• Transactions of Materials Processing
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• v.21 no.2
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• pp.119-125
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• 2012

The present study addresses a direct patterning process on a plastic film using ultrasonic vibration energy. In this process, a tool horn containing micro-patterns is attached to an ultrasonic power supply, and is used with ultrasonic vibration to replicate micro-patterns on the surface of a plastic film. To improve the replication characteristics of the micro-patterns, the effect of the die shape of the ultrasonic patterning process was investigated with respect to the flow direction control. Finite element analyses were performed to predict the flow characteristics of the polymer with variations in die design parameters. Experiments were conducted using the optimally-designed die, from which it was possible to attain much improved pattern replication.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.79-82
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• 2005

Fresnel lens has number of applications in the optical systems because of its advantages. It is nearly flat lens that has small weight. It is conventionally used in lighthouse beacons, condensing unit of overhead projector and etc. Recently, demands of small size optical systems such as display units, information storage systems, optical detecting units had increased. Conventional manufacturing process of high quality Fresnel lens is direct machining. But it is not suitable for mass production because of high cost and long cycle time. Replication process is more suitable for mass production. But the Fresnel lens has number of sharp blade shape prism. In the replication process, this blade shape causes defects that can affect optical efficiency. In this study, replication process of blade shape pattern that has maximum height of $280{\mu}m$, aspect ratio 1.4 for Fresnel lens application.

• Journal of the Optical Society of Korea
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• v.19 no.2
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• pp.159-164
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• 2015

In the injection-molded light guide plate the replication quality, i.e. the reproduction accuracy, of micro-patterns should be high and uniform over the entire surface area. However technical difficulty in meeting the necessary replication quality arises as the plate size becomes large for TV applications. We propose a simulation technique to optimize the distribution of micro-patterns on a 55-inch injection molded light guide plate considering non-ideal replication quality of micro-patterns. The luminance uniformity could be improved by more than 16% by optimizing the pattern distribution in spite of the same replication quality.

• Transactions of Materials Processing
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• v.21 no.2
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• pp.126-130
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• 2012

Accurate optical texturing of light guide plate over the entire surface area is an important technical issue in LCD TV industry. Injection molding process has the potential to produce large light guide plates having highly efficient optical textures such as micro-prism array. This study is focused on the effect of the degree of replication of the micro texture of the 40" injection molded light guide plates on the overall optical performance of the display panel. Measured replication ratios of the micro-textures formed with three different types of injection molding process were considered in the modeling of prismatic micro segment array. Optical simulation was conducted and results were discussed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.901-902
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• 2009

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2008.06a
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• pp.579-580
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• 2008

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.3
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• pp.291-298
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• 2014

This study uses two numerical approaches to analyze the filling behavior of micro patterns on micro-injection molding for V-grooves pattern which cannot be simulated with conventional CAE packages. The parametric studies have been performed to examine the fidelity of micro patterns with respect to temperature, pressure, inlet velocity and pattern location on the mold according to the boundary condition from the macro pressure and velocity data which can be obtained by conventional CAE packages. Through these numerical approaches, the filling behavior of polymer melt in micro patterns can be understood, the quality of replication can be predicted, and the V-groove pattern can be shaped uniformly during the process of injection molding.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.11-16
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• 2011

Recently, according to the rapid development of display, many display applications, such as, cellular phone, navigation, monitor and LCD TV have been changed from CRT type to LCD type. BLU(Back Light Unit) is one of main parts in LCD unit and generally, it consists of a light source, a reflective sheet, a LGP(Light Guide Plate), a diffuser sheet, and two prism sheets. The most important component of BLU is a light guide plate, which diffuses the input light to the TFT-LCD module uniformly. The LGP is usually made by injection molding process, and it has numerous optical micro patterns on the surface. In the present study the micro-patterned stamper which has cylindrical shape was fabricated by using the UV-LiGA process. And the replication characteristics have been compared among three different kinds of injection molding process; general injection molding, injection/compression molding and RHCM(Rapid Heating and Cooling Molding). Average replication ratios of CIM and ICM were 19.1% and 64.6%, respectively. On the other hand, the average replication ratio of RHCM process showed the higher value of 98.4% among these. It show that maintaining the mold surface above $T_g$ could increase the replication ratio of micro patterns substantially.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.533-534
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• 2006

Micro pyramid pattern and its array are designed to enhance the brightness and its uniformity of LGP which is one of key parts in LCD. The designed micro pyramid patterns are fabricated on a Si-wafer first through MEMS process and then a Ni-stamper is electro-plated from the Si pattern master. Adopting the fabricated Ni-stamper, LGPs are injection molded at different mold temperatures and the fidelity of the pattern replication is estimated for each molding conditions and pattern locations. The replicated patterns are found to have some defect such as local short shot or micro weld line which are believed to have negative effect on the performance of the LGP.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.151-152
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• 2010