Patent ID: 8728366

Claim:
A method for making an optical plate formed with a microstructure, comprising: extruding a substrate material and advancing the same to pass through a first nip formed between an embossing roller and a first pressing roller at a temperature ranging from a glass transition temperature (Tg) of the substrate material to Tg+100° C., the embossing roller having a micropatterned surface formed with a plurality of protrusions and a plurality of grooves, the protrusions and the grooves cooperatively defining a microstructure-forming space; applying a photosensitive resin to the micropatterned surface and filling the same into the microstructure-forming space upstream of the first nip to form a plurality of microelements respectively in the microstructure-forming space; allowing the photosensitive resin applied to the micropatterned surface to pass through the first nip together with the substrate material, such that the substrate material is in contact with the embossing roller and slightly protrudes into the microstructure-forming space, thereby bonding the microelements to the substrate material; and irradiating and curing the photosensitive resin downstream of the first nip to form the optical plate.