The present invention provides processes (100, 200, 300, 400) for making a flexible packaging substrate having one or more Fresnel lenses (410, 602) and a product made therefrom. The said process comprises providing one or more Fresnel lenses (410, 602) on a first surface (408a, 610a) of a substrate/film (408, 610); and overlapping a predetermined portion (411, 603) of the Fresnel lenses (410, 602) on the substrate/film (408, 610) by printing or foil stamping. The flexible packaging substrate having one or more Fresnel lenses comprises a substrate (408) having the Fresnel lens or the pattern of Fresnel lenses (410) on the first surface (408a) thereof, wherein a predetermined portion (411) of the Fresnel lenses (410) is covered to hide irregular/uneven/torn edges.

This invention discloses a method of forming a prism sheet. The method comprises: providing a substrate having a major light input surface and a major light output surface opposite to the major light input surface; forming a prismatic structure on the major light output surface of the substrate; and forming an uneven structure on the major light input surface of the substrate, wherein forming the uneven structure on the major light input surface of the substrate comprises: providing a hard tool having a smoothly-curved shape such that the penetrating width of the hard tool increases as the penetrating depth of the hard tool increases; penetrating the hard tool into a mold and repeatedly moving the hard tool up and down to form a plurality of smoothly-curved concave shapes along a first path on the mold; and using the cut surface of the mold to emboss a thin film on the second path corresponding to the first path on the major light input surface of the substrate to form a plurality of convex shapes one-to-one corresponding to the plurality of smoothly-curved concave shapes on the second path on the major light input surface of the substrate; wherein the hard tool is not pulled away from the uncut surface of the mold so as to form the cut mold for embossing the thin film on the major light input surface of the substrate such that there is no space between each two adjacent convex shapes along the second path on the major light input surface of the substrate to maximize the uneven optical diffusing area on the second path on the major light input surface of the substrate.

A continuous polymer sheet casting apparatus includes first and second endless belts positioned in face to face relationship to each other for a portion of their lengths to form between their inside surfaces a mold cavity for molding a polymeric sheet therebetween, and a container in fluid communication with the mold cavity, the container configured to introduce a liquid monomer or liquid polymer and curing agent and/or initiator to the cavity for polymerization therein; a controlled cooling apparatus in thermal communication with the mold cavity, configured to cool and solidify the polymeric sheet as it moves through the mold cavity, wherein either the first, the second, or the first and second endless belts include a microstructured optical quality tool area on at least a portion of said belt or belts. A mold and process for molding is also disclosed.

A method for manufacturing netted dots on a light guide plate is disclosed, including: engraving, on a surface of a metal plate with a preset roughness, a female mould or a male mould corresponding to a shape of the netted dots on the light guide plate; coating the metal plate onto a surface of a roller; heating the roller so that a temperature of the metal plate rises to a preset temperature; adjusting a distance of a center of the roller in relation to a light guide plate feeding passage so that the metal plate applies a preset pressure onto the light guide plate to be machined; and making the light guide plate to be machined pass through the light guide plate feeding passage, wherein the metal plate transfer-prints a shape of netted dots of the female mould or the male mould onto the light guide plate to be machined at a preset pressure and a preset temperature to form the netted dots on the light guide plate. A device for manufacturing netted dots on a light guide plate is also disclosed.

A method of applying a pattern formed of two different materials to a pattern support layer includes: providing a die form having a surface with recesses defining the pattern; applying a first curable material to a surface first region, received in some of the first region recesses and partially filling a first region recess set; applying a second curable material to some of the surface first region, the second curable material at least partially fills the first set of the first region recesses; contacting a pattern support layer with the die form surface to cover the recesses containing both the first and second curable materials; separating the pattern support layer from the die form surface, the first and second curable materials in the covered recesses removed therefrom and retained on the pattern support layer; and curing the first and second curable materials during and/or after the second and third steps.

By providing a rib portion 40 having a constant height in the range from 50% to 120% of the height of the highest point of a split lens structure between a plurality of split lenses, even when roll forming is performed at a high speed, trapping of air bubbles can be inhibited, and resin flow can be promoted; therefore, an optical element 10 having a surface on which a lens shape is formed and having a special optical effect can be obtained with few structural defects and high productivity.

A method for manufacturing netted dots on a light guide plate is disclosed, including: engraving, on a surface of a metal plate with a preset roughness, a female mould or a male mould corresponding to a shape of the netted dots on the light guide plate; coating the metal plate onto a surface of a roller; heating the roller so that a temperature of the metal plate rises to a preset temperature; adjusting a distance of a center of the roller in relation to a light guide plate feeding passage so that the metal plate applies a preset pressure onto the light guide plate to be machined; and making the light guide plate to be machined pass through the light guide plate feeding passage, wherein the metal plate transfer-prints a shape of netted dots of the female mould or the male mould onto the light guide plate to be machined at a preset pressure and a preset temperature to form the netted dots on the light guide plate. A device for manufacturing netted dots on a light guide plate is also disclosed.

An optical film production method for suppressing air bubbles in microlenses, comprising rotating a roll die having a plurality of concave-shaped microlens transfer portions on the surface and running a substrate in the rotation direction; supplying an active energy ray-curable composition onto a coating roll adjacent to the roll die surface, flattening the composition , coating the flattened composition on the roll die surface; supplying an active energy ray-curable composition on the substrate and coating the composition on a surface of the substrate; associating the compositions and between the roll die and the substrate to form a liquid pool; and irradiating a region between the roll die surface and the substrate surface with an active energy ray so the compositions and are sandwiched between the roll die surface and the substrate surface to cure the compositions and .

The present invention describes the use of embossed patterns for producing striking visual patterns and/or security features on the package surface such as holographic images, 3-dimensional patterns, optical patterns, Fresnel lenses, sterling lenses or any similar optical features in registered or unregistered manner on a specified portion on a web, sheet or package. The present invention eliminates intermediate products and processes such as manufacturing and using stamping foils avoiding wastage of carrier films. This result in high speed operation with accurate registration for packaging substrate in web roll form or in sheet form.

The present invention provides processes (100, 200, 300, 400) for making a flexible packaging substrate having one or more Fresnel lenses (410, 602) and a product made therefrom. The said process comprises providing one or more Fresnel lenses (410, 602) on a first surface (408a, 610a) of a substrate/film (408, 610); and overlapping a predetermined portion (411, 603) of the Fresnel lenses (410, 602) on the substrate/film (408, 610) by printing or foil stamping. The flexible packaging substrate having one or more Fresnel lenses comprises a substrate (408) having the Fresnel lens or the pattern of Fresnel lenses (410) on the first surface (408a) thereof, wherein a predetermined portion (411) of the Fresnel lenses (410) is covered to hide irregular/uneven/torn edges.