Variable index light extraction layer and method of making the same

• US 10,139,550 B2
• Filed: 08/21/2013
• Issued: 11/27/2018
• Est. Priority Date: 08/24/2012
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Thompson, David Scott, Dodds, Shawn C., Pekurovsky, Mikhail L., Schaffer, Kevin R., Stay, Matthew S., Solomonson, Steven D., Wheatley, John A., Yang, Zhaohui, Woody, V, Joseph W.
• Primary Examiner(s): Guharay, Karabi
• Application Number:
  US14/423,654
• Publication Number:
  US 20150192728A1
• Time in Patent Office: 1,924 Days
• CPC Class Codes: G02B 6/0005 the light guides being of the fibre type G02B6/0003 takes precedence
• CPC Class Codes: G02B 6/0043 provided on the surface of the light guide
• CPC Class Codes: G02B 6/005 provided by one optical element, or plurality thereof, placed on the light output side of the light guide
• CPC Class Codes: G02B 6/0055 Reflecting element, sheet or layer
• CPC Class Codes: G02B 6/006 to produce indicia, symbols, texts or the like
• CPC Class Codes: G02B 6/0063 for extracting light out both the major surfaces of the light guide
• CPC Class Codes: G02B 6/0065 Manufacturing aspects; Material aspects

Abstract

Variable index light extraction layers that contain a first region with a first material and a second region including a second material are described, where the first region has a lower effective index of refraction than the second region. Optical films and stacks may use the variable index light extraction layers in front lit or back lit display devices and luminaires.

Claims

1. A method of forming a variable index extraction layer, comprising

patterning a first substance on a substrate and overcoating a second substance to form a layer;

wherein first regions of the layer correspond to areas where the first substance was selectively printed and second regions of the layer correspond at least to areas between where the first substance was selectively printed;

wherein the first region has a lower effective index of refraction than the second region;

wherein a difference between an effective index of refraction of the first region and an effective index of refraction of the second region is greater than about 0.03;

wherein the first substance is a nanovoided polymeric material;

wherein the second substance is not a nanovoided polymeric material; and

wherein the first and second regions of the layer are disposed such that the layer selectively extracts guided mode light from the substrate based on the geometric arrangement of the first and second regions.

2. The method of claim 1, further comprising forming a plurality of optical microstructures on a major surface of the layer opposite the substrate.

3. The method of claim 2, wherein forming a plurality of optical microstructures of a major surface of the layer opposite the substrate uses a cast and cure method.

4. The method of claim 2, wherein the plurality of optical microstructures is a diffractive surface.

5. The method of claim 1, wherein patterning a first substance on a substrate uses flexographic printing.

6. The method of claim 1, wherein patterning a first substance on a substrate uses indirect gravure printing.

7. The method of claim 1, wherein patterning a first substance on a substrate uses direct gravure printing.

8. The method of claim 1, wherein patterning a first substance on a substrate uses inkjet printing.