Methods and apparatus for forming polarized films and glasses
AssigneeMicroContinuum, Inc.
InventorsW. Dennis Slafer, Christine Higgins, B. Diane Martin
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Abstract
Methods are disclosed for forming polarized films and glasses having polarization efficiency that is varied in a predetermined design. In particular, such designs include monochrome and color polarization density gradients, where the non-polarized areas of films and glasses allow viewing of polarized displays without distortion. The methods include forming films and glasses that have visually uniform density while still incorporating polarization gradients. The disclosed methods also enable creation of polarization filters and glasses with increased optical density and reduced glare from multiple angles.
Claims20
1) A method for fabricating a polarizing film having a degree of polarization that is varied in a pre-determined manner, said method comprising:
- a. providing a first support substrate;
- b. bonding a second layer to said first substrate, said second substrate having a polymer layer whose molecule structure is predominately oriented in one direction;
- c. forming a polymeric dye controlling layer over said second substrate;
- d. forming a dyed film by selectively applying one or more dyes onto said polymeric dye controlling layer;
- e. imbibing (absorbing) said selectively applied dyes into said second layer by exposing said dyed film to an environment having controlled temperature and humidity for a fixed time;
- f. removing said dyed film from said controlled humidity and temperature zone;
- and
- g. forming a final dyed image in said second layer by removal of said polymeric dye controlling layer and excess said dichroic dye from said second layer.
8) The method of claim 8 in which said dichroic dyes are selectively applied to form a polarizer having an intensity gradient.
9) The method of claim 9 in which a film of uniform visual appearance is formed from a combination of a polarized gradient in one direction and a non-polarized gradient in the opposite direction.
19) A method for continuously fabricating a selectively patterned polarizing film by means of a roll-to-roll process, said method comprising:
- a. unwinding a substrate including at least an oriented polymeric film with a overlaid polymeric dye controlling layer;
- b. said substrate traversing a zone in which one or more dichroic inks are selectively applied using ink jet, gravure or other graphic arts printing techniques;
- c. said printed substrate subsequently traversing a zone having controlled temperature and humidity;
- d. said substrate subsequently traversing a zone in which said dye controlling layer and any excess of said dyes are removed;
- and
- e. subsequently rewinding said substrate onto a take-up spool.
20) A system for continuously fabricating a selectively patterned polarizing film by means of a roll-to-roll process, said system comprising:
- a. a spool for unwinding a substrate having at least an oriented polymeric film with a overlaid polymeric dye controlling layer;
- b. a subsequent zone through which said substrate traverses having a means of applying one or more dichroic inks;
- c. a next zone through which said substrate traverses having a means to control temperature and humidity;
- d. a next zone through which said substrate traverses having a means of removal of said dye controlling layer and excess of said dyes;
- and
- e. a rewind spool onto which said substrate is taken up after completion of said previous steps.
Dependencies are inferred from the claim text.