Double-sided microstructured diffusion film

Abstract

The utility model discloses double -sided microstructure diffusion membrane, including base material, the upper and lower surface of base material is equipped with haze microstructure layer and antireflection microstructure layer respectively, the haze microstructure layer is composed of several particle array paving, and the diameter of particle is 5um~20um, and the thickness of haze microstructure layer is 15um~30um, the antireflection microstructure layer includes three kinds of prism array forming, and its section is sawtooth shape, and the vertex angle of three kinds of prism is 50, 75 and 100 respectively, and the thickness of antireflection microstructure layer is 25um~45um, and the adjacent prism interval is 45um~90um, the utility model discloses using adopts double -sided microstructure, realizes high haze and high light transmittance through microprism structure simultaneously, that is, the light transmittance can reach above 80%, and simultaneously the haze can reach above 80%, thereby under the premise of effectively shielding lamp pearl, has higher light transmittance, makes the light efficiency and luminous flux of lamp more higher.

Description

Technical Field

[0001] This invention belongs to the field of diffusion membrane technology, specifically relating to a double-sided microstructure diffusion membrane. Background Technology

[0002] Diffuser films control light by utilizing specific geometric shapes and the different refractive indices of polymer materials. They are often used to reduce the eye strain of displayed images, making the user feel more comfortable. Currently, most LED panel lights on the market use traditional diffuser films, which rely primarily on high haze (typically around 80%) to achieve the desired LED chip shielding effect. However, high haze is accompanied by low light transmittance (generally around 50%), significantly limiting their application in lighting fixtures requiring high luminous efficacy and high lumens. To achieve the required brightness, lighting manufacturers often need to increase the number of LED chips or increase power, which not only increases costs but also leads to higher overall energy consumption and poor economic efficiency. Although the display industry has experimented with single-sided microstructure diffuser films, their function is mainly limited to diffusion effects, and they usually require multiple layers of film, resulting in high costs and failing to provide lighting manufacturers with a feasible solution that balances high light transmittance and high haze. Summary of the Invention

[0003] Based on the shortcomings of traditional diffusion films, the inventors proposed a double-sided microstructure diffusion film that achieves both high haze and high transmittance through a haze microstructure layer and an antireflection microstructure layer, breaking the deadlock that traditional diffusion films cannot achieve high transmittance at high haze.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A double-sided microstructure diffusion film includes a substrate. The upper and lower surfaces of the substrate are respectively provided with a haze microstructure layer and an antireflection microstructure layer. The haze microstructure layer is composed of several particle arrays with a particle diameter of 5 μm to 20 μm and a thickness of 15 μm to 30 μm. The antireflection microstructure layer includes three types of prisms arranged in a serrated cross-section. The apex angles of the three types of prisms are 50°, 75°, and 100°, respectively. The thickness of the antireflection microstructure layer is 25 μm to 45 μm, and the spacing between adjacent prisms is 45 μm to 90 μm.

[0005] Furthermore, the substrate is made of optical-grade PET film or PC film.

[0006] Furthermore, the haze microstructure layer and the antireflection microstructure layer are fixed to the upper and lower surfaces of the substrate by UV photocuring adhesive.

[0007] Furthermore, the particle array consists of irregular and / or spherical particles.

[0008] Furthermore, three types of prisms with apex angles of 50°, 75° and 100° are grouped together, and several groups of the three types of prisms are arranged in a pattern.

[0009] The above technical solution can achieve the following beneficial effects: This invention utilizes a double-sided microstructure layer, achieving both high haze and high light transmittance simultaneously through a haze microstructure layer and an anti-reflection microstructure layer. Specifically, the light transmittance can reach over 80%, while the haze can also reach over 80%. This effectively shields the LED chips while maintaining higher light transmittance, resulting in higher luminous efficacy and luminous flux for the lamp. It breaks the deadlock of traditional diffusion films failing to achieve high light transmittance in high haze conditions. Lighting manufacturers no longer need to increase the number of LED chips to improve the luminous efficacy and lumens of LED lamps, saving resources and being environmentally friendly. Attached Figure Description

[0010] Figure 1 This is a diagram of the diffusion membrane structure.

[0011] Figure 2 It is a cross-sectional view.

[0012] In the figure: 1. Substrate; 2. Haze microstructure layer; 3. Antireflection microstructure layer. Detailed Implementation

[0013] The present invention will be further described below with reference to the accompanying drawings: like Figure 1 and 2 As shown, a double-sided microstructure diffusion film includes a substrate 1. The upper surface of the substrate is a haze microstructure layer 2, and the lower surface is an antireflective microstructure layer 3. The haze microstructure layer is composed of several particle arrays. The diameters of the particles do not need to be exactly the same, and the particle diameters are between 5 μm and 20 μm. The thickness of the haze microstructure layer is 15 μm to 30 μm. The particle array consists of irregular or circular particles. The antireflective microstructure layer includes three types of prisms arranged in a serrated cross-section. The apex angles of the three prisms are 50°, 75°, and 100°, respectively. The thickness of the antireflective microstructure layer is 25 μm to 45 μm, and the spacing between adjacent prisms is 45 μm to 90 μm. The substrate is made of optical-grade PET film or PC film, which has excellent resistance to yellowing and flame retardancy. The haze microstructure layer and the antireflective microstructure layer are fixed to the upper and lower surfaces of the substrate by UV curing adhesive. Three types of prisms with apex angles of 50°, 75° and 100° are grouped together. The order of the prisms in a group can be set arbitrarily, and several groups of the three types of prisms are arranged to form a shape.

[0014] Traditional diffusion films exhibit an inverse relationship between haze and light transmittance; higher haze corresponds to lower light transmittance. However, this application, through microstructure design, separates haze control from light transmittance. Furthermore, the microstructures on both sides can be fine-tuned according to customer needs, creating diffusion films with different combinations of haze and light transmittance. This helps LED panel lights achieve excellent diffusion while maintaining over 80% haze and over 80% light transmittance. This effectively shields the LED chips while ensuring high luminous efficacy and high lumen output, significantly reducing LED chip costs for lighting manufacturers and making the lights more energy-efficient and environmentally friendly.

[0015] The method for preparing the diffusion membrane is as follows: First, the haze microstructure layer and the antireflection microstructure layer were designed; the specific morphology is shown in [reference needed]. Figure 1 The product's haze microstructure layer consists of an array of irregular spherical particles with diameters ranging from 5µm to 20µm and a thickness of 15µm to 30µm. The antireflective microstructure layer is composed of a combination of prisms with apex angles of 50°, 75°, and 100°, with a thickness of 25µm to 45µm and a prism spacing of 45µm to 90µm. Simulations using Lighttools software confirmed that this combination of structures can achieve 80% haze while maintaining 80% light transmittance.

[0016] The designed haze microstructure layer is seamlessly engraved on the roller mold. In a Class 10,000 cleanroom, a special UV curing adhesive is evenly coated onto the optical-grade PET film using a UV coating device. After the mold is rolled, the microstructure is printed onto the optical-grade PET film by UV curing, forming a semi-finished product with a haze microstructure on one side.

[0017] The designed anti-reflective microstructure layer is then engraved onto the roller mold. In a Class 10,000 cleanroom, a special UV curing adhesive is evenly applied to the other side of the semi-finished product that already has a hazy microstructure using a UV coating device. This forms a finished roll material with a double-sided microstructure.

[0018] We cut the finished roll material into different sizes and shapes according to customer needs to meet the requirements of different lighting fixtures.

[0019] The above descriptions are all preferred embodiments of this utility model. For those skilled in the art, any modifications to this utility model in various equivalent forms without departing from the principle of this utility model shall fall within the protection scope of the appended claims.

Claims

1. A double-sided microstructured diffusion film, characterized in that: The substrate includes a haze microstructure layer and an antireflection microstructure layer on its upper and lower surfaces, respectively. The haze microstructure layer is composed of an array of particles with a diameter of 5 μm to 20 μm and a thickness of 15 μm to 30 μm. The antireflection microstructure layer includes three types of prisms arranged in a serrated cross-section. The apex angles of the three prisms are 50°, 75°, and 100°, respectively. The thickness of the antireflection microstructure layer is 25 μm to 45 μm, and the spacing between adjacent prisms is 45 μm to 90 μm.

2. The double-sided microstructure diffusion film according to claim 1, characterized in that: The substrate is made of optical grade PET film or PC film.

3. The double-sided microstructure diffusion film according to claim 1, characterized in that: The haze microstructure layer and the antireflection microstructure layer are fixed to the upper and lower surfaces of the substrate by UV photocuring adhesive.

4. The double-sided microstructure diffusion film according to claim 1, characterized in that: The particle array consists of irregular and / or spherical particles.

5. The double-sided microstructure diffusion film according to claim 1, characterized in that: Three types of prisms with apex angles of 50°, 75° and 100° are grouped together, and several groups of the three types of prisms are arranged in a pattern.

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