Method for making a polarization-sensitive optical element

• US 5,999,239 A
• Filed: 06/29/1998
• Issued: 12/07/1999
• Est. Priority Date: 04/07/1995
• Status: Expired due to Term

• Current Assignee: Honeywell Incorporated (Honeywell International Inc.)
• Original Assignee: Honeywell Incorporated (Honeywell International Inc.)
• Inventors: Larson, Brent D.
• Primary Examiner(s): Sikes, William L.
• Assistant Examiner(s): DUDEK, JAMES A
• Application Number:
  US09/106,996
• Time in Patent Office: 526 Days
• Field of Search: 349/87, 349/96, 349/62, 349/67, 359/494, 359/487
• US Class Current: 349/96
• CPC Class Codes: G02B 19/0047 for use with a light source G02B19/009, G02B19/0095 take precedence; details of lighting devices in general F21V; non-semiconductor lasers having optical devices external to the laser cavity H01S3/005
• CPC Class Codes: G02B 27/283 used for beam splitting or combining
• CPC Class Codes: G02B 27/286 for controlling or changing the state of polarisation, e.g. transforming one polarisation state into another G02B5/3083 takes precedence; light guide coupling means utilising polarising elements G02B6/34
• CPC Class Codes: G02B 3/005 arranged along a single direction only, e.g. lenticular sheets G02B3/0043 takes precedence
• CPC Class Codes: G02B 3/0056 arranged along two different directions in a plane, e.g. honeycomb arrangement of lenses G02B3/0043 takes precedence; miniaturised objectives for electronic devices employing wafer level optics G02B13/0085
• CPC Class Codes: G02B 5/3008 comprising dielectric particles, e.g. birefringent crystals embedded in a matrix
• CPC Class Codes: G02B 5/3033 in the form of a thin sheet or foil, e.g. Polaroid
• CPC Class Codes: G02B 5/305 including organic materials, e.g. polymeric layers
• CPC Class Codes: G02B 5/3083 Birefringent or phase retarding elements G02B5/3008, G02B5/3016 take precedence; systems for polarisation control G02B27/286; manufacturing phase modulating patterns by lithographic processes G03F7/001
• 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: G02F 1/133504 Diffusing, scattering, diffracting elements associated to illuminating devices G02F1/133606
• CPC Class Codes: G02F 1/133528 Polarisers
• CPC Class Codes: G02F 1/133536 Reflective polarizers G02F1/13362 takes precedence
• CPC Class Codes: G02F 1/13362 providing polarized light, e.g. by converting a polarisation component into another one
• CPC Class Codes: G02F 1/133638 Waveplates, i.e. plates with a retardation value of lambda/n
• CPC Class Codes: G02F 2203/03 scattering
• CPC Class Codes: G03B 21/604 Polarised screens

Abstract

An image display apparatus which employs a polarization-sensitive scattering element (PSSE). In the display, a light source is used to illuminate a panel which modulates light in order to form an image. Positioned between the light source and the panel is the PSSE which acts to effectively separate light of different polarizations. The PSSE provides a means for recapturing light energy which would otherwise be lost in the display, while reducing degradation and heat build-up due to light absorption.

Claims

1. A method for producing a polarization-sensitive optical element, comprising the steps of:

providing a composition, the composition comprising at least two materials, wherein at least one of the two materials is a birefringent material; and

operating on the composition such it has a first scattering distribution to receive light rays of a first polarization, wherein the first scattering distribution is such that the light rays of the first polarization are randomly diffuse and back scattered, and a second scattering distribution to receive light rays of a second polarization.

2. The method of claim 1, wherein the second scattering distribution is such that the light rays of the second polarization are substantially non-scattered.

3. The method of claim 1, wherein the composition is comprised of distinct domains of a first material disposed within a matrix of a second material.

4. The method of claim 1, wherein the composition is comprised of interconnected domains of a first material disposed within a matrix of a second material.

5. The method of claim 1, wherein the step of providing a composition comprises the step of:

selecting a liquid crystal material and a polymer material to form the composition; and

selecting refractive indices of the liquid crystal material such that a first index of refraction of the liquid crystal material matches a corresponding first index of refraction of the polymer material;

and wherein the step of operating on the composition comprises the steps of;

disposing the liquid crystal material in the polymer material; and

orienting the plurality of droplets in the polymer material in at least one direction.

6. The method of claim 5, wherein the liquid crystal material is disposed in the form of a plurality of droplets.

7. The method of claim 5, wherein the polymer material is a matrix that surrounds the liquid crystal material.

8. The method of claim 5, wherein the liquid crystal material forms a network of interconnected domains in a polymer matrix.

9. The method of claim 5, wherein the polymer material is birefringent.

10. The method of claim 5, wherein the polymer material is non-birefringent.

11. The method of claim 5, wherein the at least one direction is a common direction.

12. The method of claim 5, wherein the at least one direction is a uniaxial direction.

13. The method of claim 5, wherein the step of disposing the liquid crystal material comprises the step of forming the plurality of droplets so that they are distinct with respect to each other.

14. The method of claim 5, wherein the step of disposing the liquid crystal material comprises the step of forming the plurality of droplets so that they are interconnected with respect to each other.

15. The method of claim 5, wherein the step of orienting comprises the step of physically orienting the plurality of droplets.

16. The method of claim 15, wherein the step of physically orienting comprises the step of stretching the plurality of droplets.

17. The method of claim 5, wherein the step of orienting comprises the step of applying an electric field to orient the plurality of droplets.

18. The method of claim 5, wherein the step of orienting comprises the step of applying an electro-magnetic field to orient the plurality of droplets.

19. The method of claim 5, wherein the liquid crystal material is a polymeric liquid crystal material.

20. The method of claim 5, further comprising the step of converting the liquid crystal material to a polymer material.

21. The method of claim 5, wherein the first index of refraction of the liquid crystal material is an ordinary index of refraction.

22. The method of claim 5, wherein the first index of refraction of the liquid crystal material is an extraordinary index of refraction.

23. The method of claim 5, wherein the first index of refraction of the liquid crystal material is an ordinary index of refraction and the corresponding first index of refraction of the polymer material is an ordinary index of refraction.

24. The method of claim 5, wherein the step of selecting further comprises the step of selecting the refractive indices of the liquid crystal material such that a second index of refraction of the liquid crystal material mismatches a corresponding second index of refraction of the polymer material.

25. The method of claim 1, wherein the step of providing a composition comprises the step of:

disposing a plurality of elements within either a birefringent or non-birefringent matrix to form the composition; and

orienting the plurality of elements with respect to each other along a common axis.

26. The method of claim 25, wherein the plurality of elements are fibers.

27. The method of claim 25, wherein the plurality of elements are particles.

28. The method of claim 27, wherein the particles are birefringent crystals.

29. The method of claim 26, wherein the fibers are comprised of a birefringent material.

30. The method of claim 25, wherein the plurality of elements are comprised of a substantially non-birefringent material and the matrix is birefringent.

31. The method of claim 25, wherein the plurality of elements are comprised of a birefringent material.

32. The method of claim 25, wherein the plurality of elements are glass.

33. The method of claim 25, wherein the plurality of elements are polymers.

34. The method of claim 26, wherein the fibers are elongated along one axis.

35. The method of claim 26, wherein the fibers comprise a plurality of dopant particles.

36. The method of claim 25, wherein the matrix is in the form of a fiber.

37. The method of claim 36, wherein the fiber comprises birefringent particles and the matrix is birefringent.

38. The method of claim 36, wherein the fiber comprises birefringent particles and the matrix is non-birefringent.

39. The method of claim 36, wherein the fiber comprises non-birefringent particles and the matrix is birefringent.

40. The method of claim 26, further comprising the step of:

selecting refractive indices of the fibers such that a first index of refraction of the fibers matches a corresponding first index of refraction of the birefringent matrix.

41. The method of claim 25, wherein the matrix is a polymer material.

42. The method of claim 25, wherein the plurality of elements are non-birefringent and the matrix is birefringent.

43. The method of claim 1, wherein the step of operating on the composition comprises the step of generating domains in the composition from a single material.

44. The method of claim 1, wherein the composition is comprised of domains of at least two polymer types, wherein the domains have a common index of refraction and an opposite birefringence.

45. The method of claim 1, wherein the composition is comprised of domains of at least two polymer types, wherein the domains have a common index of refraction and a different birefringence.

46. The method of claim 1, wherein the composition is comprised of domains of at least two polymer types, wherein the index of refraction of the domains along a first axis are matched and the index of refraction of the domains along a second axis are mismatched.

47. The method of claim 1, wherein the step of operating on the composition comprises the step of forming alternating domains from a single material.

48. A method for producing a polarization-sensitive optical element, comprising the steps of:

providing a composition, the composition comprising composites material domains in a matrix; and

operating on the composition such it has a first scattering distribution to receive light rays of a first polarization, wherein the first scattering distribution is such that the light rays of the first polarization are back scattered, and a second scattering distribution to receive light rays of a second polarization.

49. The method of claim 48, wherein the material domains are non-birefringent.

50. The method of claim 48, wherein the material domains are substantially non-birefringent.

51. The method of claim 48, wherein the matrix is non-birefringent.

52. The method of claim 48, wherein the matrix is substantially non-birefringent.

53. The method of claim 48, wherein the matrix is birefringent.

54. The method of claim 48, wherein the birefringent matrix is a polymer material.

55. The method of claim 48, further comprising the step of controlling the first scattering distribution of the first polarization by, controlling the surface texture of the optical element.

56. The method of claim 55, wherein the composition comprises a plurality of elements oriented along a common axis and disposed within the birefringent matrix.

57. The method of claim 48, further comprising the step of controlling the first scattering distribution of the first polarization by controlling a scale of the length of a refractive index variation in the axis of the first polarization.

58. The method of claim 48, wherein the material domains are distinct with respect to each other.

59. The method of claim 48, wherein the material domains are interconnected with respect to each other.

60. A method of producing a polarization-sensitive scattering element to improve the efficiency of a display, comprising the steps of:

providing a composite of material domains in a matrix; and

using the composite to recapture a loss of polarization in a diffusely illuminated housing by passing a desired polarization to an area external to the housing and reflecting an undesired polarization to an area internal to the housing.

61. The method of claim 60, wherein the matrix is birefringent.

62. The method of claim 60, wherein the matrix is non-birefringent.