1. A method for manufacturing an optical film, comprising:
providing a template;
coating an aluminum film on a surface of the template;
forming a number of regular cone-shaped microstructures on a surface of the aluminum film;
providing a substrate made of a transparent polymer material;
transferring the cone-shaped microstructures on the surface of the aluminum film to the substrate to form a number of cone-shaped micro-protrusions on the substrate; and
modifying the surfaces of the cone-shaped micro-protrusions on the substrate to obtain a layer containing hydrophobic-functional-groups on the surfaces of the cone-shaped micro-protrusions on the substrate;
wherein forming a number of regular cone-shaped microstructures on a surface of the aluminum film comprises:
putting the template into an electrolytic oxidation tank containing electrolyte;
applying a voltage on the electrolyte to form an alumina layer on the surface of the aluminum film, with a number of cone-shaped micro pores formed on the surface of the alumina layer;
dipping the template with the micro pores in a phosphoric acid solution with a concentration of about 5% by weight and the temperature of about 30\xb0 C.;
applying another voltage to the phosphoric acid solution to ream the micro pores;
cleaning the template; and
repeatedly applying the another voltage to the phosphoric acid solution to ream the micro pores and cleaning the template for 5 times.
2. The method of claim 1, wherein the surface of the template is a polished surface.
3. The method of claim 1, wherein the template is made from monocrystal or metal.
4. The method of claim 1, wherein the electrolyte is selected from the group consisting of sulfuric acid solution, phosphoric acid solution and oxalic acid solution.
5. The method of claim 1, wherein the material of the substrate is poly methyl methacrylate.
6. The method of claim 1, further comprising: forming a self-assembled monolayer on the surfaces of the cone-shaped microstructures after anodizing the aluminum film and before transferring the cone-shaped microstructures on the surface of the aluminum film to the substrate.
7. The method of claim 6, wherein the step of forming the self-assembled monolayer comprises:
putting the template with the regular cone-shaped microstructures in a vacuum chamber;
introducing one kind of inert gas into the vacuum chamber; and
introducing a long carbon chain perfluorinated fatty acids into the vacuum chamber.
8. The method of claim 7, wherein the step of forming the self-assembled monolayer further comprises:
cooling the template to a room temperature; and
scouring the self-assembled monolayer successively by chloroform, acetone, ethanol and deionized water.
9. The method of claim 1, wherein the step of modifying the surfaces of the micro-protrusions of the substrate to obtain a layer containing hydrophobic-functional-groups comprises: introducing a gas into a plasma machine.
10. The method of claim 9, wherein the gas introduced into the plasma machine is carbon tetrafluoride.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method for manufacturing a honeycomb panel laminate,
the honeycomb panel laminate including a sound absorbing face, a sound absorbing layer, and a sound insulating face,
the sound absorbing face being made of a sponge foam,
the sound absorbing layer being composed of a honeycomb material and a layer obtained by filling spaces in cells of the honeycomb material with a hard foam material,
the method comprising the steps of:
(a) before filling the cell spaces in the honeycomb material, which constitutes the sound absorbing layer, with the hard foam material, bonding the honeycomb material to the sound absorbing face by applying an adhesive to hexagonal linear edges of cell walls of the honeycomb material and to rising wall surfaces of the cell walls, pushing the hexagonal linear edges of the cell walls against the sound absorbing face made of the sponge foam, and applying further pressure to press the hexagonal linear edges, to which the adhesive has been applied, of the cell walls against the sponge foam so that the hexagonal linear edges of the cell walls bite into the sponge foam;
(b) after step (a), forming the sound absorbing layer by filling the cell spaces in the honeycomb material with the hard foam material by pressing the hard foam material into the cell spaces in the honeycomb material from a side of the honeycomb material opposite the sound absorbing face while applying pressure to such an extent that bubbles in the hard foam material do not get destructed, in order that the sound absorbing layer is in a plane state where the cell walls of the honeycomb material and the hard foam material are at substantially a same level, the hard foam material having substantially a same thickness as that of the honeycomb material,
the sound insulating face, which is parallel to the sound absorbing face and which faces the sound absorbing face across the honeycomb material, being made of a sponge foam; and
(c) bonding the honeycomb material to the sound insulating face by applying an adhesive all over a surface of the sound insulating face that is to be in contact with the honeycomb material, pushing opposite edges of the cell walls of the honeycomb material of the sound absorbing layer against the surface, to which the adhesive has been applied, of the sound insulating face made of the sponge foam, the opposite edges being opposite the hexagonal linear edges to which the adhesive was applied, the sound absorbing layer remaining in the plane state where the cell walls of the honeycomb material and the hard foam material are at substantially the same level, and applying further pressure to press the opposite edges against the surface, all over which the adhesive has been applied, of the sponge foam so that the opposite edges bite into the sponge foam.
2. A honeycomb panel laminate which is manufactured by the method as set forth in claim 1,
the sponge foam of which the sound absorbing face is made being an open-cell sponge foam,
the hard foam material constituting the sound absorbing layer being an open-cell hard foam material,
the sponge foam of which the sound insulating face is made being a closed-cell sponge foam.
3. The honeycomb panel laminate as set forth in claim 2, wherein the sponge foams of which the sound absorbing face and the sound insulating face are made, are polyethylene foam materials.
4. The honeycomb panel laminate as set forth in claim 2, wherein the foam material with which the cells spaces in the honeycomb material are filled is a hard phenol foam material.