Claims
- 1. A method for manufacturing a film or sheet comprising:
deforming a polymeric alloy at a temperature effective to impart to the deformed alloy a birefringence retardation of greater than or equal to about 350 nanometers.
- 2. The method of claim 1, wherein the polymeric alloy is thermoplastic, wherein the polymeric alloy comprises a UV stabilizer and wherein the polymeric alloy comprises at least two resins.
- 3. The method of claim 1, wherein the polymeric alloy comprises oligomers, polymers, branched polymers, dendrimers, ionomers, copolymers, star block copolymers, graft copolymers, block copolymers, random copolymers, or a combination comprising at least one of the foregoing polymers.
- 4. The method of claim 1, wherein the polymeric alloy comprises a polymeric resin, and wherein the polymeric resin is polyethylene, polypropylene, polyamide, polyester, polyimide, polyacetal, polyacrylic, polycarbonate, polystyrene, polyamideimide, polyarylate, polyacrylate, polymethacrylate, polyurethane, polyarylsulfone, polyethersulfone, polyarylene sulfide, polyvinyl chloride, polysulfone, polyetherimide, polytetrafluoroethylene, polyetherketone, polyether etherketone, polyarylene ether, liquid crystalline polymer, or a combination comprising at least one of the foregoing thermoplastic resins.
- 5. The method of claim 4, wherein the polyester is polyethelene terephthalate, polybutylene terephthalate, poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate), poly(trimethylene terephthalate), poly(cyclohexanedimethanol-co-ethylene glycol terephthalate), a blend comprising the copolymer of 100 mole percent terephthalic acid, about 1 to about 99 mole percent 1,4-cyclohexanedimethanol and about 1 to about 99 mole percent ethylene glycol, or a blend comprising a copolymer of 100 mole percent cyclohexane dimethanol, 1 to 100 mole percent terephthalic acid and 1 to 100 mole percent isophthalic acid, or a combination comprising at least one of the foregoing.
- 6. The method of claim 1, wherein the polymeric alloy comprises a polycarbonate-polyester blend.
- 7. The method of claim 6, wherein the polycarbonate-polyester blend comprises polycarbonate and poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate).
- 8. The method of claim 7, wherein the polycarbonate has a number average molecular weight of about 10,000 to about 35,000 g/mole when measured using a polystyrene standard, and wherein the poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate) has an intrinsic viscosity of about 0.82 to about 1.12.
- 9. The method of claim 1, wherein the polymeric alloy comprises polycarbonate-poly(cyclohexanedimethanol-co-ethylene glycol terephthalate), polycarbonate-polyethylene terephthalate, polycarbonate-polybutylene terephthalate, polycarbonate with a blend comprising a copolymer of 100 mole percent terephthalic acid, about 1 to about 99 mole percent 1,4-cyclohexanedimethanol and about 1 to about 99 mole percent ethylene glycol, polycarbonate-copolyester-carbonate, polycarbonate-polymethylmethacrylate, polycarbonate with a blend comprising a copolymer of 100 mole percent terephthalic acid, about 1 to about 99 mole percent 1,4-cyclohexanedimethanol and about 1 to about 99 mole percent ethylene glycol, polycarbonate-poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate)-poly(cyclohexanedimethanol-co-ethylene glycol terephthalate), polycarbonate-copolyester-carbonate with a blend comprising a copolymer of 100 mole percent terephthalic acid, about 1 to about 99 mole percent 1,4-cyclohexanedimethanol and about 1 to about 99 mole percent ethylene glycol, a blend comprising a copolymer of 100 mole percent cyclohexane dimethanol, 1 to 100 mole percent terephthalic acid and 1 to 100 mole percent isophthalic acid, or a combination comprising at least one of the foregoing.
- 10. The method of claim 1, further comprising annealing the film or sheet at a temperature effective to impart to the deformed alloy a birefringence retardation of less than or equal to about 150 nanometers.
- 11. The method of claim 1, wherein the deforming occurs by shear, compression or elongational forces, or a combination of any two of the foregoing forces, or all three of the foregoing forces.
- 12. The method of claim 1, wherein the deforming occurs in a two roll mill or in a three roll mill.
- 13. The method of claim 1, wherein the polymeric alloy may be deformed into a film or a sheet.
- 14. The method of claim 1, wherein the film or sheet is used in an optical device.
- 15. The method of claim 14, wherein the film or sheet is substantially free of comets or veins or both.
- 16. The method of claim 1, wherein the film or sheet is used in an optical device having light polarization, photo-chromism, tint, color, decor, indicia, hardness, anti-abrasion, anti fog, X-ray recording, photographic filming, digital storage, light management capabilities or a combination comprising at least one of the optical devices.
- 17. The method of claim 1, wherein the polymeric alloy has a melt viscosity rate of greater than or equal to about 5 cubic centimeters/10 minutes when measured at 265° C. with a load of 2.16 kilograms and a dwell time of four minutes.
- 18. The method of claim 17, wherein the polymeric alloy has a glass transition temperature of less than or equal to about 205° C.
- 19. The method of claim 1, wherein the polymeric alloy is free from UV stabilizer.
- 20. The method of claim 1, further comprising affixing the sheet or film to a substrate to form a multilayered composite.
- 21. The method of claim 20, wherein the substrate is back molded onto the sheet or film to form a multilayered composite.
- 22. The method of claim 20, wherein the substrate and the sheet or film are coextruded to form a multilayered composite.
- 23. The method of claim 20, further comprising an adhesive layer disposed in between the substrate and the sheet or film.
- 24. The method of claim 20, wherein the film has a thickness of less than or equal to about 1000 micrometers and wherein the sheet has a thickness of greater than or equal to about 1001 micrometers, and wherein the substrate is a polarizer in an optical device.
- 25. The method of claim 20, wherein the affixing comprises injection molding the substrate onto the sheet or film.
- 26. A method of substantially eliminating comets and veins in an optical film or sheet comprising:
annealing the film or sheet comprising a polymeric alloy to a temperature proximate to a glass transition temperature of a polymeric resin contained in the alloy.
- 27. The method of claim 26, wherein the annealing temperature is greater than or equal to about a highest glass transition temperature of the polymeric resins contained in the polymeric alloy.
- 28. The method of claim 26, wherein the annealing is conducted at a temperature of greater than or equal to about 10° C. below the lowest glass transition temperature of the alloy.
- 29. The method of claim 26, wherein the annealing temperature is greater than a glass transition temperature of the polymeric alloy.
- 30. The method of claim 26, wherein the film or sheet has a birefringence retardation of less than or equal to about 150 nm after the annealing, and wherein the optical transmissivity is greater than or equal to about 85%.
- 31. The method of claim 26, wherein the alloy comprises a polycarbonate-polyester blend.
- 32. The method of claim 31, wherein the polycarbonate-polyester blend comprises polycarbonate-poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate).
- 33. The method of claim 32, wherein the polycarbonate has a number average molecular weight of about 10,000 to about 35,000 g/mole when measured using a polystyrene standard, and wherein the poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate) has an intrinsic viscosity of about 0.82 to about 1.12.
- 34. The method of claim 26, further comprising deforming the sheet or the film at a temperature effective to impart to the sheet or film a birefringence retardation of greater than or equal to about 350 nanometers.
- 35. The method of claim 26, further comprising affixing the sheet or film to a substrate that is used as an optical device.
- 36. The method of claim 35, wherein the polymeric alloy is in the form of a film of thickness of less than or equal to about 1000 micrometers and the substrate is a polarizer in a polarizing optical sheet.
- 37. The method of claim 35, wherein the affixing comprises injection molding the sheet or film to the substrate to form a multilayered composite.
- 38. The method of claim 35, wherein the affixing comprises back molding the substrate to the alloy to form a multilayered composite.
- 39. The method of claim 35, wherein the affixing comprises coextruding the substrate with the sheet or film to form a multilayered composite.
- 40. The method of claim 26, further comprising deforming the multilayered composite to form an article.
- 41. The method of claim 40, wherein the deforming comprises thermoforming.
- 42. A composition comprising:
a first polymeric resin in an amount of about 1 to about 99 wt %; and a second polymeric resin in an amount of about 1 to about 99 wt %, wherein the polymeric resins are treated with a deforming force or with an energy effective to produce a polymeric alloy having a birefringence retardation of greater than or equal to about 350 nanometers or with a birefringence retardation of less than or equal to about 150 nanometers.
- 43. The composition of claim 42, wherein the first and second polymeric resins are thermoplastic resins and wherein the composition has a transmissivity of greater than or equal to about 86%.
- 44. The composition of claim 42, wherein the first and second polymeric resins are not chemically identical and are polyethylene, polypropylene, polyamide, polyester, polyimide, polyacetal, polyacrylic, polycarbonate, polystyrene, polyamideimide, polyarylate, polyacrylate, polymethacrylate, polyurethane, polyarylsulfone, polyethersulfone, polyarylene sulfide, polyvinyl chloride, polysulfone, polyetherimide, polytetrafluoroethylene, polyetherketone, polyether etherketone, polyarylene ether, liquid crystalline polymer, or a combination comprising at least one of the foregoing thermoplastics.
- 45. The composition of claim 42, wherein the polyester is polyethelene terephthalate, polybutylene terephthalate, poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate), poly(trimethylene terephthalate), poly(cyclohexanedimethanol-co-ethylene glycol terephthalate), a blend comprising the copolymer of 100 mole percent terephthalic acid, about 60 to about 90 mole percent 1,4-cyclohexanedimethanol and about 10 to about 40 mole percent ethylene glycol, or a blend comprising a copolymer of 100 mole percent cyclohexane dimethanol, 1 to 100 mole percent terephthalic acid and 1 to 100 mole percent isophthalic acid.
- 46. The composition of claim 42, wherein the first polymeric resin is a polycarbonate having a molecular weight of about 10,000 g/mole to about 65,000 g/mole as measured using a polystyrene standard and the second polymeric resin is polyester, and wherein the composition has a glass transition temperature of less than or equal to about 200° C.
- 47. The composition of claim 46, wherein the polyester comprises poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate) having an intrinsic viscosity of about 0.82 to about 1.12.
- 48. An optical device manufactured by the method of claim 1.
- 49. An optical device manufactured by the method of claim 26.
- 50. An film or sheet manufactured from the composition of claim 42.
- 51. An optical device manufactured from the composition of claim 42.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/467,630 filed May 2, 2003 and U.S. Provisional Application Serial No. 60/524,790, filed Nov. 25, 2003.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60467630 |
May 2003 |
US |
|
60524790 |
Nov 2003 |
US |