Abstract
A combination of silicon anisotropic etch and mechanical hotembossing techniques is used to demonstrate the feasibility of manufacturingplastic micropyramids. These micropyramids have the desirable opticalcharacteristics to enhance the brightness of LCD (liquid crystal displays) inbattery-powered laptop computers, personal TVs and camcorders. Silicon moldinserts, 4-inch in diameter, are first micromachined and used directly in themicro hot embossing process by applying plastic sheets made of polymethylmethacrylate (PMMA) or polyvinyl chloride (PVC). Micropyramids which have basewidths of 30 µm, heights of 21 µm and apex angles of70° are hot embossed on the surface of plastic sheets. The fabricatedplastic films are tested optically and the results show that up to 20%brightness enhancement within the front viewing angles of ±35° havebeen achieved. An optical model has been established to simulate thebrightness enhancement effects and it is concluded that the optimal pyramidangle for the brightness enhancement application is 90°.
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