微结构聚合物漫反射材料的设计及成型基础研究
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摘要
微光学元件具有体积小、质量轻、设计灵活、易于大批量复制形成阵列化等优点,因而广泛用作微光学体系中的微型元件。通过在聚合物基材表面构造球冠型微透镜及其阵列,可以得到聚合物微透镜光学材料,其表面微结构可以赋予聚合物材料许多特殊的功能。聚合物光反射材料的内部组成以及表面添加的球冠型微透镜阵列的微结构对于反射光的利用起着决定性的作用。本文以具有球冠型微透镜阵列微结构的聚合物漫反射复合材料为研究对象,采用理论研究、仿真试验、成型试验和光效对比相结合的方法,对微结构聚合物漫反射复合材料的体系进行了设计,给出了其反射性能表征及测试方法；在仿真试验的基础上,采用挤出辊压技术制备了具有球冠型微透镜阵列微结构的漫反射复合材料,最后注塑成型了漫反射罩,并对其光学性能进行了分析。研究的主要内容如下：
(1)对微结构聚合物漫反射材料的体系进行了设计。提出在聚合物基材内部添加具有高折射率的反射粒子的同时在聚合物基材表面添加球冠型微透镜阵列的微结构,得到一种微结构漫反射复合材料；通过理论分析,材料可以具备较好的反射性能和光照均匀度。
(2)基于蒙特卡洛光线追迹法,建立了漫反射材料光学性能测试仿真模型。采用光学设计软件(Light Tools)分别建立了漫反射复合材料、微结构漫反射材料以及微结构漫反射复合材料光学性能测试模型,给出了测试方法并对所建模型进行了误差分析。
(3)基于光学设计软件对不同漫反射材料分别进行了仿真实验。重点研究了反射粒子的添加浓度、粒径以及折射率对漫反射复合材料光学性能的影响。结果表明,当粒子的添加浓度为90万个/mm3,粒径4μm,粒子折射率为2.4时,漫反射复合材料具有较好的反射性能和光照均匀度。
(4)研究了微结构的高度、半径以及排布方式对微结构漫反射材料光学性能的影响。结果表明,当基材表面添加以优化正六边形排布的球冠型微透镜阵列的微结构,且微结构的高度和半径均为0.1mm时,微结构漫反射材料具有较好的光学性能。在此基础上,向基材内部添加反射粒子,当粒子的添加浓度为90万个/mm3,粒径41μm,粒子折射率为2.4时,微结构漫反射复合材料具有较好的光学性能。
(5)对微结构漫反射复合材料的成型工艺进行了研究。采用挤出辊压法成型了微结构漫反射复合材料,研究了二氧化钛的添加浓度,微结构的高度、半径以及排布方式对漫反射材料光学性能的影响。结果表明,漫反射复合材料总反射比为91.4%,漫反射比为88.7%,漫反射比占总反射比的97%,光照均匀度为61.3%；微结构漫反射材料总反射比为90.6%,漫反射比为86.2%,漫反射比占总反射比的95.1%,光照均匀度为62.9%；微结构漫反射复合材料总反射比为93%,漫反射比为91%,漫反射比占总反射比的98%,光照均匀度为63%。试验结果和仿真结果具有很好的一致性。
(6)采用超细电火花技术在反射罩模具型芯表面制作了球冠型微透镜阵列的微结构。通过挤出成型,注塑成型,得到具有微结构的漫反射罩；和金属反射罩进行光效对比,结果表明所制得的漫反射罩光能利用率高,光照均匀度较好。
Micro-optical elements have the advantages of small size, light weight, flexible design, and easily mass-produced reproductions to form arrays. Therefore, it's widely used as microcomponent in micro-optics system. Through structuring spherical microlens array on the surface of polymer material, the polymer microlens optical material can be obtained, the microstructure on surface can give many special function to polymer material. The internal composition and microstructure of spherical microlens array of polymeric reflective materials play a decisive role in the use of reflected light. This paper takes the polymer diffuse reflection composite material with spherical microlens array microstructure as the research object, and with the combination of theoretical research, simulation test, forming test and light effect contrast, the system of the polymer microstructure diffuse reflection composite materials is designed, and its reflection performance characterization and testing method are given out. On the basis of simulation test, the spherical microlens array microstructure diffuse reflection composite materials is produced by the squeeze roller technology, the diffuse reflection cover is processed by injection molding finally, and the optical performance is analyzed. The main research content is as follows:
(1) The system of microstructure polymer diffuse reflection material is design. Putting forward within the polymer material to add reflective particles with high refractive index of polymer material surface, at the same time add microstructure of a spherical microlens array, a microstructure diffuse reflection composite material can be obtained, through theory analysis, the material can have a good reflection performance and illumination uniformity.
(2) Based on the Monte Carlo ray tracing method, the test simulation mode for optical performance of diffuse reflection material is established. By using Light Tools, the diffuse reflection composite materials, and the microstructure diffuse reflection optical composite materials, and microstructure performance testing model is respectively established, the test method is obtained and the error of the model is analyzed.
(3) Based on the optical design software, different diffuse reflection material simulation experiment was carried out respectively. Research is mainly focused on the adding concentration of reflective particles, particle size and the influence of refractive index on diffuse reflection composite optical performance. Results show that when the concentration of particles are added to900000/mm3, size4μm, particle refractive index of2.4, diffuse reflection composite material has good reflection performance and illumination uniformity.
(4) The influence of height, radius and configuration mode of microstructure on optical properties of microstructure diffuse reflection material is researched. Results show that the reflective properties of the material were preferable when the radius and height of the microstructure were both0.1mm and the microstructure was optimized hexagonal arrangement. On this basis, by adding reflective particles into the material, When the concentration of particles was added to900000/mm3, size4μm, particle refractive index of2.4, microstructure diffuse reflection composite material has good optical properties.
(5) The molding process of diffuse reflection composites with microstructure is researched, the diffuse reflection composites with microstructure is formed by squeeze roller pressuring method, the adding concentration of titanium dioxide, the height, radius, configuration mode of the microstructure and their influence on optical properties of diffuse reflection material is researched. The total reflectance of diffuse reflection composites is91.4%, diffuse reflection ratio is88.7%, accounted for97%of the total reflectance, illumination uniformity is 61.3%. The total reflectance of diffuse reflection material with microstructure is90.6%, diffuse reflection ratio is86.2%, accounted for95.1%of the total reflectance, illumination uniformity is62.9%. The total reflectance of microstructure diffuse composites is93%, diffuse reflection ratio is91%, accounted for98%of the total reflectance, illumination uniformity is63%. The test results and simulation results have good consistency.
(6) The MEDM was used to produce microstructure of spherical microlens array on reflector surface of mould core. Through the extrusion molding, injection molding, diffuse reflecting cover with microstructure was produced. Compared with metal reflecting cover, the results show that the light energy utilization rate of the diffuse reflecting cover is higher, and the illumination uniformity is better.
(1)对微结构聚合物漫反射材料的体系进行了设计。提出在聚合物基材内部添加具有高折射率的反射粒子的同时在聚合物基材表面添加球冠型微透镜阵列的微结构,得到一种微结构漫反射复合材料；通过理论分析,材料可以具备较好的反射性能和光照均匀度。
(2)基于蒙特卡洛光线追迹法,建立了漫反射材料光学性能测试仿真模型。采用光学设计软件(Light Tools)分别建立了漫反射复合材料、微结构漫反射材料以及微结构漫反射复合材料光学性能测试模型,给出了测试方法并对所建模型进行了误差分析。
(3)基于光学设计软件对不同漫反射材料分别进行了仿真实验。重点研究了反射粒子的添加浓度、粒径以及折射率对漫反射复合材料光学性能的影响。结果表明,当粒子的添加浓度为90万个/mm3,粒径4μm,粒子折射率为2.4时,漫反射复合材料具有较好的反射性能和光照均匀度。
(4)研究了微结构的高度、半径以及排布方式对微结构漫反射材料光学性能的影响。结果表明,当基材表面添加以优化正六边形排布的球冠型微透镜阵列的微结构,且微结构的高度和半径均为0.1mm时,微结构漫反射材料具有较好的光学性能。在此基础上,向基材内部添加反射粒子,当粒子的添加浓度为90万个/mm3,粒径41μm,粒子折射率为2.4时,微结构漫反射复合材料具有较好的光学性能。
(5)对微结构漫反射复合材料的成型工艺进行了研究。采用挤出辊压法成型了微结构漫反射复合材料,研究了二氧化钛的添加浓度,微结构的高度、半径以及排布方式对漫反射材料光学性能的影响。结果表明,漫反射复合材料总反射比为91.4%,漫反射比为88.7%,漫反射比占总反射比的97%,光照均匀度为61.3%；微结构漫反射材料总反射比为90.6%,漫反射比为86.2%,漫反射比占总反射比的95.1%,光照均匀度为62.9%；微结构漫反射复合材料总反射比为93%,漫反射比为91%,漫反射比占总反射比的98%,光照均匀度为63%。试验结果和仿真结果具有很好的一致性。
(6)采用超细电火花技术在反射罩模具型芯表面制作了球冠型微透镜阵列的微结构。通过挤出成型,注塑成型,得到具有微结构的漫反射罩；和金属反射罩进行光效对比,结果表明所制得的漫反射罩光能利用率高,光照均匀度较好。
Micro-optical elements have the advantages of small size, light weight, flexible design, and easily mass-produced reproductions to form arrays. Therefore, it's widely used as microcomponent in micro-optics system. Through structuring spherical microlens array on the surface of polymer material, the polymer microlens optical material can be obtained, the microstructure on surface can give many special function to polymer material. The internal composition and microstructure of spherical microlens array of polymeric reflective materials play a decisive role in the use of reflected light. This paper takes the polymer diffuse reflection composite material with spherical microlens array microstructure as the research object, and with the combination of theoretical research, simulation test, forming test and light effect contrast, the system of the polymer microstructure diffuse reflection composite materials is designed, and its reflection performance characterization and testing method are given out. On the basis of simulation test, the spherical microlens array microstructure diffuse reflection composite materials is produced by the squeeze roller technology, the diffuse reflection cover is processed by injection molding finally, and the optical performance is analyzed. The main research content is as follows:
(1) The system of microstructure polymer diffuse reflection material is design. Putting forward within the polymer material to add reflective particles with high refractive index of polymer material surface, at the same time add microstructure of a spherical microlens array, a microstructure diffuse reflection composite material can be obtained, through theory analysis, the material can have a good reflection performance and illumination uniformity.
(2) Based on the Monte Carlo ray tracing method, the test simulation mode for optical performance of diffuse reflection material is established. By using Light Tools, the diffuse reflection composite materials, and the microstructure diffuse reflection optical composite materials, and microstructure performance testing model is respectively established, the test method is obtained and the error of the model is analyzed.
(3) Based on the optical design software, different diffuse reflection material simulation experiment was carried out respectively. Research is mainly focused on the adding concentration of reflective particles, particle size and the influence of refractive index on diffuse reflection composite optical performance. Results show that when the concentration of particles are added to900000/mm3, size4μm, particle refractive index of2.4, diffuse reflection composite material has good reflection performance and illumination uniformity.
(4) The influence of height, radius and configuration mode of microstructure on optical properties of microstructure diffuse reflection material is researched. Results show that the reflective properties of the material were preferable when the radius and height of the microstructure were both0.1mm and the microstructure was optimized hexagonal arrangement. On this basis, by adding reflective particles into the material, When the concentration of particles was added to900000/mm3, size4μm, particle refractive index of2.4, microstructure diffuse reflection composite material has good optical properties.
(5) The molding process of diffuse reflection composites with microstructure is researched, the diffuse reflection composites with microstructure is formed by squeeze roller pressuring method, the adding concentration of titanium dioxide, the height, radius, configuration mode of the microstructure and their influence on optical properties of diffuse reflection material is researched. The total reflectance of diffuse reflection composites is91.4%, diffuse reflection ratio is88.7%, accounted for97%of the total reflectance, illumination uniformity is 61.3%. The total reflectance of diffuse reflection material with microstructure is90.6%, diffuse reflection ratio is86.2%, accounted for95.1%of the total reflectance, illumination uniformity is62.9%. The total reflectance of microstructure diffuse composites is93%, diffuse reflection ratio is91%, accounted for98%of the total reflectance, illumination uniformity is63%. The test results and simulation results have good consistency.
(6) The MEDM was used to produce microstructure of spherical microlens array on reflector surface of mould core. Through the extrusion molding, injection molding, diffuse reflecting cover with microstructure was produced. Compared with metal reflecting cover, the results show that the light energy utilization rate of the diffuse reflecting cover is higher, and the illumination uniformity is better.
引文
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