Design and fabrication of micro optical film by ultraviolet roll imprinting

With increasing demand for large-scale functional optical films with microstructure in the field of flat panel displays, a technology capable of fabricating large-scale polymeric micro-patterns has received much attention. To fabricate large-area micro-optical films, we designed and constructed an ultraviolet roll imprinting system consisting of a roll stamp, a material dispensing unit, a pair of flattening rollers, a contact roller, and a releasing roller. Two methods for fabricating roll stamps were considered: direct machining of the roll base and wrapping a flat stamp around the roll base. As practical examples of the roll imprinting process, we designed and fabricated a lenticular lens array, a pyramidal pattern, and a microlens array, and measured and analyzed their geometrical and optical properties. Our results suggest that the proposed UV roll imprinting process is a feasible method for mass producing large-scale functional optical films.