Optical bodies and methods for making optical bodies

• US 20060093809A1
• Filed: 10/29/2004
• Published: 05/04/2006
• Est. Priority Date: 10/29/2004
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Hebrink, Timothy J., Taylor, Robert D., Derks, Kristopher J., Strobel, Joan M., Bluem, Gregory L., Black, William B., Rosell, Barry S., Hamer, Kevin M., Purcell, John P.
• Application Number:
  US10/977,211
• Publication Number:
  US 20060093809A1
• Time in Patent Office: Days
• US Class Current: 428/323
• CPC Class Codes: B29C 55/023 using multilayered plates or sheets
• CPC Class Codes: B32B 2260/025 Particulate layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2457/202 LCD, i.e. liquid crystal displays
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 27/325 comprising polycycloolefins
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/14 characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 7/06 permitting easy separation
• CPC Class Codes: C09D 5/20 for coatings strippable as coherent films, e.g. temporary coatings strippable as coherent films
• CPC Class Codes: G02B 5/00 Optical elements other than lenses light guides G02B6/00; optical logic elements G02F3/00
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

Optical bodies are disclosed that include an optical film and at least one rough strippable skin layer operatively connected to a surface of the optical film. The at least one rough strippable skin layer can include a continuous phase and a disperse phase. Alternatively, the at least one rough strippable skin layer can include a first polymer, a second polymer different from the first polymer and an additional material that is substantially immiscible in at least one of the first and second polymers. In some exemplary embodiments, a surface of the at least one rough strippable skin layer adjacent to the optical film comprises a plurality of protrusions and the adjacent surface of the optical film comprises a plurality of asymmetric depressions substantially corresponding to said plurality of protrusions. In addition, optical bodies are disclosed that include an optical film having a surface with asymmetric depressions, the asymmetric depressions having a major dimension substantially collinear with a major axis of the optical film and a minor direction substantially collinear with a minor axis of the optical film. Methods of making such exemplary optical bodies are also disclosed.

Claims

1. An optical body, comprising:

an optical film; and

at least one rough strippable skin layer operatively connected to an adjacent surface of the optical film, the at least one rough strippable skin layer comprising;

a first polymer,

a second polymer different from the first polymer,

and an additional material that is substantially immiscible in at least one of the first and second polymers.

2. The optical body of claim 1, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 2 to about 120 g/in.

3. The optical body of claim 1, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 4 to about 50 g/in.

4. The optical body of claim 1, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 5 to about 35 g/in.

5. The optical body of claim 1, wherein the first polymer has a crystallinity that is lower than a crystallinity of the second polymer.

6. The optical body of claim 1, wherein the material substantially immiscible in at least one of the first and second polymers comprises a third polymer.

7. The optical body of claim 6, wherein the third polymer is selected from the group consisting of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene and polymethyl methacrylate.

8. The optical body of claim 1, wherein the material substantially immiscible in at least one of the first and second polymers includes inorganic material.

9. The optical body of claim 1, wherein the first polymer is selected from the group consisting of:

syndiotactic polypropylene, polypropylene copolymer, linear low density polyethylene and random copolymer of propylene and ethylene.

10. The optical body of claim 1, wherein the second polymer is selected from the group consisting of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene and polymethyl methacrylate.

11. The optical body of claim 1, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

12. The optical body of claim 1, wherein the optical film comprises at least one underskin layer.

13. The optical body of claim 12, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

14. The optical body of claim 12, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

15. The optical body of claim 1, wherein the optical body comprises at least two rough strippable skin layers operatively connected to each of two opposing sides of the optical film.

16. The optical body of claim 1, wherein the rough strippable skin layer further comprises a coloring agent.

17. The optical body of claim 1, said optical body being substantially transparent.

18. The optical body of claim 1, wherein the optical body comprises a birefringent material.

19. The optical body of claim 1, further comprising at leas one smooth outer skin layer disposed over the at least one rough strippable skin layer.

20. An optical body, comprising:

an optical film having a major axis and a minor axis; and

at least one rough strippable skin layer operatively connected to an adjacent surface of the optical film, the at least one rough strippable skin layer comprising a continuous phase and a disperse phase;

wherein a surface of the at least one rough strippable skin layer adjacent to the optical film comprises a plurality of protrusions and the adjacent surface of the optical film comprises a plurality of asymmetric depressions substantially corresponding to said plurality of protrusions.

21. The optical body of claim 20, wherein the asymmetric protrusions have a major dimension substantially collinear with the major axis and a minor dimension substantially collinear with the minor dimension.

22. The optical body of claim 21, wherein an average ratio of the major dimension to the minor dimension is at least about 1.5.

23. The optical body of claim 21, wherein an average ratio of the major dimension to the minor dimension is from about 1.5 to about 23.

24. The optical body of claim 20, wherein the continuous phase comprises a first polymer and the disperse phase comprises a second polymer that is substantially immiscible in the first polymer.

25. The optical body of claim 24, wherein the at least one rough strippable skin further comprises a nucleating agent.

26. The optical body of claim 24, wherein the first polymer has a crystallinity that is lower than a crystallinity of the second polymer.

27. The optical body of claim 24, wherein the first polymer is selected from the group consisting of:

syndiotactic polypropylene, linear low density polyethylene and random copolymer of propylene and ethylene.

28. The optical body of claim 24, wherein the second polymer is selected from the group consisting of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene and polymethyl methacrylate.

29. The optical body of claim 20, wherein the disperse phase includes inorganic material.

30. The optical body of claim 20, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

31. The optical body of claim 20, wherein the optical film comprises at least one underskin layer.

32. The optical body of claim 31, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

33. The optical body of claim 31, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

34. The optical body of claim 20, wherein the optical body comprises at least two rough strippable skin layers operatively connected to each of two opposing sides of the optical film.

35. The optical body of claim 20, wherein the rough strippable skin layer further comprises a coloring agent.

36. The optical body of claim 20, said optical body being substantially transparent.

37. The optical body of claim 20, wherein the optical body comprises a birefringent material.

38. The optical body of claim 20, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 2 to about 120 g/in.

39. The optical body of claim 20, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 4 to about 50 g/in.

40. The optical body of claim 20, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 5 to about 35 g/in.

41. The optical body of claim 20, further comprising at least one smooth outer skin layer disposed over the at least one rough strippable skin layer.

42. An optical body, comprising:

an optical film having a first surface, a major axis and a minor axis, said first surface comprising a plurality of asymmetric depressions, each asymmetric depression having a major dimension substantially collinear with the major axis and a minor direction substantially collinear with the minor axis.

43. The optical body of claim 42, wherein the first major surface comprises a birefringent material.

44. The optical body of claim 42, wherein the asymmetric depressions have an average depth from about 0.2 micron to about 4 microns.

45. The optical body of claim 42, wherein the asymmetric depressions have an average minor dimension from about 0.2 micron to about 5 microns.

46. The optical body of claim 42, wherein the asymmetric depressions have an average major dimension from about 4 micron to about 40 microns.

47. The optical body of claim 42, wherein the asymmetric depressions have an average ratio of the major dimension to the minor dimension from about 1.1 to about 23.

48. The optical body of claim 42, wherein the optical film is characterized by a haze of at least about 10%.

49. The optical body of claim 42, wherein the optical film is characterized by a haze of at least about 35%.

50. The optical body of claim 42, wherein the optical film is characterized by a haze of at least about 50%

51. The optical body of claim 42, wherein the first surface of the optical film is characterized by a Bearing Ratio Rvk of at least about 130 nm.

52. The optical body of claim 42, wherein the first surface of the optical film is characterized by Bearing Ratio Rpk of at least about 200 nm.

53. The optical body of claim 42, wherein the first surface of the optical film is characterized by Stylus Rv of at least about 100 nm.

54. The optical body of claim 42, wherein the first surface of the optical film is characterized by Stylus Rvk of at least about 50 nm.

55. The optical body of claim 42, wherein the optical film comprises at least one of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, and a layer comprising a cycloaliphatic polyester/polycarbonate.

56. The optical body of claim 42, wherein the optical film comprises at least one underskin layer.

57. The optical body of claim 56, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

58. The optical body of claim 56, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

59. An optical body, comprising:

an optical film; and

at least one rough strippable skin layer operatively connected to a surface of the optical film, the at least one rough strippable skin layer comprising a continuous phase and a disperse phase, said continuous phase comprising at least one of;

a polypropylene, a polyester, a linear low density polyethylene, a nylon and copolymers thereof.

60. The optical body of claim 59, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 2 to about 120 g/in.

61. The optical body of claim 59, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 4 to about 50 g/in.

62. The optical body of claim 59, wherein the at least one rough strippable skin layer has adhesion to the adjacent surface of the optical film characterized by a peel force of about 5 to about 35 g/in.

63. The optical body of claim 59, wherein the disperse phase comprises a polymer that is substantially immiscible in the continuous phase.

64. The optical body of claim 63, wherein the at least one rough strippable skin further comprises a nucleating agent.

65. The optical body of claim 63, wherein the polymer of the disperse phase has a crystallinity that is higher then a crystallinity of the continuous phase.

66. The optical body of claim 63, wherein the disperse phase comprises at least one of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene, CaCO₃ and polymethyl methacrylate.

67. The optical body of claim 59, wherein the continuous phase comprises at least one of:

syndiotactic polypropylene, linear low density polyethylene and random copolymer of propylene and ethylene.

68. The optical body of claim 59, wherein the disperse phase includes inorganic material.

69. The optical body of claim 59, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

70. The optical body of claim 59, wherein the optical film comprises at least one underskin layer.

71. The optical body of claim 70, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

72. The optical body of claim 70, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

73. The optical body of claim 59, wherein the optical body comprises at least two rough strippable skin layers operatively connected to each of two opposing sides of the optical film.

74. The optical body of claim 59, wherein the rough strippable skin layer further comprises a coloring agent.

75. The optical body of claim 59, said optical body being substantially transparent.

76. The optical body of claim 59, wherein the optical body comprises a birefringent material.

77. The optical body of claim 59, further comprising at least one smooth outer skin layer disposed over the at least one rough strippable skin layer.

78. A method of making an optical body, comprising the steps of:

disposing at least one rough strippable skin layer on an adjacent surface of an optical film, such that the at least one rough strippable skin layer is operatively connected to the adjacent surface of the optical film, the at least one strippable skin layer comprising a first polymer, a second polymer different from the first polymer, and an additional material that is substantially immiscible in at least one of the first and second polymers.

79. The method of claim 78, wherein the first polymer is selected from the group consisting of:

syndiotactic polypropylene, linear low density polyethylene and random copolymer of propylene and ethylene.

80. The method of claim 78, wherein the second polymer is selected from the group consisting of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene and polymethyl methacrylate.

81. The method of claim 78, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

82. The method of claim 78, wherein the optical film comprises at least one underskin layer.

83. The method of claim 82, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

84. The optical body of claim 82, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

85. The method of claim 78, wherein two rough strippable skin layers are disposed on two opposing surfaces of the optical film.

86. The method of claim 78, wherein the rough strippable skin layer further comprises a coloring agent.

87. The method of claim 78, further comprising disposing at least one smooth outer skin layer disposed over the at least one rough strippable skin layer.

88. The method of claim 78, wherein the step of disposing comprises co-extruding, coating, casting or laminating the at least one rough strippable skin layer with the optical film.

89. The method of claim 78, wherein disposing at least one rough strippable skin layer on an adjacent surface of an optical film comprises forming the at least one rough strippable skin layer on said optical film.

90. The method of making an optical body of claim 78, further comprising orienting the optical body.

91. The method of forming an optical body according to claim 90, wherein orienting comprises stretching the rough strippable skin layer with the optical film.

92. The method of forming an optical body according to claim 90, wherein orienting comprises uniaxial stretching.

93. The method of forming an optical body according to claim 90, wherein orienting comprises biaxial stretching.

94. The method of forming an optical body according to claim 93, wherein the biaxial stretching is unbalanced in at least two substantially orthogonal directions.

95. The method of forming an optical body according to claim 93, wherein the unbalanced stretching has a draw ratio of from about 1.1 to about 8.

96. A method of making an optical body, comprising the steps of:

disposing at least one rough strippable skin layer on an adjacent surface of an optical film, such that the at least one rough strippable skin layer is operatively connected to the adjacent surface of the optical film, the at least one strippable skin layer comprising a continuous phase and a disperse phase; and

subjecting the optical film together with the at least one rough strippable skin layer to uniaxial or unbalanced biaxial orientation.

97. The method of claim 96, wherein the continuous phase comprises at least one of:

syndiotactic polypropylene, linear low density polyethylene and random copolymer of propylene and ethylene.

98. The method of claim 96, wherein the disperse phase comprises at least one of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene)copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene, CaCO₃ and polymethyl methacrylate.

99. The method of claim 96, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

100. The method of claim 96, wherein the optical film comprises at least one underskin layer.

101. The method of claim 100, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

102. The optical body of claim 100, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

103. The method of claim 96, wherein two rough strippable skin layers are disposed on two opposing surfaces of the optical film.

104. The method of claim 96, wherein the rough strippable skin layer further comprises a coloring agent.

105. The method of claim 96, further comprising disposing at least one smooth outer skin layer disposed over the at least one rough strippable skin layer.

106. The method of claim 96, wherein the step of disposing comprises co-extruding, coating, casting or laminating the at least one rough strippable skin layer with the optical film.

107. The method of claim 96, wherein disposing at least one rough strippable skin layer on an adjacent surface of an optical film comprises forming the at least one rough strippable skin layer on said optical film.

108. The method of forming an optical body according to claim 96, wherein orienting comprises stretching the rough strippable skin layer with the optical film.

109. The method of forming an optical body according to claim 108, wherein the unbalanced stretching has a draw ratio of from about 1.1 to about 8.

110. A method of making an optical body, comprising the step of:

disposing at least one rough strippable skin layer on an adjacent surface of an optical film, such that the at least one rough strippable skin layer is operatively connected to the adjacent surface of the optical film, the at least one strippable skin layer comprising a continuous phase and a disperse phase, said continuous phase comprising at least one of;

a polypropylene, a polyester, a linear low density polyethylene, a nylon and copolymers thereof.

111. The method of claim 110, wherein the continuous phase comprises at least one of:

syndiotactic polypropylene and random copolymer of propylene and ethylene.

112. The method of claim 110, wherein the disperse phase comprises at least one of:

styrene acrylonitrile, medium density polyethylene, modified polyethylene, polycarbonate and copolyester blend, ε

-caprolactone polymer, propylene random copolymer, poly(ethylene octene) copolymer, anti-static polymer, high density polyethylene, linear low density polyethylene, CaCO₃ and polymethyl methacrylate.

113. The method of claim 110, wherein the optical film is selected from the group consisting of:

a multilayer polarizer, a multilayer reflector, an optical film having a continuous and a disperse phase, a layer comprising styrene acrylonitrile, a layer comprising polycarbonate, a layer comprising PET, a layer comprising a cycloaliphatic polyester/polycarbonate and any number or combination thereof.

114. The method of claim 110, wherein the optical film comprises at least one underskin layer.

115. The method of claim 114, wherein the underskin layer comprises styrene acrylonitrile, polycarbonate, PET or cycloaliphatic polyester/polycarbonate.

116. The optical body of claim 114, wherein the underskin layer comprises a first material and a second material substantially immiscible in the first material, said second material being polymeric or inorganic.

117. The method of claim 110, wherein two rough strippable skin layers are disposed on two opposing surfaces of the optical film.

118. The method of claim 110, wherein the rough strippable skin layer further comprises a coloring agent.

119. The method of claim 110, further comprising disposing at least one smooth outer skin layer disposed over the at least one rough strippable skin layer.

120. The method of claim 110, wherein the step of disposing comprises co-extruding, coating, casting or laminating the at least one rough strippable skin layer with the optical film.

121. The method of claim 110, wherein disposing at least one rough strippable skin layer on an adjacent surface of an optical film comprises forming the at least one rough strippable skin layer on said optical film.

122. The method of making an optical body of claim 110, further comprising orienting the optical body.

123. The method of forming an optical body according to claim 122, wherein orienting comprises stretching the rough strippable skin layer with the optical film.

124. The method of forming an optical body according to claim 122, wherein orienting comprises uniaxial stretching.

125. The method of forming an optical body according to claim 122, wherein orienting comprises biaxial stretching.

126. The method of forming an optical body according to claim 125, wherein the biaxial stretching is unbalanced in at least two substantially orthogonal directions.

127. The method of forming an optical body according to claim 125, wherein the unbalanced stretching has a draw ratio of from about 1.1 to about 8.