U.S. patent application number 10/269628 was filed with the patent office on 2004-04-15 for waveguide with nanoparticle induced refractive index gradient.
This patent application is currently assigned to Eastman Kodak Company. Invention is credited to Aylward, Peter T., Dontula, Narasimharao, Majumdar, Debasis, Miller, Anne M..
Application Number | 20040071422 10/269628 |
Document ID | / |
Family ID | 32030391 |
Filed Date | 2004-04-15 |
United States Patent
Application |
20040071422 |
Kind Code |
A1 |
Aylward, Peter T. ; et
al. |
April 15, 2004 |
WAVEGUIDE WITH NANOPARTICLE INDUCED REFRACTIVE INDEX GRADIENT
Abstract
An optical element comprising an elongated channel for light
travel comprising a light transmitting polymeric central core and
further comprising multilayer particles, wherein a majority of the
particles have both a longest dimension less than 1 micrometer and
an aspect ratio of longest to smallest dimension of from 1000:1, to
10:1, wherein the particles are arranged in a concentration
differential in at least a portion of a plane normal to the length
of the channel so as to create a refractive index gradient in that
plane.
Inventors: |
Aylward, Peter T.; (Hilton,
NY) ; Majumdar, Debasis; (Rochester, NY) ;
Miller, Anne M.; (Batavia, NY) ; Dontula,
Narasimharao; (Rochester, NY) |
Correspondence
Address: |
Paul A. Leipold
Patent Legal Staff
Eastman Kodak Company
343 State Street
Rochester
NY
14650-2201
US
|
Assignee: |
Eastman Kodak Company
|
Family ID: |
32030391 |
Appl. No.: |
10/269628 |
Filed: |
October 11, 2002 |
Current U.S.
Class: |
385/124 ;
385/129 |
Current CPC
Class: |
G02B 1/048 20130101;
G02B 6/02033 20130101; G02B 6/1221 20130101; G02B 1/046 20130101;
G02B 2006/12095 20130101; B82Y 20/00 20130101; G02B 6/02038
20130101; G02B 6/0229 20130101 |
Class at
Publication: |
385/124 ;
385/129 |
International
Class: |
G02B 006/18; G02B
006/10 |
Claims
What is claimed is:
1. An optical component comprising an elongated channel for light
travel comprising a light transmitting polymeric central core and
further comprising multilayer particles, wherein a majority of the
particles have both a longest dimension less than 1 micrometer and
an aspect ratio of longest to smallest dimension of from 1000:1 to
10:1, wherein the particles are arranged in a concentration
differential in at least a portion of a plane normal to the length
of the channel so as to create a refractive index gradient in that
plane.
2. The optical component of claim 1 wherein the central core
comprises a planar shape.
3. The optical component of claim 2 wherein said central core
contains layered particles in a concentration gradient so as to
provide a decreasing differential refractive index from the center
to the outer edges of the central core.
4. The optical component of claim 2 that further comprises a clad
layer on one or both sides of the central core.
5. The optical component of claim 3 wherein said clad layer is
opaque.
6. The optical component of laim 3 wherein said clad layer has a
lower refractive index than said central core.
7. The optical component of claim 4 wherein said clad layer is
light absorbing.
8. The optical component of claim 7 wherein said clad layer is
black.
9. The optical component of claim 4 wherein said clad layer further
comprises an adhesive.
10. The optical component of claim 1 wherein the central core is
arcuate.
11. The optical component of claim 1 wherein the central core is
cylinder shaped.
12. The optical component of claim 11 wherein said central core is
a fiber.
13. The optical component of claim 11 wherein said cylinder has at
least one annular shaped clad layer surrounding the cylinder.
14. The optical component of claim 1 wherein the central core is
shaped like a lens.
15. The optical component of claim 14 wherein said lens-like shape
is convex.
16. The optical component of claim 14 wherein said lens-like shape
is concave.
17. The optical component of claim 14 wherein the central core
comprises multiple lenses.
18. The optical component of claim 1 wherein the central core is a
lens array.
19. The optical component of claim 18 wherein said lens array has a
geometric shape.
20. The optical component of claim 1 wherein said layered particles
are disposed in said central core in a weight percent of between 0
to 90%.
21. The optical component of claim 1 wherein said layered particles
form a concentration gradient with increasing concentration with
distance from the center of the light channel in a plane of normal
to the direction of the length of the channel.
22. The optical component of claim 1 wherein said concentration
gradient represents a linear rate of change.
23. The optical component of claim 1 wherein said concentration
gradient represents an exponential rate of change.
24. The optical component of claim 1 wherein said concentration
gradient decreases linearly from the central axis to the outer
edges.
25. The optical component of claim 1 wherein the multilayer
particles have an average thickness of between 0.5 to 10 nm.
26. The optical component of claim 1 wherein the layered particles
have an aspect ratio of the largest to smallest particle dimension
of between 10:1 and 1000:1.
27. The optical component of claim 1 wherein said multilayer
particles comprise a hydrotalcite.
28. The optical component of claim 1 wherein said multilayer
particles comprise a phyllosilicate.
29. The optical component of claim 28 wherein said phyllosilicate
comprises a smectite.
30. The optical component of claim 29 wherein said smectite
comprises montmorillonite.
31. The optical component of claim 30 wherein said montmorillonite
comprises aluminum silicate.
32. The optical component of claim 29 wherein said smectite
comprises hectorite.
33. The optical component of claim 32 wherein said hectorite is
fluorinated.
34. The optical component of claim 32 wherein said hectorite
comprises magnesium silicate.
35. The optical component of claim 29 wherein said smectite is
synthetic.
36. The optical component of claim 29 wherein said smectite is
organically modified.
37. The optical component of claim 29 wherein said smectite is
fluorinated.
38. The optical component of claim 1 wherein said polymeric channel
has a thickness of between 0.5-1000 micrometers.
39. The optical component of claim 1 wherein said gradient is
formed by a series of step changes with a refractive index change
of less than 0.01 per step.
40. A method of guiding light comprising allowing light to enter
the waveguide of claim 1.
41. A display screen comprising the waveguide of claim 1.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a waveguide containing layered
particles having lateral dimension of less than 1 micrometer
arranged in a concentration gradient and to a method of making the
same, and a display screen employing same.
BACKGROUND OF THE INVENTION
[0002] Optical screens typically use cathode ray tubes (CRTs) for
projecting images onto the screen. The standard screen has a width
to height ratio of 4:3 with 525 vertical lines of resolution. An
electron beam is scanned both horizontally and vertically across
the screen to form a number of pixels which collectively form the
image.
[0003] Conventional cathode ray tubes have a practical limit in
size, and are relatively deep to accommodate the required electron
gun. Larger screens are available which typically include various
forms of image projection. However, such screens have various
viewing shortcomings including limited viewing angle, resolution,
brightness, and contrast, and such screens are typically relatively
cumbersome in weight and shape. Furthermore, it is desirable for
screens of any size to appear black in order to improve viewing
contrast. However, it is impossible for direct view CRTs to
actually be black because they utilize phosphors to form images,
and those phosphors are non-black.
[0004] Optical panels used for viewing images may be made by
stacking waveguides. Such a panel may be thin in its depth compared
to its height and width, and the cladding of the waveguides may be
made black to increase the black surface area. It is known in the
art that waveguide componentis utilized for transmission of light.
It is further known in the art that a waveguide has a central
transparent core that is clad with a second material of a lower
refractive index. In order to provide total internal reflection of
light within this waveguide, the central core has a higher
refractive index of refraction than the clad. By adjusting the
difference in refractive index the acceptance angle of incoming
light may be varied. The larger the difference in refractive index,
the larger the incoming light acceptance angle.
[0005] In related work, U.S. Pat. No. 6,307,995 discloses a
gradient refractive index in a planar optical waveguide in which
the core material contains fluorinated polymer, silicone, silica,
polytetrafluoroethylene and other materials. While this patent
discloses certain concentration gradients, there is no practical
disclosure as how to make a gradient.
[0006] However, optical waveguides of the step index cladding type
have some significant drawbacks. In the formation of a large
optical panel using stepped index clad waveguides many layers are
stacked on top of each other and adhered to each other. In a
typical 50" diagonal screen there may be several hundreds or even
thousands of waveguides that are adhered to one another. Handling
and cutting many strips of thin polymer is very difficult. The
compatibility of materials that have a refractive index difference
from core to clad is limited. This may contribute to problems such
as inadequate adhesion between layers. Such incompatibility may
result in layer to layer interface problems such as air gaps or
rough surface or layer separation. These types of problem may cause
a loss of light at each bounce at the interface between the core
layer and surrounding cladding layers. Although the loss of light
at each bounce within the optical waveguide may be small, a light
ray may undergo a large number of bounces as it traverses the core
layer. Therefore, the amount of light loss that occurs in optical
panels becomes a significant detriment to the overall efficiency
and performance of the optical panel, as well as the quality such
as brightness, and sharpness of the image. When there is a discrete
step or boundary between the core and cladding of a waveguide, it
is important to control the angle of the incoming light. Light
entering a waveguide at acute angles typically will penetrate
deeper into the cladding layer than those entering at more oblique
angles and therefore it has a higher probability of being scattered
resulting in light loss. It would be useful if there was a way to
have light within a waveguide turn in a gradual manner and
therefore minimize losses due to scattering.
[0007] Since there are a limited number of materials that can be
used in combination between the core and the clad that provide the
desired delta refractive index, adequate adhesion between the
layers and can absorb ambient room light, it is important to have a
means of controlling or modifying the refractive index of polymers
to assure that both optical and physical characteristics are
optimized. In stepped refractive index clad waveguides of the type
described in U.S. Pat. Nos. 6,002,826, 6,301,417 and 6,307,995 it
is important to control or modify the refractive index difference
between two different materials or modify the refractive index of
the same polymer. If the difference is too large, the ambient light
acceptance of the screen becomes large and does not appear to be
black. There remains a need for improved control of refractive
index as well as a broader selection of materials that can be
used.
[0008] Another drawback of using optical waveguides of step index
cladding type is as follows. When light entering a core layer
comprises two or more different wavelengths, a phenomenon known as
chromatic dispersion results. Each wavelength portion of light will
travel at a slightly different speed and may result in the light
exiting the waveguide core at slightly different angles resulting
in poor color quality of the image. This means that the exit angle
of the light at the outlet face of the optical panel is dependent
on the wavelength, or color, of the components of the input light.
As can be envisioned, this phenomenon is further exaggerated when
the light path that a light ray follows through the core layer
increases. The chromatic dispersion that occurs in optical panels
using optical waveguides of step index cladding type is another
significant detriment to the performance of the optical panel, as
well as the quality (e.g. color, sharpness, etc.) of the image.
[0009] Ever since the seminal work conducted at Toyota Central
Research Laboratories, polymer-clay nanocomposites have generated a
lot of interest across industry. The utility of inorganic
nanoparticles as additives to enhance polymer performance has been
well established. Over the last decade or so, there has been an
increased interest in academic and industrial sectors towards the
use of inorganic nanoparticles as property enhancing additives. The
unique physical properties of these nanocomposites have been
explored by such varied industrial sectors as the automotive
industry, the packaging industry, and plastics manufacturers. These
properties include improved mechanical properties, such as elastic
modulus and tensile strength, thermal properties such as
coefficient of linear thermal expansion and heat distortion
temperature, barrier properties, such as oxygen and water vapor
transmission rate, flammability resistance, ablation performance,
solvent uptake, etc. Some of the related prior art is illustrated
in U.S. Pat. Nos. 4,739,007; 4,810,734; 4,894,411; 5,102,948;
5,164,440; 5,164,460; 5,248,720; 5,854,326; and 6,034,163.
[0010] In general, the physical property enhancements for these
nanocomposites are achieved with less than 20 vol. % addition, and
usually less than 10 vol. % addition of the inorganic phase, which
is typically clay or organically modified clay. Although these
enhancements appear to be a general phenomenon related to the
nanoscale dispersion of the inorganic phase, the degree of property
enhancement is not universal for all polymers. It has been
postulated that the property enhancement is very much dependent on
the morphology and degree of dispersion of the inorganic phase in
the polymeric matrix.
[0011] The clays in the polymer-clay nanocomposites are ideally
thought to have three structures: (1) clay tactoids wherein the
clay particles are in face-to-face aggregation with no organics
inserted within the clay lattice; (2) intercalated clay wherein the
clay lattice has been expanded to a thermodynamically defined
equilibrium spacing due to the insertion of individual polymer
chains, yet maintaining a long range order in the lattice; and (3)
exfoliated clay wherein singular clay platelets are randomly
suspended in the polymer, resulting from extensive penetration of
the polymer into the clay lattice and its subsequent delamination.
The greatest property enhancements of the polymer-clay
nanocomposites are expected with the latter two structures
mentioned herein above. Most of the work with nanoclays has been
for physical properties modification. Therefore, the need exists
for a waveguide that can be made with finite control of the
refractive index between the core and the clad that will provide a
broader selection of materials that can be used.
PROBLEM TO BE SOLVED BY THE INVENTION
[0012] There is a continuing need to improve waveguides that have
efficiency problems due to light loss as well as problems with
chromatic dispersion. The present invention solves problems
experienced in the prior art, such as the decrease in efficiency,
performance and quality resulting from the light loss from the
discreet bounces that the light undergoes in the optical waveguides
of step index cladding type, and the adverse affects of chromatic
dispersion when using optical waveguides of step index cladding
type, by providing a plurality of planar optical waveguides for an
optical panel, the planar optical waveguides comprising a core
material having a gradient refractive index.
SUMMARY OF THE INVENTION
[0013] The invention provides an optical component comprising an
elongated channel for light travel comprising a light transmitting
polymeric central core and further comprising multilayer particles,
wherein a majority of the particles have both a longest dimension
less than 1 micrometer and an aspect ratio of longest to smallest
dimension of from 1000:1, to 10:1, wherein the particles are
arranged in a concentration differential in at least a portion of a
plane normal to the length of the channel so as to create a
refractive index gradient in that plane. The invention also
provides a method of imaging using the waveguide and a display
incorporating the waveguide.
ADVANTAGEOUS EFFECT OF THE INVENTION
[0014] The invention provides a means to convey light with improved
efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic of a typical stepped clad waveguide
with an opaque material in the clad.
[0016] FIG. 2 is a schematic of a typical stepped clad waveguide in
which the clad is clear.
[0017] FIG. 3 is a schematic of a waveguide in which the core has a
gradient refractive index.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The invention has numerous advantages. It provides layered
particles of a size less than 1 micrometer which can be effectively
incorporated with a polymer to form a concentration gradient that
results in changing refractive index from the center transparent
polymeric channel to the outside. Such a material is very useful in
the formation of optical components such as optical panels that use
gradient refractive index to refract light. The layered particles
are typically intercalated clays belonging to the general class of
smectite materials that are either natural or synthetic. As the
concentration of layered particles is increased the refractive
index is decreased and by forming a concentration gradient within a
polymer layer, the refractive index is changed as a function of the
concentration.
[0019] For the purpose of this invention, FIG. 1 is a stepped
waveguide 11 that has a transparent core 14 and is surrounded by
clads 12 on the top and 16 on the bottom that have a lower
refractive index than the transparent core and contain black light
absorbing materials and also contain adhesive. The refractive index
of the core is higher than that of either clads. It is preferable
for clads 12 and 16 to be of approximately the same refractive
index. A waveguide as shown in FIG. 1 has a uniform refractive
index throughout in the transparent core 14 and a lower but uniform
refractive index in the clads 12 and 16. FIG. 2 is another type of
waveguide in which there is transparent core 24 with clear top clad
layer 22 and clear bottom clad layer 26 on either side of core 24.
Layers 22 and 26 have a lower refractive index than core 24. Clad
cap layers 20 and 28 are black adhesive layers.
[0020] As noted in FIG. 2, as light ray 30 enters the core of the
waveguide, it travels to the interface formed by core 24 and top
clad 22. If clad 22 is a lower refractive index than core 24 and
the light is below the critical angle, then it will be totally
internally reflected back into the core where it will travel until
it hits the interface between core 24 and bottom clad 26. Thus, it
is broken into segments that reflect off the cladding and travel
through the transparent core. The light will travel a small
distance into the clad before it is reflected. If there is
roughness or large particles that may cause light scattering, some
of the light will be lost and not reflected back into the core 24.
This will result in lower efficiency waveguides.
[0021] In simple terms, the action of a waveguide can be partially
understood by considering FIG. 3. A light-wave entering the
waveguide is either refracted into the cladding, and attenuated
(absorbed), or is totally internally reflected at the core/clad
boundary. In this manner light travels along the length of the
waveguide. The maximum angle at which it may enter the transparent
core and travel by total internal reflection is termed the
acceptance angle. FIG. 3 is a gradient waveguide with a
concentration gradient of layered particles. The center of the
waveguide has a lower concentration of layered particles than the
outer surfaces. This results in a progressive concentration
increase and therefore a progressive lowering of the refractive
index as light travels from the center to the outer surface. Since
there is a gradual change in refractive index, light will be bent
slowly as it is redirected back towards the center. Such a device
will have less loss and therefore transmit more of the light
entering the waveguide.
[0022] Thus, a waveguide 41 with a gradient refractive index within
the core 40 is a gradient refractive index waveguide. Light ray 44
enters the waveguide from the air or other media, and the light ray
42 is gradually turned within the core as it travels the length of
the waveguide. Top clad layer 46 has a lower refractive index than
the gradient core and contains black light absorbing materials and
also contains adhesive. Bottom clad 48 is a layer that has a lower
refractive index than the gradient core and contains black light
absorbing materials and also contains adhesive
[0023] The behavior of light entering a material is fundamentally
controlled by the property of the material. Perhaps the most
important property for waveguiding is to understand the term
refractive index. The refractive index of a material is the ratio
of the velocity of propagation of an electromagnetic wave in vacuum
to its velocity in the medium. The refractive index (n) of a
substance is defined as:
n=V.sub.v/V
[0024] where V.sub.v is the velocity of light in a vacuum, and V is
the velocity of light in the substance. In general light slows down
when it enters a substance, so the refractive index will always be
greater than 1. Most materials have refractive indices between 1.32
and 2.40, with values between 1.40 and 1.80 being of the most
interest for this invention. It should also be noted that the
refractive index of some materials are not necessarily the same in
all directions. The internal symmetry of a material is a reflection
of the orientation of atoms into layers. The arrangement of the
atoms determines how light interacts with the material. Two basic
types of behavior are exhibited:
[0025] 1. Isotropic--same properties (refractive index) in all
directions exhibit the same physical properties regardless of where
the light enters the crystal
[0026] 2. Anistropic--different properties (different refractive
index) in different directions. These materials are either uniaxial
that have two refractive indices in the length direction and width
of a sheet or biaxial that are characterized by three refractive
indices. These materials add a third refractive index in the
thickness plane of the material.
[0027] Light entering a waveguide follows Snell's law. Snell's law
of geometric optics defines the amount of bending that takes place
when a light ray strikes a refractive boundary, e.g., an air-glass
interface or the interface of two different polymer, at a
non-normal angle. In the following discussion of Snell's law
n.sub.a is the index of refraction of the material in which the
light ray travels, .alpha. is the angle, with respect to the normal
at the refractive boundary, at which the light ray strikes the
boundary, n.sub.r is the index of refraction of the material in
which the refracted ray travels, and .beta. is the angle, with
respect to the normal at the refractive boundary, at which the
refracted ray travels. The light ray and refracted ray travel in
the same plane, on opposite sides of the normal at the point of
incidence. If a ray travels from a material of lower refractive
index into a medium of higher refractive index, it is bent toward
the normal; if it travels from a medium of higher refractive index
to a medium of lower index, it is bent away from the normal. If the
light ray travels in a material of higher refractive index toward a
material of lower refractive index at such an angle that Snell's
law would call for the sine of the refracted ray to be greater than
unity (a mathematical impossibility). As a result, the "refracted"
ray in actuality becomes a reflected ray and is totally reflected
back into the medium of higher refractive index, at an angle equal
to the incident angle (and thus still "obeys" Snell's Law). This
reflection occurs even in the absence of a metallic reflective
coating (e.g., aluminum or silver). This phenomenon is called total
internal reflection. The smallest angle of incidence, with respect
to the normal at the refractive boundary, at which total internal
reflection occurs is called the critical angle. In other words
total internal reflection is the reflection that occurs when light,
in a higher refractive index material, strikes an interface, with a
medium with a lower refractive index, at an angle of incidence
(with respect to the normal) greater or equal to the critical
angle.
n.sub.a*sin.alpha.=n.sub.r*sin.beta. Snell's Law
[0028] The angle of incidence is measured with respect to the
normal at the refractive boundary. At critical angle, since no
refraction occurs, .beta.=90 and sin .beta.=1. Thus the critical
angle is given by
.alpha..sub.c=sin.sup.-1(n.sub.r/n.sub.a)
[0029] where .alpha..sub.c is the critical angle, n.sub.r is the
refractive index of the less dense material and n.sub.a is the
refractive index of the denser medium.
[0030] Geometric optics is the branch of optics that describes
light propagation in terms of rays. Rays are bent at the interface
between two dissimilar materials. A refracted ray is a ray that
undergoes a change of velocity, or in the general case, both
velocity and direction, as a result of interaction with the
material in which it travels.
[0031] The speed of light is not constant. It varies as it passes
through different transparent substances. Light travels more slowly
through air than it does through the vacuum of empty space, more
slowly through water than air, slower yet through quartz, and
slower yet through diamond. The speed of light is equal to its
wavelength times its frequency. As light passes through different
substances or materials (polymers), its frequency remains constant
and its wavelength changes. This change of wavelength (speed) at
the interface between different materials causes light passing
through one and into the other to be bent.
[0032] The refractive index for any substance is the ratio of the
velocity of light in a vacuum to its velocity in the substance. It
is also the ratio of the sine of the angle of incidence to the sine
of the angle of refraction ASTM D642. Some typical refractive
indexes of material are: Fluorcarbon (FEP)
1.34-Polytetrafluoro--Ethylene (TFE) 1.35 Chlorotrifiuoro--Ethylene
(CTFE) 1.42-Cellulose Propionate 1.46-Cellulose Acetate Butyrate
1.46-1.49Cellulose Acetate 1.46-1.50Methylpentene Polymer
1.485-Ethyl Cellulose 1.47-Acetal Homopolymer 1.48-Acrylics
1.49-Cellulose Nitrate 1.49-1.51Polypropylene (Unmodified)
1.49-Polyallomer 1.492-Polybutylene 1.50-Ionomers 1.51-Polyethylene
(Low Density) 1.51Nylons (PA) Type II 1.52-Acrylics Multipolymer
1.52-Polyethylene (Medium Density) 1.52. -Styrene Butadiene
Thermoplastic 1.52-1.55PVC (Rigid) 1.52. -1.55 Nylons (Polyamide)
Type 6/6 1.53-Urea Formaldehyde 1.54-1.58Polyethylene (High
Density) 1.54-Styrene Acrylonitrile Copolymer 1.56-1.57Polystyrene,
1.57-1.60 Polycarbomate (Unfilled)
1.586-Polystyrene1.59Polysulfone. As can be noted from this
information many polymers that might be used for waveguiding have
refractive indexes that are fairly close together.
[0033] As the difference in refractive index between the core and
clad of a waveguide becomes larger, the greater is the acceptance
angle of light entering the waveguide. That is, light entering from
steeper angles can be totally internally reflected without being
absorbed. When the refractive index difference between the core and
the clad becomes smaller, less light will be totally internally
reflected. This becomes important in that the selection of
compatible materials is limited. In order to make a waveguide
useful for rear projection or other applications, the core and clad
material must adhere to each other. Additionally, it is desirable
to have a black dye or pigment in the clad. Finding materials that
adhere to each other and have an optimal difference in refractive
index is difficult.
[0034] Additionally, it should be noted that the optimization of a
waveguide's performance for rear projection screen that will also
minimize ambient room light from entering the waveguide from the
viewing side of the screen is to have a controlled difference in
the refractive index between the core and the clad. Unmodified
polymers have limited versatility for this application. Having the
ability to control or modify the refractive index of a polymer is
very important and useful when designing waveguide screens.
Surprisingly it has been found that by controlling the
concentration of nanoparticles such as clays in a polymer martix,
that within reason there is infinite control of the refractive
index between the polymer and the clay. The clays of this invention
help to lower the refractive index of the polymer. In this case the
same polymer can be used for the core and the clad and therefore
adhesion problems are no longer a concern. Furthermore the control
of both incoming light angle acceptance from the light engine and
ambient room light from the viewing side can optimized. By forming
clays in a concentration gradient within a layer or by forming very
thin multiple layers in which the concentration is varied slightly,
a waveguide may be formed that has lower losses than stepped
waveguides in which a single layer with a large delta refractive
index is paired with the central core. This discovery also allows
the modification of refractive index of different polymers for the
core and cladding.
[0035] Whenever used in the specification the terms set forth shall
have the following meaning:
[0036] Core means one or more layers of a transparent material.
[0037] Clad or cladding or clad layer means a layer that is
adjacent to the transparent core or adjacent to another clad layer
and has a lower refractive index than the central core.
[0038] Stepped clad means a layer that has a uniform but lower
refractive index than the transparent core.
[0039] Gradient refractive index means a changing refractive index
from one side of a layer to the other.
[0040] Polymeric channel means one or more layers that can be used
to transmit light.
[0041] "Nanocomposite" means a composite material wherein at least
one component comprises an inorganic phase, such as a smectite
clay, with at least one dimension in the 0.1 to 100 nanometer
range.
[0042] "Plates" means particles with two comparable dimensions
significantly greater than the third dimension.
[0043] "Layered material" means an inorganic material such as a
smectite clay that is in the form of a plurality of adjacent bound
layers.
[0044] "Platelets" means individual layers of the layered
material.
[0045] "Intercalation" means the insertion of one or more foreign
molecules or parts of foreign molecules between platelets of the
layered material, usually detected by X-ray diffraction technique,
as illustrated in U.S. Pat. No. 5,554,670.
[0046] "Intercalant" means the aforesaid foreign molecule inserted
between platelets of the aforesaid layered material.
[0047] "Exfoliation" or "delamination" means separation of
individual platelets in to a disordered structure without any
stacking order.
[0048] "Polymer" shall include oligomers, copolymers and
interpolymers
[0049] "ionomer" means a polymer in which the linkages are ionic as
well as covalent bonds. There are positively and negatively charged
groups that are associated with each other and this polar character
makes a unique resin.
[0050] "organically modified" means the addition of an organic
material or organic end group.
[0051] Phyllosilicates such as those described in U.S. Pat. Nos.
4,739,007; 4,810,734; 4,889,885; 4,894,411; 5,102,948; 5,164,440;
5,164,460; 5,248,720; 5,973,053; 5,578,672; and incorporated herein
by reference are preferred layered particles for the invention,
because of their availability and cost. Particularly preferred
phyllosilicates are those, which are fluorinated because of their
desirable refractive index value. It is known that phyllosilicates,
such as smectite clays, e.g., sodium montmorillonite and calcium
montmorillonite, can be treated with organic molecules such as
ammonium ions to intercalate the organic molecules between adjacent
planar silicate layers and/or exfoliate the individual silicate
layers. These silicate layers when admixed with a host polymer
before, after or during the polymerization of the host polymer have
been found (vide U.S. Pat. Nos. 4,739,007; 4,810,734; and
5,385,776) to improve one or more properties of the polymer, e.g.,
mechanical strength and/or high temperature characteristics.
Phyllosilicates suitable for the present invention include smectite
clay, e.g., montmorillonite, particularly sodium montmorillonite,
magnesium montmorillonite, and/or calcium montmorillonite,
nontronite, beidellite, volkonskoite, hectorite, saponite,
sauconite, sobockite, stevensite, svinfordite, vermiculite,
magadiite, kenyaite, talc, mica, kaolinite, and mixtures
thereof.
[0052] Additional clay based useful layered particles include
illite, mixed layered illite/smectite minerals, such as ledikite
and admixtures of illites with the clay minerals named above. The
aforesaid clay based materials are described in detail in relevant
literature, such as "Clay Colloid Chemistry" by H.van Olphen,
2.sup.nd Ed., Publishers:John Wiley & Sons, (1977). Other
useful layered particles, particularly useful with anionic
polymers, are the layered hydrotalcites or double hydroxides, such
as Mg.sub.6Al.sub.3 4(OH).sub.18 8(CO.sub.3).sub.1.7H.sub.2O, which
have positively charged layers and exchangeable anions in the in
the interlayer spaces. Yet other useful layered particles include
chlorides such as FeCl.sub.3, FeOCl, chalcogenides, such as
TiS.sub.2, MoS.sub.2, and MoS.sub.3, cyanides such as Ni(CN).sub.2
and oxides such as H.sub.2Si.sub.2O.sub.5, V.sub.6O.sub.13,
HTiNbO.sub.5, Cr.sub.0.5V.sub.0.5S.sub.2, V.sub.2O.sub.5, Ag doped
V.sub.2O.sub.5, W.sub.0 2V.sub.2.8O7, Cr.sub.3O.sub.8,
MoO.sub.3(OH).sub.2, VOPO.sub.4--2H.sub.2O,
Zr(HPO.sub.4).sub.2--2H.sub.2 O, CaPO.sub.4CH.sub.3--H.sub.2O,
MnHAsO.sub.4--H.sub.2O, Ag.sub.6Mo.sub.10O.sub.33 and the like.
[0053] Particularly preferred layered particles are those, which
are fluorinated because of their desirably low refractive index
value. Preferred layered particles can be swellable so that other
agents, such as ions or molecules, can intercalate and/or exfoliate
the layered particle resulting in a desirable dispersion of the
inorganic phase. These swellable layered particles include
phyllosilicates of the 2:1 type having a negative charge on the
layers and a commensurate number of exchangeable cations in the
interlayer space to maintain overall charge neutrality. Typical
phyllosilicates with cation exchange capacity of 50 to 300
milliequivalents per 100 grams are preferred. Most preferred
layered particles for the present invention include smectite clay
such as montmorillonite, nontronite, beidellite, volkonskoite,
hectorite, saponite, sauconite, sobockite, stevensite, svinfordite,
halloysite, magadiite, kenyaite and vermiculite as well as
hydrotalcites, chalcogenites and oxides.
[0054] The aforementioned smectite clay can be natural or
synthetic. This distinction can influence the particle size and/or
the level of associated impurities. Typically, synthetic clays are
smaller in lateral dimension, and therefore possess smaller aspect
ratio. However, synthetic clays are purer and are of narrower size
distribution, compared to natural clays and may not require any
further purification or separation. For this invention, the clay
particles should have a lateral dimension of between 0.01 .mu.m and
1 .mu.m, and preferably between 0.01 .mu.m and 0.05 .mu.m. The
thickness or the vertical dimension of the clay particles can vary
but is preferably between 0.5 nm and 10 nm, and more preferably
between 1 nm and 5 nm. The aspect ratio, which is the ratio of the
largest and smallest dimension of the clay particles should be at
least 10:1 and up to 1000:1 for this invention. The aforementioned
limits regarding the size and shape of the particles are to ensure
adequate improvements in some properties of the nanocomposites
without deleteriously affecting others. For example, a large
lateral dimension may result in an increase in the aspect ratio, a
desirable criterion for improvement in mechanical and barrier
properties. However, very large particles can cause optical
defects, such as haze, and can be abrasive to processing,
conveyance and finishing equipment. Aspect ratio of less than 10:1
may be difficult to obtain and may have limited utility for the
added expense. Preferred aspect ratio for the clay for this
invention is between 20:1 and 200:1, for optimum properties.
[0055] The clay used in this invention can be an organoclay.
Organoclays are produced by interacting the unfunctionalized clay
with suitable intercalants. These intercalants are typically
organic compounds, which are neutral or ionic. Useful neutral
organic molecules include polar molecules such as amides, esters,
lactams, nitrites, ureas, carbonates, phosphates, phosphonates,
sulfates, sulfonates, nitro compounds, and the like. The neutral
organic intercalants can be monomeric, oligomeric or polymeric.
Neutral organic molecules can cause intercalation in the layers of
the clay through hydrogen bonding, without completely replacing the
original charge balancing ions. Useful ionic compounds are cationic
surfactants including onium species such as ammonium (primary,
secondary, tertiary, and quaternary), phosphonium, or sulfonium
derivatives of aliphatic, aromatic or arylaliphatic amines,
phosphines and sulfides. Typically onium ions can cause
intercalation in the layers through ion exchange with the metal
cations of the preferred smectite clay. A number of commercial
organoclays are available from clay vendors, such as Southern Clay
Products and Nanocor, which may be used in the practice of this
invention.
[0056] The smectite clay of the invention can also be further
treated with a compatibilizing agent. The purpose of the
compatibilizing agent is to render the inorganic clay phase
compatible with the binder polymer in which the clay is preferably
dispersed. Typically, the compatibilizing agent comprises a
component that bonds with the clay surface and another component
that interacts favorably with the binder polymer. Effective
compatibilization leads to a homogenous dispersion of the clay in
the binder polymer.
[0057] Intercalants and compatibilizers, which can also be an
intercalants, can vary widely depending on the particular polymer
and the particular clay material chosen. Examples of various types
of intercalants and compatiblizers useful for treating the
preferred smectite clay of this invention are included in, but not
limited to, the disclosures of U.S. Pat. Nos. 4,739,007; 4,810,734;
4,889,885; 4,894,411; 5,102,948; 5,164,440; 5,164,460; 5,248,720;
5,973,053; 5,578,672; 5,698,624; 5,760,121; 5,804,613; 5,830,528;
5,837,763; 5,844,032; 5,877,248; 5,880,197; 6,057,396; 5,384,196;
5,385,776; 5,514,734; 5,747,560; 5,780,376; 6,036,765; 6,034,163;
6,084,019; 5,952,093; which are incorporated herein by
reference.
[0058] The optical component of this invention contains a
transparent polymeric channel for light travel as a central core
containing multilayer particles, wherein a majority of the
particles have a projected size less than 1 micrometer and an
aspect ratio in the range of longest to smallest dimension of
between 1000:1 and 10:1, and the particles are arranged in a
concentration differential in at least a portion of a plane normal
to the direction of light travel so as to create a refractive index
differential. In such an optical component, light is guided in such
a manner as to minimize the absorption of light and therefore
minimize the loss of light. Such a component is useful for
directing or conveying light and information from an entrance point
to an exit point within the component.
[0059] In one embodiment of this invention the central core may
comprise a layer. Useful cores may also be clad on one or more
sides of the central core. Typical clad layer may contain a stepped
or gradient refractive index that is either the same or different
from the core. For waveguiding purposes it is desirable to have a
gradient refractive index in the central transparent core that has
a decreasing differential refractive index from the center axis to
the outer sides. The clad layer may either have a further step
change in refractive index or a gradient refractive index within
itself. The clad may be a polymer or material such as glass that
has a lower refractive index than thee core. Additionally the clad
may have other functionality such as adhesion, light absorbing or
black materials that are opaque.
[0060] Central cores useful in this invention may be arcuate. In
such a case the optical component may be used for a curved
projection screen or a lens shaped device that will bend or direct
light. Other useful optical components may have a central core that
is cylinder shape such as an optical fiber or light pipe. Such a
component may be used as an optical coupling that shapewise could
join fiber or interface with other optical components. In the case
of the optical component that is cylinder shaped there may be at
least one surrounding clad layer around the cylinder shaped
core.
[0061] Additional embodiments of this invention may form an optical
component in which the central core is shaped like a lens, which
may be convex, concave or complex. By providing a gradient
refractive index within the central core of these lens shapes and
or within a clad layer associated with the lens shape, light
entering the lens may be better controlled. Light entering a lens
will see a refractive index change and will be bent either towards
the normal or away from the normal depending on whether the lens
has a higher or lower refractive index than the media in which the
light was traveling prior to entering the lens. The same is true as
light exits the lens into air or some other media. If a lens is
provided with a gradient refractive index the light tends to curve
more rather than turn a sharp angle. Such lenses are more efficient
in controlling light. It should be noted that the gradient may be
applied to only part of the lens to further enhance its ability to
control light. Other optical components useful in this invention
are central cores that form lens arrays as well as lens arrays that
may form a geometric shape. These types of arrays may be useful as
light directing sheet in which a shape is further enhanced with
layered particles to provide better improved light turning or
shaping properties.
[0062] The multilayered particles may be added to the central core
in a weight percent from 0 to 90%. At 0 percent the refractive
index gradient starts with the native material and the gradient may
be formed with a concentration of layered particles within the
core. As the concentration of layered particles is increased the
refractive index is further decreased. It should be noted that a
clad may be used with the central core in which a further
refractive index change or gradient index change is provided.
[0063] In a preferred embodiment of this invention the optical
component has layered particles that form a concentration gradient
with increasing concentration with distance from the central axis
of the light channel in a plane normal to the direction of light
travel. This is preferred because such a gradient will provide a
waveguide that has less losses than one that has a single or abrupt
change in refractive index. In this case light will be kept within
the core.
[0064] Concentration gradients useful in this invention may provide
a constant rate of change or an exponential rate of change. A
series of very small step changes in refractive index may also
approximate a gradient. In an embodiment of this invention a
gradient is formed by a series of steps changes with a refractive
index change of less than 0.01 per step. When such a series is
heated (still in liquid form) with air there may be a migration of
layered particles from one layer into the next therefore smoothing
the concentration from a step to a gradient.
[0065] Another useful embodiment of this invention provides a
concentration gradient with a decreasing refractive index from the
central core to the outer edges. Such an optical component provides
a privacy screen that is useful for games and computer screens to
reduce vertical and or horizontal viewing angle of the screen. This
restricts others sitting next to the screen from seeing information
that is displayed on the screen.
[0066] Layered particles useful in this invention may have a
thickness of between 0.5 and 10 nm. Such particles may have an
aspect ratio of the largest to smallest dimension of between 10:1
and 1000:1 The aforementioned limits regarding the size and shape
of the particles are to ensure adequate improvements in some
properties of the nanocomposites without deleteriously affecting
others. For example, a large lateral dimension may result in an
increase in the aspect ratio, a desirable criterion for improvement
in mechanical and barrier properties. However, very large particles
can cause optical defects, such as haze, and can be abrasive to
processing, conveyance and finishing equipment as well as the
imaging layers. Aspect ratio of less than 10:1 may be difficult to
obtain and may have limited utility for the added expense.
Preferred aspect ratio for the clay for this invention is between
20:1 and 200:1, for optimum properties.
[0067] The layered particles that are useful in the optical
components of this invention may comprise hydrotalcite,
phyllosilicate, smectite, montmorillonite, hectorite. These
particles and their advantages are described above. Furthermore the
smectite may be synthetic or organically modified to further
enhance the refractive index property of the particle.
[0068] The montmorillonite based layered particles may comprise
aluminum silicate while hectorite based particles comprises
magnesium silicate.
[0069] In a preferred embodiments of this invention the smectite
and hectorite layered particle may be fluorinated. Such particles
are lower in refractive index than non-fluorinated particles and
are therefore useful in extending the range of the concentration
gradient or providing more efficient light control. Additional
details are provided above.
[0070] In order to provide useful optical components for this
invention the layered particles are dispersed in a transparent
polymer that hold them in place. Useful transparent polymers have
percent transmission of between 70 and 100%. Percent transmission
below 80% typically are not very efficient and tend to absorb or
scatter light. Transparent polymers substantially at or near 100%
are the most desirable because there is little or no loss as light
travels through the polymer. It should be recognized that all
polymers may absorb or scatter some very small fraction of light
making 100% transmission difficult to achieve.
[0071] Useful transparent polymers of this invention may comprise
at least one material selected from the group consisting of
water-soluble polymers, hydrophilic colloids, and water insoluble
polymers. It should be noted that the transparent polymer may also
act as a binder polymer to hold the layered particles.
[0072] The binder polymer in which the layered particles,
particularly the smectite clays, are preferably dispersed can
comprise a wide variety of polymers. Specifically, the binder
polymer can comprise a water soluble polymer, hydrophilic colloid
or water insoluble polymer, for application from an aqueous or
organic solvent based coating composition. Alternatively, the
binder polymer can comprise thermally processable thermoplastic or
thermosetting polymers, for application from a thermally
processable melt.
[0073] The water soluble polymers can preferably comprise
polyalkylene oxides such as polyethylene oxide, poly 6,
(2-ethyloxazolines), poly(ethyleneimine), poly(vinylpyrrolidone),
poly(vinyl alcohol), poly (vinyl acetate), polystyrene sulfonate,
polyacrylamides, polymethacrylamide, poly(N,N-dimethacrylamide),
poly(N-isopropylacrylamid- e), polysaccharides, dextrans or
cellulose derivatives such as carboxymethyl cellulose, hydroxyethyl
cellulose, and the like. Water soluble polymers provide the
advantage of an environmentally attractive coating composition.
Also, a number of these water soluble polymers can also intercalate
the clay, thus, providing a uniform dispersion.
[0074] The hydrophilic colloid can preferably comprise gelatin or
gelatin grafted polymers. The aforementioned gelatin may comprise,
for example, alkali-treated gelatin (cattle bone or hide gelatin),
acid-treated gelatin (pigskin or bone gelatin), and gelatin
derivatives such as partially phthalated gelatin, acetylated
gelatin, and the like, and preferably the deionized gelatins.
Gelatin and gelatin based polymers are particularly attractive
because of their relatively low cost and ability to intercalate
clays.
[0075] The water insoluble polymers can comprise polymers soluble
in organic solvents or polymers in the form of aqueous dispersions
or latexes. Such polymers can preferably comprise polymers of
styrene and styrene derivatives, alkyl acrylate, alkyl methacrylate
and their derivatives, olefins, acrylonitrile, acrylic acid,
methacrylic acid, maleic acid, itaconic acid, vinyl acetate, vinyl
halide, vinylidene halide, cellulose esters such as cellulose
acetate and cellulose acetate butyrate, polyurethane, polyester and
polyester ionomer. The aforesaid water insoluble polymers can
provide useful physical properties, such as adhesion to adjacent
layers, toughness, compatibility with organic solvents, etc. A
particularly suitable water dispersible polymer comprises polyester
ionomer for its excellent film forming characteristics,
compatibility with smectite clay and commercial availability.
[0076] The thermally processable polymer can be a thermoplastic or
a thermosetting polymer. Thermosetting polymers provide an added
advantage because they typically are good adhesives and therefore
may stick well to a variety of core materials. Thermally
processable polymeric materials can comprise polyester, polyolefin,
polyurethane, polyamide, polyimide, polycarbonate, polystyrene,
polymethyl methacrylate, cellulose esters, polyether, and polyvinyl
alcohol. The addition of layered particles to thermally processable
polymers can modify their refractive index. Being able to use the
same polymer for the core and the clad while being able to lower
the clad refractive index from that of the core is very useful
particular for adhesion between the layers. Additionally, when more
than one layer is being coated at the same time, being able to use
the same base polymers in both layers provides improved layer
stability and will result in minimal interface problems. Thermally
processable polymers are useful as waveguides because the clad may
be coextruded or cocast as a separate layer simultaneously with the
core. This provides very smooth interface between the layers that
will have minimal refraction losses has light travel from the core
to the clad layer. These materials provide excellent optical
properties for the transmission of images for use as
waveguides.
[0077] Other materials that are useful as binder polymers in
waveguides are radiation curable and may be selected from the group
of those containing an acrylate, epoxy and isobutylene moiety.
Radiation curable materials provide excellent adhesion between
materials and are easily coated on and cured. These materials are
also very durable when cured and are able to be within a range of
temperatures and humidity.
[0078] In general, the choice of the binder polymer in the clad
layer may depend on the choice of the core. As a rule of thumb, the
binder polymer in the clad should be the same or similar to the
polymer in the core to ensure good adhesion, although exception to
this rule may abound. As per the invention, the layered particles
when dispersed in the binder polymer of the clad, reduces its
refractive index, without significantly altering its adhesion to
the core. The choice of the core material depends on a number of
criteria: the optical properties such as refractive index and
transparency, physical properties, dimensional stability, ease of
manufacture, availability, cost and the like. Preferred core
materials can comprise a cellulose derivative such as cellulose
acetate or cellulose acetate butyrate, or polyesters, including
amorphous or crystalline polyesters such as polyethylene
terephthalate, and polyethylene naphthalate, mainly because of
their excellent optical properties, availability, and relatively
low cost. Preferred binder polymers in the clad layer for a
cellulosic core, are cellulose derivatives such as carboxymethyl
cellulose, hydroxyethyl cellulose, cellulose acetate, and cellulose
acetate butyrate. Similarly, preferred binder polymers in the clad
layer for a polyester core are polyesters such as polyester
ionomers.
[0079] The optical components useful in this invention may form
polymeric channels and may have a thickness of between 0.5 and 1000
micrometers. Below 0.5 micrometers it is difficult to form
polymeric channels and maintain good control of the light.
Polymeric channels above 1000 micrometers are possible but with
increasing thickness become more difficult to build.
[0080] The optical components of this invention may form a
waveguide that is useful in carrying information. The waveguide may
also be used as a display screen. Such display may be used for the
projection of images, which may either be still or moving images.
In other embodiments of this invention the optical component may
form a flat planar waveguide.
[0081] The following examples illustrate the practice of this
invention. They are not intended to be exhaustive of all possible
variations of the invention. Parts and percentages are by weight
unless otherwise indicated.
EXAMPLES
[0082] The materials used in the examples and comparative samples
of the invention include the following.
[0083] Layered Particles Within Prescribed Size Range
[0084] Laponite S is a fluorinated synthetic clay comprising
hydrous magnesium lithium silicate supplied by Southern Clay
Products, with the following reported composition (weight %):
1 SiO.sub.2 50-52 MgO 22-24 Li.sub.2O 1.1-1.4 Na.sub.2O 6.0-8.0
P.sub.2O.sub.5 3.3-5.5 F 4.7-5.2 Loss on ignition 8.5-9.0
[0085] Laponite RDS is a synthetic clay comprising hydrous
magnesium lithium silicate supplied by Southern Clay Products, with
the following composition (weight %) as per the product
bulletin.
2 SiO.sub.2 55-56 MgO 25-27 Li.sub.2O 0.8 Na.sub.2O 5.4-5.8
P.sub.2O.sub.5 4.0-4.2 Loss on ignition 8.0
[0086] Binder Polymer
[0087] AQ55 is an aqueous dispersible polyester ionomer supplied by
Eastman Chemical Company.
[0088] Aqueous coating compositions comprising materials described
herein above are spin-coated on silicon wafers, for refractive
index measurement.
[0089] The thickness and optical characterization of the thin films
of the invention can be carried out by using any convenient means,
including, by way of example only, a variable angle spectroscopic
ellipsometer (VASE), obtained for example, from the J.A. Woollam
Company. The wavelengths of light to be used can vary from about
400 nm to about 1000 nm and three angles, 65.degree., 70.degree.
and 75.degree. normal to the sample can be typically used. The
parameters obtained from VASE can be delta and psi, which are
trigonometric parameters which define the resultant ellipsoid after
linearly polarized light is ellipsometrically polarized after
interacting with the thin film. A Cauchy model and other oscillator
models can be fit to delta and psi to derive a thickness value and
dispersion curves for the indices of refraction and the extinction
coefficients for organic polymer films on silicon substrate. Data
are reported at 589 nm.
[0090] The refractive index data for layers containing varying
amounts of Laponie S dispersed in AQ55 are compiled in Table 1.
3TABLE 1 Layer Composition Sample Laponite S:AQ55 (wt. ratio)
Refractive index 1 0:100 1.56 2 5:95 1.56 3 10:90 1.55 4 20:80 1.53
5 40:60 1.52 6 50:50 1.50 7 60:40 1.49 8 70:30 1.48 9 80:20 1.47 10
90:10 1.46 11 95:5 1.42
[0091] It is clear from the data in Table 1 that with increasing
weight fraction of Laponite S dispersed in AQ55, the overall
refractive index of the layer was reduced, showing the efficacy of
the layered particles of the invention in reducing the refractive
index of a water dispersible polyester matrix. Since oriented
polyethylene terephthalate sheets typically attain a refractive
index of greater than 1.6 depending on degree of orientation, any
of the layers of samples (2-11) can serve as an effective clad
layer of lowered refractive index for an oriented polyethylene
terephthalate core.
[0092] The refractive index data of Laponite S and Laponite RDS,
without any binder polymer, are compared in Table 2. Note that
Laponite S and Laponite RDS are very similar in composition except
that Laponite S is fluorinated.
4 TABLE 2 Layered particle Refractive index Laponite RDS 1.44
(un-fluorinated) Laponite S 1.40 (fluorinated)
[0093] It is clear that Laponite S has a lower refractive index
than Laponite RDS, demonstrating the desirability of a fluorinated
smectite for the practice of the present invention.
[0094] Example of Waveguide Component
[0095] A waveguide component of the present invention may be
constructed as follows:
5 L1: Black Adhesive Clad Layer L2 Top Layer 3 with 20% by weight
Laponite S* L3 Top Layer 2 with 10% by weight Laponite S* L4 Top
Layer 1 with 5% by weight Laponite S* L5 Polyester with
polytetrafluoroethylene Layer L6 Bottom Layer 1 with 5% by weight
Laponite S* L7 Bottom Layer 2 with 10% by weight Laponite S* L8;
Bottom Layer 3 with 20% by weight Laponite S* L9 Black Adhesive
Clad layer *Concentration at time of coating prior to drying.
[0096] The core of the waveguide component comprises a .about.120
.mu.m thick polyester film base (L5) that has
polytetrafluoroethylene added to adjust the refractive index to
1.56 with 3 substantially clear clad layers on each side of the
polyester film (L4,L3,L2 on the top and L6,L7 and L8 on the
bottom). There is a different and increasing concentration of
layered clay particles in each of the clad layer on the same side
of the polyester film base. Each layer of L2, 3, 4, 6, 7, and 8 is
coated at 1 .mu.m thick (dry) thickness, comprising Laponite S as
the layered particle and AQ55 as the binder polymer. The coating is
made from an aqueous coating composition using a three-layer
slide-hopper in which all L2,3 and 4 layers are coated
simultaneously and dried thoroughly. The Laponite S:AQ55 weight
ratio in the clad layers L2, 3 and 4, is maintained at 20:80, 10:90
and 5:95, respectively. When drying the layers, the air impingement
force is adjusted to force a slight migration of the particles
between layers and therefore creating a gradient effect between the
layers. In this example L2, 3 and 4 are coated on the polyester
film and dried and then L6, 7 and 8 are coated and dried in a
similar manner on the opposite side. In a third coating pass a
.about.2 .mu.m thick (dry) black adhesive layer comprising a fine
dispersion of carbon black and a co-polyester resin (L1 and L9) are
coated and dried on each side.
[0097] After coating the waveguide structure as describe above, it
is slit and chopped into thin strips of 250 mils width by 10000
mils length. The strips are stacked 6000 mils high by placing one
on top of the other, clamping the stack with approximately 0.07 MPa
pressure and placing the stack in a hot oven (90.degree. C.) for 10
hours. This allows the adhesive layers to fuse together forming a
flat planar waveguide.
[0098] The refractive index of the polyester and
polytetrafluoroethylene core is 1.56 and that of the coated layer
formed a gradient with increasing concentration from approximately
1.56 adjacent to the polyester layer to 1.53 on the side furthest
from the polyester core.
[0099] Embodiments of the invention include those where:
[0100] the central core has a percent transmission of between 80 to
100%;
[0101] the light transmitting polymer comprises at least one
material selected from the group consisting of water-soluble
polymers, hydrophilic colloids, and water insoluble polymers and
may be thermosetting, such as polyester, cellulose acetate,
polycarbonate, polymethylmethacrylate, cyclic olefins and
copolymers thereof.
[0102] The entire contents of the patents and other publications
referred to in this specification are incorporated herein by
reference.
PARTS LIST
[0103] 11 Light channel
[0104] 12 top clad layer
[0105] 14 light transmitting core
[0106] 16 bottom clad layer
[0107] 21 double clad waveguide
[0108] 20 top clad cap layer
[0109] 22 top clad layer
[0110] 24 light transmitting core
[0111] 26 bottom clad layer
[0112] 28 bottom clad cap layer
[0113] 30 light ray
[0114] 40 light transmitting core
[0115] 41 gradient refractive index waveguide
[0116] 42 light ray
[0117] 44 light ray entering the waveguide from air or other
media
[0118] 46 top clad layer
[0119] 48 bottom clad layer
* * * * *