Pre-stacked optical films

• US 20060158592A1
• Filed: 01/14/2005
• Published: 07/20/2006
• Est. Priority Date: 01/14/2005
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Marushin, Patrick H., Kotchick, Keith M., Freking, Anthony J., Ruegsegger, Michael L.
• Granted Patent: US 7,339,635 B2
• Time in Patent Office: Days
• US Class Current: 349/122
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/5042 covering both elements to be joined
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/1222 comprising at least a lapped joint-segment
• CPC Class Codes: B29C 66/1224 comprising at least a butt joint-segment
• CPC Class Codes: B29C 66/12461 being rounded, i.e. U-shaped or C-shaped
• CPC Class Codes: B29C 66/24244 forming a rectangle
• CPC Class Codes: B29C 66/53461 joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/61 Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms
• CPC Class Codes: C09K 2323/00 Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
• 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 6/0056 for producing polarisation effects, e.g. by a surface with polarizing properties or by an additional polarizing elements
• CPC Class Codes: G02B 6/0088 of the light guide or other optical sheets in the package
• CPC Class Codes: G02F 1/133507 Films for enhancing the luminance
• CPC Class Codes: G02F 1/133606 including a specially adapted diffusing, scattering or light controlling members
• CPC Class Codes: G02F 2202/28 Adhesive materials or arrangements
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/24612 Composite web or sheet

Abstract

Pre-aligned optical layers are stacked and arranged such that an adhesive layer, which is stacked onto the optical layers, contacts at least the uppermost layer and lowermost layer. The resulting subassemblies can be assembled into an optical display without individual handling of the layers, which reduces installation time and manufacturing costs.

Claims

1. An optical subassembly for use in an optical display, the optical subassembly comprising:

a plurality of stacked optical films having an uppermost film and a lowermost film; and

a first adhesive layer contacting the uppermost and lowermost films of the stack to hold the stack together as a unit, so that the stack can be assembled into an optical display without individual handling of the optical films of the stack.

2. The optical subassembly of claim 1 and further comprising:

at least one intermediate film between the uppermost and lowermost films of the stack.

3. The optical subassembly of claim 2 wherein edges of the optical films are staggered and further comprising:

a second adhesive layer between two adjacent films of the stack.

4. The optical subassembly of claim 2 wherein the optical films are configured such that each optical film contacts the first adhesive layer.

5. The optical subassembly of claim 4 wherein edges of the optical films and the first adhesive layer are staggered.

6. The optical subassembly of claim 1 wherein at least a portion of a perimeter of at least one optical film is shaped to allow the first adhesive layer to contact the lowermost film.

7. The optical subassembly of claim 1 wherein at least one optical film includes voids to allow the first adhesive layer to contact the lowermost film.

8. The optical subassembly of claim 1 and further comprising:

a light guide stacked under the lowermost film which is configured to allow the first adhesive layer to contact the light guide.

9. An optical film package comprising:

a light guide having a first perimeter;

an optical film unit comprising;

a plurality of stacked optical films, each optical film having a perimeter, the plurality of stacked optical films including first and second exterior optical films, the first exterior optical film being adjacent the light guide, at least a portion of a perimeter of the first exterior optical film being recessed from the first perimeter of the light guide such that a portion of the light guide is exposed, at least portions of perimeters of each remaining optical film being recessed such that a portion of at least the second exterior optical film is exposed; and

an adhesive layer having a second perimeter extending beyond the first perimeter of the light guide, the adhesive layer contacting the exposed portions of the optical films and light guide.

10. The optical film package of claim 9 wherein the adhesive layer has a frame-type shape.

11. The optical film package of claim 9 wherein the adhesive layer has a portion of a frame-type shape.

12. The optical film package of claim 9 wherein the plurality of stacked optical films are pre-aligned.

13. An optical display comprising:

a backlight unit;

a display panel unit; and

an optical film unit positioned between the backlight unit and the display panel unit, the optical film unit comprising a plurality of pre-aligned stacked optical films, wherein at least an uppermost optical film of the stack and a lowermost optical film of the stack contact an adhesive layer.

14. The optical display of claim 13 wherein the backlight unit further comprises:

a light guide; and

at least one light source.

15. The optical display of claim 13 wherein the adhesive layer secures the optical film unit to the display panel unit.

16. The optical display of claim 13 wherein the adhesive layer seals edges of the optical film unit such that there is no entry point for debris.

17. The optical display of claim 13 wherein the optical films each include at least one edge, which are serially recessed by distances.

18. The optical display of claim 13 wherein the distances are about 2.0 mm or less.

19. The optical display of claim 13 wherein the distances are about 1.0 mm or less.