CN1086606A - Polymeric reflector/refractor with improved surface or geometric configuration - Google Patents

Abstract

Be easy to make the reflection multiple layer of polymeric material body of multiple shape, can be used as optical reflector, refractor, polarizer, lens and level crossing.Owing to the reflection multilayer surface in the body, eliminated the surface imperfection or the heterogeneity of the harmful light effect in the individual layer reflection unit.The reflection multilayer surface can provide the controlled distribution of direct reflection and/or transmission, also can provide linearly polarized light.By multilayer reflector is combined with other optical elements, triple prism type reflection and refraction when this body can provide radial distribution light, the back reflective when combining with transparent beads of specific orientation and be that stacked or mold pressing triangular parts are used in combination.

Description

Polymeric reflector/refractor with improved surface or geometric configuration

The present invention relates to reflect and/or the full polymeric material body of multilayer of refract light and make and can be used for the article of mirror, reverberator, lens, polarizer and refractor with it in desirable mode.

The classic method of making reflecting surface comprises this class surface that is formed by press polished metal.Owing to adopt the related expensive and making problem of metal, the fabricator has adopted the frosting that comprises thin metal coating on it recently.Like this, the present common plastic article that is coated with metal is used as ornamental and functional product in some industry.These class article can commercial, industry, and the inhabitation illumination aspect be used as reverberator, and can in auto industry, be used to such as preceding lamp reflector.This reverberator is designed to utilize its lighttight basically reflecting surface to produce required light distribution usually.

Generally, go out the layer of metal thin layer, make this metallized plastics article by plating on article surface or vacuum, vapour phase or chemical deposition.But the wearing and tearing and the shattered crack of metal coating easily take place the passing in time of this coating reaches corrosion of metal.If will add on metal coating that other protective seam to protect it, then needs extra manpower and material consumption.The problem that also can have in addition, the clear place of Employee Security and environment to some metal depositing technics.

Multi-layer product of polymkeric substance and preparation method thereof is known with device.For example, this class multi-layer product can be with such as the United States Patent (USP) the 3rd, 733,882 and 3,884 that together transfers Schrenk, and the MULTILAYER COMPOSITE pressurizing unit described in No. 606 prepares.' No. 882 patent has been announced a kind of method that is used to prepare the mixed flow of the various synthetic resin material of interdigital.The step of this method comprises: provide at least the first and second thermoplastifications can extrude the heat-stabilized wood materials flow; Per share flow point is not divided into a plurality of first son streams and a plurality of second son stream; Bundle stream is combined into first son stream with interdigital and the mixed flow that second son flows, and the position that son stream mixes roughly is positioned on one section circular arc; Make the son stream of mixed flow roughly radially inwardly flow to the exhaust position that roughly is positioned at circle centre position, thereby make the mixed flow distortion; Exhaust position is equidistant substantially with the first and second adjacent sub positions of mixing of flowing; Remove mixed flow from exhaust position; Make mixed flow deformation become to be roughly the structure of sheet shape, wherein the interface between the stream is roughly parallel to the first type surface of slab organization.' No. 606 patent of Shrenk has been announced the device of preparation multilayer film or plate, and this device comprises: a body, and it has determined at least the first polymkeric substance admission passage; First supercharger that is connected with the first polymkeric substance admission passage; Part flow arrangement is used for the material stream from first passage is divided into a plurality of first son streams; The second polymkeric substance receiving trap that is connected with one second supercharger, second supercharger discharges to part flow arrangement, the latter is divided into a plurality of second son streams to second stream and a plurality of second son streams is intersected with the first sub-stream, part flow arrangement is connected with the 3rd or mixed flow reception supercharger, and this mixed flow comprises the first and second son streams of combination; The 3rd supercharger discharge-channel; It is connected with the 3rd supercharger and is suitable for receiving mixed flow from the 3rd supercharger, and this discharge-channel and has and is roughly the extrusion that stitches shape and is connected, and discharge-channel has first or receiving end and second or discharge end; Its improvement comprises discharge unit that the mode with arc is provided with part flow arrangement to form one section circular arc, and wherein discharge unit is roughly equidistant with the discharge end of the 3rd supercharger discharge-channel.This device can be extruded multiple thermo-plastic polymeric material simultaneously with substantially uniform layer thickness.The number of layer can be doubled by the device of together transferring the possession of to described in No. the 3rd, 759,647, people's such as Shrenk the United States Patent (USP); This patent has been described a kind of device that is used to prepare the composite synthetic resin sheet article, and it comprises: the device that is used to provide thermoplastic resin material's stream of at least two strands of thermoplastifications; Be used for two plume machineries are arranged to have the device of combined-flow of the layer of a plurality of almost parallels, wherein the part of a plume surrounds combined-flow; Be used for mechanically handling this combined-flow to provide number more to flow at the stream of handling; Be used to make the stream of processing to be configured as the device of desired structure, a plurality of surfaces that this structure has and other surface is parallel substantially.

Recently, the MULTILAYER COMPOSITE extruding technology has been used to make reflection multilayer film and the sheet, the optics that constitute with optical thick layer (greater than the optical thickness of about 0.45 μ m) are thick and the combination of optics thin layer (optical thickness is less than about 0.09 μ m) or optics is thick, optically thin, and the combination of optics thin layer.See together the people's such as Weatley that transfer the possession of No. 5,122,905, United States Patent (USP), No. 5,122,906, the United States Patent (USP) of Weatley, and No. 5,126,880, people's such as Weatley United States Patent (USP).' No. 905 patent of Weatley has been described a kind of multilayer reflector, and it is thermoformable and can be made into thicker part, keeps uniform reflection unit simultaneously.The reflection condensate comprises more than at least the first and second kinds of polymeric material layers and the alternating layer of first and second compound substances of enough numbers arranged, thereby is reflected at least 30% of the light that is mapped on the material bodies.Great majority in each layer of material bodies have at least 0.45 micron optical thickness, and the difference of the refractive index of the first and second adjacent polymeric material layers is not less than about 0.03.Reflecting body can be made into sheet, mirror, corrosion resistant metal ornament and parts, reverberator, refractor etc.' No. 906 patent has been described a kind of multilayer reflector, and it is also being made into film, sheet, reaching various parts and keeping uniform reflection external form simultaneously of thermoformable.This reflection polymeric acceptor comprises more than at least the first and second kinds of polymeric materials and the alternating layer of first and second polymeric materials of enough numbers arranged, and can be reflected so that incide at least 30% of light on the reflecting body.Most of layers optical thickness of reflecting body is not more than 0.09 micron or be not less than 0.05 micron, and the optical thickness of at least one layer is not more than 0.09 micron, and the refractive index of the adjacent layer of first and second polymeric materials differs at least about 0.03.' No. 880 patent has been described the high reflection of a kind of multilayer condensate, comprises at least two kinds of optical layers, and thermoformable and be made into film, sheet and various parts, keeps uniform reflection external form simultaneously.First and second polymeric material layers that this reflection condensate has more than at least the first and second kinds of polymeric materials and enough numbers are arranged project at least 30% of light on the reflecting body with reflection.The part of layer has the optical thickness between 0.09 and 0.45 micron, and remaining layer has the optical thickness that is not more than 0.09 micron or is not less than 0.45 micron.The refractive index of first and second polymeric materials differs at least about 0.03.

Prior art also relates to the problem of the space distribution of utilizing traditional reflective and/or refractive material control light.For example, people's such as Howe United States Patent (USP) has been announced a kind of light source of polarized light radially for the 3rd, 912, No. 921.One comprises the light regulator of radial polarisation device/refractor and linear polarization, makes light polarization that light source sends and direct light radially.Linear polarization comprises metal oxide, sulfide or/or the halogenide alternative stacked of the height made with vapour deposition method and low-refraction.

People's such as Barnes United States Patent (USP) has shown for the 4th, 839, No. 781 to have and has been used for reducing directly and a light-emitting device of the reflector/refractor of the bright spot of indirect lighting system and dim spot.This parabolical light-emitting device has some districts, and the vertical moving of light source in light-emitting device causes from the different spaces orientation of the light of its reflection.Light-emitting device comprises a plurality of along its intimate arrangement and vertical orientated prism, and they come reflected light by inner full-reflection.

The United States Patent (USP) of Ngai also discloses a kind of light-emitting device the 5th, 051, No. 878, and it has the lens that are used for the indirect lighting system.This device utilizes triangular lens and diffuse reflection substrate that diffuse reflection and direct reflection are combined.The emission characteristics of light-emitting device depends on the viewing angle to device.

The United States Patent (USP) of MacNeille has been announced a kind of beam splitter the 2nd, 403, No. 731, and it is by multilayer laminatedly constituting of alternately forming such as the height of zinc sulphide and magnesium fluoride and low-index material.This lamination combines with a compound prism, to separate and light beam.

The United States Patent (USP) of Marks has been announced a kind of sheet polarizers the 2nd, 492, No. 809, wherein with " it " font mode stacked a plurality of thin plastic sheets of making by height that replaces and low-index material.Marks points out that the refringence of plastics must not and comprise 15 to 30 layers less than 0.2.

The United States Patent (USP) the 4th, 025,159 of McGrath has been announced a kind of backreflection sheet, and it has adopted in bonding agent and partly has been embedded in the individual layer of the transparent beads in the specular layer.

But the design of prior art has certain shortcoming.Unevenness such as the reflecting surface of the individual layer reverberator of metal, polymkeric substance or glass makes the light reorientation that impinges upon in the inhomogeneous district, and these light are pooled to the deviser envision position outside the zone.This collecting at random produced harmful bright spot in the surround.Even existing multilayer thin dielectric film also faces same problem, i.e. reflection occur over just the number of plies less (be generally 10 to 20 or still less), thickness is respectively in the layer for about 0.1 μ m magnitude.Even in this multilayer thin dielectric film, little defective can cause all or be close to the distortion of all layers.

The formation of prism and interval in the complex geometric shapes of paraboloid are to need accurate another problem of making and designing.The vapour phase constant volume of metal oxide, sulfide and halid multiple dielectric layer, promptly costliness is time-consuming again.In addition, the design based on the inner full-reflection principle depends on clear and definite air-reverberator interface.Drop on the generation that dust granule on this interface can destroy this interface and stop required reflection effectively.

Therefore, need such reverberator and refractor technically, they are easy to make and required characteristic can be provided, as provide direct reflection and/or transmission controlled distribution, make polarization of light and light radially distributed.Also need not have surface imperfection and/or heteropical reflective optical system and refractor.

The present invention has satisfied these needs by the reflection multilayer polymeric object that is easy to make various useful shapes is provided.This shaping reflecting body can be used as reflective optical system, refractor, polarizer, lens and mirror.Because only thing reflection multilayer surface of body, this polymeric acceptor does not have to cause the surface imperfection and the heterogeneity of the harmful light effect in the individual layer reflection unit.In addition, this uniqueness reflection multilayer surface can provide the controlled distribution of direct reflection and/or transmission.And the reflection multilayer surface can provide linearly polarized photon.By multilayer reflector is combined with other optical elements, this reflecting body can provide the edge of predetermined orientation that backreflection is provided to distribute light, with the transparent beads logotype time and advance to provide prism or reflection and refraction with lamination or the logotype of mold pressing prism parts.

Term " reflection ", " reflectivity ", " reflection " reach " reflectivity ", referred to herein as the total reflectivity (being reflected energy and the ratio of incident wave energy) of abundant minute surface character, so polymeric acceptor has the appearance of metal.These terms also comprise half minute surface or diffuse reflection.Generally, albedo measurement refer to enter with the specular angle be the center, drift angle is the reflectivity of light in the outgoing tapers of 15 degree.

The certain strength of reflectivity is in the intensity that absorbs the reflection that insignificant wavelength place takes place at this.For example, the article of silvery appearance (colourless) almost reflect all visible wavelengths, and are to reach other metallic luster to add dyestuff and will reduce the reflectivity of article at the absorbing wavelength place.The wavelength that is not affected will be reflecting with the substantially identical intensity of sample of being unstained, and these unaffected wavelength just that reflection strength refers to.

According to an aspect of the present invention, provide and be used for directed and distribute from the polymkeric substance reflective optical system/refractor of the light of light source.Light is directed and distribution by a reflection multilayer polymeric acceptor, and the latter is made by more than first and second kind of polymeric material being arranged to parallel substantially plane alternating layer.This polylayer forest comprises first and second first type surfaces, and comprises enough several zone of interest, thereby makes at least 30% of light in polylayer forest reflection incident first and second first type surfaces at least one.As mentioned above, " incide visible light on the body at least 30% " referred to herein as and absorbing the reflected light that insignificant wavelength place takes place.This reflection comprises the contribution at multilayer interface in the body.

For the reflection characteristic of body is provided, the refractive index of first and second polymeric materials differs at least 0.03.In a most preferred embodiment of the present invention, at least 50 layers that replace are arranged.Generally, can produce and comprise that hundreds of is to the polylayer forest of several thousand alternating layers.

Best, the overwhelming majority (promptly about more than 75%) of each of body layer has such optical thickness, and promptly the optical thickness of the repetitive of polymeric material is greater than about 190nm.In typical two component bodies, the repetitive of polymeric material is AB, and wherein A is different polymkeric substance with B.For three or polycomponent body more, may have other repetitive, as ABCB or ABCABC.

In certain embodiments of the present invention, wish in one or more layer of polymerization body, to add colorant, as dyestuff or pigment.Can do like this outer or top layer of body, or colorant be added the internal layer of body.Used colorant can be to the different metal appearance of the original silvery appearance of polymeric acceptor and its, as bronze, copper or gold.

Also can adopt different colors, as black, grey, blue, red, yellow or white.Can in internal layer, adopt pigment colorant so that the texture of opacity and two-sided mirror to be provided, and on extexine, use dyestuff.But the colorant combination is to provide required optics and painted characteristic.For example, can use the Chinese white colorant at an inside surface, and in one or more superficial layer, add illuminating colour, as blue, yellow, red or green, so that unique reflection coloring effect to be provided.Can adopt thermocolour pigment or dyestuff, to produce color change when the temperature variation of body.

Because layer has parallel plane relation substantially, body is a minute surface to reflection of light substantially.Yet a feature of the present invention is that the cardinal principle parallel plane relation of some alternating layer at least is changed, thereby makes at least a portion reflected light from body have the angle to distribute.This provides a kind of reverberator, and it is because the slope variation of sublayer boundary, and with controlled fan-shaped distribution reflection and/or transmitted light.Like this, when be used to resemble industry, commerce, and the inhabitation illumination Design in light source the time, when be used for automotive fittings and illumination, railway illumination, signal, and clothes on safety notice the time, when being used for vehicle and railway, this body provides a kind of sheen effect, thereby has eliminated harmful speck substantially.

At least the change of the plane relation of some layer can be by realizing on one or more surface that some layer at least is embossed in body.Perhaps, also can change nearly all layer geometric configuration.Can adopt any known mould pressing method, comprise cooperating the mold pressing forming method, wherein body is placed in the mould and by moulding.Perhaps, can after being made into, carry out mold pressing by mold pressing roll to it immediately by making body.Can utilize the degree of depth of mold pressing to come the number of plies that is affected in the control body.

A lot of useful shapes can be over-molded on the body, so that unique optical effect to be provided.In addition, according to required effect, whether the degree of depth of mold pressing and polylayer forest have the top layer, the geometric configuration that only causes the top layer is changed or body in the geometric configuration of microbedding change.For example, but the taper of mold pressing pattern, the microbedding geometric configuration is changed radially to reflect the light that projects on the body surface to all directions.The layer of mold pressing can be crooked, to produce catoptrical angular dispersion.The layer of mold pressing can be prismatoidal, with the optical effect that utilizes prism to produce.In the another kind distortion, can embed diameter in one or two surface of reflecting body is the beaded glass of 10 μ m to 10mm, to produce the object of retroeflection.

The unique distinction of reflecting body of the present invention, the catoptrical angle that is body distributes and depends on the gradient of the layer that is changed.Like this, by the change song of key-course, promptly may command is from the scattered intensity and the angle of these layers.The reformed layer of geometric configuration can be close to one of first and second first type surfaces or both in the body, also can spread all over the nearly all layer in the body.

Usually, in use, the shape that polymeric acceptor of the present invention will be made into to be scheduled to comprises the chamber that second first type surface is limited, and light source is located in this chamber.For example, body can be made to part transmission and partial reflection, and is made into to have the tail light lenses for automotive of embossing inside surface, with directed and distribution rear light assembly issued light.Perhaps.Body can be made into high reflection, and makes automobile headlamp or tail reflective optical system, with through the outside sky light of a lens subassembly.Similarly, this body can be made into light source or paraboloid, is used for industry, commerce or the illumination of living.Body can be made into high reflection, shines most of visible light on it with reflection.Perhaps, body can be made into a part of light that the transmissive light source sends and reflect another part light simultaneously.By the appropriate structuring of body, the printing opacity of may command body and volume reflection.It is very important that this control needs the application of control " up " and " descending " light (i.e. the light quantity that upwards transmits or reflect) downwards to some.

In another embodiment of the present invention, provide and had reflexive reverberator of enhancing, it comprises a reflection multilayer polymeric acceptor, and the latter is by being arranged to parallel substantially plane alternating layer and having more than at least the first and second kinds of polymeric materials of first and second first type surfaces to constitute.Body comprises enough several zone of interest, shine at least 30% of light at least one of first and second first type surfaces with reflection, and the refractive index of first and second polymeric materials differs at least 0.03.Body preferably includes at least 50 alternating layers, and can comprise that hundreds of is to several thousand layers.Body also comprises on its first first type surface or near device, is used for going back through the multilayer proprioceptive reflex inciding the light that also sees through the multilayer body on second first type surface.This device can comprise such as triangular shape parts or groove.

In the optimised form of this embodiment of the present invention, prismatic parts or groove vertically are orientated substantially along first first type surface of body.Perhaps, prismatic parts or groove can suitably be orientated, with around body.Polymeric acceptor has predetermined shape, comprises the chamber that is limited by second first type surface, and comprises the light source that is positioned at the chamber.A part of light that light source sends is by a plurality of layers surface reflection in the body.The light that body is crossed in transmission was reflected body by prismatic parts or groove, to increase its total reflection.

Polymeric acceptor can be made into multiple shape, comprises bowl-type or paraboloid, prismatic parts or groove, can by mold pressing at least some contiguous first first type surface layer or prefabricated parts be fixed in first first type surface make.Fixedly a kind of method of prismatic parts or groove is that the sheet that comprises formation parts thereon is stacked on the multilayer polymeric object.

In another embodiment of the present invention, provide polarizer with polarization from the not reflection and the transmitted light of polarized light source, and comprise the reflection multilayer polymeric acceptor, the latter is made of the first and second various polymeric materials of being arranged to parallel substantially plane alternating layer at least.This body comprises first and second first type surfaces and comprises enough several zone of interest so that the body direct reflection incides at least 30% of light at least one of first and second first type surfaces.Body preferably includes at least 50 layers, and can comprise that hundreds of is to several thousand layers.The refractive index of first and second polymeric materials differs 0.03 at least.

In addition, the most orientation of the first type surface of body, make light with or shine on the surface near Brewster (Brewster) angle, cause reflection and transmission polarisation of light.The orientation of V-arrangement-these V-arrangements that can be by polarizer being made V-arrangement or a series of Zhe of being converted into makes the light that shines on it be in given polymkeric substance used in the body or near polarization angle (Brewster angle), the orientation of coming the first type surface of control body.Polarization angle also can change according to the number of plies in the body.This polarization angle can be calculated with known technology.For example, a kind of such technology is described in the article " On the Use of a Pole of Plates Polarizer " of J.L.Weinberg, Applied Optics, 3(9), pp.1057-61(1964) in.Also can be by in body, forming a plurality of tapers, pyramid or semisphere mold pressing pattern, in high incident angle (promptly apart from normal above 55 °) introducing body.According to used concrete shape, the reflection and/or the distribution of transmission-polarizing light are also different, for example radially or biax.

Therefore, purpose of the present invention provides a kind of reflection multiple layer of polymeric material body that is easy to make various useful shapes, and these shapes can be used as optical reflector, refractor, polarizer, lens and mirror.Another object of the present invention provides unique reflection multilayer surface, but the controlled distribution of its cremasteric reflex and/or transmitted light also can provide the linearly polarized photon that distributes in many ways.These and other advantages of the present invention and purpose will become clear by the detailed description of doing below in conjunction with accompanying drawing and appended claims.

Fig. 1 is the schematic sectional view of typical two parts multiple layer polymer reflecting body of the present invention, and wherein first polymer A has refractive index n 1, the second polymer B that refractive index n 2 is arranged, and the top layer that has terpolymer C to form on two first type surfaces of body;

Fig. 2 is the schematic sectional view of two parts polylayer forest, and the part in its middle level is gone out spherical substantially pit by inside mold pressing, with the parallel minute surface and the angle distribution reflection of show ontology;

Fig. 3 is the schematic sectional view of two parts multiple layer polymer retroeflection body of a lip-deep beaded glass that is included in body of the present invention;

Fig. 4 is the front elevation of reflection tail light lenses for automotive;

Fig. 5 is the cut-open view along the 5-5 line of Fig. 4, has shown the mold pressing on the lamp inner lens surfaces;

Fig. 6 is the side view to the folding Zhe shape polylayer forest that incides the polarization of light on it;

Fig. 7 is the schematic sectional view of two parts polylayer forests of the present invention, wherein a part of layer of a plurality of taper mold pressing pattern that is molded out;

Fig. 8 is the view that the multilayer reflector of a plurality of vertical orientated prismatic parts is also arranged on its outer surface as parabolic reflector of the present invention;

Fig. 9 is the cut-open view along 9-9 line among Fig. 8;

Figure 10 is the curve map of light intensity to the position of mold pressing individual layer sample;

Figure 11 is the curve map of light intensity to the position of mold pressing multilayer sample;

Figure 12 is the polarized light of the light intensity diagonal position of the clean glass reflector line chart of writing music;

Figure 13 is the polarized light of the light tail diagonal position of the mattress reflector of the present invention line chart of writing music.

The invention provides can the directed in many ways also multilayer reflector of distribute light.The present invention can be used for being made into shaped object, as optical reflector, refractor, polarizer, mirror, diffuser and lens.The instruction that used multilayer reflector is preferably pressed in people's such as No. 5,122,906, United States Patent (USP), Weatley No. 5,126,880, the United States Patent (USP) of people's such as Weatley No. 5,122,905, United States Patent (USP), Weatley one or more among the present invention is made.

Referring to Fig. 1, typical two component multilayer reflectors have wherein been shown.Body 10 comprises that refractive index is n ₁First polymkeric substance (A) 12 and refractive index be n ₂The alternating layer of second polymkeric substance (B) 14.In addition, shown body has the top layer that the terpolymer C on two first type surfaces of body constitutes.Polymkeric substance C can be identical or different with one of polymer A or B, and can have and polymer A or the identical or different refractive index of B.As people such as above-mentioned Weatley, Weatley, and people's such as Sshrenk reference paper as described in, a variety of roughly transparent thermoplastic polymers all can be used to make reflecting body and/or top layer. is for example; United States Patent (USP) 5 such as Weatley; 122; 905 instruct; Listed can be used for suitable thermoplastic resin of the present invention; Together with its refractive index; Include but not limited to: perfluoroalkoxy resin (refractive index=1.35); Polytetrafluoroethylene (PTFE) (1.35); The ethylene/propene copolymer of fluoridizing (1.34); Organic siliconresin (1.41); Polyvinylidene fluoride (1.42); Polychlorotrifluoroethylene (1.42); Epoxy resin (1.45); Butyl polyacrylate (1.46); Poly-(4-methylpentene-1) (1.46); Polyvinyl acetate (1.47); Ethyl cellulose (1.47); Polyformaldehyde (1.48); Polyisobutyl methacrylate (1.48); Polypropylmethacryla,es (1.48); PMA (1.48); Polyethyl methacrylate (1.48); Polyether block amide (1.49); Polymethyl methacrylate (1.49); Cellulose acetate (1.49); Cellulose propionate (1.49); Cellulose acetate-butyrate (1.49); Celluloid (1.49); Polyvinyl butyral (1.49); Polypropylene (Isosorbide-5-Nitrae 9); Polybutene (1.50); Ionomer resin is such as the Surlyn(trade mark) (1.51); Low density polyethylene (LDPE) (1.51); Polyacrylonitrile (1.51); Polyisobutene (1.51); Thermoplastic polyester is such as the Ecdel(trade mark) (1.52); Natural rubber (1.52); Butadiene-styrene rubber (1.52); Polybutadiene (1.52); Nylon (1.53); Polyacrylic acid imines (1.53); Poly chloroacetic acid vinyl acetate (1.54); Polyvinyl chloride (1.54); High density polyethylene (HDPE) (1.54); Methyl methacrylate and styrol copolymer are such as the Zerlon(trade mark) (1.54); Transparent propene nitrile/butadiene/styrene ter-polymer (1.54); Allyl diglycol resin (1.55); Polyvinylidene chloride and poly (vinyl chloride) blend are such as Saran resin (trade mark) (1.55); Poly-(AMS (1.56); The phenylethylene/butadiene latex is such as Dow 512-K(trade mark) (1.56); Polyurethane (1.56); Neoprene (1.56); Styrene and acrylonitrile copolymer are such as Tyril resin (trade mark) (1.57); Copolymer from styrene and butadiene (1.57); Merlon (1.59); Other thermoplastic polyester is such as PET and PET glycol (1.60); Polystyrene (1.60); Polyimides (1.61); Polyvinylidene chloride (1.61); Polydichlorstyrene (1.62); Polysulfones (1.63); Polyether sulfone (1.65) and PEI (1.66). On the refractive index reported what can change when different wavelength, for example, the refractive index of poly-carbon ester wants big, smaller to the light of red area to the blue look area light of spectrum.The multipolymer of above-mentioned resin also is useful, such as ethene and vinyl alcohol, styrene and hydroxy acrylic acid ethyl ester, styrene and maleic anhydride, styrene/butadiene block copolymer, styrene and methyl methacrylate, styrene and acrylic acid.Other useful polymeric material comprises that polyolefin such as the Admer (of polyetheretherketone, polybutylene, maleic anhydride grafting derives from Mitsui Chemicals) and Plexar (derive from Ouantum Chemicals) and multipolymer such as the CXA (of ethene and vinyl acetate derive from du Pont company) .The three kinds of polymkeric substance in back are used in the adhesive linkage that engages other polymeric layers in the sandwich construction.Selective polymer is that the refractive index of selected polymkeric substance differs at least 0.03 each other with the condition of the alternating layer of formation body.In addition, instruct as these documents, available three or multiple polymers partly form polylayer forest.Like this, though with simple two parts system specific embodiments of the invention are described, adopt three or more the system of heteropolymer part also belong to scope of the present invention.

Referring to Fig. 2, replace A and B polymeric layer by as shown in Figure 1 cardinal principle parallel plane, be subjected to mold pressing, to change the almost parallel plane relation of some layer at least.Also shown the top layer that the terpolymer on a first type surface of body constitutes among the figure.Fig. 2 has shown the reflected light space distribution control that the present invention realizes.As shown, embossing 18 has hemispheric structure substantially, and can make of any known thermoplastic polymer's mould pressing method.For example, embossing 18 can be made with thermoforming or cold forming process sheet 16 in mating die.Perhaps embossing 18 can be made by mold pressing roll by making sheet 16.In addition, though only shown a semisphere embossing at this for purposes of illustration, the people who understands prior art should understandablely be, can adopt a plurality of embossings of different sizes, the mold pressing degree of depth and shape.For example, forms such as the desirable Atria prismatic of mold pressing, taper, pyramid.

The refringence between A and B polymkeric substance as shown in Figure 2, impinges upon on the surface of sheet 16 and passes its light R, owing to will partly be reflected on each bed interface.According to interface number and two kinds of polymkeric substance refractive index separately of layer, body can reflect incident light thereon at least 30% to more than 90%.Partial reflection is represented as reflection ray R ₁To R _n, they are reflected back toward the surface of sheet 16 by the form with parallel minute surface light.These light are rendered as colourless substantially direct reflection at observer's eyes.

A part of light of light R will arrive in the sheet other the layer and from these the layer be reflected, the geometric configuration of these laminar surfaces is changed by embossing 18.These reflected light are denoted as R ₁' to R _n' and along angular distribution or be fan-shaped ejaculation, because each light incides the angle difference on the interface of different layers.In addition, though for clarity sake do not show to have the light transmission to cross body and in body, have the angle to distribute in the accompanying drawings.Concerning eyes, reflection ray R ₁' to R _n' will be rendered as diffusion or scattered light (, not showing among the figure) as the angular distribution light of transmission.

In single plane along angular distribution or along the light of fan-shaped ejaculation, be unique to multi-ply construction of the present invention, because light will incide the diverse location and the scattering therefrom in the reformed zone of geometric configuration at the interface of layer.This has caused optics " smoothly " effect.Promptly seeing through or reflect can be controlled from the light of polylayer forest, to realize that the basic of light intensity evenly distributes in whole illumination or the echo area.

Like this, by the present invention, eliminated harmful bright spot (being the bigger zone of light intensity) that the surperficial heterogeneity in the individual layer reverberator of prior art causes.Even the bright spot that prior art multilayer dielectric optical thin film coating also can occur being harmful to, (20 or still less) and its thickness (each is in the magnitude of 0.1 μ m) because the number of plies of less generation reflection.To this prior art dielectric film, even little defective also can make the layer distortion of nearly all layer or sufficient amount, so that the optically smooth effect can't appear.A very big advantage of the present invention is hundreds of to be arranged to several thousand bed interfaces, thereby the top layer can be molded with the distribution reflected light, keeps the geometric configuration and the properties of specular reflection of the substantitally planar of remainder layer in the body simultaneously.

Like this, can carry out mold pressing or moulding to polylayer forest of the present invention selectively for the mode of required final use " customized ", and this customizedization can be realized by the general available former of this human of final user.In the body some layer can remain on its parallel substantially flat state, with minute surface ground reflected light, utilizes the geometric configuration that the mold pressing of other layers is changed these layers simultaneously, with distribute light in the desired manner.In addition, can on one or more first type surface of body, add thicker top layer, only influence the top layer and make following microbedding remain on its substantially parallel plane relation so that be embossed in.According to mold pressing the layer geometric configuration, the complete internal reflection or the polarization of incident light can take place, to describe in detail as following.And for single layer device of the prior art or in case be covered with the thin layer dielectric coating that just can't be shaped or change, it all is impossible that this multilayer geometric configuration is controlled.

By the minor diameter beaded glass being embedded one or more surface of the body of multilayer tablet form, multilayer reflector of the present invention can be made into back reflective body or sheet.Shown in Fig. 3 (it is drawn not in scale for purposes of illustration), beaded glass 20 is embedded on the surface 21 of the sheet 22 that the multi-turn layer made by first and second polymer A and B forms.Generally, this pearl will be embedded in the degree of depth of the 55-60% of its diameter.The light R that shines on the surface 21 is directly reflected back into light source.Like this, this can be used to the reflected signal board, on safety notice on the clothes or the road surface or the like.Thereby, though do not show that a thicker top layer can be arranged on the sheet 22, so that make the parallel plane geometric shape of cardinal principle that on the surface on top layer, embeds pearl 20 unlikely change A and B polymkeric substance microbedding.

In the another embodiment of the present invention shown in the Figure 4 and 5, polylayer forest can be made into part transmission and partial reflection, and is made into the device such as lens subsequently, as tail light lenses for automotive 24.The inside surface 26 of lens 24 is molded (geometric configuration that has changed some alternating polymer layer of near surface), with the light of and distribute taillight directed from lens.For example, as shown, embossing can be got a series of bigger shallow mold pressing pincushions 28 and less and darker mold pressing district 30 respectively, this light that causes taillight when leaving lens 24 by diffuse reflection and distribution.Part alternating polymer layer is maintained at it at the parallel plane relation of body, so that lens present colourless substantially mirror lens in reflection.

Referring to Fig. 6, thereby multilayer reflector of the present invention can be made into by making the originally body formed bigger incident angle of the maintenance of the light on the polymeric layer that replaces on the major part that impinges upon body that is.A kind of method of this high incident angle is provided, and is that body is shaped to the V-arrangement of wedge angle or the V-arrangement of a series of folding Zhe.

As shown, polarizer 32 comprises a polylayer forest, and it has by being shaped to or being converted into and is the polymer A of a series of acute angle V-arrangements and the alternating layer of B.Like this, the most orientation of the first type surface of polarizer 32 makes the light R from light source, to equal or near the angle rate of the polarization angle of used concrete polymkeric substance in the polarizer 32 , shine on the multiple layer of polarizer 32 and formation polarizer 32.Right to typical polymkeric substance, polarization angle is about apart from 58 ° of the normals of layer.

Reflected light from polarizer 32 will be complete linear polarization, and its E field is perpendicular to the plane of incidence.This polarizer can be utilized for the room or working surface provides the illumination of not too dazzling the eyes.The common examples of the dazzle-free illumination of needs is the workspace that one or more video terminal and computing machine etc. are arranged, and the dazzle of video terminal screen is not only annoying but also harmful to the workman there.In addition, the light that sees through polarizer 32 also is polarized, and its E field is parallel to the plane of incidence.

By in body, forming taper, pyramid or semisphere mold pressing, also can in reflection polylayer forest of the present invention, introduce suitable high incident angle (promptly equal or near the angle of polarization angle).As shown in Figure 7, the multilayer reflector by the multi-turn layer of multiple polymers A and B constitutes can form a series of taper mold pressings 36 thereon.As previously shown, this mold pressing can be made of known forming process, and can change the geometric configuration of some superficial layer of all layers or sheet.

Adopt taper embossing 36 that unique optical effect is provided.For example, equaling or to incide a row light C on the awl near the polarization angle of used polymkeric substance, will be by linear polarization, and reflection and transmitted light all will radially be distributed.Promptly from the light R of polymeric layer reflection, by from taper along when distributing, will be subjected to polarization.In addition, the light R ' through taper 36 also will be polarized and radially distribution.To other required illuminating effects, also can adopt other embossings.

This optical effect also can be used for providing the illumination of not too dazzling the eyes for room or working surface.As previously mentioned, a feature of the present invention is to control the relative light quantity that the reflection polylayer forest is crossed in reflection oneself or transmission by the interface number of key-course and the relative index of refraction of used polymkeric substance.

The present invention also can be used to live and commercial lighting, as light source, reverberator, refractor or diffuser.Shown in Fig. 8 and 9, paraboloid 40 is made up of the matrix band of multilayer reflector of the present invention, and the latter comprises the alternating layer of multiple polymers A and B.Reverberator 40 also comprises a plurality of triangles or slyness (promptly sine-shaped) groove 42; Groove 42 be positioned on the surface 44 of reverberator 40 or near.As shown in Figure 8, groove 42 is vertical orientated along the surface 44 of reverberator 40, although they can be around the periphery of reverberator in the another embodiment of the present invention (not shown).

Like this, shown in the embodiment of the invention in, by in conjunction with the reflection of multilayer tablet and the groove of under the inner full-reflection principle, working, increased the total reflectivity of reverberator 40.As Fig. 9 (for clarity sake it be painted as flat, but in fact should be crooked) shown in, from the incident ray R of light source (show, but be usually located within the reverberator 40) at least by each bed interface partial reflection, as arrow R ₁' to R _n' shown in.For purposes of illustration, incident and reflection ray all drawn off-normal slightly.

In addition, that part of incident light R of reverberator 40 is crossed in transmission, is returned shining on the surface of one of groove 42 and through reverberator 40.These reflected light are denoted as R ".Like this, because the contribution of the reflectivity of multilayer reflector and inner full-reflection, the total reflectivity of reverberator 40 has increased.In addition, as directed, by between adjacent groove 42, staying at interval, by some light shown in the arrow L with penetration device 40.Number by control flume, shape, and at interval and the number of bed interface and the respective indices of refraction of two kinds of polymkeric substance, reverberator of the present invention can be used to reflect, the incident light of refraction and directed required part.

According to polylayer forest of the present invention, be suitable for most with United States Patent (USP) the 3rd, 773,882 and 3,884, the multilayer extrusion device described in No. 606 is made.This device provides and has prepared the method that multilayer is extruded thermoplastic material simultaneously.Preferably can adopt as United States Patent (USP) the 3rd, 759 a series of laminated devices described in No. 647.

For making the present invention be easier to understand, can be referring to following example, they just are used to illustrate the present invention, but not for limiting its scope.

Example 1

Compared from individual layer mold pressing reflection sample (sample #1), reflection polymer multi-layer sheet (sample #2), reached surperficial mold pressing reflection multilayer tablet (sample #3) of the present invention.The individual layer sample is the polymethylmethacrylate sheet.Two kinds of multilayer samples by make according to the instruction of No. the 5th, 122,905, people's such as Wheatley United States Patent (USP), form with 2609 polycarbonate of the coating of pure polycarbonate and the alternating layer of polymethylmethacrylate.

Be imprinted on the mold pressing pattern on individual layer esters of acrylic acid and the multilayer sample surfaces, form by 0.466 inch wide 0.0625 inch dark triangle mold pressing line respectively.The both sides of embossing are isometric and become 15 ° of angles with the remainder of sample surfaces.It is level and smooth that the reverse side of each sample keeps.

In order to experimentize, set up the He-Ne laser instrument of 0.5mm beam diameter, so that light beam is shone on the surface of sample with the sample normal with becoming 30 ° of angles.When using the sample of mold pressing, the surface of mold pressing is facing to laser beam.The photodiode that is located on the motor driven platform moves with a radius around sample, and to collect intensity signal in 0 ° to 160 ° scope, wherein 0 ° of position is taken as arbitrarily and faces the position of sample back to laser beam one side.

For each sample, make recording the curve map of intensity to detector location.Figure 10 has shown sample #1(mold pressing individual layer sample) record the curve map of light intensity to detector location.Adopt above-mentioned reference system, locate three discrete spikes (being respectively transmission, reflection and reflection) at about 18 °, 105 ° and 145 °.As shown, the light intensity that records between the peak is zero substantially.By comparison, Figure 11 has shown sample #3(mold pressing multilayer sample) record the curve map of light intensity to detector location.Three discrete peaks (being respectively transmission, reflection and reflection) are arranged but between the peak, measured bigger intensity at 18 °, 105 ° and 145 ° equally.Light shows that to this scattering of other angles mold pressing multilayer reflector of the present invention along the angle direction scattered light, has caused even light effect.To the measurement of not mold pressing multilayer sample #2, demonstrate very local, resemble the transmission and the reflection peak of mold pressing individual layer sample very much.

For directly observing the light scattering characteristic of mold pressing multilayer sample #3 better, aerosol has been introduced in the zone around sample.This makes it possible to the angle covering of the fan effect of Direct observation sample in transmission and reflection.In some cases, the sectored light bright line clearly, these bright lines show the reflection of each layer from sample.

Example 2

According to the instruction in No. the 5th, 122,905, people's such as Wheatley the United States Patent (USP), made the sheet of 2625 layers (alternating layers of polycarbonate and polymethylmethacrylate).Make with Lancaster Glass subsequently, model is the mould of 6323-000 glass reflector, and sheet is thermoformed into diameter 10 1/8(ten not only 1/8th) inch high 4 11/16(four but also 11/16ths) the triangular paraboloid of inch.In reverberator apart from the base 3.1 inches locate to place a two-tube dulnx7 watt tungsten filament fluorescent light.Lighting pattern on the target that impinges upon 4 feet distant places is carried out photometric analysis.

Observe high reflex strength and extremely uniform lighting pattern, almost do not had unevenness.Figure 13 has shown that with candle light (candela) be the polar coordinates luminosity figure of the illumination intensity of unit to angle.Although because the pit on used mould has caused around the parts in the thermoforming has still produced uniform illumination.Illumination intensity reaches 100 candle lights at 0 °.To the microcosmic observation of the multilayer sample microbedding in the zone of pit on every side occurring, confirm that the angle of some layer has been changed, caused the equal light effect of being seen.

The glass triangular reverberator (Lancaster Glass board, 10 1/8 inch diameters, model 6323-000) that structure is identical produces bright spot owing to some surface deformation of reverberator on target.As from the luminosity figure of Figure 12 as seen, illumination intensity is irregular, and peak value only is 60 candle lights.This intensity is irregular to conform to the concentric ring pattern that observes on target.It is believed that this irregular be because of reflector surface around pit cause.

Example 3

Two kinds of different multilayer samples have been carried out polarimetry, provide effective light polarization to show multilayer polymeric object of the present invention.According to the instruction of No. the 5th, 122,905, people's such as Wheatley United States Patent (USP), 2625 layers sample (alternating layer of polycarbonate and polymethylmethacrylate) is made into sheet.Make the normal of sheet become 65 ° incident angle with light source subsequently, and observe polarization effect.

Observation shows that the reflected light of sample has significant polarization.Especially, in the plane of polarization in transmission, sample has seen through about 75% incident light.But in plane orthogonal (changeing 90 °), only there is 1% incident light to pass through.

The above-mentioned sheet of being made by 2625 layers sample is converted into folding Zhe shape, so that incident light incides on the surface of sheet to be about 65 ° angle with normal.This sample almost becomes black when being intersected by two traditional chromatic polarization sheets, shows that polarization of reflected light efficient is very high.This sample shows that the present invention is for living and commercial use provides effect aspect the low dazzle illumination.When folding Zhe shape sample was rolled into taper, the light that observes the transmission of sheet institute radially distributed.

Though shown some representational embodiment and details, those skilled in the art be it is evident that, under the situation of the scope of the invention that does not break away from appended claims and limited, can method and apparatus disclosed herein is done multiple modification for describing the present invention.

Claims (35)

1, be used for directed also distribution from the polymeric material optical reflector/refractor of the light of light source, comprise the reflection multilayer polymeric material body that constitutes by more than at least the first and second kinds of polymeric materials being arranged to parallel substantially plane alternating layer, it is characterized in that this body comprises first and second first type surfaces and comprises enough several zone of interest so that this body is reflected at least 30% of light at least one that is mapped to first and second first type surfaces, and the refractive index of first and second polymeric materials differs 0.03 at least, and wherein at least the cardinal principle parallel plane of some alternating layer relation be changed so that at least a portion light quilt that this body reflected and/or reflected is scattered along angle.

2, the optical reflector/refractor of claim 1, wherein some layer obtains mold pressing to change the cardinal principle parallel plane relation of layer at least.

3, the optical reflector/refractor of claim 2, wherein the layer of mold pressing is taper.

4, the optical reflector/refractor of claim 2, wherein the layer of mold pressing is crooked.

5, the optical reflector/refractor of claim 2, wherein the layer of mold pressing is a triangular.

6, the optical reflector/refractor of claim 1 wherein has 50 alternating layers at least.

7, the optical reflector/refractor of claim 1, wherein catoptrical scattering angle depend on the gradient of reformed layer.

8, the optical reflector/refractor of claim 1, contiguous first first type surface of wherein reformed layer.

9, the optical reflector/refractor of claim 1, contiguous second first type surface of wherein reformed layer.

10, the optical reflector/refractor of claim 1, wherein the polymeric material body has reservation shape, comprises a chamber that is limited by second first type surface.

11, the optical reflector/refractor of claim 10, wherein light source is positioned at the chamber.

12, have the reflector group compound that strengthens reflection characteristic, comprising:

(a) the reflection multilayer polymeric material body that constitutes by at least the first and second various polymeric materials of being arranged to cardinal principle parallel plane alternating layer, this body comprises first and second first type surfaces, it is characterized in that this body comprises enough numbers of plies so that this body is reflected at least 30% of light at least one that is mapped to first and second first type surfaces, and the refractive index of first and second polymeric materials differs at least 0.03;

(b) on first first type surface or near device, be used for inciding on second first type surface and at least a portion reflected back polylayer forest of the light of polylayer forest is crossed in transmission.

13, the composition of claim 12, the device that wherein is used to reflect comprise a plurality of triangular shape parts or groove.

14, the composition of claim 13, wherein triangular shape parts or groove first first type surface generally along vertical direction along body.

15, the composition of claim 12 wherein has 50 alternating layers at least.

16, the composition of claim 12, wherein the polymeric material body has the reservation shape that comprises the chamber that is limited by second first type surface.

17, the composition of claim 16 comprises the light source that is positioned at the chamber.

18, the composition of claim 17, wherein the polymeric material body is bowl-shape.

19, the composition of claim 17, wherein the polymeric material body is made into parabolic reflectors.

20, the composition of claim 13, wherein triangular shape parts or groove by mold pressing at least some the layer form.

21, the composition of claim 13, wherein triangular shape parts or groove are fixed on first first type surface.

22, be used for polarization from the not reflection of polarized light source and the polarizer of transmitted light, comprise the reflection multilayer polymeric material body that constitutes by at least the first and second various polymeric materials of being arranged to parallel substantially plane alternating layer, it is characterized in that this body comprises first and second first type surfaces and comprises enough numbers of plies so that this body is reflected at least 30% of light at least one that is mapped to first and second first type surfaces, and the refractive index of first and second polymeric materials differs at least 0.03, and the most orientation of the first type surface of this body makes from the light of light source to equal or to shine on this surface so that light is carried out polarization near the angle of polarization angle.

23, the polarizer of claim 22, wherein the light of crossing this body from the light and the transmission of this body reflection all is polarized.

24, the polarizer of claim 22 wherein has at least 50 alternating layers.

25, the polarizer of claim 22, wherein the surface of this body is a V-arrangement.

26, the polarizer of claim 22, wherein Zhe is rolled over to form a plurality of V-arrangements in the surface of this body.

27, the polarizer of claim 22, wherein the surface of this body comprises a plurality of conical die embossings.

28, the polarizer of claim 22, wherein the surface of this body comprises a plurality of pyramid mold pressing lines.

29, the polarizer of claim 22, wherein the surface of this body comprises a plurality of hemispheric mold pressing lines.

30, the polarizer of claim 27, wherein Fan She polarized light radially distributes.

31, the polarizer of claim 27, wherein the polarized light of transmission radially distributes.

32, back reflective sheet or film comprise:

A) the reflection multilayer polymeric material body that constitutes by more than at least the first and second kinds of polymeric materials being arranged to cardinal principle parallel plane alternating layer, it is characterized in that this body comprises first and second first type surfaces and comprises enough numbers of plies so that body is reflected at least 30% of light at least one that is mapped to first and second first type surfaces, and the refractive index of first and second polymeric materials differs at least 0.03.

B) one deck beaded glass in one or two surface of embedding reflecting body.

33, the back reflective sheet or the film of claim 32, wherein, the diameter of beaded glass is in the scope of 10 μ m to 10mm.

34, the back reflective sheet or the film of claim 32, wherein in the multilayer reflector at least the beaded glass that is embedded into of the cardinal principle parallel plane of some layer relation change.

35, the back reflective sheet or the film of claim 32 are included in the polymeric surface layer on one or more first type surfaces of body, and beaded glass is embedded on this top layer.

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