Fabrication and optical design of pyramid microstructure on the base of light guide used for the backlight module

This paper proposed the pyramid microstructure (PYM) used on the base of the light guide as the micro-optical components to replace the conventional diffuser dot made by direct etching on the steel stamper. The PYM is made by MEMS technology, which uses silicon wafer as original mold of PYM and to replicate it on Ni micro-mold by using electroforming method. The effective optical design tool is used to find the optimal distribution of the PYM, which integrates the random microstructure generation scheme developed based on the molecular dynamics method and the optical commercial software. The SEM images show the intact PYM can be produced on the Si micro-mold and replicated fully on the Ni micro-mold by the electroforming process. The intact PYM on the base of the light guide can also be produced by the injection molding showing the complete transformation of the Ni micro-mold to the light guide. The luminance measurement of a 2.4 inches backlight module with 4 LEDs shows the average luminance of 4769 nit with 86.3% uniformity for the PYM on the base of light guide, which is 10% higher than that for the diffuser dot microstructure.