Substrate mounting for organic, dielectric, optical film

• US 6,676,859 B2
• Filed: 09/19/2001
• Issued: 01/13/2004
• Est. Priority Date: 09/19/2001
• Status: Expired due to Fees

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Hartley, Scott M., Sallavanti, Robert A.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US09/955,903
• Publication Number:
  US 20030059616A1
• Time in Patent Office: 846 Days
• Field of Search: 264/1.7, 264/1.9, 264/1.36, 264/1.31, 264/1.37, 264/1.32, 264/482, 264/248, 264/255, 264/247, 264/250, 264/328.7, 264/328.8, 427/162, 427/163.1, 156/272.2, 156/272.4
• US Class Current: 264/1.36
• CPC Class Codes: B29C 2045/14319 bonding by a fusion bond
• CPC Class Codes: B29C 2948/92647 Thickness
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 2948/92742 Optical properties
• CPC Class Codes: B29C 2948/92752 Colour
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 65/1616 Near infrared radiation [NIR], e.g. by YAG lasers
• CPC Class Codes: B29C 65/1635 at least passing through one of the parts to be joined, i.e. laser transmission welding
• CPC Class Codes: B29C 65/1654 scanning at least one of the parts to be joined
• CPC Class Codes: B29C 65/1674 making use of laser diodes B29C65/167 takes precedence
• CPC Class Codes: B29C 65/1683 coated on the article
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• 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 66/341 Measures for intermixing the material of the joint interlayer
• CPC Class Codes: B29C 66/41 Joining substantially flat articles B29C66/47 and subgroups take precedence; Making flat seams in tubular or hollow articles B29C66/51 and subgroups take precedence
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/545 one hollow-preform being placed inside the other
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/73115 : Melting point
• CPC Class Codes: B29C 66/73117 : Tg, i.e. glass transition temperature
• CPC Class Codes: B29C 66/73343 : at least one of the parts to be joined being matt or refractive
• CPC Class Codes: B29K 2033/12 : Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/005 : Heat sensitisers or absorbers
• CPC Class Codes: B29K 2105/256 : Sheets, plates, blanks or films
• CPC Class Codes: B29K 2995/0006 : Dielectric
• CPC Class Codes: B29K 2995/0026 : Transparent
• CPC Class Codes: B29L 2011/0066 : Optical filters
• CPC Class Codes: G02B 5/287 : comprising at least one layer of organic material
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31681 : Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers

Abstract

A method for optically coupling a thermoplastic material to an outer surface layer of an organic, dielectric, optical film and the resulting optical filter. Initially, a dielectric film is selected that includes (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film. A thermoplastic material which is miscible with the exterior film surface is fused to the refractive boundary with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundary. Add-on filters in the form of hardcoat layers, anti-reflection layers, holograms, metal dielectric stacks and combinations of these may be combined with the thermoplastic-film construct.

Claims

1. A method for optically coupling a thermoplastic material to an outer surface layer of an organic, dielectric, optical film comprising the steps of:

selecting a dielectric film including (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film; and

fusing a thermoplastic material which is miscible with the exterior film surface to the refractive boundary with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundary the polydisperse region comprising a mixture of said exterior film surface and said thermoplastic material.

2. The method of claim 1, further comprising selecting a thermoplastic with a molecular weight having a sufficiently low glass transition temperature to limit the total energy delivered to the film to below the delamination threshold.

3. The method of claim 1, wherein said thermoplastic material includes an organic absorber dye to alter the optical transmission properties of the thermoplastic material.

4. The method of claim 3, wherein said organic absorber dye is selected from the group consisting of a UV absorbing dye, a visible light absorbing dye, a cosmetic dye, a laser absorbing dye, a near infrared absorbing dye, an infrared absorbing dye and combinations thereof.

5. The method of claim 1, further comprising an anti-reflection coating applied to the thermoplastic material.

6. The method of claim 5, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

7. The method of claim 1, further comprising a hardcoat layer applied to the organic, dielectric optical film.

8. The method of claim 7, additionally comprising an anti-reflection coating applied to the hardcoat layer.

9. The method of claim 8, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

10. The method of claim 1, further comprising a hardcoat layer applied to the thermoplastic material.

11. The method of claim 10, additionally comprising an anti-reflection coating applied to the hardcoat layer.

12. The method of claim 11, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

13. The method of claim 1, further comprising a hologram applied to the organic, dielectric optical film.

14. The method of claim 13, additionally comprising a protective optical cap applied to the hologram.

15. The method of claim 14, additionally comprising an anti-reflection coating applied to the cap.

16. The method of claim 15, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

17. The method of claim 14, comprising a metal dielectric stack disposed between the hologram and the cap.

18. The method of claim 17, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

19. The method of claim 17, additionally comprising an anti-reflection coating applied to the cap.

20. The method of claim 19, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

21. The method of claim 1, further comprising a protective optical cap with a metal dielectric layer disposed between the cap and the organic, dielectric optical film.

22. The method of claim 21, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

23. The method of claim 21, additionally comprising an anti-reflection coating applied to the cap.

24. The method of claim 22, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

25. A method for optically coupling a thermoplastic substrate to an outer surface layer of an organic, dielectric, optical film comprising the steps of:

selecting a dielectric film including (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film;

selecting a thermoplastic material which is miscible with the exterior film surface; and

molding the thermoplastic material into a substrate while simultaneously fusing the substrate to the refractive boundary with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundary the polydisperse region comprising a mixture of said exterior film surface and said thermoplastic material.

26. The method of claim 25, wherein said exterior film surface has a first melting temperature range and said selecting step comprises selecting a thermoplastic material that has a second melting temperature range that overlaps said first melting temperature range.

27. The method of claim 25, further comprising the step of inserting the film into a mold cavity, prior to said fusing step.

28. The method of claim 27, wherein said molding and fusing steps comprise injecting the thermoplastic into the mold cavity.

29. The method of claim 28, further comprising heating the thermoplastic above the thermoplastic'"'"'s glass transition temperature in a barrel of an injection molding machine, prior to said fusing step, and

wherein the thermoplastic experiences a temperature drop from the glass transition temperature to the cavity temperature as it exits the barrel and enters the cavity.

30. The method of claim 29, wherein said thermoplastic selecting step comprises selecting a thermoplastic with a molecular weight having a sufficiently low glass transition temperature and corresponding temperature drop to limit the total energy delivered to the film to below the delamination threshold in at least part of the cavity.

31. The method of claim 28, wherein said thermoplastic material includes an organic absorber dye to alter the optical transmission properties of the thermoplastic material.

32. The method of claim 31, wherein said organic absorber dye is selected from the group consisting of a UV absorbing dye, a visible light absorbing dye, a cosmetic dye, a laser absorbing dye, a near infrared absorbing dye, an infrared absorbing dye and combinations thereof.

33. The method of claim 25, further comprising an anti-reflection coating applied to the thermoplastic material.

34. The method of claim 33, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

35. The method of claim 25, further comprising a hardcoat layer applied to the organic, dielectric optical film.

36. The method of claim 35, additionally comprising an anti-reflection coating applied to the hardcoat layer.

37. The method of claim 36, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate and a dielectric stack and combinations thereof.

38. The method of claim 25, further comprising a hardcoat layer applied to the thermoplastic material.

39. The method of claim 38, additionally comprising an anti-reflection coating applied to the hardcoat layer.

40. The method of claim 39, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

41. The method of claim 25, further comprising a hologram applied to the organic, dielectric optical film.

42. The method of claim 41, additionally comprising a protective optical cap applied to the hologram.

43. The method of claim 42, additionally comprising an anti-reflection coating applied to the cap.

44. The method of claim 43, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

45. The method of claim 42, comprising a metal dielectric stack disposed between the hologram and the cap.

46. The method of claim 45, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

47. The method of claim 45, additionally comprising an anti-reflection coating applied to the cap.

48. The method of claim 47, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

49. The method of claim 25, further comprising a protective optical cap with a metal dielectric layer disposed between the cap and the organic, dielectric optical film.

50. The method of claim 49, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

51. The method of claim 49, additionally comprising an anti-reflection coating applied to the cap.

52. The method of claim 50, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

53. A method for optically coupling a thermoplastic substrate to an outer surface layer of an organic, dielectric, optical film comprising the steps of:

selecting a dielectric film including (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a first refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film;

selecting a thermoplastic substrate which is miscible with the exterior film surface and includes an exterior substrate surface and a second refractive boundary along said exterior substrate surface; and

fusing the refractive boundaries together with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundaries the polydisperse region comprising a mixture of said exterior film surface and said thermoplastic substrate.

54. The method of claim 53, wherein said exterior film surface has a first melting temperature range and said selecting step comprises selecting a thermoplastic material that has a second melting temperature range that overlaps said first melting temperature range.

55. The method of claim 53, further comprising the step of placing a radiation absorbing material near one of the refractive boundaries, and

said fusing step comprises irradiating said radiation absorbing material.

56. The method of claim 55, wherein said irradiating step comprises irradiating the radiation absorbing material through the film.

57. The method of claim 55, wherein said irradiating step comprises irradiating the radiation absorbing material through the thermoplastic.

58. The method of claim 55, wherein said placing step comprises applying a radiation absorbing dye and solvent mixture to the film.

59. The method of claim 55, wherein said placing step comprises applying a radiation absorbing dye and solvent mixture to the thermoplastic.

60. The method of claim 53, wherein said thermoplastic material includes an organic absorber dye to alter the optical transmission properties of the thermoplastic material.

61. The method of claim 60, wherein said organic absorber dye is selected from the group consisting of a UV absorbing dye, a visible light absorbing dye, a cosmetic dye, a laser absorbing dye, a near infrared absorbing dye, an infrared absorbing dye and combinations thereof.

62. The method of claim 53, further comprising an anti-reflection coating applied to the thermoplastic material.

63. The method of claim 62, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

64. The method of claim 53, further comprising a hardcoat layer applied to the organic, dielectric optical film.

65. The method of claim 64, additionally comprising an anti-reflection coating applied to the hardcoat layer.

66. The method of claim 65, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

67. The method of claim 53, further comprising a hardcoat layer applied to the thermoplastic material.

68. The method of claim 67, additionally comprising an anti-reflection coating applied to the hardcoat layer.

69. The method of claim 68, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

70. The method of claim 53, further comprising a hologram applied to the organic, dielectric optical film.

71. The method of claim 70, additionally comprising a protective optical cap applied to the hologram.

72. The method of claim 71, additionally comprising an anti-reflection coating applied to the cap.

73. The method of claim 72, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

74. The method of claim 71, comprising a metal dielectric stack disposed between the hologram and the cap.

75. The method of claim 74, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

76. The method of claim 74, additionally comprising an anti-reflection coating applied to the cap.

77. The method of claim 76, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

78. The method of claim 53, further comprising a protective optical cap with a metal dielectric layer disposed between the cap and the organic, dielectric optical film.

79. The method of claim 78, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

80. The method of claim 78, additionally comprising an anti-reflection coating applied to the cap.

81. The method of claim 79, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

82. A method for optically coupling a thermoplastic substrate to an outer surface layer of an organic, dielectric, optical film comprising the steps of:

selecting a dielectric film including (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film;

selecting a thermoplastic material which is miscible with the exterior film surface;

extruding the thermoplastic material into a substrate having an exterior substrate surface and a second refractive boundary along said exterior substrate surface; and

fusing the refractive boundaries together with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the initial refractive boundaries the polydisperse region comprising a mixture of said exterior film surface and said thermoplastic material.

83. The method of claim 82, wherein said exterior film surface has a first melting temperature range and said selecting step comprises selecting a thermoplastic material that has a second melting temperature range that overlaps said first melting temperature range.

84. The method of claim 82, wherein the thermoplastic material experiences a temperature drop as it exits the extrusion nozzle, and

wherein said thermoplastic selecting step comprises selecting a thermoplastic with a molecular weight having a sufficiently low extrusion temperature and corresponding temperature drop to limit the total energy delivered to the film to below the delamination threshold.

85. The method of claim 82, wherein said thermoplastic material includes an organic absorber dye to alter the optical transmission properties of the thermoplastic material.

86. The method of claim 85, wherein said organic absorber dye is selected from the group consisting of a UV absorbing dye, a visible light absorbing dye, a cosmetic dye, a laser absorbing dye, a near infrared absorbing dye, and infrared absorbing dye and combinations thereof.

87. The method of claim 82, further comprising an anti-reflection coating applied to the thermoplastic material.

88. The method of claim 87, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

89. The method of claim 82, further comprising a hardcoat layer applied to the organic, dielectric optical film.

90. The method of claim 89, additionally comprising an anti-reflection coating applied to the hardcoat layer.

91. The method of claim 90, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

92. The method of claim 82, further comprising a hardcoat layer applied to the thermoplastic material.

93. The method of claim 92, additionally comprising an anti-reflection coating applied to the hardcoat layer.

94. The method of claim 93, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

95. The method of claim 82, further comprising a hologram applied to the organic, dielectric optical film.

96. The method of claim 95, additionally comprising a protective optical cap applied to the hologram.

97. The method of claim 96, additionally comprising an anti-reflection coating applied to the cap.

98. The method of claim 97, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

99. The method of claim 96, comprising a metal dielectric stack disposed between the hologram and the cap.

100. The method of claim 99, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

101. The method of claim 99, additionally comprising an anti-reflection coating applied to the cap.

102. The method of claim 101, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.

103. The method of claim 82, further comprising a protective optical cap with a metal dielectric layer disposed between the cap and the organic, dielectric optical film.

104. The method of claim 103, wherein the cap includes a concave side with the metal dielectric stack sputtered onto the concave side.

105. The method of claim 103, additionally comprising an anti-reflection coating applied to the cap.

106. The method of claim 104, wherein the anti-reflection coating is selected from the group consisting of a metal halide, a metal calcide, a rugate, a dielectric stack and combinations thereof.