CA2222486A1 - Metal-coated multilayer mirror - Google Patents

Abstract

A metal-coated multilayer mirror having high reflectivity and high specularity. The mirror comprises a multilayered polymer film (10) and a reflective metal layer. The multilayered polymer film preferably comprises layers of a crystalline, semi-crystalline or liquid crystalline material, such as a naphthalene dicarboxylic acid polyester (12), having an average thickness of not more than 0.5 microns and layers of a second polymer (14) having an average thickness of not more than 0.5 microns. Preferably, the layers of semicrystalline naphthalene dicarboxylic acid polyester have a stress optical coefficient. The reflective metal layer comprises a metal selected from the group consisting of silver, gold, aluminium, nickel, copper, titanium, with silver and aluminium being particularly preferred. The metal-coated multilayer mirrors are useful in applications requiring broad bandwidth reflection, high specularity, low manufacturing costs, high reflectivity.

Description

CA 02222486 l997-ll-26 W O 97/01439 PCTrUS96/10665 ~DETAL,C O ATE~D nqmLTnLAYER MIRURO R

BACKGROUND
The present invention relates to optical films useful, e.~., as mirrors, which are combined with a reflective metal layer to form bro~clh~nd, high reflectivitymirrors having high specularity.
Light-refl~ting devices based upon multiple polymeric layers are known.
FY~mples of s,uch devices include polarizers made of alternating polymeric layers iin which the layers have different refractive indices. Mirrors made from smooth, ~reflective metal surfaces are also known.

SUMMARY
The optical properties and design considerations of birefringent optical films described herein allow the construction of multilayer stacks for which the]Brewster angle (the angle at which reflect~nce of p polarized light goes to zero) is very large or is noneyic~ent for the polymer layer interfaces. This allows for the construction of multilayer mirrors whose reflectivity for p polari~(J light decreases slc~ ly with angle of incidence7 is in~eppnd~nt of angle of incj~ence, or increases with angle of in-jdenre away from the normal. As a result, multilayered iilnns having high reflectivity (for both s and p polarized light for any incident clirection in the case of mirrors) over a wide banciwidth can be achieved. Thesemultilayered films are combined with a reflective metal layer, such as silver oraLlulminum, to provide mirrors having high reflectivity and high specularity.
Briefly, the present invention incluc~es a multilayered polymer film in whicll the layers have an average thinl~n~cc of not more than 0.5 microns. More particularly, in one aspect of the present invention the multilayered polymer film comprises layers of a birefringent polymer, especi~lly a crystalline, semi-cryst~lline, or liquid crystalline m~tPri~l, such as naphth~l~nP dicarboxylic acid pol~yester, for eY~mple a 2,6-polyethylene n~phth~l~te ("PEN") or a copolymer clerived from ethylene glycol, n~phth~l.one dicarboxylic acid and some other acids such as terephth~l~te ("coPEN"), having an average thi~ l~n~s of not more than 0.5 W O 97/01439 PCTrUS96/10665 microns, and preferably with a positive stress optical coefficient, ~, upon stretching, its index of refraction in the stretch direction increases; and layers of a sto-lectP~ second polymer, for eY~mple a polyethylene terephth~l~tto (UPET") or a coPEN, having an average thic~nPcc of not more than 0.5 microns. Preferably, after stretching these multilayered polymer films in at least one direction, thelayers of said n~rhth~lPne dicarboxylic acid polyester have a higher index of refraction ~csoci~ted with at least one in-plane axis than the layers of the second polymer.
Another aspect of the present invention includes a multilayered polymer film comprising layers of a birefringent polymer, especially a crystalline, semi-cryst~llinP, or liquid crystalline material, for example a polyester such as PETpolymer, having an average thirknPcc of not more than 0.5 microns; and layers ofa sPIected second polymer, for example a polyester or a polystyrene, having an average thinkn~osc of not more than 0.5 microns; wherein said film has been sLretched in at least one direction to at least twice that direction's unstretched dimenci"~ .
The multilayered polymer films used in the present invention are combined with a reflective metal layer, preferably silver or alnminum, to provide a high reflectivity mirror also having high specularity. The reflective metal layer maybe deposited on the multilayered polymer film by convention~l means, such as vacuum deposition, c~thode sputtering, and the like, or it may be a separate mPt~li7Pd polymer or glass sheet or a metal sheet that is l~min~tPd to the multilayered polymer film, such as by a suitable transparent adhesive. The resnlting metal-coated multilayer mirror has higher reflectivity than either themultilayered polymer film or the reflective metal alone, higher color uniformitytblan known multilayered polymer films, and provides desired manufacturing flexibility.

BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further ~yl~;n~ with reference to the drawings.

W 0917/01439 PCTrUS96/10665 Figur~s la and lb are diagr~mm~ti~l views of the polarizer of the present invention.
Figure 2 shows a two layer stack of films forming a single interface.
Figures 3-8 show the optical pe.~rl,latlce of multilayer mirrors given in 5 Examples 1-4.
Figures 9-11 show the optical ~.rolll,ance of multilayer polarizers given in FY~nirles 5-7.
Figure 12 shows the optical pelro-l"~lce of the multilayer mirror given in FY~mple 8.
Figure 13 shows the optical ~.ro.",allce of the multilayer polarizer given in FY~mple 9.
Figure 14 shows the optical IJelÇ~llllance of the metal-coated multilayer mirror of Example 10.
Figure 15 shows the optical ~.Çu-",ance of the metal-coated multilayer 15 miirror of Example 12.

DETATT.Fl- DESCRIPTION OF ILL,USTRATIVE EMBQDTMENTS
The present invention as i~ str~tp~d in Figures la and lb includes a multilayered polymer film 10, also referred to herein as a multilayer stack, having 20 alternating layers of at leaLst two materials 12 and 14. Preferably, at least one of thle materials has the p,o~.ly of stress induce~ birefringence, such that the index o~f refraction (n) of the material is affected by the stretching process. Figure la shows an exemplary multilayer stack before the stretching process in which both rnaterials have the same index of refr~ctiom Light ray 13 t A~.i~nces relatively2 5 little change in index of refraction and passes through the stack. In Figure lb, the same stack hlas been stretched, thus increasing the index of refraction of material 12 in the stretched direction or direction~ The difference in refractive index at each bounda~ry between layers will cause part of ray 15 to be reflected. By s~retching the multilayer stack over a range of nni~xi~l to biaxial orientation, a 3 0 film is created with a range of reflectivities for differently oriented plane-polarized incident light. The multilayer stack can thus be made useful as reflective W O97/01439 PCT~US96/10665 polarizers or mirrors. If stretched biaxially, the sheet can be stretched asymmetric~lly along orthogonal axes or symmetrically along orthogonal axes to obtain desired polarizing and reflP~ting ~,ope,Lies.
The optical ~ pe.Lies and design conciderations of multilayer stacks is 5 described most completely in copending and commonly ~ccigned U.S. Patent Application 08/402,041, filed March 10, 1995, the disclosure of which is hereby incorporated herein by reference. Very briefly, that application describes the construction of multilayer stacks (mirrors and polarizers) for which the Brewster angle (the angle at which rçflç~t~nce goes to zero) is very large or is nonexistent lO for the polymer layer interfaces. This allows for the construction of multilayer mirrors and polarizers whose reflectivity for p polarized light decreases slowlywith angle of incidence, is in(iepen(l-pnt of angle of incidPnce, or increases with angle of in--idçncP~ away from the normal. As a result, multilayer stacks havinghigh reflectivity for both s and p polarized light over a wide bandwidth, and over 15 a wide range of angles can be achieved.
Figure 2 shows two layers of a multilayer stack, and indic~tPs the three rnencional indices of refraction for each layer. The indices of refraction for each layer are nlx, nly, and nlz for layer 102, and n2x, n2y, and n2z for layer 104.
The rçl~ionchirs between the indices of refraction in each film layer to each other

2 o and to those of the other layers in the film stack determine the reflectance behavior of the multilayer stack at any angle of incidçnce, from any azimuthal direction.The principles and design considerations described in U.S. patent application Serial Number 08/402,041 can be applied to create multilayer stacks having the desired optical effects for a wide variety of circumct~nrps and applic~ionc The indices 25 of refraction of the layers in the multilayer stack can be manipulated and tailored to produce devices having the desired optical prope.lies. Many useful devices, such as mirrors and polarizers having a wide range of pelro."-ance characteristics, can be decignpd and fabricated using the principles described therein.
Referring again to Figure 1, the multilayer stack 10 can include tens, 30 hundreds or tho--c~n-lc of layers, and each layer can be made from any of a number of different materials. The chqr~tprictics which determine the choice of W O 9'~/01439 PCT~US96/10665 materials for a particular stack depend upon the desired optical performance of the sta~ck. The stack can contain as many materials as there are layers in the stack.
For ease of m~nllf~ctl~re, plcf~ d optical thin film stacks contain only a few dii~ferent materials. To minimi7P optical absorption, the p~efellcd multilayer stack ensures that wavelengths that would be most strongly absorbed by the stack are the first wavelengths rçflectP11 by the stack. For most clear optical materials, includir~g most polymers, absorption increases toward the blue end of the visible spectrum. Thus, it is preferred to design or "tune" the multilayer stack such that the "blue" k~rers are on the incid~nt side of the multilayer stack.
The boundaries between the materials, or chernir~lly identir~l materials with differenl! physical propellies, can be abrupt or gradual. Except for some sinnple cases with analytical solutions, analysis of the latter type of stratified media with continuously varying index is usually treated as a much larger number of thinner uniform layers having abrupt boundaries but with only a small change in 15 plope.lies between ~-ljacent layers.
The preferred multilayer stack is comprised of low/high index pairs of film layers, wherein each low/high index pair of layers has a combined optical ~hic~nPc$ of ] /2 the center wavelength of the band it is d~pcigne~ to reflect. Stacks of such films are commonly l~f~.l~ to as quarterwave stacks. Preferably, the 20 llayers have a l/4 wavelength thi~l~nPcc with different sets of layers dPcignPd to reflect different wavelength ranges. Each layer does not have to be exactly l/4 wavelength thick. The overriding l~uin -l-ent is that the ~rij~cent low/high index film pair have: a total optical thi~nPcc of 0.5 wavelength.
As noted above, the multilayered polymer films used in the present 25 invention include layers that can be made from any number of different materials, including che~ lly iclentic~l materials having different physical ~l~pc~ ~ies, which have an average thicknecc of not more than 0.5 microns. Preferably, the multilayered polymer film comprises layers of a cryst~lline, semi-crystalline, or liquid crystalline polymer, such as n~phth~l~n.o dicarboxylic acid polyester having

3 0 a ~sitive stress optical coefficient, Le., upon stretching, its index of refraction in the stretch direction increases, and layers of a s~le~ted second polymer. After ~5-W O 97/01439 PCT~US96/10665 stretching such multilayered polymer films in at least one direction, the layers of the n~phth~l~onP dicarboxylic acid polyester preferably have a higher index of refraction ~C~oci~t~A with at least one in-plane axis than the layers of the second polymer. Particularly preferred semi-crystalline naphth~llone dicarboxylic acid 5 polyesters incl~lcie, for example, a 2,6-polyethylene n~phth~l~te ("PEN") or acopolymer derived from ethylene glycol, n~rhth~l-one dicarboxylic acid, and someo~her acids such as terephthalate ("coPEN"). Particularly, preferred sele~t~d second polymers include, for example, a polyethylene terephth~l~t~ ("PET") or a coPEN.
The multilayered polymer films alternately may comprise layers of a birefringent polymer, especi~lly a cryst~lline, semi-crystalline, or liquid crystalline material, for ey~mple a semi-crystalline polyester such as PET, and of a second select~d polymer in which the layers have an average thirl~nec~ of not more than0.5 microns, and the films are ~lr. lched in at least one direction to at least twice 15 that direction's unstretched dimen~iom When the multilayered polymer films used in the present invention include a semi-crystalline n~rhth~lene dicarboxylic acid polyester, it preferably exhibits a difference in refractive indices ~oci~t~ with different in-plane axes of at least O.OS and preferably above 0.20. PEN is a preferred material because of its high 2 o positive stress optical coefficient and permanent birefringence after stretching, with the refractive index for polarized incident light of 550 nm wavelength increasing when the plane of polarization is parallel to the stretch direction from about l.64 to as high as about 1.9. The birefringence (difference in refractive index) can be increased by increasing the molec~ul~r orientation. Although PEN has been 25 specific~lly ~iscuc~d above as the prefell~;d polymer for the birefringent layer, polybutylene n~phth~l~te is also a suitable material as well as other crystalline or semi-crystalline n~l)htl.~lerl.o dicarboxylic acid polyesters.
The polymers used to make the multilayer stacks preferably have similar melt vi~co~iti~s so as to obtain uniform multilayer coextrusion. When two 30 different polymers are used, the two polymers prefe.~bly have a melt viscosity within a factor of 5 at shear rates typically eA~.ienced in coextrusion. The CA 02222486 l997-ll-26 W O 97/01439 PCTrUS96/10665 preferred selected polymer layers of the present invention also exhibit good adhesion properties to each other while still rem~ining as discrete layers within the multilayered sheet. The glass t~nCition Le-,.pcldtllres of the polymers used in the ~ present inven~ion are compatible so adverse effects such as cracking of one set of 5 polymer layers during stretching does not occur. For mirrors that predominantly reilect in one polarization, the pl~fc.~d selected polymer layer remains isotropic in refractive index and subst~nti~lly m~trhPs the refractive index of the other layer oci~t~ with the transverse axis as illustrated in Figure la. Light with its plane of polarization in this direction will be predominantly tr~ncmitt~i by the polarizer 0 while light with its plane of polarization in the oriented direction will be reflected as illustrated in Figure lb.
To make a mirror, two uni~xi~lly stretched polarizing sheets are positioned with their respective orientation axes rotated 90~, or the sheet 10 (Fig. Ib) isbiaxially stretched. In the latter case, both refractive indices in the plane of the 5 sheet for a la,yer made from PEN increase and the sel.-~ polymer should be chosen with as low of a refractive index as possible to reflect light of both planes of polarization. Ri~xi~lly stretching the multilayered sheet will result in dii ferences between refractive indices of adjoining layers for planes parallel to both axes, thereby res~lting in refl~tion of light in both planes of polarization 20 directionc Differences between the tra~nsverse - axis - ~ccoci~tPd indices ofrei~raction of adjoining layers after stretching should be less than 0.1 and preferably less than 0.05.
In the case of mirrors, the desired average tr~ncmiccion for light of each polarization and plane of incidenre generally depen~lc upon the intended use of the 2 5 mirror. The a~verage tr~ncmiccion along each stretch direction at normal innidence for a narrow bandwidth mirror across a 100 nm bandwidth within the visible s~xtrum is desirably less than about 30%, preferably less than about 20% and more preferably less than about lO~. A desirable average tpncmiccion along each stretch clirection at normal inl icl~nne for a partial mirror ranges anywhere 30 from, for ey:lmrle~ about 10% to about 50%, and can cover a bandwidth of aLnywhere b,~ ~n, for eY~mrle, I00 nm and 450 nm, depen~ling upon the W O 97/01439 PCT~US96/10665 particular application. For a high effic;Pnry mirror, average tr~ncmiccion alongeach stretch direction at normal inci(lence over the visible spectrum (380-750 nm) is desirably less than about 10%, preferably less than about 5%, more preferablyless than about 2%, and even more preferably less than about 1%. In addition, 5 asymmetric mirrors may be desirable for certain applic~tionc. In that case, average tr~ncmiccion along one stretch direction may be desirably less than, foreY~mplè, about 50%, while the average tr~ncmicsion along the other stretch direction may be desirably less than, for example, about 20%, over a bandwidth of', for example, the visible spectrum (380-750 nm), or over the visible spectrum lO and into the near infrared (e.g, 380-850 nm).
If desired, two or more sheets of the invention may be used in a composite to increase reflectivity, optical bandwidth, or both, or to form a mirror from two polarizers. If the optical thicl~nPssçs of pairs of layers within the sheets aresnbs~nti~lly equal, the composite will reflect, at somewhat greater efficiency, 15 subst~nti~lly the same bandwidth and spectral range of reflectivity (i.e., "band") as the individual sheets. If the optical thirl~npc~es of pairs of layers within the sheets are not subst~n-i~lly equal, the composite will reflect across a broader band width than the individual sheets. A composite combining mirror sheets with polarizer sheets is useful for increasing total reflPct~nce while still polarizing 20 tr~ncmittP~ light. Alternatively, a single sheet may be asymmetrically biaxially stretched to produce a film having selective reflective and polarizing plupellies.
The ~lefell~d selected polymer for use in a biaxially stretched mirror applic~tion is based on te.~htl.~lic, isophthalic, sebacic, azelaic, or cyclohPY~ne~lir~rboxylic acid to attain the lowes~ possible refractive index while 25 still m~inL~ining ~rlhP$ion to the layers made from, ~,~, PEN. It is not required that the selPct~d polymer be a copolyester or copolycarbonate. Preferably, the se~ecte~l polymer has an index of refr~rtion of less than about 1.65 and more preferably an index of refraction of less than about 1.55.
Multilayer refl~o~tin~ polarizers can be decignpfl to give high reflectivity 3 0 for light with its plane of polarization parallel to one axis, for a broad range of angles of inridenre, and simnll;~n~ously have low reflectivity and high W 09'7/01439 PCTrUS96/10665 tr~nsmiCciC~n for light with its plane of polarization parallel to the other axis for a broad ran'ge of angles of in~idence By controlling the three indices of refraction of each film, nx, ny and nz, the desired polarizer behavior can be obtained.
For nnany applications, the ideal reflecting polarizer has high reflect~nce along one axis (the so-called eYtinction axis) and zero reflect~n~e along the other (the so-callecl tr~nsmicciQn axis), at all angles of incid~nce For the tr~ncrniscic-n axis of a polarizer, it generally desirable to m~ximi7P tr~ncmi!Ccion of light pol~ri7ed in the direction of the tr~ncmiccion axis over the bandwidth of interest and also over the range of angles of interest. Average tr~ncmiscion at normal inciden~e for, a narrowband polarizer across a 100 nm bandwidth is desirably at le,ast about 50%, preferably at least about 70% and more preferably at least about 90%. The average tr~n~rniCcion at ~0 degrees from the normal for p polarized light (measured along the tr~ncmiccioll axis) for a narrow band polarizer acrossa 100 nm b;mdwidth is desirably at least about 50%, preferably at least about 70% and more preferably at least about 80%.
The average tr~ncmiCciQn at normal in~iclence for a polarizer in the h~nsmiccion axis across most of the visible spectrum (400-700 nm for a bandwidth of 300 nm) is desirably at least about 50%, preferably at least about 2 0 70%, more preferably at least about 85 %, and even more preferably at least about 90%. The average tr~ncmicsion at 60 degrees from the normal (measured along the tr~ncmiccion axis) for a polarizer from 400-700 nm is desirably at least about 50%, preferably at least about 70%, more preferably at least about 80~, and even more preferably at least about 90%.
2 5 For certain applic~tionc~ high reflectivity in the tr~ncmiccion axis at off-normal angles are pl~fe.l-,d. The average reflectivity for light polarized along the tr~ncmiccio~ axis should be more than 20% at an angle of at least 20 degreesfrom the normal.
The preferred s~lect~rl polymer for the polarizer of the present invention i'5 a copolyester of the reaction prod-lcl of a naphth~lene dicarboxylic acid or its ester such as dimethyl n~phth~l~te ranging from 20 mole percent to ~0 mole g W 097/01439 PCT~US96/10665 percent and isophthalic or terephth~lic acid or their esters such as terephthalate ranging from 20 mole percent to 80 mole percent reacted with ethylene glycol.
Olther copolyesters within the scope of the present invention have the piopc.lies .l~ccucc~d above and have a refractive index ~ccoci~t~d with the ~ransverse axis of s appro~im~tçly 1.59 to 1.69.
If some reflectivity occurs along the transmission axis, the efficiency of the polarizer at off-normal angles may be reduced. If the reflectivity along thetr~ncmiccion axis is different for various wavelengths, color may be introduced into the tr~ncmittP~ light. One way to l"e~ure the color is to determine the root 0 meadn square (RMS) value of the ~r~ncmiCcivity at a selected angle or angles over the wavelength range of interest. The % RMS color, CRMS. can be determined according to the equation:

¦((T- )~)~dl C _AI
R~S T

where the range Al to A2 is the wavelength range, or bandwidth, of interest, T is 15 the tr~ncmi~civity along the tr~n~mi~iorl axis, and T is the average tr~ncmi~sivity along the tr~ncmiccion axis in the wavelength range of interest.
For applications where a low color polarizer is desirable, the % RMS color should be less than about 10%, preferably less than about 8%, more preferably less than about 3.5 %, and even more preferably less than about 2.1% at an angle of at 20 least 30 degrees from the normal, ~.-cfe.dbly at least 45 degrees from the normal, and even more preferably at least 60 degrees from the normal.
P~,fe.dbly, a reflective polarizer combines the desired % RMS color along the tr~ncmi~ci--n axis for the particular application with the desired amount ofreflectivity along the eYtinction axis across the bandwidth of interest. For example, 25 for narrow band polarizers having a bandwidth of appro~tim~t~ly 100 nm, average tl~ncmiccion along the eYtinction axis at normal in~ çnce is desirably less than W 09l7/a~1439 PCTrUS96/10665 about 50%, preferably less than about 30%, more preferably less than about lO~o,anld even more preferably less than about 3%. For polarizers having a bandwidth within the visible range (400-700 nm, or a bandwidth of 300 nm), average tr~ncmi~ion along the eYtinction axis a~ normal incidence is desirably less thanabDUt 40%, more desirably less than about 25%, preferably less than about 15%, more preferably less than about 5% and even more l~lel~-dbly less than about 3%.

Materials Selection and Ploces:,ing With the design con~ Pr~tic!n~ described in the above mentioned U.S.
Patent Application Serial Number 08/402,041, one of ordinary skill will readily appreciate that a wide variety of materials can be used to form multilayer mirrors or polarizers according to the invention when processed under conditions s~PhPctPd to yield the desired refractive index rel~tion~hips. The desired refractive index relationships can be achieved in a variety of ways, including stretching during or after film fon~nation (e ~., in the case of organic polymers), ex~ruding (e.~., in the case of liquid crystalline materials), or coating. In ~ ition~ it is preferred that the two materials, have similar rheological p~u~Lies (_~,, melt vi~cositip~s) such that they can be co-extruded.
In general, app.op.iate combin~ion~ may be achieved by sele~tinE, as the first material, a cryst~llimP, semi-cryst~llinp~ or liquid crystalline material,preferably a polymer. The second material, in turn, may be cryst~llinP-~ semi-cryst~llimP-, or amorphous. It should be understood that in the polymer art it is generally reoQgni7ecl that polymers are typically not entirely crystalline, and thc;rcfolc, in the context of the present invention, crystalline or semi-crystalline polymers refer to those polymers that are not amorphous and inc1ll(1es any of those materials commonly refered to as cryst~llinP" partially crys~lline~ semi-crystalline, etc. The second material may have a birçfringPnt~e opposite to or the same as that of the first material. Or, the second material may have no birefringence.
Specific eY~mples of suitable materials include polyethylene n~phth~l~tP
(PEN) and isomers thereof (~" 2,6-, 1,4-, 1,5-, 2,7-, and 2,3-PEN), CA 02222486 l997-ll-26 W O 97/01439 PCT~US96/10665 polyalkylene terephth~l~tes (~,~, polyethylene terephth~l~tç, polybutylene terephth~l~te, and poly-l,4-cyclohPY~nP~imethylene terephthalate), polyimides (e~, polyacrylic imides), polyetherimides, atactic polystyrene, polycarbonates, }~lymeth~crylates (e.~., polyisobutyl methacrylate, polypropylmeth~rylate, 5 polyethylmethacrylate, and polymethylm~th~rylate), polyacrylates (e.g., polybutylacrylate and polymethylacrylate), syndiotactic polystyrene (sPS), syndiotactic poly-alpha-methyl styrene, syndiotactic polydichlorostyrene, copolymers and blends of any of these polystyrenes, cellulose derivatives (e.~.,ethyl celll-lose, cellulose acetate, cellulose propionate, cellulose acetate butyrate, 10 and cellulose nitrate), polyalkylene polymers (e , polyethylene, polypropylene, polybutylene, polyisobutylene, and poly(4-methyl)pentene), fluorinated polymers (e. ~., perfluoroalkoxy resins, polytetrafluoroethylene, fluorinated ethylene-propylene copolymers, polyvinylidene fluoride, and polychlorotrifluoroethylene), chlorinated polymers (~, polyvinylidene chloride 15 and polyvinylchloride), polysulfones, polyethersulfones, polyacrylonitrile, polyamides, silicone resins, epoxy resins, polyvinyl~e~tP, polyether-amides, ionomeric resins, el~ctorners (~, polybut~liPnç, polyisoprene, and neoprene), and polyureth~n~s. Also suitable are copolymers, e.~., copolymers of PEN ~, copolymers of 2,6-, 1,4-, l ,5-, 2,7-, and/or 2,3-naphthalene dicarboxylic acid, or 20 es~ers thereof, with (a) terephthalic acid, or esters thereof; (b) isophthalic acid, or esEers thereof; (c) phthalic acid, or esters thereof; (d) alkane glycols; (e) cycloallcane glycols (e g., cycloheY~n~ ~imeth~nol diol); (fl alkane dicarboxylic acids; and/or (g) cyclo~lk~ne dicarboxylic acids (ç,g~, cycloheY~ne dicarboxylicacid)), copolymers of polyalkylene terephth~l~ttos (~, copolymers of terephthalic 25 acid, or esters thereof, with (a) n~phth~lpnp dicarboxylic acid, or esters thereof;
(b) isophthalic acid, or esters thereof; (c) phthalic acid, or esters thereof; (d) alkane glycols; (e) cycloalkane glycols (~., cycloheY~n~ ~imeth~ne diol); (f) alkane dicarboxylic acids; and/or (g) cyc1o~lk~ne dicarboxylic acids (e ~., cyclohPx~n~ dicarboxylic acid)), and styrene copolymers (~,~, styrene-but~ ne 3 o copolymers and styrene-acrylonitrile copolymers), 4 ,4' -bibenzoic acid and ethylene glycol. In ~AAitit:nl, each individual layer may include blends of two or more of CA 02222486 l997-ll-26 W 0~7/01439 PCTrUS96/1066S
the above-described polymers or copolymers (~,&, blends of SPS and atactic polystyrene). The coPEN described may also be a blend of pellets where at least onl component is a polymer based on n~phth~lene dicarboxylic acid and other components a;re other polyesters or polyc~l,onates, such as a PET, a PEN or a co-5 PEN.
Particularly ~l~felled combin~tion~ of layers in the case of polarizers include PENlcoPEN, polyethylene terephth~l~t~ (PET)/coPEN, PEN/sPS, PET/sPS, PEN/Eastar, and PET/Estar, where "coPEN" refers to a copolymer or Iblend based upon n~rhth~ ne dicarboxylic acid (as described above) and "Estar"
10 iS polycyclrlhPY~neAimethylene te~hll.~ .o. commercially available from F~ctm~n ~herniç~l Co.
Partic ularly preferred combin~ti~llc of layers in the case of mirrors include PET/Ecdel, PEN/Ecdel, PEN/sPS, PEN/THV, PEN/coPET, and PET/sPS, where Il'coPET" refers to a copolymer or blend based upon terephthalic acid (as described 15 above), "Ecdel" is a thermoplastic polyester commercially available from F~ctm~n C'h~emi~l Co., and "THV" is a fluoro~Dlymer commercially available from 3M
~o.
The number of layers in the device is sPlected to achieve the desired optical pralperties using the minimum number of layers for reasons of film thicl~ne~c, 20 ~lexibility and economy. In the case of both polarizers and mirrors, the number of layers is ~,iereidbly less than about I0,000, more preferably less than about$,000, and (even more preferably) less than about 2,000.
As ~i~cucced above, the ability to achieve the desired relationships among the various inciices of refraction (and thus the optical l~upc~lies of the multilayer 25 clevice) is inflllence~ by the ~loc~;ng conrlitionc used to prepare the multilayer dlevice. In the case of organic polymers which can be oriented by stretching, the dlevices are g~enerally prepared by co-extruding the individual polymers to form a multilayer film and then orienting the film by stretching at a s~le~ted te-~l~.dture, optiionally followed by heat-setting at a sele~t~l te"~pe,dture. Alternatively, the 30 extrusion dnd orient~tiQn steps may be ~.Ço~ cd simlllt~npollsly. In the case of pol lri7Prs~ the film is stretched s~ s~ lly in one direction (nni~xi~l orient~ti~n)~

W O97/~01439 PCT~US96/10665 while in the case of mirrors the film is stretched subs~n~i~lly in two directions (biaxial orientation).
The film may be allowed to dimçn~iQn~lly relax in the cross-stretch direction from the natural reduction in cross-stretch, (equal to the square root of 5 the stretch ratio) to being constrained (i.e., no substantial change in cross-stretch ~imçn~ioll~). The film may be stretched in the m~hine direction, as with a length orienter; and/or in width using a tenter.
The pre-stretch temperature, stretch ~"-~.~ture, stretch rate, stretch ratio, heat set tc~ dture, heat set time, heat set rel~Y~tion, and cross-stretch rP~ tiQn 0 are sele~t~d to yield a multilayer device having the desired refractive index relationship. These variables are inter-dependent; thus, for example, a relatively low stretch rate could be used if coupled with, e g., a relatively low stretch temperature. It will be apparent to one of ordinary skill how to select the app, o~flate combination of these variables to achieve the desired multilayer device.
15 In general, however, a stretch ratio in the range from about 1:2 to about 1:10 (more yl~re.dbly about 1:3 to about 1:7) in the stretch direction and from about1:0.2 to about 1:10 (more preferably from 1:0.2 to about 1:7) orthogonal to the stretch direction is p,~fe.lcd.
Suitable multilayer devices may also be prepared using techniques such as 20 spin coating, e.~., as described in Boese et al., J. Polym. Sci.: Part B, 30:1321 1(1992) for birefringent polyimides, and vacuum r~eposition~ e g., as described by Zang et. al., Appl. Phys. Letters, 59:823 (1991) for crystalline organic compounds; the latter technique is particularly useful for certain combinations of crystalline organic compounds and inorganic materials.
Reflective Metal L~yer The multilayered polymer films described above are combined with a reflective metal layer to provide a metal-coated multilayer mirror having higherreflectivity than either the multilayered polymeric film or the reflective metal3 o alone, higher color uniformity than known polymer-based multilayer mirrors, and desirable m~n~-fa~ ring flexibility.

W O 97/01439 PCT~US96/10665 The reflective metals useful in the present invention are those having smlooth, reflective metal surfaces with a high degree of ~pPcul~r reflectivity. Any rellective metal may be used, although ~r~_f~ d metals include silver, gold, ~hlmimlm, copper, nickel, and tit~nillm Silver and aluminum are particularly The reflective metal layer may be applied to the multilayered polymer films by conventional coating techniques well-known to those of ordinary skill in this art. Such known processes include pyrolysis, powder coating, vapor deposition, caLthode sputtering, ion plating, and the like. Cathode sputtering and 0 vapor deposition are often ~lcf~ ;d in view of the uniformity of structure and thickness that can be obtained. Altemately, the reflective metal may be a separate metal sheet, such as a metal foil or a mPt~li7P~d polymer or glass sheet, that is l~min~tPA to the multilayered polymer film by means of a suitable adhesive, for example, a hlot melt adhesive such as the VITEL 3300 adhesive from Shell Chemical Company, 4040 Embassy Parkway, Akron, Ohio 44333, or a pressure sensitive adhesive such as a 90/10 IOA/AA or a 95/5 IOA/acrylamide acrylic PSAs from 3M Company, St. Paul, MN 55144.
The t~ ne~c of the reflective metal or rnet~li7PA layer applied to the multilayered polymer films to form the metal-coated multilayer mirrors of the present inven~ion can be seleotPA to provide the desired reflectivity. By adjusting the thicknp~ of the metal layer for a particular metal, the reflective layer canprovide the desired reflectivity in the desired bandwidth. The reflective metal layer must ble thick enough to reflect the desired amount of visible light;
preferably, the reflective metal layer is at least about 75 nm to about 100 nm thick for metals such as silver and gold, and at least about 20 nm to about 30 nm thick for me~ls such as ahlminl~m, nickel, and tit~nillm, although in typical production all of these metals are coated to a thil~knP~c of about 50 nm to about 100 nm. These thiçkrl~P~ ranges are suitable whether the reflective metal layer is applied as a coating or as a sep~r~tP mPt~li7ed sheet.
3 0 The metal-coated multilayer mirrors of the present invention have desirable optical l)lo~..lies in that they have high specul~rity and high reflectivity over a W O 97101439 PCT~US96/10665 broad bandwidth. Preferably, the mirrors of the present invention have a reflectivity of more than about 90% in the visible range of the spectrum, preferably more than about 95%, and most preferably more than about 99%.
The metal-coated multilayer mirrors of the present invention may be 5 l~min~ttod to a rigid support, typically aluminum or steel sheet metal, to be used effectively as is well known to those of ordinary skill in the art. The rigid support can then be bent and sized for proper optical configuration.
Alternatively, the metal support may be the metal layer in the metal-coated multilayer mirror of the present invention. For those applications using multiple 10 reflections, the spe~ rity of the reflection is important. The surface smoothness of the support can affect the specular reflectiQn, with more expensively prepared surfaces producing higher spe~ul~r refle~tionc When supported in such a manner, the metal-coated multilayer mirror of the present invention can be used in those applications where light is efficiently 15 diverted with a high degree of spe~ul~rity. Combining a reflective metal layer with a multilayered polymer film that reflects visible light to form the metal-coated multilayer mirror of the present invention reduces the amount of color that results from edge b~n~iing and leaks in the band center. Thus, mirrors of the present invention are useful in applir~tion~ requiring broad bandwidth reflection, 2 o high specul~rity, low manuf~ntllrinE costs, and high reflectivity. Examples include solar reflectors, light pipes, fluorescent light reflectors, reflectors for back lights in liquid crystal displays, back lights for computer displays, sign back lighting, and re~.oreflective sh.o~ting. While each of these varied applicationshave particular requirements unique to that applir~tio~, all of them rely on 25 efflcient and highly specul~r refl~tic n. Other uses would be apparent to those of ol-lin~y skill in this art where high specul~rity is desired, e.~., applications requiring a large number of reflP~tions In order to more fully and clearly describe the present invention so that those skilled in the art may better understand how to practice the present invention, 30 the invention will now be ~e~sc,il)~fl by way of the following examples. The W O 97/01439 PCTrUS96tlO665 examples are inten~ed to il1ustrate the invention and should not be construed aslimitin~ the invention rlicclos~p~ and cl~im~ herein in any manner.

E'XAMPT.F I (PET:Ecdel. 601. Mirror~
A caextruded film cont~ining 601 layers was made on a sequential flat-film-making line via a coextrusion process. A polyethylene terephth~l~tP (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt. ~o phenol/40 wt. % dichlolobe,--,e.-e) was delivered by one extruder at a rate of 75 pounds per hour and Ecdel 9966 (a thermoplastic elastomer available from F~ctm~n Chemi~l) was delivered by o another extnlder at a rate of 65 pounds per hour. The PET was on the skin layers. The feedblock method (such as that described in U.S. Patent 3,801,429) w,as used to generate 151 layers which was passed through two multipliers producing an extrudate of 601 layers. U,S. Patent 3,565,985 describes exemplary coextrusion multipliers. The web was length oriented to a draw ratio of about 3.6 with the web temperature at about 210~F, The film was subsequently preheated to about 235~F in about 50 seCo~1c and drawn in the transverse direction to a draw ratio of about 4.0 at a rate of about 6% per second, The film was then relaxed about 5% of its m~imum width in a heat-set oven set at 400~F, The finished film thi~l~nPcc was 2.5 mil.
2 0 The c,ast web produced was rough in texture on the air side, and provided the tr~ncmission as shown in Figure 3. The % tr~ncmiccio~ for p polarized light polarized in tlhe non-stretched direction at a 60~ angle (curve b) is similar the value at normal incidence (curve a) (with a wavelength shift).
For comparison, film made by Mearl Corporation, presumably of relatively isotropic ma~erials (see Fig. 4) shows a notice~hle loss in reflectivity for p polarized lighlt at a 60~ angle (curve b, co~ ,d to curve a for normal inci~ience).

EXAMPT.F. 2 (PET:Ecdel. 151. Mirror) A coextruded film ct nt~ining 151 layers was made on a sequential fla~-film-3 o making line via a coextrusion process. A polyethylene terephth~l~t~o (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt phenol/40 wt. 9~o dichlorob~n~nP) was delivered by one extruder at a rate of 75 pounds per hour and Ecdel 9966 (a thermoplastic elastomer available from F~ctm~n Chern~ ) was delivered by another extruder at a rate of 65 pounds per hour. The PET was on the skin layers. The feedblock method was used to generate 151 layers. The web was 5 length oriented to a draw ratio of about 3.5 with the web lc.~ ture at about 210~F. The film was subsequently preheated to about 215~F in about 12 seconds and drawn in the transverse direction to a draw ratio of about 4.0 at a rate of about 25% per second. The film was then relaxed about 5% of its maximum width in a heat-set oven set at 400~F in about 6 seCoru~c The finished film thir~nP$s was10 about 0.6 mil.
The tr~ncmiccion of this film is shown in Figure 5. The 9to tr~ncmis~ion for p polarized light polarized in the non-sLretchcd direction at a 60~ angle (curve b) is similar the value at normal in~i~lPnce (curve a) with a wavelength shift. At the same extrusion con~liti( ns the web speed was slowed down to make an infrared 5 reflecting film with a thickness of about 0.8 mils. The tr~n~miccion is shown in Fig. 6 (curve a at normal incidence~ curve b at 60 degrees).

EXAMP!.F. 3 (PE~N:Ecdel. ~25. Mirror) A coextruded film cont~ining 225 layers was made by extruding the cast 20 web in one operation and later orienting the film in a laboratory film-stretching apparatus. A polyethylene n~phth~l~tP (PEN) with an Intrinsic Viscosity of 0.5 dl/g (60 wt. % phenol/40 wt. % dichlorobenzene) was delivered by one extruder at a rate of 18 pounds per hour and Ecdel 9966 (a thermoplastic elastomer available from F~m~n (~hPmir~l) was delivered by another extruder at a rate of 2 s 17 pounds per hour. The PEN was on the skin layers. The feedblock method wasused to generate 57 layers which was passed through two multipliers produring anextrudate of 225 layers. The cast web was 12 mils thick and 12 inches wide. The web was later biaxially oriented using a labo,dto~ stretching device that uses apantograph to grip a square section of film and simultaneously stretch it in both 30 directions at a uniform rate. A 7.46 cm square of web was loaded into the stretcher at about 100~C and heated to 130~C in 60 secon-l~. Stretching then =

CA 02222486 l997-ll-26 w 097/01439 PCT~US96/10665 comlmer~ced at 100%/sec (based on original dinnç~sions) until the sample was stn~tched to about 3.5x3.5. ~mmeAi~tçly after the stretching the sample was cooled 'by blowing room temperature air on it.
Figure 7 shows the optical response of this multilayer film (curve a at S normal inridenee, curve b at 60 degrees). Note that the % tr~ncmiccion for p po]arized light polarized in the non-stretched direction at a 60~ angle is similar to what it ;s at normal inri(lenre (with some wavelength shift).

'EX'AMPLE 4 (PEN:THV 500. 449, Mirror) A coextruded film corl~ining 449 layers was made by extruding the cast ~web in one operation and later orienting the film in a laboratory film-stretching apparatus. A polyethylene n~phth~ t.o. (PEN) with an Intrinsic Viscosity of 0.53 dl/g (60 wt. % phenol/40 wt. % dichlorobenzene) was delivered by one extruder at a rate of 56 pounds per hour and THV 500 (a fluoropolymer available 5 ~From Minnesota Mining and ~nufact--ring Company) was delivered by another extruder at a rate of l l 'pounds per hour, The PEN was on the skin layers and '50% of the PEN was present in the two skin layers. The feedblock method was used to generate 57 layers which was passed through three multipliers producing an extrudate of 449 layers. The cast web was 20 mils thick and 12 inches wide.
2 o The web was ]ater biaxially oriente~ using a laboratory stretching device that uses a p,antograph to grip a square section of film and simultaneously stretch it in both directions at 'a uniform rate. A 7.46 cm square of web was loaded into the stre:tcher at about 100~C and heated to 140~C in 60 sçcon-lc Stretching then connnnenre~ at 10%/sec (based on original rlimencionc) until the sample was 2 5 stre:tched to about 3.5x3.5 . TmmeAi~t~ly after the stret~hing the sample was cooled by blowing room tel.l~.~ture air at it.
Figure 8 shows the tr~ncmission of this multilayer film. Again, curve a s,hows the rÇsr~nce at normal inci~enr~e~ while curve b shows the response at 60degrees for p-polarized light pol~ri7~d in the non s~l~,t~hcd direction.

CA 02222486 l997-ll-26 W O 97/01439 PCTrUS96/10665 F.XAMpLE S (PEN:coPEN. 601--Hi~h Color Polarizer) A coextruded film cont~ining 601 layers was produced by extruding the web and two days later orienting the film on a different tenter than described in all the other ~Y~mples A polyethylene naphthalate (PEN) with an Intrinsic 5 Viscosity of 0.5 dl/g (60 wt. % phenol/40 wt. % dichlorobenze. e) was delivered by one extruder at a rate of 75 pounds per hour and a coPEN (70 mol% 2,6 NDC
[a methyl ester of naphth~lfne dicarboxylic acid~ and 30 mol% DMT [dimethyl terephth~l~t~-]) with an IV of 0.55 dl/g (60 wt. % phenol/40 wt. %
dichlorobenzene) was delivered by another extruder at a rate of 65 pounds per 10 hour. The feedblock method was used to generate 151 layers, and was designed to produce a gradient distribution of layers with a ratio of thir1~nPcs of the optical layers of 1.22 for PEN and 1.22 for coPEN. The PEN skin layers were coextruded on the outside of the optical stack with a total thickness of about 8%
of the coextruded layers. The optical stack was passed through two multipliers 15 producing an extrudate of 601 layers. U.S. Patent 3,565,985 describes similarcoextrusion multipliers. All sL-clching was done in the tenter. The film was preheated to about 280~F in about 20 seconllc and drawn in the transverse direction to a draw ratio of about 4.4 at a rate of about 6% per second. The film was then relaxed about 2~ of its m~ximum width in a heat-set oven set at 460~F.
20 l[he finished film thirl~ess was 1.8 mil.
The tr~nsmiccion of the film is shown in Figure 9. Curve a shows tr~ncmiccion of light polarized in the non-streech direction at normal incidence, curve b shows tr~ncmiccion of p polarized light polarized in the non-stretched direction at 60~ incirlence~ and curve c shows tr~nsmiccion of light polarized in the 25 stretch direction at normal incid~nce Note the nonuniform tr~ncmi~cion of p polarized light at both normal and 60~ inriri~nre The average tr~nsmiccion for curve a over 400-700 nm is 84.1%, while the average tr~nsmiccion for curve b over 400-700 nm is 68.2%. The average tr~ncmicsion for curve c is 9.1%. The % RMS color for curve a is 1.4%, and the % RMS color for curve b is 11.2%.

CA 02222486 l997-ll-26 W O917/C~1439 PCT~US96/10665 E;5~AMPI,~ 6 (P~N:coPEN. 601. pol~rizer) A coextruded film cont~ining 601 layers was made on a sequential flat-film-making line via a coextrusion process. A polyethylene nal)htl.~l~tç (PEN) with an Intrinsic Viscosity of 0.54 dl/g (60 wt % phenol plus 40 wt % dichlorobenzene) 5 was delivered by on extruder at a rate of 75 pounds per hour and the coPEN was de livered by another extruder at 65 pounds per hour. The coPEN was a copolyrner of 70 mole % 2,6 naphth~lenP decarboxylate methyl ester, 15 %
dimethyl isophth~l~te and 15% dimethyl terephth~l~te with ethylene glycol. The feedblock method was used to gen~.~te 151 layers. The feedblock was decign~od 10 to produce a gradient distribution of layers with a ratio of thic~ ss of the optical layers of 1.22 for the PEN and 1.22 for the coPEN. The PEN skin layers were ca,extruded on the outside of the optical stack with a total ~hicl~n~P,cc of 8% of the coextruded la,yers. The optical stack was multiplied by two sequential multipliers.
The nominal multiplication ratio of the multipliers were 1.2 and 1.27, respectively.
5 The film was subsequently pl~heatcd to 310~F in about 40 secon(ls and drawn inthe transverse direction to a draw ratio of about 5.0 at a rate of 6% per second.
The finished film thirlrnçcc was about 2 mils.
Figure 10 shows the tr~n~mic~ion for this multilayer film. Curve a shows tr~nsmissic-n of light polarized in the non-stretch direction at normal incidence, 20 curve b shows tr~n~mic~ion of p polarized light polarized in the non-stretch direction at 60~ inrirlPnr,e, and curve c shows tr~n~miccion of light polarized in the stretch direction at normal inridenre, Note the very high tr~ncmicsion of p polarized light at both normal and 60~ inrid~nce (80-100%). Also note the very high extinction of light polarized in the stretched direction in the visible range 25 (400-700 nm)l shown by curve c. FY~inr,tiorl is nearly 100% between S00 and 650 nm.

F,XAMPLE 7 (PEN:sPS. 481. Polarizer) A 4~1 layer multilayer film was made from a polyethylene naphth~l~te 30 (PEN) with aLn intrinsic viscosity of 0.56 dl/g (60 wt. % phenol and 40 wt %
dichlo.~ben7.e,l1e) pu-~has~l from r~ n ~hemir~lc and a syndiotactic CA 02222486 l997-ll-26 W O 97/01439 PCTrUS96/1066 polystyrene (sPS) homopc,lymer (weight average molecular weight = 200,000 Daltons, s~mrled from Dow Co~ tion). The PEN was on the outer layers and was extruded at 26 pounds per hour and the sPS at 23 pounds per hour. The feedblock used produced 61 layers with each of the 61 being approxim~tely the 5 same thicknPss. After the feedblock three (2x) multipliers were used. Equal thirl-n.occ skin layers cont~ining the same PEN fed to the feedblock were added a~.ter the final multiplier at a total rate of 22 pounds per hour. The web was e;ctruded through a 12" wide die to a thirl~nP~c or about 0.011 inches (0.276 mm).
The extrusion te.~ ture was 290~C.
This web was stored at ambient con-litionc for nine days and then llni~xi~lly oriented on a tenter. The film was ~ ,healed to about 320~F (160~C) in about 25 seconrlc and drawn in the transverse direction to a draw ratio of about 6: l at a rate of about 28% per second. No rel~Y~tior- was allowed in the stretched direction.
I'he finished film thickness was about 0.0018 inches (0.046 mm).
Figure 11 shows the optical ~.~r.. ance of this PEN:sPS reflective polarizer cont~inin~ 481 layers. Curve a shows tr~ncmiccioll of light polarized in the non-stretch direction at normal inr;dence~ curve b shows tr~ncmic~io~- of p polarized light polarized in the non-stretched direction at 60~ in~ nce7 and curve c shows tr~ncrniCcion of light polarized in the stretch direction at normal incidence.
20 Note the very high tr~n~miCcio~ of p polarized light at both normal and 60~
inci~P~ce Average tr~ncmicciQr~ for curve a over 400-700 nm is 86.2%, the average tran~mi~sion for curve b over 400-700 nm is 79.7%. Also note the very high eYtinction of light polarized in the stretched direction in the visible range (400-700 nm) shown by curve c. The film has an average tr~n~mi~ion of 1.6%
25 for curve c between 400 and 700 nm. The % RMS color for curve a is 3.2%, while the % RMS color for curve b is 18.2%.

lEXAMPT F. 8 (PEI':Ecdel. 601. Mirror) A coextruded film cont~ining 601 layers was made on a sequential flat-film-30 making line via a coextrusion process. A polyethylene te~.~hlh~l~t~ (PET) with ~n Intrinsic Viscosity of 0.6 dl/g (60 wt. % phenol/40 wt. % dichloroben7~ne) was _ W O ~7/01439 PCTrUS96/10665 delivered to the feedblock at a rate of 75 pounds per hour and Ecdel 9967 (a thermoplastic elastomer available from F~ctm~n Chernic~l) was delivered at a rate of 60 pounds per hour. The PET was on the skin layers. The feedblock rnethod was used to generate 151 layers which was passed through two multipliers ~producin~ an extrudate of 601 layers. The multipliers had a nominal multiplication ratio of 1.2 (next to feedblock) and 1.27. Two skin layers at a total throughputof 24 pounds per hour were added symmetrically between the last multiplier and l:he die. The !~kin layers were composed of PET and were extruded by the same extruder supplying the PET to the feedblock. The web was length oriented to a 0 draw ratio of about 3.3 with the web len~ tllre at about 205~F. The film was subsequently preheated to about 205~F in about 35 c~Con-ls and drawn in the traLnsverse dire,ction to a draw ratio of about 3.3 at a rate of about 9% per second.
Thlo film was then relaxed about 3% of its m~ximllrn width in a heat-set oven set at 450~F. The fini~hed film thi~kne~c was about 0.0027 inches.
The film provided the optical pe-ro---~ance as shown in Figure 12.
'rr~lrlcmiccion is plotted as curve a and reflectivity is plotted as curve b. The lunlinous reflectivity for curve b is 91.5%.

l_XAMPLE 9 (PEN:PCTG. 481. Polarizer) A coextruded film cont~ining 481 liyers was made by extruding the cast web in one operation and later orienting the film in a laboratory film-stretching applaratus. Thle feedblock method was used with a 61 layer feedblock and 3 (2x) rnultipliers. Thick skin layers were added between the final multiplier and the die.
Polyethylene nAI~h~ e (PEN) with an Intrinsic Viscosity of 0.47 dl/g (60 wt. %
phenol/40 wt. % dichlG.oben~,ne) was delivered to the feedblock by one extruder a,t a rate of 25.0 pounds per hour. Glycol mo~lified polyethylene dimethyl cyclQheY~ne terephth~l~te (PCTG 5445 from F~ctm~n Chemi~l) was delivered by another extruder at a rate of 25.0 pounds per hour. PEN was on the skin layers.
Another stream of PEN from the above extruder was added as skin layers at a rate3 o of 25 pounds per hour. The cast web was 0.007 inches thick and 12 inches wide.
1'he web was later llni~xi~lly o.icn~ using a laboratory sL.~t,tclling device that uses W O 97/01439 PCTrUS96/1066 a pantograph to grip a section of film and stretch it in one direction at a uniform ra~e while it is allowed to freely relax in the other direction. The sample of web loaded was about 5.40 cm wide (the unconstrained direction) and 7.45 cm long between the grippers of the pantograph. The web was loaded into the stretcher at5 about 100~C and heated to 135~C for 45 seCQn~lc Stretching then co~nmence~d at20%/sec (based on original dim~ncions) until the sample was stretched to about 6:1 (based on gripper-to-gripper measurements). Irnmefli~ttoly after stretching, thesample was cooled by blowing room temperature air at it. In the center of the sample the film was found to relax by a factor of 2Ø
Figure 13 shows the tr~ncmiccion of this multilayer film where curve a shows tr~nsmicsion of light polarized in the non-stretch direction at normal inciden~e, cuNe b shows tr~ncmicsiQn of p polarized light polarized in the non-stretch direction at 60~ incider1ce, and curve c shows tr~ncmicsion of light polarized in the stretch direction at normal inCi~lçnce EXAMPLE lO (PET.~cdel. 151. Ag-Coated and Al-Coated Mirror) A coextruded film cont~ining 151 layers was made on a sequential flat-film-making line via a coextrusion process. A polyethylene terephthalate (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt. % phenol/40 wt. %
20 dichlorobenzene) was delivered to a feedblock by one extruder at a rate of 75pounds per hour and Ecdel 9966 (a thermoplastic elastomer available from F~ctm~n ~hemic~l) was delivered to the feedblock by another extruder at a rate 65 pounds per hour. The feedblock method was used to generate 151 layers with a casting wheel speed of 10 ft./min. The skin layers were PET and were thicker 25 than the internal layers, with the skin layers accounting for about 8% of the film's thicknPcs. The web was length oriented to a draw ratio of about 3.5 with the web~c.l,p~,lature at about 210~F. The film was subsequently preheated to about 212~F
in about 12 seco~ c and drawn in the transverse direction to a draw ratio of about

4.0 at a rate of about 25 percent per second. The film was then relaxed about 5 %

CA 02222486 l997-ll-26 W O'37/lD1439 PCTrUS96/10665 of its m~xi7~nlllm width in a heatset oven at 400~F in about 6 secon~s. The finiched film thickness was about 0.6 mil. The thi''l~n~c~ of this multilayered polymer film was sele~te~ to be reflective in the visible region of the sl~ect~
This multilayered polymer refll~octing film was vacuum metZ~Ii7f~d in a continuous m~lltirh~mher vacuum coater. One multilayered polymer refl~xting filmwas coated w~ith aluminum evaporated from an aluminum oxide crucible heated by a tnngct~n filament. The web speed was 10 ft/min and was not backed with a chillroll. The aluminum layer was coated to a tPnsmiccion level of 0.5% at 550 nm and a condt~ctivity of 0.25 mhos/sq. A second multilayered polymer reflectingfilm was coated with silver e~ or~ted from an alllminllm oxide crlcible heated by a tungsten fil~ment The web speed was 10 ft/min and the substrate was not chilled with a chillroll. The silver layer was coated to a tr~n~mic~i-n level of0.5% at 550 nm and a conductivity of 2.6 mhos/sq. Both films were adherent to the multilayered polymer refle~fing film, passing a standard tape removal test, ASTM Tape Removal Test B571. In addition, after met~li7ing a noticeable improvement could be seen by the naked eye in the visible reflection of both mirrors which appeared to be unifonTIly reflective as compared to visible coloration ot the unco~t~d multilayered polymer reflective films with a non-repeating pat~ern shifting with the angle of observation.
These mirrors were then ch~r~ct~rized by measuring their optical spectra reflection in a Perkin Elmer ~-9. An analysis of the results is shown in the Table I below. R,~",,, is the measured reflectivity of the sample that is integrated over the wavelength sensitivity of the human eye. The dominant wavelength is the apl~a,G,-t color of the sample that is c~lcul~t~d with CIE techniques using Illuminant C and the 10~ observer according to ASTM E308 "Standard Test Method For Computing Thle Colors of Objects Using the CIE System". The color purity is the saturationof the color, with 0% being white and 100% being a pure color. The multilayered polymer refle~ting film before m~t~li7z~tiorl iS highly colored and has a modestluminous refl~xtion. When met~li7ed with either silver or aluminum~ the luminousreilection of both metal-coated multilayer mirrors is greater than 90%. Both mirrors have a higher reflectivity than a PET film m~t~li7P~I with al~lminnm. The CA 02222486 l997-ll-26 W O 97/01439 PCTrUS96/10665 color purity of the metal-coated multilayer mirrors is subst~nt~ y lower than that of the unco~t~d multilayered polymer reflecting film.
TABLE I

Integrated Reflectivity of Metal-Coated Multilayer Mirror and PET Substr~t~, Measured from the Su~)st~t~o Side Sample Total R""" Dominant Purity Wavelength lo (%) (nm.) (%) Multilayer 70.1 572 53.7 Optical Film Ag coated 97.9 568 1.8 Multilayer 15Optical Film Ag coated 95.8 571 2.4 PET
Al coated 90.9 533 3.3 Multilayer 2 oOptical Film Al coated PET 82.1 493 0.1 All of the measurements shown in Table I were made with light incident on the polymer side of the sample. Typically, aluminum co~tingc on PET films are 4 percent more reflective and silver films are 1 percent more reflective when viewed from the metal side. In co~tr~ct to this, metal-coated multilayer mirrorsare more reflective when viewed from the polymer side. The side-to-side differences for metal-coated multilayer mirrors are more pronounced when the metal is aluminum than when it is silver.
Figure 14 is a spectra from the ~lllminum and silver coated multilayer mirrors diccussed above. Initially, it should be noted that this particular mirror construction is less than optimum in that a wider reflective band can be achieved by using more layers and a greater distribution of quarterwave reflectors.

-2~

W 0'97/lD1439 PCTrUS96/10665 Additionally, a higher reflectivity in the reflective band can be achieved by using polymers wilh a larger index change or by using more layers. No~P~hPle~c, the spectra clearly shows that the reflective metal coating adds reflection to the portions of the visible spectrum not already covered by the multilayered polymer5 film.

FXAMPLE l l (PET:Ecdel Film laminated to Al Substrate To evaluate metal l~min~-~i multilayer mirrors of the present invention multilayered ~polymer films as described in Example 1, with skin layers coextruded 1O on the outside of the optical stack with a total thickness of about 14% of the coextruded Layers, were l~min~-f?d to Everbrite0 T ighting Sheet Aluminum, available from the Sheet and Plating Division of Aluminum Company of America, Rettendorf, Iowa,using a 95/5 IOA/acrylamide acrylic pl~s~lrt; sensitive adhesive from 3M Company, St. Paul, MN 55144, which is commonly used on Scotchtint0 fillmS.
These multilayer film, aluminum b~ckin~, and multilayer film/aluminum l~min~te were then characterized by measuring their optical spectra reflection in a Perkin Elmer A-9. An analysis of the results is shown in Table II below. R~,....
is the measured reflectivity of the sample that is integrated over the wavelength 20 sensitivity of the human eye. The do~ n~llt wavelength is the appar~nt color of l~he sample that is c~lc~ t~d with CIE techniques using Tlhlmin~nt C and the 10~observer according to ASTM E308 "Standard Test Method For Computing The l~olors of Objects Using the CIE System". The color purity is the saturation of lhe color, with 0% being white and 100% being a pure color. The mirror gloss, 2 5 ~,vhich is an indi~-ion of specul~r refl~rt~n~e, was measured using a Pocket Gloss Specular 60 Mirror-Gloss Meter from BUIK-Gardner, Inc., Silver Spring, Maryland.

W O 97/01439 . PCTrUS96/10665 TABLE II

Integrated Reflectivity and Color for l~et~1i7P~ Multilayer Film on Everbrite~
~ mimlm R~ ing Sample Total R~ Dominant Color Mirror Wavelength Purity Gloss (%) (nm.) (%) (%) Multilayer 87 572 32.3 79.5 Film Everbrite~ 88 482 0.7 80.6 ~ minll~
Multilayer/ 96 577 4.9 88.2 Aluminum backing 15 As can be seen, the reflectivity of the multilayer/~ mim~m laminate is sig~ific~ntly greater than that of either the multilayer mirror or the Everbrite0 aluminum alone.

EXAMPLE 12 (PET:Ecdel. A~-Coated and Al-Coated Mirrors) To evaluate metal-coated multilayer mirrors of the present invention in applications using multiple refle~tionc, vapor-coated multilayered polymer filmsas described in Example 16 were l~min~tP~ to 3105-H14 ~luminllm using a 90/10 IOA/AA acrylic ~ S~ne sensiqve adhesive from 3M Company, St. Paul, MN
55144, which is commonly used on Silverlux~ films. This type of aluminum is inexpensive and lacks a specially prepared surface for higher reflectivity. It also has a high diffuse reflection and, therefore, is not useful for appli~ on~ requiring geometrical refle~tions. Standard SS95P Silverlux~ material available from the Minnesota Mining and M~n--fa~tll in~ Company was also pr~ared in this same manner.
3 0 The spectral curves of l~min~tP~ ~mplP$ and Iml~min~tp~ alnminum ~heetin~ are shown in Figure 15. As can be seen, the silver-coated multilayered polymer mirror and the Silverlux0 material have very similar reflectivities. Table W O 97/l01439 PCT~US96/10665 ]II below shows the data reduced from their spectra shown in Figure 15. As can be seen, the reflectivity of the mirrors have not suffered from this l~min~fion process. The reflectivity of the bulk ~lumimlm is only 72%, nearly half of whichis diffuse reflection. Thus, any film applied to this b~ ing both increases the total

5 reflection and reduces the diffuse rf fle~.tion The mirrors of the present invention had subsf~nti~lly less diffuse reflection than the metal-coated Silverlux0, which providès an ~tiditiorl~l advantage to the mirrors of the present invention.

TABLE III

Integrated Reflectivity and Color for Mef~1i7~d Multilayer Film, SS95P
Silverlux~D, and Aluminum RaCL-ing~ All Samples Applied To Aluminum R~kin~
Sample Total R",~" Dominant Color Diffuse Wavelength Purity Reflection (%) (nm.) (%) (%) SS95P -98.7 574 0.3 2.5 Silverlux0 Al coaeed 92.6 566 3.3 O.5 MultilayerlAI
2 0 ba.~kin~
Ag coate~d 97.6 574 1.5 O.9 Multilayer/AI
backing Al R~l~ki,l~72.3 574 2.2 31.6 Other modifications and variations of the present invention are possible in light of the above ~e~rhin~s- For eY~mrle~ additives and other modifying agents,such as UV abso-b~.~, may be added to one or more of the layers of the 30 mlultilayered polymer films used in the present invention. It is to be understood, however, that changes may be made in the particular embo~iimpn~ described above which are within the full in~fnded scope of the invention as defined in the appended cl2dms.

Claims (10)

CLAIMS:

1. A metal-coated multilayer mirror comprising a multilayered polymer film in which the layers have an average thickness of not more than 0.5 microns, and a metal layer comprising a reflective metal.

2. A metal-coated multilayer mirror comprising a multilayered polymer film and a metal layer;
the multilayered polymer film comprising:
(A) layers of a birefringent polymer having an average thickness of not more than 0.5 microns; and (B) layers of a selected second polymer having an average thickness of not more than 0.5 microns;
and the metal layer comprising a reflective metal.

3. A metal-coated multilayer mirror comprising a multilayered polymer film and a metal layer;
the multilayered polymer film comprising:
(A) layers of a birefringent polymer having an average thickness of not more than 0.5 microns; and (B) layers of a selected second polymer having an average thickness of not more than 0.5 microns;
wherein the film has been stretched in at least one direction to at least twice that direction's unstretched dimension;
and the metal layer comprising a reflective metal.

4. The mirror of claims 2 or 3 wherein the birefringent polymer is a semi-crystalline polyester.

5. The mirror of any preceding claim wherein the reflective metal is selected from the group consisting of aluminum, silver, gold, copper, nickel, and titanium.

6. The mirror of claim 5 wherein the metal is silver and the silver layer has a thickness of at least about 75 nm to about 100 nm.

7. The mirror of any preceding claim wherein the reflective metal comprises a metalized polymer or glass sheet that is laminated to the multilayered polymer film.

8. The mirror of claim any of Claims 1 through 6 wherein the reflective metal comprises a metal sheet laminated to the multilayered polymer film.

9. The mirror of any preceding claim wherein its reflectivity of visible light is greater than 95%.

10. The mirror of any preceding claim wherein the film has been stretched in at least two directions.