U.S. patent application number 09/759387 was filed with the patent office on 2001-05-31 for method of manufacturing a diffuser master using a buffing agent.
This patent application is currently assigned to Physical Optics Coporation. Invention is credited to Kostrzewski, Andrew A., Savant, Gajendra D., Yu, Kevin H..
Application Number | 20010002355 09/759387 |
Document ID | / |
Family ID | 22477247 |
Filed Date | 2001-05-31 |
United States Patent
Application |
20010002355 |
Kind Code |
A1 |
Savant, Gajendra D. ; et
al. |
May 31, 2001 |
Method of manufacturing a diffuser master using a buffing agent
Abstract
A diffuser master is provided which is manufactured mechanically
instead of holographically. The master can be made from a suitable
substrate including relatively hard materials such as plastic,
glass or metal. A substrate having a first side is worked to form a
diffuser surface relief structure thereon. The substrate can be
buffed using a buffing agent of a selected grit in order to form
surface scratches in the first side of the substrate. The substrate
can also be blasted with shot particles in order to form
indentations and depressions in the first side. The substrate can
alternatively be acid or alkali etched in order to form surface
irregularities in the first side. The scratches, depressions or
irregularities can be formed in order to create a desired surface
relief and hence desired diffuser output characteristics.
Inventors: |
Savant, Gajendra D.;
(Torrance, CA) ; Yu, Kevin H.; (Temple City,
CA) ; Kostrzewski, Andrew A.; (Garden Grove,
CA) |
Correspondence
Address: |
NILLES & NILLES, SC
FIRSTAR CENTER, SUITE 2000
777 EAST WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Assignee: |
Physical Optics Coporation
|
Family ID: |
22477247 |
Appl. No.: |
09/759387 |
Filed: |
January 12, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09759387 |
Jan 12, 2001 |
|
|
|
09137398 |
Aug 20, 1998 |
|
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Current U.S.
Class: |
451/38 |
Current CPC
Class: |
G02B 5/0268 20130101;
G02B 5/0226 20130101; G02B 5/0221 20130101 |
Class at
Publication: |
451/38 |
International
Class: |
B24B 001/00 |
Claims
What is claimed is:
1. A method of making a non-Lambertian diffuser, the method
comprising the steps of: providing a substrate body having at least
a first side; selecting a buffing agent having a desired grit; and
buffing the first side of the substrate body with the buffing agent
to form a plurality of irregularities in the first side according
to the grit of the buffing agent to thereby form a diffuser surface
having light propagating characteristics defined by the
orientation, contour and depth of the plurality of
irregularities.
2. The method according to claim 1, wherein the step of providing
further includes providing a substrate body from a plastic material
selected from one of the group consisting of at least
polycarbonate, polyester, acrylic, nylon, polystyrene,
tetrafluoroethylene, polyimide, polyvinyl chloride, polymethyl
methacrylate, TPX.TM., and ARTON.TM..
3. The method according to claim 1, further comprising the step of:
placing the buffing agent directly on the first side of the
substrate body prior to the step of buffing.
4. The method according to claim 1, further comprising the steps
of: placing the buffing agent on a buffing apparatus; moving the
buffing apparatus into contact with the first side of the substrate
body; and buffing the first side with the buffing apparatus.
5. The method according to claim 1, wherein the step of selecting
further includes selecting a buffing agent from at least one of the
group consisting of aluminum oxide, silicon carbide, and cerium
oxide.
6. A method of making a non-Lambertian diffuser, the method
comprising the steps of: providing a substrate body having at least
a first side; selecting an etching agent; placing the etching agent
on the first side of the substrate body for an etching time
duration; and etching a plurality of irregularities into the first
side, the plurality of irregularities having at least a size, a
depth and a contour formed according to a reaction between the
substrate body and the etching agent and according to the etching
time duration to thereby form a diffuser surface on the first side
having light propagation characteristics defined by the size, depth
and contour of the irregularities.
7. The method according to claim 6, wherein the step of providing
further includes providing a substrate body formed from a glass
material.
8. The method according to claim 6, wherein the step of providing
further includes providing a substrate body formed from a glass
material selected from at least one of the group consisting of
light barium crown, phosphate crown, crown, flint, extralight
flint, light flint, fused silica, and borosilicate.
9. The method according to claim 6, wherein the step of selecting
further includes selecting an etching agent from at least one of
the group consisting of sodium hydroxide, potassium hydroxide,
hydrofluoric acid, and ammonium fluoride.
10. The method according to claim 6, further comprising the steps
of: mixing a plurality of solid particles with the acid agent to
form a working compound, each of the plurality of particles having
a size, a shape and a mass; and etching the plurality of
irregularities into the first side, the size, depth and contour of
the plurality of irregularities determined by the size, shape and
mass of the plurality of particles as well as the reaction between
the etching agent and the substrate body and the etching time
duration.
11. The method according to claim 10, further comprising the step
of: applying pressure against the first side after the step of
placing the working compound thereon in order to increase the depth
of the plurality of irregularities.
12. The method according to claim 10, wherein the step of mixing
further includes providing a plurality of particles each having a
general shape selected from the group consisting of hexagonal,
rhombohedral, and spherical, and a diameter within a range of
diameters from about 4 mm to about 0.045 mm.
13. The method according to claim 11, wherein the plurality of
particles are provided having a number of different diameters, the
diameter of each of the plurality of particles being within the
range of diameters.
14. The method according to claim 10, wherein the step of mixing
further includes providing the plurality of particles selected form
at least one of the group consisting of silicon carbide and boron
carbide.
15. The method according to claim 6, further comprising the steps
of: selecting a mask having a plurality of openings passing through
the mask, each of the plurality of openings having a length, a
width, an orientation and a shape; securing the mask flush against
the first side of the substrate body; placing the etching agent
over the mask on the first side; and etching the plurality of
irregularities into the first side of the substrate body whereby
the size, depth and contour of the plurality of irregularities are
determined by the length, width, orientation and shape of the
plurality of openings in the mask as well as the reaction between
the etching agent and the substrate body and the etching time
duration.
16. The method according to claim 15, wherein the step of selecting
a mask further includes selecting a mask made from a material
selected from the group consisting of polyester and
polycarbonate.
17. A method of making a non-Lambertian diffuser, the method
comprising the steps of: providing a substrate body having at least
a first side; selecting a blasting agent including a plurality of
shot particles each having a size, a shape and a mass; and forcing
the blasting agent against the first side of the substrate body at
a predetermined velocity to form a plurality of irregularities in
the first side according to the size, shape and mass of the
plurality of shot particles and the predetermined velocity to
thereby form a diffuser surface structure in the first side
according to a depth, contour and size of the plurality of
irregularities.
18. The method according to claim 17, wherein the step of providing
further includes providing a substrate body formed from a glass
material.
19. The method according to claim 17, wherein the step of providing
further includes providing a substrate body formed from a glass
material selected from at least one of the group consisting of
light barium crown, phosphate crown, crown, flint, extralight
flint, light flint, fused silica, and borosilicate.
20. The method according to claim 17, wherein the step of providing
further includes providing a substrate body formed from a metal
material.
21. The method according to claim 17, wherein the step of selecting
further includes selecting the plurality of shot particles each
having a diameter within a range from about 4 mm to about 0.045 mm
and a general shape selected from the group consisting of
hexagonal, rhombohedral, and spherical.
22. The method according to claim 17, wherein the step of selecting
further includes selecting the plurality of shot particles from
shot particles made from a metal material.
23. A non-Lambertian diffuser comprising: a substrate body having
at least a first side; and a diffuser surface relief structure
formed non-holographically in the first side, the surface relief
structure defining a plurality of irregularities in the first side
and having light propagating characteristics defined by at least
one of the size, depth, length, width, orientation, and contour of
the plurality of irregularities.
24. The diffuser according to claim 23, wherein the substrate body
is a glass material substrate.
25. The diffuser according to claim 23, wherein the substrate body
is a plastic material substrate.
26. The diffuser according to claim 23, wherein the substrate body
is a metallic material substrate.
27. The diffuser according to claim 23, wherein the surface relief
structure comprises a plurality of scratches in the first side
formed by buffing the first side with a buffing agent having a
predetermined grit, each of the plurality of scratches having a
depth, a contour, a length, a width, and a shape.
28. The diffuser according to claim 23, wherein the surface relief
structure comprises a plurality of closely spaced depressions in
the first side each having a depth and a contour and each formed by
forcing a plurality of shot particles at a predetermined velocity
against the first side, the shot particles each having a
predetermined size, shape and mass.
29. The diffuser according to claim 23, wherein the surface relief
structure is etched into the first side by an etching agent
carrying a plurality of particles each having a size, shape and
mass.
30. The diffuser according to claim 29, wherein the surface relief
structure is further etched into the first side by pressing the
plurality of particles into the first side.
31. The diffuser according to claim 23, wherein the surface relief
structure is further etched into the first side by an etching agent
contacting the first side through a plurality of openings in a
mask, the plurality of openings each having a length, a width, an
orientation and a shape.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to optical elements,
and more particularly to a non-Lambertian diffuser fabricated using
mechanical means instead of light and mechanical methods for
fabricating the diffuser.
[0003] 2. Description of the Related Art
[0004] Methods for manufacturing and replicating optical components
such as a master diffuser exhibiting desired light diffusing
characteristics are well known. Many of these methods involve
creating a master diffuser by exposing a photoresist material to a
source of light and then replicating this master diffuser into one
or more submasters of a more durable nature. Many of these methods
inherently destroy the master diffuser when creating the
submasters. There are also other methods of making replicas of a
master diffuser which contain the optical features in the master
without destroying the master diffuser. With each of these methods,
the master diffuser is initially created optically. Submasters are
created from these master diffusers utilizing a number of methods
whereby the master diffuser surface is replicated into a submaster
surface. These other methods are described in one or more pending
U.S. applications, referenced below, which are assigned to the
assignee of the present invention.
[0005] One such method involves creating a submaster for an optical
product by recording optical features on a photosensitive medium
using coherent or incoherent light. The photosensitive medium is
then further processed to create a master optical product. A layer
of two part silicone epoxy is then poured over the master to
replicate the optical surface features of the master photosensitive
medium in the silicone epoxy material. The silicone epoxy layer
cures at room temperature and becomes rubber. The silicone material
is then further cured and separated from the master to obtain a
silicone rubber submaster. The soft silicone submaster is then used
to make successive generations of submasters or final optical
products by covering the soft submaster with a layer of epoxy,
covering the layer of epoxy with a plastic substrate, curing the
epoxy and separating the epoxy and plastic substrate from the
submaster. This particular method of creating a diffuser is highly
labor intensive, requires use of many different materials, requires
performing a number of steps, and must be conducted in a sterile
environment.
[0006] The specific embodiments described above regarding the
rubber submaster and the silver and nickel submaster are disclosed
in co-pending U.S. application Ser. No. 09/052,586 entitled "Method
of Making Replicas While Preserving Master," commonly assigned to
the assignee of the present invention.
[0007] Another method of creating a diffuser involves recording
optical features in a photosensitive medium using coherent or
incoherent light and then processing the medium to create a master.
The photosensitive medium is then coated with a layer of silver. A
layer of nickel is electroplated onto the silver layer and then the
silver layer and layer of nickel are removed from the
photosensitive material or medium to form the submaster. The
combined silver and nickel backing form a metal shim submaster
which is then replicated to fabricate final optical products by
embossing the surface features of the submaster into epoxies,
plastics or polycarbonate materials, or by injection molding such
materials into a mold carrying the submaster. Again, this process
is costly, labor intensive, wasteful of material and requires a
sterile environment.
[0008] Another significant problem with each of these methods is
that the submasters or final optical products created from the
master optical elements are made from materials such as plastics,
epoxies, or polycarbonate composites and exhibit relatively poor
long-term characteristics. These materials are also not suited for
use near extremely high temperature light sources because they have
relatively low melting or softening temperatures when compared to
other more durable materials.
[0009] Other commonly assigned U.S. patents and pending
applications disclose somewhat related methods for making and
recording optical products and replicating those products so that
they may be mass produced. For example, U.S. Pat. No. 5,365,354
entitled "Grin Type Diffuser Based on Volume Holographic Material,"
U.S. Pat. No. 5,534,386 entitled "Homogenizer Formed Using Coherent
Light and a Holographic Diffuser," and U.S. Pat. No. 5,609,939
entitled "Viewing Screen Formed Using Coherent Light," all owned by
the present assignee relate to methods for recording and
replicating optical products. Each of these U.S. patents is
incorporated herein by reference for purposes including, but not
limited to, indicating the background of the present invention and
illustrating the state of the art.
[0010] Related U.S. patent applications include Ser. No. 08/595,307
entitled "LCD With Light Source Destructuring and Shaping Device,"
Ser. No. 08/601,133 entitled "Liquid Crystal Display System with
Collimated Backlighting and Non-Lambertian Diffusing," Ser. No.
08/618,539 entitled "Method of Making Liquid Crystal Display
System," Ser. No. 08/800,872 entitled "Method of Making Replicas
and Compositions for Use Therewith," and Ser. No. 09/075,023
entitled "Method and Apparatus for Making Optical Masters Using
Incoherent Light." All the above applications are owned by the
present assignee and are hereby incorporated by reference for
purposes including, but not limited to, indicating the background
of the present invention and illustrating the state of the art.
Additionally, each of these patents and applications disclose
methods of making optical products wherein the methods or the
products exhibit many or all of the above-noted disadvantages.
SUMMARY OF THE INVENTION
[0011] A primary object of the present invention is to provide a
method for making a diffuser optical product utilizing conventional
mechanical means instead of the aforementioned holographic and
complex and costly methods. Another primary object of the present
invention is to provide a diffuser from an extremely durable
material such as glass or metal. It is another object of the
present invention to provide a diffuser which is suitable for use
under extreme temperature conditions such as adjacent a high
temperature active light source in a liquid crystal display or the
like. It is a further object of the present invention to provide a
method for producing such a diffuser which requires fewer steps for
creating the diffuser and is less costly in materials, cost of
labor and cost of the manufacturing environment.
[0012] In accordance with the present invention, these objects are
achieved by several methods for producing a diffuser from highly
durable materials such as glass or metal and by the resulting
diffuser optical products themselves.
[0013] In one embodiment, a method for producing such a diffuser
first includes providing a substrate body having at least a first
side. A working material is then selected which has desired
qualities for altering the characteristics of the first side of the
substrate body. The working material is applied to the first side
in order to form a plurality of irregularities thereon which define
a diffuser surface. The diffuser surface exhibits light propagating
characteristics defined by the particular characteristics of the
plurality of irregularities.
[0014] In one embodiment, the working material is a buffing agent
having a desired grit. The first side of the substrate body is
buffed utilizing the buffing agent which forms a plurality of
scratches in the first side according to the particular grit of the
agent. The scratches define the diffuser surface and thereby
exhibit light propagating characteristics defined by the
orientation, contour, length and depth of the plurality of
irregularities.
[0015] In another embodiment, the working material is an acid or
alkali agent selected to react with a particular substrate body
material. The acid or alkali agent is placed on the first side of
the substrate body for an etching time duration. The acid or alkali
agent etches a plurality of irregularities into the first side of
the substrate body. The plurality of irregularities each have at
least a size, a depth, and a contour formed according to the
reaction between the substrate body and the acid or alkali agent as
well as etching time duration. The diffuser surface on the first
side exhibits light propagation characteristics defined by the
size, depth and contour of the irregularities formed by the etching
or acid or alkali agent.
[0016] In another embodiment, the acid or alkali etching agent also
includes a plurality of particles mixed therein each having a size,
a shape and a mass. The particles enhance the etching reaction
between the substrate body and the acid or alkali agent by forming
deeper depressions where the particles are located on the first
side of the substrate body. In another embodiment, a pressure may
be applied to the first side of the substrate body while the acid
or alkali agent and particles are disposed thereon to further
enhance penetration of the particles into the first side of the
substrate body as the acid or alkali agent reacts with the
substrate body material.
[0017] In one embodiment, a mask having a plurality of openings
formed therein is applied to the first side of the substrate body.
The acid or alkali agent is placed on the first side over the mask
and thereby etches a plurality of irregularities into the first
side where the first side is exposed through the openings of the
mask. The irregularities each have a size, depth and contour which
are essentially determined by the length, width, orientation and
shape of the plurality of openings in the mask as well as the
particular reaction between the acid agent and the substrate body
as well as the etching time duration.
[0018] In one embodiment, the working material is a blasting agent
which includes a plurality of shot particles each having a size, a
shape and a mass. The blasting agent is forced against the first
side of the substrate body such as in a sandblasting operation at a
predetermined velocity to form a plurality of irregularities or
depressions. The depressions are formed according to the size,
shape and mass of the shot particles as well as the predetermined
velocity. The diffuser surface structure is defined by the depth,
contour and size of the plurality of irregularities formed in the
first side of the substrate body.
[0019] In another embodiment of the invention, a diffuser is
disclosed having a substrate body and at least a first side. A
diffuser surface relief structure formed non-holographically in the
first side defines a plurality of irregularities therein. The
irregularities have light propagating characteristics which are
defined by at least one of the size, depth, length, width,
orientation, and contour of the plurality of irregularities.
[0020] In one embodiment, the substrate body is formed from a glass
material substrate. In another embodiment, the substrate body is
formed from a hard plastic material substrate. In another
embodiment, the substrate body is formed from a metallic material
substrate.
[0021] In one embodiment, the surface relief structure is comprised
of a plurality of scratches formed by buffing the first side with a
buffing agent having a predetermined grit. In another embodiment,
the surface relief structure is comprised of a plurality of closely
spaced depressions in the first side formed by forcing a plurality
of shot particles at a predetermined velocity against the first
side. In a further embodiment, the surface relief structure is acid
etched into the first side by an acid agent placed on the first
side of the substrate body.
[0022] These and other aspects and objects of the present invention
will be better appreciated and understood when considered in
conjunction with the following description and accompanying
drawings. It should be understood, however, that the following
description, while indicating preferred embodiments of the present
invention, is given by way of illustration and not of limitation.
Many changes and modifications may be made within the scope of the
present invention without departing from the spirit thereof and the
invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A clear conception of the advantages and features of the
present invention, and of the construction and operation of typical
mechanisms provided with the present invention, will become more
readily apparent by referring to exemplary and therefore
non-limiting embodiments illustrated in the drawings accompanying
and forming a part of this specification, and in which:
[0024] FIG. 1A illustrates an elevational perspective view of a
glass diffuser constructed in accordance with one embodiment of the
present invention;
[0025] FIG. 1B illustrates an elevational perspective view of a
metal diffuser constructed in accordance with another embodiment of
the present invention;
[0026] FIG. 1C illustrates an elevational perspective view of a
plastic diffuser constructed in accordance with another embodiment
of the present invention;
[0027] FIG. 2 illustrates a schematic view of a buffing process for
forming one of the diffusers of FIGS. 1A-1C;
[0028] FIG. 3 illustrates a schematic view of an etching process
for forming one of the diffusers illustrated in FIGS. 1A-1C;
[0029] FIG. 4 illustrates an alternative etching process for
forming one of the diffusers illustrated in FIGS. 1A-1C;
[0030] FIG. 5A illustrates another alternative etching process for
forming one of the diffusers illustrated in FIGS. 1A-1C;
[0031] FIG. 5B illustrates a perspective view of the diffuser
illustrated in FIG. 5A;
[0032] FIG. 6 illustrates a schematic view of a blasting process
for forming one of the diffusers illustrated in FIGS. 1A-1C;
[0033] FIG. 7A illustrates an elevational plan view of the diffuser
surface of a diffuser; and
[0034] FIG. 7B illustrates a cross-sectional view of the diffuser
surface taken along lines 7B-7B of FIG. 7A.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0035] Referring now to the drawings, FIGS. 1A-1C illustrate
several simplified elevational perspective views of diffusers
formed by one of the methods of the present invention. The present
invention may be utilized to form diffusers from substrate
materials such as plastics, glass or metal. The methods are
appropriate for forming diffusers from conventional diffuser
materials such as epoxy, polycarbonate, polyester, acrylic, nylon,
polystyrene, tetrafluoroethylene, polyimide, polyvinyl chloride,
polymethyl methacrylate, TPX.TM., ARTON.TM., and other plastic
materials but also may be utilized to form diffusers from much more
durable materials such as glass and metal for which previous
methods were not suitable. Glass materials that can be used include
light barium crown, phosphate crown, crown, flint, extralight
flint, light flint, fused silicon, and borosilicate. FIG. 1A
illustrates a glass diffuser 20 constructed according to one
embodiment of the present invention. FIG. 1B illustrates a metal
diffuser 22 constructed in accordance with one embodiment of the
present invention. FIG. 1C illustrates a plastic diffuser 24
constructed in accordance with one embodiment of the present
invention. The glass diffuser 20, metal diffuser 22, and plastic
diffuser 24 will be described in greater detail below with
reference to the processes of the invention.
[0036] FIG. 2 illustrates a schematic view of a process of forming
a random surface relief structure on a diffuser substrate body. The
substrate body 30 includes a first side 32 onto which a diffuser
surface relief structure will be formed. The substrate 30 is
illustrated in the form of a flat rectangular plate and the
diffusers 20, 22 and 24 are illustrated in the form of rectangles
in FIGS. 1A-1C. It is intended that the diffusers and the substrate
material may take on any number of configurations and constructions
without departing from the scope of the present invention. The
simple shapes and configurations illustrated herein are shown for
simplification of description and not by way of limitation.
[0037] The substrate 30 of the present embodiment can also be in
the form of a glass substrate, a metal substrate, or a plastic
substrate without departing from the scope of the present
invention. Depending upon the type of substrate material selected,
the process shown in FIG. 2 may vary slightly in order to produce
the desired surface relief structure as described below. The method
of the invention is capable of forming a surface relief structure
on a common material such as plastic but is also capable of forming
such a surface relief structure on hard and highly durable
materials such as glass and metal. Prior methods of forming
diffuser surface relief structures are not capable of producing
suitable surface relief structures on such hard and durable
materials.
[0038] Referring again to FIG. 2, the first side 32 of the
substrate 30 is facing upward although this orientation can be
altered without departing from the scope of the invention. The
substrate 30 can also be held in a suitable fixture (not shown) or
other apparatus for affixing the substrate in place while it is
being worked.
[0039] As illustrated in FIG. 2, a suitable buffing agent 34 is
disposed on the first side 32 of the substrate 30. Buffing agents
that can be used include agents such as aluminum oxide, silicon
carbide, and cerium oxide. A buffing apparatus 36 is disposed over
the substrate 30 and is utilized to work the buffing agent 34
against the first side 32 to produce scratches or other such
irregularities in the substrate first side 32. Depending upon the
materials selected for the substrate 30, the buffing agent is
selected including a particular grit in the form of buffing
particles 35 which are suspended within a compound or which are
otherwise attached to the buffing apparatus 36. The buffing
particles 35 are determined by the type of substrate material 30
selected.
[0040] For example, if the substrate 30 is a plastic material, the
buffing agent 34 may be a buffing compound having suspended therein
a plurality of buffing particles 35 in the form of sand or silica
of a particular grit or size. Alternatively, the buffing agent can
be in the form of what is commonly known as sandpaper which
includes a paper substrate having sand or silica particles adhered
thereto of a particular grit. In either case, the buffing particles
must be suitable for working and abrading the surface of the
relatively soft plastic substrate.
[0041] FIG. 2 illustrates that a buffing agent 34 including
suspended silica particles is disposed on the first side 32 of the
substrate 30. The buffing apparatus 36 includes a buffing pad 38
that is brought into contact with the buffing compound 34 and
rotated or otherwise moved against the buffing compound 34. The
buffing pad 38 works the buffing agent 34 including the suspended
silica particles into the first side 32 to form a plurality of
surface irregularities in the form of scratches and indentations in
the surface. In an alternative embodiment, the buffing apparatus 36
may have a sheet or pad of sandpaper mounted to the pad 38, where
the sheet includes the silica particles adhered thereto. In this
embodiment, the buffing compound 34 is not necessary and is
replaced by the sandpaper carried on the buffing pad 38.
[0042] FIG. 2 illustrates that the buffing pad 38 is rotated about
a rotary shaft 40 in order to work the buffing agent 34 into the
first side 32. The buffing pad 38 can alternatively be a surface
which moves back and forth across the first side 32 in order to
produce the scratches and indentations. In a further alternative,
the buffing pad 38 can be connected via a mechanism (not shown) and
electronic means to a computer system 42 for guiding the buffing
pad 38 over the first side 32. In such an embodiment, the
particular surface scratches and indentations are preprogrammed
into the computer and replicated onto the first side 32 as
desired.
[0043] In this embodiment, the surface irregularities, indentations
or scratches are formed in the first side 32 of the substrate 30 by
the silica or buffing particles of the buffing agent 34 physically
cutting into the first side 32. The depth, cross-sectional contour,
length and shape of the scratches depends on the direction of
rotation and/or linear movement of the buffing pad 38 of the
buffing apparatus 36 relative to the first side of the
substrate.
[0044] If the substrate body 30 is alternatively formed from a
material such as glass or a very hard plastic or a soft metal such
as gold, the buffing agent 34 may include a more durable type of
sand or silica particle 35 is suitable for forming scratches and
indentations and otherwise deforming such hard materials.
Alternatively, if the substrate material is any type of glass
including extremely hard composite glass, the buffing agent 34 may
include buffing particles 35 in the form of a diamond powder or
diamond particles suitable for scratching or otherwise deforming
such a hard surface. The type of buffing agent 34 as well as the
particular construction of the buffing apparatus 36 is selected and
designed according to the desired diffuser characteristics and the
substrate 30 material.
[0045] Referring now to FIG. 3, a substrate body 50 includes a
first side onto which a surface relief structure is to be formed.
Again, the substrate material can be any suitable material but
preferably is a metal or glass substrate material. Additionally,
the substrate 50 can be supported in a suitable fixture or machine
(not shown) in order to perform the process of the invention.
[0046] An acid or alkali etching agent 54, such as hydrochloric
acid, hydrofluoric acid, ammonium fluoride, potassium hydroxide or
sodium hydroxide is poured on or otherwise disposed over the first
side 52 of the substrate 50. The etching agent 54 reacts with the
substrate material and forms irregularities or depressions in the
first side 52 to define the diffuser surface relief structure as is
described in more detail below. The etching acid or alkali can be
any type of acid or alkali that is selected to react as desired
with a particular substrate material from which the substrate body
50 is manufactured. The etching acid in one preferred embodiment is
a solution containing either hydrofluoric acid or ammonium
fluoride. The etching alkali in one preferred embodiment is a
solution containing either potassium hydroxide or sodium hydroxide.
Depending on the amount of time the acid or alkali is left on the
first side of the substrate and on the concentration of the acid or
alkali, the etching agent 54 reacts with the first side to form the
irregularities thereon. The etching acid or alkali essentially eats
away at the surface of the substrate body 50 where it is located
and where it is most concentrated. For example, the etching acid or
alkali can be applied to the first side 52 for less than 2 minutes
on a glass or metal substrate body 50 to produce the desired
result.
[0047] After the desired duration of acid or alkali etching has
expired, the first side 52 is washed with water or another cleaning
solution in order to remove all of the remaining etching agent 54.
A suitable hose 58 connected to a reservoir of water other solution
60 can be retained near the substrate 50 in order to wash the
etching agent 54 from the substrate.
[0048] In the present embodiment, a plurality of solid particles 56
are suspended in the acid or alkali etching agent 54 to further
enhance the etching process and to produce a more desirable surface
relief structure in the first side 52 of the substrate.
Alternatively, the particles can be first placed on top of the
substrate body 50, such as a glass substrate, and then the etching
agent 54 poured over the first side 52 and the particles 56 to
produce the desired surface relief. The particles 56 enhance the
surface relief structure by penetrating deeper into the first side
52 according to the mass and size of each particle and according to
the chemical reaction between the etching agent 54 and the
substrate body 50 beneath each particle. The greater the mass of
each particle 56, the deeper the depression left beneath each
particular particle.
[0049] FIG. 4 illustrates another alternative embodiment of the
acid or alkali etching process whereby a pressure plate or pressing
tool 62 is placed over the first side 52 sandwiching therebetween
the acid or alkali etching agent 54 and the particles 56. A force
in the direction of arrows F is applied to the pressure plate or
pressing tool 62 to increase penetration of the particles deeper
into the first side 52. The more force applied to the plate 62, the
deeper the particles 56 will embed into the first side 52 thereby
enhancing the surface relief structure.
[0050] The size, shape and mass of the particular particles 56 can
vary considerably depending on the desired surface relief
characteristics formed in the first side 52. In one embodiment, a
powder such as a ceramic powder including very fine particles can
be utilized and placed on the first side 52 of the substrate body
50. The ceramic powder particles are particularly useful for
etching a substrate of glass. Particular examples of suitable
powder particles include silicon carbide and boron carbide. Such
powder particles can either be in the form of irregular and
randomly shaped particles in a range of sizes from about 4 mm to
about 0.045 mm. Alternatively, particles can have a general shape
of hexagonal, rhombohedral, spherical, or any other suitable shape
and range in sizes from about 4 mm to about 0.045 mm. The larger
the particle size, the deeper the impression made in the first side
52. Spherical particles 56 will leave essentially semi-circular or
spherical depressions in the first side 52.
[0051] FIGS. 5A and 5B illustrate another alternative embodiment
which can be utilized to etch a surface relief structure in a
substrate body 50. FIG. 5B illustrates a perspective view of
substrate body 50 and the mask 64. In this embodiment, a mask 64
made of a material such as polyester or polycarbonate is placed
over the first side 52 of the substrate body 50. A portion of the
first side 52 is exposed through a plurality of openings 66 formed
in the mask 64. The openings 66 can be randomly produced in the
mask or can be computer generated in order to produce a particular
and predetermined surface relief structure in the substrate body
50.
[0052] In this embodiment, the etching agent 54 does not
necessarily include particles 56 therein but may instead be a
purely liquid solution. The etching acid solution 54 is then poured
over the mask 66 and etches the first side 52 of the substrate body
50 only where exposed through the openings 66. The surface contour
and configuration of the surface relief structure formed on the
first side 52 is determined by the length, width, contour, spacing
and shape of the openings 66 provided in the mask 64 as well as the
acid concentration, duration and etching and acid and substrate
compositions. Virtually any pattern of openings can be produced in
the mask 64 to form any number of surface relief structures in the
substrate body 50.
[0053] Referring now to FIG. 6, another alternative embodiment for
producing a surface relief structure in a substrate body is
disclosed. In this embodiment, a substrate body 70 is provided
having a first side 72 onto which a diffuser surface relief
structure is to be formed. The substrate body 70 is placed adjacent
a blasting apparatus 74 having a nozzle 76 from which a blasting
material is ejected at a high velocity in the direction of the
arrows B toward the first side 72 of the substrate. A hose 78 is
connected to a supply (not shown) of blasting material or particles
80 drawn into the hose 78 of the apparatus 74 and ejected toward
the substrate. The particles 80 can be in the form of shot
particles and may be provided from any number of materials such as
spherical metal balls or sand or silica particles of various sizes
and shapes. The particles 80 are ejected from the blasting
apparatus 74 and bombard the first side 72 of the substrate. Upon
impact with the substrate, the particles 80 form small depressions
or pits in the first side. These depressions or pits define the
surface relief structure of the diffuser created on the substrate
70. The shape, size and contour of the depressions or pits are
defined by the mass, size and shape of the shot particles 80, the
velocity of the particles exiting the nozzle 76, and the material
which forms the particles and the substrate body 70. Additionally,
the angle of incidence of the nozzle 76 relative to the first side
72 and the path of travel of the shot particles 80 relative to the
first side 72 also affects the structure formed on the first side.
Additionally, the size and shape of the nozzle 76 may also be
varied in order to change the surface relief structure
characteristics formed on the first side of the substrate.
[0054] Referring now to FIG. 7A, an elevation plan view of a
diffuser and a diffuser surface formed by any of the above
embodiments is illustrated. The diffuser has a substrate 30, 50, or
70 and a diffuser surface 33, 53, or 73 formed by the buffing,
etching, and blasting embodiments, respectively. FIG. 7B
illustrates a cross-sectional view of the diffuser surface taken
along lines 7B-7B of FIG. 7A.
[0055] The shape and orientation of the scratches and indentations
determine the light output characteristics of the diffuser,
including non-Lambertian output. For example if the scratches are
long and narrow in one direction the light output from the diffuser
will be a distribution which is long and narrow in the
perpendicular direction. If, for example, a circular light
distribution is desired, scratches or indentations of a more
circular shape, such as might be achieved by pressing the buffing
material into the surface in the presence of acid, are preferably
used.
[0056] Though the invention was described referring to particular
embodiments, many other changes and modifications may be made to
the invention as described without departing from the spirit and
scope thereof. The scope and spirit of these changes and
modifications will become apparent from the appended claims. The
scope of the invention is therefore intended only to be limited by
the appended claims.
* * * * *