Integrally formed resin diffusing component, doe, and manufacturing method therefor

A manufacturing method for an integrally formed resin diffusing component, comprising:

• step A, arranging a preset amount of a light-curable resin material in a liquid state on at least one flat supporting surface;
• step B, relatively reducing a spacing between a mold and a flat supporting surface of the at least one flat supporting surface until reaching a preset distance, wherein the mold has at least one microstructured surface for forming a microlens layer of the diffusing component, and the resin material is located between a microstructured surface of the at least one microstructured surface and the flat supporting surface, at the preset distance, the resin material in the liquid state is spread between the microstructured surface and the flat supporting surface and has a spread area, wherein the microstructured surface of the mold is imprinted on a surface of the resin material to form the microlens layer;
• step C, performing a light-curing treatment on the resin material in the liquid state to obtain a light-cured resin material as the diffusing component;
• and
• step D, removing the light-cured resin material from between the mold and the flat supporting surface;
• wherein the microlens layer is a microlens array composed of a group of stochastically arranged microlens units, wherein part of parameters of the microlens units are different, to prevent light from producing interference fringes when light passes through the diffusing component and propagates in space;
• wherein a design method of the microstructured surface of the mold and the microlens array of the diffusing component corresponding to the microstructured surface comprises:
• marking off regions where the microlens units are located respectively on a surface of a substrate, cross-sectional shapes or sizes of the regions where the microlens units are located respectively are basically consistent;
• establishing a global coordinate system (X, Y, Z) for the microlens array, and establishing a local coordinate system (xi, yi, zi) for a microlens unit, and a central coordinate of a region corresponding the local coordinate system is (x0, y0, z0), where the central coordinate of the region represent an initial central position of the microlens unit;
• setting a real center position of the microlens unit to be a position obtained by adding a random offset XOffset, and a random offset YOffset to central coordinate of the region in an X-axis direction and a Y-axis direction respectively;
• and
• representing a surface profile of the microlens unit in an Z-axis direction by a camber function f:
• f
• =
• cr
• 2
• 1
• +
• 1
• -
• (
• 1
• +
• k
• )
• ⁢
• c
• 2
• ⁢
• r
• 2
• +
• ∑
• i
• =
• 1
• N
• A
• i
• ⁢
• E
• i
• (
• x
• i
• -
• x
• 0
• -
• X
• Offset
• ,
• y
• i
• -
• y
• 0
• -
• Y
• Offset
• )
• +
• Z
• offset
• wherein, r2=(xi−x0−XOffset)2+(yi−y0−YOffset)2, is the curvature of the microlens unit, k is a conic constant, Ai is a coefficient of an i-th extended polynomial, and ZOffset is an offset in the Z-axis direction corresponding to the microlens unit.