Optical film with co-continuous phases

• US 6,590,705 B1
• Filed: 02/18/1997
• Issued: 07/08/2003
• Est. Priority Date: 02/29/1996
• Status: Expired due to Term

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Weber, Michael F., Ouderkirk, Andrew J., Nevitt, Timothy J., Stover, Carl A., Allen, Richard C., Majumdar, Biswaroop, Carlson, Lockwood W., Kotz, Arthur L.
• Primary Examiner(s): Shafer, Ricky D.
• Application Number:
  US08/801,329
• Time in Patent Office: 2,331 Days
• Field of Search: 359/488, 359/490, 359/491, 359/494, 359/495, 359/500, 359/492, 252/585, 349/86, 349/88, 349/92, 349/96
• US Class Current: 359/487.02
• CPC Class Codes: G02B 1/04 made of organic materials, e.g. plastics G02B1/08 takes precedence
• CPC Class Codes: G02B 5/3008 comprising dielectric particles, e.g. birefringent crystals embedded in a matrix
• 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: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component

Abstract

An optical film is provided which comprises a disperse phase of polymeric particles disposed within a continuous birefringent matrix. The film is oriented, typically by stretching, in one or more directions. The size and shape of the disperse phase particles, the volume fraction of the disperse phase, the film thickness, and the amount of orientation are chosen to attain a desired degree of diffuse reflection and total transmission of electromagnetic radiation of a desired wavelength in the resulting film.

Claims

1. A polarizer, comprising an interpenetrating polymer network of first and second diverse thermoplastic polymers, wherein at least one of said first and second polymers is a polyester.

2. The polarizer of claim 1, wherein each of said first and second polymers are polyesters.

3. The polarizer of claim 1, wherein at least one of said first and second polymers is polyethylene naphthalate.

4. A polarizer, comprising an interpenetrating polymer network of first and second diverse thermoplastic polymers, wherein said first polymer is a syndiotactic vinyl aromatic polymer derived from a vinyl aromatic monomer.

5. The polarizer of claim 4, wherein said second polymer comprises polyethylene naphthalate.

6. A polarizer, comprising an interpenetrating polymer network of first and second diverse thermoplastic polymers, wherein said polarizer has a total reflectivity of greater than about 70% for a first polarization of light and a total transmission of greater than about 70% for a second polarization of light orthogonal to said first polarization.

7. The polarizer of claim 6, wherein the refractive index difference between said first and second polymers is at least about 0.05 along a first axis and is less than about 0.05 along a second axis.

8. The polarizer of claims 7, wherein said polarizer is a film, and wherein said first and second axes are disposed within the plane of said film.

9. The polarizer of claim 7, wherein said polarizer is a film, and wherein said second axis is perpendicular to the plane of said film.

10. The polarizer of claim 6, wherein said second polymer is co-continuous with said first polymer along three mutually orthogonal axes.

11. The polarizer of claim 6, wherein said first polymer has a birefringence of greater than 0.05, and said second polymer has a birefringence of less than 0.05.

12. The polarizer of claim 6, wherein said first polymer has a birefringence of at least about 0.1, and said second polymer has a birefringence of less than about 0.02.

13. The polarizer of claim 6, wherein said polarizer has a total diffuse reflectivity along at least one axis of at least about 30%.

14. The polarizer of claim 6, wherein said polarizer has a total reflectivity of greater than about 80% for said first polarization of light.

15. The polarizer of claim 6, wherein said polarizer has a total transmission of greater than about 80% for said second polarization of light.

16. The polarizer of claim 6, wherein said polarizer substantially diffusely reflects the first polarization of light, and wherein said polarizer transmits at least about 40% of the second polarization of light with an angle of deflection of less than about 8°

.

17. The polarizer of claim 6, wherein at least about 70% of said second polarization of light is transmitted through said polarizer with an angle of deflection of less than about 8°

.

18. The polarizer of claim 6, wherein said first polymer is a syndiotactic vinyl aromatic polymer derived from a vinyl aromatic monomer.

19. The polarizer of claim 18, wherein said second polymer comprises polyethylene naphthalate.

20. The polarizer of claim 6, wherein at least one of said first and second polymers is a polyester.

21. The polarizer of claim 6, wherein each of said first and second polymers are polyesters.

22. The polarizer of claim 6, wherein at least one of said first and second polymers is strain-hardening.

23. The polarizer of claim 6, wherein said polarizer is stretched to a stretch ratio of at least about 2.

24. The polarizer of claim 6, wherein said polarizer has a plurality of layers, and wherein at least two of said plurality of layers comprises an interpenetrating polymer network.

25. The polarizer of claim 6, further comprising a dichroic dye.

26. The polarizer of claim 6, wherein the absolute value of the difference in index of refraction of said first and second polymers is Δ

n₁ along a first axis and Δ

n₂ along a second axis orthogonal to said first axis, and wherein the absolute value of the difference between Δ

n₁ and Δ

n₂ is at least about 0.05.

27. The polarizer of claim 6, wherein said polarizer comprises a liquid crystal.

28. A polarizer, comprising:

an open-celled polymeric first phase; and

a second phase, disposed within the cells of said first phase;

wherein said first phase has a larger birefringence than said second phase.

29. A polarizer, comprising:

an open-celled polymeric first phase; and

a second phase, disposed within the cells of said first phase;

wherein said first and second phases taken together have a diffuse reflectivity along at least one axis for at least one polarization of visible light of at least about 30%.

30. The polarizer of claim 29, wherein the absolute value of the difference in index of refraction of said first and second phases is Δ

n₁ along a first axis and Δ

n₂ along a second axis orthogonal to said first axis, and wherein the absolute value of the difference between Δ

₁ and Δ

n₂ is at least about 0.05.

31. The polarizer of claim 29, wherein the absolute value of the difference between Δ

_n and Δ

n₂ is at least about 0.1.

32. The polarizer of claim 29, wherein said first phase has a larger birefringence than said second phase.

33. The polarizer of claim 32, wherein the birefringence of said first phase is at least 0.02 greater than the birefringence of said second phase.

34. The polarizer of claim 32, wherein the birefringence of said first phase is at least 0.05 greater than the birefringence of said second phase.

35. The polarizer of claim 29, wherein said first and second phases are polyesters.

36. The polarizer of claim 29, wherein said polarizer comprises a liquid crystal.

37. The polarizer of claim 29, wherein said first and second phases comprise thermoplastic polymers.

38. A polarizer, comprising:

an open-celled polymeric first phase; and

a second phase, disposed within the cells of said first phase;

wherein said first and second phases comprise diverse thermoplastic polymers.

39. The polarizer of claim 38, wherein said polarizer is stretched to a stretch ratio of at least about 2.

40. The polarizer of claim 38, wherein at least one of said first and second polymers is a polyester.

41. The polarizer of claim 38, wherein both of said first and second polymers are polyesters.

42. The polarizer of claim 38, wherein said first phase has a larger birefringence than said second phase.

43. The polarizer of claim 42, wherein the birefringence of said first phase is a least 0.02 greater than the birefringence of said second phase.

44. The polarizer of claim 42, wherein the birefringence of said first phase is at least 0.05 greater than the birefringence of said second phase.