Manufacturing method of roller for manufacturing patterned retarder film

Abstract

A method for producing a roller used for manufacturing a retarder film is provided. The method includes providing a roller having a roller axis and a roller surface; providing an embossing tool having an embossing end; rotating the roller with respect to the roller axis; embossing the roller surface with the embossing tool with a first depth in a first predetermined distance and a second depth in a second predetermined distance; and removing the embossing from the roller surface. The embossing end has a plurality of parallel microgroove structures. The embossing tool embosses the roller surface to generate a first embossing area having a plurality of first embossing patterns and a second embossing area having a plurality of second embossing patterns.

1 . A method for making a roller used for manufacturing a retarder film, comprising:
 providing the roller having a roller axis and a roller surface, said roller surface having a first end and a second end;   providing an embossing tool comprising an embossing end having a plurality of parallel micro-groove structures;   rotating the roller along a rotation direction with respect to the roller axis in a rotation speed and embossing the roller surface with the embossing tool with a first depth in a first predetermined distance from the first end to the second end to generate a first embossing area having a plurality of first embossing patterns;   removing the embossing tool from the roller surface and moving the embossing tool to the second end;   embossing the roller surface with the embossing tool with a second depth in a second predetermined distance from the second end to the first end to generate a second embossing area having a plurality of second embossing patterns; and   removing the embossing tool from the roller surface and moving the embossing tool to the first end.   
     
     
         2 . The method of  claim 1 , further comprising:
 embossing the roller surface repeatedly to generate the plurality of first and second embossing areas to cover all area of the roller surface,   wherein the plurality of first and second embossing areas are assembled in ring structures, and the first embossing areas are parallel and staggered linking to the second embossing areas.   
     
     
         3 . The method of  claim 1 , wherein the depth of the first depth and the second depth are substantially the same. 
     
     
         4 . The method of  claim 1 , wherein the depth of the first depth and the second depth are substantially different. 
     
     
         5 . The method of  claim 1 , wherein the first depth and the second depth are in a range of 0.1 μm and 10.0 μm in depth. 
     
     
         6 . The method of  claim 1 , wherein the plurality of first and second embossing areas are in a range of 100 μm and 1000 μm in width. 
     
     
         7 . The method of  claim 1 , wherein the rotation speed is in a range of 1 rpm and 300 rpm. 
     
     
         8 . The method of  claim 1 , wherein the embossing tool moves in a moving speed in a range of 10 mm/min and 20000 mm/min. 
     
     
         9 . The method of  claim 1 , wherein the embossing tool is controlled by a Fast-tool-servo system. 
     
     
         10 . The method of  claim 1 , wherein the roller is made of copper and the embossing tool is made of diamond. 
     
     
         11 . A method for making a roller used for manufacturing a retarder film, comprising:
 providing the roller having a roller axis and a roller surface, said roller surface having a first end and a second end;   providing an embossing tool comprising an embossing end having a plurality of parallel micro-groove structures;   rotating the roller along a rotation direction with respect to the roller axis in a rotation speed and embossing the roller surface with the embossing tool with a first depth in a first predetermined distance in a direction from the first end to the second end to generate a first embossing area having a plurality of first embossing patterns;   removing the embossing tool from the roller surface and moving the embossing tool toward the second end with the first predetermined distance;   rotating the roller along an opposite rotation direction with respect to the roller axis in the rotation speed; and   embossing the roller surface with the embossing tool toward the second end with a second depth in a second predetermined distance to generate a second embossing area having a plurality of second embossing patterns;   removing the embossing tool from the roller surface and moving the embossing tool to the second end.   
     
     
         12 . The method of  claim 11 , further comprising:
 embossing the roller surface repeatedly to generate the plurality of first and second embossing areas to cover all area of the roller surface,   wherein the plurality of first and second embossing areas are assembled in ring structures, and the first embossing areas are parallel and staggered linking to the second embossing areas.   
     
     
         13 . The method of  claim 11 , wherein the depth of the first depth and the second depth are substantially the same. 
     
     
         14 . The method of  claim 11 , wherein the depth of the first depth and the second depth are substantially different. 
     
     
         15 . The method of  claim 11 , wherein the first depth and the second depth are in a range of 0.1 μm and 10.0 μm in depth. 
     
     
         16 . The method of  claim 11 , wherein the plurality of first and second embossing areas are in a range of 100 μm and 1000 μm in width. 
     
     
         17 . The method of  claim 11 , wherein the rotation speed is in a range of 1 rpm and 300 rpm. 
     
     
         18 . The method of  claim 11 , wherein the embossing tool moves in a moving speed in a range of 10 mm/min and 20000 mm/min. 
     
     
         19 . The method of  claim 11 , wherein the embossing tool is controlled by a Fast-tool-servo system. 
     
     
         20 . The method of  claim 11 , wherein the roller is made of copper and the embossing tool is made of diamond.