Liu Shih-Jung, Huang Yu-Chin
Department of Mechanical Engineering Chang Gung University, Tao-Yuan 333, Taiwan.
Opt Express. 2009 Sep 28;17(20):18083-92. doi: 10.1364/OE.17.018083.
This paper reports a simple and effective ultrasonic embossing method which enables the rapid fabrication of dual-side surface-relief plastic diffusers with various cross angles. Metallic master molds bearing microstructures are fabricated using a tungsten carbide turning machine. A 1500-Watt ultrasonic vibrator with an output frequency of 20 kHz was used to replicate the microstructure onto 1 mm thick PMMA and PET films in the experiments. During ultrasonic embossing, the ultrasonic energy is converted into heat through intermolecular friction at the master mold/plastic plate interface due to asperities to melt the thermoplastic at the interface and thereby to replicate the microstructure. Under the proper processing conditions, high-performance dual-sided plastic diffusers of various cross-angles can be successfully fabricated. The proposed method shows great potential for fast fabrication of micro-optical components due to its simplicity and versatility.
本文报道了一种简单有效的超声压花方法，该方法能够快速制造具有各种交叉角的双侧表面浮雕塑料扩散器。使用碳化钨车床制造带有微结构的金属母模。在实验中，使用一台输出频率为20 kHz的1500瓦超声振动器将微结构复制到1毫米厚的聚甲基丙烯酸甲酯（PMMA）和聚对苯二甲酸乙二酯（PET）薄膜上。在超声压花过程中，由于粗糙不平，超声能量通过母模/塑料板界面处的分子间摩擦转化为热量，从而熔化界面处的热塑性塑料，进而复制微结构。在适当的加工条件下，可以成功制造出各种交叉角的高性能双侧塑料扩散器。由于其简单性和通用性，该方法在快速制造微光学元件方面显示出巨大潜力。
