Continuous R2R Coating Methodology to Manufacture Precision Microstructures for Displays, High-Brightness LEDs, Traffic Signs, Solar Concentrators and other Light Management Products

摘要

Annual sales for microstructured products will exceed 5 billion dollars this year and is projected to reach 11 billion dollars by 2009. Two examples of microreplicated products we see on a daily basis are the plastic films used in lap-top computer screens and reflective sheeting used in the latest version of high-brightness traffic signs. These two markets currently represent 3 billion dollars and 1.5 billion dollars respectively in annual sales. Reflective traffic signs have been around for decades but the latest products are the result of a manufacturing process that produces 150 micron film having 22,000 microreplicated prisms per square inch. Microprisms capture and reflect light with much greater efficiency than the previous technology using encapsulated glass spheres which had been used since the early 50's. The new technology improved product performance by a factor of four allowing the better performing products to be sold at a higher price while reducing manufacturing cost compared to the previous generation of products. Two primary plastic layers that improve the optical efficiency of LCD displays are called Brightness Enhancing Film (BEF) and consist of microscopic lenticular grooves that enhance and direct light uniformly towards the viewer while consuming less battery power than previous designs.