Multilayer optical film with output confinement in both polar and azimuthal directions and related constructions

• US 8,988,776 B2
• Filed: 11/16/2009
• Issued: 03/24/2015
• Est. Priority Date: 11/19/2008
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Weber, Michael F., Nevitt, Timothy J., Benoit, Gilles J.
• Primary Examiner(s): Chapel, Derek S
• Application Number:
  US13/129,455
• Publication Number:
  US 20110222295A1
• Time in Patent Office: 1,954 Days
• Field of Search: None
• US Class Current: 359/489.01
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/418 Refractive
• CPC Class Codes: B32B 2307/514 Oriented
• CPC Class Codes: B32B 2307/518 bi-axially
• CPC Class Codes: B32B 2307/52 multi-axially
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 7/023 Optical properties
• 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: G02F 1/133536 Reflective polarizers G02F1/13362 takes precedence
• CPC Class Codes: G02F 1/13362 providing polarized light, e.g. by converting a polarisation component into another one
• CPC Class Codes: G02F 2203/07 Polarisation dependent
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree

Abstract

A film includes microlayers arranged into optical repeat units. Adjacent microlayers have in-plane refractive index mismatches Δnx, Δny tailored to provide mirror-like on-axis properties, such that the film has a reflectivity for normally incident light in an extended wavelength band of at least 75% for any polarization. Adjacent microlayers also have a refractive index mismatch Δnz that provides the film with reduced reflectivity R1 and increased transmission for p-polarized light in the extended wavelength band incident on the film in a first plane of incidence at an angle θoblique, where R1 is no more than half of the minimum of on-axis reflectivity. Further, Δnx and Δny are different enough so that for light incident on the film in a second plane of incidence orthogonal to the first plane, the film has a reflectivity R2 of at least 75% for such light that is p-polarized and incident at any angle.

Claims

1. A reflective film having substantially flat outer surfaces, comprising:

a plurality of microlayers arranged into optical repeat units for reflecting light over an extended wavelength band, adjacent microlayers exhibiting substantial in-plane refractive index mismatches Δ

nx along an x-axis and Δ

ny along a y-axis, such that for normally incident light in the extended wavelength band, the film has a reflectivity Rnormalx for such light polarized along the x-axis and a reflectivity Rnormaly for such light polarized along the y-axis, Rnormalx and Rnormaly both being at least 75%;

wherein adjacent microlayers also exhibit a substantial refractive index mismatch Δ

nz along an out-of-plane z-axis, such that for light in the extended wavelength band incident on the film in a first plane of incidence, the film has a reflectivity R1 of no more than half of Rnormalmin for such light that is p-polarized and incident at an angle θ

oblique, where Rnormalmin is the lesser of Rnormalx and Rnormaly; and

wherein Δ

nx and Δ

ny are different enough so that for light in the extended wavelength band incident on the film in a second plane of incidence orthogonal to the first plane, the film has a reflectivity R2 of at least 75% for such light that is p-polarized, for all angles of incidence.

2. The film of claim 1, wherein Rnormalx, Rnormaly, Rnormalmin, R1, and R2 each include effects of two film/air interfaces.

3. The film of claim 1, wherein Rnormalx, Rnormaly, Rnormalmin, R1, and R2 each include no effects of any film/air interface.

4. The film of claim 1, wherein the extended wavelength band includes the visible spectrum from 400 to 700 nm, and wherein Rnormalx, Rnormaly, Rnormalmin, R1, and R2 are each averages over the visible spectrum.

5. The film of claim 1, wherein the film exhibits a transmission as a function of angle for light in the extended wavelength band characterized by two transmission lobes, each lobe having an angular width Δ

θ

e in polar angle θ and

an angular width Δ

φ

e in azimuthal angle φ

.

6. The film of claim 5, wherein Δ

φ

e is a full angular width at half-maximum transmission (FWHM), and is no more than 140 degrees.

7. The film of claim 6, wherein Δ

φ

e is no more than 130 degrees.

8. The film of claim 6, wherein Δ

φ

e is no more than 80 degrees.

9. The film of claim 1, wherein Δ

nx and Δ

ny are of opposite sign.

10. The film of claim 1, wherein each optical repeat unit includes a first microlayer composed of a negatively birefringent material and a second microlayer composed of a positively birefringent material.

11. The film of claim 1, wherein the film exhibits an internal Brewster angle in the first plane of incidence but exhibits no internal Brewster angle in the second plane of incidence.

12. The film of claim 1, wherein Δ

nx and Δ

ny are of the same sign.

13. The film of claim 1, wherein the film exhibits internal Brewster angles in both the first and second planes of incidence.

14. A lighting system comprising the reflective film of claim 1.

15. The system of claim 14, further comprising:

a back reflector disposed to form a recycling cavity with the reflective film.

16. The system of claim 14, further comprising:

a light source extending along a length axis and disposed behind the reflective film;

wherein the reflective film is oriented such that the length axis is substantially perpendicular to the first plane of incidence.

17. The reflective film of claim 1 in combination with a diffuser.

18. The combination of claim 17, wherein the reflective film attaches to the diffuser with no intervening air gap.

19. The combination of claim 17, wherein the diffuser substantially scrambles polarization.

20. The combination of claim 17, wherein the diffuser comprises a volume diffuser.

21. The reflective film of claim 1 in combination with a linear prismatic film coupled to the film, wherein the prisms extend parallel to a prism axis, and wherein the prism axis of the prismatic film is substantially perpendicular to the first plane of incidence of the reflective film.