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A fine surface roughness electroless Ni–P–PTFE composite modified stamper for light guide plate application

Electroless Ni–P–PTFE composite coating technology takes advantage of the beneficial properties from both Ni–P alloy and PTFE, such as good wear resistance, good anti-adhesion, dry lubrication, low coefficient of friction and good corrosion resistance. It has been applied in many mold industries. However, the Ni–P–PTFE composite coating suffers from bad surface roughness, when the PTFE particles incorporate into a Ni–P matrix. This severely hampers the technology to be applied to optical grade applications. In this paper, we propose a trick to generate a fine surface roughness (FSR) electroless Ni–P–PTFE composite to modify a nickel stamper. Using this new method, the nickel stamper can be covered by a Ni–P–PTFE functional layer and can keep the original surface property at the same time, namely the optical properties. We have chosen 4.5 inch (97 mm × 59 mm × 0.6 mm) light guide plates (LGPs) to demonstrate the effectiveness of the procedure. For the sake of comparison, the LGPs were produced by injection molding with three kinds of stampers including an original SUS430 master, an electroless Ni–P–PTFE composite coated nickel stamper and an FSR electroless Ni–P–PTFE composite modified stamper. We measured and discussed the optical performances at both the element level and system level, namely complete back light units.