U.S. patent application number 11/900208 was filed with the patent office on 2008-04-17 for light polarizer.
Invention is credited to Michael J. Hanrahan, Patrick W. Mullen, Robert B. Nilsen, Edward D. Phillips.
Application Number | 20080088923 11/900208 |
Document ID | / |
Family ID | 34677128 |
Filed Date | 2008-04-17 |
United States Patent
Application |
20080088923 |
Kind Code |
A1 |
Nilsen; Robert B. ; et
al. |
April 17, 2008 |
Light polarizer
Abstract
A polarizer comprising at least one subwavelength optical
microstructure that includes linear prisms, and wherein said
microstructure is partially covered with a light-transmissive
inhibiting surface.
Inventors: |
Nilsen; Robert B.; (Mystic,
CT) ; Mullen; Patrick W.; (Barkhamsted, CT) ;
Hanrahan; Michael J.; (Danbury, CT) ; Phillips;
Edward D.; (Oakville, CT) |
Correspondence
Address: |
HAMILTON, BROOK, SMITH & REYNOLDS, P.C.
530 VIRGINIA ROAD
P.O. BOX 9133
CONCORD
MA
01742-9133
US
|
Family ID: |
34677128 |
Appl. No.: |
11/900208 |
Filed: |
September 10, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10728128 |
Dec 4, 2003 |
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11900208 |
Sep 10, 2007 |
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09927781 |
Aug 10, 2001 |
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10728128 |
Dec 4, 2003 |
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60225246 |
Aug 15, 2000 |
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Current U.S.
Class: |
359/485.05 ;
359/489.06; 427/163.1 |
Current CPC
Class: |
G02B 5/3058 20130101;
G02B 27/4277 20130101; B42D 25/328 20141001; G02B 5/1809 20130101;
G02B 6/126 20130101; G02B 1/118 20130101; G02B 5/3025 20130101;
G02B 2006/12107 20130101; G02B 1/11 20130101; G02B 5/008 20130101;
B42D 25/391 20141001; G02B 5/1814 20130101; G02B 2006/12116
20130101; G02B 5/3033 20130101 |
Class at
Publication: |
359/486 ;
427/163.1 |
International
Class: |
G02B 5/30 20060101
G02B005/30; G02B 1/10 20060101 G02B001/10 |
Claims
1. A polarizer, comprising: at least one subwavelength optical
microstructure, said microstructure being partially covered with a
light-transmissive inhibiting surface; and a coating disposed over
at least part of the optical microstructure and the inhibiting
surface.
2. The polarizer of claim 1, wherein the coating is
collimating.
3. The polarizer of claim 2, wherein the coating is formed into at
least one linear prism.
4. The polarizer of claim 1, wherein the coating is formed into a
cube-corner prism to form a transparent polarizing cube-corner
film.
5. The polarizer of claim 1, wherein the coating is formed into a
lens.
6. The polarizer of claim 1, wherein the coating is formed into a
surface relief diffuser.
7. The polarizer of claim 1, wherein the optical microstructure
include moth-eye structures, linear prisms, or a combination
thereof.
8. The polarizer of claim 1 wherein the light-transmissive
inhibiting surface includes reflective surface.
9. The polarizer of claim 1 wherein the light-transmissive
inhibiting surface is a metalized coating.
10. The polarizer of claim 1, wherein the optical microstructure
includes a flat surface upon which the light-transmissive
inhibiting surface is disposed.
11. The polarizer of claim 1, wherein the optical microstructure
includes peaks and valleys, wherein the light-transmissive
inhibiting surface is primarily disposed on the peaks.
12. The polarizer of claim 11, wherein the light-transmissive
inhibiting surface is disposed on one side of substantially all of
the peaks.
13. A filter, comprising: at least one subwavelength optical
microstructure having at least a part of a surface covered with a
light-transmissive inhibiting surface; and a resonance structure
adjacent to the microstructure for reflecting light of a
predetermined wavelength that has passed through the
microstructure.
14. A method of forming a polarizer, comprising: partially covering
a subwavelength optical microstructure with light-transmissive
inhibiting surface, wherein optical microstructure includes linear
prisms; and disposing a coating over at least part of the optical
microstructure and the metalized surface.
Description
RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 10/728,128, filed Dec. 4, 2003, which is a continuation-in-part
of U.S. application Ser. No. 09/927,781, filed on Aug. 10, 2001,
which claims the benefit of U.S. Provisional Application No.
60/225,246, filed on Aug. 15, 2000. The entire teachings of the
above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Sunlight is typically regarded as unpolarized light. In
order to reduce the glare on reflected light, glass lenses have
incorporated polarizing elements. The light is typically polarized
by introducing a polarization film to each lens element to produce
polarized light wherein the impinging light is divided into
reflected, absorbed and transmitted polarized light beams by the
polarizing lens elements. Coatings have also been applied to lens
elements in order to produce a mirrored appearance for the lenses
and to decrease transmission of visible light in order to reduce
the associated glare.
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present invention is a polarizer
comprising at least one subwavelength optical microstructure that
includes linear prisms, wherein said microstructure is partially
covered with a light-transmissive inhibiting surface.
[0004] In another embodiment, the present invention is a polarizer
comprising a substrate having a plurality of linear prisms formed
thereon, the linear prisms having a partially metalized
surface.
[0005] In another embodiment, the present invention is a method of
forming a polarizer, comprising partially covering a subwavelength
optical microstructure with light-transmissive inhibiting surface,
wherein optical microstructure includes linear prisms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing and other objects, features and advantages of
the invention will be apparent from the following more particular
description of various embodiments of the invention, as illustrated
in the accompanying drawings in which like reference characters
refer to the same parts throughout the different views. The
drawings are not necessarily to scale, emphasis instead being
placed upon illustrating the principles of the invention.
[0007] FIG. 1 is partial isometric view of a polarizing film
utilizing moth-eye structures in accordance with the present
invention.
[0008] FIG. 2 is a side view of a subwavelength optical
microstructure.
[0009] FIG. 3 is a partial isometric view of a polarizing film
utilizing moth-eye structures in accordance with the present
invention.
[0010] FIG. 4 is a partial isometric view of a polarizing film
utilizing moth-eye structures in accordance with the present
invention.
[0011] FIG. 5 is a partial isometric view of a polarizing film
utilizing moth-eye structures in accordance with the present
invention.
[0012] FIG. 6 is a partial isometric view of a polarizing film
utilizing linear prisms in accordance with the present
invention.
[0013] FIG. 7 is a partial isometric view of a polarizing film
utilizing modified moth-eye structures in accordance with the
present invention.
[0014] FIG. 8 is a partial isometric view of a polarizing film
utilizing linear prisms having a transparent coating thereon in
accordance with the present invention.
[0015] FIG. 9 is a side view of an apparatus for metalizing
polarizing film in accordance with the present invention.
[0016] FIG. 10 is a partial isometric view of a polarizing film
utilizing moth-eye structures which have both sides of the peaks
metalized in accordance with the present invention.
[0017] FIG. 11 is a partial isometric view of a polarizing film
utilizing linear prisms which have both sides of the peaks
metalized in accordance with the present invention.
[0018] FIG. 12 is a partial isometric view of a polarizing film
utilizing multiple moth-eye structures in accordance with one
embodiment of the present invention.
[0019] FIG. 13 is a partial isometric view of a polarizing film
utilizing multiple moth-eye structures in accordance with another
embodiment of the present invention.
[0020] FIG. 14 is a partial isometric view of a polarizing film
utilizing multiple moth-eye structures in accordance with yet
another embodiment of the present invention.
[0021] FIG. 15 is a partial isometric view of a polarizing film
utilizing multiple moth-eye structures in accordance with another
embodiment of the present invention.
[0022] FIG. 16 is a partial isometric view of a linear prism having
a polarizing film on one surface.
[0023] FIG. 17 is an isometric view of a cube-corner prism having a
polarizing film on one surface.
[0024] FIG. 18 is a partial isometric view of a lens having a
polarizing film on one surface.
[0025] FIG. 19 is a partial isometric view of a surface relief
diffuser having a polarizing film on one surface.
[0026] FIG. 20 is a side view of a tool used to form linear prisms
for use in polarizing films in accordance with the present
invention.
[0027] FIG. 21 is a side view of the tool of FIG. 20 forming the
linear prisms.
[0028] FIG. 22 is a partial isometric view of a liquid crystal
display utilizing a polarizing film in accordance with the present
invention.
[0029] FIG. 23 is a partial isometric view of a liquid crystal
display utilizing a polarizing film in accordance with the present
invention.
[0030] FIG. 24 is a partial isometric view of a color filter
utilizing a polarizing film in accordance with the present
invention.
[0031] FIG. 25 is a side view of a moth-eye structure having a
conductive surface and a conductive coating thereon for forming a
polarizing film.
[0032] FIG. 26 is a side view of a polarizing film utilizing a
moth-eye structure in which a conductive surface and a conductive
coating are provided in the valleys of the moth-eye structure.
[0033] FIG. 27 is a side view of a polarizing film utilizing a
moth-eye structure in which a conductive surface is provided on
peaks of the moth-eye structure.
[0034] FIG. 28 is a side view of a polarizing film utilizing a
moth-eye structure in which conductive particles are provided in
the valleys of the moth-eye structure.
[0035] FIG. 29 is a side view of a polarizing film utilizing a
moth-eye structure in which conductive filler is provided in the
valleys of the moth-eye structure.
[0036] FIG. 30 is a side view of a polarizing film utilizing a
moth-eye structure in which an opaque filler is provided in the
valleys of the moth-eye structure.
[0037] FIG. 31 is a side view of a tool used to form a moth-eye
structure in which particles are disposed in a resin used to form
the moth-eye structure.
[0038] FIG. 32 is a side view of a moth-eye structure formed by the
tool illustrated in FIG. 31 in which particles are disposed in the
peaks of the moth-eye structure.
DETAILED DESCRIPTION OF THE INVENTION
[0039] A description of various embodiments of the invention
follows. FIG. 1 illustrates an embodiment of a polarizing film,
generally designated as reference numeral 10. A subwavelength
optical microstructure, such as a linear moth-eye structure 12, is
formed on a substrate 14. Moth-eye structures are explained in more
detail in U.S. application Ser. No. 09/438,912, now issued as U.S.
Pat. No. 6,356,389 on Mar. 12, 2002, filed Nov. 12, 1999, now
issued the teachings of which are incorporated herein in their
entirety. In one embodiment, the moth-eye structure 12 is formed
from the same material as the substrate 14. The moth-eye structure
can be formed, for example, through embossing, molding, or casting.
In another embodiment, the moth-eye structure 12 is formed from a
material having a different index of refraction than the substrate
14. The substrate 14 can include light-transmissive materials such
as plastics. In one manufacturing technique, the substrate 14 is
relatively soft such that the moth-eye tool penetrates the
substrate so excess resin layer is not present.
[0040] As shown in FIG. 2, the moth-eye structure 12 applied in one
embodiment has an amplitude (A) of about 0.4 micrometers and a
period (P) of less than about 0.2 micrometers. The structure is
sinusoidal in appearance and can provide a deep green to deep blue
color when viewed at grazing angles of incidence. If the period (P)
is made to be about 180 nm or less, this color will not be present.
In one embodiment, the amplitude is about three times the period to
provide a three to one aspect ratio.
[0041] The moth-eye structure 12 provides anti-reflection
properties to the previously smooth light entrance surface of the
substrate even at entrance angles that are near grazing incidence.
The moth-eye structure is more effective than standard thin film
anti-reflection coatings at wide angles of incidence especially
angles of incidence beyond 30 degrees up to 80 degrees. This
characteristic can cause many types of optical microstructure films
including linear prism films to process light very differently than
the standard linear prism collimating films which have smooth
entrance surfaces with or without standard anti-reflection thin
film (vacuum deposited or liquid applied) coatings. The addition of
the moth-eye structures helps to more efficiently recycle light and
also redirects the normally reflected grazing angle incidence rays
into the optical microstructure (such as linear prisms) sheet where
the rays are refracted, reflected or retroreflected depending on
the respective angles of incidence. This moth-eye improvement
concept can be added to many types of brightness enhancement films
(BEF). An advantage is that functional optical microstructures can
be applied to both sides of a film or substrate.
[0042] A moth-eye anti-reflection surface is one in which the
reflection of light is reduced by the presence of a regular array
of small protuberances covering the surface. The spacing of the
protuberances is less than the wavelength of light for which
anti-reflection is sought. A moth-eye surface can be understood in
terms of a surface layer in which the refractive index varies
gradually from unity to that of the bulk material. Without such a
layer, the Fresnel reflection coefficient at an interface of two
media is equal to ((n.sub.1-n.sub.2)/(n.sub.1+n.sub.2)).sup.2,
where n.sub.1 and n.sub.2 are the refractive indices of the media.
However, if there is a gradual change of index, net reflectance can
be regarded as the result of an infinite series of reflections at
each incremental change in index. Since each reflection comes from
a different depth from the surface, each has a different phase. If
a transition takes place over an optical distance of .lamda./2, all
phases are present, there is destructive interference and the
reflectance falls to zero.
[0043] When the height of the protuberance (h) is significantly
less than the wavelength (.lamda.), the interface appears
relatively sharp and the reflectance is essentially that of a
discontinuous boundary. As the ratio of h/.lamda. increases, the
reflectance decreases to a minimum value at about h/.lamda.=0.4.
Further increases in h/.lamda. show a series of successive maxima
and minima, but the value does not again approach that of a sharp
interface. The details of the curve shown in FIG. 2 vary depending
on the profile of the change of the index of refraction, but if the
thickness is of the order of half a wavelength or more the
reflectance is considerably reduced. The spacing of the
protuberances should be sufficiently fine to avoid losses by
diffraction. Preferably, it should be less than the shortest
wavelength involved divided by the refractive index of the
material.
[0044] It is important that the spacing P between the peaks of the
protuberances on the moth-eye surface is sufficiently small that
the array cannot be resolved by incident light. If this is not the
case, the array can act as a diffraction grating and, although
there may well be a reduction in the specular reflection (zero
order), the light is simply redistributed into the diffracted
orders. In other words, P is less than .lamda. for normal incidence
and d is less than .lamda./2 for oblique incidence if for
reflection only, and that d is less than .lamda./2n in the case of
transmission where diffraction inside the material is
suppressed.
[0045] For a given moth-eye surface, where the height of the
protuberances is h and the spacing is d, the reflectance is
expected to be very low for wavelengths less than about 2.5h and
greater than d at normal incidence, and for wavelengths greater
than 2d for oblique incidence. In one embodiment, the spacing is as
close as possible, and the depth as great as possible, in order to
give the widest possible bandwidth. For example, a h/d ratio can be
about three.
[0046] The moth-eye effect should not be confused with that of
reducing the specular reflectance by roughening. Roughness merely
redistributes the reflected light as diffuse scattering and
degrades the transmitted wavefront. With the moth-eye structure,
there is no increase in diffuse scattering, the transmitted
wavefront is not degraded and the reduction in reflection gives
rise to a corresponding increase in transmission.
[0047] The moth-eye structure 12 has many advantages. There is no
extra coating process necessary. The structure can be transferred
to the sheet by a pressure molding process, such as with a Fresnel
structure. The reflection reduction does not depend on the
wavelength. There is only a lower limit (on the ultraviolet side of
the spectrum) set by the structure period. If the wavelength is too
small compared to the period, the light is diffracted. In regard to
angular dependence, with conventional anti-reflective coatings, the
transmission curve shifts with the light incidence angle. With the
moth-eye structure, the critical wavelength for diffraction shifts
to higher values, but there are no changes above this wavelength.
Another advantage for moth-eye structures is that there can be no
adhesion problems between lens and gradient layer because it can be
one bulk material. From a high incident angle, the surfaces can
appear blue or violet.
[0048] In one embodiment of forming a moth-eye structure, the
structure is first produced on a photoresist-covered glass
substrate by a holographic exposure using an ultraviolet laser. A
suitable device is available from Holographic Lithography Systems
of Bedford, Mass. 01730. An example of a method is disclosed in
U.S. Pat. No. 4,013,465, issued to Clapham et al. on Mar. 22, 1977,
the teachings of which are incorporated herein by reference. This
method is sensitive to changes in the environment, such as
temperature and dust, and care must taken. The structure is then
transferred to a nickel shim by an electroforming process. In one
embodiment, the shims are about 300 micrometers thick or less.
[0049] The moth-eye structures can be made one dimensional in a
grating type pattern. In this embodiment, the structure has a
nearly rectangular profile, which means they have no gradient
layers, but more of a one layer anti-reflective coating with a
lowered refractive index in the structure region. Control of the
grating depth is important as is control of thickness for the
evaporated layers. Control of depth and thickness is achieved by
maintaining uniformity of beam exposure, substrate flatness and
exposure time.
[0050] A two-dimensional structure is formed by two exposures with
a linear sinus-grid, turned by 90 degrees for the second exposure.
A third type of structure is formed by three exposures with turns
of 60 degrees to provide a hexagonal or honeycomb shape.
[0051] In one embodiment, the material which forms the moth-eye
structure 12 is substantially transparent as formed. Exemplary
materials include a thermoplastic or thermoset, such as
polymethalmythacrylate, polyurethane, or polycarbonate. In one
embodiment, ultraviolet cured thermoset materials which have a low
viscosity prior to curing provide the preferred replication
fidelity. The moth-eye structure 12 can include valleys 16 and
peaks 18. The pitch P, or distance between valleys 16, in one
embodiment, is less than or equal to about 250 nm. The amplitude A,
or vertical distance from peak 18 to valley 16, in one embodiment,
is greater than or equal to about 250 nm for visible wavelength
light.
[0052] In one embodiment, at least part of the surface of the
moth-eye structure 12 includes a light-transmissive inhibiting
surface, such as a reflective or diffuse surface 20. As shown, the
surfaces 20 are spaced apart and substantially parallel. In one
embodiment, the reflective surface 20 is formed from a metalized
coating, such as aluminum or the like. The diffuse surface, in one
embodiment, includes an engineered surface relief diffuser such
that light incident upon the surface is redirected in transmission
and by reflection. An example of suitable diffusers is disclosed in
U.S. Pat. No. 5,600,462, issued to Suzuki, et al. on Feb. 4, 1997,
the teachings of which are incorporated herein by reference.
Another example of a suitable relief diffuser is disclosed in an
article entitled "Holographic surface-relief microstructures for
large area applications" by V. Boerner, et al. of Fraunhofer
Institute for Solar Energy Systems ISE, Oltmansstr. 5, 79100
Freiburg, Germany, which was presented in a conference held in
Copenhagen, Denmark from May 28-30, 2000, the teachings of which
are incorporated herein by reference.
[0053] It is known that closely spaced parallel electrical
conductors can be used to polarize electromagnetic waves. The
conductors reflect and absorb waves that are polarized in a plane
that is parallel to the length of the conductors. A wave that is
polarized in a plane perpendicular to the length of the conductors
passes through the conductors with little transmission loss.
[0054] As shown in FIG. 3, the polarizing film 10 reflects and
absorbs light rays, such as light ray 22, which travel in a plane
24 parallel to the film. More particularly, plane 24 is parallel to
valleys 16, peaks 18, and surfaces 20. As shown in FIG. 4, if light
ray 22 were traveling in a non-parallel plane, for example, plane
26, the light ray would pass through the film 10 with little
transmission loss. In this manner, only light rays which are
substantially perpendicular to the valleys 16, peaks 18, and
surfaces 20 are allowed to pass through the film 10. The amount of
light reflected or diffused is dependent upon the reflection and
transmission properties of surface 20. Thus, a simple and
relatively inexpensive polarizing film has been discovered.
[0055] FIG. 5 illustrates the same concept of FIGS. 3 and 4. An
incoming randomly polarized light wave 19 is polarized. More
particularly, the film 10 reflects the component 23 of the light
wave 19 which lies in plane parallel to the surfaces 20 and allows
transmission of the component 21 of the light wave perpendicular to
the surfaces 20.
[0056] FIG. 6 illustrates another embodiment of the polarizing film
10 which includes linear prisms 28 formed on substrate 14. In one
embodiment, the linear prisms 28 are isosceles triangles with the
height greater than the base with the pitch as described before. As
illustrated in FIG. 7, yet another embodiment of a polarizing film
10 is illustrated. A moth-eye type structure 30 having a flat top
32 having surface 20 thereon. In this embodiment, the light which
is reflected back can reflect back in a direction consistent with
the angle of incidence equaling the angle of reflection from flat
top 32. If surface 20 is metalized and combined with a surface
relief diffuser or structured surface as shown in FIG. 19, the
surface serves as a type of anti-glare surface. Directional light,
such as from an overhead light fixture, is reflected at a defined
angle(s) away from the surface. Light passing through the polarizer
is viewed without interference from the reflected light.
Applications range from a window film to a computer monitor film.
Other shapes of the polarizing film, or combinations of the
disclosed shapes of the structures, are contemplated herein.
Further, the substrate 14 can be formed from the same material as
the structure having surface 20.
[0057] FIG. 8 illustrates a transparent coating 34 formed over
linear prisms 28 to protect the surface 20. Transparent coating 34
can be formed over any of the disclosed embodiments. The shape of
this structure reflects ambient light 36 away in a controlled
direction and is one form of construction that can be used as an
anti-glare light redirection film as well as a polarizing film.
This structure can also be used to create an anti-counterfeit
document feature because when superimposed upon a document with an
optically clear adhesive, the document is easily viewed in specific
directions. However, when the document is photocopied, the copy is
darker as a result of much of the light being reflected. Other
indicia, such as logos and water marks, can be added into the film,
for example, by removing a portion of the moth-eye structure or
pattern metalizing. In one embodiment, laser etching is used to
remove the structure in the moth-eye tooling without effecting the
transmission of the film 10.
[0058] FIG. 9 illustrates one embodiment of the manufacturing
process for producing surface 20. In this embodiment, the optical
microstructure is wrapped about a cylinder 38, which can be about 5
centimeters in diameter. A metal source 40, such as aluminum, is
positioned about 19 centimeters inches from the center of cylinder
38. A baffle or mask 41, disposed between the cylinder 38 and the
metal source 40, prevents the metal from covering the entire
microstructure. The baffle or mask 41 can be sized sufficiently to
block the surface of the microstructure from the metal source 40
except in area "A". This arrangement is positioned within a bell
jar vacuum. Angle .alpha. in this embodiment is about 7.5 degrees.
In one embodiment, the microstructure included a moth-eye structure
and it was found that in area "A", the moth-eye structure had the
optimal amount of metalization on one side of the peaks 18. The
cylinder 38 can be rotated such that the entire moth-eye structure
is coated at area "A". In alternative embodiments, as illustrated
in FIGS. 10 and 11, both sides of the peaks 18 are coated by
setting the coating features to allow the coating to impact the
surface when coming from different angles. The position of the
metal source 40 and masks can be adjusted to created a desired
coated area.
[0059] In alternative embodiments, the entire microstructure is
metalized for example, with aluminum. More metal is deposited on
the peaks than on the walls and valleys because of the various
directions the metal impacts the microstructure. The microstructure
is then etched with a caustic for a defined period of time to
remove the thinner metal layer while leaving the metal on the
peaks.
[0060] FIG. 12 illustrates another embodiment of a polarizing film
10. It is known that essentially 0% of the light component which is
perpendicular to the linear moth-eye rows is reflected at each
moth-eye boundary because the moth-eye acts as an anti-reflection
surface in this direction. It is further known that approximately
4% of the light component which is parallel to the linear moth-eye,
for example, light ray 22 in plane 24, is reflected at each linear
moth-eye boundary because the light wave sees a flat surface rather
than a moth-eye surface. Thus, with enough moth-eye layers,
substantially all of the light component which is parallel to the
linear moth-eye structures is reflected and only the light
perpendicular to the moth-eye structures are transmitted
therethrough to create a linear reflecting polarizer. Other
structures can be stacked on one another to create a polarizer,
such as a linear prism structure (FIG. 6) or a modified type
moth-eye structure (FIG. 7).
[0061] FIG. 13 illustrates multiple moth-eye structures 12 stacked
on one another to form a polarizing film 10. In one embodiment,
approximately 40 layers or 80 surfaces can be used to achieve
effective polarization of the light, which polarizes approximately
96% of the light passing through the film.
[0062] FIG. 14 illustrates another embodiment of a stack moth-eye
structure 12 which forms a polarizing film 10. In this embodiment,
a fill layer 44 is provided between each moth-eye structure 12 to
vary the reflection properties by changing the refractive index of
the moth-eye structure relative to the substrate 14 and fill layer.
Fill layer 44 can include low index of refraction materials such as
silicone based and fluoropolymer based materials.
[0063] For optimal performance, n1 is greater than n2. In one
embodiment, n1 is greater than n2 by 0.5 units or more to reduce
the number of layers which can be used to achieve effective
polarization of the light. The number of layers is reduced because
the greater the index of refraction, the more light is reflected at
each boundary. In one embodiment, n1 is approximately 1.59 and n2
is approximately 1.42 with a delta of 0.16. In this case,
approximately 100 layers or 200 surfaces can be used to achieve
effective polarization of the light.
[0064] FIG. 15 illustrates another embodiment of a polarizing film
10. A coating 34, such as a transparent coating, can be applied
over surfaces 20 to protect the same. Moth-eye structures 12 can be
added to either surface 46 and 48, or both, to improve the light
transmission of the film 10. In the embodiment shown in FIG. 15, a
moth-eye structure 12 has been added to both surfaces 46 and 48.
The location of the surface 20 can be defined such that it will act
as an anti-glare surface by reflecting unwanted light away from a
display. This structure further acts as a contrast enhancing film
because of the anti-reflection, polarization and dark line pattern
created by the surface 20.
[0065] FIGS. 16, 17, 18, and 19 illustrate exemplary applications
for the polarizing film 10. FIG. 16 illustrates the protective
coating 34 formed into a linear prism to form a transparent
polarizing linear prism collimating film. In one embodiment, the
linear prisms have a height in the range of between about 10 and
200 micrometers and a pitch in the range of between about 20 and
400 micrometers. An example of suitable linear prisms is disclosed
in U.S. Pat. No. 4,260,220 issued to Whitehead on Apr. 7, 1981, the
teachings of which are incorporated herein by reference. FIG. 17
illustrates the protective coating 34 formed into a cube-corner
prism to form a transparent polarizing cube-corner film. In one
embodiment, the cube-corner prisms can have a height in the range
of between about 20 and 200 micrometers and a pitch in the range of
between about 50 and 500 micrometers. Examples of suitable
cube-corner prisms are disclosed in U.S. Pat. No. 3,684,348, issued
to Rowland on Aug. 15, 1972, the teachings of which are
incorporated herein by reference. FIG. 18 illustrates the
protective coating 34 formed into a lens. Many types of polarizing
lenses can be formed including lenticulars, linear bar lenses,
single lenses, lens arrays, etc. FIG. 19 illustrates the protective
coating 34 formed into the shape of a surface relief diffuser for
use in applications such as front and rear projection screens.
[0066] FIGS. 20 and 21 illustrate a method of manufacturing
subwavelength linear prisms having a different index of refraction
than the supporting substrate. FIG. 20 is a side view of a drum
that is ruled to form a tool 50 having linear prisms at
approximately the pitch of a moth-eye structure. In one embodiment,
this pitch is about 250 nm. Resin 52 is cast onto a relatively soft
substrate 54, such as urethane or vinyl, which allows the linear
prism tips 55 to penetrate the substrate leaving resin in
subwavelength size (FIG. 21). In this embodiment, the resin 52 has
an index of refraction different than substrate 54.
[0067] In any of the disclosed embodiments, if surface 20 is
metalized or includes a conductive material, it can be used as a
narrow conducting path for use in products such as liquid crystal
displays. Thus, the same film 10 can be used to polarize the light
and serve as a conducting path. Additionally, the channels, such as
the valleys 16 of the moth-eye structures, can act as alignment
grooves for the liquid crystal material, as illustrated in the
embodiment of FIG. 22.
[0068] Generally, in one embodiment, a pair of moth-eye structures
12 having conductive surfaces 20 for polarizing incoming random
light are positioned 90 degrees relative to one another. A
passivation coating or layer 56, such as an oxide layer, can be
formed on the moth-eye structure 12 to protect the structure
against contamination and to increase electrical stability. The
moth-eye channels or valleys 16 act as alignment grooves for the
liquid crystals 58 which turn through 90 degrees with the material
directly adjacent the valleys 16 being substantially parallel
thereto. As understood in the art, when an electric current is
carried, for example, by surfaces 20, the liquid crystals 58 are
aligned such that light polarized by a polarizer in a first
direction is blocked by the adjacent polarizer, which is 90 degrees
offset. With no electric current, the liquid crystals are aligned
as illustrated in FIG. 22 such that the light's plane of vibration
twists through a right angle so light passes through the adjacent
polarizer.
[0069] In the embodiment of FIG. 23, layer 60 is made using
existing standard technology and includes a passivation coating 56
formed over the entire surface. A plurality of brushed alignment
channels 62 are used to align the liquid crystals 58. A polarizer
10, such as a moth-eye structure 12 having surfaces 20, can be
placed on the outside surface for polarizing incoming light. The
other polarizer (shown on top in FIG. 23) can be similar to the
polarizers as shown in FIG. 22. Thus, in accordance with the
present invention, the expensive secondary step of brushing
alignment channels can be beneficially avoided.
[0070] FIG. 24 illustrates a moth-eye 12 polarizer in accordance
with the present invention, used in conjunction with a resonance
structure 64, such as an Aztec structure developed by Dr. Jim
Cowan, to provide a high contrast color filter. Unpolarized light
66 is polarized by the moth-eye structure 12 such that polarized
light 68 impinges upon the resonance structure 64. Only light of a
predetermined wavelength is reflected by the resonance structure at
a given location to produce a high contrast output wavelength
70.
[0071] The polarizing film of the present invention can be used in
a wide range of applications including sunglasses, LCD displays,
windows, and security documents. The polarizing film can be made
very thin and light in weight. The thickness of the film can be as
small as one wavelength of light. In one embodiment, the thickness
of the moth-eye structure carried on a substrate is in the order of
12.7 micrometers or greater (0.0005 inches or greater).
[0072] Also, the materials used can be very temperature stable
relative to the material used to make traditional polarizing films.
Traditional polarizers are made by aligning microscopic crystals in
a suitable base. A traditional polarizer typically performs in a
range of 25 to 40% efficiency because of absorption losses. The
polarizer of the present invention achieves a near 50% efficiency
with the only losses occurring from absorption within the clear
polymers used to construct the polarizer and imperfections in the
reflective coating process.
[0073] Also, because the approximately 50% or less of light that is
reflected from the coated surfaces is not absorbed, it is available
to be recycled back through the new polarizer material. Thus, an
efficient polarizer is provided in accordance with the present
invention.
[0074] FIGS. 25 and 26 illustrate an embodiment for forming a
reflective or absorptive polarizing film 10. A subwavelength
optical microstructure, such as a moth-eye structure or film 12, is
cast or otherwise provided. A conductive or metal surface or
coating 72, which can have a thickness 74 of about 500 angstroms in
a particular embodiment, can be formed, such as by vacuum
metallization or other suitable techniques, on the moth-eye film
12. A conductive coating 76 can be electroplated or otherwise
formed on the conductive surface 72. The conductive surface 72 can
be used to grow the conductive coating 76. The conductive coating
76 and surface 72 can be removed from the moth-eye peaks 18 leaving
valleys 16 fully conductive. The conductive coating 76 and surface
72 can be removed from the peaks 18 by caustic chemical etching
techniques, mechanical brushing, skiving, or other suitable
techniques. A substantially transparent coating 34 can be provided
to protect the polarizing film 10.
[0075] In another embodiment of a polarizing film 10 as illustrated
in FIG. 27, a soluble coating can be applied to the valleys 16 of
the moth-eye film 12 prior to forming the conductive surface 72 on
the film. This allows the conductive surface 72 to be rinsed off
the valleys 16 leaving the conductive surface on the peaks 18. A
substantially transparent coating 34 can be provided on the film
10.
[0076] In other embodiments of a polarizing film 10, a moth-eye
film 12 can be cast or otherwise provided as illustrated in FIG.
28. A plurality of conductive particles 78 can be provided in the
moth-eye valleys 16 while leaving the peaks 18 exposed. In one
embodiment, the particles 78 can include nano particles. In other
embodiments, the particles 78 can include about 0.2 micrometer or
smaller size metal particles, such as silver (Ag), aluminum (Al),
titanium dioxide (TiO.sub.2), or other suitable materials. In a
particular embodiment, a magnet can be used to pull the particles
78 into the valleys 16, and excess particles can be removed leaving
the peaks 18 exposed. A substantially transparent coating 34 can be
provided on the polarizing film 10.
[0077] In another embodiment of a polarizing film 10 illustrated in
FIG. 29, a conductive filler 80, which can include conductive
fibers, can be provided in the valleys 16 of a moth-eye film 12. In
a particular embodiment, the conductive filler 80 can be brushed
into the valleys 16 and excess filler removed so that the peaks 18
are substantially clean. A substantially transparent coating 34 can
be provided on the polarizing film 10.
[0078] FIG. 30 illustrates another embodiment of a polarizing film
10 in which an opaque filler 82, which can include opaque fibers,
is provided in the valleys 16 of a moth-eye film 12. In a
particular embodiment, the filler 82 can be brushed or coated into
the valleys 16 and excess filler removed so that the moth-eye peaks
18 are clean. A substantially transparent coating 34 can be
provided on the polarizing film 10.
[0079] In another embodiment, a resin 84, which can be conductive,
is cast on a linear moth-eye mold 11, as illustrated in FIG. 31, to
form moth-eye film 12. A plurality of particles 86 can be provided
in resin 84 that sink to the bottom of the mold 11, which forms the
peaks 18 of the resulting moth-eye film 12. In a particular
embodiment, the particles 86 can be conductive. When the moth-eye
film 12 is cured and removed, as illustrated in FIG. 32, the
particles 86 are thus formed in at least some of the peaks 18. A
substantially transparent coating 34 can be provided on the
polarizing film 10.
[0080] While this invention has been particularly shown and
described with references to various embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
scope of the invention encompassed by the appended claims.
* * * * *