US 7,604,381 B2 · Optical article and method of making

Abstract

Disclosed herein is an optical article having a top layer with a structured surface that collimates light, a core layer secured to the top layer opposite the structured surface, and a bottom layer secured to the core layer opposite the top layer. Either the top layer or the core layer includes a first extrudable polymer having a flexural modulus of greater than 2.5 GPa, and the other layer includes a second extrudable polymer having a flexural modulus of 2.5 GPa or less, an impact strength of greater than about 40 J/m, and tensile elongation at break of greater than about 5%. The bottom layer includes a third extrudable polymer. The bottom layer of the optical article may be structured to diffuse light. One or two optical articles may be secured to an optical film such as a polarizer film. Methods and display devices are also disclosed herein.

Claims42

Dependent claims

An optical article, comprising:

a top layer having a top structured surface that collimates light;
a core layer secured to the top layer opposite the top structured surface;
and
a bottom layer secured to the core layer opposite the top layer;
wherein:
either the top layer or the core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638;
and
the bottom layer comprises a third extrudable polymer.

5 more elements

An optical body comprising:

a first optical article comprising:
a first top layer having a first top structured surface that collimates light;
a first core layer secured to the first top layer opposite the first top structured surface;
and
a first bottom layer secured to the first core layer opposite the first top layer;
wherein:
either the first top layer or the first core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638;
and
the first bottom layer comprises a third extrudable polymer;
a second optical article comprising:
a second top layer having a second top structured surface that diffuses light;
a second core layer secured to the second top layer opposite the second top structured surface;
and
a second bottom layer secured to the second core layer opposite the second top layer;
wherein:
either the second top layer or the second core layer comprises a fourth extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a fifth extrudable polymer, the fifth extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638;
and
the second bottom layer comprises a sixth extrudable polymer;
and
an optical film secured to the first and second bottom layers, the optical film comprising a polarizer film, a reflective polarizer film, a diffuse blend reflective polarizer film, a diffuser film, a brightness enhancing film, a turning film, a mirror film, or a combination thereof.

17 more elements

An optical body comprising:

a first optical article comprising:
a first top layer having a first top structured surface that collimates light;
a first core layer secured to the first top layer opposite the first top structured surface;
and
a first bottom layer secured to the first core layer opposite the first top layer;
wherein:
either the first top layer or the first core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638;
and
the first bottom layer comprises a third extrudable polymer;
a second optical article comprising:
a second top layer having a second top structured surface that diffuses light;
and
a second bottom layer secured to the second top layer opposite the second top structured surface;
wherein:
the second top layer comprises either:
a fourth extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, or
a fifth extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638;
and
the second bottom layer comprises a sixth extrudable polymer;
and
an optical film secured to the first and second bottom layers, the optical film comprising a polarizer film, a reflective polarizer film, a diffuse blend reflective polarizer film, a diffuser film, a brightness enhancing film, a turning film, a mirror film, or a combination thereof.

18 more elements

Dependencies are inferred from the claim text.

Optical article and method of making

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Optical article and method of making

Life of this patent

Abstract

Claims42