Optical elements containing a polymer fiber weave

• US 7,406,239 B2
• Filed: 02/28/2005
• Issued: 07/29/2008
• Est. Priority Date: 02/28/2005
• Status: Expired due to Fees

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Breister, James C., Ouderkirk, Andrew J., Thunhorst, Kristin L., Fleming, Patrick R., Kopecky, William J., Wilson, Bruce B., Benson, Olester Jr., Stumo, Roger J., Chou, Yeun-Jong, North, Diane, Allen, Richard C., Rude, Harold E.
• Primary Examiner(s): KIANNI, KAVEH C
• Application Number:
  US11/068,590
• Publication Number:
  US 20060194487A1
• Time in Patent Office: 1,247 Days
• Field of Search: 385/131, 385/123, 385/127
• US Class Current: 385/131
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• 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 5/3033 in the form of a thin sheet or foil, e.g. Polaroid
• 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 6/001 the light being emitted along at least a portion of the lateral surface of the fibre
• CPC Class Codes: G02B 6/0051 Diffusing sheet or layer
• CPC Class Codes: G02B 6/0053 Prismatic sheet or layer; Brightness enhancement element, sheet or layer
• CPC Class Codes: G02B 6/04 formed by bundles of fibres G02B6/24 takes precedence
• CPC Class Codes: G02B 6/105 having optical polarisation effects
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2967 Synthetic resin or polymer
• CPC Class Codes: Y10T 428/2973 Particular cross section
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/30 Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3065 Including strand which is of specific structural definition

Abstract

A polarizer is formed with an arrangement of polymer fibers substantially parallel within a polymer matrix. The polymer fibers are formed of at least first and second polymer materials. At least one of the polymer matrix and the first and second polymer materials is birefringent, and provides a birefringent interface with the adjacent material. Light is reflected and/or scattered at the birefringent interfaces with sensitivity to the polarization of the light. In some embodiments, the polymer fibers are formed as composite fibers, having a plurality of scattering polymer fibers disposed within a filler to form the composite fiber. In other embodiments, the polymer fiber is a multilayered polymer fiber. The polymer fibers may be arranged within the polymer matrix as part of a fiber weave.

Claims

1. An optical body, comprising:

a polymer matrix comprising a matrix polymer material; and

at least one fiber weave disposed within the polymer matrix, the fiber weave comprising a plurality of polymer fibers, the polymer fibers comprising a first polymer fiber material, the first polymer fiber material being birefringent,

wherein the optical body functions as a reflective polarizer.

2. The reflective polarizer as recited in claim 1, wherein the polymer fibers further comprise at least a second polymer fiber material.

3. The optical body as recited in claim 2, wherein one of the first and second polymer fiber materials is the same as the matrix polymer material.

4. The optical body as recited in claim 1, wherein the polymer fibers are polymer composite fibers comprising scattering polymer fibers formed of the first polymer fiber material disposed within a filler of a second fiber polymer material.

5. The optical body as recited in claim 4, wherein the scattering polymer fibers comprise disperse phase scattering polymer fibers comprising a disperse phase in a continuous phase.

6. The optical body as recited in claim 4, wherein the composite fiber has a substantially non-circular cross-section, and the orientation of the non-circular cross-section is substantially constant along the weave.

7. The optical body as recited in claim 1, wherein the polymer fibers comprise polymer fiber yarn.

8. The optical body recited in claim 1, wherein the polymer fibers comprise alternating layers of the first polymer fiber material and a second polymer fiber material.

9. The optical body as recited in claim 8, wherein the layers of the first and second polymer materials are substantially planar.

10. The optical body as recited in claim 8, wherein the layers of the alternating first and second polymer materials are arranged concentrically.

11. The optical body as recited in claim 1, wherein the polymer fibers comprise disperse phase fibers comprising a disperse phase of the first polymer material and a continuous phase of a second polymer material.

12. The optical body as recited in claim 1, wherein the fiber weave comprises warp fibers and weft fibers, and wherein at least one of the warp and weft fibers comprise the plurality of polymer fibers.

13. The optical body as recited in claim 12, wherein at least one of the warp fibers and weft fibers comprises optically isotropic polymer fibers.

14. The optical body as recited in claim 12, wherein at least one of the warp fibers and the weft fibers comprises optically isotropic natural fibers.

15. The optical body as recited in claim 12, wherein at least one of the warp fibers and the weft fibers comprises inorganic fibers, the inorganic, fibers comprising at least one of glass, ceramic and glass-ceramic.

16. The optical body as recited in claim 12, wherein at least one of the warp fibers and the weft fibers comprises optically isotropic polymer fibers having a refractive index substantially similar to the refractive index of the polymer matrix.

17. The optical body as recited in claim 12, wherein at least one of the warp fibers and the weft fibers comprises optically isotropic polymer fibers having a refractive index substantially different from the refractive index of the polymer matrix.

18. The optical body as recited in claim 1, wherein the polymer fibers in the fiber weave are substantially straight.

19. The optical body as recited in claim 1, wherein the polymer matrix is formed as a layer containing the plurality of polymer fibers, the layer having substantially flat and parallel surfaccs.

20. The optical body as recited in claim 1, wherein the polymer matrix is formed as a layer having at least one structured surface.

21. The optical body as recited in claim 20, wherein the at least one structured surface provides optical power to light transmitted through the body.

22. The optical body recited in claim 20, wherein the at least one structured surface comprises an array of prismatic structures.