U.S. patent application number 13/634587 was filed with the patent office on 2013-01-03 for optical stack.
Invention is credited to Gary T. Boyd, William F. Edmonds, Vivian W. Jones, Keith M. Kotchick, Tri D. Pham, John F. Van Derlosfske III.
Application Number | 20130004728 13/634587 |
Document ID | / |
Family ID | 44227521 |
Filed Date | 2013-01-03 |
United States Patent
Application |
20130004728 |
Kind Code |
A1 |
Boyd; Gary T. ; et
al. |
January 3, 2013 |
OPTICAL STACK
Abstract
Optical stack is disclosed. The optical stack includes a light
redirecting film that includes a first structured major surface
that includes a plurality of unitary discrete structures. The
optical stack also includes an optical adhesive layer that is
disposed on the light directing film. At least portions of at least
some unitary discrete structures in the plurality of unitary
discrete structures penetrate into the optical adhesive layer. At
least portions of at least some unitary discrete structures in the
plurality of unitary discrete structures do not penetrate into the
optical adhesive layer. The peel strength of the light redirecting
film and the optical adhesive layer is greater than about 30
grams/inch. The average effective transmission of the optical stack
is not less or is less than by no more than about 10% as compared
to an optical stack that has the same construction except that no
unitary discrete structure penetrates into the optical adhesive
layer.
Inventors: |
Boyd; Gary T.; (Woodbury,
MN) ; Edmonds; William F.; (Minneapolis, MN) ;
Jones; Vivian W.; (Woodbury, MN) ; Kotchick; Keith
M.; (St. Paul, MN) ; Pham; Tri D.; (Oakdale,
MN) ; Van Derlosfske III; John F.; (Minneapolis,
MN) |
Family ID: |
44227521 |
Appl. No.: |
13/634587 |
Filed: |
April 11, 2011 |
PCT Filed: |
April 11, 2011 |
PCT NO: |
PCT/US11/31910 |
371 Date: |
September 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61323163 |
Apr 12, 2010 |
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61323128 |
Apr 12, 2010 |
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61323147 |
Apr 12, 2010 |
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Current U.S.
Class: |
428/172 ;
359/485.01; 385/31 |
Current CPC
Class: |
G02B 5/045 20130101;
F21V 11/00 20130101; G02F 1/133606 20130101; G02B 6/0053 20130101;
G02F 2001/133607 20130101; Y10T 428/24612 20150115 |
Class at
Publication: |
428/172 ;
359/485.01; 385/31 |
International
Class: |
B32B 3/10 20060101
B32B003/10; G02B 6/00 20060101 G02B006/00; G02B 5/30 20060101
G02B005/30 |
Claims
1. An optical stack comprising: a light redirecting film comprising
a first structured major surface comprising a plurality of unitary
discrete structures; and an optical adhesive layer disposed on the
light directing film, at least portions of at least some unitary
discrete structures in the plurality of unitary discrete structures
penetrating into the optical adhesive layer, at least portions of
at least some unitary discrete structures in the plurality of
unitary discrete structures not penetrating into the optical
adhesive layer, a peel strength of the light redirecting film and
the optical adhesive layer being greater than about 30 grams/inch,
an average effective transmission of the optical stack not being
less or being less than by no more than about 4% as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into the optical adhesive layer.
2. The optical stack of claim 1, wherein each of at least some
unitary discrete structures in the plurality of unitary discrete
structures comprises: a light directing portion primarily for
directing light and comprising a plurality of side facets, each
side facet making an angle that is greater than about 40 degrees
with a normal to the light directing film; and a bonding portion
primarily for penetrating at least partially into the optical
adhesive layer and comprising: a base having a minimum dimension;
and a maximum height, a ratio of the maximum height to the minimum
dimension being at least about 1.5.
3-10. (canceled)
11. The optical stack of claim 1 comprising a reflective polarizer
layer.
12. An optical stack comprising: a light directing film comprising
a plurality of unitary discrete structures; and an optical adhesive
layer disposed on the light directing film for adhering the light
directing film to a surface, portions of each unitary discrete
structure penetrating into the optical adhesive layer, portions of
each unitary discrete structure not penetrating into the optical
adhesive layer, each unitary discrete structure defining a
penetration depth and a penetration base at an interface between
the penetrating and non-penetrating portions of the unitary
discrete structure, the penetration base having a minimum
penetration base dimension, the plurality of unitary discrete
structures having an average penetration depth and an average
minimum penetration base dimension, a ratio of the average
penetration depth to the average minimum penetration base dimension
being at least 1.5, a peel strength between the light directing
film and the surface being greater than about 30 grams/inch.
13. The optical stack of claim 12 comprising a plurality of voids
between the optical adhesive layer and the light directing
film.
14. The optical stack of claim 12, wherein each unitary discrete
structure comprises a light directing portion primarily for
directing light and a bonding portion primarily for bonding the
light directing film to the surface, at least portions of the
bonding portion of each unitary discrete structure penetrating the
optical adhesive layer, at least portions of the light directing
portion of each unitary discrete structure not penetrating the
optical adhesive layer.
15. The optical stack of claim 12, wherein the average minimum
penetration base dimension is less than about 10 microns.
16. The optical stack of claim 12, wherein the average minimum
penetration base dimension is less than about 5 microns.
17. The optical stack of claim 12, wherein each unitary discrete
structure has a base and a minimum base dimension, the plurality of
unitary discrete structures having an average minimum base
dimension, the average minimum penetration base dimension being
less than about 10% of the average minimum base dimension.
18. An optical stack comprising: a light directing film comprising
a first plurality of unitary discrete structures; and an optical
layer disposed on the light directing film, portions of each
unitary discrete structure in the first plurality of unitary
discrete structures penetrating into the optical layer, portions of
each unitary discrete structure in the first plurality of unitary
discrete structures not penetrating into the optical layer, each
unitary discrete structure in the first plurality of unitary
discrete structures defining a penetration depth and a penetration
base at an interface between the penetrating and non-penetrating
portions of the unitary discrete structure, the penetration base
having a minimum penetration base dimension, the first plurality of
unitary discrete structures having an average penetration depth and
an average minimum penetration base dimension, a ratio of the
average penetration depth to the average minimum penetration base
dimension being at least 1.5, a peel strength between the light
directing film and the optical layer being greater than about 30
grams/inch.
19. The optical stack of claim 18, wherein the optical layer is a
pressure sensitive adhesive.
20. The optical stack of claim 18, wherein the optical layer is a
lightguide having means for extracting light that propagates within
the lightguide by total internal reflection.
21. The optical stack of claim 18, wherein the optical layer
comprises a glass transition temperature that is greater than a
maximum operating temperature of the optical stack.
22. The optical stack of claim 18, wherein the light directing film
comprises a second plurality of unitary discrete structures, at
least one unitary discrete structure in the second plurality of
unitary discrete structures not penetrating into the optical
layer.
23. The optical stack of claim 18, wherein the unitary discrete
structures in the second plurality of discrete structures are
shorter than the unitary discrete structures in the first plurality
of discrete structures.
Description
RELATED APPLICATIONS
[0001] This application is related to the following U.S. patent
applications, filed on even date herewith and which are
incorporated by reference: "Light Directing Film" (Attorney Docket
No. 65903US002), and "Optical Stack and Lightguide" (Attorney
Docket No. 66401US002).
FIELD OF THE INVENTION
[0002] This invention generally relates to optical stacks and
displays incorporating same.
[0003] In particular, the invention relates to optical stacks that
have reduced thickness and high peel strength with no or very
little loss in optical properties.
BACKGROUND
[0004] Flat panel displays, such as displays that incorporate a
liquid crystal panel, often incorporate one or more light directing
films to enhance display brightness along a pre-determined viewing
direction. Such light directing films typically include a plurality
of linear microstructures that have prismatic cross-sectional
profiles.
[0005] In some applications a single prismatic film is used, while
in others two crossed prismatic films are employed, in which case,
the two crossed prismatic films are often oriented normal to each
other.
SUMMARY OF THE INVENTION
[0006] Generally, the present invention relates to optical stacks.
In one embodiment, an optical stack includes a light redirecting
film that includes a first structured major surface that includes a
plurality of unitary discrete structures. The optical stack also
includes an optical adhesive layer that is disposed on the light
directing film. At least portions of at least some unitary discrete
structures in the plurality of unitary discrete structures
penetrates into the optical adhesive layer. At least portions of at
least some unitary discrete structures in the plurality of unitary
discrete structures do not penetrate into the optical adhesive
layer. The peel strength of the light redirecting film and the
optical adhesive layer is greater than about 30 grams/inch. The
average effective transmission of the optical stack is not less or
is less than by no more than about 10% as compared to an optical
stack that has the same construction except that no unitary
discrete structure penetrates into the optical adhesive layer. In
some cases, the average effective transmission of the optical stack
is not less or is less than by no more than about 8%, or about 6%,
or about 4%, as compared to an optical stack that has the same
construction except that no unitary discrete structure penetrates
into the optical adhesive layer. In some cases, the optical stack
includes a substrate that is directly bonded to the optical
adhesive layer. In some cases, the optical stack includes another
light directing film that is bonded to the optical adhesive layer
and includes a plurality of linear prismatic structures. In some
cases, the optical stack includes a reflective polarizer layer. In
some cases, the peel strength of the light redirecting film and the
optical adhesive layer is greater than about 40 grams/inch, or
about 50 grams/inch, or about 60 grams/inch. In some cases, an
illumination system includes a light source that emits light and
the optical stack receiving the emitted light. In some cases, the
light directing film is disposed between the optical film and the
light source. In some cases, the optical film is disposed between
the light directing film and the light source.
[0007] In some cases, each of at least some unitary discrete
structures in the plurality of unitary discrete structures includes
a light directing portion that is primarily for directing light and
includes a plurality of side facets, where each side facet makes an
angle that is greater than about 40 degrees with the normal to the
light directing film. Each unitary discrete structure also includes
a bonding portion that is primarily for penetrating at least
partially into the optical adhesive layer and includes a base that
has a minimum dimension. The bonding portion also has a maximum
height. The ratio of the maximum height to the minimum dimension is
at least about 1.5.
[0008] In another embodiment, an optical stack includes a light
directing film that includes a plurality of unitary discrete
structures, and an optical adhesive layer that is disposed on the
light directing film for adhering the light directing film to a
surface. Portions of each unitary discrete structure penetrate into
the optical adhesive layer and portions of each unitary discrete
structure do not penetrate into the optical adhesive layer. Each
unitary discrete structure defines a penetration depth and a
penetration base at the interface between the penetrating and
non-penetrating portions of the unitary discrete structure. The
penetration base has a minimum penetration base dimension. The
plurality of unitary discrete structures has an average penetration
depth and an average minimum penetration base dimension. The ratio
of the average penetration depth to the average minimum penetration
base dimension is at least 1.5. The peel strength between the light
directing film and the surface is greater than about 30 grams/inch.
In some cases, the optical stack includes a plurality of voids
between the optical adhesive layer and the light directing film. In
some cases, each unitary discrete structure includes a light
directing portion that is primarily for directing light and a
bonding portion that is primarily for bonding the light directing
film to the surface. At least portions of the bonding portion of
each unitary discrete structure penetrate the optical adhesive
layer. At least portions of the light directing portion of each
unitary discrete structure do not penetrate the optical adhesive
layer. In some cases, the ratio of the average penetration depth to
the average minimum penetration base dimension is at least 2, or at
least 3, or at least 4, or at least 5, or at least 7, or at least
10. In some cases, the peel strength between the light directing
film and the surface is greater than about 40 grams/inch, or about
60 grams/inch, or about 80 grams/inch. In some cases, the average
minimum penetration base dimension is less than about 10 microns,
or about 7 microns, or about 5 microns, or about 4 microns, or
about 3 microns.
[0009] In some cases, each unitary discrete structure has a base
and a minimum base dimension. The plurality of unitary discrete
structures has an average minimum base dimension. The average
minimum penetration base dimension is less than about 10% of the
average minimum base dimension. In some cases, the average minimum
penetration base dimension is less than about 8%, or about 6%, or
about 5%, or about 4%, or about 3%, of the average minimum base
dimension.
[0010] In another embodiment, an optical stack includes a light
directing film that includes a first plurality of unitary discrete
structures, and an optical layer that is disposed on the light
directing film. Portions of each unitary discrete structure in the
first plurality of unitary discrete structures penetrate into the
optical layer, and portions of each unitary discrete structure in
the first plurality of unitary discrete structures do not penetrate
into the optical layer. Each unitary discrete structure in the
first plurality of unitary discrete structures defines a
penetration depth and a penetration base at the interface between
the penetrating and non-penetrating portions of the unitary
discrete structure. The penetration base has a minimum penetration
base dimension. The first plurality of unitary discrete structures
has an average penetration depth and an average minimum penetration
base dimension. The ratio of the average penetration depth to the
average minimum penetration base dimension is at least 1.5. The
peel strength between the light directing film and the optical
layer is greater than about 30 grams/inch. In some cases, the
optical layer is a pressure sensitive adhesive, or a structural
adhesive. In some cases, the optical layer is a lightguide that
includes means for extracting light that propagates within the
lightguide by total internal reflection. In some cases, the optical
layer includes a glass transition temperature that is greater than
the maximum operating temperature of the optical stack. In some
cases, the light directing film includes a second plurality of
unitary discrete structures, where at least one unitary discrete
structure in the second plurality of unitary discrete structures
does not penetrate into the optical layer. In some cases, the
unitary discrete structures in the second plurality of discrete
structures are shorter than the unitary discrete structures in the
first plurality of discrete structures.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The invention may be more completely understood and
appreciated in consideration of the following detailed description
of various embodiments of the invention in connection with the
accompanying drawings, in which:
[0012] FIG. 1 is a schematic side-view of a light directing
film;
[0013] FIG. 2 is a schematic side-view of a composite
structure;
[0014] FIG. 3 is a schematic three-dimensional view of a unitary
discrete structure;
[0015] FIG. 4 is a schematic three-dimensional view of another
unitary discrete structure;
[0016] FIG. 5 is a schematic side-view of a unitary discrete
structure partially penetrating an optical layer;
[0017] FIG. 6 is a schematic three-dimensional view of a light
directing film;
[0018] FIG. 7 is a schematic three-dimensional view of another
light directing film;
[0019] FIGS. 8A-8E are schematic top-view of bases of different
structures;
[0020] FIG. 9 is a schematic three-dimensional view of a unitary
discrete structure;
[0021] FIG. 10 is a schematic three-dimensional view of another
unitary discrete structure;
[0022] FIG. 11 is a schematic three-dimensional view of another
unitary discrete structure;
[0023] FIG. 12 is a schematic three-dimensional view of yet another
unitary discrete structure;
[0024] FIG. 13 is a schematic three-dimensional view of yet another
unitary discrete structure;
[0025] FIG. 14 is a schematic three-dimensional view of yet another
unitary discrete structure;
[0026] FIG. 15 is a schematic side-view of a light directing
film;
[0027] FIG. 16 is a schematic side-view of another light directing
film;
[0028] FIG. 17 is a schematic side-view of another light directing
film;
[0029] FIG. 18 is a schematic side-view of yet another light
directing film;
[0030] FIG. 19 is a schematic side-view of a display system;
[0031] FIG. 20 is a schematic side-view of an optical stack;
[0032] FIG. 21 is a schematic three-dimensional view of a light
directing film;
[0033] FIG. 22 is a schematic side-view of a display system;
[0034] FIG. 23 is a schematic side-view of a light directing
film;
[0035] FIG. 24 is a schematic side-view of another light directing
film;
[0036] FIG. 25 is a schematic three-dimensional view of a unitary
discrete structure;
[0037] FIG. 26 is a schematic three-dimensional view of another
unitary discrete structure;
[0038] FIG. 27 is a schematic three-dimensional view of another
unitary discrete structure;
[0039] FIG. 28 is a schematic three-dimensional view of yet another
unitary discrete structure;
[0040] FIG. 29 is a schematic side-view of an optical stack;
[0041] FIG. 30 is a schematic side-view of another optical
stack;
[0042] FIG. 31 is a schematic side-view of a display system;
[0043] FIG. 32 is a schematic side-view of another display
system;
[0044] FIG. 33 is a schematic side-view of a light directing
film;
[0045] FIG. 34 is a schematic side-view of an optical stack;
[0046] FIG. 35 is a schematic three-dimensional view of a unitary
discrete structure;
[0047] FIG. 36 is a schematic three-dimensional view of another
unitary discrete structure;
[0048] FIG. 37 is a schematic side-view of an optical system;
[0049] FIG. 38 is a schematic three-dimensional view of a cutting
tool;
[0050] FIG. 39 is a schematic side-view of a light directing
film;
[0051] FIG. 40 is a schematic side-view of a substrate;
[0052] FIG. 41 is a schematic side-view of a light directing
film;
[0053] FIG. 42 is a schematic side-view of a reflective
polarizer;
[0054] FIG. 43 is a schematic side-view of a light directing
film;
[0055] FIG. 44 is a schematic side-view of another light directing
film;
[0056] FIG. 45 is an exemplary SEM of a cutting tool;
[0057] FIG. 46 is an exemplary SEM of a unitary discrete structure
partially penetrating an optical layer;
[0058] FIG. 47 is a plot of average effective transmission as a
function of peel strength;
[0059] FIG. 48 is a schematic side-view of a display system;
[0060] FIG. 49 is a schematic side-view of an optical stack;
[0061] FIG. 50 is a schematic side-view of a display system;
[0062] FIG. 51 is a schematic side-view of another display system;
and
[0063] FIG. 52 is a schematic side-view of a lightguide.
[0064] In the specification, a same reference numeral used in
multiple figures refers to the same or similar elements having the
same or similar properties and functionalities.
DETAILED DESCRIPTION
[0065] The present invention generally relates to light directing
films and displays that incorporate such light directing films. In
particular, the invention relates to a light directing film that
has a plurality of unitary discrete structures for directing and/or
recycling light. The light directing film can bond to a surface,
such as a major surface of an optical film or glass, via an optical
adhesive layer, where the unitary discrete structures partially
penetrate into the optical adhesive layer with no or very little
loss in optical properties, such as optical gain or effective
optical transmission.
[0066] FIG. 1 is a schematic side-view of a light directing film
100 that includes a first structured major surface 110 and an
opposing second major surface 120. First structured major surface
110 includes a plurality of unitary discrete structures 150. Each
unitary discrete structure 150 includes an upper portion or bonding
portion 170 and a lower portion or light directing portion 160. As
used herein, a unitary structure refers to a structure that is a
single unit with no interior or internal physical or detectable
interfaces between the different portions or segments of the
structure. In other words, a unitary structure does not include any
interfaces, such as a sharp interface, a gradient interface, or a
distributed interface, within the interior of the structure. In
some cases, a unitary structure is made of the same material
composition meaning that different locations or portions within the
structure have the same material composition and the same index of
refraction. In some cases, a unitary structure can have a
non-uniform material composition or index of refraction
distribution. For example, in some cases, a unitary structure can
have a gradient refractive index distribution along, for example,
the thickness direction of the unitary structure.
[0067] For example, each unitary discrete structure 150 includes an
upper portion 170 and a lower portion 160 that form a single unit
without a physical or detectable interface between the upper and
lower portions. As another example, FIG. 2 is a schematic side-view
of a composite structure 200 that includes an upper portion 210
that is disposed on a lower portion 220, but is separated from the
lower portion by a physical interface 230. Hence, exemplary
composite structure 200 includes an internal and physical interface
that physically separates two different portions in the composite
structure. In some cases, portions 210 and 220 can have the same
material composition. In such cases, structure 200 is still
considered to be non-unitary if interface 230 can be detected
between the two portions. A unitary structure is typically made or
fabricated in a single step, meaning that the process of
fabricating the unitary structure cannot reasonably be divided into
multiple or separate steps. In some cases, however, a unitary
structure can be made or fabricated in two or more steps. A
non-unitary or composite structure is typically made in multiple
steps. For example, composite structure 200 is made by first making
lower portion 220 and then forming upper portion 210 on the lower
portion.
[0068] Referring back to FIG. 1, unitary discrete structures 150
can have any shape, such as any regular or irregular shape, that
may be desirable in an application. For example, in some cases,
unitary discrete structures 150 can be or include a
three-dimensional rectilinear body, such as a tetrahedron, a prism,
or a pyramid, or a portion, or a combination, of such bodies, such
as a frustum. In some cases, unitary discrete structures 150 can be
or include a three-dimensional curvilinear body, such as a segment
of a sphere, an asphere, an ellipsoid, a spheroid, a paraboloid, a
cone, or a cylinder. In some cases, at least some of the unitary
discrete structures 150 have prismatic profiles.
[0069] Unitary structures 150 are discrete, meaning that each
unitary structure can be identified individually and as being
separate from other similar unitary structures disposed on
substrate 130. Each unitary discrete structure 150 includes light
directing portion 160 that is primarily designed to direct light.
Light directing portion 160 can also be designed to perform other
functions, but the primary function of the light directing portion
is to redirect light by, for example, refracting or reflecting,
such as totally internally reflecting, light.
[0070] In general, light directing portion 160 can have any shape,
such as any regular or irregular shape, that may be desirable in an
application. For example, in some cases, light directing portion
160 can be or include a three-dimensional rectilinear body, such as
a tetrahedron, a prism, or a pyramid, or a portion, or a
combination, of such bodies, such as a frustum. In some cases,
light directing portion 160 can be or include a three-dimensional
curvilinear body, such as a segment of a sphere, an asphere, an
ellipsoid, a spheroid, a paraboloid, a cone, or a cylinder. In some
cases, light directing portions 160 can have a rotationally
symmetric bullet-shape structure.
[0071] Light directing portion 160 includes a plurality of first
side facets 162. For example, in the exemplary light directing film
100, light directing portion 160A includes a first side facet 162A
and an opposing first side facet 162B. In general, light directing
portion 160 can have two or more side facets. For example, FIG. 3
is a schematic three-dimensional view of a unitary discrete
structure 300 that is linear and extends along the y-axis or
y-direction. Unitary discrete structure 300 includes a light
directing portion 360 that includes opposing side facets 362A and
362B. In some cases, unitary discrete structure 300 can have
in-plane (xy-plane) serpentine variations. As another example, FIG.
4 is a schematic three-dimensional view of a unitary discrete
structure 400 that includes a light directing portion 460 that
includes four first side facets: two opposing first side facets
462A and 462C, and two opposing first side facets 462B and
462D.
[0072] The light directing portions of the unitary discrete
structures disclosed herein are primarily designed to redirect
light by, for example, refraction or reflection. For example, FIG.
5 is a schematic side-view of a unitary discrete structure 500 that
includes an upper or bonding portion 570 and a lower or light
directing portion 560 that includes first side facets 562A and 562B
and is primarily designed to direct light. For example, light
directing portion 560 directs a light ray 540 as light ray 542 by
first totally internally reflecting light ray 540 at side facet
562B as light ray 541 and then totally internally reflecting light
ray 541 as light ray 542 at side facet 562A. As another example,
light directing portion 560 directs light ray 545 as light ray 546
by refracting light ray 545 at side facet 562A.
[0073] Referring back to FIG. 1, each light directing portion 160
of unitary discrete structure 150 of light directing film 100 has a
base that is the largest cross-section of the light directing
portion that is parallel to the plane of the light directing film
and is bound by the side facets of the light directing portion. For
example, light directing portion 160 has a base 164 that is the
largest cross-section of the light directing portion in a direction
parallel to a plane 105 of the light directing film and is bound by
side facets 162C and 162D. The exemplary light directing film 100
defines a plane 105 of the light directing film that is in the
xy-plane.
[0074] As another example, FIG. 6 is a schematic three-dimensional
view of a light directing film 600 that includes a first structured
major surface 610 and an opposing second major surface 620. Light
directing film 600 defines a plane 605 that is the plane of the
light directing film, where in the exemplary light directing film
600, plane 605 is parallel to the xy-plane. In general, light
directing film 600 is capable of generally defining plane 605 even
though the light directing film has a major surface 610 that is
structured. Structured major surface 610 includes a plurality of
unitary discrete structures 650, where at least some structures 650
include a light directing portion 660 and a bonding portion 670
that is disposed on the light directing portion. Each light
directing portion 660 is a linear structure that extends along the
y-direction and includes two definable side facets that also extend
along the y-axis or direction. Each light directing portion 660 has
a base that is the largest cross-section of the light directing
portion in the direction parallel to plane 605 and is bound by all
the side facets of the light directing portions that are capable of
being defined or identified. For example, light directing portion
660A includes a rectangular base 661A that is bound on one side by
a side facet 612A defining an edge 613A of the base and on the
other side by a side facet 612B defining an edge 613B of the base,
light directing portion 660B includes a rectangular base 661B that
is bound on one side by a side facet 622A defining an edge 623A of
the base and on the other side by a side facet 622B defining an
edge 623B of the base, light directing portion 660C includes a
rectangular base 661C that is bound on one side by a side facet
632A defining edge 623B of the base and on the other side by a side
facet 632B defining an edge 633B of the base, and light directing
portion 660D includes a rectangular base 661D that is bound on one
side by a side facet 642A defining an edge 643A of the base and on
the other side by a side facet 642B defining an edge 643B of the
base.
[0075] As another example, FIG. 7 is a schematic three-dimensional
view of a light directing film 700 that includes a light directing
portion 710A that has a base 720A, a light directing portion 710B
that has a base 720B, and a light directing portion 710C that has a
base 720C.
[0076] Referring back to FIG. 1, base 164 includes a minimum
dimension d.sub.1 that, in the exemplary light directing film 100,
is along the x-direction. For example, referring to FIG. 6, base
661D of light directing portion 660D has a minimum dimension 671D
that is along the x-direction. As another example, referring to
FIG. 4, light directing portion 460 has a base 470 in the xy-plane
that includes a minimum dimension 471 along the y-direction. As yet
another example, referring to FIG. 7, base 720A has a minimum
dimension 730A that is along the x-direction, base 720B has a
minimum dimension 730B that is along the x-direction, and base 720C
has a minimum dimension 730C that is along the x-direction.
[0077] In general, the minimum dimension of the base of a light
directing portion can be any value or size that may be desirable in
an application. For example, in some cases, the minimum dimension
d.sub.1 can be less than about 500 microns, or less than about 400
microns, or less than about 350 microns, or less than about 300
microns, or less than about 250 microns, or less than about 200
microns, or less than about 150 microns, or less than about 100
microns, or less than about 90 microns, or less than about 80
microns, or less than about 70 microns, or less than about 60
microns, or less than about 50 microns, or less than about 40
microns, or less than about 30 microns, or less than about 20
microns.
[0078] In general, the base of a light directing portion can have
any shape, such as any regular or irregular shape, and any size
minimum dimension that may be desirable in an application. For
example, FIG. 8A is a schematic top-view of a linear base 810A that
extends along the y-direction and has a minimum dimension 810B,
FIG. 8B is a schematic top-view of a linear base 820A that extends
along the y-direction and has a minimum dimension 820B, FIG. 8C is
a schematic top-view of a base 830A that has a minimum dimension
830B, FIG. 8D is a schematic top-view of a hexagonal base 840A that
has a minimum dimension 840B, and FIG. 8E is a schematic top-view
of a linear base 850A that extends along the y-direction and has a
minimum dimension 850B. In general, a base of a light directing
portion can be linear meaning that the dimension, such as the
average dimension, of the base along the linear direction of the
base is substantially larger than the dimension, such as the
average dimension, of the base along the orthogonal direction. For
example, in such cases, the ratio of the average dimension of the
base along the linear direction to the average dimension of the
base along the orthogonal direction is at least about 10, or at
least about 50, or at least about 100, or at least about 500, or at
least about 1000. In some cases, such as when the ratio of the
average dimension of the base along the linear direction to the
average dimension of the base along the orthogonal direction is at
least about 10,000, the base and the light directing portion and
unitary discrete structure associated with the base can be
considered to have an infinite or unlimited extent or dimension
along the linear direction and a finite or limited extent or
dimension along the orthogonal direction. In some cases, the base
of a light direction portion can be in the shape of a rectilinear
figure, such as a polygon. In some cases, the polygon can be an
irregular polygon, such as a rectangle, or a regular polygon, such
as an equilateral triangle, a square, a regular hexagon, or a
regular octagon. In some cases, the base can be a trapezium, a
trapezoid, a parallelogram, a rhombus, or deltoid. In some cases,
the base can be in the shape of a curvilinear figure, such as a
circle, an ellipse, or a parabola.
[0079] Referring back to FIG. 1, light directing portion 160 has a
maximum height h.sub.1 which is the maximum dimension or distance
between base 164 and bonding portion 170 in a direction that is
perpendicular to base 164 or plane 105. For example, referring to
FIG. 4, light directing portion 460 has a maximum height 472 that
is along the z-direction and is the largest distance between base
470 and bonding portion 480 along the z-axis. As another example,
referring to FIG. 7, light directing portion 710A has a maximum
height 740A along the z-direction, light directing portion 710B has
a maximum height 740B along the z-direction, and light directing
portion 710C has a maximum height 740C along the z-direction. In
general, the height of the light directing portions disclosed
herein can vary along one or more directions. For example, FIG. 9
is a schematic three-dimensional view of a linear unitary discrete
structure 900 that extends along the y-direction and includes a
light directing portion 960 and a bonding portion 970 disposed on
the light directing portion. Light directing portion 960 has a base
940 that lies in the xy-plane and extends along the y-direction,
and a height 950 that is the distance between base 940 and bonding
portion 970 along the z-direction. Height 950 varies along the
y-direction. Light directing portion 960 has a maximum height 951
which is the largest distance between base 940 and bonding portion
970 along the z-direction, and a minimum height 952 which is the
smallest distance between base 940 and bonding portion 970 along
the z-direction.
[0080] In some cases, each first side facet of a light directing
portion makes an angle with the plane of the light directing film
that is in a range from about 30 degrees to about 60 degrees. For
example, in light directing film 100, side facet 162C makes an
angle .alpha..sub.1 with plane 105 of the light directing film and
side facet 162D makes an angle .alpha..sub.2 with plane 105 of the
light directing film, where each of .alpha..sub.1 and .alpha..sub.2
is in a range from about 30 degrees to about 60 degrees. As another
example, referring to FIG. 7, light directing portion 710B includes
four side facets that make angles .beta..sub.1, .beta..sub.2,
.beta..sub.3 and .beta..sub.4 with base 720B, where each of the
four angles .beta..sub.1-.beta..sub.4 can be in a range from about
30 degrees to about 60 degrees. In some cases, each first side
facet of a light directing portion makes an angle with the plane of
the light directing film that is in a range from about 35 degrees
to about 55 degrees, or from about 40 degrees to about 50 degrees,
or from about 41 degrees to about 49 degrees, or from about 42
degrees to about 48 degrees, or from about 43 degrees to about 47
degrees, or from about 44 degrees to about 46 degrees. In some
cases, each first side facet of a light directing portion makes an
angle with the plane of the light directing film that is about 45
degrees. For example, in some cases, each of angles .alpha..sub.1
and .alpha..sub.2 can be about 45 degrees.
[0081] Referring back to FIG. 1, unitary discrete structure 150
includes bonding portion 170 that is primarily designed to bond the
light directing film to a surface. In some cases, bonding portion
170 can also perform, or be designed to perform, other functions,
but the primary function of the light directing portion is to bond
the light directing film to a neighboring surface via, for example,
an adhesive layer. Bonding portion 170 is disposed on light
directing portion 160. Bonding portion 170 is also disposed on and
between side facets 162. For example, bonding portion 170A is
disposed on and between side facets 162C and 162D.
[0082] In general, bonding portion 170 can have any shape, such as
any regular or irregular shape, that may be desirable in an
application. For example, in some cases, bonding portion 170 can be
or include a three-dimensional rectilinear body, such as a
tetrahedron, a prism, or a pyramid, or a portion, or a combination,
of such bodies, such as a frustum. In some cases, bonding portion
170 can be or include a three-dimensional curvilinear body, such as
a segment of a sphere, an asphere, an ellipsoid, a spheroid, a
paraboloid, a cone, or a cylinder.
[0083] Bonding portion 170 includes a plurality of side facets 172.
For example, in the exemplary light directing film 100, bonding
portion 170A includes a side facet 172A and an opposing side facet
172B. In general, bonding portion 170 can have two or more side
facets. For example, referring to FIG. 3, unitary discrete
structure 300 includes a bonding portion 370 that includes opposing
side facets 372A and 372B. As another example, referring to FIG. 4,
unitary discrete structure 400 includes a bonding portion 480 that
includes four side facets: two opposing side facets 472A and 472C,
and two opposing side facets 472B and 472D.
[0084] The bonding portions of the unitary discrete structures
disclosed herein are primarily designed to bond the light directing
portions to a neighboring surface. For example, referring to FIG.
5, unitary discrete structure 500 includes bonding portion 570 that
includes side facets 572A and 572B and bonds or attaches light
directing portion 560 to a neighboring surface 595 via an optical
adhesive layer 580. The primary function of bonding portion 570 is
to bond unitary discrete structure 500 or light directing portion
560 to surface 595. In some cases or applications, bonding portion
570 can also direct light. For example, bonding portion 570 can
direct a light ray 550 as a light ray 551, but such light directing
function is not the primary function of the bonding portion.
Rather, the light directing function is a secondary function of the
bonding portion.
[0085] The bonding portions and light directing portions of the
unitary discrete structures disclosed herein have multiple or
pluralities of side facets. In general, a side facet disclosed
herein can have any shape, such as any regular or irregular shape,
that may be desirable in an application. For example, in some
cases, a side facet can be or include a planar portion. For
example, referring to FIG. 4, side facets 462A-462D of light
directing portion 460 and side facets 472A-472D of bonding portion
480 are planar. In some cases, a side facet can be piecewise
planar. For example, FIG. 10 is a schematic three-dimensional view
of a unitary discrete structure 1000 that includes a light
directing portion 1060 and a bonding portion 1070 that is disposed
on the light directing portion. Each of the light directing and
bonding portions has a piecewise planar side facet. In particular,
light directing portion 1060 includes a piecewise planar side facet
1062 that includes planar portions 1062A and 1062B, and bonding
portion 1070 includes a piecewise planar side facet 1072 that
includes planar portions 1072A and 1072B.
[0086] In some cases, a side facet can be or include a curved
portion. For example, FIG. 11 is a schematic three-dimensional view
of a unitary discrete structure 1100 that includes a light
directing portion 1160 and a bonding portion 1170 that is disposed
on the light directing portion. Each of the light directing and
bonding portions has curved side facets.
[0087] In particular, light directing portion 1160 includes curved
side facets 1162A and 1162B, and bonding portion 1170 includes
curved side facets 1172A and 1172B.
[0088] In some cases, a side facet can be piecewise curved. For
example, FIG. 12 is a schematic three-dimensional view of a unitary
discrete structure 1200 that includes a light directing portion
1260 and a bonding portion 1270 that is disposed on the light
directing portion. Each of the light directing and bonding portions
has a piecewise curved side facet. In particular, light directing
portion 1260 includes a piecewise curved side facet 1262 that
includes curved portions 1262A and 1262B, and bonding portion 1270
includes a piecewise curved side facet 1272 that includes curved
portions 1272A and 1272B. In some cases, a side facet of a unitary
discrete structure can be planar, or piecewise planar and another
side facet of the unitary discrete structure can be curved or
piecewise curved.
[0089] Referring back to FIG. 1, each bonding portion 170 of
unitary discrete structure 150 of light directing film 100 has a
base that is the largest cross-section of the bonding portion that
is parallel to the plane of the light directing film and is bound
by the side facets of the bonding portion. Base 174 is bound by
side facets 172. For example bonding portion 170 has a base 174
that is the largest cross-section of the bonding portion that is
parallel to plane 105 of the light directing film and is bound by
side facets 172A and 172B of the bonding portion. As another
example, referring to FIG. 4, bonding portion 480 has a base 482
that is the largest cross-section of the bonding portion in the
direction parallel to the xy-plane. Base 482 is bound by all the
side facets of the light directing portions that are capable of
being defined. In the exemplary unitary discrete structure 400,
base 482 is rectangular and bound by side facets 472A-472D.
[0090] As another example, referring to FIG. 7, light directing
film 700 includes a bonding portion 750A that has a base 760A, a
bonding portion 750B that has a base 760B, and a bonding portion
750C that has a base 760C. As another example, FIG. 13 is a
schematic three-dimensional view of a unitary discrete structure
1300 that is linear and extends along the y-direction. The unitary
discrete structure includes a light directing portion 1310 that has
a base 1315 that is in the xy-plane, and a bonding portion 1320
that has a base 1330 that is the largest cross-section of the
bonding portion that is parallel to the xy-plane and is bound by
side facet 1321 defining an edge 1331 of the base and side facet
1322 defining an edge 1332 of the base.
[0091] Referring back to FIG. 1, base 174 includes a minimum
dimension d.sub.2 that, in the exemplary light directing film 100,
is along the x-direction. For example, referring to FIG. 4, base
482 has a minimum dimension 474 that is along the y-direction. As
another example, referring to FIG. 7, base 760A has a minimum
dimension 770A that is along the x-direction, base 760B has a
minimum dimension 770B that is along the x-direction, and base 760C
has a minimum dimension 770C that is along the x-direction.
[0092] In general, a base of a bonding portion can have any shape,
such as any regular or irregular shape, and any size minimum
dimension that may be desirable in an application. For example,
linear base 810 in FIG. 8A can be the base of a bonding portion
that extends along the y-direction and has a minimum dimension
810B, linear base 820A in FIG. 8B can be the base of a bonding
portion that extends along the y-direction and has a minimum
dimension 820B, base 830A in FIG. 8C can be the base of a bonding
portion that has a minimum dimension 830B, base 840A in FIG. 8D can
be the base of a bonding portion that has a minimum dimension 840B,
and linear base 850A in FIG. 8E can be the base of a bonding
portion that extends along the y-direction and has a minimum
dimension 850B. In general, the base of a bonding portion can be
linear meaning that the dimension, such as the average dimension,
of the base along the linear direction of the base is substantially
larger than the dimension, such as the average dimension, of the
base along the orthogonal direction. For example, in such cases,
the ratio of the average dimension of the base along the linear
direction to the average dimension of the base along the orthogonal
direction is at least about 10, or at least about 50, or at least
about 100, or at least about 500, or at least about 1000. In some
cases, such as when the ratio of the average dimension of the base
along the linear direction to the average dimension of the base
along the orthogonal direction is at least about 10,000, the base,
the bonding portion and the unitary discrete structure associated
with the base can be considered to have an infinite or unlimited
extent or dimension along the linear direction and a finite or
limited extent or dimension along the orthogonal direction. In some
cases, the base of a bonding portion can be in the shape of a
rectilinear figure, such as a polygon. In some cases, the polygon
can be an irregular polygon, such as a rectangle, or a regular
polygon, such as an equilateral triangle, a square, a regular
hexagon, or a regular octagon. In some cases, the base can be a
trapezium, a trapezoid, a parallelogram, a rhombus, or deltoid. In
some cases, the base can be in the shape of a curvilinear figure,
such as a circle, an ellipse, or a parabola.
[0093] Referring back to FIG. 1, bonding portion 170 has a maximum
height h.sub.2 which is the maximum dimension or distance between
base 174 and the top of the bonding portion in a direction that is
perpendicular to base 174 or plane 105 of the light directing film.
For example, referring to FIG. 4, bonding portion 480 has a maximum
height 476 that is along the z-direction and is the largest
distance between base 482 and a top surface 490 of the bonding
portion. As another example, referring to FIG. 7, bonding portion
750A has a maximum height 780A along the z-direction, bonding
portion 750B has a maximum height 780B along the z-direction, and
bonding portion 750C has a maximum height 780C along the
z-direction. In general, the height of the bonding portions
disclosed herein can vary along one or more directions. For
example, FIG. 14 is a schematic three-dimensional view of a linear
unitary discrete structure 1400 that extends along the y-direction
and includes a light directing portion 1460 and a bonding portion
1470 disposed on the light directing portion. Bonding portion 1470
has a base 1475 that lies in the xy-plane and extends along the
y-direction, and a height 1480 that is the distance between base
1475 and the top of the bonding portion along the z-direction.
Height 1480 varies along the y-direction. Bonding portion 1470 has
a maximum height 1482 which is the largest distance between base
1475 and the top of the bonding portion along the z-direction, and
a minimum height 1484 which is the smallest distance between base
1475 and the top of the bonding portion along the z-direction.
Light directing portion 1460 has a base 1440 that is in the
xy-plane, and a constant height 1445 that is the distance between
base 1440 of the light directing portion and base 1475 of the
bonding portion along the z-direction.
[0094] In general, the height of the disclosed linear unitary
discrete structures can remain constant or vary along the length of
the unitary discrete structures. For example, the height of unitary
discrete structure 1400 varies along the linear extent of the
structure. As another example, unitary discrete structure 1300 in
FIG. 13 has a constant height along the linear direction of the
structure.
[0095] In some cases, each side facet of a bonding portion makes an
angle with the plane of the light directing film that is greater
than about 60 degrees. For example, in unitary discrete structure
300, side facet 372A makes an angle .alpha..sub.3 with the xy-plane
and side facet 372B makes an angle .alpha..sub.4 with the xy-plane,
where each of .alpha..sub.3 and .alpha..sub.4 is greater than about
60 degrees. As another example, referring to FIG. 10, bonding
portion 1070 includes four side facets that make angles
.gamma..sub.1, .gamma..sub.2, .gamma..sub.3 and .gamma..sub.4 with
the xy-plane or the plane of the light directing film associated
with unitary discrete structure 1000, where each of the four angles
.gamma..sub.1-.gamma..sub.4 can be greater than about 60 degrees.
In some cases, each side facet of a bonding portion makes an angle
with the plane of the light directing film that is greater than
about 65 degree, or greater than about 70 degrees, or greater than
about 75 degrees, or greater than about 80 degrees, or greater than
about 85 degrees.
[0096] In some cases, each unitary discrete structure in a light
directing film disclosed herein includes a plurality of side
facets, where the side facets that make an angle with the plane of
the light directing film that is in a range from about 35 degrees
to about 55 degrees, or from about 40 degrees to about 50 degrees,
or from about 41 degrees to about 49 degrees, or from about 42
degrees to about 48 degrees, or from about 43 degrees to about 47
degrees, or from about 44 degrees to about 46 degrees, form or
define the light directing portion of the unitary discrete
structure, and the side facets that make an angle with the plane of
the light directing film that is greater than about 60 degree, or
greater than about 65 degrees, or greater than about 70 degrees, or
greater than about 75 degrees, or greater than about 80 degrees, or
greater than about 85 degrees, form or define the bonding portion
of the unitary discrete structure.
[0097] In some cases, the minimum dimension of the base of the
bonding portion of a unitary discrete structure is substantially
less than the minimum dimension of the base of the light directing
portion of the unitary discrete structure. For example, referring
to FIG. 1, in some cases, the minimum dimension d.sub.2 is
substantially less than the minimum dimension d.sub.1. For example,
in such cases, the minimum dimension d.sub.2 is less than about
20%, or less than about 18%, or less than about 16%, or less than
about 14%, or less than about 12%, or less than about 10%, or less
than about 9%, or less than about 8%, or less than about 7%, or
less than about 6%, or less than about 5%, or less than about 4%,
or less than about 3%, or less than about 2%, or less than about
1%, of the minimum dimension d.sub.1.
[0098] In some cases, bonding portions 170 have aspect ratios that
are greater than 1. For example, in some cases, the ratio of the
maximum height h.sub.2 of bonding portion 170 to the second minimum
dimension d.sub.2 of the bonding portion is greater than 1. For
example, in such cases, the ratio h.sub.2/d.sub.2 is at least about
1.2, or at least about 1.4, or at least about 1.5, or at least
about 1.6, or at least about 1.8, or at least about 2, or at least
about 2.5, or at least about 3, or at least about 3.5, or at least
about 4, or at least about 4.5, or at least about 5, or at least
about 5.5, or at least about 6, or at least about 6.5, or at least
about 7, or at least about 8, or at least about 9, or at least
about 10, or at least about 15, or at least about 20.
[0099] FIG. 15 is a schematic side-view of a light directing film
1500 that includes a plurality of unitary discrete structures, such
as unitary discrete structures 1510 and 1520, disposed on a
substrate 1505, where the substrate provides support for the
unitary structures. Unitary discrete structure 1510 includes a
bonding portion 1514 disposed on a light directing portion 1512
that has a base 1515, and unitary discrete structure 1520 includes
a bonding portion 1524 disposed on a light directing portion 1522
that has a base 1525. In some cases, such as in the exemplary light
directing film illustrated in FIG. 15, at least some of the unitary
discrete structures include a landing portion disposed between the
base of the light directing portion and the substrate that supports
the unitary discrete structure. In some cases, the primary
functions of the land portion can include transmitting light with
high efficiency, providing support for the light directing portion
and the bonding portion, and providing sufficient adhesion between
the unitary discrete structure and the substrate. For example,
unitary discrete structure 1510 includes a land portion 1516 that
is disposed between base 1515 and substrate 1505, and unitary
discrete structure 1520 includes a land portion 1526 that is
disposed between base 1525 and substrate 1505.
[0100] In general, the unitary discrete structures in a light
directing film may or may not have land portions. In some cases,
such as in the case of light directing film 1500 illustrated
schematically in FIG. 15, the unitary discrete structures have land
portions. In some cases, the unitary discrete structures do not
have land portions. For example, FIG. 16, is a schematic side-view
of a light directing film 1600 that is similar to light directing
film 1500 except that the unitary discrete structures do not have
land portions. In particular, base 1515 of light directing portion
1512 coincides, or substantially coincides, with a top surface 1506
of substrate 1505, and base 1525 of light directing portion 1522
coincides, or substantially coincides, with top surface 1506 of
substrate 1505. In some cases, some unitary discrete structures in
a light directing film have land portions and some unitary discrete
structures in the light directing film do not have land portions.
For example, FIG. 17 is a schematic side-view of a light directing
film 1700 that includes a plurality of unitary light structures,
such as unitary discrete structures 1710, 1720, 1730 and 1740,
disposed on a top surface 1706 of a substrate 1705. Unitary
discrete structure 1710 includes a light directing portion 1712
that has a base 1715, a bonding portion 1714 that is disposed on
the light directing portion, and a land portion 1716 that is
disposed between base 1715 of the light directing portion and top
surface 1706 of the substrate. Unitary discrete structure 1720
includes a light directing portion 1722 that has a base 1725, a
bonding portion 1724 that is disposed on the light directing
portion, and a land portion 1726 that is disposed between base 1725
of the light directing portion and top surface 1706 of the
substrate. Unitary discrete structure 1730 includes a light
directing portion 1732 that has a base 1735, a bonding portion 1734
that is disposed on the light directing portion, and a land portion
1736 that is disposed between base 1735 of the light directing
portion and top surface 1706 of the substrate. Unitary discrete
structure 1740 includes a light directing portion 1742 that has a
base 1745 that coincides, or substantially coincides, with top
surface 1706 of substrate 1705, and a bonding portion 1744 that is
disposed on the light directing portion. Unitary discrete
structures 1710, 1720 and 1730 include land portions and unitary
discrete structure 1740 does not include a land portion.
[0101] In some cases, at least some of the unitary discrete
structures in a plurality of unitary discrete structures in a light
directing film have symmetric cross-sectional profiles in a
direction perpendicular to the light directing film, where by a
symmetric unitary discrete structure it is meant that the light
directing portion and the bonding portion of the unitary discrete
structure have symmetric profiles. For example, a unitary discrete
structure is considered to have a symmetric profile if the bonding
and light directing portions of the unitary discrete structure have
symmetric profiles, even if other parts, such as the land portion,
of the unitary discrete structure have asymmetric profiles.
[0102] For example, referring to FIG. 15, unitary discrete
structures 1510 and 1520 have symmetric cross-sectional profiles in
directions that are perpendicular to the light directing film. In
particular, unitary discrete structure 1510 in light directing film
1500 has a symmetric cross-sectional profile in a direction 1511
that is perpendicular to the light directing film, and unitary
discrete structure 1520 in light directing film 1500 has a
symmetric cross-sectional profile in a direction 1521 that is
perpendicular to the light directing film. Direction 1511 is a
symmetry axis for unitary discrete structure 1510, and direction
1521 is a symmetry axis for unitary discrete structure 1520.
[0103] In some cases, at least some of the unitary discrete
structures in a plurality of unitary discrete structures in a light
directing film have asymmetric cross-sectional profiles in a
direction perpendicular to the light directing film. For example,
FIG. 18 is a schematic side-view of a light directing film 1800
that includes symmetric unitary discrete structures 1810, 1820 and
1840, and asymmetric unitary discrete structure 1830 disposed on a
top surface 1806 of a substrate 1805. Unitary discrete structure
1810 includes a light directing portion 1812 that includes a base
1815 and a land portion 1816 that is disposed between base 1815 of
the light directing portion and top surface 1806 of substrate 1805.
Unitary discrete structure 1810 has a symmetric cross-sectional
profile in a direction 1818 that is along the z-direction and
perpendicular to the light directing film. Unitary discrete
structure 1820 includes a light directing portion 1822 that
includes a base 1825 and a land portion 1826 that is disposed
between base 1825 of the light directing portion and top surface
1806 of substrate 1805. Unitary discrete structure 1820 has a
symmetric cross-sectional profile in a direction 1828 that is along
the z-direction and perpendicular to the light directing film.
Unitary discrete structure 1830 includes a light directing portion
1832 that includes a base 1835 that coincides, or substantially
coincides, with top surface 1806 of substrate 1805. Unitary
discrete structure 1830 has an asymmetric cross-sectional profile.
Unitary discrete structure 1840 includes a light directing portion
1842 that includes a base 1845 that coincides, or substantially
coincides, with top surface 1806 of substrate 1805. Unitary
discrete structure 1840 has a symmetric cross-sectional profile in
a direction 1848 that is along the z-direction and perpendicular to
the light directing film.
[0104] FIG. 20 is a schematic side-view of an optical stack 2000
that includes an optical film 2090 that is disposed on a light
directing film 2010, where light directing film 2010 can be any
light directing film disclosed herein. Light directing film 2010
includes a first structured major surface 2020 and an opposing
second major surface 2025. First structured major surface 2020
includes a plurality of unitary discrete structures 2030 that are
disposed on a substrate 2005. Each of at least some unitary
discrete structures include a light directing portion 2040
primarily for directing light and a bonding portion 2050 primarily
for bonding the light directing film to optical film 2090. In some
cases, such as in the case of the exemplary optical stack 2000, at
least portions of at least some bonding portions 2050 of light
directing film 2010 penetrate into optical film 2090 and at least
portions of at least some light directing portions 2040 of light
directing film 2010 do not penetrate into optical film 2090. In
such cases, optical stack 2000 includes a plurality of unfilled
voids 2015 between light directing film 2010 and optical film 2090,
where the unfilled voids can contain air and/or a gas. In some
cases, each of at least some of the plurality of unfilled voids
2015 substantially covers a region that is defined by optical film
2090 and portions of two or more adjacent unitary discrete
structures 2030 that do not penetrate into the optical film and
immediately surround the region. For example, in such cases, an
unfilled void covers at least 50%, or at least 60%, or at least
70%, or at least 80%, or at least 90%, of a region that is defined
by optical film 2090 and portions of two or more adjacent unitary
discrete structures 2030 that do not penetrate into the optical
film. For example, in the case of linear unitary discrete
structures 2030, unfilled void 2015 substantially covers the region
that is defined on the top by optical film 2090, on the right side
by portion 2021 of linear unitary discrete structure 2030A that has
not penetrated into the optical film, and on the left side by
portion 2022 of linear unitary discrete structure 2030B that has
not penetrated into the optical film.
[0105] Optical film 2090 includes an optical layer 2070 that is
disposed on an optical adhesive layer 2060. The portions of bonding
portions 2050 of light directing film 2010 that penetrate into the
optical film penetrate into the optical adhesive layer. Optical
adhesive layer 2060 attaches or bonds light directing film 2010 to
optical layer 2070 or major surface 2071 of optical layer 2070
while substantially maintaining an air environment or surrounding
for light directing portions 2040. In some cases, bonding portions
2050 have high aspect ratios which can result in strong bonding
between optical film 2090 and light directing film 2010.
[0106] Bonding portions 2050 that penetrate into optical adhesive
layer have an average maximum height h.sub.2,avg which is the
average of the maximum heights h.sub.2 of the individual bonding
portions that have penetrated into the optical adhesive layer. In
some cases, h.sub.2,avg is greater than the average thickness
h.sub.3 of optical adhesive layer 2060. For example, in such cases,
h.sub.2,avg is greater than h.sub.3 by at least 0.2 microns, or at
least 0.3 microns, or at least 0.4 microns, or at least 0.5
microns, or at least 0.7 microns, or at least 1 micron, or at least
1.2 microns, or at least 1.5 microns, or at least 1.7 microns, or
at least 2 microns.
[0107] In general, optical film 2090 can include any optical layer
2070 that may be desirable in an applications. For example, in some
cases, optical layer 2070 can be or include an absorbing polarizer.
As another example, in some cases, optical film 2090 or optical
layer 2070 can include a reflective polarizer. In some cases, the
reflective polarizer can include a multilayer optical film wherein
at least some of the layers are birefringent. In some cases, the
reflective polarizer can include alternating layers, where at least
one of the alternating layers includes a birefringent material. In
some cases, the reflective polarizer can include a wire grid
reflective polarizer, or a cholesteric reflective polarizer. In
some cases, the reflective polarizer can be or include a fiber
polarizer. In such cases, the reflective polarizer includes a
plurality of substantially parallel fibers that form one or more
layers of fibers embedded within a binder with at least one of the
binder and the fibers including a birefringent material. The
substantially parallel fibers define a transmission axis and a
reflection axis. The fiber polarizer substantially transmits
incident light that is polarized parallel to the transmission axis
and substantially reflects incident light that is polarized
parallel to the reflection axis. Examples of fiber polarizers are
described in, for example, U.S. Pat. Nos. 7,599,592 and 7,526,164,
the entireties of which are incorporated herein by reference.
[0108] In some cases, the reflective polarizer can be a partially
reflecting layer that has an intermediate on-axis average
reflectance in the pass state. For example, the partially
reflecting layer can have an on-axis average reflectance of at
least about 90% for visible light polarized in a first plane, such
as the xy-plane (for example, for visible light linearly polarized
along the x-direction), and an on-axis average reflectance in a
range from about 25% to about 90% for visible light polarized in a
second plane, such as the xz-plane (for example, for visible light
linearly polarized along the z-direction) perpendicular to the
first plane.
[0109] In some cases, the reflective polarizer can be an extended
band reflective polarizer that is capable of polarizing light at
smaller incident angles and substantially reflecting one
polarization state, or two mutually perpendicular polarization
states, at larger incident angles as described in U.S. Patent
Application Ser. No. 61/254,691 titled "Immersed Reflective
Polarizer with High Off-Axis Reflectivity", Attorney Docket Number
65809US002, filed on Oct. 24, 2009; and U.S. Patent Application
Ser. No. 61/254,692 "Immersed Reflective Polarizer With Angular
Confinement in Selected Planes of Incidence", Attorney Docket No.
65900US002, filed on Oct. 24, 2009, the disclosures of which are
incorporated herein in their entireties by reference.
[0110] In some cases, the reflective polarizer can be a diffuse
reflective polarizer substantially transmitting one polarization
state and substantially diffusely reflecting an orthogonal
polarization state. Diffuse reflective polarizer films typically
include a disperse phase of polymeric particles disposed within a
continuous birefringent matrix. The film is oriented, typically by
stretching, in one or more directions to develop the birefrengence.
Examples of diffuse reflective polarizers are described in, for
example, U.S. Pat. Nos. 6,999,233 and 6,987,612 the disclosures of
which are incorporated herein in their entireties by reference.
[0111] As another example, optical layer 2070 can be or include a
substrate for providing, for example, support to optical film 2090.
In general, a substrate disclosed herein, such as substrate 130,
substrate 2005, or substrate 2070, can be or include any material
that may be desirable in an application. For example, a substrate
2070 can include or be made of glass and/or polymers such as
polyethylene terapthalate (PET), polycarbonates, and acrylics. In
some cases, the substrate can have multiple layers. In some cases,
optical layer 2070 can be glass. For example, a glass layer 2070
can be a glass layer in a liquid crystal panel.
[0112] As another example, optical layer 2070 can be or include a
release liner that provides a transferable light directing film
2010, meaning that, for example, the exposed major surface 2025 of
the light directing film may be placed in contact with a substrate
or surface and the release liner may thereafter be stripped away to
expose a major surface 2061 of optical adhesive layer 2060 that
can, for example, be bonded to another substrate or surface. The
release force for releasing optical adhesive layer 2060 or light
directing film 2010 from a release liner 2070 is generally less
than about 200 g-force/inch, or less than about 150 g-force/inch,
or less than about 100 g-force/inch, or less than about 75
g-force/inch, or less than about 50 g-force/inch.
[0113] As yet another example, in some cases, optical layer 2070
can be or include a second light directing film that includes a
plurality of linear prismatic structures. For example, FIG. 21 is a
schematic three dimensional view of a light directing film 2100
that includes a plurality of linear prismatic structures 2110 that
are disposed on a substrate 2120 and extend linearly along the
y-direction. In some cases, optical layer 2070 can be or include
light directing film 2100. In such cases, unitary discrete
structures 2030 of light directing film 2010 can also be linear
structures that extend in a direction that is perpendicular to the
linear direction of linear prismatic structures 2110. In some
cases, substrate 2120 can be similar to optical layer 2070 and may
include any optical layer and provide any function that may be
desirable in an application.
[0114] In general, a substrate disclosed herein, such as substrate
130 or substrate 2005, can include any optical layer and provide
any function that may be desirable in an application. For example,
in some cases, a disclosed substrate may primarily provide support
for other layers. As another example, in some cases, a disclosed
substrate may polarize light by including, for example, a
reflective or absorbing polarizer, diffuse light by including an
optical diffuser, direct or redirect light by including a light
directing film, or have transferring capabilities by, for example,
including a release liner.
[0115] Bonding portions 2050 allow for secure attachment of light
directing film 2010 to optical film 2090 or surface 2071 with no or
very little loss in optical properties, such as brightness. In
particular, the bonding portions have sufficiently large aspect
ratios to provide sufficient exterior surface to enhance adhesion
between the light directing film and the optical film. The bonding
portions are also sufficiently narrow relative to the width of the
light directing portions so that there is no or very little loss in
the effective transmission of the light directing film and/or the
optical stack. As used herein, effective transmission (ET), or
optical gain, is the ratio of the luminance of an optical system,
such as a display system, with the film in place in the optical
system to the luminance of the optical system without the film in
place.
[0116] Unitary discrete structures 2030 can have any index of
refraction that may be desirable in an application. For example, in
some cases, the index of refraction of the unitary discrete
structures is in a range from about 1.4 to about 1.8, or from about
1.5 to about 1.8, or from about 1.5 to about 1.7. In some cases,
the index of refraction of the unitary discrete structures is not
less than about 1.5, or not less than about 1.55, or not less than
about 1.6, or not less than about 1.65, or not less than about
1.7.
[0117] In general, the peel strength of light redirecting film 2010
and optical adhesive layer 2060, surface 2071, or optical film 2090
is sufficiently large to provide secure adhesion between light
directing film 2010 and optical film 2090 so that optical stack
2000 can be handled as a single film or unit without bonding
portions 2050 delaminating or separating from optical film 2090. In
some cases, the peel strength of light redirecting film 2010 and
optical adhesive layer 2060 is greater than about 20 grams/inch, or
about 25 grams/inch, or about 30 grams/inch, or about 35
grams/inch, or about 40 grams/inch, or about 45 grams/inch, or
about 50 grams/inch, or about 60 grams/inch, or about 70
grams/inch, or about 80 grams/inch, or about 90 grams/inch, or
about 100 grams/inch, or about 110 grams/inch, or about 120
grams/inch, or about 130 grams/inch, or about 140 grams/inch, or
about 150 grams/inch.
[0118] Bonding portions 2050 are designed primarily to provide
sufficient adhesion between light directing film 2010 and optical
film 2090 by sufficiently penetrating into the optical film. While
providing sufficient adhesion between the two films, the bonding
portions are sufficiently narrow so as to have no, or very little,
effect on the effective transmission of light directing film 2010
or optical stack 2000. For example, in some cases, an optical stack
that is similar to optical stack 2000 except that no bonding
portion 2050 or unitary discrete structure 2030 penetrates into
optical adhesive layer 2060 or optical film 2090, has the same
effective transmission or an effective transmission that is only
slightly larger than the effective transmission of optical stack
2000. For example, FIG. 29 is a schematic side-view of an optical
stack 2900 that has the same construction as optical stack 2000
except that no unitary discrete structure 2030 penetrates into
optical adhesive layer 2060. In some cases, the effective
transmission of optical stack 2000 is not less or is less than by
no more than about 20%, or about 15%, or about 10%, or about 9%, or
about 8%, or about 7%, or about 6%, or about 5%, or about 4%, or
about 3%, or about 2%, or about 1%, as compared to optical stack
2900.
In some cases, in FIG. 29, optical adhesive layer 2060 can be
absent or can be replaced with an optical layer that is
non-adhesive. In such cases, such as when optical adhesive layer
2060 is absent, bonding portions 2050 can be anti-wet-out
structures preventing, or substantially reducing, optical coupling
between light directing film 2010 and optical layer 2070. In some
cases, at least some bonding portions 2050 of unitary discrete
structures 2030 physically contact but do not penetrate into
optical layer 2070. In some cases, no bonding portion 2050 of
unitary discrete structures 2030 penetrates into optical layer
2070.
[0119] In some cases, a light directing portion of a disclosed
unitary discrete structure is designed to recycle light so that,
for example, the brightness of an image viewed by a viewer is
increased or enhanced. For example, FIG. 19 is a schematic
side-view of a display system 1900 that includes an image forming
panel 1950 that is capable of forming an image and displaying the
image to a viewer 1990 and is disposed to receive light from an
illumination system 1905. Illumination system 1905 includes optical
stack 2000 disposed on a light source 1915 that includes a
lightguide 1920; a lamp 1930 for emitting light 1936 that enters
the lightguide, propagates within the lightguide by total internal
reflection, and exits the lightguide as light 1940 towards the
image forming panel; and a back reflector 1910 for redirecting
light that is incident on the back reflector towards the image
forming panel. Light directing portions 2040 are designed primarily
to either redirect light that exits lightguide 1920 toward image
forming panel 1950, or reflect light that exits the lightguide for
recycling. For example, light directing portions 2040 redirect
light 1941 that exits lightguide 1920 as light 1942 towards the
image forming panel or the viewer. As another example, light
directing portions 2040 receive light 1943 that exits the
lightguide and totally internally reflect back the received light
as light 1944 for recycling.
[0120] In general, image forming panel 1950 can be any type panel
that is capable of forming and image and displaying the image to
viewer 1990. In some cases, image forming panel 1950 can be or
include a liquid crystal panel. In such cases, a liquid crystal
image forming panel 1950 can include a layer of liquid crystal
disposed between two panel plates such as glass plates, an upper
light absorbing polarizer layer disposed above the liquid crystal
layer and a lower absorbing polarizer disposed below the liquid
crystal layer. The upper and lower light absorbing polarizers and
the liquid crystal layer, in combination, control the transmission
of light to viewer 1990. In some cases, image forming panel 1950
can be a monolithic image forming panel or a tiled image forming
panel that includes a plurality of image forming tiles. In some
cases, light source 1915 can be a monolithic light source or a
tiled light source that includes a plurality of light source tiles.
In some cases, display system 1900 includes a monolithic image
forming panel 1950 and a tiled light source 1915. A tiled light
source 1915 can include a plurality of independently controlled
tiled lightguides 1920, where each lightguide can illuminate a
different zone in a displayed image.
[0121] In some cases, display system 1900 or illumination system
1905 can include one or more optional layers 1935 that are disposed
between optical stack 2000 and lightguide 1920. Exemplary optional
layers 1935 include, light diffusing layers and polarization
retardation layers.
[0122] In general, the disclosed light directing films include a
first structured major surface that include a plurality of unitary
discrete structures, and a second major surface that opposes the
first structured major surface. In some cases, a disclosed light
directing film is designed primarily to receive light from the
second major surface side of the light directing film. For example,
light directing film 2010 in FIG. 19, is designed primarily to
receive light from second major surface 2025 and emit or transmit
light from first structured major surface 2020.
[0123] In some cases, a light directing portion of a disclosed
unitary discrete structure is designed primarily to redirect, but
not recycle, light. For example, FIG. 22 is a schematic side-view
of a display system 2200 for displaying information or an image to
viewer 1990. Display system 2200 includes image forming panel 1950
disposed on an illumination system 2202 that includes an optical
stack 2201 that is disposed on light source 1915. Optical stack
2201 includes a light directing film 2210 disposed on an optical
film 2290. Light directing film 2210 can be any light directing
film disclosed herein and includes a first structured major surface
2220 that includes a plurality of unitary discrete structures 2230
disposed on a substrate 2205 and a second major surface 2225 that
opposes major surface 2220. Unitary discrete structures 2230
include bonding portions 2250 disposed on light directing portions
2240. At least portions of bonding portions 2250 penetrate optical
film 2290 and at least portions of light directing portions 2240 do
not penetrate the optical film. Light directing film 2210 and light
directing portions 2240 are designed primarily to direct or
redirect, but not recycle, light. For example, light directing
portion 2240A is designed primarily to direct light 2211 that exits
lightguide 1920 as light 2212 towards image forming panel 1950 and
viewer 1990.
[0124] In general, the disclosed light directing films include a
first structured major surface that include a plurality of unitary
discrete structures, and a second major surface that opposes the
first structured major surface. In some cases, a disclosed light
directing film is designed primarily to receive light from the
first structured major surface side of the light directing film.
For example, light directing film 2210 in FIG. 22, is designed
primarily to receive light from first structured major surface 2220
and emit or transmit light from second major surface 2225.
[0125] In some cases, optical film 2290 does not include optical
layer 2170. In such cases, optical adhesive layer 2060 can directly
adhere to lightguide 1920 resulting in light directing film 2210
being securely adhered to lightguide 1920.
[0126] In some cases, such as in the exemplary illumination system
2200 illustrated in FIG. 22, optical film 2290 is disposed between
light directing film 2210 and light source 1915. In some cases,
such as in the exemplary illumination system 1905 illustrated in
FIG. 19, light directing film 2010 is disposed between optical film
2090 and light source 1915.
[0127] In some cases, optical layer 2170 can be a lightguide, such
as lightguide 1920. In such cases, unitary discrete structures 2230
can extract light from the lightguide and can be considered as
light extractors of a lightguide 2170. In some cases, unitary
discrete structures 2230 may penetrate directly into a lightguide,
an exemplary side-view of which is illustrated schematically in
FIG. 52. In particular, in FIG. 52, a light source 5230 includes a
lightguide 5210 that is disposed on back reflector 1910. Lightguide
5210 includes a lightguide layer 5220 that receives light 1936 that
is emitted by lamp 1930 from a side 5550 of the lightguide layer.
The light that enters the lightguide layer propagates across the
lightguide layer along, for example, the x-direction by total
internal reflection. Light directing film 2210 is disposed on
lightguide 5210 and includes a plurality of discrete structures
5280 that are similar to unitary discrete structures 2230. Each
discrete structure 5280 is partially embedded in lightguide layer
5220 and extracts light that propagates within the lightguide layer
by total internal reflection from the lightguide layer. For
example, discrete structures 5280 extract light 5240 that
propagates within lightguide layer 5220 by total internal
reflection from the lightguide layer as light 5241. As a result,
each discrete structure 5280 can be considered to be a discrete
light extractor 5280 of lightguide 5210. Each discrete light
extractor 5280 includes a first portion 5260 that penetrates into,
or is embedded in, lightguide layer 5220 and a second portion 5270
that does not penetrate into, or is not embedded in, lightguide
layer 5220. In general, each discrete light extractor 5280 can be
unitary or composite.
[0128] In some cases, the index of refraction of each discrete
light extractor 5280 is different than the index of refraction of
lightguide layer 5220. In some cases, the index of refraction of
each discrete light extractor 5280 is equal to the index of
refraction of lightguide layer 5220.
[0129] Referring back to FIG. 1, in some cases, second major
surface 120 includes a plurality of structures to assist in, for
example, diffusing light, hiding or masking defects such as dust
particles or scratches, and/or reducing the visibility of an
undesirable optical effect such as moire. For example, FIG. 23 is a
schematic side-view of a light directing film 2300 that is similar
to light directing film 100 and includes a first structured major
surface 2310 and an opposing second structured major surface 2350.
First structured major surface 2310 includes a plurality of unitary
discrete structures 2320. Each unitary discrete structure 2320
includes a light directing portion 2330 that is designed primarily
to direct light and a bonding portion 2340 that is disposed on the
light directing portion and is designed primarily to bond the light
directing film to a surface.
[0130] Structured major surface 2350 includes a plurality of
structures 2360. In some cases, structures 2360 are irregularly
arranged. For example, in such cases, structures 2360 can form a
random pattern. In some cases, structures 2360 are regularly
arranged. For example, in such cases, structures 2360 can form a
periodic pattern along one direction or two mutually orthogonal
directions.
[0131] The exemplary light directing film 2300 is a unitary film as
there are no internal interfaces within the light directing film.
In some cases, structures 2360 can be part of a separate layer that
can, for example, be coated onto the light directing film. For
example, FIG. 24 is a schematic side-view of a light directing film
2400 that includes first structured major surface 2310 and an
opposing second structured major surface 2450 that includes a
plurality of structures 2460. Light directing film 2400 is similar
to light directing film 2300 except that second structured major
surface 2450 is part of a light diffusing layer 2410 that is
applied to, for example coated on, light directing film 2400. In
general, light diffusing layer 2410 may or may not include
particles. In some cases, such as in the exemplary case illustrated
in FIG. 24, light diffusing layer 2410 includes a plurality of
particles 2420. In general, the plurality of structures 2460 have a
first average height and the plurality of particles 2420 have a
second average size. In some cases, such as when the average size
of particles 2420 is of the same order of magnitude as the average
height of structures 2460, the ratio of the first average height to
the second average size is less than about 50, or less than about
40, or less than about 30, or less than about 20, or less than
about 10, or less than about 5, or less than about 2, or less than
about 1. In some cases, such as when the average size of particles
2420 is substantially less than the average height of structures
2460, the ratio of the first average height to the second average
size is greater than about 50, or greater than about 100, or
greater than about 500, or greater than about 1000.
[0132] Referring back to FIG. 1, in some cases, at least some of
the unitary discrete structures 150 are linear structures and
extend along the same direction. For example, referring to FIG. 6,
unitary discrete structures 650 are linear structures and extend
along the y-direction. In some cases, the heights of the light
directing portions of the unitary discrete structures that extend
along the same direction do not vary along that direction. For
example, referring to FIG. 7, heights of light directing portions
710A, 710B and 710C do not vary along the y-direction which is the
linear direction of the light directing portions or their
associated unitary discrete structures. In some cases, the heights
of the light directing portions of the unitary discrete structures
that extend along the same direction vary along that direction. For
example, referring to FIG. 9, height 950 of light directing portion
960 varies along the y-direction which is the linear direction of
light directing portion 960 or unitary discrete structure 900. In
some cases, height 950 can vary regularly along the y-direction. In
some cases, height 950 can vary irregularly along the
y-direction.
[0133] In general, the light directing portions can have multiple
side facets. In some cases, such as in the case of linear unitary
discrete structures, each light directing portion can include two
opposing side facets. For example, referring to FIG. 6, light
directing film 600 includes a plurality of linear unitary discrete
structures 650 that extend along the y-direction, and where each
light directing portion includes two opposing side facets. For
example, light directing portion 660A includes two opposing side
facets: side facet 612A and opposing side facet 612B. In some
cases, each light directing portion includes only two opposing side
facets.
[0134] As another example, light directing portion 710A in FIG. 7
includes four side facets or two pairs of opposing side facets. In
particular, light directing portion 710A includes a first pair of
opposing side facets 701A and 701B and a second pair of opposing
side facets 701C and 701D.
[0135] Referring back to FIG. 1, opposing side facets 162 of light
directing portions 160 define an included angle .theta..sub.1 which
is the angle between the two opposing side facets. In some cases,
the included angle .theta..sub.1 is in a range from about 60
degrees to about 120 degrees, or about 65 degrees to about 115
degrees, or about 70 degrees to about 110 degrees, or about 75
degrees to about 105 degrees, or about 80 degrees to about 100
degrees, or about 85 degrees to about 95 degrees. In some cases,
the included angle .theta..sub.1 is about 88 degrees, or about 89
degrees, or about 90 degrees, or about 91 degrees, or about 92
degrees.
[0136] Side facet 162A of light directing portion 160A makes and
angle .theta..sub.3 with a normal line 180 that is perpendicular to
light directing film 100 or plane 105 of the light directing film.
In some cases, the angle .theta..sub.3 between a side facet of a
light directing portion and the normal to the light directing film
is in a range from about 30 degrees to about 60 degrees, or from
about 35 degrees to about 55 degrees, or from about 40 degrees to
about 50 degrees, or from about 42 degrees to about 48 degrees, or
from about 43 degrees to about 47 degrees, or from about 44 degrees
to about 46 degrees.
[0137] Opposing side facets 172 of bonding portion 170 define an
included angle .theta..sub.2 which is the angle between the two
opposing side facets. In some cases, the included angle
.theta..sub.2 between two opposing side facets of a bonding portion
is less than about 40 degrees, or less than about 35 degrees, or
less than about 30 degrees, or less than about 25 degrees, or less
than about 20 degrees, or less than about 15 degrees, or less than
about 12 degrees, or less than about 10 degrees, or less than about
9 degrees, or less than about 8 degrees, or less than about 7
degrees, or less than about 6 degrees, or less than about 5
degrees, or less than about 4 degrees, or less than about 3
degrees, or less than about 2 degrees, or less than about 1 degree.
In some cases, opposing side facets 172 of bonding portion 170 are
parallel to each other. In such cases, the included angle between
the two opposing side facets is zero.
[0138] Side facets 172 of bonding portions 170 make an angle
.theta..sub.4 with a normal line 181 that is perpendicular to light
directing film 100 or plane 105 of the light directing film. In
some cases, the angle .theta..sub.4 between a side facet 172 of a
bonding portion 170 and a normal 181 to the light directing film
100 is in a range from about zero degree to about 40 degrees, or
from about zero degree to about 35 degrees, or from about zero
degree to about 30 degrees, or from about zero degree to about 25
degrees, or from about zero degree to about 20 degrees, or from
about zero degree to about 15 degrees, or from about zero degree to
about 10 degrees, or from about zero degree to about 5 degrees.
[0139] In some cases, a side facet of the light directing portion
of a unitary discrete structure 150 makes an angle .theta..sub.3
with a normal, such as normal 180, to light directing film 100, and
a side facet of the bonding portion of the same unitary discrete
structure makes an angle .theta..sub.4 with the normal, such as
normal 180, to light directing film 100. In some cases,
.theta..sub.4 is less than .theta..sub.3. In some cases,
.theta..sub.4 is less than .theta..sub.3 by at least about 5
degrees, or about 10 degrees, or about 15 degrees, or about 20
degrees, or about 25 degrees, or about 30 degrees, or about 35
degrees, or about 40 degrees.
[0140] In some cases, each side facet of the light directing
portion of a unitary discrete structure 150 makes an angle
.theta..sub.3 with a normal, such as normal 180, to light directing
film 100, and each side facet of the bonding portion of the same
unitary discrete structure makes an angle .theta..sub.4 with the
normal, such as normal 180, to light directing film 100. In some
cases, .theta..sub.4 is less than .theta..sub.3. In some cases,
.theta..sub.4 is less than .theta..sub.3 by at least about 5
degrees, or about 10 degrees, or about 15 degrees, or about 20
degrees, or about 25 degrees, or about 30 degrees, or about 35
degrees, or about 40 degrees.
[0141] In some cases, the light directing portions of a light
directing film can have substantially equal maximum heights. For
example, light directing portions 160 can have substantially equal
maximum heights h.sub.1. In some cases, at least two light
directing portions can have unequal maximum heights. For example,
referring to FIG. 7, maximum height 740A of light directing portion
710A is different than maximum height 740C of light directing
portion 710C. In some cases, the maximum heights of some of the
light directing portions is less than the maximum heights of some
other light directing portions. For example, maximum height 740C is
less than maximum height 740A.
[0142] In some cases, the maximum height of a disclosed light
directing portion is less than about 500 microns, or less than
about 400 microns, or less than about 300 microns, or less than
about 200 microns, or less than about 100 microns, or less than
about 90 microns, or less than about 80 microns, or less than about
70 microns, or less than about 60 microns, or less than about 50
microns, or less than about 40 microns, or less than about 30
microns, or less than about 20 microns, or less than about 10
microns.
[0143] Referring back to FIG. 1, each bonding portion 170 includes
a top surface 190 that connects the plurality of side facets 172 of
the bonding portion. In some cases, top surface 190 can be
substantially planar. For example, referring to FIG. 3, top surface
390 of bonding portion 370 is substantially planar. As another
example, referring to FIG. 4, top surface 490 of bonding portion
480 is substantially planar.
[0144] In general, the top surface of a bonding portion can have
any shape, such as any regular or irregular shape, or profile that
may be desirable in an application. For example, in some cases, the
top surface of a bonding portion is substantially piecewise planar.
For example, FIG. 25 is a schematic three-dimensional view of a
linear unitary discrete structure 2500 that extends along the
y-direction and includes a light directing portion 2510 and a
bonding portion 2520 that is disposed on the light directing
portion. Bonding portion 2520 includes a side facet 2530 and an
opposing side facet 2532, where the two side facets have an
included angle .theta..sub.2. In some cases, each side facet 2530
makes an angle with the xy-plane or the plane of the light
directing film that is associated with unitary discrete structure
2500, that is greater that about 60 degrees, or about 65 degrees,
or about 70 degrees, or about 75 degrees, or about 80 degrees, or
about 85 degrees. The bonding portion also includes and a top
surface 2540 that connects side facets 2530 and 2532. Top surface
2540 is piecewise planar and includes a first planar surface 2545
and a second planar surface 2547. In some cases, each of the top
planar surfaces 2545 and 2547 makes an angle with the xy-plane that
is less than about 60 degrees, or about 55 degrees, or about 50
degrees, or about 45 degrees, or about 40 degrees, or about 35
degrees, or about 30 degrees, or about 25 degrees, or about 20
degrees, or about 15 degrees, or about 10 degrees. The two planar
surfaces intersect at a peak 2560 of top surface 2540, bonding
portion 2520, and unitary discrete structure 2500, where peak 2560
is a line peak. Peak 2540 of the top surface or the bonding portion
has an included angle .theta..sub.5 between the two planar surfaces
that, in some cases, can be different than included angle
.theta..sub.2. In general, included angle .theta..sub.5 can be any
angle, such as any angle from about zero degree to about 180
degrees, that may be desirable in an application. For example, in
some cases, included angle .theta..sub.5 can be greater than about
90 degrees, or about 100 degrees, or about 110 degrees, or about
120 degrees, or about 130 degrees, or about 140 degrees, or about
150 degrees, or about 160 degrees, or about 170 degrees. In some
cases, the included angle .theta..sub.5 is less than about 70
degrees, or about 65 degrees, or about 60 degrees, or about 55
degrees, or about 50 degrees, or about 45 degrees, or about 40
degrees, or about 35 degrees, or about 30 degrees, or about 25
degrees, or about 20 degrees.
[0145] As another example, FIG. 26 is a schematic three-dimensional
view of a linear unitary discrete structure 2600 that extends along
the y-direction and includes a light directing portion 2610 and a
bonding portion 2620 that is disposed on the light directing
portion. Bonding portion 2620 includes a side facet 2630 and an
opposing side facet 2632, where the two side facets have an
included angle .theta..sub.2. The bonding portion also includes a
top surface 2640 that connects side facets 2630 and 2632. Top
surface 2640 is piecewise planar and includes a first planar
surface 2642, a second planar surface 2644, and a third planar
surface 2646. Planar surface 2644 also forms a peak of top surface
2640, bonding portion 2620, and unitary discrete structure 2600.
Peak 2644 has an included angle .theta..sub.5 that, in some cases,
can be different than included angle .theta..sub.2.
[0146] In some cases, such as when the facets are planar, facets of
a bonding portion of a light directing film that make an angle with
the plane of the light directing film that is greater that about 60
degrees, or about 65 degrees, or about 70 degrees, or about 75
degrees, or about 80 degrees, or about 85 degrees, form the side
facets of the bonding portion and facets of the bonding portion
that make an angle with the plane of the light directing film that
is less than about 60 degrees, or about 55 degrees, or about 50
degrees, or about 45 degrees, or about 40 degrees, or about 35
degrees, or about 30 degrees, or about 25 degrees, or about 20
degrees, or about 15 degrees, or about 10 degrees, form the top
facets of the bonding portion.
[0147] In some cases, the top surface of a bonding portion can be
substantially curved. For example, referring to FIG. 9, top surface
980 of bonding portion 970 is substantially curved. In some cases,
the top surface of a bonding portion can be substantially piecewise
curved. For example, FIG. 27 is a schematic three-dimensional view
of a linear unitary discrete structure 2700 that extends along the
y-direction and includes a light directing portion 2710 and a
bonding portion 2720 that is disposed on the light directing
portion. Bonding portion 2720 includes a side facet 2730 and an
opposing side facet 2732, where the two side facets have an
included angle .theta..sub.2. The bonding portion also includes a
top surface 2740 that connects side facets 2730 and 2732. Top
surface 2740 is piecewise curved and includes a first curved
surface 2742 and a second curved surface 2744. The two curved
surfaces intersect at a peak 2760 of top surface 2740, bonding
portion 2720, and unitary discrete structure 2700, where peak 2760
is a line peak. Peak 2760 of the top surface, the bonding portion,
and the unitary discrete structure has an included angle
.theta..sub.5 between the two curved surfaces that, in some cases,
can be different than included angle .theta..sub.2. In some cases,
the included angle .theta..sub.5 is less than about 70 degrees, or
about 65 degrees, or about 60 degrees, or about 55 degrees, or
about 50 degrees, or about 45 degrees, or about 40 degrees, or
about 35 degrees, or about 30 degrees, or about 25 degrees, or
about 20 degrees.
[0148] In some cases, the top surface of a bonding portion can
include one or more recessions. For example, FIG. 28 is a schematic
three-dimensional view of a linear unitary discrete structure 2800
that extends along the y-direction and includes a light directing
portion 2810 and a bonding portion 2820 that is disposed on the
light directing portion. Bonding portion 2820 includes a side facet
2830 and an opposing side facet 2832, where the two side facets
have an included angle .theta..sub.2. The bonding portion also
includes a top surface 2840 that connects side facets 2830 and
2832. Top surface 2840 is piecewise planar and includes a first
planar surface 2842, a second planar surface 2844, a third planar
surface 2846, and a fourth planar surface 2848. Adjacent planar
surfaces 2842 and 2844 intersect at a first peak 2860 of top
surface 2840, bonding portion 2820, and unitary discrete structure
2800, where first peak 2860 is a line peak. Top planar surfaces
2842 and 2844 define an included angle .theta..sub.6 at first peak
2860 that, in some cases, can be different than included angle
.theta..sub.2. Adjacent planar surfaces 2846 and 2846 intersect at
a second peak 2862 of top surface 2840, bonding portion 2820, and
unitary discrete structure 2800, where first peak 2862 is a line
peak. Top planar surfaces 2846 and 2848 define an included angle
.theta..sub.7 at second peak 2862 that, in some cases, can be
different than included angles .theta..sub.2 and/or .theta..sub.6.
Top surface 2840 includes a recession 2870 in the form of a
recessed surface that is disposed between first peak 2860 and
second peak 2862. In some cases, a sharp peak of a top surface of a
bonding portion of a light directing film can assist the bonding
portion in penetrating into an optical film or an optical adhesive
layer of an optical film that is to be attached to the light
directing film. In some cases, the top surface of a bonding
portion, or a cross-section of the top surface in a direction
perpendicular to the base of the bonding portion, can have multiple
discrete peaks. For example, top surface 2840 of bonding portion
2820 includes two discrete peaks 2860 and 2862. In general, the
peak angles .theta..sub.6 and .theta..sub.7 of respective peaks
2860 and 2862 of top surface 2840 can have any value that may be
desirable in an application. For example, in some cases, the peak
angle of at least one of the multiple discrete peaks 2860 and 2862
can be less than about 70 degrees, or about 65 degrees, or about 60
degrees, or about 55 degrees, or about 50 degrees, or about 45
degrees, or about 40 degrees, or about 35 degrees, or about 30
degrees, or about 25 degrees, or about 20 degrees.
[0149] FIG. 30 is a schematic side-view of an optical stack 3000
that includes a light directing film 3020 that includes a plurality
of unitary discrete structures 3030 disposed on a first substrate
3010, a second substrate 3015 having a major surface 3018 facing
the light directing film and an opposing major surface 3019 facing
away from the light directing film, and an optical adhesive layer
3025 disposed between light directing film 3020 and second
substrate 3015 for bonding or adhering the light directing film to
surface 3018 of the second substrate.
[0150] Portion 3040 of each unitary discrete structure 3030
penetrates into optical adhesive layer 3025 and can be referred to
as the penetrating portion 3040 of the unitary discrete structure.
Portion 3045 of each unitary discrete structure 3030 does not
penetrate into optical adhesive layer 3025 and can be referred to
as the non-penetrating portion 3045 of the unitary discrete
structure. Each penetrating unitary discrete structure defines a
penetration depth 3050 which is the longest penetration distance
normal to the optical stack (z-direction). For example, unitary
discrete structure 3030A has a penetration depth PD.sub.1 and
unitary discrete structure 3030B has a penetration depth PD.sub.2.
Each unitary discrete structure also defines a penetration base
3054 at interface 3056 between penetrating portion 3040 and
non-penetrating portion 3045 of the unitary discrete structure.
Penetration base 3054 has a minimum penetration base dimension 3058
that, in some cases, can be the width of the penetration base along
the x-axis. For example, unitary discrete structure 3030A has a
minimum penetration base dimension MD.sub.1 and unitary discrete
structure 3030B has a minimum penetration base dimension MD.sub.2.
The plurality of unitary discrete structures 3030 has an average
penetration depth and an average minimum penetration base
dimension. For example, the unitary discrete structures 3030A and
3030B have an average penetration depth PD.sub.avg that is equal to
(PD.sub.1+PD.sub.2)/2 and an average minimum penetration base
dimension MD.sub.avg that is equal to (MD.sub.1+MD.sub.2)/2. The
ratio of the average penetration depth to the average minimum
penetration base dimension is sufficiently large so as to provide
sufficient adhesion between light directing film 3020 and surface
3018. In some cases, the ratio of the average penetration depth to
the average minimum penetration base dimension is at least about
1.2, or at least about 1.4, or at least about 1.5, or at least
about 1.6, or at least about 1.8, or at least about 2, or at least
about 2.5, or at least about 3, or at least about 3.5, or at least
about 4, or at least about 4.5, or at least about 5, or at least
about 5.5, or at least about 6, or at least about 6.5, or at least
about 7, or at least about 8, or at least about 9, or at least
about 10, or at least about 15, or at least about 20.
[0151] Each unitary discrete structure 3030 includes a base 3031
that has a minimum base dimension 3032, where base 3031 is also the
base of light directing portion 3070. For example, the base of
unitary discrete structure 3030A has a minimum base dimension
BMD.sub.1 and the base of unitary discrete structure 3030B has a
minimum base dimension BMD.sub.2. The plurality of unitary discrete
structures 3030 has an average minimum base dimension. For example,
the unitary discrete structures 3030A and 3030B have an average
minimum base dimension BMD.sub.avg that is equal to
(BMD.sub.1+BMD.sub.2)/2. The average minimum penetration base
dimension MD.sub.avg is sufficiently smaller than the average
minimum base dimension BMD.sub.avg so that there is no, or very
little loss, in the effective transmission of optical stack 3000.
For example, in some cases, the average minimum penetration base
dimension is less than about 20%, or about 15%, or about 10%, or
about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, of the average
minimum base dimension.
[0152] In some cases, the peel strength between light directing
film 3020 and surface 3018 or second substrate 3015 is greater than
about 20 grams/inch, or about 25 grams/inch, or about 30
grams/inch, or about 35 grams/inch, or about 40 grams/inch, or
about 45 grams/inch, or about 50 grams/inch, or about 60
grams/inch, or about 70 grams/inch, or about 80 grams/inch, or
about 90 grams/inch, or about 100 grams/inch, or about 110
grams/inch, or about 120 grams/inch, or about 130 grams/inch, or
about 140 grams/inch, or about 150 grams/inch.
[0153] In some cases, optical stack 3000 includes a plurality of
voids 3060 between optical adhesive layer 3025 and light directing
film 3020. In some cases, the voids are discrete meaning that each
void can be identified individually and as being separate from
other voids. In some cases, a discrete void is bound on top by
optical adhesive layer 3025, on bottom by light directing film
3020, on one side by the non-penetrating portion of a unitary
discrete structure, and on the opposite side by the non-penetrating
portion of a neighboring or adjacent unitary discrete
structure.
[0154] In some cases, the penetration of penetrating portions 3040
or unitary discrete structures 3030 into optical adhesive layer
3025 results in no, or very little, loss in the effective
transmission of optical stack 3000. For example, in such cases, the
average effective transmission of optical stack 3000 is not less or
is less than by no more than about 20%, or about 15%, or about 10%,
or about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into optical adhesive layer 3025.
[0155] Each unitary discrete structure 3030 includes a light
directing portion 3070 that is designed primarily for directing
light and a bonding portion 3080 that is designed primarily for
bonding light directing film 3020 to surface 3018 or second
substrate 3015. In some cases, at least portions of the bonding
portion of each unitary discrete structure penetrates into optical
adhesive layer 3025 and at least portions of the light directing
portion of each unitary discrete structure does not penetrate into
the optical adhesive layer. In some cases, such as when it is
desirable to effectively direct light to enhance brightness, only
at least portions of bonding portions 3080 penetrate into optical
adhesive layer 3025 and no, or very little, portions of light
directing portions 3070 penetrate into optical adhesive layer
3025.
[0156] In the exemplary optical stack 3000, unitary discrete
structures 3030 of light directing film 3020 penetrate into optical
adhesive layer 3025. In general, unitary discrete structures 3030
may penetrate into any optical layer that is capable of being
penetrated and is desirable in an application. In general, optical
stack 3000 includes light directing film 3020 that includes a first
plurality of unitary discrete structures 3030. Optical stack 3000
also includes an optical layer 3025 that is disposed on light
directing film 3020. Portions of each unitary discrete structure
3030 in the first plurality of unitary discrete structures
penetrate into optical layer 3025. Portions of each unitary
discrete structure 3030 in the first plurality of unitary discrete
structures does not penetrate into optical layer 3025. Each unitary
discrete structure (for example, unitary discrete structure 3030A)
in the first plurality of unitary discrete structures defines a
penetration depth (for example, PD.sub.1) and a penetration base
(for example, penetration base 3054) at an interface (for example,
interface 3056) between the penetrating and non-penetrating
portions of the unitary discrete structure. The penetration base
has a minimum penetration base dimension (for example, MD.sub.1).
The first plurality of unitary discrete structures 3030 has an
average penetration depth and an average minimum penetration base
dimension. The ratio of the average penetration depth to the
average minimum penetration base dimension is at least 1.5 and the
peel strength between light directing film 3020 and optical layer
3025 is greater than about 30 grams/inch.
[0157] In some cases, optical layer 3025 can be a pressure
sensitive adhesive, a structural adhesive, or a hot melt adhesive.
In some cases, optical layer 3025 can be a lightguide, such as
lightguide 3110 in FIG. 32, that includes means, such as light
extractors 3112, for extracting light that propagates within the
lightguide by total internal reflection.
[0158] In some cases, optical stack 3000 has a maximum operating
temperature T.sub.max and optical layer 3025 has a glass transition
T.sub.g that is greater than T.sub.max. In such cases, optical
stack 3000 can be prepared by first increasing the temperature of
optical layer 3025 to a temperature that is greater than T.sub.g of
the optical layer. Next, the heated optical layer and light
directing film 3070 can be pressed against each other so that
portions of unitary discrete structures 3030 penetrate into the
heated optical layer. Next, the temperature of the optical layer
can be reduced to, for example, room temperature. Since, T.sub.max
is less than T.sub.g, the optical stack remains intact and
laminated when used at temperatures less than T.sub.max.
[0159] All the structures in the first plurality of unitary
discrete structures are unitary. Furthermore, only a portion of
each structure penetrates into optical layer 3025 resulting in an
average penetration depth and an average minimum penetration base
dimension. In addition, the ratio of the average penetration depth
to the average minimum penetration base dimension is at least about
1.2, or at least about 1.4, or at least about 1.5, or at least
about 1.6, or at least about 1.8, or at least about 2, or at least
about 2.5, or at least about 3, or at least about 3.5, or at least
about 4, or at least about 4.5, or at least about 5, or at least
about 5.5, or at least about 6, or at least about 6.5, or at least
about 7, or at least about 8, or at least about 9, or at least
about 10, or at least about 15, or at least about 20.
[0160] In some cases, light directing film 3020 can include a
second plurality of unitary discrete structures, where at least one
unitary discrete structure in the second plurality of unitary
discrete structures does not penetrate into optical layer 3025. For
example, some unitary discrete structures in the second plurality
of structures may be sufficiently shorter than structures 3030 so
that they do not penetrate into optical layer 3025. For example,
referring to FIG. 34, the first plurality of unitary discrete
structures may include structures 3320 and the second plurality of
unitary discrete structures may include structures 3330 that do not
penetrate into an optical layer 3420 because they are shorter than
structures 3320. In some case, light directing film 3020 can
include a second plurality of structures that are composite and not
unitary. For example, the second plurality of structures can
include composite structures similar to composite structure 200
illustrated in FIG. 2.
[0161] FIG. 31 is a schematic side-view of a display system 3100
that includes image forming panel 1950 for forming and displaying
information to viewer 1990. Image forming panel 1950 is disposed on
an illumination system 3145 that includes a back reflector 3105 for
reflecting light that is incident on the back reflector towards
image forming panel 1950 and viewer 1990, a lightguide 3110
receiving light 3116 emitted by a lamp 3115 and emitting the
received light towards image forming panel 1950, and an optical
stack 3135 disposed on and adhering to lightguide 3110.
[0162] Optical stack 3135 includes a first optical stack 3115
disposed on and securely attached to a second optical stack 3125.
First optical stack 3115 includes a first optical adhesive layer
3170 for adhering the first optical stack to the second optical
stack and a reflective polarizer layer 3180 disposed on first
optical adhesive layer 3170. Reflective polarizer layer 3180
substantially reflects light of a first polarization state and
substantially transmits light of a second polarization state
orthogonal to the first polarization state. For example, reflective
polarizer layer 3180 reflects at least 50%, or at least 60%, or at
least 70%, or at least 80%, or at least 90%, of a first
polarization state and transmits at least 50%, or at least 60%, or
at least 70%, or at least 80%, or at least 90%, of a second
polarization state orthogonal to the first polarization state. In
general, the pass or transmission axis of reflective polarizer
layer 3180 can be oriented along any direction that may be
desirable in an application. For example, in some cases, the pass
axis of the reflective polarizer layer can be along the x-axis or
the y-axis or make a 45 degree angle with the x- and y-axes. In
some cases, reflective polarizer layer 3180 can have light
collimating effects along one or more directions meaning that the
reflective polarizer layer can confine light into a narrower
viewing cone in one or more directions. For example, in some cases,
reflective polarizer layer 3180 can reduce the viewing cone in the
xz-plane, yz-plane or both.
[0163] In some cases, display system 3100 does not include a
reflective polarizer layer 3180. In such cases, the display system
may include a second light directing film adhered to first optical
adhesive layer 3170.
[0164] Second optical stack 3125 includes a second optical adhesive
layer 3120 for adhering the second optical stack to lightguide
3110, a low index layer 3130 disposed on the second optical
adhesive layer, and a light directing film 3140 disposed on low
index layer 3130.
[0165] Low index layer 3130 includes a plurality of voids dispersed
in a binder having an index of refraction n.sub.b. In some cases,
the plurality of voids is or includes a plurality of interconnected
voids dispersed in the binder.
[0166] In some cases, the low index layer has low optical haze. For
example, in such cases, the optical haze of low index layer is not
greater than about 8%, or not greater than about 7%, or not greater
than about 6%, or not greater than about 5%, or not greater than
about 4%, or not greater than about 3%, or not greater than about
2%, or not greater than about 1%. For light normally incident on
low index layer 3130, optical haze, as used herein, is defined as
the ratio of the transmitted light that deviates from the normal
direction by more than 4 degrees to the total transmitted light.
Haze values disclosed herein were measured using a Haze-guard Plus
haze meter (BYK-Gardiner, Silver Springs, Md.) according to the
procedure described in ASTM D1003.
[0167] In some cases, the voids in low index layer 3130 are
sufficiently smaller than the wavelengths in the visible range of
the spectrum, so that the low index layer has an effective index of
refraction that is substantially less than the index of refraction
n.sub.b of the binder in the low index layer. In such cases, the
effective index of the low index layer is the volume weighted
average of the indices of refraction of the voids and the binder.
For example, a low index layer 3130 that has a void volume fraction
of about 50% and a binder that has an index of refraction of about
1.5, has an effective index of about 1.25. In some cases, the
average effective refractive index of the low index layer in the
visible range of the spectrum is less than about 1.4, or less than
about 1.35, or less than about 1.3, or less than about 1.25, or
less than about 1.2, or less than about 1.15, or less than about
1.1, or less than about 1.09, or less than about 1.08, or less than
about 1.07, or less than about 1.06, or less than about 1.05.
[0168] In some cases, low index layer 3130 has a large optical
haze. In such cases, the optical haze of low index layer is not
less than about 10%, or not less than about 15%, or not less than
about 20%, or not less than about 25%, or not less than about 30%,
or not less than about 35%, or not less than about 40%, or not less
than about 45%, or not less than about 50%, or not less than about
60%, or not less than about 70%, or not less than about 80%. In
such cases, low index layer 3130 can be capable of enhancing
internal reflection meaning that the reflection is greater than
what a material with index n.sub.b (binder index) would produce. In
such cases, low index layer 3130 is sufficiently thick so that the
evanescent tail of a light ray that undergoes total internal
reflection at a surface of the low index layer, does not optically
couple, or optically couples very little, across the thickness of
the low index layer. In such cases, the thickness of low index
layer 3130 is not less than about 1 micron, or not less than about
1.1 micron, or not less than about 1.2 microns, or not less than
about 1.3 microns, or not less than about 1.4 microns, or not less
than about 1.5 microns, or not less than about 1.7 microns, or not
less than about 2 microns. A sufficiently thick low index layer
3130 can prevent or reduce an undesired optical coupling of the
evanescent tail of an optical mode across the thickness of the low
index layer.
[0169] In some cases, low index layer 3130 also includes a
plurality of particles dispersed in the binder. The particles can
have any size or shape, such as any regular or irregular shape,
that may be desirable in an application. For example, in some
cases, at least a majority of the particles, such as at least 60%,
or at least 70%, or at least 80%, or at least 90%, or at least 95%,
of the particles have a size that is in a desired range. For
example, in some cases, at least a majority of the particles, such
as at least 60%, or at least 70%, or at least 80%, or at least 90%,
or at least 95%, of the particles have a size that is not greater
than about 5 microns, or not greater than about 3 microns, or not
greater than about 2 microns, or not greater than about 1 micron,
or not greater than about 700 nm, or not greater than about 500 nm,
or not greater than about 200 nm, or not greater than about 100 nm,
or not greater than about 50 nm.
[0170] In some cases, the particles have an average particle size
that is not greater than about 5 microns, or not greater than about
3 microns, or not greater than about 2 microns, or not greater than
about 1 micron, or not greater than about 700 nm, or not greater
than about 500 nm, or not greater than about 200 nm, or not greater
than about 100 nm, or not greater than about 50 nm.
[0171] In some cases, the particles in the low index layer are
sufficiently small so that the primary optical effect of the
particles is to affect the effective index of low index layer 3130.
For example, in such cases, the particles have an average size that
is not greater than about .lamda./5, or not greater than about
.lamda./6, or not greater than about .lamda./8, or not greater than
about .lamda./10, or not greater than about .lamda./20, where X is
the average wavelength of visible light. As another example, in
such cases, the average particle size is not greater than about 70
nm, or not greater than about 60 nm, or not greater than about 50
nm, or not greater than about 40 nm, or not greater than about 30
nm, or not greater than about 20 nm, or not greater than about 10
nm.
[0172] The particles in low index layer 3130 can have any shape
that may be desirable in an application. For example, the particles
can have a regular or irregular shape. For example, the particles
can be approximately spherical. As another example, the particles
can be elongated.
[0173] In general, low index layer 3130 can have uniform or
non-uniform effective index of refraction and/or optical haze. For
example, in some cases, low index layer 3130 can have uniform
effective index of refraction and uniform optical haze. As another
example, in some cases, low index layer 3130 can have non-uniform
optical haze. For example, in some cases, low index layer 3130 can
have a gradient optical haze along, for example, the thickness
direction of the low index layer. As another example, low index
layer 3130 can include multilayers, where at least some of the
layers have different effective refractive indices and/or optical
haze values. For example, in some cases, low index layer 3130 can
include multilayers, where each layer has a different effective
index of refraction and/or optical haze. In such cases, the low
index layer 3130 can have a staircase effective refractive index
profile. As another example, low index layer 3130 can include
multilayers having alternating high and low optical haze. Exemplary
low index layers 3130 having non-uniform optical haze and/or
effective refractive index are described in, for example, U.S.
Patent Application Ser. No. 61/254,673 titled "Gradient Low Index
Article and Method", Attorney Docket Number 65716US002, filed on
Oct. 24, 2009, and U.S. Patent Application Ser. No. 61/254,674
titled "Process for Gradient Nanovoided Article", Attorney Docket
No. 65766US002, filed on Oct. 24, 2009, the disclosures of which
are incorporated herein in their entireties by reference.
[0174] Light directing film 3140 includes a plurality of unitary
discrete structures 3155. A portion 3156 of each unitary discrete
structure 3155 penetrates into first optical adhesive layer 3170
and can be considered as the penetrating portion 3156 of the
unitary discrete structure. A portion 3157 of each unitary discrete
structure 3155 does not penetrate into first optical adhesive layer
3170 and can be considered as the non-penetrating portion 3157 of
the unitary discrete structure. Each unitary discrete structure
3155 defines a penetration depth 3172 and a penetration base 3158
at an interface 3162 between the penetrating portion 3156 and the
non-penetrating portion 3157 of the unitary discrete structure.
Penetration base 3158 has a minimum penetration base dimension 3159
that, in some cases, can be the width of the penetration base along
the x-direction. The plurality of unitary discrete structures 3155
has an average penetration depth which is the average of the
penetration depths of the individual unitary discrete structures,
and an average minimum penetration base dimension that is the
average of the minimum penetration base dimensions of the all the
penetration bases. In some cases, the ratio of the average
penetration depth to the average minimum penetration base dimension
is at least about 1.2, or at least about 1.3, or at least about
1.4, or at least about 1.5, or at least about 1.6, or at least
about 1.8, or at least about 2, or at least about 2.5, or at least
about 3, or at least about 3.5, or at least about 4, or at least
about 4.5, or at least about 5, or at least about 5.5, or at least
about 6, or at least about 6.5, or at least about 7, or at least
about 8, or at least about 9, or at least about 10, or at least
about 15, or at least about 20.
[0175] Each unitary discrete structure 3155 includes a base 3198
that has a minimum base dimension 3199, where base 3198 is also the
base of light directing portion 3150. The plurality of unitary
discrete structures 3155 has an average minimum base dimension. The
average minimum penetration base dimension is sufficiently smaller
than the average minimum base dimension so that there is no, or
very little loss, in the effective transmission of optical stack
3135. For example, in some cases, the average minimum penetration
base dimension is less than about 20%, or about 15%, or about 10%,
or about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, of the average
minimum base dimension.
[0176] In some cases, the peel strength between first optical stack
3115 and second optical stack 3125 is greater than about 20
grams/inch, or about 25 grams/inch, or about 30 grams/inch, or
about 35 grams/inch, or about 40 grams/inch, or about 45
grams/inch, or about 50 grams/inch, or about 60 grams/inch, or
about 70 grams/inch, or about 80 grams/inch, or about 90
grams/inch, or about 100 grams/inch, or about 110 grams/inch, or
about 120 grams/inch, or about 130 grams/inch, or about 140
grams/inch, or about 150 grams/inch.
[0177] In some cases, unitary discrete structures 3155 are linear
structures that extend along any direction that may be desirable in
an application. For example, in some cases, the linear direction of
structures 3155 can be parallel to the pass axis of reflective
polarizer layer 3180. As another example, in some cases, the linear
direction of structures 3155 can be perpendicular to the pass axis
of reflective polarizer layer 3180.
[0178] In some cases, substantial portions of each two neighboring
major surfaces in each of the first and second optical stacks are
in physical contact with each other. For example, in such cases, at
least 50%, or at least 60%, or at least 70%, or at least 80%, or at
least 90%, of each two neighboring major surfaces in each of the
first and second optical stacks are in physical contact with each
other.
[0179] Light 3116 emitted by lamp 3115 enters lightguide 3110 from
a side 3127 of the lightguide and propagates across the length of
the lightguide along the x-direction. Low index layer 3130
facilitates the propagation of light within lightguide 3110 by
supporting total internal reflection and/or enhancing internal
reflection at an interface 3122 between low index layer 3130 and
second optical adhesive layer 3120. In general, lightguide 3110
includes one or more means for extracting light that propagates
within the lightguide toward the general direction of image forming
panel 1950. For example, in some cases, lightguide 3110 includes a
plurality of light extractors 3112 disposed, in some cases, on a
bottom surface 3124 of the lightguide for extracting light. As
another example, in some cases, the lightguide can be a wedge
lightguide. Light extractors 3112 can be any type structure that is
capable of extracting light by disrupting TIR. For example, light
extractors 3112 can be depression or protrusions. In some cases,
light extractors can be formed by printing, such as inkjet or
screen printing or etching, such wet or dry etching.
[0180] In general, the lightguides disclosed herein, such as
lightguides 1920 and 3110, can be any type lightguide that may be
desirable in an application. For example, in some cases, a
disclosed lightguide can be a thin film lightguide having a
thickness that is less than about 500 microns, or about 400
microns, or about 300 microns, or about 200 microns, or about 100
microns, or about 75 microns, or about 50 microns, or about 25
microns. As another example, in some cases, a disclosed lightguide
can be a plate lightguide having a thickness that is greater than
about 0.5 mm, or about 1 mm, or about 1.5 mm, or about 2 mm. In
some cases, a disclosed lightguide can be a slab lightguide having
parallel major surfaces or a wedge lightguide having non-parallel,
such as converging or diverging, major surfaces. In some cases, a
disclosed lightguide can be rectangular or square. In some cases, a
disclosed lightguide can be substantially flat or curved. In
general, the disclosed lightguides can be made of any sufficiently
optically transparent material that may be desirable in an
application. Exemplary materials include polymers such as
polycarbonate, acrylic and cyclo olefin polymer (COP) and
glass.
[0181] First optical stack 3115 also includes a light diffusing
layer 3190 that can be a surface and/or bulk diffuser. Light
diffusing layer 3190 can assist in diffusing light, hiding or
masking defects such as dust particles or scratches, and/or
reducing the visibility of undesirable optical effects such as
moire. In some cases, light diffusing layer 3190 can be replaced
by, or include, an optical layer or film disclosed herein. For
example, in some cases, light diffusing layer 3190 can be replaced
by a reflective polarizer or a light directing film such as light
directing film 4100 or 4300. In such cases, a light directing film
3190 can include linear structures that extend along a first
direction and light directing film 3140 can include linear unitary
discrete structures that extend along a second direction, where the
angle between the first and second directions can be any angle that
may be desirable in an application. For example, the angle between
the first and second directions can be about 90 degrees, or less
than about 90 degrees, or less than about 80 degrees, or less than
about 70 degrees, or less than about 60 degrees, or less than about
50 degrees, or less than about 40 degrees, or less than about 30
degrees, or less than about 20 degrees, or less than about 10
degrees. In some cases, reflective polarizer layer 3180 can be
replaced by, or include a light directing film such as light
directing film 4100 or 4300. In some cases, display system 3100
does not include any light diffusing layer, such as light diffusing
layer 3190, between reflective polarizer layer 3180 and image
forming panel 1950.
[0182] Each unitary discrete structure 3155 includes a light
directing portion 3150 primarily for directing light and a bonding
portion 3160 primarily for securely bonding second optical stack
3125 to first optical stack 3115 without reducing, or reducing very
little, the effective transmission of optical stack 3135. In some
cases, the penetration of penetrating portions 3156 or unitary
discrete structures 3155 into first optical adhesive layer 3170
results in no, or very little, loss in the effective transmission
of optical stack 3135. For example, in such cases, the average
effective transmission of optical stack 3135 is not less or is less
than by no more than about 20%, or about 15%, or about 10%, or
about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into first optical adhesive layer
3170.
[0183] In some cases, unitary discrete structures 3155 are linear
structures that are substantially parallel to side 3127 of
lightguide 3110, where side 3127 is the side of the lightguide that
receives light 3116 emitted by lamp 3115. For example, in such
cases, linear unitary discrete structures 3155 and side 3127 can
extend along the y-direction. In some cases, side 3127 may extend
along one direction, such as the y-direction, and the linear
unitary discrete structures may extend along an orthogonal
direction, such as the x-direction.
[0184] In general, display system 3100 can include any additional
optical layer that is not expressly illustrated in FIG. 31. For
example, in some cases, display system 3100 can include one or more
additional layers between, for example, reflective polarizer layer
3180 and first optical adhesive layer 3170. As another example, in
some cases, display system 3100 can include a sealing or barrier
layer disposed between low index layer 3130 and second optical
adhesive layer 3120 for preventing the adhesive layer from
diffusing into and filling the voids in the low index layer.
[0185] Back reflector 3105 can be any light reflector that may be
desirable in an application. For example, in some cases, back
reflector 3105 can be primarily a specular reflector or primarily a
diffuse reflector. As another example, in some cases, back
reflector 3105 can be partially a diffuse reflector and partially a
specular reflector. In some cases, back reflector 3105 can be an
aluminized film, a silver coated film, or a multilayer polymeric
reflective film, such as an enhanced specular reflector (ESR) film
available from 3M Company, St. Paul, Minn. In some cases, back
reflector 3105 can diffusely reflect light by including a surface
and/or volume diffuser.
[0186] In the exemplary display system 3100 light that is extracted
from lightguide 3110 is directed along the positive z-direction
towards image forming device 1950. In some cases, light that is
extracted from the lightguide may be directed along more than one
direction. For example, FIG. 49 is a schematic side-view of an
optical stack 4900 that directs a portion of light that is
extracted from lightguide along the positive z-direction and
directs another portion of the extracted light along the negative
z-direction.
[0187] In some cases, the reflective polarizers, such as reflective
polarizer layer 3180, disclosed herein can be replaced with a
partially reflecting layer that reflects a portion of an incident
light and transmits another portion of the incident light. In
general, each of the reflected and transmitted beams can have a
specular portion and a diffuse portion. For example, a portion of
an incident light can be specularly reflected by the partially
reflecting layer and another portion of the incident light can be
diffusely reflected by the partially reflecting layer. As another
example, a portion of an incident light can be specularly
transmitted by the partially reflecting layer and another portion
of the incident light can be diffusely transmitted by the partially
reflecting layer. As another example, a partially reflecting layer
3180 can specularly transmit light and diffusely reflect light, or
diffusely transmit light and specularly reflect light. In some
cases, a partially reflecting layer 3180 can be a non-polarizing
partially reflecting layer. For example, a partially reflecting
layer 3180 can include a partially reflective metal and/or
dielectric layer. In some cases, a partially reflecting layer 3180
can be a polarizing partially reflecting layer similar to the
reflective polarizers disclosed herein.
[0188] FIG. 32 is a schematic side-view of a display system 3200
that is similar to display system 3100. In display system 3200,
reflective polarizer layer 3180 is disposed on and adhered to image
forming panel 1950 and light diffusing layer 3190 is disposed on
first optical adhesive layer 3170. An optical stack 3210 in display
system 3200 includes second optical adhesive layer 3120, low index
layer 3130 disposed on the second optical adhesive layer, light
directing film 3140 that is disposed on the low index layer and
includes plurality of unitary discrete structures 3155, and first
optical adhesive layer 3170 that is disposed on the light directing
film. Portions 3156 of each unitary discrete structure penetrates
into first optical adhesive layer 3170 and portions 3157 of each
unitary discrete structure does not penetrate into first optical
adhesive layer 3170. Each unitary discrete structure 3155 defines a
penetration depth 3172 and a penetration base 3158 at an interface
3162 between the penetrating and non-penetrating portions of the
unitary discrete structure. Penetration base 3158 has a minimum
dimension 3159. Plurality of unitary discrete structures 3155 has
an average penetration depth and an average minimum dimension. The
ratio of the average penetration depth to the average minimum
dimension is at least about 1.2, or at least about 1.3, or at least
about 1.4, or at least about 1.5, or at least about 1.6, or at
least about 1.8, or at least about 2, or at least about 2.5, or at
least about 3, or at least about 3.5, or at least about 4, or at
least about 4.5, or at least about 5, or at least about 5.5, or at
least about 6, or at least about 6.5, or at least about 7, or at
least about 8, or at least about 9, or at least about 10, or at
least about 15, or at least about 20.
[0189] In some cases, the penetration of penetrating portions 3156
or unitary discrete structures 3155 into first optical adhesive
layer 3170 results in no, or very little, loss in the effective
transmission of optical stack 3210. For example, in such cases, the
average effective transmission of optical stack 3210 is not less or
is less than by no more than about 20%, or about 15%, or about 10%,
or about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into first optical adhesive layer
3170.
[0190] Each unitary discrete structure 3155 includes a base 3198
that has a minimum base dimension 3199. The plurality of unitary
discrete structures 3155 has an average minimum base dimension. The
average minimum penetration base dimension is sufficiently smaller
than the average minimum base dimension so that there is no, or
very little loss, in the effective transmission of optical stack
3210. For example, in some cases, the average minimum penetration
base dimension is less than about 20%, or about 15%, or about 10%,
or about 9%, or about 8%, or about 7%, or about 6%, or about 5%, or
about 4%, or about 3%, or about 2%, or about 1%, of the average
minimum base dimension.
[0191] In some cases, the peel strength between light directing
film 3140 and first optical adhesive layer 3170 is greater than
about 20 grams/inch, or about 25 grams/inch, or about 30
grams/inch, or about 35 grams/inch, or about 40 grams/inch, or
about 45 grams/inch, or about 50 grams/inch, or about 60
grams/inch, or about 70 grams/inch, or about 80 grams/inch, or
about 90 grams/inch, or about 100 grams/inch, or about 110
grams/inch, or about 120 grams/inch, or about 130 grams/inch, or
about 140 grams/inch, or about 150 grams/inch.
[0192] In some cases, a light directing film that is primarily
designed to direct, but not recycle light, can be adhered to a
lightguide via a low index layer. For example, FIG. 50 is a
schematic side-view of a display system 5000 that includes light
directing film 2210 from FIG. 22 laminated to lightguide 1920 via
optical adhesive layer 2060 and low index layer 3130. In some
cases, light directing film 2210 can be laminated to image forming
device 1950 via an optical adhesive layer not expressly illustrated
in FIG. 50.
[0193] Low index layer 3130 can be any optical layer that includes
a plurality of voids dispersed in a binder. For example, low index
layer 3130 can be an optical layer described in U.S. Patent
Application Ser. No. 61/169,466 titled "Optical Film", Attorney
Docket Number 65062US002, filed on Apr. 15, 2009; and U.S. Patent
Application Ser. No. 61/169,521 "Optical Construction and Display
System Incorporating Same", Attorney Docket No. 65354US002, filed
on Apr. 15, 2009. As another example, low index layer 3130 can be
an optical layer described in U.S. Patent Application Ser. No.
61/254,676 titled "Voided Diffuser", Attorney Docket Number
65822US002, filed on Oct. 24, 2009; and U.S. Patent Application
Ser. No. 61/254,243 "Optical Construction and Method of Making the
Same", Attorney Docket No. 65619US002, filed on Oct. 23, 2009; the
disclosures of which are incorporated herein in their entireties by
reference.
[0194] The disclosed optical adhesive layers, such as optical
adhesive layers 2060, 3025, 3120 and 3170 can be or include any
optical adhesive that may be desirable in an application. Exemplary
optical adhesives include pressure sensitive adhesives (PSAs),
heat-sensitive adhesives, solvent-volatile adhesives, and
UV-curable adhesives such as UV-curable optical adhesives available
from Norland Products, Inc. Exemplary PSAs include those based on
natural rubbers, synthetic rubbers, styrene block copolymers,
(meth)acrylic block copolymers, polyvinyl ethers, polyolefins, and
poly(meth)acrylates. As used herein, (meth)acrylic (or acrylate)
refers to both acrylic and methacrylic species. Other exemplary
PSAs include (meth)acrylates, rubbers, thermoplastic elastomers,
silicones, urethanes, and combinations thereof. In some cases, the
PSA is based on a (meth)acrylic PSA or at least one
poly(meth)acrylate. Exemplary silicone PSAs include a polymer or
gum and an optional tackifying resin. Other exemplary silicone PSAs
include a polydiorganosiloxane polyoxamide and an optional
tackifier.
[0195] In some cases, an optical adhesive layer disclosed herein
can be or include a structural adhesive. Generally, useful
structural adhesives contain reactive materials that cure to form a
strong adhesive bond. The structural adhesive may cure
spontaneously upon mixing (such as a 2 part epoxy adhesive) or upon
exposure to air (such as a cyanoacrylate adhesive) or curing may be
effected by the application of heat or radiation (such as UV
light). Examples of suitable structural adhesives include epoxies,
acrylates, cyanoacrylates, urethanes, and the like.
[0196] In some cases, a disclosed optical adhesive layer can be a
removable adhesive such as those described in, for example, U.S.
Pat. Nos. 3,691,140; 4,166,152; 4,968,562; 4,994,322; 5,296,277;
5,362,516, the disclosures of which are incorporated herein in
their entireties by reference. The phrase "removable adhesive" for
adhering a film to a substrate means an adhesive that affords
convenient, manual removal of the film from the substrate without
damaging the substrate or exhibiting excessive adhesive transfer
from the film to the substrate.
[0197] In some cases, a disclosed optical adhesive layer can be a
reusable and/or repositionable adhesive such as those described in,
for example, U.S. Pat. No. 6,197,397; U.S. Patent Publication No.
2007/0000606; and PCT Publication No. WO 00/56556, the disclosures
of which are incorporated herein in their entireties by reference.
The phrases "reusable adhesive" or "repositionable adhesive" for
adhering a film to a substrate mean an adhesive that (a) affords a
temporary, secure attachment of the film to the substrate while
affording convenient, manual removal of the film from the substrate
without damaging the substrate or exhibiting excessive adhesive
transfer from the film to the substrate, and (b) then affords
subsequent reuse of the film on, for example, another
substrate.
[0198] In some cases, a disclosed optical adhesive layer can be
optically diffusive. In such cases, the optical adhesive layer can
be optically diffusive by including a plurality of particles
dispersed in an optical adhesive where the particles and the
optical adhesive have different indices of refraction. The mismatch
between the two indices of refraction can result in light
scattering. In some cases, a disclosed optical adhesive can be a
continuous layer. In some cases, a disclosed optical adhesive layer
can be patterned.
[0199] In some cases, some discrete structures in a light directing
film can have bonding portions and light directing portions and
some other discrete structures may have no bonding portions and may
only have light directing portions. For example, FIG. 33 is a
side-view schematic of a light directing film 3300 that includes a
first plurality of unitary discrete structures 3320 and a second
plurality of discrete structures 3330 disposed on a substrate 3310.
Unitary discrete structures 3320 includes bonding portions 3340
designed primarily for bonding the light directing film to a
surface and light directing portions 3350 designed primarily for
directing light and have an included angle 3355. Discrete
structures 3330 do not include bonding portions and only include
light directing portions 3360 that are prismatic and have an apex
angle 3365. In some cases, apex angle 3365 and included angle 3355
can be substantially equal and can, for example, be about 90
degrees. In general, unitary discrete structures can be any unitary
discrete structure disclosed herein and discrete structures 3330
can be any discrete structure that is capable of directing light.
In some cases, unitary discrete structures 3320 and discrete
structures 3330 can be linear structures extending along the same
direction, such as, for example, the y-direction. In the exemplary
light directing film 3300, the rows of the discrete structures
alternate between unitary discrete structures 3320 and discrete
structures 3330. In general, each of unitary discrete structures
3320 and discrete structures 3330 can form any pattern or
arrangement that may be desirable in an application. For example,
discrete structures 3320 and 3330 can form a regular, such as
periodic, or an irregular, such as a random, pattern.
[0200] FIG. 34 is a schematic side-view of an optical stack 3400
that includes light directing film 3300 laminated to a surface 3410
via an optical adhesive layer 3420. Bonding portions 3340 of
unitary discrete structures 3320 at least partially penetrate into
optical adhesive layer 3420 to provide secure attachment between
light directing film 3300 and surface 3410. In the exemplary
optical stack 3400, discrete structures 3330 do not penetrate into
the optical adhesive layer, although, in some cases, portions of at
least some discrete structures 3330 can penetrate into the optical
adhesive layer. Light directing film 3300 includes sufficient
number of bonding portions 3340 to provide sufficient adhesion
between light directing film 3300 and surface 3410. At the same
time, the number or density of bonding portions 3340 is
sufficiently low so that there is no, or very little, loss in the
optical gain or effective transmission of optical stack 3400.
[0201] Some of the exemplary display systems disclosed herein, such
as display system 1900 in FIG. 19 or display system 3100 in FIG.
31, illustrate "edge-lit" displays. In an edge-lit display, one or
more lamps, such as lamp 3115 in FIG. 31, are disposed along an
edge or side, such as side 3127, of the display and outside an
output or viewing face, such as viewing face 3182, of the display,
where the viewing face of the display is the area across which
information is displayed to viewer 1990. Light, such as light 3116,
emitted by the lamps typically enters a lightguide, such as
lightguide 3110, which spreads and redirects the light towards the
viewing face of the display. In a direct-lit display, one or more,
or an array of, lamps are disposed directly behind the major
surfaces, such as output face 3182, of the various layers in the
display system. For example, FIG. 48 is a schematic side-view of a
display system 4800 that is similar to display 1900 except that
display system 4800 is a direct-lit display and includes a
plurality of lamps 4810 that are disposed behind the major surfaces
of the various layers in the display system. In particular, lamps
4810 are disposed directly behind viewing face 4830 of display
system 4800 or image forming panel 1950. Lamps 4810 emit light 4820
towards the image forming panel. In some cases, optional layer 1935
can include an optical diffuser layer for diffusing light 4820 and
masking lamps 4810. As another example, FIG. 51 is a schematic
side-view of a display system 5100 that is similar to display
system 3100 except that lamps 3115 have been replaced with a
plurality of lamps 5110 that emit light 5120 into lightguide 3110
and are housed in cavities 5130 formed within the lightguide.
[0202] In general, the light directing films in the disclosed
optical stacks, such as optical stacks 3000, 3135 and 3210, may or
may not have unitary structures. For example, referring to FIG. 31,
in some cases, structures 3155 may be composite structures. For
example, in such cases, bonding portions 3160 may form detectable
interfaces with light directing portions 3150.
[0203] In some cases, only portions of a unitary discrete structure
includes bonding portions. For example, FIG. 35 is a schematic
three-dimensional view of a linear unitary discrete structure 3500
that extends along the y-direction and includes a plurality of
discrete bonding portions 3510 disposed on a light directing
portion 3520. Bonding portions 3510 and light directing portion
3520 can be any bonding portion and light directing portion
disclosed herein. Each bonding portion 3510 includes a base 3530
that has a minimum dimension 3550. Each bonding portion also has a
maximum height 3540. The density of bonding portions 3510 is
sufficiently high, the ratio of maximum height 3540 to minimum
dimension 3550 is sufficiently large, and minimum dimension 3550 is
sufficiently small so that the bonding portions can provide
sufficient adhesion between unitary discrete structure and a
surface with no, or very little, loss in the effective transmission
of the unitary discrete structure or the light directing film that
is associated with the unitary discrete structure. In general,
bonding portions 3510 can forms any distribution or arrangement
that may be desirable in an application. For example, in some
cases, bonding portions 3510 can be irregularly, such as randomly,
arranged in a light directing film.
[0204] In some cases, at least portions of the side facets and/or
the top surface of the bonding portions of unitary discrete
structures can be structured, such as roughened, to enhance
adhesion of the bonding portions to a surface. For example, FIG. 36
is a schematic three-dimensional view of a linear unitary discrete
structure 3600 that extends along the y-direction and includes a
bonding portion 3610 disposed on a light directing portion 3620.
Side facets 3630 and top surface 3640 of the bonding portion are
roughened to improve adhesion of the bonding portion to a surface.
Light directing portion 3620 includes smooth side facets 3650 to
provide efficient light directing or recycling.
[0205] Effective transmission (ET) can be measured using optical
system 3700, a schematic side-view of which is shown in FIG. 37.
Optical system 3700 is centered on an optical axis 3750 and
includes a hollow lambertian light box 3710 that emits a lambertian
light 3715 through an emitting or exit surface 3712, a linear light
absorbing polarizer 3720 for polarizing light 3715, and a
photodetector 3730. Light box 3710 is illuminated by a stabilized
broadband light source 3760 that is connected to an interior 3780
of the light box via an optical fiber 3770. A test sample 3705, the
ET of which is to be measured by the optical system, is placed at
location 3740 between the light box and the absorbing linear
polarizer.
[0206] Test sample 3705 can be any light directing film or optical
stack disclosed herein. For example, test sample 3705 can be light
directing film 100 having a plurality of linear unitary discrete
structures 150 extending along the y-direction. The ET of light
directing film 100 can be measured by placing the light redirecting
film in location 3740 with unitary discrete structures 150 facing
the photodetector and second major surface 120 facing the light
box. Next, the spectrally weighted axial luminance I.sub.1
(luminance along optical axis 3750) is measured through the linear
absorbing polarizer by the photo detector. Next, light directing
film 100 is removed and the spectrally weighted luminance I.sub.2
is measured without the light directing film placed at location
3740. ET is the ratio I.sub.1/I.sub.2. ET0 is the effective
transmission when linear unitary discrete structures 150 extend
along a direction that is parallel to the polarizing axis of linear
absorbing polarizer 3720, and ET90 is the effective transmission
when linear unitary discrete structures 150 extend along a
direction that is perpendicular to the polarizing axis of the
linear absorbing polarizer. The average effective transmission
(ETA) is the average of ET0 and ET90.
[0207] Effective transmission values disclosed herein were measured
using an EPP2000 spectrometer (available from StellarNet Inc,
Tampa, Fla.) for detector 3730. The spectrometer was connected to a
collimating lens via a Vis-NIR fiber optic cable (available as
F1000-Vis-NIR from StellarNet Inc, Tampa, Fla.). The collimating
lens included a lens tube (available as SM1L30 from Thorlabs,
Newton, N.J.) and a plano-convex lens (available as LA1131 from
Thorlabs, Newton, N.J.). The collimating lens produced a focused
spot size of about 5 mm at the detector. Detector 3730 was oriented
along optical axis 3750. Linear absorbing polarizer 3720 (Melles
Griot 03 FPG 007 available from CVI Melles Griot, Albuquerque, N.
Mex.) was mounted on a rotary stage. Location 3740 was adjacent to
emitting surface 3712 of lambertian light box 3710. The light box
was a six-sided hollow rectangular solid with approximate
dimensions 12.5 cm by 12.5 cm by 11.5 cm made from diffuse PTFE
plates about 0.6 mm thick. The light box had an average total
diffuse reflectance of about 83%, measured at emitting surface
3712, over the visible range. Light source 3760 and optical fiber
3770 were a stabilized broadband incandescent light source attached
to a fiber optic bundle (available as Fostec DCR-III with a one cm
diameter fiber bundle extension from Schott North America,
Southbridge Mass.).
[0208] Peel strength values reported herein were measured using an
IMASS SP-2000 tester (available from IMASS Inc., Accord, Mass.).
Test strips (optical stacks with a bottom prismatic light directing
film) approximately 2.54 cm wide and 20.3 cm long were prepared
with the linear prisms of the bottom light directing film extending
along the length of the test strips. The test strips were adhered
to the tester platform using 2.54 cm wide Scotch double-coated tape
(available as Scotch 665 from 3M Company, St. Paul, Minn.). The
tester was configured to measure the 180 degree peel force. Test
strips were oriented so that the plano side (the side opposite the
prismatic structures) of the bottom prism film was adhered to the
tester platform and the top film was attached to the force balance.
The load cell capacity was 10 lb-ft (13.6 nt-m). Peel force was
measured at a rate of 12 in/min (30.5 cm/min). Data was collected
after an initial delay of 2 seconds. Measurements were then
averaged over a test period of 10 seconds. For each test strip, a
minimum of two sequential 10 second measurements were collected and
averaged.
[0209] Light directing films disclosed herein, such as light
directing film 100, can be fabricated by first fabricating a
cutting tool, such as a diamond cutting tool. The cutting tool can
then be used to create the desired unitary discrete structures,
such as linear unitary discrete structures, in a microreplication
tool. The microreplication tool can then be used to microreplicate
the structures into a material or resin, such as a UV or thermally
curable resin, resulting in a light directing film. The
microreplication can be achieved by any suitable manufacturing
method, such as UV cast and cure, extrusion, injection molding,
embossing, or other known methods.
[0210] FIG. 38 is a schematic three-dimensional view of an
exemplary cutting tool, such as a diamond cutting tool, 3800 that
can be used to create a microreplication tool. Cutting tool 3810 is
designed to plunge into a workpiece along a plunging direction 3830
to a desired and pre-determined depth. Next, the cutting tool can
cut, for example, a linear unitary discrete structure, by moving
the cutting tool along a desired and predetermined cutting
direction 3840 where, in some cases, direction 3840 can be
generally parallel to a major surface of the workpiece. Cutting
tool 3800 includes a top surface 3820 for leading the plunging of
the cutting tool into the workpiece and a cutting surface 3810 for
cutting a desired profile as the cutting tool moves inside the
workpiece along cutting direction 3840. In some cases, cutting
surface 3810 can be planar and in the xz-plane. In such cases, top
surface 3820 can be recessed relative to the xy-plane so that the
top surface does not interferes with the cutting. Cutting tool 3800
and similar cutting tools can be fabricated using focused ion beam
milling processes described in, for example, U.S. Pat. No.
7,140,812, the disclosure of which is incorporated in its entirety
herein by reference thereto.
[0211] FIG. 45 is an exemplary scanning electron micrograph (SEM)
of a diamond cutting tool that was fabricated according to the
processes disclosed herein. The diamond cutting tool had a cutting
surface 4505 designed to cut linear structures in a
microreplication tool that once replicated, would result in linear
unitary discrete structures disclosed herein. Cutting surface 4505
included a bottom portion 4510 for fabricating the light directing
portions of the unitary discrete structures and a top portion 4530
for fabricating the bonding portions of the unitary discrete
structures. Bottom portion 4510 had two opposing side facets 4520
that defined an included angle 4525 that was about 88.4 degrees.
Top portion 4530 had two opposing side facets that defined an
included angle close to 90 degrees, and a top surface 4550 that had
a recession similar to recession 2870 in FIG. 28. Top portion 4530
was about 6.4 microns long and 3.1 microns wide.
[0212] The light directing films and optical stacks disclosed
herein can be employed in any application that may be desirable to
increase brightness, reduce the number of separate components or
layers, and reduce the overall thickness. Exemplary applications
include televisions, computer monitors, projectors, potable
displays such as portable video players, and hand-held devices such
as cell-phones. Other exemplary application include large displays,
such as large area televisions, and small displays, such as
cell-phone displays. Other exemplary applications include displays
for displaying an image or information or general lighting optical
systems.
[0213] Some of the advantages of the disclosed light directing
films, optical stacks, and optical systems are further illustrated
by the following examples. The particular materials, amounts and
dimensions recited in this example, as well as other conditions and
details, should not be construed to unduly limit the present
invention.
[0214] In the examples, the index of refraction was measured using
a Metricon Model 2010 Prism Coupler (available from Metricon Corp.,
Pennington, N.J.).
Example A
[0215] A light directing film 3900, a schematic side-view of which
is illustrated in FIG. 39, was made. A microreplication tool was
made using the processes outlined and described in, for example,
U.S. Patent Publication No. 2009/0041553, the disclosure of which
is incorporated in its entirety herein by reference thereto. The
microreplication tool was then used to make light directing film
using the processes outlined and described in, for example, U.S.
Pat. No. 5,175,030, the disclosure of which is incorporated in its
entirety herein by reference thereto. Light directing film 3900
included a structured layer 3920 disposed on a substrate 3910.
Substrate 3910 was made of PET, had a thickness of about 29 microns
and an index of refraction of about 1.65. Structured layer 3920
included a plurality of linear prisms 3930 that extended along the
y-direction (cross-web direction). Apex angle 3940 of each prism
3930 was about 90 degrees. The prism had a pitch P.sub.1 of about
24 microns along the x-direction. The index of refraction of the
linear prisms was about 1.56. Light directing film 3900 had an
average effective transmission ETA of about 1.67.
Example B
[0216] A substrate 4000, a schematic side-view of which is
illustrated in FIG. 40, was provided. Substrate 4000 was made of
PET, had a thickness of about 50 microns and an index of refraction
of about 1.65. Substrate 4000 had an average effective transmission
ETA of about 1.02.
Example C
[0217] A light directing film 4100, a schematic side-view of which
is illustrated in FIG. 41, was made. Light directing film 4100 was
a Vikuiti.TM. BEF-RP-II 90/24r, which is a brightness-enhanced,
reflective polarizer having a prismatic surface, available from 3M
Company, St. Paul, Minn. Light directing film 4100 included a
structured layer 4120 disposed on a reflective polarizer 4110.
Reflective polarizer 4110 had a thickness of about 96 microns.
Structured layer 4120 included a plurality of linear prisms 4130
that extended along the y-direction. Apex angle 4140 of each prism
4130 was about 90 degrees. The prism had a pitch P.sub.2 of about
24 microns along the x-direction. The index of refraction of the
linear prisms was about 1.58. Light directing film 4100 had an
average effective transmission ETA of about 2.42.
Example D
[0218] A reflective polarizer 4200, a schematic side-view of which
is illustrated in FIG. 42, was made. Reflective polarizer 4200 was
a Vikuiti.TM. reflective polarizer available from 3M Company, St.
Paul, Minn. Reflective polarizer 4200 had a thickness of about 96
microns and an average effective transmission ETA of about
1.73.
Example E
[0219] A light directing film 4300, a schematic side-view of which
is illustrated in FIG. 43, was made. Light directing film 4300 was
a Vikuiti.TM. TBEF3, which is a brightness-enhanced film having a
prismatic surface, available from 3M Company, St. Paul, Minn.
[0220] Light directing film 4300 included a structured layer 4320
disposed on a substrate 4310. Substrate 4310 was made of PET, had a
thickness of about 29 microns and an index of refraction of about
1.65. Structured layer 4320 included a plurality of linear prisms
4330 that extended along the y-direction. Apex angle 4340 of each
prism 4330 was about 90 degrees. The prism had a pitch P.sub.3 of
about 24 microns along the x-direction. Every fourteenth prism was
slightly raised relative to the other prisms. The maximum height
difference S.sub.1 between the tallest prisms and the shortest
prisms was about 2 microns. The index of refraction of the linear
prisms was about 1.56. Light directing film 4300 had an average
effective transmission ETA of about 1.65.
Example F
[0221] A light directing film 4400, a schematic side-view of which
is illustrated in FIG. 44, was made. Light directing film 4400 was
similar to light directing film 3300 and included a first plurality
of linear symmetric unitary discrete structures 4420 and a second
plurality of linear symmetric discrete structures 4460. Structures
4420 and 4460 extended along the y-direction and were disposed on a
substrate 4410. Substrate 4410 was made of PET, had a thickness of
about 29 microns and an index of refraction of about 1.65. The
index of refraction of structures 4420 and 4460 was about 1.56.
Each unitary discrete structure included a bonding portion 4430
designed primarily for bonding the light directing film to a
surface and disposed on a light directing portion 4440 designed
primarily for directing and recycling light. Discrete structures
4460 did not include any bonding portions and were primarily
designed to direct and recycle light. Unitary discrete structures
4420 alternated with discrete structures 4460.
[0222] Each bonding portion 4430 included two opposing side facets
4432 that made angles .omega..sub.1 with the xy-plane (the plane of
the light directing film) that was about 85-90 degrees. Each
bonding portion had a base 4434, a minimum base dimension t.sub.2
that was about 0.9 (.+-.0.2) microns, and a maximum height t.sub.1
that was about 3.4 (.+-.0.2) microns. Each bonding portion also
included a curved or rounded top surface that had a minimum top
surface dimension t.sub.3 of about 0.9 (.+-.0.2) microns.
[0223] Each light directing portion 4420 included two opposing side
facets 4422 that made angles .omega..sub.2 with the xy-plane (the
plane of the light directing film) that was about 45 degrees. Each
light directing portion had a base 4444, a minimum base dimension
t.sub.5 of about 24 microns, and a maximum height t.sub.4 that was
about 11.9 microns. Light directing film 4400 had an average
effective transmission ETA of about 1.65.
Example G
[0224] An adhesion solution was prepared. The adhesion solution
included the following components: (a) a pressure sensitive
adhesive (29.39 gr, 26% solids, available as RD2739 from 3M
Company, St. Paul, Minn.; (b) aliphatic urethane diacrylate (1.84
gr, 100% solids, available as CN964 from Sartomer Company, Exton,
Pa.); (c) tripropylene glycol diacrylate (3.69 gr, 100% solids,
available as SR306 from Sartomer Company); (d) toluene (15.15 gr,
0% solids, available from Aldrich Company, Milwaukee, Wis.); (e)
methanol (10.81 gr, 0% solids, available from Aldrich Compnay); (f)
ethyl acetate (37.76 gr, 0% solids, available from Aldrich
Company); (g) photoinitiator (0.14 gr, 100% solids, available as
Lucirin TPO from BASF, Charlotte, N.C.): (h) photoinitiator (0.16
gr, 100% solids, available as Irgacure 907 from Ciba, Tarrytown,
N.Y.); and polyvinylcaprolactam (0.477 gr, 40% solids, available as
Luviskol Plus from BASF).
Example H
[0225] A coating process for coating the adhesive solution of
Example G was developed. The adhesive solution was coated on the
plano side of the substrate of the upper film using a No. 8 or No.
20 Mayer rod (available from RD Specialties, Webster, N.Y.). The
wet adhesive layer thickness for the No. 8 Meyer rod was about 9
microns. The wet adhesive layer thickness for a No. 20 Mayer rod
was about 26 microns. The coating was then dried at 60.degree. C.
for about 2.5 minutes resulting in a dry optical adhesive layer.
For a No. 8 Mayer rod, the thickness of the optical adhesive layer
was about 1.0 micron (.+-.0.2 microns). For a No. 20 Mayer rod, the
thickness of the optical adhesive layer was about 3.0 microns
(.+-.0.2 microns). The dry thickness values were measured using a
TranSpec Spectrometer and light source (available from Applied
Spectroscopy, Aalen Germany). The upper film was then laminated to
the lower film using a rubber hand roller with 30 Shore A hardness
at 0.5 lbf/in (0.88 N/cm). The resulting laminated optical stack
was then cured through the lower film at 60 ft/min (18.3 m/min)
using a Fusion belt processor (available from Fusion UV Systems,
Gaithersburg Md.). The UV dosages were 920 mJ/cm.sup.2 (UV-A), 375
mJ/cm.sup.2 (UV-B), and 43 mJ/cm.sup.2 (UV-C). The dosage was
measured using a UV PowerPuck II (available from EIT Inc., Sterling
N.Y.).
Example I
[0226] An adhesion solution was prepared. The adhesion solution
included the following components: (a) a pressure sensitive
adhesive (29.11 kg, 26% solids, available as RD2739 from 3M
Company, St. Paul, Minn.; (b) aliphatic urethane diacrylate (1.75
kg, 100% solids, available as CN964 from Sartomer Company, Exton,
Pa.); (c) tripropylene glycol diacrylate (3.55 kg, 100% solids,
available as SR306 from Sartomer Company); (d) toluene (24.06 kg,
0% solids, available from Aldrich Company, Milwaukee, Wis.); (e)
methanol (17.21, 0% solids, available from Aldrich Compnay); (f)
ethyl acetate (59.38 kg, 0% solids, available from Aldrich
Company); (g) photoinitiator (0.27 kg, 100% solids, available as
Lucirin TPO from BASF, Charlotte, N.C.): (h) photoinitiator (0.27
kg, 100% solids, available as Irgacure 907 from Ciba, Tarrytown,
N.Y.); and polyvinylcaprolactam (0.48 kg, 40% solids, available as
Luviskol Plus from BASF).
Example J
[0227] A coating process for coating the adhesive solution of
Example I was developed. The adhesive solution was coated on the
plano side of the substrate of the upper film using a slot-type
coating die. The coating width was 50.8 cm, and the web speed of
the coating process was 18.3 m/min. Solution was pre-metered using
a Zenith gear pump and delivered at a flow rate of 400 cubic
centimeters per minute. The wet adhesive layer thickness was
approximately 43 microns. The coating was then dried at
65.6.degree. C. for approximately 2.5 minutes resulting in a dry
optical adhesive layer with a thickness of approximately 3.5
microns. The dry thickness value was measured using a TranSpec
Spectrometer and light source (available from Applied Spectroscopy,
Aalen Germany). The upper film was then laminated to the lower film
between a rubber nip roll (60 Shore A hardness) and a steel roll at
a nip force of 1.8 lbf/in (3.2 N/cm). The laminate was then nipped
again between a second rubber nip roll (60 Shore A hardness) and a
temperature controlled UV backup roll; the nip force of the UV
laminator was 4.8 lbf/in (8.4 N/cm). The resulting laminated
optical stack was then cured using Fusion F600 light sources
equipped with "D" bulbs (available from Fusion UV Systems,
Gaithersburg Md.). The laminated optical stack was cured through
the lower film at 18.3 m/min on the temperature controlled UV
backup roll. The temperature set point of the UV backup roll was
43.4.degree. C. The delivered UV dosages were 993 mJ/cm.sup.2
(UV-A), 312 mJ/cm.sup.2 (UV-B), and 29 mJ/cm.sup.2 (UV-C). The
dosage was measured using a UV PowerPuck (available from EIT Inc.,
Sterling N.Y.).
Example 1A
[0228] An optical stack was made by placing a light directing film
3900 of Example A on another light directing film 4300 of Example
E. The plano side of the top light directing film faced the
structured side of the bottom light directing film. Each light
directing film 4300 was about 22.9 cm wide and 30.5 cm long. The
linear prisms in the two films extended along orthogonal
directions. There was no optical adhesive layer bonding the two
light directing films. The ETA of the optical stack was about
2.51.
Example 1B
[0229] An optical stack similar to the optical stack of Example 1A
was made except that the two light directing films were bonded to
each other via a 1 micron thick optical adhesive layer and the
bonding process described in Example H. The resulting optical stack
had a peel strength of about 34 gr/in and an ETA of about 2.39.
Example 1C
[0230] An optical stack similar to the optical stack of Example 1A
was made except that the two light directing films 4300 were bonded
to each other via a 3 micron thick optical adhesive layer and the
bonding process described in Example H. The resulting optical stack
had a peel strength of about 39 gr/in and an ETA of about 2.01.
Example 2A
[0231] An optical stack was made by placing a light directing film
3900 of Example A on a light directing film 4400 of Example F. The
plano side of the top light directing film faced the structured
side of the bottom light directing film. The linear prisms in the
two films extended along orthogonal directions. There was no
optical adhesive layer bonding the two light directing films. The
ETA of the optical stack was about 2.45.
Example 2B
[0232] An optical stack similar to the optical stack of Example 2A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4400 via a 1 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
28 gr/in and an ETA of about 2.37.
Example 2C
[0233] An optical stack similar to the optical stack of Example 2A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4400 via a 3 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
49 gr/in and an ETA of about 2.38.
Example 2D
[0234] An optical stack similar to the optical stack of Example 2A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4400 via a 3.5 micron
thick optical adhesive layer and the bonding process described in
Example J. The resulting optical stack had a peel strength of about
79.9 gr/in and an ETA of about 2.32.
Example 2E
[0235] An optical stack similar to the optical stack of Example 2A
was made except that the top light directing film 4300 was
laminated to the bottom light directing film 4400 via a 3.5 micron
thick optical adhesive layer and the bonding process described in
Example J except that the plano side of the substrate of the upper
film was first nitrogen corona treated at a dosage of 1.5 J/cm2.
The resulting optical stack had a peel strength of about 100.6
gr/in and an ETA of about 2.31.
[0236] FIG. 47 is ETA as a function of peel strength for Examples
1B-1C where the prisms did not have any portions designed primarily
for bonding the prisms to a neighboring surface and Examples 2B-2E
where every other prism was a unitary discrete structure that
included a bonding portion designed primary to bond the unitary
discrete structure to a neighboring surface. In Examples 2B-2E, the
peel strength was significantly increased with no, or very little,
drop in the ETA. In sharp contrast, in Examples 1B-1C, even a
slight increase in the peel strength resulted in a significant drop
in the ETA.
Example 3A
[0237] An optical stack was made by placing a substrate 4000 of
Example B on a light directing film 4300 of Example E. Each film
was about 22.9 cm wide and 30.5 cm long. There was no optical
adhesive layer bonding the two light films. The ETA of the optical
stack was about 1.61.
Example 3B
[0238] An optical stack similar to the optical stack of Example 3A
was made except that the top substrate 4000 was laminated to the
bottom light directing film 4300 via a 1 micron thick optical
adhesive layer and the bonding process described in Example H. The
resulting optical stack had a peel strength of about 26 gr/in and
an ETA of about 1.55.
Example 3C
[0239] An optical stack similar to the optical stack of Example 3A
was made except that the top substrate 4000 was laminated to the
bottom light directing film 4300 via a 3 micron thick optical
adhesive layer and the bonding process described in Example H. The
resulting optical stack had a peel strength of about 32 gr/in and
an ETA of about 1.37.
Example 4A
[0240] An optical stack was made by placing a substrate 4000 of
Example B on a light directing film 4400 of Example F. Each film
was about 22.9 cm wide and 30.5 cm long. There was no optical
adhesive layer bonding the two light films. The ETA of the optical
stack was about 1.61.
Example 4B
[0241] An optical stack similar to the optical stack of Example 4A
was made except that the top substrate 4000 was laminated to the
bottom light directing film 4400 via a 1 micron thick optical
adhesive layer and the bonding process described in Example H. The
resulting optical stack had a peel strength of about 21 gr/in and
an ETA of about 1.58.
Example 4C
[0242] An optical stack similar to the optical stack of Example 4A
was made except that the top substrate 4000 was laminated to the
bottom light directing film 4400 via a 3 micron thick optical
adhesive layer and the bonding process described in Example H. The
resulting optical stack had a peel strength of about 30 gr/in and
an ETA of about 1.58.
Example 5A
[0243] An optical stack was made by placing a light directing film
4100 of Example C on a light directing film 4300 of Example E. The
plano side of the top light directing film faced the structured
side of the bottom light directing film. Each light directing film
was about 22.9 cm wide and 30.5 cm long. The linear prisms in the
two films extended along orthogonal directions. There was no
optical adhesive layer bonding the two light directing films. The
ETA of the optical stack was about 3.06.
Example 5B
[0244] An optical stack similar to the optical stack of Example 5A
was made except that the top light directing film 4100 was
laminated to the bottom light directing film 4300 via a 1 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
37 gr/in and an ETA of about 2.84.
Example 5C
[0245] An optical stack similar to the optical stack of Example 5A
was made except that the top light directing film 4100 was
laminated to the bottom light directing film 4300 via a 3 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
106 gr/in and an ETA of about 2.51.
Example 6A
[0246] An optical stack was made by placing a light directing film
4100 of Example C on a light directing film 4400 of Example F. The
plano side of the top light directing film faced the structured
side of the bottom light directing film. Each light directing film
was about 22.9 cm wide and 30.5 cm long. The linear prisms in the
two films extended along orthogonal directions. There was no
optical adhesive layer bonding the two light directing films. The
ETA of the optical stack was about 3.07.
Example 6B
[0247] An optical stack similar to the optical stack of Example 6A
was made except that the top light directing film 4100 was
laminated to the bottom light directing film 4400 via a 1 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
37 gr/in and an ETA of about 2.93.
Example 6C
[0248] An optical stack similar to the optical stack of Example 6A
was made except that the top light directing film 4100 was
laminated to the bottom light directing film 4400 via a 3 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
88 gr/in and an ETA of about 2.82. FIG. 46 is an exemplary SEM of a
unitary discrete structure 4610 that included a bonding portion
4620 and a light directing portion 4630. Bonding portion 4620 had
partially penetrated into an optical adhesive layer 4640. Bonding
portion 4620 was about 3 microns tall and a bout 1 micron wide.
Example 7A
[0249] An optical stack was made by placing a light directing film
3900 of Example A on a light directing film 4300 of Example E. The
plano side of the top light directing film faced the structured
side of the bottom light directing film. Each light directing film
was about 22.9 cm wide and 30.5 cm long. The linear prisms in the
two films extended along orthogonal directions. There was no
optical adhesive layer bonding the two light directing films. The
ETA of the optical stack was about 2.35.
Example 7B
[0250] An optical stack similar to the optical stack of Example 7A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4300 via a 1 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
37 gr/in and an ETA of about 2.24.
Example 7C
[0251] An optical stack similar to the optical stack of Example 7A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4300 via a 3 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
90 gr/in and an ETA of about 1.97.
Example 8A
[0252] An optical stack was made by placing a light directing film
3900 of Example A on a light directing film 4400 of Example F. The
plano side of the top light directing film faced the structured
side of the bottom light directing film. Each light directing film
was about 22.9 cm wide and 30.5 cm long. The linear prisms in the
two films extended along orthogonal directions. There was no
optical adhesive layer bonding the two light directing films. The
ETA of the optical stack was about 2.36.
Example 8B
[0253] An optical stack similar to the optical stack of Example 8A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4400 via a 1 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
33 gr/in and an ETA of about 2.33.
Example 8C
[0254] An optical stack similar to the optical stack of Example 8A
was made except that the top light directing film 3900 was
laminated to the bottom light directing film 4400 via a 3 micron
thick optical adhesive layer and the bonding process described in
Example H. The resulting optical stack had a peel strength of about
64 gr/in and an ETA of about 2.29.
Item 1. An optical stack comprising:
[0255] a light redirecting film comprising a first structured major
surface comprising a plurality of unitary discrete structures;
and
[0256] an optical adhesive layer disposed on the light directing
film, at least portions of at least some unitary discrete
structures in the plurality of unitary discrete structures
penetrating into the optical adhesive layer, at least portions of
at least some unitary discrete structures in the plurality of
unitary discrete structures not penetrating into the optical
adhesive layer, a peel strength of the light redirecting film and
the optical adhesive layer being greater than about 30 grams/inch,
an average effective transmission of the optical stack not being
less or being less than by no more than about 10% as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into the optical adhesive layer.
Item 2. The optical stack of item 1, wherein the average effective
transmission of the optical stack is not less or is less than by no
more than about 8% as compared to an optical stack that has the
same construction except that no unitary discrete structure
penetrates into the optical adhesive layer. Item 3. The optical
stack of item 1, wherein the average effective transmission of the
optical stack is not less or is less than by no more than about 6%
as compared to an optical stack that has the same construction
except that no unitary discrete structure penetrates into the
optical adhesive layer. Item 4. The optical stack of item 1,
wherein the average effective transmission of the optical stack is
not less or is less than by no more than about 4% as compared to an
optical stack that has the same construction except that no unitary
discrete structure penetrates into the optical adhesive layer. Item
5. The optical stack of item 1, wherein each of at least some
unitary discrete structures in the plurality of unitary discrete
structures comprises:
[0257] a light directing portion primarily for directing light and
comprising a plurality of side facets, each side facet making an
angle that is greater than about 40 degrees with a normal to the
light directing film; and
[0258] a bonding portion primarily for penetrating at least
partially into the optical adhesive layer and comprising: [0259] a
base having a minimum dimension; and [0260] a maximum height, a
ratio of the maximum height to the minimum dimension being at least
about 1.5. Item 6. The optical stack of item 1 comprising a
substrate directly bonded to the optical adhesive layer. Item 7.
The optical stack of item 1 comprising another light directing film
bonded to the optical adhesive layer and comprising a plurality of
linear prismatic structures. Item 8. The optical stack of item 1
comprising a reflective polarizer layer. Item 9. The optical stack
of item 1, wherein the peel strength of the light redirecting film
and the optical adhesive layer is greater than about 40 grams/inch.
Item 10. The optical stack of item 1, wherein the peel strength of
the light redirecting film and the optical adhesive layer is
greater than about 50 grams/inch. Item 11. The optical stack of
item 1, wherein the peel strength of the light redirecting film and
the optical adhesive layer is greater than about 60 grams/inch.
Item 12. An illumination system comprising:
[0261] a light source emitting light; and
[0262] the optical stack of item 1 receiving the emitted light.
Item 13. The illumination system of item 12, wherein the light
directing film is disposed between the optical film and the light
source. Item 14. The illumination system of item 12, wherein the
optical film is disposed between the light directing film and the
light source. Item 15. An optical stack comprising:
[0263] a light directing film comprising a plurality of unitary
discrete structures; and
[0264] an optical adhesive layer disposed on the light directing
film for adhering the light directing film to a surface, portions
of each unitary discrete structure penetrating into the optical
adhesive layer, portions of each unitary discrete structure not
penetrating into the optical adhesive layer, each unitary discrete
structure defining a penetration depth and a penetration base at an
interface between the penetrating and non-penetrating portions of
the unitary discrete structure, the penetration base having a
minimum penetration base dimension, the plurality of unitary
discrete structures having an average penetration depth and an
average minimum penetration base dimension, a ratio of the average
penetration depth to the average minimum penetration base dimension
being at least 1.5, a peel strength between the light directing
film and the surface being greater than about 30 grams/inch.
Item 16. The optical stack of item 15 comprising a plurality of
voids between the optical adhesive layer and the light directing
film. Item 17. The optical stack of item 15, wherein each unitary
discrete structure comprises a light directing portion primarily
for directing light and a bonding portion primarily for bonding the
light directing film to the surface, at least portions of the
bonding portion of each unitary discrete structure penetrating the
optical adhesive layer, at least portions of the light directing
portion of each unitary discrete structure not penetrating the
optical adhesive layer. Item 18. The optical stack of item 15,
wherein the ratio of the average penetration depth to the average
minimum penetration base dimension is at least 2. Item 19. The
optical stack of item 15, wherein the ratio of the average
penetration depth to the average minimum penetration base dimension
is at least 3. Item 20. The optical stack of item 15, wherein the
ratio of the average penetration depth to the average minimum
penetration base dimension is at least 4. Item 21. The optical
stack of item 15, wherein the ratio of the average penetration
depth to the average minimum penetration base dimension is at least
5. Item 22. The optical stack of item 15, wherein the ratio of the
average penetration depth to the average minimum penetration base
dimension is at least 7. Item 23. The optical stack of item 15,
wherein the ratio of the average penetration depth to the average
minimum penetration base dimension is at least 10. Item 24. The
optical stack of item 15, wherein the peel strength between the
light directing film and the surface is greater than about 40
grams/inch. Item 25. The optical stack of item 15, wherein the peel
strength between the light directing film and the surface is
greater than about 60 grams/inch. Item 26. The optical stack of
item 15, wherein the peel strength between the light directing film
and the surface is greater than about 80 grams/inch. Item 27. The
optical stack of item 15, wherein the average minimum penetration
base dimension is less than about 10 microns. Item 28. The optical
stack of item 15, wherein the average minimum penetration base
dimension is less than about 7 microns. Item 29. The optical stack
of item 15, wherein the average minimum penetration base dimension
is less than about 5 microns. Item 30. The optical stack of item
15, wherein the average minimum penetration base dimension is less
than about 4 microns. Item 31. The optical stack of item 15,
wherein the average minimum penetration base dimension is less than
about 3 microns. Item 32. The optical stack of item 15, wherein
each unitary discrete structure has a base and a minimum base
dimension, the plurality of unitary discrete structures having an
average minimum base dimension, the average minimum penetration
base dimension being less than about 10% of the average minimum
base dimension. Item 33. The optical stack of item 32, wherein the
average minimum penetration base dimension is less than about 8% of
the average minimum base dimension. Item 34. The optical stack of
item 32, wherein the average minimum penetration base dimension is
less than about 6% of the average minimum base dimension. Item 35.
The optical stack of item 32, wherein the average minimum
penetration base dimension is less than about 5% of the average
minimum base dimension. Item 36. The optical stack of item 32,
wherein the average minimum penetration base dimension is less than
about 4% of the average minimum base dimension. Item 37. The
optical stack of item 32, wherein the average minimum penetration
base dimension is less than about 3% of the average minimum base
dimension. Item 38. An optical stack comprising:
[0265] a light directing film comprising a first plurality of
unitary discrete structures; and
[0266] an optical layer disposed on the light directing film,
portions of each unitary discrete structure in the first plurality
of unitary discrete structures penetrating into the optical layer,
portions of each unitary discrete structure in the first plurality
of unitary discrete structures not penetrating into the optical
layer, each unitary discrete structure in the first plurality of
unitary discrete structures defining a penetration depth and a
penetration base at an interface between the penetrating and
non-penetrating portions of the unitary discrete structure, the
penetration base having a minimum penetration base dimension, the
first plurality of unitary discrete structures having an average
penetration depth and an average minimum penetration base
dimension, a ratio of the average penetration depth to the average
minimum penetration base dimension being at least 1.5, a peel
strength between the light directing film and the optical layer
being greater than about 30 grams/inch.
Item 39. The optical stack of item 38, wherein the optical layer is
a pressure sensitive adhesive. Item 40. The optical stack of item
38, wherein the optical layer is a structural adhesive. Item 41.
The optical stack of item 38, wherein the optical layer is a
lightguide having means for extracting light that propagates within
the lightguide by total internal reflection. Item 42. The optical
stack of item 38, wherein the optical layer comprises a glass
transition temperature that is greater than a maximum operating
temperature of the optical stack. Item 43. The optical stack of
item 38, wherein the light directing film comprises a second
plurality of unitary discrete structures, at least one unitary
discrete structure in the second plurality of unitary discrete
structures not penetrating into the optical layer. Item 44. The
optical stack of item 38, wherein the unitary discrete structures
in the second plurality of discrete structures are shorter than the
unitary discrete structures in the first plurality of discrete
structures.
[0267] As used herein, terms such as "vertical", "horizontal",
"above", "below", "top", "bottom" "left", "right", "upper" and
"lower", "clockwise" and "counter clockwise" and other similar
terms, refer to relative positions as shown in the figures. In
general, a physical embodiment can have a different orientation,
and in that case, the terms are intended to refer to relative
positions modified to the actual orientation of the device. For
example, even if the image in FIG. 38 is flipped as compared to the
orientation in the figure, surface 3820 is still considered to be
the top surface.
[0268] All patents, patent applications, and other publications
cited above are incorporated by reference into this document as if
reproduced in full. While specific examples of the invention are
described in detail above to facilitate explanation of various
aspects of the specifics of the examples. Rather, the intention is
to cover all modifications, embodiments, and alternatives falling
within the spirit and scope of the invention as defined by the
appended claims.
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