transfer to prepare the interference-dissolving prism structure film, and improves the transfer effect and the service life of the mold.

[0034] It should be understood that all combinations of the foregoing concepts and the additional concepts described in more detail below can be considered part of the inventive subject matter of this disclosure, provided that such concepts do not contradict each other.

[0035] The foregoing and other aspects, embodiments, and features of the teachings of the present invention will be more fully understood from the following description in conjunction with the accompanying drawings. Other additional aspects of the invention, such as features and / or beneficial effects of exemplary embodiments, will become apparent from the following description or may be learned through practice of specific embodiments according to the teachings of the present invention. Attached Figure Description

[0036] The accompanying drawings are not drawn to scale. In the drawings, each identical or nearly identical component shown in the various figures may be denoted by the same reference numeral. For clarity, not every component is labeled in each figure. Embodiments of various aspects of the invention will now be described by way of example and with reference to the accompanying drawings, wherein:

[0037] Figure 1 This is a three-dimensional structural diagram of the base roller according to an embodiment of the present invention;

[0038] Figure 2 This is a three-dimensional structural diagram of the forming roller according to an embodiment of the present invention;

[0039] Figure 3 This is a three-dimensional structural diagram of the mold according to Embodiment 1 of the present invention;

[0040] Figure 4 This is a three-dimensional structural diagram of the mold according to Embodiment 2 of the present invention;

[0041] Figure 5 This is a three-dimensional structural diagram of the mold of Embodiment 3 of the present invention.

[0042] The meanings of the reference numerals in the figure are as follows:

[0043] 11-Base Roller 12-Metal Plating 13-Second Interference Resolving Prism Structure Layer 111-Substrate Film 121-First Prism Structure Array 122-Bottom Edge of First Prism Structure Array 123-First Free Curve 131-Frost Layer Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention. Unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by those skilled in the art.

[0045] The terms "first," "second," and similar words used in the specification and claims of this patent application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, unless the context clearly indicates otherwise, the singular forms of "an," "a," or "the," etc., do not indicate a quantity limitation, but rather indicate the presence of at least one. Terms such as "comprising" or "including" indicate that the element or object preceding "comprising" encompasses the features, wholes, steps, operations, elements, and / or components listed following "comprising" or "including," and do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or collections thereof. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0046] An embodiment of the present invention provides a mold for a deinterference prism structure film. The mold is a substrate film 111 with a first deinterference prism structure layer on its surface. The first deinterference prism structure layer includes a plurality of first prism structure arrays 121.

[0047] like Figures 3 to 5 As shown, the cross-section of each of the first prism structure arrays 121 along the array extension direction is triangular, and the first side of the triangle grows on the surface of the mold. The extension direction of the prism structure array 121 is parallel to the longitudinal direction of the substrate film 111, and is also the length direction of the first prism structure array 121. The line connecting the opposite vertices of the first side of the same first prism structure array 121 forms a continuous first free curve 123. The first free curve 123 is any one or a combination of two of the following: a simple harmonic wave curve perpendicular to the mold surface and a waveform curve with random and disordered changes. The simple harmonic wave curve is any one or a combination of two of the following: a sine wave curve and a cosine wave curve.

[0048] When the first free curve 123 of each first prism structure array 121 follows a sine wave change, a cosine wave change, or a combination of both perpendicular to the surface of the substrate film 111, the first disinterference prism structure layer has excellent disinterference effect and high brightness gain effect; when the first free curve 123 of each first prism structure array 121 follows a random and disordered change with up and down undulations perpendicular to the surface of the substrate film 111, the first disinterference prism structure layer has even better disinterference effect and high shielding effect.

[0049] The vertical distance between any point on the first free curve 123 and the first side of the triangle containing that point is equal to the height of the triangle, wherein the height of the triangle is 2μm-40μm, preferably 10μm-28μm. Because the first free curve 123 is a simple harmonic wave curve perpendicular to the surface of the substrate film 111 or a waveform curve with random and disordered up-and-down fluctuations, each first free curve 123 has multiple high points and multiple low points. The high points and low points on the same first free curve 123 are arranged alternately. The height difference between any adjacent high point and low point on the same first free curve 123 is 0.1μm-10μm, preferably 0.5μm-5μm. The length of the variation period of the first free curve 123 is 50μm-50000μm, preferably 150μm-800μm.

[0050] The length of the first side is any one of 3μm-80μm, preferably 16μm-28μm; the diagonal of the first side is the vertex angle of a triangle, wherein the vertex angle of the triangle is a sharp angle of 80°-110° or a rounded corner with a corresponding arc radius of 0.1μm-30μm, preferably a sharp angle of 88°-92° or a rounded corner with a corresponding arc radius of 0.1μm-10μm. The line connecting the intersection points of two adjacent first sides forms the base edge 122 of the first prism structure array 121 to which these two first sides belong, and the base edge 122 is shared by the two first prism structure arrays 121.

[0051] In the above embodiment, the mold is a substrate film 111 with the first interference-dissolving prism structure layer and the matte layer 131 respectively on both sides; the substrate film 111 is made of PET or PC, the thickness of the substrate film 111 is 150mm-300mm, and the angle between the first prism structure array 121 and the edge of the substrate film 111 is 0°-90°, preferably 0°-45°; the first interference-dissolving prism structure layer is transferred to one surface of the substrate film 111 by UV transfer adhesive with a refractive index of 1.45-1.68 through molding roller imprinting and then curing by UVA ultraviolet irradiation. The UV transfer adhesive is preferably acrylic resin with a refractive index of 1.46-1.5. At the same time, the UV transfer adhesive also contains 0.05%-2% release agent, which improves the release effect of the mold and is beneficial to better prepare the interference-dissolving prism structure film by further UV transfer. The matte layer 131 is formed by coating with a coating liquid and then UV curing. The coating liquid contains 0.02%-3% PMMA or PBMA particles, preferably 0.05%-0.5%. The particle size of the PMMA or PBMA particles is 1μm-15μm, preferably 2μm-7μm. The coating liquid also contains 0.05%-1% antistatic agent.

[0052] like Figure 2 As shown, this embodiment depicts a forming roller with a second interference-disinterference prism structure layer on its surface. The first interference-disinterference prism structure layer is formed by imprinting the second interference-disinterference prism structure layer onto the surface of the forming roller. Therefore, the second interference-disinterference prism structure layer and the first interference-disinterference prism structure layer are mirror images of each other. Furthermore, the second prism structure array included in the second interference-disinterference prism structure layer is also mirror image of the first prism structure array included in the first interference-disinterference prism structure layer. The second free curves formed by the two are also mirror images of each other, with the second free curve perpendicular to the tangent formed by its corresponding second prism structure array and the forming roller. Therefore, a high point on the first free curve is equal to a low point on the second free curve, and vice versa. However, regardless of whether it is the first or second free curve, the range of the height difference between adjacent high and low points on the same free curve is the same.

[0053] like Figure 1 As shown, the cylindrical base roller 11 used to prepare the forming roller is made of an alloying element, such as stainless steel mainly composed of alloying elements such as iron, carbon, chromium, and nickel, or aluminum alloy composed of alloying elements such as aluminum, zinc, manganese, and silicon. The base roller 11 is first subjected to surface activation treatment, then surface electroplating treatment to give it a metal coating 12, and finally the forming roller is obtained by machining the surface of the metal coating with forming cutting tools such as diamond tools.

[0054] This invention also provides a method for preparing a mold for a deinterference prism structure film, comprising the following steps:

[0055] Step 1: Take a cylindrical base roller 11 and place it horizontally on a precision engraving machine. After calibrating the runout values ​​on both sides of the base roller 11, use a rounded diamond tool with a radius of 2μm-10μm to perform surface leveling. Clean the surface of the base roller 11 with a cleaning agent, then rinse it with clean water. Activate the surface of the base roller 11 with dilute sulfuric acid to form a thin oxide layer, thus obtaining a surface-activated base roller. The oxide layer enhances the adhesion between the metal plating layer 12 and the base roller 11 during subsequent electroplating and improves the corrosion resistance and stability of the base roller 11 surface, thereby extending the service life of the forming roller.

[0056] The base roller 11 is mainly made of stainless steel composed of alloying elements such as iron, carbon, chromium, and nickel, or aluminum alloy composed of alloying elements such as aluminum, zinc, manganese, and silicon. The diameter of the base roller 11 is 200mm-320mm, and the length of the base roller 11 is 1000mm-2800mm.

[0057] Step 2: Place the surface-activated base roller horizontally in the electroplating tank as the cathode of the workpiece to be plated. Add an appropriate amount of electroplating solution to the electroplating tank as the anode. Apply direct current to electrodeposit the anode electroplating solution onto the surface of the surface-activated base roller, so that a uniform and firm metal coating 12 is formed on the surface of the surface-activated base roller. Cool at a constant temperature for 20-30 hours to obtain an electroplating roller blank with a single-sided thickness of 300μm-3000μm of metal coating 12.

[0058] The electroplating solution is heated to 50℃-70℃ and its concentration is 100g / L-300g / L. The electroplating solution is either a copper plating solution or a nickel plating solution, and the corresponding metal plating layer 12 is either a copper plating layer or a nickel plating layer. The thickness of the metal plating layer 12 on one side is preferably 1000μm-1500μm. The pH of the copper plating solution is 9-12, and the hardness of the copper plating layer is 200HB-300HB, preferably 220HB-260HB. The pH of the nickel plating solution is 3.5-5.0, and the hardness of the nickel plating layer is 550HB-580HB, preferably 565HB-575HB.

[0059] Step 3: Place the electroplating roller blank horizontally on a precision cutting machine. After calibrating the runout values ​​on both sides of the electroplating roller blank, use a leveling cutting tool to level the center of the side of the electroplating roller blank 2 to 5 times to obtain the shaped roller blank.

[0060] Among them, the leveling cutting tool is a rounded diamond tool with a corresponding arc radius R = 1.5μm-4μm, the cutting depth of the leveling process is 10μm-100μm, and the cutting depth of the final leveling process is 10μm-30μm.

[0061] Step 4: Next, adjust the longitudinal speed of the forming roll blank to 200-300 RPM, and use a forming cutting tool to perform forming cutting on the forming roll blank using a threaded cutting method to obtain a forming roll with a second interference prism structure layer. For the forming roll, its surface is first activated before electroplating, and finally forming cutting is performed. The surface activation treatment can form an oxide layer on the surface of the base roll, which enhances the adhesion between the metal plating layer and the base roll during the electroplating process, and at the same time improves the corrosion resistance and wear resistance of the base roll; while the metal plating layer has excellent ductility, which facilitates subsequent forming cutting processing and reduces energy consumption.

[0062] The forming cutting tool is supplied with a voltage of 0.5V-20V, which is continuously varying and is formed by one or a combination of simple harmonic wave variation and random disordered waveform variation. This results in a varying cutting depth perpendicular to the forming roller surface, causing the second free curve formed by the cutting to be a curve formed by one or a combination of simple harmonic wave curve perpendicular to the forming roller surface and random disordered waveform curve. The frequency of the voltage variation is 50Hz-20000Hz, preferably 100Hz-12000Hz. z; The forming cutting tool is a diamond tool with a sharp angle of 80°-110° or a radius of 0.1μm-30μm corresponding to a rounded corner, preferably a diamond tool with a sharp angle of 88°-92° or a radius of 0.1μm-10μm corresponding to a rounded corner; the horizontal cutting tilt angle of the cutting tool tip is 0°-90°, preferably 0°-45°; the transverse cutting spacing of the cutting tool tip is 10μm-70μm, preferably 20μm-25μm; the cutting depth of the cutting tool tip is 5μm-50μm, preferably 10μm-28μm.

[0063] Step 5: Take the substrate film 111. The substrate film 111 is made of PET or PC and has a thickness of 150mm-300mm. Use a precision coating machine to evenly coat the coating liquid on the lower surface of the substrate film 111 through a micro-groove roller and a doctor blade. Then, apply UVA curing to form a matte layer 131. After drying, the substrate film 111 with the matte layer is obtained.

[0064] The haze of the matte layer 131 ranges from 1% to 60%, preferably from 2% to 8%; the thickness of the matte layer is 1μm to 10μm, preferably from 2μm to 4μm; the coating liquid contains 0.02% to 3% PMMA or PBMA particles, preferably from 0.05% to 0.5%, the particle size of the PMMA or PBMA particles is 1μm to 15μm, preferably from 2μm to 7μm; the coating liquid also contains 0.05% to 1% antistatic agent, the main component of which is acrylate quaternary ammonium salt, used to reduce the static electricity effect during mold release when transferring during mold production.

[0065] Step Six: Place the forming roller on a precision coating machine, and use UV transfer adhesive to press the forming roller and cure it under UVA ultraviolet light, thereby transferring the second interference prism structure layer on the surface of the forming roller onto the upper surface of the substrate film 111 with the matte layer 131 cured, to obtain a mold with the first interference prism structure layer, and the structure of the second interference prism structure layer is a mirror image of the structure of the first interference prism structure layer.

[0066] The UV transfer adhesive is an acrylic resin with a refractive index of 1.45-1.68, preferably 1.46-1.50. The UV transfer adhesive contains 0.05%-2% of a release agent, which is a methyl silicone resin. Using a release agent to improve the mold's release effect facilitates better UV transfer of the mold to prepare a disinterference prism structure film.

[0067] The mold in this embodiment of the invention has a good transfer effect, which can completely mirror the interference-dispersion prism structure on its surface onto the interference-dispersion prism structure film. In addition, the first free curve formed by connecting all the vertices of the first prism structure array on the mold presents a simple harmonic wave perpendicular to the mold surface and / or random disordered changes with up and down fluctuations, thereby reducing the overall regularity of the prism structure. This makes the interference-dispersion prism structure film prepared by the mold improve the interference-dispersion effect, with a wider viewing angle and a higher shielding effect. It achieves improved product versatility and reduced cost while ensuring the brightness gain effect.

[0068] Example 1

[0069] This invention provides a mold for a deinterference prism structure film, wherein the cross-section of each of the first prism structure arrays 121 along the array extension direction is an isosceles triangle. For example... Figure 3 As shown, the first free curve 123 of the first prism structure array 121 is a sine wave curve perpendicular to the mold surface. The free curve 123 follows the sine wave variation, so that the first deinterference prism structure layer has excellent deinterference effect and high brightness gain effect.

[0070] In this embodiment of the invention, the height of the triangle is 15.8μm-22.2μm, the height difference between any adjacent high and low points on the same first free curve 123 is 6.4μm, and the variation period length of the first free curve 123 is 493.06μm. The length of the first side is any one of 35μm-41μm, and the vertex angle α of the triangle is a 90° apex angle.

[0071] In this embodiment of the invention, the mold is made of PET with a thickness of 250 mm, and the angle between the edge of the first prism structure array 121 and the substrate film 111 is 0°. The UV transfer adhesive used in the first interference prism structure layer is an acrylic resin with a refractive index of 1.47, which contains 0.05% methyl silicone resin release agent.

[0072] In this embodiment of the invention, the cylindrical base roller used to prepare the forming roller is made of stainless steel, which mainly contains alloying elements such as iron, carbon, chromium, and nickel.

[0073] This invention also provides a method for preparing a mold for a deinterference prism structure film, comprising the following steps:

[0074] Step 1: Take a cylindrical base roller 11 with a diameter of 300mm and a length of 2100mm. Place the base roller 11 horizontally on a precision engraving machine. After calibrating the runout values ​​on both sides of the base roller 11, perform surface leveling using a rounded diamond tool with a corresponding arc radius of 6μm. Clean the surface of the base roller 11 with a cleaning agent, then rinse it with clean water. Activate the surface of the base roller 11 with dilute sulfuric acid to form a thin oxide layer on the surface of the base roller 11, thus obtaining a surface-activated base roller.

[0075] Step 2: Place the surface-activated base roller in an electroplating tank and add an appropriate amount of copper plating solution with a temperature of 55℃, a concentration of 180g / L, and a pH of 9.5. Apply direct current to form a copper plating layer with a single-sided thickness of 1500μm and a hardness of 250HB-260HB on the surface of the surface-activated base roller. Cool at a constant temperature for 25 hours to obtain an electroplated roller blank with a copper plating layer.

[0076] Step 3: Place the electroplating roller blank horizontally on a precision cutting machine. After calibrating the runout values ​​on both sides of the electroplating roller blank, use a rounded diamond tool with a radius of R = 2.5 μm to level the side of the electroplating roller blank three times. The cutting depths of the three leveling processes are 70 μm, 50 μm and 20 μm, respectively, to obtain the shaped roller blank.

[0077] Step 4: Adjust the longitudinal speed of the forming roller blank to 250 RPM, and use a forming cutting tool to perform forming cutting on the forming roller blank using a straight thread cutting method to obtain a forming roller with a second interference prism structure layer.

[0078] The forming cutting tool is equipped with a 12V voltage applied to its tip. The voltage is continuously varying in a sinusoidal pattern, resulting in a varying cutting depth perpendicular to the forming roller surface. This causes the second free curve formed by the cutting to be a sinusoidal curve perpendicular to the forming roller surface. The voltage variation frequency is 8000Hz. The forming cutting tool is a diamond tool with a 90° sharpness. The horizontal cutting tilt angle of the forming cutting tool tip is 0°. The transverse cutting spacing of the forming cutting tool tip is 38μm. The cutting depth of the forming cutting tool tip is 23μm, and the cutting cycle length is 493.06μm.

[0079] Step 5: Take substrate film 111. The substrate film 111 is made of PET and has a thickness of 250mm. Use a precision coating machine to evenly coat the coating liquid on the lower surface of the substrate film through a micro-groove roller and a doctor blade. Then, use UVA ultraviolet light to cure it to form a matte layer. After drying, a substrate film with a matte layer is obtained.

[0080] The haze of the matte layer ranges from 4%, and the thickness of the matte layer is 1μm-3μm. The rotation speed of the micro-grooved roller is 53RPM, corresponding to a substrate film running speed of 15m / min. The UVA ultraviolet curing energy is 1000mJ. The coating liquid contains 0.05%-0.5% PMMA or PBMA particles and 0.05% antistatic agent. The particle size of the PMMA or PBMA particles is 2μm-7μm. The main component of the antistatic agent is acrylate quaternary ammonium salt, which is used to reduce the static electricity effect during mold production transfer.

[0081] Step Six: Place the forming roller on a precision coating machine, and transfer the second interference prism structure layer on the surface of the forming roller onto the upper surface of the substrate film with a cured matte layer by pressing acrylic resin with a refractive index of 1.47 onto the forming roller and irradiating it with UVA ultraviolet light, thus obtaining a mold with the first interference prism structure layer.

[0082] The acrylic resin has a viscosity of 225 Cps at 25°C and contains 0.05% methyl silicone resin release agent. The release agent enhances the mold release effect, which is beneficial for further UV transfer printing to prepare the interference-dissolving prism structure film. The UVA pre-curing and curing energies are 120 mJ and 1200 mJ, respectively.

[0083] The mold obtained by further UV transfer using the forming roller prepared above has a first free curve that follows a sine wave change. This allows the deinterference prism structure film prepared by the mold to maintain a certain regularity of the prism structure while exhibiting specific variability, thereby achieving excellent deinterference effect and high brightness gain effect of the deinterference prism structure film.

[0084] Example 2

[0085] This invention provides a mold for a deinterference prism structure film, wherein the cross-section of each of the first prism structure arrays 121 along the array extension direction is an isosceles triangle. For example... Figure 4As shown, the first free curve 123 of the prism structure array 121 is a waveform curve that fluctuates randomly and disorderly vertically to the mold surface. The first free curve 123 follows the random and disorderly fluctuations vertically to the mold surface, which greatly reduces the regularity of the prism structure array 121, so that the interference-disrupting prism structure layer 13 has a better interference-disrupting effect and a high shielding gain effect.

[0086] In this embodiment of the invention, the height of the triangle is 10.65μm-13.35μm, and the height difference between any adjacent high and low points on the same free curve 123 is 0.5μm-1.7μm. The variation period length of the free curve 123 is 237.37μm. The length of the first side is any one of 22μm-26μm, and the vertex angle β of the triangle is an 89° sharp angle.

[0087] In this embodiment of the invention, the mold is made of PET with a thickness of 250 mm. The angle between the edge of the prism structure array 121 and the substrate film 111 is 15°. The first interference prism structure layer is made of acrylic resin with a refractive index of 1.47, which contains 1% methyl silicone resin release agent.

[0088] In this embodiment of the invention, the cylindrical base roller used to prepare the forming roller is made of stainless steel, which mainly contains alloying elements such as iron, carbon, chromium, and nickel.

[0089] This invention also provides a method for preparing a mold for a deinterference prism structure film, comprising the following steps:

[0090] Step 1: Take a cylindrical base roller with a diameter of 301mm and a length of 2100mm. The rest of the operation is the same as Step 1 in Example 1.

[0091] Step 2: Place the surface-activated base roller in an electroplating tank and add an appropriate amount of copper plating solution with a temperature of 55℃, a concentration of 180g / L, and a pH of 9.5. Apply direct current to form a copper plating layer with a single-sided thickness of 1400μm and a hardness of 245HB-255HB on the surface of the surface-activated base roller. Cool at a constant temperature for 25 hours to obtain an electroplated roller blank with a copper plating layer.

[0092] Step 3: The operation is the same as step 3 in Example 1.

[0093] Step 4: Adjust the longitudinal speed of the forming roller blank to 270 RPM, and use a forming cutting tool to perform forming cutting on the forming roller blank using a helical thread cutting method to obtain a forming roller with a second interference prism structure layer.

[0094] The forming cutting tool is equipped with a 1.5V voltage applied to its tip. This voltage is continuously varying and exhibits random, disordered fluctuations, resulting in a varying cutting depth perpendicular to the forming roller surface. Consequently, the second free curve formed after cutting is a waveform curve with random, disordered fluctuations perpendicular to the forming roller surface. The frequency of the voltage variation is 18000Hz. The forming cutting tool is a diamond tool with an 89° sharpness. The horizontal cutting inclination angle of the cutting tool tip is 15°. The transverse cutting spacing of the two cutting tools is 23μm and 25μm, respectively. The cutting depth of the cutting tool tip is 15μm, and the cutting cycle length is 237.37μm.

[0095] Step 5: The operation and process parameters are exactly the same as those in Step 5 of Example 1.

[0096] Step Six: Except for adding 1% methyl silicone resin release agent to the acrylic resin, the other operations and working parameters are exactly the same as Step Six of Example 1.

[0097] The first free curves 123 of the deinterference prism structure film obtained by further UV transfer using the mold prepared above all follow the random and disordered changes of up and down undulations perpendicular to the surface of the forming roller, which greatly reduces the regularity of the prism structure, thereby achieving a better deinterference effect and a higher shielding gain effect for the deinterference prism structure film prepared by it.

[0098] Example 3

[0099] This invention provides a mold for a deinterference prism structure film, wherein the cross-section of each of the first prism structure arrays 121 along the array extension direction is an isosceles triangle. The first free curve 123 of the first prism structure array 121 is a sine wave curve perpendicular to the mold surface. The first free curve 123 follows a sine wave variation, which makes the first deinterference prism structure layer have excellent deinterference effect and high brightness gain effect.

[0100] In this embodiment of the invention, the height of the triangle is 22.82μm-27.18μm, and the height difference between any adjacent high and low points on the same first free curve is 6.4μm. The variation period length of the first free curve 123 is 395.76μm. The length of the first side is any one of 48μm-52μm, such as... Figure 5 As shown, the vertex angle γ of the triangle is a rounded corner with a radius of 1.5 corresponding to the arc.

[0101] In this embodiment of the invention, the mold is made of PET with a thickness of 250 mm, and the angle between the edge of the first prism structure array 121 and the substrate film 111 is 5°. The first interference prism structure layer is made of acrylic resin with a refractive index of 1.47, and the acrylic resin also contains 0.07% methyl silicone resin release agent.

[0102] In this embodiment of the invention, the cylindrical base roller 111 used to prepare the forming roller is made of stainless steel, which mainly contains alloying elements such as iron, carbon, chromium, and nickel.

[0103] This invention also provides a method for preparing a mold for a deinterference prism structure film, comprising the following steps:

[0104] Step 1: The operation and process parameters are the same as in Example 2.

[0105] Step 2: Place the surface-activated base roller in an electroplating tank and add an appropriate amount of copper plating solution with a temperature of 55℃, a concentration of 180g / L, and a pH of 9.5. Apply direct current to form a copper plating layer with a single-sided thickness of 1500μm and a hardness of 240HB-250HB on the surface of the surface-activated base roller. Cool at a constant temperature for 25 hours to obtain an electroplated roller blank with a copper plating layer.

[0106] Step 3: The operation and process parameters are the same as those in Step 3 of Example 2.

[0107] Step 4: Adjust the longitudinal speed of the forming roller blank to 250 RPM, and use a forming cutting tool to perform forming cutting on the forming roller blank using a slanted thread cutting method to obtain a forming roller with a deinterference prism structure, which is the forming roller.

[0108] The forming cutting tool is equipped with an 8V voltage applied to its tip. This voltage is continuously variable and exhibits a sinusoidal wave pattern, resulting in a varying cutting depth perpendicular to the forming roller surface. Consequently, the second free curve formed after cutting is a sinusoidal curve perpendicular to the forming roller surface. The voltage variation frequency is 10000Hz. The forming cutting tool is a rounded diamond tool with a corresponding arc radius of 1.5μm. The horizontal cutting tilt angle of the forming cutting tool tip is 5°, the transverse cutting spacing of the forming cutting tool tip is 50μm, the cutting depth of the forming cutting tool tip is 28μm, and the cutting cycle length is 395.76μm.

[0109] Step 5: The operation and process parameters are the same as those in Step 5 of Example 2.

[0110] Step Six: Except for adding 0.07% methyl silicone resin release agent to the acrylic resin, the other operations and working parameters are exactly the same as Step Six of Example 2.

[0111] The mold obtained by further UV transfer using the forming roller prepared above has a first free curve 123 that follows a sine wave variation. At the same time, the apex of the prism structure is a rounded corner with a corresponding arc radius R = 1.5 μm, which further widens the viewing angle and scratch resistance. It also maintains a certain regularity of the prism structure while exhibiting specific variability, thereby achieving excellent interference resolution and wide viewing angle effect of the prism structure film.

[0112] Experimental Example

[0113] The interference-dissipating prism structure films prepared in Examples 1-3 above were further prepared by UV transfer printing, and each film was tested. The interference-dissipating prism structure films were prepared using acrylic resin with a refractive index of 1.53, and the transfer substrate was PET with a thickness of 125 μm. The performance of the prepared interference-dissipating prism structure films was compared with that of existing prism structure sheet films. Brightness, viewing angle, interference dissipation angle, and shielding performance were all tested using a TOPCONBM-7AS 55-inch display screen. The comparison results are shown in Table 1.

[0114] Table 1 Comparison of optical film performance results

[0115]

[0116] The performance test results of the aforementioned optical films show that the interference-resolving prism structure film prepared by mold transfer using the interference-resolving prism structure film in this embodiment of the invention has excellent interference-resolving effect, improves cutting utilization, and reduces production costs. Furthermore, when the free curve of the same prism structure array follows a sinusoidal wave perpendicular to the mold surface, the transferred optical film exhibits excellent interference-resolving effect and high brightness gain. When the free curve of the same prism structure array follows a random, disordered variation perpendicular to the mold surface, the transferred optical film exhibits even better interference-resolving effect and high shielding effect. When the free curve of the same prism structure array follows a sinusoidal wave variation and the prism apex corner is rounded, the transferred optical film exhibits excellent interference-resolving effect and wide viewing angle, further enhancing the product's versatility.

[0117] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A mold for resolving interference prism structure films, characterized in that, The mold is a substrate film with a first interference prism structure layer on its surface, and the first interference prism structure layer includes a plurality of first prism structure arrays. Each of the first prism structure arrays has a triangular cross-section along the array extension direction, and the first side of the triangle grows on the surface of the mold. The lines connecting the opposite vertices of the first side belonging to the same first prism structure array form a continuous first free curve. The first free curve is any one or a combination of two of the following: a simple harmonic wave curve perpendicular to the surface of the mold and a waveform curve with random and disordered changes. The method for preparing a mold for a deinterference prism structure film includes the following steps: Step 1: Take a cylindrical base roller, level its surface and clean it. Then, activate the surface of the base roller to obtain a surface-activated base roller. Step 2: Electroplating the surface-activated base roller to obtain an electroplated roller blank with a metal coating; Step 3: The electroplating roller blank is leveled and cut to obtain a shaped roller blank; Step 4: The rotating forming roller blank is formed by using a forming cutting tool in a threaded cutting manner. After the forming cutting is completed, a forming roller is obtained. The surface of the forming roller has a second interference prism structure layer that is mirror-symmetrical to the first interference prism structure layer. The cutting tool tip is subjected to a voltage of 0.5V-20V. The voltage is continuously changing and is formed by any one or a combination of simple harmonic wave changes and random disordered waveform changes. The frequency of the voltage change is 50Hz-20000Hz. Step 5: Take a substrate film, apply a coating liquid to one of the surfaces of the substrate film and let it cure to form a matte layer. The coating liquid contains 0.02%-3% PMMA or PBMA particles with a particle size of 1μm-15μm. Step 6: The second interference-dissipating prism structure layer on the surface of the forming roller is imprinted onto the other surface of the substrate film with the cured matte layer using UV transfer adhesive, thereby obtaining the mold with the first interference-dissipating prism structure layer, wherein the UV transfer adhesive contains 0.05%-2% release agent.

2. The mold for disinterference prism structure membrane according to claim 1, characterized in that, The mold is a substrate film with the first interference prism structure layer and the frosted layer respectively on both sides.

3. The mold for disinterference prism structure membrane according to claim 1 or 2, characterized in that, The simple harmonic wave curve is any one or a combination of two of the sine wave curve and the cosine wave curve.

4. The mold for resolving interference prism structure films according to claim 1, characterized in that, The activation treatment of the surface of the base roller in step one includes: The surface of the base roller is activated by dilute sulfuric acid to form an oxide layer on the surface of the base roller.

5. The mold for resolving interference prism structure films according to claim 1, characterized in that, Step two, which involves electroplating the surface-activated base roller, includes: The surface-activated base roller is placed in an electroplating tank containing an electroplating solution at a temperature of 50°C-70°C and a concentration of 100g / L-300g / L. A direct current is applied to form a coating on the surface of the surface-activated base roller. The roller is then cooled at a constant temperature for 20-30 hours to obtain an electroplated roller blank with a single-sided metal coating thickness of 300μm-3000μm. The electroplating solution is a copper plating solution or a nickel plating solution. The pH of the copper plating solution is 9-12, and the hardness of the copper plating layer is 200HB-300HB. The pH of the nickel plating solution is 3.5-5.0, and the hardness of the nickel plating layer is 550HB-580HB.

6. The mold for resolving interference prism structure films according to claim 1, characterized in that, The coating liquid also contains 0.05%-1% of an antistatic agent.

7. The mold for resolving interference prism structure films according to claim 1, characterized in that, Step three, which involves leveling and cutting the electroplating roller blank, includes: The electroplating roller blank is placed on a precision cutting machine and leveled and cut 2 to 5 times with a leveling cutting tool. The cutting depth of each leveling cut is 10μm-100μm, and the cutting depth of the last leveling cut is 10μm-30μm.

8. The mold for resolving interference prism structure films according to claim 1, characterized in that, Step four, which involves using a forming cutting tool to perform forming cutting on the rotating forming roll blank using a threaded cutting method, includes: The forming roll blank is placed on a precision cutting machine, and the longitudinal speed of the forming roll blank is adjusted to 200rpm-300rpm. The forming cutting tool is used to perform straight thread or oblique thread cutting on the forming roll blank. After cutting, a forming roll with the second interference prism structure layer is obtained. The cutting angle of the cutting head in the horizontal direction of the forming cutting tool is 0°-90°, the transverse cutting distance of the cutting head is 10μm-70μm, and the cutting depth of the cutting head is 5μm-50μm.

9. The mold for resolving interference prism structure films according to any one of claims 4-8, characterized in that, The simple harmonic wave variation is any one or a combination of two of the sine wave variation and the cosine wave variation.

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