OPTICAL ARTICLE AND METHOD OF MAKING
First Claim
1. An optical article, comprising:
- a top layer having a top structured surface that collimates light;
a core layer secured to the top layer opposite the top structured surface; and
a bottom layer secured to the core layer opposite the top layer;
wherein;
either the top layer or the core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and
the bottom layer comprises a third extrudable polymer.
1 Assignment
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Accused Products
Abstract
Disclosed herein is an optical article having a top layer with a structured surface that collimates light, a core layer secured to the top layer opposite the structured surface, and a bottom layer secured to the core layer opposite the top layer. Either the top layer or the core layer includes a first extrudable polymer having a flexural modulus of greater than 2.5 GPa, and the other layer includes a second extrudable polymer having a flexural modulus of 2.5 GPa or less, an impact strength of greater than about 40 J/m, and tensile elongation at break of greater than about 5%. The bottom layer includes a third extrudable polymer. The bottom layer of the optical article may be structured to diffuse light. One or two optical articles may be secured to an optical film such as a polarizer film. Methods and display devices are also disclosed herein.
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Citations
49 Claims
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1. An optical article, comprising:
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a top layer having a top structured surface that collimates light; a core layer secured to the top layer opposite the top structured surface; and a bottom layer secured to the core layer opposite the top layer; wherein; either the top layer or the core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and the bottom layer comprises a third extrudable polymer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 33, 34, 43, 46, 47)
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29. A method of making an optical article, comprising:
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providing a first extrudable polymer having a flexural modulus greater than 2.5 GPa as measured according to ASTM D790; providing a second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and a tensile elongation at break of greater than about 5% as measured according to ASTM D638; providing a third extrudable polymer; coextruding the first, second, and third extrudable polymers to form top, core, and bottom layers, respectively, the core layer secured to the top and bottom layers; and structuring a top surface of the top layer using a molding tool, thereby forming a top structured surface that collimates light. - View Dependent Claims (30)
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31. A method of making an optical article, comprising:
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providing a first extrudable polymer having a flexural modulus greater than 2.5 GPa as measured according to ASTM D790; providing a second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and a tensile elongation at break of greater than about 5% as measured according to ASTM D638; providing a third extrudable polymer; coextruding the second, first, and third extrudable polymers to form top, core, and bottom layers, respectively, the core layer secured to the top and bottom layers; and structuring a top surface of the top layer using a molding tool, thereby forming a top structured surface that collimates light. - View Dependent Claims (32)
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35. An optical body comprising:
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a first optical article comprising; a first top layer having a first top structured surface that collimates light; a first core layer secured to the first top layer opposite the first top structured surface; and a first bottom layer secured to the first core layer opposite the first top layer; wherein; either the first top layer or the first core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and the first bottom layer comprises a third extrudable polymer; a second optical article comprising; a second top layer having a second top structured surface that diffuses light; a second core layer secured to the second top layer opposite the second top structured surface; and a second bottom layer secured to the second core layer opposite the second top layer; wherein; either the second top layer or the second core layer comprises a fourth extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a fifth extrudable polymer, the fifth extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and the second bottom layer comprises a sixth extrudable polymer; and an optical film secured to the first and second bottom layers, the optical film comprising a polarizer film, a reflective polarizer film, a diffuse blend reflective polarizer film, a diffuser film, a brightness enhancing film, a turning film, a mirror film, or a combination thereof. - View Dependent Claims (36, 37, 38, 48)
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39. An optical body comprising:
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a first optical article comprising; a first top layer having a first top structured surface that collimates light; a first core layer secured to the first top layer opposite the first top structured surface; and a first bottom layer secured to the first core layer opposite the first top layer; wherein; either the first top layer or the first core layer comprises a first extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, and the other layer comprises a second extrudable polymer, the second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and the first bottom layer comprises a third extrudable polymer; a second optical article comprising; a second top layer having a second top structured surface that diffuses light; and a second bottom layer secured to the second top layer opposite the second top structured surface; wherein; the second top layer comprises either; a fourth extrudable polymer having a flexural modulus of greater than 2.5 GPa as measured according to ASTM D790, or a fifth extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and tensile elongation at break of greater than about 5% as measured according to ASTM D638; and the second bottom layer comprises a sixth extrudable polymer; and an optical film secured to the first and second bottom layers, the optical film comprising a polarizer film, a reflective polarizer film, a diffuse blend reflective polarizer film, a diffuser film, a brightness enhancing film, a turning film, a mirror film, or a combination thereof. - View Dependent Claims (40, 41, 42, 49)
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44. A method of making an optical body, comprising:
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providing a first extrudable polymer having a flexural modulus greater than 2.5 GPa as measured according to ASTM D790; providing a second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and a tensile elongation at break of greater than about 5% as measured according to ASTM D638; providing a third extrudable polymer; coextruding the first, second, and third extrudable polymers onto an optical film to form top, core, and bottom layers, respectively, on the optical film, the core layer secured to the top and bottom layers, the optical film secured to the bottom layer opposite the core layer; and contacting the top layer with a molding tool thereby forming a top structured surface that collimates light.
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45. A method of making an optical body, comprising:
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providing a first extrudable polymer having a flexural modulus greater than 2.5 GPa as measured according to ASTM D790; providing a second extrudable polymer having a flexural modulus of 2.5 GPa or less as measured according to ASTM D790, an impact strength of greater than about 40 J/m as measured according to ASTM D256, and a tensile elongation at break of greater than about 5% as measured according to ASTM D638; providing a third extrudable polymer; coextruding the second, first, and third extrudable polymers onto an optical film to form top, core, and bottom layers, respectively, on the optical film, the core layer secured to the top and bottom layers, the optical film secured to the bottom layer opposite the core layer; and contacting the top layer with a molding tool thereby forming a top structured surface that collimates light.
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Specification