| 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. |
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