An electrosprayed coating process for fabricating hemispherical PMMA droplets for an optical diffuser

A modified electrospraying process is proposed for fabricating uniform microsized poly(methyl methacrylate) (PMMA) hemispherical droplets on poly(ethylene terephthalate) films for use as optical diffusers. In this process, an electrode controlled by an electric field is attached to a rotating collector, and various electric field conditions are applied to the droplets ejected from a positively charged nozzle. The distribution of small hemispherical droplets and the surface roughness resulting from this modified electrospraying process are more uniform than those achieved in the normal electrospraying process. The frequency of the field applied to the electrode is not critical to the production of stable PMMA droplets. The optical diffusivity of the PMMA film fabricated using this process is greater than that of normally fabricated film, demonstrating the feasibility of using this process to create newly designed optical diffusers.