Patent Application
20050238852
The present invention relates to optical films. In particular, the present invention relates to optical sheets formed by bonding adhesive to optical films.
Optical films are used to increase the amount of light exiting an optical display in a direction normal, or “on-axis,” to the surface of the display. Increasing the amount of on-axis light reduces the amount of energy required to generate a desired amount of on-axis luminance. This is particularly important for optical displays that use battery powered light sources such as those used in laptop computers, calculators, digital wristwatches, cellular phones, and personal digital assistants.
The 3M brand Brightness Enhancement Film is used to address this problem. The film collects light from “off-axis” and redirects or “recycles” this light on-axis toward the viewer. In use, this material increases the on-axis luminance at the expense of off-axis luminance.
A “turning” film is also used to increase the amount of on-axis light exiting a display. Turning films are usually used in combination with a wedge-shaped light guide. Light rays exiting the light guide at the glancing angle, usually less than 30° to the output surface, are internally reflected such that they are directed substantially on-axis. Representative embodiments of turning films are described in U.S. Pat. Nos. RE 38,243 and 4,984,144.
Another film used to increase on-axis light exiting a display is a multilayer polymer film such as DBEF from 3M Company. The film is formed of about 700 to 800 layers of polymer each having about 150 nm thickness and provides high reflectivity over a wide bandwidth. Representative embodiments are described in U.S. Pat. No. 6,613,421.
Other films, such as diffuser-type films, along with the films described above, are used extensively in optical displays. Multiple films are arranged between the optical light guide and liquid crystal panel of a liquid crystal display (LCD), and it is difficult and inefficient to insert each film individually. This is especially true for small displays.
In addition, these films have a structured surface that is fragile and easily damaged and must be protected until the films are assembled into a display. To prevent scratching or other damage prior to assembly in a display, a protective cover, or pre-mask, is laminated to the film to protect the structured surface. Placing and then removing the pre-mask from each film are added steps in the manufacture of displays, which increases the cost and time required for assembly.
The present invention is an optical sheet and a method of making the optical sheet. The optical sheet includes an optical film laminated onto an adhesive layer. The perimeter of the adhesive layer is inset from the perimeter of the optical film so that no adhesive is exposed to collect dust and particles or to transfer to other films or components of an optical display.
a and 5b are top views and
f is a side view illustrating a method of making optical sheet sets in accordance with the present invention.
In use, optical sheet set 10 is removed from liner 14 and assembled into an optical display, such as an LCD, between the optical light guide and liquid crystal panel. Laminating the optical films together prior to installation into an optical display decreases the time and cost associated with assembly of the optical display by avoiding individually inserting each film. Installation of optical sheet set 10 into an optical display can also be performed using an automated assembly line. Optical sheet set 10 can also reduce the amount of debris between films and reduce damage to the films.
Although optical sheet set 10 is shown having three optical films, the number of optical films varies depending on the display in which it is used. Some or all of the optical films may be of the same type, again, depending on the optical display. Examples of the types of optical films that may be used in the present invention include light directing films, turning films, multilayer polymer films, diffuser-type films, etc. In addition, the presence of adhesive layer 18a is optional.
Optical sheets 12a and 12b are initially made individually in a process that is described below. Once made, optical sheet 12b is laminated onto optical sheet 12a, which requires aligning the edges of film 16b with the edges of film 16a. As shown in
If an adhesive layer were applied all the way to the edges of the optical films, any misalignment during stacking of the optical sheets would result in exposed adhesive along the edges. The exposed adhesive presents two problems. First, dust and particles collect on the exposed adhesive, and second, the exposed adhesive is easily transferred to other optical films or parts of the display, which may interfere with viewing.
The present invention avoids these problems by recessing the outer edges of the adhesive layers from the edges of the optical films. In
Adhesive layer 18a has a frame-type shape such that it will not interfere with the viewing area of optical film 16a. However, it is not required that adhesive layer 18a include all of frame sides 36, 38, 40, and 42. Adhesive layer 18a may include any combination of one or more of, or portions of, frame sides 36, 38, 40, and 42 and be effective. In fact, there is no specific shape requirement for adhesive layer 18a. In addition, adhesive layer 18a is laminated to structured surface 20 of film 16a. Structured surface 20 contains arrays of prism elements for directing light. Prism elements are fragile and require protection prior to installation of the optical film into an optical display, usually by the addition of a pre-mask. However, when optical sheet 12a is laminated to liner 14 or to another optical sheet, structured surface 20 is protected, which circumvents applying the protective cover or pre-mask to structured surface 20. This benefit provides further time and cost savings in the manufacturing process. Adhesive layer 18a may also be applied to the smooth surface of film 16a, opposite structured surface 20, if preferred.
The limitations and preferred ranges of distances dτ1 and dτ2 were described in reference to
The present invention may also be described in terms of the perimeters of optical film 16a and adhesive layer 18a. Referring, again, to
Here, adhesive layer 48 does not have a frame-type shape. This embodiment may only be used with adhesives that do not interfere with viewing of the optical display.
a through 5e show a method of making the present invention.
b is a top view of the formation of adhesive layer 18a laminated to liner 14. Adhesive material 50 is kiss-cut, and the waste material is stripped away. Any of a number of different methods of kiss-cutting may be carried out in order to form adhesive layer 18a. For example, cuts to form the outer perimeter and the inner perimeter may be carried out concurrently or separately. Alternatively, adhesive layer 18a may be applied directly to liner 14.
A cross-sectional side view through line 5c-5c of
d is a cross-sectional side view illustrating the position of die cuts 56 through optical film material 52. As shown, die cuts 56 are made a distance beyond the edges of adhesive layer 18a.
e is another cross-sectional side view illustrating the result of cutting optical film material 52 with die cuts 56, and stripping the waste material away to form optical film 16a. Optical film 16a is laminated to adhesive layer 18a resulting in optical sheets 12a. These are in turn laminated to liner 14. Alternatively, adhesive layer 18a may be applied directly to optical film 16a.
Optical sheets 12a may subsequently be laminated together or to other optical sheets, such as optical sheets 12b and 12c, to form optical sheet sets 10.
As discussed above, an important benefit of the present invention is the avoidance of exposed adhesive, which is detrimental to the display. The following examples illustrate the effectiveness of the present invention.
An optical sheet set formed from three optical sheets was produced by the method of the present invention. The bottom and middle optical sheets included Thin-BEF by 3M Company, and the top optical sheet included DBEF by 3M Company. Double-sided tape, such as Sumitomo 3M #4040 or #4037, formed the adhesive layer. Each film measured 40mm×50 mm. The adhesive layers had a frame-type shape with a 1 mm strip extending around the films. The outer perimeters of each adhesive layer were recessed by a distance of about 0.5 mm from the perimeters of the films.
The optical sheet set was exposed to room conditions (23° C., 50% relative humidity). After seven days, the appearance of the edges was checked. There was no dust or particle accumulation at the edges.
Next, the optical sheet set was positioned between glass plates, and a 500 g weight was placed on top. The sample was stored at 65° C. and 95% relative humidity. After three days, the glass plates were checked. There was no adhesive transferred to the glass plates.
A second optical sheet set was produced that was identical to the previous example except that the adhesive layers were not recessed from the edges of the films. Instead, the outer perimeters of the adhesive layers were aligned with the perimeters of each film.
This optical sheet set was exposed to the identical conditions as described for the previous example. Here, however, dust and particles attached to exposed adhesive on the edges, adhesive transferred to the glass plates, and the optical sheets adhered to the glass plates.
In addition to the advantages illustrated by these examples, the present invention provides a way to efficiently assemble multiple optical films into an optical display. A pre-mask is no longer required, and multiple films can be installed simultaneously. This reduces the time and cost associated with manufacturing optical displays, which is desirable to the manufacturer.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
