WO2005108073A1 - Optical products for displays - Google Patents
Optical products for displays Download PDFInfo
- Publication number
- WO2005108073A1 WO2005108073A1 PCT/US2005/007387 US2005007387W WO2005108073A1 WO 2005108073 A1 WO2005108073 A1 WO 2005108073A1 US 2005007387 W US2005007387 W US 2005007387W WO 2005108073 A1 WO2005108073 A1 WO 2005108073A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- optical
- adhesive layer
- optical film
- optical sheet
- films
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/20—Adhesives in the form of films or foils characterised by their carriers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24777—Edge feature
Definitions
- the present invention relates to optical films.
- the present invention relates to optical sheets formed by bonding adhesive to optical films.
- Optical films are used to increase the amount of light exiting an optical display in a direction normal, or "on-axis," to the surface of the display. Increasing the amount of on-axis light reduces the amount of energy required to generate a desired amount of on-axis luminance. This is particularly important for optical displays that use battery powered light sources such as those used in laptop computers, calculators, digital wristwatches, cellular phones, and personal digital assistants.
- the 3M brand Brightness Enhancement Film is used to address this problem.
- the film collects light from "off-axis” and redirects or “recycles” this light on-axis toward the viewer. In use, this material increases the on-axis luminance at the expense of off-axis luminance.
- a "turning" film is also used to increase the amount of on-axis light exiting a display. Turning films are usually used in combination with a wedge-shaped light guide. Light rays exiting the light guide at the glancing angle, usually less than 30° to the output surface, are internally reflected such that they are directed substantially on-axis. Representative embodiments of turning films are described in U.S. Patent Nos. RE38,243 and 4,984,144.
- Another film used to increase on-axis light exiting a display is a multilayer polymer film such as DBEF from 3M Company.
- the film is formed of about 700 to 800 layers of polymer each having about 150 run thickness and provides high reflectivity over a wide bandwidth. Representative embodiments are described in U.S. Patent No. 6,613,421.
- Other films, such as diffuser-type films, along with the films described above, are used extensively in optical displays. Multiple films are arranged between the optical light guide and liquid crystal panel of a liquid crystal display (LCD), and it is difficult and inefficient to insert each film individually. This is especially true for small displays.
- these films have a structured surface that is fragile and easily damaged and must be protected until the films are assembled into a display.
- a protective cover, or pre-mask is laminated to the film to protect the structured surface. Placing and then removing the pre-mask from each film are added steps in the manufacture of displays, which increases the cost and time required for assembly.
- the present invention is an optical sheet and a method of making the optical sheet.
- the optical sheet includes an optical film laminated onto an adhesive layer.
- the perimeter of the adhesive layer is inset from the perimeter of the optical film so that no adhesive is exposed to collect dust and particles or to transfer to other films or components of an optical display.
- Figure 1 is a front view of a representative embodiment of an optical sheet set for use in a display in accordance with the present invention.
- Figure 2 is a cross-sectional side view of a representative embodiment of an optical sheet set for use in a display in accordance with the present invention.
- Figure 3 is a top view of a representative embodiment of an optical sheet.
- Figure 4 is a top view of a representative alternate embodiment of an optical sheet.
- Figures 5a and 5b are top views and Figures 5c, 5d, and 5e are cross-sectional side views illustrating a method of making an optical sheet in accordance with the present invention.
- Figure 5f is a side view illustrating a method of making optical sheet sets in accordance with the present invention.
- Figure 1 shows an optical sheet set in accordance with the present invention.
- Figure 1 is a front view of an optical sheet set 10 for use in displays.
- optical sheet set 10 includes three optical sheets 12a, 12b, and 12c and is carried by liner 14.
- Optical sheet 12a includes optical film 16a and adhesive layer 18a
- optical sheet 12b includes optical film 16b and adhesive layer 18b
- optical sheet 12c includes optical film 16c and adhesive layer 18c.
- Adhesive layer 18a is laminated onto liner 14, and optical films 16a, 16b, and 16c are laminated, in alternating fashion, with adhesive layers 18b and 18c.
- optical sheet set 10 is removed from liner 14 and assembled into an optical display, such as an LCD, between the optical light guide and liquid crystal panel.
- optical sheet set 10 Laminating the optical films together prior to installation into an optical display decreases the time and cost associated with assembly of the optical display by avoiding individually inserting each film.
- Installation of optical sheet set 10 into an optical display can also be performed using an automated assembly line.
- Optical sheet set 10 can also reduce the amount of debris between films and reduce damage to the films.
- optical sheet set 10 is shown having three optical films, the number of optical films varies depending on the display in which it is used. Some or all of the optical films may be of the same type, again, depending on the optical display. Examples of the types of optical films that may be used in the present invention include light directing films, turning films, multilayer polymer films, diffuser-type films, etc.
- the presence of adhesive layer 18a is optional.
- Figure 2 is a cross-sectional side view of optical sheet set 10 having only two optical films for simplicity.
- Optical sheet set 10 includes optical sheet 12a with film 16a and adhesive layer 18a and optical sheet 12b with film 16b and adhesive layer 18b.
- Figure 2 includes distances d ⁇ l and d ⁇ 2, which is shown as the distance between the edges of film 16b and the edges of adhesive layer 18b. Distances d ⁇ l and d ⁇ 2 are representative of the corresponding distances for any optical sheet.
- shift length S which is the distance between the edges of films 16a and 16b. Shift length S is also representative of the corresponding shift length between any pair of adjacent films.
- Optical sheets 12a and 12b are initially made individually in a process that is described below.
- optical sheet 12b is laminated onto optical sheet 12a, which requires aligning the edges of film 16b with the edges of film 16a.
- the process of alignment is imperfect, and often the optical sheets are misaligned by some distance.
- the misalignment is shown here as shift length S.
- the present invention is advantageous even when there is no misalignment between the optical sheets. If an adhesive layer were applied all the way to the edges of the optical films, any misalignment during stacking of the optical sheets would result in exposed adhesive along the edges.
- the exposed adhesive presents two problems. First, dust and particles collect on the exposed adhesive, and second, the exposed adhesive is easily transferred to other optical films or parts of the display, which may interfere with viewing.
- the edges of adhesive layer 18b are recessed from the edges of optical film 16b by distances d ⁇ l and d ⁇ 2.
- Distances d ⁇ l and d ⁇ 2 are preferably between about 0.1 mm to about 1.0 mm and most preferably between about 0.1 mm to about 0.5 mm. To be effective, however, distances d ⁇ l and d ⁇ 2 must be longer than shift length S.
- Figure 3 is a top view of optical sheet 12a.
- Optical sheet 12a includes optical film 16a with structured surface 20 and perimeter 22.
- Optical film 16 also includes longitudinal edge 24, transverse edge 26, longitudinal edge 28, and transverse edge 30.
- Optical sheet 12a further includes adhesive layer 18a with outer perimeter 32 and inner perimeter 34.
- Adhesive layer 18a is also shown having frame side 36 with outer edge 36o and inner edge 36i, frame side 38 with outer edge 38o and inner edge 38i, frame side 40 with outer edge 40o and inner edge 40i, and frame side 42 with outer edge 42o and inner edge 42i.
- Figure 3 further shows distances d ⁇ l, d ⁇ 2, dtl, and d .
- Distance d ⁇ l is the distance outer edge 42o is inset from transverse edge 30 and, distance d ⁇ 2 is the distance outer edge 38o is inset from transverse edge 26.
- Adhesive layer 18a has a frame-type shape such that it will not interfere with the viewing area of optical film 16a. However, it is not required that adhesive layer 18a include all of frame sides 36, 38, 40, and 42. Adhesive layer 18a may include any combination of one or more of, or portions of, frame sides 36, 38, 40, and 42 and be effective. In fact, there is no specific shape requirement for adhesive layer 18a. In addition, adhesive layer 18a is laminated to structured surface 20 of film 16a. Structured surface 20 contains arrays of prism elements for directing light.
- Prism elements are fragile and require protection prior to installation of the optical film into an optical display, usually by the addition of a pre-mask.
- structured surface 20 is protected, which circumvents applying the protective cover or pre-mask to structured surface 20. This benefit provides further time and cost savings in the manufacturing process.
- Adhesive layer 18a may also be applied to the smooth surface of film 16a, opposite structured surface 20, if preferred.
- Distances d ⁇ l, d ⁇ 2, dtl, and dl2 may or may not be equal for each optical sheet.
- distance d ⁇ l may or may not be equal to distance d ⁇ 2
- distance dll may or may not be equal to distance dtl.
- distances d ⁇ l, d ⁇ 2, dtl, and dt2 must be longer than shift length S but may all be different from one another.
- the present invention may also be described in terms of the perimeters of optical film 16a and adhesive layer 18a. Referring, again, to Figure 3, outer perimeter 32 of adhesive layer 18a is inset from perimeter 22 of optical film 16a. Inner perimeter 34 of adhesive layer 18a is inset from perimeters 22 and 32.
- Figure 4 is a top view of an alternate embodiment of an optical sheet 44.
- Optical sheet 44 includes optical film 46 and adhesive layer 48.
- Figure 4 additionally shows distances d ⁇ l, d ⁇ 2, dtl, and dt2, which have the identical limitations and preferred ranges as those discussed above.
- adhesive layer 48 does not have a frame-type shape. This embodiment may only be used with adhesives that do not interfere with viewing of the optical display.
- Figures 5a through 5e show a method of making the present invention.
- Figure 5a is a top view showing adhesive material 50 bonded to a liner.
- Adhesive material 50 preferably but not necessarily is a plastic adhesive and may be, for example, double-sided tape laminated onto the liner, liquid adhesive coated on the liner, or any of a number of forms of bonding an adhesive to a liner.
- Figure 5b is a top view of the formation of adhesive layer 18a laminated to liner 14.
- Adhesive material 50 is kiss-cut, and the waste material is stripped away. Any of a number of different methods of kiss-cutting may be carried out in order to form adhesive layer 18a. For example, cuts to form the outer perimeter and the inner perimeter may be carried out concurrently or separately. Alternatively, adhesive layer 18a may be applied directly to liner 14.
- Figure 5b also illustrates that multiple adhesive layers 18a can be made simultaneously.
- Figure 5c A cross-sectional side view through line 5c-5c of Figure 5b is shown is Figure 5c.
- optical film material 52 is laminated to adhesive layers 18a to form intermediate material 54.
- adhesive layers 18a may be applied to optical film material 52 before being applied to liner 14.
- Figure 5d is a cross-sectional side view illustrating the position of die cuts 56 through optical film material 52. As shown, die cuts 56 are made a distance beyond the edges of adhesive layer 18a.
- Figure 5e is another cross-sectional side view illustrating the result of cutting optical film material 52 with die cuts 56, and stripping the waste material away to form optical film 16a.
- Optical film 16a is laminated to adhesive layer 18a resulting in optical sheets 12a. These are in turn laminated to liner 14.
- optical sheet 12a may subsequently be laminated together or to other optical sheets, such as optical sheets 12b and 12c, to form optical sheet sets 10.
- Figure 5f is a side view illustrating the formation of optical sheet set 10 by stacking three optical sheets.
- Optical sheet 12a forms the bottom layer and maintains contact with liner 14.
- Optical sheet 12b is removed from its liner 14 and stacked on top of optical sheet 12a.
- Optical sheet 12c is then removed from its liner 14 and stacked on top of optical sheet 12b.
- an important benefit of the present invention is the avoidance of exposed adhesive, which is detrimental to the display.
- the following examples illustrate the effectiveness of the present invention.
- EXAMPLE An optical sheet set formed from three optical sheets was produced by the method of the present invention.
- the bottom and middle optical sheets included Thin-BEF by 3M Company, and the top optical sheet included DBEF by 3M Company.
- Double-sided tape such as Sumitomo3M #4040 or #4037, formed the adhesive layer.
- Each film measured 40 mm x 50 mm.
- the adhesive layers had a frame-type shape with a 1 mm strip extending around the films.
- the outer perimeters of each adhesive layer were recessed by a distance of about 0.5 mm from the perimeters of the films.
- the optical sheet set was exposed to room conditions (23°C, 50% relative humidity). After seven days, the appearance of the edges was checked. There was no dust or particle accumulation at the edges.
- optical sheet set was positioned between glass plates, and a 500 g weight was placed on top.
- the sample was stored at 65°C and 95% relative humidity. After three days, the glass plates were checked. There was no adhesive transferred to the glass plates.
- COMPARISON EXAMPLE A second optical sheet set was produced that was identical to the previous example except that the adhesive layers were not recessed from the edges of the films. Instead, the outer perimeters of the adhesive layers were aligned with the perimeters of each film.
- This optical sheet set was exposed to the identical conditions as described for the previous example. Here, however, dust and particles attached to exposed adhesive on the edges, adhesive transferred to the glass plates, and the optical sheets adhered to the glass plates.
- the present invention provides a way to efficiently assemble multiple optical films into an optical display.
- a pre-mask is no longer required, and multiple films can be installed simultaneously. This reduces the time and cost associated with manufacturing optical displays, which is desirable to the manufacturer.
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05724844A EP1768839A1 (en) | 2004-04-23 | 2005-03-07 | Optical products for displays |
JP2007509465A JP2007534026A (en) | 2004-04-23 | 2005-03-07 | Optical products for displays |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/830,733 US20050238852A1 (en) | 2004-04-23 | 2004-04-23 | Optical products for displays |
US10/830,733 | 2004-04-23 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005108073A1 true WO2005108073A1 (en) | 2005-11-17 |
Family
ID=34961936
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/007387 WO2005108073A1 (en) | 2004-04-23 | 2005-03-07 | Optical products for displays |
Country Status (6)
Country | Link |
---|---|
US (1) | US20050238852A1 (en) |
EP (1) | EP1768839A1 (en) |
JP (1) | JP2007534026A (en) |
CN (1) | CN1946553A (en) |
TW (1) | TW200535503A (en) |
WO (1) | WO2005108073A1 (en) |
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US7413336B2 (en) * | 2003-08-29 | 2008-08-19 | 3M Innovative Properties Company | Adhesive stacking for multiple optical films |
US7339635B2 (en) * | 2005-01-14 | 2008-03-04 | 3M Innovative Properties Company | Pre-stacked optical films with adhesive layer |
US20070171325A1 (en) * | 2006-01-20 | 2007-07-26 | Byung-Soo Ko | Light Management Film Package For Display Systems and Systems Using Same |
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- 2005-03-07 WO PCT/US2005/007387 patent/WO2005108073A1/en active Application Filing
- 2005-03-07 EP EP05724844A patent/EP1768839A1/en not_active Withdrawn
- 2005-03-07 JP JP2007509465A patent/JP2007534026A/en active Pending
- 2005-03-21 TW TW094108642A patent/TW200535503A/en unknown
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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EP1969578A1 (en) * | 2005-12-01 | 2008-09-17 | FUJIFILM Corporation | Optical sheet for display, and manufacturing method and apparatus therefor |
EP1969578A4 (en) * | 2005-12-01 | 2010-05-05 | Fujifilm Corp | Optical sheet for display, and manufacturing method and apparatus therefor |
WO2013104542A1 (en) | 2012-01-13 | 2013-07-18 | Plus Inventia Ag | Device and method for assembling insulating glass panes |
EP2808477A1 (en) | 2012-01-13 | 2014-12-03 | Plus Inventia AG | Apparatus for assembling insulating glass units |
Also Published As
Publication number | Publication date |
---|---|
US20050238852A1 (en) | 2005-10-27 |
EP1768839A1 (en) | 2007-04-04 |
TW200535503A (en) | 2005-11-01 |
CN1946553A (en) | 2007-04-11 |
JP2007534026A (en) | 2007-11-22 |
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