Optical structures for diffusing light

• US 6,261,664 B1
• Filed: 10/04/1999
• Issued: 07/17/2001
• Est. Priority Date: 12/02/1996
• Status: Expired due to Fees

• Current Assignee: Advanced Display Technologies of Texas LLC (Advanced Display Technologies)
• Original Assignee: Honeywell International Inc.
• Inventors: Beeson, Karl, Zimmerman, Scott, Diaz, Jose, Maxfield, Mac
• Primary Examiner(s): Loney, Donald J.
• Application Number:
  US09/411,115
• Time in Patent Office: 652 Days
• Field of Search: 428/141, 428/156, 428/172, 428/220, 428/332, 428/913, 359/453, 359/455, 430/946, 430/14, 430/321, 362/317, 362/355
• US Class Current: 428/141
• CPC Class Codes: G02B 2006/12195 Tapering
• CPC Class Codes: G02B 5/0215 the surface having a regular structure
• CPC Class Codes: G02B 5/0231 the surface having microprismatic or micropyramidal shape macroscopic prism arrays G02B5/045
• CPC Class Codes: G02B 5/0242 by means of dispersed particles
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: G02B 5/0289 used as a transflector
• CPC Class Codes: G02B 6/1221 made from organic materials
• CPC Class Codes: G02B 6/241 Light guide terminations
• CPC Class Codes: G02F 1/133524 Light-guides, e.g. fibre-optic bundles, louvered or jalousie light-guides
• CPC Class Codes: G02F 1/133607 the light controlling member including light directing or refracting elements, e.g. prisms or lenses
• CPC Class Codes: G03B 21/625 Lenticular translucent screens
• CPC Class Codes: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10S 430/147 Lenticular
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24669 Aligned or parallel nonplanarities

Abstract

Optical diffusing structures can be fabricated from photopolymerizable material by directing light through a transparent or translucent substrate and then through the photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the material. The resultant structure can be utilized as a diffuser, a viewing screen, and in other applications, and can be combined with other light-directing structures such as arrays of tapered optical waveguides.

Claims

1. An optical diffuser comprising a polymerized material layer on a transparent or translucent substrate, which layer has a highly modulated surface having smooth bumps ranging from about 1 micron to about 20 microns in both height and width.

2. An optical diffuser as set forth in claim 1, where the substrate is fabricated from a material from one or more of the classes of (a) amorphous materials;

(b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and

(c) purely crystalline materials.

3. An optical diffuser as set forth in claim 1, where the polymerized material layer is fabricated from at least one photopolymerizable monomer or oligomer.

4. An optical diffuser as set forth in claim 1, where the polymerized material layer is fabricated from at least one photopolymerizable monomer or oligomer, and a photoinhibitor.

5. An optical diffuser as set forth in claim 1, which is produced by exposing a photopolymerizable material on the substrate to a source of collimated or nearly collimated light for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material and then removing the unphotopolymerized portion of the photopolymerizable material.

6. An optical diffuser as set forth in claim 5, where the light has a divergence angle of less than ten degrees.

7. An optical diffuser as set forth in claim 1, where the light is directed through the substrate in more than one dose.

8. An optical diffuser as set forth in claim 1, further comprising a layer of transparent or translucent fill material on the surface of the polymerized material layer.

9. An optical diffuser as set forth in claim 8, where the fill material has an index of refraction less than that of the polymerized material layer.

10. An optical diffuser as set forth in claim 8, where the fill material contains light-scattering particles.

11. An optical diffuser as set forth in claim 1, further comprising an array of tapered optical waveguides, each tapered optical waveguide comprising:

an input surface that admits light;

an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and

a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.

12. An optical diffuser as set forth in claim 11, where the photopolymerized polymerized material layer is in juxtaposition to the input or the output surface of the tapered optical waveguides.

13. An optical diffuser as set forth in claim 11, where the tapered optical waveguides are lenticular.

14. An optical diffuser comprising a polymerized material layer on a transparent or translucent substrate, which layer has a highly modulated surface having smoother bumps ranging from about 1 micron to about 20 microns in both height and width, wherein the polymerized material layer is formed by photopolymerizing a composition which comprises at least one photopolymerizable monomer or oligomer, and a photoinitiator, and the substrate comprises at least one material selected from the group consisting of amorphous materials, semi-crystalline materials having crystalline domains interspersed in an amorphous matrix, purely crystalline materials and combinations thereof.