Method for manufacturing large-size light-guide sheet by using mask

A method for fabricating a light-guide sheet, comprising:

• (1) providing a mask, wherein the mask comprises a plurality of regional mask patterns and a plurality of clearance regions separating the plurality of regional mask patterns from one another;
• and each of the regional mask patterns comprises a combination of light-transmitting openings and light-blocking portions or a combination of light-blocking patterns and light-transmitting portions;
• and in at least one of the regional mask patterns a density of the light-transmitting openings or a density of the light-blocking patterns gradually increases in at least one direction;
• (2) coating a mixture of photopolymerizable materials on a light-guide substrate to form a coating layer and placing the light-guide substrate with a coating layer on the mask;
• (3) projecting light beams or electron beams through the mask onto the coating layer on the light-guide substrate so as to polymerize portions of the coating layer exposed to the light beams or the electron beams;
• (4) separating the light-guide substrate from the mask and washing the light-guide substrate with a solvent chosen from methanol, acetone, isopropanol, or water to remove portions of the coating layer that is not polymerized so as to form a plurality of clearance regions on the light-guide substrate that correspond to the clearance regions in the mask;
• and
• (5) cutting the light-guide substrate from step (4) along the clearance regions to obtain a plurality of unitary light-guide sheets, wherein each of the plurality of the unitary light-guide sheets is configured to receive an incident light into one side of the unitary light guide sheet and emit the light from a planar surface of the unitary light guide sheet,
• wherein the plurality of clearance regions on the light-guide substrates separate the light-guide substrate into a plurality of microstructure regions, and each of the plurality of the unitary light-guide sheets comprises one or more of the microstructure regions.