U.S. patent application number 10/937941 was filed with the patent office on 2006-03-16 for brightness enhancement film, and methods of making and using the same.
Invention is credited to Kevin Patrick Capaldo, Brian Thomas Carvill, Dennis Joseph Coyle, Yu Hu, Chunghei Yeung, Yan Zhang.
Application Number | 20060056031 10/937941 |
Document ID | / |
Family ID | 35734929 |
Filed Date | 2006-03-16 |
United States Patent
Application |
20060056031 |
Kind Code |
A1 |
Capaldo; Kevin Patrick ; et
al. |
March 16, 2006 |
Brightness enhancement film, and methods of making and using the
same
Abstract
A brightness enhancement film comprises a base film, wherein a
stress retardation gradient of the base film is calculated to be
less than or equal to 50 nanometers per inch, wherein a first
surface of the base film is textured, and wherein a
light-redirecting structure is disposed on a first surface of the
base film.
Inventors: |
Capaldo; Kevin Patrick;
(Mount Vernon, IN) ; Carvill; Brian Thomas;
(Evansville, IN) ; Coyle; Dennis Joseph; (Clifton
Park, NY) ; Hu; Yu; (Evansville, IN) ; Yeung;
Chunghei; (Evansville, IN) ; Zhang; Yan;
(Shanghai, CN) |
Correspondence
Address: |
CANTOR COLBURN, LLP
55 GRIFFIN ROAD SOUTH
BLOOMFIELD
CT
06002
US
|
Family ID: |
35734929 |
Appl. No.: |
10/937941 |
Filed: |
September 10, 2004 |
Current U.S.
Class: |
359/619 |
Current CPC
Class: |
G02B 6/0065 20130101;
G02B 5/0278 20130101; G02B 5/0242 20130101; G02B 6/0053 20130101;
G02B 5/0221 20130101 |
Class at
Publication: |
359/619 |
International
Class: |
G02B 27/10 20060101
G02B027/10 |
Claims
1. A brightness enhancement film comprising: a base film, wherein a
stress retardation gradient of the base film is calculated to be
less than or equal to 50 nanometers per inch, wherein a first
surface of the base film is textured, and wherein a
light-redirecting structure is disposed on the first surface of the
base film.
2. The brightness enhancement film of claim 1, wherein the stress
retardation gradient is calculated to be less than or equal to 30
nanometers per inch.
3. The brightness enhancement film of claim 2, wherein the stress
retardation gradient is calculated to be less than or equal to 15
nanometers per inch.
4. The brightness enhancement film of claim 1, wherein the first
surface comprises a surface roughness (Ra) of 0.3 micrometers to
2.2 micrometers.
5. The brightness enhancement film of claim 1, wherein the second
surface is a polished surface comprising a surface roughness (Ra)
of less 0.3 micrometers.
6. The brightness enhancement film of claim 1, wherein the second
surface is a textured surface comprising a surface roughness (Ra)
greater than 0.3 micrometers.
7. The brightness enhancement film of claim 1, wherein the base
film comprises a haze value of about 20% to about 80% as measured
according to ASTM D1003, and a transmission of greater than or
equal to about 85%.
8. The brightness enhancement film of claim 1, wherein the base
film comprises a haze value of less than or equal to about 50% as
measured according to ASTM D1003, and a transmission of greater
than or equal to about 89%.
9. The brightness enhancement film of claim 1, further comprising a
curable coating disposed on the first surface of the base film,
wherein the curable coating comprises an index of refraction of
greater than or equal to about 1.5
10. The brightness enhancement film of claim 9, wherein the curable
coating comprises a polymerizable compound comprising a functional
group selected from the group consisting of acrylate, methacrylate,
vinyl, and epoxide.
11. The brightness enhancement film of claim 9, wherein the curable
coating further comprises metal oxide nanoparticles.
12. The brightness enhancement film of claim 1, wherein the base
film comprises polycarbonate and phosphonium sulfonate.
13. The brightness enhancement film of claim 12, wherein the
phosphonium sulfonate is fluorinated phosphonium sulfonate.
14. The brightness enhancement film of claim 1, wherein the
light-redirecting structure is a random prismatic structure, and
wherein the random prismatic structure comprises a plurality of
prisms each comprising a peak comprising a radius of curvature of
about 0.1% to about 30% of a pitch of the prismatic structure.
15. A brightness enhancement film comprising: a thermoplastic base
film comprising greater than or equal to about 80 wt. %
polycarbonate, wherein weight percents are based on a total weight
of the thermoplastic base film, wherein a stress retardation
gradient of the thermoplastic base film is calculated to be less
than or equal to 15 nanometers per inch, and wherein a
light-redirecting structure is disposed on a first surface of the
thermoplastic base film.
16. A brightness enhancement film comprising: a thermoplastic base
film comprising about 93 wt. % to about 99.6 wt. % polycarbonate;
and about 0.4 wt. % to about 7 wt. % fluorinated phosphonium
sulfonate, wherein weight percents are based on a total weight of
the thermoplastic base film, and wherein a stress retardation
gradient of the base film is calculated to be less than or equal to
50 nanometers per inch, and wherein a light-redirecting structure
is disposed on a first surface of the base film.
17. The brightness enhancement film of claim 16, wherein the first
surface of the base film is textured.
18. The brightness enhancement film of claim 17, wherein a second
surface is textured.
19. A method of making a brightness enhancement film comprising:
disposing a light-redirecting structure onto a first surface of a
base film, wherein a stress retardation gradient of the
thermoplastic base film is calculated to be less than or equal to
50 nanometers per inch, wherein the first surface of the
thermoplastic base film is textured.
20. The method of claim 19, further comprising forming the base by
melting a thermoplastic resin at a temperature greater than or
equal to a glass transition temperature of the thermoplastic resin;
extruding the thermoplastic resin into a gap between a first
calendering roll and a second calendering roll, wherein the first
calendering roll comprises a textured surface and an elastomeric
material; and cooling the thermoplastic resin to a temperature
below the glass transition temperature of the thermoplastic resin
to produce the thermoplastic base film.
21. The method of claim 19, further comprising coating the first
surface of the base film with a curable coating material.
22. A method of making a brightness enhancement film comprising:
disposing a light-redirecting structure onto a surface of a base
film, wherein a stress retardation gradient of the base film is
calculated to be less than or equal to 15 nanometers per inch.
23. A method of making a brightness enhancement film comprising:
disposing a light-redirecting structure onto a surface of a
thermoplastic base film comprising about 93 wt. % to about 99.6 wt.
% polycarbonate; and about 0.4 wt. % to about 7 wt. % fluorinated
phosphonium sulfonate, wherein weight percents are based on a total
weight of the thermoplastic base film, and wherein a stress
retardation gradient of the thermoplastic base film is calculated
to be less than or equal to 50 nanometers per inch.
24. A display device comprising: an optical source; a light guide
in optical and physical communication with the light source; and a
brightness enhancement film comprising a base film, wherein a
stress retardation gradient of the base film is calculated to be
less than or equal to 50 nanometers per inch, wherein a first
surface of the base film is textured, and wherein a
light-redirecting structure is disposed on the first surface of the
base film.
Description
BACKGROUND
[0001] In flat panel displays (e.g., backlight computer displays),
optical film (which can also be referred to as a sheet, layer,
foil, and the like) materials are commonly used, for example, to
direct, diffuse, or polarize light. For example, in backlight
displays, brightness enhancement films use prismatic structures on
the surfaces thereof to direct light along a viewing axis (i.e., an
axis normal (perpendicular) to the display). This enhances the
brightness of the light viewed by the user of the display and
allows the system to consume less power in creating a desired level
of on-axis illumination. Such films can also be used in a wide
range of other optical designs, such as in projection displays,
traffic signals, and illuminated signs.
[0002] Currently, backlight displays, for example, employ a
plurality of films arranged in a manner to obtain the desired
brightness and diffusion of the light directed to the viewer. It is
noted that as the number of films employed increases, the over
thickness of the backlight display increases. It is noted, however,
that consumers are increasingly demanding thinner backlight display
devices. Moreover, it is also desirable to eliminate color bands
that may be observable in the back light display device to further
meet consumer demands.
[0003] Since a demand exists for increasingly thinner backlight
display devices, what is needed in the art is a multifunctional
brightness enhancement with no visible color bands.
SUMMARY
[0004] Disclosed herein are brightness enhancement films, and
methods of making and using the same.
[0005] One embodiment of a brightness enhancement film comprises a
base film, wherein a stress retardation gradient of the base film
is calculated to be less than or equal to 50 nanometers per inch,
wherein a first surface of the base film is textured, and wherein a
light-redirecting structure is disposed on a first surface of the
base film.
[0006] Another embodiment of a brightness enhancement film
comprises a thermoplastic base film comprising greater than or
equal to about 80 wt. % polycarbonate, wherein weight percents are
based on a total weight of the thermoplastic base film, wherein a
stress retardation gradient of the base film is calculated to be
less than or equal to 15 nanometers per inch, and wherein a
light-redirecting structure is disposed on a first surface of the
base film.
[0007] A third embodiment of a brightness enhancement film
comprises a thermoplastic base film comprising about 93 wt. % to
about 99.6 wt. % polycarbonate; and about 0.4 wt. % to about 7 wt.
% fluorinated phosphonium sulfonate, wherein weight percents are
based on a total weight of the thermoplastic base film, and wherein
a stress retardation gradient of the base film is calculated to be
less than or equal to 50 nanometers per inch, and wherein a
light-redirecting structure is disposed on a first surface of the
base film.
[0008] One embodiment of a method of making a brightness
enhancement film comprises disposing a light-redirecting structure
onto a first surface of a base film, wherein a stress retardation
gradient of the thermoplastic base film is calculated to be less
than or equal to 50 nanometers per inch, wherein the first surface
of the thermoplastic base film is textured.
[0009] Another embodiment of a method of making a brightness
enhancement film comprises disposing a light-redirecting structure
onto a surface of a base film, wherein a stress retardation
gradient of the base film is calculated to be less than or equal to
15 nanometers per inch.
[0010] A third embodiment of a method of making a brightness
enhancement film comprises disposing a light-redirecting structure
onto a surface of a thermoplastic base film comprising about 93 wt.
% to about 99.6 wt. % polycarbonate; and about 0.4 wt. % to about 7
wt. % fluorinated phosphonium sulfonate, wherein weight percents
are based on a total weight of the thermoplastic base film, and
wherein a stress retardation gradient of the thermoplastic base
film is calculated to be less than or equal to 50 nanometers per
inch.
[0011] An embodiment of a display device comprises an optical
source; a light guide in optical and physical communication with
the light source; and a brightness enhancement film comprising a
base film, wherein a stress retardation gradient of the base film
is calculated to be less than or equal to 50 nanometers per inch,
wherein a first surface of the base film is textured, and wherein a
light-redirecting structure is disposed on the first surface of the
base film.
[0012] The above-described and other features will be appreciated
and understood by those skilled in the art from the following
detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Refer now to the figures, which are exemplary embodiments,
and wherein the like elements are numbered alike.
[0014] FIG. 1 is a perspective view of an exemplary embodiment of a
backlight display device including a brightness enhancement
film.
[0015] FIG. 2 is a perspective view of an exemplary embodiment of a
brightness enhancement film with prismatic surfaces.
[0016] FIG. 3 is a cross-sectional view of the brightness
enhancement film of FIG. 2.
[0017] FIG. 4 is a cross-sectional view and schematic illustration
of an exemplary embodiment of a light-diffusing film receptive of
light and diffusing the light emanating therefrom.
[0018] FIG. 5 is a perspective view of an exemplary embodiment of
two brightness enhancement films.
[0019] FIG. 6 is a perspective view of an exemplary embodiment of a
backlight display device including a plurality of brightness
enhancement films and a plurality of light-diffusing films.
[0020] FIG. 7 is a schematic view of an extrusion system for
producing a base film for a brightness enhancement film.
DETAILED DESCRIPTION
[0021] Disclosed herein are optical films, more particularly
brightness enhancement films capable of being employed in a flat
panel display (e.g., a backlight display device). It is noted that
the brightness enhancement films can be a single layer (e.g., a
unitary or monolithic film characterized by the absence of
coatings) or a multi-layered structure. The term "total" that is
used in relation to reflection is used herein to refer to the
combined reflectance of all light from a surface.
[0022] It should further be noted that the terms "first," "second,"
and the like herein do not denote any order, quantity, or
importance, but rather are used to distinguish one element from
another, and the terms "a" and "an" herein do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced item. Furthermore, all ranges disclosed
herein are inclusive and combinable (e.g., ranges of "up to about
25 weight percent (wt. %), with about 5 wt. % to about 20 wt. %
desired, and about 10 wt. % to about 15 wt. % more desired," is
inclusive of the endpoints and all intermediate values of the
ranges, e.g., "about 5 wt. % to about 25 wt. %, about 5 wt. % to
about 15 wt. %," etc.).
[0023] Several embodiments of backlight display devices are
discussed hereunder with reference to individual drawing figures.
One of skill in the art will easily recognize that many of the
components of each of the embodiments are similar or identical to
the others. Each of these elements is introduced in the discussion
of FIG. 1, but is not repeated for each embodiment. Rather,
distinct structure is discussed relative to each
figure/embodiment.
[0024] Referring now to FIG. 1, a perspective view of a backlight
display device generally designated 100 is illustrated. The
backlight display device 100 comprises an optical source 102 for
generating light 104. A light guide 106 in optical communication
with optical source 102 guides the light 104 by total internal
reflection (TIR) of the light 104 within the light guide 106. A
reflective film 108 in physical and/or optical communication with a
first surface 110 of light guide 106 reflects the light 104 out of
the light guide 106. A brightness enhancement film 112 located in
physical and/or optical communication with a second surface 114 of
light guide 106 receives the light 104 from the light guide
106.
[0025] More particularly, in this embodiment, the brightness
enhancement film 112 comprises a planar surface 116 in physical
and/or optical communication with the second surface 114 of light
guide 106, and a prismatic surface 118 in physical and/or optical
communication with light-diffusing film 120. Still further, it will
be appreciated that the prismatic surfaces 118 can comprise a peak
angle, .alpha., a height, h, a pitch, p, and a length, l (see FIGS.
2 and 3) such that the structure of the brightness enhancement film
112 can be deterministic, periodic, random, and the like. For
example, films with prismatic surfaces with randomized or
pseudo-randomized parameters are described for example in U.S.
patent application No. 2003/0214728 to Olcazk. Moreover, it is
noted that for each prism the sidewalls (facets) can be
straight-side, concave, convex, and the like. The peak of the prism
can be pointed, rounded, blunted, and the like. More particularly,
in an embodiment the prisms comprise straight-sided facets having a
pointed peak (e.g., a peak comprising a radius of curvature of
about 0.1% to about 30% of the pitch (p)), particularly about 1% to
about 5%).
[0026] The brightness enhancement film 112 receives the light 104
and acts to direct the light 104 in a direction that is
substantially normal to the brightness enhancement film 112 as
indicated schematically by an arrow representing the light 104
being directed in a z-direction shown in FIG. 1. The
light-diffusing film 120 is receptive of the light 104 from the
brightness enhancement film 112 and diffuses (e.g., scatters) the
light as illustrated schematically in FIG. 4. The light 104
proceeds from the light-diffusing film 120 to a liquid crystal
display (LCD) 122.
[0027] Further, it is noted that in various embodiments a backlight
display device can comprise a plurality of brightness enhancement
films and a plurality of light-diffusing films in optical
communication with each other. The plurality of brightness
enhancement films and light-diffusing films can be arranged in any
configuration to obtain the desired results in the LCD. For
example, the plurality of brightness enhancement films can be
arranged in physical and/or optical communication with each other
as illustrated in FIG. 5. More particularly, referring to FIG. 5, a
first brightness enhancement film 212 comprises a first brightness
enhancement film planar surface 216 and a first brightness
enhancement film prismatic surface 218. A second brightness
enhancement film 224 comprises a second brightness enhancement film
planar surface 226 and a second brightness enhancement film
prismatic surface 228. The first brightness enhancement film 212
and the second brightness enhancement film 224 can be arranged such
that the prismatic surfaces (218 and 228, respectively) are
positioned at an angle with respect to one another, e.g., 90
degrees. Generally, the arrangement and type of brightness
enhancement films and light-diffusing films depends on the
backlight display device in which they are employed. It is noted,
however, that embodiments are envisioned where one or more
brightness enhancement films and/or light-diffusing films can be
replaced by a single multifunctional brightness enhancement film,
as will be discussed in greater detail below.
[0028] Additionally, as briefly mentioned above, the arrangement,
type, and amount of brightness enhancement film (s) and
light-diffusing film(s) depends on the backlight display device in
which they are employed. An increasingly common use of a backlight
display device is in a laptop computer. While reference is made to
a laptop computer throughout this disclosure, it is to be
understood that one of skill in the art can readily use brightness
enhancement films disclosed herein in other applications without
undue experimentation.
[0029] An exemplary backlight display device 300 for use in a
laptop computer is illustrated in FIG. 6. The backlight display
device 300 comprises an optical source 302 for generating light
304. A light guide 306 in optical communication with optical source
302 guides the light 304 by total internal reflection of the light
304, as discussed above in relation to FIG. 1. A reflective film
308 in physical and/or optical communication with a first surface
310 of light guide 306 reflects the light 304 out of the light
guide 306. A bottom light-diffusing film 320 and a top
light-diffusing film 330 are in optical communication with a first
brightness enhancement film 312 and a second brightness enhancement
film 324 disposed between the bottom light-diffusing film 320 and
the top-diffusing film 330. In an embodiment, the light 304
proceeds from the top light-diffusing film 330 to a liquid crystal
display (LCD) 322.
[0030] With regards to the embodiment illustrated in FIG. 6, it is
noted that the bottom light-diffusing film 320 can primarily
function to enhance the uniformity of the light 304. The top
light-diffusing film 330 can primarily function to minimize glare
and optical coupling (Newton Rings) between the brightness
enhancement films (e.g., 312 and 324). In addition, the top
light-diffusing film 330 can also function as a protective film for
the brightness enhancement films (312, 324), thereby reducing the
likelihood of fracturing or damaging the prismatic surfaces of the
brightness enhancement films. Furthermore, it is noted that top
light-diffusing films (e.g., 330), i.e., the light-diffusing film
nearest to the liquid crystal display (e.g., 322), can comprise a
haze value of less than or equal to about 85%, more particularly a
haze value of less than or equal to about 50%. Whereas, bottom
light-diffusing films (e.g., 320), i.e., the light-diffusing film
nearest the light guide (e.g., 306), generally comprise a haze
value of greater than or equal to about 90%, more particularly a
haze value of greater than or equal to about 95%.
[0031] It is noted that the percent haze can be predicted and
calculated from the following equation: % .times. Haze = 100
.times. Total .times. .times. Diffuse .times. .times. Trasmission
Total .times. .times. Transmission ( 1 ) ##EQU1##
[0032] wherein total transmission is the integrated transmission;
and the total diffuse transmission is the light transmission that
is scattered by the film as defined by
[0033] Optical source (e.g., 102, 302) can include any light source
suitable to backlight a liquid crystal display (LCD) device, which
includes both high-brightness and low brightness light sources. The
high-brightness light source can include a cold cathode fluorescent
lamp (CCFL), a fluorescent lamp, and the like. The low-brightness
light source can include a light emitting diode (LED), and the
like.
[0034] Light guide (e.g., 106, 306) preferably comprises a material
that assumes a low internal absorption of the light, including an
acrylic film and desirably transparent materials including acryl,
PMMA (polymethylmethacrylate), polycarbonate, polyethylene,
selenium (Se), silver chloride (AgCl), and the like. The shape of
the light guide can be in a shape suitable for the desired
transmission of the light, such as a bar, a curved surface, a
plate, a sheet, and the like. The light guide can be a single sheet
or a plurality of sheets.
[0035] Reflective film (e.g., 108, 308) can be in any usable shape
for reflecting light, e.g., a planar shape, such as a plate, sheet,
coating and the like, wherein the reflective film comprises a
reflective material. For example, suitable reflective materials
include an aluminum, a silver, titanium oxide, and the like, as
well as combinations comprising at least one of the foregoing. In
other embodiments, the reflective film can comprise a thermoplastic
material, e.g., Spectralon.RTM. (available from Labsphere, Inc.),
titanium-oxide pigmented Lexan.RTM. (available from General
Electric Co.), and the like.
[0036] The brightness enhancement film(s) (e.g., 112, 212, 224,
312, and 324) comprise light-redirecting structure(s) (e.g.,
prismatic (pyramid-like) cube corners, spheres, edges, and the
like) to direct light along the viewing axis (i.e., normal to the
display), which enhances the luminance (brightness) of the light
viewed by the user of the display and allows the system to use less
power to create a desired level of on-axis illumination. Generally,
the brightness enhancement film comprises a base film that can
comprise an optional curable coating disposed thereon. The
light-redirecting structure can be created, for example, by
applying the curable coating to the base film and casting the
desired light-redirecting structure in the curable coating, by
hot-embossing the structure directly onto the base film, or the
like. While the base film material can vary depending on the
application, suitable materials include those base film materials
discussed in published U.S. patent application No. 2003/0108710 to
Coyle et al. More specifically, the base film material of the
brightness enhancement film can comprise metal, paper, acrylics,
polycarbonates, phenolics, cellulose acetate butyrate, cellulose
acetate propionate, poly(ether sulfone), poly(methyl methacrylate),
polyurethane, polyester, poly(vinylchloride), polyethylene
terephthalate, and the like, as well as blends copolymers, reaction
productions, and combinations comprising at least one of the
foregoing.
[0037] In one embodiment, the base film of the brightness
enhancement film is formed from a thermoplastic polycarbonate
resin, such as Lexan.RTM. resin, commercially available from
General Electric Company, Schenectady, N.Y. Thermoplastic
polycarbonate resin that can be employed in producing the base
film, include without limitation, aromatic polycarbonates,
copolymers of an aromatic polycarbonate such as polyester carbonate
copolymer, blends thereof, and blends thereof with other polymers
depending on the end use application. In another embodiment, the
thermoplastic polycarbonate resin is an aromatic homo-polycarbonate
resin such as the polycarbonate resins described in U.S. Pat. No.
4,351,920 to Ariga et al. These polycarbonate resins can be
obtained by the reaction of an aromatic dihydroxy compound with a
carbonyl chloride. Other polycarbonate resins can be obtained by
the reaction of an aromatic dihydroxy compound with a carbonate
precursor such as a diaryl carbonate. An exemplary aromatic
dihydroxy compound is 2,2-bis(4-hydroxy phenyl) propane (i.e.,
Bisphenol-A). A polyester carbonate copolymer is obtained by the
reaction of a dihydroxy phenol, a carbonate precursor and
dicarboxylic acid such as terephthalic acid or isophthalic acid or
a mixture of terephthalic and isophthalic acid. Optionally, an
amount of a glycol can also be used as a reactant.
[0038] In other embodiments, an anti-static material can optionally
be added to the base film of the brightness enhancement film in an
amount sufficient to impart anti-static properties to the film. For
example, an anti-static material comprising phosphonium sulfonate
can be added to a base film comprising polycarbonate. In an
embodiment, the anti-static material is that described in U.S. Pat.
No. 6,194,497 to Henricus et al. More specifically, the phosphonium
sulfonate can be a fluorinated phosphonium sulfonate comprising a
fluorocarbon containing an organic sulfonate anion and an organic
phosphonium cation. Examples of such organic sulfonate anions
include, but are not limited to, perfluoro methane sulfonate,
perfluoro butane sulfonate, perfluoro hexane sulfonate, perfluoro
heptane sulfonate, and perfluoro octane sulfonate. Examples of the
phosphonium cation include, but are not limited to, aliphatic
phosphonium such as tetramethyl phosphonium, tetraethyl
phosphonium, tetrabutyl phosphonium, triethylmethyl phosphonium,
tributylmethyl phosphonium, tributylethyl phosphonium,
trioctylmethyl phosphonium, trimethylbutyl phosphonium,
trimethyloctyl phosphonium, trimethyllauryl phosphonium,
trimethylstearyl phosphonium, triethyloctyl phosphonium and
aromatic phosphoniums such as tetraphenyl phosphonium,
triphenylmethyl phosphonium, triphenylbenzyl phosphonium,
tributylbenzyl phosphonium. More specifically, the fluorinated
phosphonium sulfonate can be obtained by any combination comprising
at least one of any of these organic sulfonate anions with
phosphonium cations.
[0039] Furthermore, even more specifically, the phosphonium
sulfonate employed herein can be a fluorinated phosphonium
sulfonate having the general formula:
{CF.sub.3(CF.sub.2)n(SO.sub.3)}.theta.{P(R.sub.1)(R.sub.2)(R.sub.3)(R.sub-
.4)}.PHI.
[0040] wherein F is fluorine; n is an integer of from 1-12, S is
sulfur; R.sub.1, R.sub.2, and R.sub.3 can each comprise an
aliphatic hydrocarbon radical of 1-8 carbon atoms or an aromatic
hydrocarbon radical of 6-12 carbon atoms and R4 is a hydrocarbon
radical of 1-18 carbon atoms. Anti-static compositions comprising
fluorinated phosphonium sulfonate shown by formula as having the
principle component thereof can be used in many different ways to
make use of their anti-static and compatibility characteristics and
heat resistance in providing such anti-static characteristics to
polycarbonate. The phosphonium fluorocarbon sulfonate salts are low
melting semi-solid materials, and as such, they can be handled as a
molten liquid. Some embodiments are solid crystalline materials at
room temperature (i.e., a temperature of about 15.degree. C. to
about 25.degree. C.) and are easy to weigh, handle, and add to the
polycarbonate.
[0041] While the anti-static material can be added to the
polycarbonate at any time in the process, it is desirable to add it
to the polycarbonate at the time of polymer production. For
example, the polycarbonate and anti-static material can be
processed by, for example, extrusion, and the like.
[0042] As briefly mentioned above, the base film of the brightness
enhancement film can comprise polycarbonate and an anti-static
material. For example, the base film comprises greater than or
equal to about 80 wt. % polycarbonate, and more particularly
greater than or equal to about 90 wt. % polycarbonate, wherein
weight percents are based on a total weight of the base film. For
example, in an embodiment, the base film comprises about 93 wt. %
to about 99.6 wt. % polycarbonate; and about 0.4 wt. % to about 7
wt. % anti-static material, more specifically, about 0.4 wt. % to
about 2 wt. % anti-static material.
[0043] While it is noted that the thickness of the base film of the
brightness enhancement film can vary depending on the desired
application, the base film can comprise a thickness sufficient for
use in a flat panel display, e.g., for use in a laptop computer.
For example, the base film can comprise a thickness of about 25
micrometers to about 1,000 micrometers, specifically about 175
micrometers to about 750 micrometers.
[0044] In embodiments comprising a curable coating on the base film
of the brightness enhancement film, the curable coating comprises a
curable composition, which generally comprises a polymerizable
compound. Polymerizable compounds, as used herein, are monomers or
oligomers comprising one or more functional groups capable of
undergoing radical, cationic, anionic, thermal, and/or
photochemical polymerization. Suitable functional groups include,
for example, acrylate, methacrylate, vinyl, epoxide, and the
like.
[0045] For example, the curable composition can include monomeric
and dimeric acrylates, for example, cyclopentyl methacrylate,
cyclohexyl methacrylate, methylcyclohexylmethacrylate,
trimethylcyclohexyl methacrylate, norbomylmethacrylate,
norbomylmethyl methacrylate, isobornyl methacrylate, lauryl
methacrylate 2-ethylhexyl methacrylate, 2-hydroxyethyl
methacrylate, hydroxypropyl acrylate, hexanediol acrylate,
2-phenoxyethyl acrylate, 2-hydroxyethyl acrylate, 2-hydoxypropyl
acrylate, diethyleneglycol acrylate, hexanediol methacrylate,
2-phenoxyethyl methacrylate, 2-hydroxyethyl methacrylate,
2-hydoxypropyl methacrylate, diethyleneglycol methacrylate,
ethylene glycol dimethacrylate, ethylene glycol diacrylate,
propylene glycol dimethacrylate, propylene glycol diacrylate, allyl
methacrylate, allyl acrylate, butanediol diacrylate, butanediol
dimethacrylate, 1,6hexanediol diacrylate, 1,6-hexanediol
dimethacrylate, diethyleneglycol diacrylate, trimethylpropane
triacrylate, pentaeryritol tetraacrylate, hexanediol
dimethacrylate, diethyleneglycol dimethacrylate, trimethylolpropane
triacrylate, trimethylpropane trimethacrylate, pentaeryritol
tetramethacrylate, and combinations comprising at least one of the
foregoing acrylates.
[0046] Additionally, the curable composition can comprise a
polymerization initiator to promote polymerization of the curable
components. Suitable polymerization initiators include
photoinitiators that promote polymerization of the components upon
exposure to ultraviolet radiation. Suitable photoinitiators
include, but are not limited to benzophenone and other
acetophenones, benzil, benzaldehyde and O-chlorobenzaldehyde,
xanthone, thioxanthone, 2-chlorothioxanthone,
9,10-phenanthrenenquinone, 9,10-anthraquinone, methylbenzoin ether,
ethylbenzoin ether, isopropyl benzoin ether,
1-hydroxycyclohexyphenyl ketone,
.alpha.,.alpha.-diethoxyacetophenone,
.alpha.,.alpha.-dimethoxyacetoophenone,
1-phenyl-,1,2-propanediol-2-o-benzoyl oxime,
2,4,6-trimethylbenzoyldiphenyl phosphine oxide, and,
.alpha.,.alpha.-dimethoxy-.alpha.-phenylacetopheone, as well as
combinations comprising at least one of the foregoing. In one
embodiment, the polymerization initiator is present in an amount of
about 0.1 wt. % to about 10 wt. %, more specifically about 1 wt. %
to about 8 wt. %, wherein weight percents are based upon a total
weight of the curable composition.
[0047] In an embodiment, the curable composition comprises
multifunctional (meth)acrylates, substituted or unsubstituted
arylether (meth)acrylate monomer, brominated aromatic
(meth)acrylate monomer, and polymerization initiator. The curable
coating has a refractive index of greater than or equal to about
1.50, more specifically greater than or equal to about 1.61. The
refraction index of the curable coating can be increased by
including metal oxide nanoparticles in the curable composition.
Examples of suitable metal oxides include, but are not limited to,
titanium oxide, zinc oxide, indium tin oxide, indium oxide, tin
oxide, cadmium tin oxide, and combinations comprising at least one
of the forgoing oxides. Further, suitable metal oxide nanoparticles
and methods for their preparation are also described, for example,
in U.S. Pat. No. 6,261,700 to Olson et al. and U.S. Pat. No.
6,291,070 to Arpac et al. For example, metal oxide nanoparticles
can be prepared by a method comprising hydrolyzing a metal alkoxide
with an acidic alcohol solution, wherein the acidic alcohol
solution comprises an alkyl alcohol, water, and an acid to form a
first sol comprising metal oxide nanoparticles; treating the first
sol (i.e., a colloidal solution) with an organosilane to form a
second sol comprising treated metal oxide nanoparticles; and
treating the second sol with an organic base in an amount of about
0.1:1 to about 0.9:1 molar ratio of organic base to acid to form a
third sol comprising treated metal oxide nanoparticles. The metal
of the metal alkoxide can be, for example, titanium, zinc, indium,
tin, cadmium, and combinations comprising at least one of the
foregoing. The alkoxide of the metal alkoxide can be, for example,
a linear or branched C.sub.1-C.sub.12 alkoxide.
[0048] The curable coating can comprise a thickness of about 10
micrometers to about 100 micrometers, specifically about 35
micrometers to about 100 micrometers, and more specifically about
60 micrometers to about 80 micrometers.
[0049] As will be discussed in greater detail, it has been
discovered that a flat panel display comprising no color bands
and/or shadows (when viewed from all viewing angles in a display
device with the backlight on) can be obtained when a brightness
enhancement film is employed in the flat panel display, wherein the
base film of the brightness enhancement film comprises a base film
with a low stress retardation variation. It is noted that term
"retardation" is a term readily understood in the art. A low stress
retardation variation base film can be defined mathematically as a
film comprising a low stress retardation gradient from a stress
retardation profile (i.e., stress retardation as a function of
location within the film), wherein a stress retardation gradient is
less than or equal to 50 nanometers per inch (nm/in), more
particularly less than or equal to 30 nm/in, still more
particularly less than or equal to 15 nm/in. Stress retardation can
be measured using, for example, a SCA1500 System from Strainoptic
Technologies (now Strainoptic, Inc.) according to ASTM D4093.
Stated another way, the stress retardation gradient is the first
derivative of the stress retardation profile.
[0050] Without being bound by theory, suitable low stress
retardation variation base films used to produce brightness
enhancement films that when employed in a display device do not
produce color bands, include but is not limited to, base films
comprising a first surface (i.e., the surface of the brightness
enhancement film that faces toward a LCD when employed in a flat
panel display, more particularly the surface of the brightness
enhancement film that faces toward the user of the device)
comprising a textured surface, e.g., a matte surface. Further, in
an embodiment, the base film comprises a second surface (i.e., the
surface that faces toward the light guide, more particularly the
surface that faces away from the user of the device), which can
comprise a polished surface or a textured surface (e.g., a matte
surface, velvet surface, and the like). It is noted that when a
textured second surface is employed in a laptop computer, the
overall thickness of the films employed can advantageously be
decreased by at least the thickness of a light diffusing film. More
particularly, the overall thickness can be decreased by greater
than or equal to about 50 micrometers, more specifically greater
than or equal to about 100 micrometers.
[0051] For example, suitable base films include, but are not
limited to, base films comprising a first surface comprising a
polish surface, matte surface, and the like; and a second surface
comprising a polish surface, a matte surface, a velvet surface, and
the like, wherein the light-redirecting structures are disposed on
the first surface of the base film, wherein the resulting base film
is a low stress retardation variation base film comprising a stress
retardation gradient less than or equal to 50 nanometers per inch
(nm/in), as discussed above.
[0052] The terms "polish", "matte", and "velvet" are all terms
readily understood by those skilled in the art. For example, a
polish surface can comprise a surface roughness (Ra) of less than
0.3 micrometers; a matte (e.g., fine matte, medium matte, course
matte, and the like) surface can comprise a surface roughness (Ra)
of 0.3 micrometers to 2.2 micrometers; and a velvet surface can
comprise a surface roughness (Ra) greater than 2.2 micrometers. It
is noted that the term surface roughness (Ra) is a term readily
understood by those skilled in the art. Generally, the Ra is a
measure of the average roughness of the film. It can be determined
by integrating the absolute value of the difference between the
surface height and the average height and dividing by the
measurement length for a one dimensional surface profile, or the
measurement area for a two dimensional surface profile. More
particularly, surface roughness can be measured using a Serfcorder
SE4000K, commercially available from Kosaka Laboratory Ltd.,
wherein the surface roughness is measured according to ASME
B46.1-1995.
[0053] Additionally, it is noted that embodiments of the brightness
enhancement film disclosed herein comprise a brightness performance
equivalent to a brightness enhancement film comprising
polish/polish surfaces. For example, all else being equal (e.g.,
same base film materials, prismatic structures, etc.) the
brightness enhancement film comprising matte/polish surfaces can
comprise a relative luminance of about 99.5% to about
100.5%compared to a base film comprising polish/polish surfaces.
While base films comprising a haze value of about 20% to about 80%
and transmission greater than or equal to about 85% can be
produced, those base films comprising a haze value of less than or
equal to about 50% and transmission greater than or equal to about
89% are particularly useful in obtaining the desired luminance
comparable to a polish/polish film.
[0054] In other embodiments, the base film of the brightness
enhancement film can comprise a haze value sufficient to eliminate
at least one light-diffusing film (e.g., a bottom light diffusing
film (e.g., 320)) in a backlight display device. In other words,
the brightness enhancement film can be a multifunctional brightness
enhancement film acting as both a traditional brightness
enhancement film, for example, to direct light along a viewing axis
(i.e., an axis normal (perpendicular) to the display), and as a
light diffusing film. The terms "top" and "bottom" used herein with
regards to light-diffusing films, as well as any other film
employed in a display device, e.g., a backlight display device, are
readily understood by those skilled in the art. The term "top"
generally refers to a side of a film or the film itself that is
closest to the LCD (i.e., the side or the film itself that is
closest to and/or faces toward the viewer). Conversely, the term
"bottom" generally refers to a side of a film or the film itself
that is farthest away from the LCD (i.e., the side of the film
itself that is farthest away from and/or faces away from the
viewer).
[0055] In an embodiment of making a brightness enhancement film,
the method comprises forming a base film by feeding a thermoplastic
resin(s) (e.g., polycarbonate resin) to an extruder; melting the
thermoplastic resin to a temperature greater than or equal to the
glass transition temperature (Tg) of the thermoplastic resin while
it advances through the extruder; extruding the resulting molten
resin through a die into a nip or gap between two calendering
rolls; and cooling the resulting film to below its glass transition
temperature. The resulting film can be rolled and stored for
subsequent processing (e.g., coating and casting, embossing, and
the like). Alternatively, the base film can be feed directly to a
coating and casting station, embossing station, and the like.
[0056] In an embodiment, the molten thermoplastic resin used to
produce the base film of the brightness enhancement film is passed
through two calendering rolls such that the resulting base film is
a low stress retardation variation base film comprising a stress
retardation gradient less than or equal to 50 nanometers per inch
(nm/in), as discussed above. Without being bound by theory, a low
stress variation base film can be obtained when at least one
calendering roll employed comprises a material comprising a
hardness suitable for producing the low stress retardation variance
base film. For example, the roll(s) can comprise an elastomeric
material (e.g., an EPDM (ethylene propylene diamine monomer) based
rubber). It is noted that in various embodiments the roll can be
made entirely of the elastomeric material. Alternatively, the
elastomeric material can be disposed on an outer surface of the
roll, i.e., the surface of the roll that is in physical
communication with the base film.
[0057] For example, in making the base film, a textured rubber
calendering roll can be employed to texture the first surface of
the base film, as discussed above (e.g., the surface is a matte
surface). In various embodiments, the second surface can have a
polished surface or textured surface. As discussed throughout this
disclosure, the selection of surface roughness of the second
surface is a design choice. Embodiments comprising a polished
second surface and a matte first surface can advantageously produce
a brightness enhancement film comprising a luminance (brightness)
equivalent to the luminance as a polish/polish film without color
bands. Moreover, embodiments comprising a textured second surface
and a matte first surface can advantageously produce a
multifunctional brightness enhancement film capable of acting as
both a traditional brightness enhancement film, for example, to
direct light along a viewing axis (i.e., an axis normal
(perpendicular) to the display), and as a light diffusing film.
[0058] In various other embodiments, one of the calendering roll
can comprise a chrome or chromium plated roll comprising a polished
surface or texture surface (e.g., a velvet surface). Furthermore,
it is generally noted that the size of the rollers, material of the
rollers, number of rollers, the film wrap around the rollers, and
the like can vary with the system employed. Further, it is noted
that processing conditions (e.g., the temperature of the
calendering rollers, the line speed, nip pressure, and the like)
are controlled to produce the desired haze value and luminance in
the base film for the resulting brightness enhancement film.
[0059] Referring to FIG. 7, a schematic view of an exemplary
extrusion system, generally designated 400 is illustrated. Molten
thermoplastic resin 402 is extruded from slot die 404. The molten
thermoplastic resin is then passed through a nip or gap 406 formed
by calendering rolls 408 and 410, is cooled, and is then passed
through pull rolls 412. The cooled film can be rolled (stored) to
be subsequently processed, or the cooled film can feed directly to
a station (device) to form the light-redirecting structure on the
cooled film (base film) to form the brightness enhancement film
(e.g., a coating and casting station, embossing station, and the
like).
[0060] Having formed the base film of the brightness enhancement
film, the method of making the brightness enhancement film further
comprises creating light-redirecting structure(s) on the first
surface of base film, i.e., the surface comprising the matte
surface. As briefly noted above, the light-redirecting structure
(e.g., prismatic structure) can be created by applying a curable
coating onto the first surface of the base film and casting the
structure into the curable coating as it is curing, by
hot-embossing the structure onto the base film, or the like. For
example, prismatic structures can be formed by disposing a curable
coating on the base film, and curing the coating (e.g., by exposing
the coating to ultra violet (UV) radiation) while the coating is in
physical communication with a cast, wherein the cast comprises the
negative image of the desired surface structure.
[0061] Methods of coating a curable composition on a surface of a
substrate are described, for example, in U.S. Pat. No. 5,175,030 to
Lu et al., U.S. Pat. No. 5,183,597 to Lu, U.S. Pat. No. 5,271,968
to Coyle et al., U.S. Pat. No. 5,468,542 to Crouch, 5,626,800 to
Williams et al., and U.S. Pat. No. 6,280,063 to Fong et al., as
well as U.S. patent application Publication No. 2003/0108710 Al to
Coyle et al. For example, suitable methods of disposing the coating
in physical communication with the first surface of the brightness
enhancement film include, but is not limited to, spraying,
brushing, electro-deposition, dipping, flow coating, roll coating,
gravure, and screen printing. Moreover, it is noted that coating
can be applied as continuous coating or as patches that correspond
with a pattern on the cast.
[0062] In other embodiments, the light-redirecting structures can
be formed by hot-embossing the base film, wherein the method
comprises heating the base film to a temperature sufficient to
soften the base film, and embossing the desired structure into the
base film. It is noted that roll embossing, stamping, or the like
can be employed to emboss the light-redirecting structure (e.g.,
prism(s)) into the base film. More particularly, the embossing tool
comprises a negative image of the desired surface.
[0063] For protection and convenience of handling in between
preparation of brightness enhancement film and its incorporation
into a device, the brightness enhancement film can
additionally/optionally comprise a masking layer(s). For example,
the brightness enhancement film can comprise a masking layer
disposed over the first surface of the film (e.g., in embossed
embodiments), the second surface of the base film, and/or the
curable coating (e.g., in coated embodiments). Suitable masking
layers include single or co-extruded layers of polyethylene,
polypropylene, polyester, and combinations comprising at least one
of the foregoing, wherein the adhesion to the brightness
enhancement film is controlled by a pressure sensitive adhesive, by
static, and/or the like.
[0064] With regards to the light-diffusing film (e.g., 120) of the
backlight display device, the light-diffusing film can be a
textured light-diffusing film and/or a bulk light-diffusing film
(e.g., light-diffusing can be imbedded into the film to impart the
light-diffusing properties to the film). Generally, the
light-diffusing film comprises a thermoplastic substrate such as
polyester, polycarbonate, or combinations comprising the foregoing.
As noted above, the haze value for the light-diffusing film can
vary depending on the application. For example, it is noted that
top light-diffusing films (e.g., 330) can comprise a haze value of
less than or equal to about 85%, more particularly a haze value of
less than or equal to about 50%. Whereas, bottom light-diffusing
films (e.g., 320) generally comprise a haze value of greater than
or equal to about 90%, more particularly a haze value of greater
than or equal to about 95%.
[0065] As briefly mentioned above, the brightness enhancement films
disclosed herein can be employed in various backlight display
devices, e.g., a laptop computer. In various embodiments, the
brightness enhancement film can be a multifunctional brightness
enhancement film as described above. For example, referring again
to FIG. 1, the brightness enhancement film 112 can be disposed in
physical communication with light guide 106. More particularly,
brightness enhancement film 112 can be in physical communication
with the second surface 114 of the light guide 106, i.e., the
surface opposite the first surface 110 of the light guide 106. In
other words, a bottom light-diffusing film is not disposed in
physical communication with brightness enhancement film 112 and
light guide 106.
EXAMPLES
Comparative Example 1
[0066] Polycarbonate resins were extruded at 270.degree. C. into
base films comprising a thickness of about 175 micrometers. The
film was extruded between two polished chrome calendering rolls
maintained at 127.degree. C. A base film was achieved with stress
retardation gradient greater than 50 nanometers per inch
retardation across a 50 inch (127 centimeter) wide film. It is
noted that in constructing a stress profile from which the stress
retardation gradient was obtained, stress retardation was measured
at every 0.25 inches (0.64 centimeters) across the length of the
film.
[0067] This base film was then coated with a coating comprising
about 60 wt. % brominated epoxy acrylate, and about 40 wt. %
phenylthiolethylacrylate, with a trace amount of a photoinitiator
(i.e., a bis(acyl)phosphine oxide sold as IRGACURE 819,
commercially available from Ciba Geigy, Inc., wherein weight
percents were based on a total weight of the coating. The coating
composition was applied to the bottom-masked base film by gravure
roll at a thickness of about 30 micrometers. After the coating was
applied to the film, prismatic structures were formed by curing the
coating while it was in contact with a cast comprising a surface
with the negative image of the desired surface structures as
described above. The film was then masked, and subsequently
converted into a format suitable for handling and assembly in a
backlight module in a liquid crystal display. Color-band was
observed when this coated film was assembled in a back light
display device and covered by crossed polarizer films.
Example 2
[0068] Polycarbonate resins were extruded at 270.degree. C. into
base films comprising a thickness of about 175 micrometers. The
film was extruded between a polished chrome calendering roll
maintained at 127.degree. C. and a steel calendering roll coated
with 0.5 inch (about 1.3 cm) thick, 70 durometer (Shore A) silicone
rubber calendering roll cooled with water at temperature of
43.degree. C. A base film was achieved with stress retardation
gradient less than 20 nanometers per inch retardation and 40% haze
at a line speed of 19 feet per minute (ft/min) (about 5.8 meters
per min (m/min)). It is noted that in constructing a stress profile
from which the stress retardation gradient was obtained, stress
retardation was measured at every 0.25 inches (0.64 centimeters)
across the length of the film.
[0069] This base film was then coated with a coating comprising
about 60 wt. % brominated epoxy acrylate, and about 40 wt. %
phenylthiolethylacrylate, with a trace amount of a photoinitiator
(i.e., a bis(acyl)phosphine oxide sold as IRGACURE 819,
commercially available from Ciba Geigy, Inc., wherein weight
percents were based on a total weight of the coating. The coating
composition was applied to the bottom-masked base film by gravure
roll at a thickness of about 30 micrometers. After the coating was
applied to the film, prismatic structures were formed by curing the
coating while it was in contact with a cast comprising a surface
with the negative image of the desired surface structures as
described above. The film was then masked, and subsequently
converted into a format suitable for handling and assembly in a
backlight module in a liquid crystal display. Substantially the
same luminance was obtained after replacing a brightness
enhancement film made from a polish/polish base film in a backlight
display device with a brightness enhancement film comprising a
matte/polish base film. More particularly, the luminance at a zero
degree view angle (i.e., on-axis) was measured (with the liquid
crystal panel removed from a backlight display device) using an
Eldim EZ Contrast 160D instrument, and found to be about 102% to
about 104% of the value obtained when a commercial brightness
enhancement film was used, i.e., a BEF II film commercially
available from 3M, Inc. No color-band was observed when this coated
film was assembled in a back light display device and covered by
crossed polarizer films.
Example 3
[0070] Polycarbonate resins and an antistatic agent
tetrabutylphosphonium perfluorobutylsulfonate ("FC-1") present in
an amount of about 1.1 wt. % based on a total weight of the blend
were extruded at 263.degree. C. into base films comprising a
thickness of about 125 micrometers. The film was extruded between a
polished chrome calendering roll maintained at 135.degree. C. and a
steel calendering roll coated with 0.5 inch (about 1.3 cm) thick,
70 durometer (Shore A) silicone rubber calendering roll cooled with
water at a temperature of 40.degree. C. A base film was achieved
with less than 15 nm/in stress retardation gradient and 40% haze at
a line speed of 16 feet per minute (ft/min) (about 4.9 meters per
min (m/min)). A coating was applied in the same manner and using
the same coating material as discussed in Example 1. In this
example however, the surface static decay of the resulting film
decreased by 3 to 4 orders of magnitude. The film was masked, and
subsequently converted into a format suitable for handling and
assembly in a backlight module in a liquid crystal display.
Substantially the same luminance was obtained after replacing a
brightness enhancement film made from a polish/polish base film in
a backlight display device with a brightness enhancement film
comprising a matte/polish base film. No color-band was observed
when this coated film was assembled in a back light display device
and covered by polarizer films.
Example 4
[0071] Polycarbonate resins and an antistatic agent
tetrabutylphosphonium perfluorobutylsulfonate ("FC-1") present in
an amount of about 1.1 wt. % based on a total weight of the blend
were extruded at 263.degree. C. into base films comprising a
thickness of about 125 micrometers. The film was extruded between a
velvet steel calendering roll maintained at 135.degree. C. and a
steel calendering roll coated with 0.5 inch (about 1.3 cm) thick,
70 durometer (Shore A) silicone rubber calendering roll cooled with
water at a temperature of 40.degree. C. A base film was achieved
with less than 15 nm/in stress retardation gradient and 45% haze at
a line speed of 12 feet per minute (ft/min) (about 3.7 meters per
min (m/min)). The base film had a matte surface on a first surface
and a velvet texture on a second surface. The first surface of the
base film was then coated with a coating comprising about 60 wt. %
brominated epoxy acrylate, and about 40 wt. %
phenylthiolethylacrylate, with a trace amount of a photoinitiator
(e.g., same as that discussed above in Example 1), wherein weight
percents are based on a total weight of the coating. After the
coating was applied to the film, prismatic structures were formed
by curing the coating while it was in contact with cast comprising
a surface with the negative image of the desired surface structures
as described above. The film was then masked, and subsequently
converted into a format suitable for handling and assembly in a
backlight module in a liquid crystal display.
[0072] It was noted that in a backlight module, most defects
(scratches, point defects, ripples, and the like) generated during
current processing and handling conditions, which were visible in a
polish/polish base film, were not visible in this textured base
film. Additionally, the luminance at a zero degree view angle
(i.e., on-axis) was measured (with the liquid crystal panel removed
from a backlight display device) using an Eldim EZ Contrast 160D
instrument, and found to be about 92% of the value obtained when a
commercial brightness enhancement film was used, i.e., a BEF II
film commercially available from 3M, Inc. Grid lines from light
guide were not visible after replacing a bottom diffuser with the
brightness enhancement film described above. Additionally, it is
noted that similar results were also obtained when the second
surface comprised a matte surface.
[0073] Advantageously, embodiments of the brightness enhancement
films disclosed herein do not produce color bands when employed in
a flat panel display device (e.g., a backlight display devices),
and perform equivalent to a polish/polish. For example, it is noted
that color bands were observed in comparative example 1, but not
color bands were observed in Examples 2-4. Additionally, it is
noted that embodiments are disclosed herein wherein the brightness
enhancement films comprising a base film comprising matte/polish
surfaces can comprise a relative luminance of about 99.5% to about
100.5% compared to a base film comprising polish/polish surfaces.
In other words, the brightness enhancement films disclosed herein
comprise substantially the same brightness performance as a
polish/polish film, but have the advantage of not producing color
bands.
[0074] Other embodiments are disclosed herein wherein at least one
light-diffusing film, or brightness enhancement film can be
eliminated in a backlight display device. In other words, the
brightness enhancement film can be a multifunctional brightness
enhancement film acting as both a traditional brightness
enhancement film, for example, to direct light along a viewing axis
(i.e., an axis normal (perpendicular) to the display), and as a
light diffusing film. Moreover, embodiments are envisioned where a
plurality of brightness enhancement films and a plurality of
light-diffusing films can be replaced by one or more
multifunctional film, thereby advantageously reducing the overall
thickness of the backlight display device.
[0075] Additionally, it is noted that embodiments are disclosed
herein comprising anti-static agent. As noted above, the static
decay can be decrease by 3 to 4 orders of magnitude compared to
embodiments not comprising the anti-static agent.
[0076] Furthermore, in various embodiments, the base film of the
brightness enhancement film comprises polycarbonate, e.g., the base
film comprise greater than or equal to about 80 wt. %
polycarbonate, and more particularly greater than or equal to about
90 wt. % polycarbonate, wherein weight percents are based on a
total weight of the base film. Compared to commercially available
brightness enhancement films comprising polyethylene terephthalate
(PET), the brightness enhancement films disclosed herein comprising
polycarbonate have superior long-term stability. For example, in a
thermal cycle test, a polycarbonate base film can out perform the
PET base film, i.e., the film flatness of the polycarbonate can
remain more flat compared to the PET film. Generally, in the
thermal cycle test, a base film is placed in a chamber where the
temperature is cycled between 85.degree. C. and -35.degree. C.
(minimal moisture content in the air, e.g., less than or equal to
60% relative humidity), with the temperature held at each extreme
for 1 hour and then changed to the other extreme at a rate of
2.degree. C. per minute. Generally, 100 such cycles are run and
then the base films are compared.
[0077] While the invention has been described with reference to
several embodiments thereof, it will be understood by those skilled
in the art that various changes can be made and equivalents can be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications can be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiments disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *