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Development of a Multilayered Optical Diffusion Sheet Using

Microcellular Foaming Technology
Kyung Soo Leea; Byungjoo Jeona; Sung Woon Chaa
a
Department of Mechanical Engineering, Yonsei University, Seodaemun-Gu, Seoul, Korea

Online publication date: 19 January 2011

To cite this Article Lee, Kyung Soo , Jeon, Byungjoo and Cha, Sung Woon(2011) 'Development of a Multilayered Optical
Diffusion Sheet Using Microcellular Foaming Technology', Polymer-Plastics Technology and Engineering, 50: 1, 102 —
111
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 Polymer-Plastics Technology and Engineering, 50: 102–111, 2011
Copyright # Taylor & Francis Group, LLC
ISSN: 0360-2559 print=1525-6111 online
DOI: 10.1080/03602559.2010.531418
Development of a Multilayered Optical Diffusion Sheet
Using Microcellular Foaming Technology
Kyung Soo Lee, Byungjoo Jeon, and Sung Woon Cha
Department of Mechanical Engineering, Yonsei University, Seodaemun-Gu, Seoul, Korea
The superior optical performance of a sheet developed using
microcellular foaming technology is demonstrated through the
development and commercialization of a reflector. In this study,
the cell morphology characteristics of reflectivity, transmittance,
and haze were analyzed to develop diffusion sheet. A basic concept
of a multilayered diffusion sheet was derived using axiomatic design,
and the design was tested and validated using a microcellular foam-
ing batch process. Diffusion sheet transmittance and haze values
were compared with commercialized products. The results show
the multilayered diffusion sheet manufactured using a microcellular
foaming process increased transmittance by 40% compared to that
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of existing products.
Keywords Axiomatic design; Diffusion sheet; Haze; Micro-
cellular foaming process; Multilayered structure;
Transmittance
INTRODUCTION
Price reductions in the liquid crystal display (LCD) mar-
ket have intensified competition to reduce the cost of parts
manufacturing in the thin-film transistor LCD industry.
Research on integration of diverse optical sheets (films) is
ongoing, with the ultimate goal of producing a back light
unit (BLU), through an efficient and simplified process[1–3].
Microcellular foaming technology is being applied in
various fields (e.g., electrical, automotive and tissue
engineering) worldwide[4–11]. It offers advantages in cost
reduction, weight reduction, and dimensional stability
while maintaining the original properties of a product[11–13].
Microcellular foaming batch processes currently have a
productivity limit, unlike continuous processes, e.g., injec-
tion molding and extrusion molding. Intensive research
continues on batch processing because it offers the poten-
tial for manufacturing high value-added products with
superior optical performance[3,14].
Furukawa Electric has developed and commercialized a
microcell polyethylene terephthalate (MCPET) foam sheet
that is used as the reflector in an LCD BLU[15,16]. However,
Address correspondence to Sung Woon Cha, Department of
Mechanical Engineering, Yonsei University, 134 Shinchon-Dong,
Seodaemun-Gu, Seoul, Korea 120-749. E-mail: swcha@yonsei.
ac.kr
102
current manufacturing cost reduction studies are focusing
on developing reflectors made from polypropylene (PP),
which is cheaper than polyethylene terephthalate (PET)[3].
Due to the characteristics of batch processing methods,
microcellular foaming is only cost effective when develop-
ing high value-added products. For this reason, implemen-
tation of a batch process to manufacture a diffusion sheet
with superior optical performance for use as an LCD BLU
reflector is worth testing.
Studies of diffusion sheet manufacturing using a
microcellular foaming batch process are limited compared
to those regarding reflector manufacturing. Uniform
microcells produced by the foaming process are much more
appropriate for use in light reflection than in light
diffusion[2,3,14]. However, since batch processes can gener-
ate bubbles of various size and density by controlling the
foaming factors, significant product improvement is
achievable if diffusion sheet cell morphology requirements
are considered. For example, if the diffusion sheet of a
large LCD TV is developed through a microcellular foam-
ing process, it is possible that the manufactured products
will gain commercial advantages through the good
base-material strength, weight savings via the foaming
process, and reduced cost of raw materials.
We used axiomatic design to develop a diffusion sheet
from an applied microcellular foaming process. The cell
morphology characteristics were analyzed to establish a
basic concept of the optical properties. Our application
of an axiomatic design plan was validated by successfully
developing a diffusion sheet using a microcellular foaming
batch process. The commercialization possibilities of the
diffusion sheet were validated by comparing its optical
performance to that of existing products.
APPLICATION OF AXIOMATIC DESIGN TO THE
DEVELOPMENT OF A MULTI-LAYER STRUCTURED
DIFFUSION SHEET
Axiomatic Design
Axiomatic design is a method for finding and evaluating
problems that could appear in the early stages of the design
process. The method’s name refers to the two axioms used,
 MULTILAYERED OPTICAL DIFFUSION SHEET
FIG. 1. Decision matrix design categories.
the independence axiom and the information axiom. The
parameters used in the method include functional require-
ments (FRs), derived from the experience and knowledge
of the designer, and design parameters (DPs). Axiomatic
design aids in finding the best path through the design pro-
cess by correlating factors through a design matrix (DM).
The DM is the core tool used in axiomatic design to vali-
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date the design plan. Through use of a DM, potential plans
are classified into coupled, decoupled, and uncoupled
designs (Figure 1).
To assure independence (the first axiom) between FRs,
designs classified as coupled should be considered invalid.
Uncoupled designs and decoupled designs meet the inde-
pendence axiom, and thus are valid designs. The corre-
lation between the FRs and DPs is used in product
design, while the correlation between the DPs and process
variables (PVs) is used for process design[13,17–19].
Microcellular Foaming Reflector and Diffusion Sheet
Characteristics
The performance of the reflector in an LCD BLU is
determined by reflectivity, whereas the diffusion sheet per-
formance is determined by transmittance. Also, due to
LCD BLU characteristics, both the reflector and diffusion
sheet should have a wide light wavelength range. Diffused
reflectivity and haze are the most important factors in
FIG. 2. Reflection and diffusion mechanisms.
103
determining performance[1,3]. The functional requirements
were selected as follows:

Functional requirements – reflector
FR1: Maximize total reflectivity (constraint: above
90%)
FR2: Maximize diffused reflectivity (constraint:
above 90%)

Functional requirements – diffusion sheet (or plate)
FR1: Maximize transmittance (constraint: above
90%)
FR2: Maximize haze (constraint: above 90%).
Maximize reflectivity indicates that light penetration
should be minimized, while maximize transmittance indi-
cates the opposite. The performance of microcellular
foaming reflectors and diffusion sheets depends on cell
morphology (e.g., size, density, and cell distribution)
because microcells operate both as reflectors and diffusers
(Figure 2)[3,14]. Therefore, two similar microcell-based
products with different cell morphologies will have differ-
ent optical performance characteristics.
The cell morphology of a microcellular foaming reflec-
tor (MFR) should be characterized by minimum cell size
and maximum cell density, since reflectivity increases as cell
size decreases and cell density increases[2,3]. In contrast,
microcellular foaming diffusion sheets (MFD) should have
optimal size and density. Transmittance in an MFD
 104 K. S. LEE ET AL.

TABLE 1 TABLE 2
Comparison of microcellular foaming reflector and Process variable condition and cost reduction expectations
diffusion sheet relative cell morphology
Process
Microcellular Microcellular Process condition
foaming foaming variables guideline Expected results
Cell morphology reflector diffusion
factor (MFR) sheet (MFD) Saturation Lower Decreased manufacturing
pressure equipment production
Cell size Smaller Larger cost
Cell number More Less Saturation time Shorter Increased productivity
Cell density Larger Smaller Foaming Lower Decreased manufacturing
Cell uniformity Same Same temperature equipment production
cost
Foaming time Shorter Increased productivity
reaches a maximum and haze reaches a minimum when

foam cells are not present. Cell uniformity is necessary Energy consumption and CO2 emission reductions are possible
for structural stability, so the size and distribution of cells as well.
for both MFR and MFD should be uniform. Development
of a diffusion sheet using a microcellular foaming process
must consider these basic cell morphology characteristics processes. To minimize production cost, minimization of
(Table 1). saturation pressure, saturation time, foaming temperature,
and foaming time is required (Table 2). The two variables
Conceptual Design of a Microcellular Foaming Diffusion
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of the gas saturation process, saturation pressure and satu-

Sheet Using Axiomatic Design ration time, are the most important factors in cost account-
The FRs for the manufacture of an MFD were listed, ing. The saturation pressure can greatly affect the
with the DP and PV candidate group selection based on manufacturing cost of the production system, specifically
the FRs. The final DPs and PVs were selected from the can- due to the cost of the high-pressure vessel needed for the
didate groups though experimentation. In selecting a DP, batch process. The saturation time determines the product
the number of cells was not considered because it is a production time, specifically the cycle time of product
known value based on the final size and density of cells. manufacturing. Thus, higher pressure equals more expens-
The cell distribution was also disregarded since it is an ive equipment, and longer time equals less product
essential parameter for assuring stable product perform- produced over a longer time period.
ance. Because the ability to mass produce the product is If the saturation time is reduced, the polymer cannot be
important, minimized cost and production time were selec- fully saturated with the gas. For example, the full satu-
ted as constraints (C). ration time of CO2 in PET with a 0.4 mm thickness is

The highest level FR-DP-PV-C 15 h[21], so decreasing the saturation time to less than 15 h
FR: Develop a high performance diffusion sheet (or
plate)
DP: Microcellular foaming diffusion sheet (or plate)
PV: Foaming conditions
Cs: Minimize manufacturing cost, uniform cell
distribution in product

Microcellular foaming diffusion sheet FR-DP-PV-C
FR1: Maximize transmittance (constraint 1: above
90%)
FR2: Maximize haze (constraint 2: above 90%)
DPs: Candidate group – cell size, cell density
PVs: Candidate group – saturation pressure, satu-
ration time, foaming temperature, foaming time.

PVs and Cost-Based MFD Product Concept Selection

Cost-Based PVs Condition Analysis and Guideline. PVs
are directly related to production costs in mass production FIG. 3. Cell morphology and gas solubility depth.
 MULTILAYERED OPTICAL DIFFUSION SHEET 105

FIG. 5. The three-layered diffusion sheet with diffusion layers and trans-
FIG. 4. Effect of process variables on cell morphology. mittance layer.

TABLE 3 and pressure can offer effective reductions in manufactur-

MFD PVs conditions and relative cost effects ing energy consumption and CO2 production.

Process Effect of Process Variable Condition on Cell Morphology.

Process condition Shorter gas saturation time results in a multilayer polymer
variables guideline Expected results (Figure 3) with differing optical properties due to the vary-
ing cell morphology (Figure 4). The cells become larger as
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Saturation Lower Decreased manufacturing

pressure equipment cost the foaming time lengthens and the foaming temperature
Saturation time Shorter Increased productivity increases. Conversely, the cells become smaller and denser
Foaming Higher Increased cost when the saturation pressure is higher and the saturation
temperature time longer[14,21,22]. Developing a cost-effective MFD
Foaming time Higher Increased cost requires process conditions that keep the saturation press-
ure low, saturation time=foaming time long, and foaming
temperature high (Table 3).

will result in CO2 not reaching the core portion of the
polymer (Figure 3). The gas dissolution depth (t) is determ-
ined by the saturation time. In a saturation condition
where the gas dissolution depths, t1 and t2, in a polymer
are equal, gas dissolution occurs equally on both sides of
the polymer sample. If the process allows sufficient satu-
ration time, then b ¼ 2 t; when the saturation time is
decreased, b > 2 t. Thus, minimizing saturation time to
cut costs limits gas saturation and results in an MFD
having three layers: two outer saturated layers and one
inner unsaturated layer.
To minimize production costs, the foaming temperature
and foaming time should be optimized by lowering the pro-
cessing temperature and decreasing the processing time.
Optimizing the process conditions of temperature, time,
PVs Condition Guidelines and Product Concept Selec-
tion. Determining saturation conditions is relatively easy
since their effects are linked together (e.g., higher satu-
ration pressures require shorter saturation times). This is
not the case for foaming conditions, since increasing foam-
ing temperature does not always result in reduced foaming
time (Table 4).
A design concept for an MFD can be derived from these
PVs condition guidelines. An MFD is manufactured through
an unsaturation process (i.e., minimum saturation time) that
results in a three-layered structure with diffusion layers and
transmittance layer (Figure 5). The product development
process creates one foam layer that meets the cell mor-
phology functional requirements of ‘‘maximized transmit-
tance’’, while the other foam layer ‘‘maximizes haze.’’

TABLE 4
PVs condition guideline for MFD development
Saturation Saturation Foaming
Process variable pressure time temperature Foaming time
Condition guideline Minimization Minimization Minimization Minimization
 106 K. S. LEE ET AL.

TABLE 5
Experimental gas saturation and foaming conditions
Saturation
pressure Saturation Foaming Foaming
(MPa) time (h) temperature ( C) time (s)
1 4 1 35 30
2 6 3 40
3 8 5 45
FIG. 6. Schematic diagram of the morphological changes of polymer=gas
systems in the gas foaming process.
penetration of a gas into the surface layer of a high mole-
EXPERIMENTAL DESIGN AND RESULTS cular weight material. PET (0.8 mm thick) was used for
the high molecular weight material, and CO2 was used
Microcellular Foaming Batch Process
for the gas. Three settings for each process variable (except
Basic approaches to producing a microcellular foam
the foaming time) were developed (Table 5). The tests were
include using a saturation process that dissolves a supercritical
conducted using combinations of the settings, e.g., for a
high-pressure, low-temperature gas in plastic materials, and
saturation time of 1 h, the saturation pressure was varied
forming stoma in polymer and gas dissolutions (Figure 6).
between 4, 6, and 8 MPa. The foaming time was set at 30 s
A microcellular foam sample can be produced using materials
for all tests, while the foaming temperature was varied
like pellets and sheets in a batch process. This is often used for
between 35 C, 40 C, and 45 C to compare the foaming
basic research into microcellular foaming processes due to the
characteristics under the given saturation time and pressure
relative ease of controlling the experimental factors and the
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conditions.
replicable nature of the experimental results.
Gas compressed at a high pressure in a microcellular Gas Saturation Experiment Absorption Results
foaming saturation process penetrates into the material
The total amount of CO2 dissolved into the PET was
by diffusion at the material’s surface. The foaming process
determined by comparing the PET sample’s weight before
is usually preceded by more than 24 h of saturation time to
(neat) and after the saturation process, reported as a
assure uniform and complete penetration of the gas inside
percent weight (w.t. %) increase (Eq. 1).
the solid material. A pump compresses CO2, which is intro-
duced into a high-pressure vessel containing the solid
Gas Absorbtion (w.t. %)
material (Figure 7).
Saturated weight (g)  Near weight (g) ð1Þ
¼
Near weight (g)
Experimental Conditions and Methods
To develop and test a cost-effective MFD manufacturing The absorption was measured for each test sample, and
process, we used an unsaturation process that limited graphically compared to the saturation time (Figure 8).

FIG. 7. Diagram of a saturation process system.

 MULTILAYERED OPTICAL DIFFUSION SHEET
FIG. 8. Change in gas absorption under different saturation time and
pressure conditions.
It is clear that the amount of gas dissolved into the high
molecular weight material increased when the saturation
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time was longer and the saturation pressure was higher.
Foaming Temperature Effects on Cell Morphology
The unsaturated samples were heated with glycerin
at 35 C, 40 C, and 45 C, and foamed under different
FIG. 9. SEM images of sample setions saturated with CO2 for 1 h at 6 MPa at (a) 35 C, (b) 40 C, and (c) 45 C.
FIG. 10. SEM images of sample sections saturated with CO2 for 1 h at 8 MP at (a) 35 C, (b) 40 C, and (c) 45 C.
107
saturation conditions (Table 5). The foaming characteris-
tics of the test materials were analyzed using a scanning
electron microscope (SEM). No cells were formed in sam-
ples saturated at 4 MPa due to very low gas absorption.
The 6 MPa and 8 MPa saturation pressure samples were
cooled in liquid nitrogen and sections were prepared for
imaging with the SEM.
Cells were formed only on the sample surface because
the saturation time was relatively short (1 h), which limited
CO2 penetration into the sample (Figures 9 and 10). The
cells were larger and present in higher quantities in the
samples saturated at 8 MPa compared to those saturated
at 6 MPa.
A thicker foam layer formed with a longer saturation
time (3 h) at both 6 MPa and 8 MPa (Figures 11 and 12)
compared to the 1-h saturation tests. This indicates that
a longer saturation time allowed more CO2 to permeate
deeper into the sample.
The foam layer for samples saturated for 5 h was thicker
than that of any other samples, and the foaming tempera-
ture effects were clearly evident (Figures 13 and 14). The
number of cells in each layer increased, and the foam layer
thickness increased as the foaming temperature was raised
from 35 C to 45 C. There was no noticeable difference in
the cell size related to the foaming temperature (as expected
from Figure 4), presumably because a foaming temperature
lower than or equal to 45 C does not transmit enough
energy to the sample.
 108 K. S. LEE ET AL.

FIG. 11. SEM images of sample sections saturated with CO2 for 3 h at 6 MPa at (a) 35 C, (b) 40 C, and (c) 45 C.
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FIG. 12. SEM images of sample sections saturated with CO2 for 3 h at 8 MPa at (a) 35 C, (b) 40 C, and (c) 45 C.

FIG. 13. SEM images of sample sections saturated with CO2 for 5 h at 6 MPa at (a) 35 C, (b) 40 C, and (c) 45 C.

FIG. 14. SEM images of sample sections saturated with CO2 for 5 h at 8 MPa at (a) 35 C, (b) 40 C, and (c) 45 C.
 MULTILAYERED OPTICAL DIFFUSION SHEET
FIG. 15. Transmittance performance over a range of wavelengths for
samples saturated at 6 MPa for 5 h.
All of the SEM images clearly show that an unsatura-
tion process produces a foam layer on the surface of the
sample, leaving an unfoamed middle layer. A longer satu-
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ration time and higher saturation pressure increased the
gas absorption, producing a thicker foam layer. As well,
a higher foaming temperature led to a thicker foam layer
with more cells in each layer.
Measurement and Analysis of Transmittance and Haze
Characteristics
The transmittance and haze were measured using a
Konica Minolta spectrophotometer (model CM-3600d)
to assess the performance of the manufactured
samples. All samples saturated at 6 MPa for 5 h had higher
FIG. 16. Transmittance performance over a range of wavelengths for
samples saturated at 8 MPa.
109
FIG. 17. Haze values for samples saturated at 6 MPa and 8 MPa.
transmittance values compared to a diffusion sheet stan-
dard (Figure 15). Samples saturated at 8 MPa for 5 h had
slightly lower or similar transmittance compared to a
diffusion sheet standard (Figure 16).
The transmittance increased as the saturation pressure
and foaming temperature decreased (Figures 15 and 16).
A higher saturation pressure and foaming temperature
increased the depth of the foam layer, and the number of
cells in a layer increased with the foaming temperature.
All samples saturated at 8 MPa for 5 h had haze values
similar to that of a diffusion sheet standard, while the
6 MPa samples were lower than the standard (Figure 17).
The haze value was proportional to the saturation pressure,
saturation time, and foaming temperature. A greater num-
ber of small cells present in a sample increased the haze
value, indicating that the number of cells in a layer was
more of a critical factor than the thickness of the foam
layer.
EXPERIMENTAL RESULTS AND DISCUSSION
The average transmittance and haze values within the
visible light spectrum were measured to compare the per-
formance of some of the MFD samples with a diffusion
sheet standard (Table 6). Samples 7 and 8 were closest in
performance to the standard. Sample 7 exhibited a 40%
increase in transmittance with only a 6% decline in haze,
which was expected since a diffusion sheet’s performance
is controlled by transmittance when the haze value exceeds
90%. Thus, the best performance from an MFD results
from using a 5 h saturation time at 6 MPa pressure (con-
trolling cell density and size) with a foaming temperature
of 45 C (controlling cell size).
We reassessed the FRs, DPs, and PVs originally set in
Section 2.3 in light of our test results, and changed the ‘‘cell
size’’ design parameter to ‘‘foam layer thickness’’.

FR-DP-PV-C for microcellular foaming diffusion
sheet manufacture
 110 K. S. LEE ET AL.

TABLE 6 Axiomatic design was used to examine the product and

Average transmittance and haze performance of MFD process design feasibility. Our results indicated that a
samples produced under varying conditions microcellular foaming diffusion sheet can be manufactured
by keeping the transmittance and haze, the two critical
Conditions functional requirements of a diffusion sheet, independent.
(saturation pressure, Transmittance When compared with a commercially available diffusion
saturation time, (%) (k ¼ 400  sheet (standard), the microcellular foaming diffusion sheet
Sample foaming temperature) 800 nm) Haze exhibited a 40% increase in transmittance with only a 6%
1 Standard 45 99.60 decrease in haze.
2 4 MPa, 1 h, 45 C 90 6.27 This shows that a microcellular foaming diffusion sheet
3 4 MPa, 3 h, 45 C 90 5.26 could be an outstanding commercial product since trans-
4 4 MPa, 5 h, 45 C 90 12.29 mittance is the most critical factor. Greater transmittance
5 6 MPa, 5 h, 35 C 81 47.76 means greater product efficiency, which allows for energy
6 6 MPa, 5 h, 40 C 75 69.56 savings. Commercial implementation of our conceptual
7 6 MPa, 5 h, 45 C 64 93.48 design could result in environmental benefits such as
8 8 MPa, 3 h, 45 C 42 99.22 energy savings in building the manufacturing facilities,
9 8 MPa, 5 h, 40 C 37 99.66 and in the actual manufacturing process as well. As such,
10 8 MPa, 5 h, 45 C 34 99.68 microcellular foaming diffusion sheets not only improve
performance but also have the potential for being marketed
as eco-friendly products. They are a product with high
FR1: Maximize transmittance (constraint 1: above potential for commercialization given the manufacturing
90%) cost savings and environmental friendliness compared
FR2: Maximize haze (constraint 2: above 90%)
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to the microcellular foaming reflectors currently on the

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