Diffuser plate and method for producing diffuser plate

• US 10,451,778 B2
• Filed: 09/29/2015
• Issued: 10/22/2019
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: Kuraray Company Limited
• Original Assignee: Kuraray Company Limited
• Inventors: Uchida, Atsushi, Hirai, Masashi, Karai, Masaru
• Primary Examiner(s): Collins, Darryl J
• Assistant Examiner(s): Sumlar, Journey F
• Application Number:
  US15/515,164
• Publication Number:
  US 20170235028A1
• Time in Patent Office: 1,484 Days
• CPC Class Codes: G02B 27/48 Laser speckle optics
• CPC Class Codes: G02B 3/00 Simple or compound lenses
• CPC Class Codes: G02B 3/0031 Replication or moulding, e.g. hot embossing, UV-casting, injection moulding
• CPC Class Codes: G02B 3/0043 Inhomogeneous or irregular arrays, e.g. varying shape, size, height
• CPC Class Codes: G02B 5/02 Diffusing elements; Afocal elements
• CPC Class Codes: G02B 5/0221 the surface having an irregular structure G02B5/0226 takes precedence
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method
• CPC Class Codes: G02B 5/0294 adapted to provide an additional optical effect, e.g. anti-reflection or filter
• CPC Class Codes: G02B 5/3083 Birefringent or phase retarding elements G02B5/3008, G02B5/3016 take precedence; systems for polarisation control G02B27/286; manufacturing phase modulating patterns by lithographic processes G03F7/001

Abstract

The present invention provides a diffuser plate and a method for producing a diffuser plate that can improve variations in luminance of transmitted light or reflected light in a simple structure and that enable easy design and production. The diffuser plate according to the present invention is a diffuser plate where a plurality of microlenses are placed on a principal surface, wherein a phase difference generation part is inserted between the plurality of microlenses and the principal surface, the plurality of microlenses have two or more types of lens shapes, and the number of microlenses having the two or more types of lens shapes is determined so that a quantity ratio of the two or more types of lens shapes is a specific value, each of the lens shape types is selected corresponding to each of coordinates on the principal surface in which centers of undersurfaces of the plurality of microlenses are placed, and an angle range in which the diffuse light intensity is substantially uniform is in a range of +10% to −10% of a desired angle range.

Claims

1. A diffuser plate, comprising:

a plurality of microlenses; and

a phase difference generation part provided between the plurality of microlenses and a principal surface, when provided on the principal surface;

wherein;

the plurality of microlenses comprises at least two different types of lens shapes, and numbers of microlenses having each of the respective different types of lens shapes satisfy a predetermined quantity ratio;

when coordinates are assigned to locations on the principal surface, the lens shape type of each microlens is selected in relation to coordinates of a location on the principal surface beneath a center of the respective microlens when provided on the principal surface;

when an arithmetic average of diffuse light intensity in a desired angle range in the diffuser plate is 1, a standard deviation of relative intensity of diffuse light intensity in the desired angle range is equal to or less than 9.00×

10<sup>−

2</sup>; and

an angle range in which the diffuse light intensity is substantially uniform is in a range of +10% to −

10% of the desired angle range, where the angle range in which the diffuse light intensity is substantially uniform is a difference between a diffusion angle at which an absolute value reaches its maximum on a positive side and a diffusion angle at which an absolute value reaches its maximum on a negative side, out of diffusion angles with a relative intensity of 90% with respect to an arithmetic average of diffuse light intensity in the desired angle range, when a direction along a light incidence direction is at a diffusion angle of 0°

, one direction in an angle distribution measurement direction is positive, and an opposite direction is negative in an angle distribution of diffuse light intensity in one direction of the diffuser plate.

2. The diffuser plate according to claim 1, wherein a maximum value of a phase difference caused by the phase difference generation part is larger than 0.2 times a wavelength of light to be used.

3. The diffuser plate according to claim 1, wherein the desired angle range AngA is 0°

≤

AngA≤

40°

.

4. The diffuser plate according to claim 1, wherein:

when coordinates are assigned to locations on the principal surface, a height of the phase difference generation part above a location on the principal surface beneath a center of a respective microlens varies in accordance with an algebraic function, an elementary function, or a composite function of coordinates of a location on the principal surface beneath a center of the respective microlens when provided on the principal surface; and

the coordinates are independent variables.

5. The diffuser plate according to claim 1, wherein when coordinates are assigned to locations on the principal surface, a height of the phase difference generation part above a location on the principal surface is selected randomly in relation to coordinates of the location on the principal surface when provided on the principal surface.

6. The diffuser plate according to claim 1, wherein:

when coordinates are assigned to locations on the principal surface, the lens shape type of each microlens is selected in accordance with an algebraic function, an elementary function, or a composite function of coordinates of a location on the principal surface beneath a center of the respective microlens when provided on the principal surface; and

the coordinates are independent variables.

7. The diffuser plate according to claim 1, wherein when coordinates are assigned to locations on the principal surface, the lens shape type of each microlens is selected randomly in relation to coordinates of a location on the principal surface beneath a center of the respective microlens when provided on the principal surface.

8. A method for producing a diffuser plate according to claim 1, the method comprising:

designing a plurality of types of microlens sets, each of the plurality of microlens sets comprising a plurality of microlenses and a phase difference generation part provided between the plurality of microlenses and a principal surface when provided on the principal surface, and each type of microlens set having a different type of lens shape providing an angle distribution of diffuse light intensity close to a desired angle range;

producing a plurality of types of sample molds having shapes respectively corresponding to the plurality of types of microlens sets;

transferring a shape of each type of microlens set to a resin with a sample mold, and thereby producing a plurality of types of sample diffuser plates each having a diffusion pattern corresponding to a respective type of microlens set;

evaluating optical properties of each of the plurality of types of sample diffuser plates;

designing a microlens array combining types of microlens sets based on evaluation results of the sample diffuser plates;

producing a diffusion pattern mold having a shape corresponding to the microlens array; and

transferring the diffusion pattern to the resin with the diffusion pattern mold.