Development of a Multilayered Optical Diffusion Sheet Using Microcellular Foaming Technology

Abstract

The superior optical performance of a sheet developed using microcellular foaming technology is demonstrated through the development and commercialization of a reflector. In this study, the cell morphology characteristics of reflectivity, transmittance, and haze were analyzed to develop diffusion sheet. A basic concept of a multilayered diffusion sheet was derived using axiomatic design, and the design was tested and validated using a microcellular foaming batch process. Diffusion sheet transmittance and haze values were compared with commercialized products. The results show the multilayered diffusion sheet manufactured using a microcellular foaming process increased transmittance by 40% compared to that of existing products.

Changes in the Reflectivity and Color Characteristics of Microcellular Foamed Plastics

“…The refractive index is also related to the reflection and transmission of light. By altering the cell morphology, the refractive index can be changed, changing the refraction of the light in the material [4][5][6] .…”

Effective Optical Diffuser Based on Interfacial Hydrogen-Bonding Polymer Complexation

“…1−6 An optical diffuser realizes photo management through positive utilization of light scattering. Microspheres (solid, core−shell or hollow), 7−14 nanofibers (cellulose nanofiber, cellulose nanocrystal, or devirite), 15,16 microvoids, 17 wrinkles, 18 micropyramids, and microlenses 19−21 have been introduced on the surface or in the bulk matrix as scattering units to produce effective optical diffusion.…”

“…The microcellular foaming technology which produces microvoids in the matrix is demonstrated for optical diffusion. 17 Microdroplets are formed during hot blending of PMMA and PET owning to the phase separation of two incompatible compounds based on the mechanism of nucleation and growth, and when cooling, the microdroplets will become solid spheres that can effectively scatter light. 9 Liquid crystal structures or polymer-dispersed liquid crystal microdroplets can manipulate light scattering with different stimuli, which have been exploited for optical diffusion.…”

Optical diffusers with enhanced properties based on novel polysiloxane@CeO2@PMMA fillers

“…However, these materials have the disadvantages of high thermal sensitivity, poor UV-shielding effect and low NIR absorption, which limits the use of diffusers in applications such as monitors, military projectors, and night vision LCDs. [8][9][10] The other relied on adding transparent micro beads or llers inside the plates to scatter light, which is called volumetric diffusers. 7 One of them is mainly dependent on the microstructures of the surface layer, such as microlenses, pyramids, rough surfaces and other microstructures, and is called surface-relief diffusers.…”

“…7 One of them is mainly dependent on the microstructures of the surface layer, such as microlenses, pyramids, rough surfaces and other microstructures, and is called surface-relief diffusers. [8][9][10] The other relied on adding transparent micro beads or llers inside the plates to scatter light, which is called volumetric diffusers. 11 Conventional diffusing plates and lms oen consist of coating mixed solutions on a substrate, which contains glass, polystyrene beads, poly(methyl methacrylate) (PMMA), CaCO 3 , SiO 2 , and core-shell microsphere.…”