Systems, methods, and apparatus for a light reflector

• US 8,400,714 B2
• Filed: 02/03/2011
• Issued: 03/19/2013
• Est. Priority Date: 03/05/2010
• Status: Expired due to Fees

• Current Assignee: Southpac Trust International
• Original Assignee: Southpac Trust International
• Inventors: Howe, Leslie D.
• Primary Examiner(s): Ben, Loha
• Application Number:
  US13/020,541
• Publication Number:
  US 20110216420A1
• Time in Patent Office: 775 Days
• Field of Search: 359/618, 359/619, 359/625, 359/627, 359/629, 359638-640, 359/599, 359/707, 359/831, 362/330, 362/331, 362/339, 362/558, 362/600, 362606-608, 362/613, 362/615, 362/621, 156/278, 156/306.8
• US Class Current: 359/627
• CPC Class Codes: B32B 37/14 characterised by the properties of the layers
• CPC Class Codes: B32B 38/00 Ancillary operations in connection with laminating processes
• CPC Class Codes: G02B 27/14 operating by reflection only
• CPC Class Codes: G02B 5/0221 the surface having an irregular structure G02B5/0226 takes precedence
• CPC Class Codes: G02B 5/0231 the surface having microprismatic or micropyramidal shape macroscopic prism arrays G02B5/045
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: G02B 5/0284 used in reflection
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: G02B 6/0053 Prismatic sheet or layer; Brightness enhancement element, sheet or layer
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

Certain embodiments of the invention may include reflector systems, methods, and apparatus for providing a light reflector. According to an example embodiment of the invention, a method is provided for manufacturing a multi-layer light reflector. The method can include attaching a rear reflective layer to a lenticular lens optical film layer. The lenticular lens optical film layer includes a smooth surface and a structured surface. The rear reflective layer is disposed adjacent to or in contact with the smooth surface of the lenticular optical film. The method also includes attaching a diffusion layer to the lenticular lens optical film layer. The diffusion layer includes a smooth film surface and a structured diffusing surface. The smooth film surface of the diffusion film is disposed adjacent to or in contact with the structured surface of the lenticular lens optical film.

Claims

1. A light reflector comprising:

a rear reflective surface;

a lenticular lens optical film comprising a smooth surface and a structured surface, wherein the smooth surface of the lenticular lens optical film is attached or disposed adjacent to the rear reflective surface; and

a diffusion film comprising a smooth film surface and a structured diffusing surface, wherein the smooth film surface of the diffusion film is attached or disposed adjacent to the structured surface of the lenticular lens optical film.

2. The light reflector of claim 1, wherein the rear reflective surface comprises reflectivity having a total reflectance value of 90% or greater and a diffused reflectance value of 90% or greater.

3. The light reflector of claim 1, wherein the lenticular lens optical film comprises a plurality of triangular prisms.

4. The light reflector of claim 1, wherein the rear reflective surface comprises a metal.

5. The light reflector of claim 1, wherein the rear reflective surface comprises foamed microcellular PET (Polyethylene Terephthalate) plastic.

6. The light reflector of claim 1, wherein the structured diffusing surface of the diffusion film comprises a surface roughness with roughness feature height,

7. The light reflector of claim 1 wherein the lenticular lens optical film comprises a prismatic optical film comprising prisms having 90-degree prism apex angles.

8. A method for manufacturing a multi-layer light reflector, the method comprising:

attaching a rear reflective layer to a lenticular lens optical film layer, wherein the lenticular lens optical film layer comprises a smooth surface and a structured surface, and wherein the rear reflective layer is disposed adjacent to or in contact with the smooth surface of the lenticular lens optical film layer; and

attaching a diffusion layer to the lenticular lens optical film layer, wherein the diffusion layer comprises a smooth film surface and a structured diffusing surface, wherein the smooth film surface of the diffusion layer is disposed adjacent to or in contact with the structured surface of the lenticular lens optical film layer.

9. The method of claim 8, wherein the rear reflective layer comprises one or more foamed microcellular PET (Polyethylene Terephthalate) plastic sheets.

10. The method of claim 8, wherein the lenticular lens optical film layer comprises a plurality of triangular prisms.

11. The prismatic optical film of claim 10, wherein the prismatic optical film layer comprises prisms having 90 degree prism apex angles.

12. The method of claim 8, wherein the rear reflective layer comprises a metallic surface.

13. The method of claim 8, wherein attaching the rear reflective surface to the lenticular lens optical film layer comprises depositing a metal on the smooth surface of the lenticular lens optical film layer.

14. The method of claim 8, wherein the smooth surface of the lenticular lens optical film layer comprises a comprises a surface roughness with roughness feature height,

15. A light reflection system comprising:

a film stack comprising;

a rear reflective surface;

a lenticular lens optical film comprising a smooth surface and a structured surface, wherein the smooth surface of the lenticular lens optical film is attached or disposed adjacent to the rear reflective surface; and

a diffusion film comprising a smooth film surface and a structured diffusing surface, wherein the smooth film surface of the diffusion film is attached or disposed adjacent to the structured surface of the lenticular lens optical film; and

a film-tensioning frame operable for mounting the film stack and providing tension to the film stack.

16. The system of claim 15, wherein the rear reflective surface comprises reflectivity having a total reflectance value of 90% or greater and a diffused reflectance value of 90% or greater.

17. The system of claim 15, wherein the lenticular lens optical film comprises a plurality of triangular prisms.

18. The system of claim 17, wherein the plurality of triangular prisms comprise 90-degree prism apex angles.

19. The system of claim 15, wherein the film-tensioning frame comprises at least two springs.

20. The system of claim 15, wherein the rear reflective surface comprises foamed microcellular PET (Polyethylene Terephthalate) plastic.

21. The system of claim 15, wherein the structured diffusing surface of the diffusion film comprises a surface roughness with roughness feature height,

22. The system of claim 15, wherein corners associated with the film-tensioning frame are further operable to engage corners associated with the film stack.

23. The system of claim 15, wherein the film-tensioning frame comprises at least two adjustable tensioners.