CN1375066A - Optical films having at least one particle-containing layer - Google Patents

Abstract

An optical film includes a reflective polarizing element and a particle-containing layer. The reflective polarizing element substantially reflects light having a first polarization state and substantially transmits a second polarization state. The particle-containing layer is disposed on the reflective polarizing element and in a same optical path as the reflective polarizing element. The particle-containing layer is configured and arranged to transmit light and includes a plurality of particles that roughen an exterior surface of the optical film. Preferably, using the optical film in an optical device does not substantially reduce the gain advantage of the optical device when compared with an optical device utilizing the same optical film without particles in the surface layer. Also described are optical devices using the optical film and methods of making and using the optical films.

Description

At least the blooming of one deck particle-containing layer is arranged

FIELD OF THE INVENTION

The present invention relates to blooming, comprise the device of this blooming and the method for manufacture and use thereof of described blooming.The present invention also relates to one deck particle-containing layer at least blooming, comprise the device of this blooming and the method for manufacture and use thereof of this blooming.

The background of invention

Polymer film is used for multiple use.A kind of concrete purposes of polymer film is to be used for reflective polarizer, and the light of a kind of polarization state of this polarizer reflection setted wavelength scope sees through the light of vertical polarization attitude substantially.Such reflective polarizer for example is used for combining with bias light in the LCD and improves display brightness.For example, a reflective polarizer can be positioned between bias light and the LCD panel.This layout can make a kind of light transmission of polarization state to display board, and the light recycle of other polarization states reflects away by bias light or from the reflecting surface that is positioned at the bias light back, gives chance of depolarizing of light, and passes through reflective polarizer.

A laminate that example is some different component polymeric layers of polarizer.A kind of structure of this laminate comprises first group of birefringent layers and second group of layer with isotropy refractive index.Second group of layer and first group of layer are alternately placed, and form a series of interfaces that light is reflected.The another kind of type of reflective polarizer is continuously/the disperse phase reflective polarizer, and it is first material that is scattered here and there in the second continuous material, and described second material is different for a kind of refractive index of polarized light and first material.Wired lattice polarization device of the reflective polarizer of other types and the polarizer that uses birefringence cholesterol material to form.

The general introduction of invention

Generally speaking, the present invention relates to blooming, comprise the device of this blooming and the method for manufacture and use thereof of this blooming.The present invention also relates to one deck particle-containing layer at least blooming, comprise the device of this blooming and the method for manufacture and use thereof of this blooming.

One embodiment of the present invention is a kind of blooming that comprises polarization by reflection element and top layer.The light of this polarization by reflection element fundamental reflection first polarization state, and see through the light of second polarization state substantially.The top layer on the polarization by reflection element, and be in the same light path of polarization by reflection element in, the top layer is made into and is arranged to is printing opacity, and comprises many particles that make the outside surface roughening on top layer.Preferably, when contrasting, in optical devices, use described blooming can not reduce the gain of optical devices basically with the optical devices that adopt the same blooming that does not have particle in the top layer.

The top layer can be arranged on the polarization by reflection element with several different methods, for example comprises coating or otherwise after forming the polarization by reflection element superficial deposit is got on.In addition, polarization by reflection element and top layer can form (for example, coextrusion) together.Basic all particle or only a part of particles can expose from the top layer or protrude in the top layer.Under some situation at least, all particles all are to be embedded in the top layer substantially, still can make the outside surface roughening on top layer.

Another embodiment is the optical devices that adopt described blooming.These optical devices also comprise at least one light source or display medium (for example, liquid crystal display medium).In some optical devices at least, polarization by reflection element and top layer are arranged between light source and the display medium, and in the optical devices such to small part, the top layer is between polarization by reflection element and display medium.

Another embodiment is the manufacture method of above-mentioned blooming.The polarization by reflection element is made into the light of fundamental reflection first polarization state, and sees through the light of second polarization state substantially.The top layer is formed on first first type surface of polarization by reflection element.The particle that has the outside surface roughening that makes the top layer in the top layer.

Another embodiment of the present invention is a kind of blooming that comprises the polarization by reflection element and be arranged on the layer that contains particle on this polarization by reflection element.The light of polarization by reflection element fundamental reflection first polarization state, and see through the light of second polarization state substantially.The layer that contains particle be arranged on polarization by reflection element same light path in, and make and be positioned to printing opacity.Contain many particles that make the outside surface roughening of blooming in the particle-containing layer.Particle-containing layer can be the top layer of blooming, perhaps has one deck overlayer can be arranged on the particle-containing layer, and particle-containing layer makes tectal outside surface roughening.

Above-mentioned general introduction of the present invention does not plan to describe each embodiment of the present invention.Following accompanying drawing and detailed description will specifically describe these embodiments.

Brief description of drawings

In conjunction with the accompanying drawings, read the detailed description of the various embodiments of following the present invention, can more fully understand the present invention, in the accompanying drawing:

Fig. 1 is the sectional view of blooming the 1st embodiment of the present invention;

Fig. 2 is the sectional view of blooming the 2nd embodiment of the present invention;

Fig. 3 is the sectional view of blooming the 3rd embodiment of the present invention;

Fig. 4 is the sectional view of blooming the 4th embodiment of the present invention;

Fig. 5 is the sectional view of blooming the 5th embodiment of the present invention;

Fig. 6 is the sectional view of blooming the 6th embodiment of the present invention;

Fig. 7 is the sectional view of blooming the 7th embodiment of the present invention;

Fig. 8 is the sectional view of an embodiment of bias light demonstration of the present invention;

Fig. 9 is the blooming (concealed wire) that adopts the cortex that does not contain particle and uses the observed spectrogram of blooming (bright line) that contains the particle cortex;

Figure 10 is the sectional view of blooming the 8th embodiment of the present invention;

Figure 11 is the vertical view of blooming shown in Figure 10;

Figure 12 has and does not contain the reflection multilayer polarizer luminance gain of grain coating and the graph of a relation at visual angle;

Figure 13 be have with do not contain grain coating continuously/diffusion graph of a relation at reflective polarizer luminance gain and visual angle mutually;

Figure 14 is the sectional view of blooming the 9th embodiment of the present invention.

Though the present invention can carry out various modifications and be modified as multiple different form, its detail is illustrated by embodiment shown in the drawings, and describes in detail,, should be understood that to the invention is not restricted to described these embodiments.On the contrary, the present invention covers all and falls into spirit and scope of the invention interior change, content of equal value and variation.

Detailed description of the preferred embodiment

Can think that the present invention is applicable to blooming, comprises the use and the manufacture method of the device and the blooming of blooming.

The present invention also relates to the use and the manufacture method of blooming, the device that comprises blooming and the blooming of one deck particle-containing layer at least.

But the present invention is not limited to this, by the discussion of the embodiment that provides below, can understand various aspects of the present invention.

Be used to illustrate when of the present invention, " luminance gain " refers under a certain viewing angles (with respect to normal axis), in desired wavelength coverage, the bias light during with the blooming that contains reflective polarizer or the brightness (a) of display are under this certain viewing angles (with respect to normal axis), in desired wavelength coverage, the bias light in the time of promptly need not containing separately the blooming of reflective polarizer or brightness (about the normal axle) ratio (a: b) (b) of display.

" normal angle gain " refers to spending the luminance gain under the visual angles with respect to blooming plane (for example surface) 90.

" gain " refers to normal angle gain subtracting 1 (corresponding to the film that does not make light polarization).

Fig. 1 has illustrated blooming 100, it comprise a polarization by reflection element 102 and at least one deck contain particle 106 the layer 104.Particle-containing layer (one or more layers) can be arranged on the first type surface of polarization by reflection element for example, in the polarization by reflection element, or these two positions on first type surface and in the polarization by reflection element.Each particle-containing layer for example can be, covers the layer on the polarization by reflection element, or forms the layer (for example, cortex or inner non-optical layers) of (for example coextrusion) with the polarization by reflection element.

The polarization by reflection element

Many polarization by reflection elements can both be applied in the blooming.Usually, the polarization by reflection element reflects the light of a different polarization state through a kind of light of polarization state.Be used to realize that these materials with function and structure can be different.The material and the structure that depend on blooming, " polarization state " for example can refer to, linear, circular, oval-shaped polarization state.

The example of suitable polarization by reflection element comprises the reflection multilayer polarizer, continuously/the disperse phase reflective polarizer, cholesterol reflective polarizer (it also can combine with quarter-wave plate) and wire grid polarizer.Generally speaking, reflection multilayer polarizer and cholesterol reflective polarizer are specular reflectors, continuously/and the disperse phase reflective polarizer is a diffuse reflector, although these features are not generally (to see for example multilayer diffuse reflective polarizer, United States Patent (USP) № 5,867,316 have description).Here the illustrative polarization by reflection element of listing does not also comprise makes all suitable polarization by reflection elements.Any penetrated preferably has the light of a polarization state and preferential reflection to have the reflection of light polarizer of another polarization state to use.

Reflection multilayer polarizer and continuous/disperse phase reflective polarizer all depend on the difference of at least two 2 kinds of different materials (preferred polymers) refractive index, thereby optionally reflect the light of a polarization direction, and see through the light of vertical polarization.Suitable diffuse reflective polarizer comprises continuously/the disperse phase reflective polarizer that United States Patent (USP) № 5,825,543 has the multilayer polarizer of description (with reference to being incorporated into this) and the reflection of diffusion ground, and United States Patent (USP) № 5,867,316 has description, (with reference to being incorporated into this).Other polarization by reflection element has description at United States Patent (USP) № 5,751,388, also with reference to being incorporated into this.

The cholesterol reflective polarizer all has description for example at United States Patent (USP) № 5,793,456 among United States Patent (USP) № 5,506,704 and the United States Patent (USP) № 5,691,789, and its all the elements are all with reference to being incorporated into this.A kind of cholesterol reflective polarizer is that E Merck ﹠ Co., Inc. is with trade mark TRANSMAX ^TMSell.The wire grid polarizer for example has description in disclosed PCT WO 94/11766, with reference to being incorporated into this.Illustrative reflection multilayer polarizer is for example having description among disclosed PCT Nos WO95/17303, WO95/17691, WO95/17692, WO95/17699, WO96/19347 and the WO99/36262, and its all the elements are with reference to being incorporated into this.A kind of commodity of reflection multilayer polarizer are the Dual BrightnessEnhanced Film (DBEF) that is sold by 3M company (Sao Paulo, the Minnesota State).Use the reflection multilayer polarizer structure of blooming of the present invention and the method for manufacture and use thereof of this blooming to be described herein as an example.Described structure, method and technology can be fit to be applied in the suitable polarization by reflection element of other types.

A kind of suitable reflection multilayer polarizer that is applicable to blooming 120 can be made like this: with birefringence first optical layers 122 and alternately (for example interlayer ground) setting of second optical layers 124 of single shaft or biaxial orienting, as shown in Figure 2.In some embodiment, second optical layers 124 has the isotropy refractive index of the interior index of a face of the oriented layer of approximating.In addition, these two kinds of optical layers 122,124 are all formed by birefringent polymer, and its orientation is to make the refractive index approximately equal on the direction in the face.No matter second optical layers is an isotropy or birefringent, the interface between two optical layers 122,124 has all formed the light plane of reflection.The light of polarization can see through basically in the plane that is parallel to described two-layer refractive index approximately equal direction.The light of polarization then is reflected to small part in the plane that is parallel to the described two-layer discrepant direction of refractive index.Increase the number of layer or increase the difference of refractive index between first and second layer 122,124, can both improve reflectivity.

Usually, the high reflectance of a specific interface occurs under such wavelength, and this wavelength is corresponding to the twice of the optical layers that forms the interface to 122,124 combination optical thickness.Optical thickness has been described the optical path difference between the right light that lower surface and upper surface reflected of optical layers.For the incident light (normal incident light) that incides the blooming plane with 90 °, described two-layer optical thickness is n1d1+n2d2, wherein n1, n2 are respectively two-layer refractive indexes, and d1, d2 are respectively corresponding two-layer thickness.Only use every layer the outer refractive index of a face (for example, nz), just can use this equation to regulate optical layers as normal incident light.In other angle, light path depends on through the distance (it is bigger than the thickness of layer) of layer and the refractive index at least two optical axises of three optical axises of layer.Usually, to form a spectrum with respect to membrane plane less than the transmittance meeting that 90 angles of spending incide on the blooming, with respect to the viewed bands of a spectrum of normal incidence transmittance, its bands of a spectrum move (for example, blue shift) to short wavelength.

For normal incident light, layer 122,124 can be that quarter-wave is thick separately, and perhaps layer 122,124 can have different optical thicknesses, if optical thickness and be wavelength half (or its multiple).There is the film of many layers can comprise the layer of different optical thickness, is used for increasing the reflectivity of film in wavelength coverage necessarily.For example, film can comprise respectively and be conditioned a pair of to layer of (for example, for normal incident light), so that obtain to have the best reflection of the light of specific wavelength.

Except first and second optical layers 122,124, reflection multilayer polarizer 120 can also comprise one or a more non-optical layers, and for example, one or more cortexes 128 or one or more inner non-optical layers 130 are shown in Fig. 2 and 3.Be similar to first and second optical layers 122,124, other paired optical layers also can be used in the reflection multilayer polarizer.The design concept of first and second optical layers in pairs as herein described can be applicable to any other paired optical layers.In addition, understand that though Fig. 2 and 3 only shows a laminate 126, the reflection multilayer polarizer can be made by a plurality of laminate that are combined to form film successively.

In addition, though Fig. 2 and 3 only illustrates 4 optical layers 122,124, reflection multilayer polarizer 120 can have a lot of optical layers.Usually, the reflection multilayer polarizer has about 2～5000 optical layers, general about 25～2000 optical layers, often about 50～1500 optical layers or about 75～1000 optical layers.

First and second optical layers

First optical layers is the birefringent polymer layer of single shaft or biaxial orienting preferably.

Second optical layers can be birefringent and the polymeric layer of single shaft or biaxial orienting, and perhaps second optical layers can have the isotropy refractive index different with at least one refractive index of first optical layers after orientation.

First and second optical layers are not more than 1 micron thickness usually, and it is thick generally to be not more than 400nm, but if desired, also can use thicker layer.These optical layers can be equally thick, also can be different thick.

First and second optical layers of reflection multilayer polarizer and also presumable non-optical layers generally by polymkeric substance for example polyester form.The polarization by reflection element of other types (for example, continuously/the disperse phase reflective polarizer, cholesterol polarizer and wire grid polarizer) the described material material formation of then available above-mentioned document.

The polyester that the reflection multilayer polarizer uses generally includes carboxylate and glycol subunit, is produced by carboxylic acid ester monomer molecule and glycol monomer molecule reaction.Each carboxylic acid ester monomer molecule has two or more carboxylic acids or ester functional group, and each glycol monomer molecule has two or more hydroxy functional groups.The carboxylic acid ester monomer molecule can be all identical, and two or more dissimilar molecules also can be arranged.This point is equally applicable to glycol monomer molecule." polymkeric substance " this speech is interpreted as here and comprises polymkeric substance or multipolymer, also comprise polymkeric substance and multipolymer the two, they can for example comprise that by coextrusion or reaction for example ester exchange reaction forms the blend that dissolves each other.Term " polymer " ", " multipolymer " and " copolyesters " comprises random and multipolymer block.Term " polyester " also comprises the polycarbonate that the reaction by the ester of glycol monomer molecule and carbonic acid forms.

The character of polymeric layer or film changes with the monomer molecule of concrete selection.Example of polyester useful in the reflection multilayer polarizer is (ethylene naphthalate) (PEN), and it can for example be made by the reaction of naphthalene diacid and ethylene glycol.

Be used to form the suitable carboxylic ester monomer molecule of the carboxylate subunit of polyester layer, for example comprise, 2,6-naphthalene diacid and and isomeride, terephthalic acids, isophthalic acid, phthalic acid, azelaic acid, hexane diacid, decanedioic acid, the rare diacid of norborneol, two-cyclooctane diacid, 1,6-cyclohexane diacid and isomeride thereof, tert-butyl isophthalic acid, trihemellitic acid, sodiosulfoisophthalic acid, 2,2 '-diphenyl diacid and isomeride thereof and these sour lower alkyl esters, for example methyl esters or ethyl ester." low alkyl group " term in this article, refers to the alkyl of C1-C10 straight or branched.

The suitable diol monomer molecule that is used to form the glycol subunit of polyester layer comprises ethylene glycol, propylene glycol, 1,4-butylene glycol and isomeride thereof, 1,6-hexanediol, neopentyl glycol, polyglycol, diethylene glycol, three ring decanediols, 1,4-cyclohexanedimethanol and isomeride thereof, norbornane glycol, two ring ethohexadiols, trimethylolpropane, pentaerythrite, 1,4-benzene dihydroxymethyl and isomeride thereof, bisphenol-A, 1,8-dihydroxy diphenyl and isomeride thereof, 1,3-two (2-hydroxyl-oxethyl) benzene.

Non-polyester polymers also can be used for forming polarizer film.For example, the polyether acid imide can with polyester for example PEN and PEN multipolymer together use, form the reflection multilayer polarizer.Also can use other polyester/non-polymer blend, for example polyethylene terephthalate and tygon (Engage for example ^TM8200, Dow chemicals company, Midland, Michigan State).

First optical layers generally is orientable polymer film, polyester film for example, it can by for example along the one or more directions that need to stretching, make birefringent." birefringence " means at vertical x, and the refractive index of y and z direction does not equate entirely.For the layer in film or the film, x, y and z axle can be chosen as x and y axle length and the width corresponding to film or layer easily, and the z axle is corresponding to the thickness of layer or film.

But the first optical layers uniaxial orientation, for example, make one direction stretching.The 2nd vertical direction can allow to take place part constriction (for example, size reduces), less than its original length.In one embodiment, draw direction corresponds essentially to x or y axle.Yet, also can select other direction.Birefringent uniaxial orientation layer is generally seeing through or reflection shows difference when having the incident light of the plane of polarization that is parallel to direction of orientation (being draw direction) and having and be parallel to laterally the light of plane of polarization of the direction of draw direction (that is, perpendicular to).For example, when a slice can be orientated polyester film when the x axle is stretched, general result is nx ≠ ny, and wherein nx and ny are respectively the refractive indexes of the light of polarization in the plane that is parallel to " x " and " y " axle.Refractive index depends on along the change degree of draw direction, the factors such as composition of the thickness of the thickness of the temperature of film, film, each individual layer, film during amount of tension, rate of extension, the stretching.Usually, first optical layers 122 orientation back birefringence indexs (absolute value of nx-ny) in the face of 632.8nm are 0.04 or bigger, and are preferred about 0.1 or bigger, more preferably from about 0.2 or bigger.Except as otherwise noted, the report value of all birefringence index and refractive index all is meant for 632.8nm light.

Second optical layers 124 can be made by many polymkeric substance.The example of suitable polymers comprises by monomer vinyl naphthalene for example, styrene, maleic anhydride, polyvinyl that acrylate and methacrylate monomers are made and multipolymer.The example of this polymkeric substance comprises polyacrylate, and polymethacrylate, for example poly-(methacrylate) are (PMMA) and isotaxy or syndiotactic polystyrene.Other polymkeric substance comprise condensed polymer, polysulfones for example, polyamide, polyurethane, polyamic acid, and polyimide.In addition, second optical layers can for example polyester and polycarbonate form by polymkeric substance and multipolymer.Use multipolymer exemplary illustration second optical layers of polyester below, yet, know, also can use above-described other polymkeric substance.Below described same consideration about the copolyesters light property, generally also be applicable to other polymkeric substance and multipolymer.

In some embodiment, second optical layers be can single shaft or biaxial orienting in other embodiment, second optical layers is not orientated in that the processing conditions that is used to make first optical layers orientation is next.These second optical layers even also kept isotropic relatively refractive index when stretching or when otherwise being orientated substantially.For example, second optical layers 632.8nm can have less than about 0.06 or less than about 0.04 birefringence index.The suitable examples of material of second optical layers has the multipolymer of PEN, PBN, PET or PBT.

Non-optical layers

Non-optical layers can be used in the reflection multilayer polarizer, for example in order that form polarizer structure, or protects polarizer to avoid infringement during processing or after the processing.Non-optical layers comprises cortex 128, and it forms the first type surface (see figure 2) and the inner non-optical layers 130 of reflection multilayer polarizer, this non-optical layers 130 (see figure 3) between the composite bed of optical layers 122 and 124.Additional coating also can be thought non-optical layers.Non-optical layers generally can not influence the polarization properties of blooming at interested wavelength region may (for example, visible light).The suitable polymeric material of reflection multilayer polarizer (with other polarization by reflection element) non-optical layers can use with first or second optical layers those are the same.

Cortex and or the comparable first and second optics bed thickness of spendable non-optical layers, thin or thick equally.At least 4 times of the thickness of at least one layer in normally single first and second optical layers of cortex and non-optical layers, generally at least 10 times, and can at least 100 times.Can change the thickness of these non-optical layers, make the reflection multilayer polarizer of specific thicknesses.

To place one or more non-optical layers in general, so that at least a portion sees through first and second optical layers, is also passed through these layers (that is, these layers are placed on by in the light path of first and second optical layers or by in the light path of first and second optical layers reflection) by the light of the first and second optical layers polarizations or reflection.

The preferred polymeric material of selecting first optical layers, second optical layers and optional non-optical layers makes them that similar rheological properties (for example melt viscosity) be arranged so that can not produce flow interfering during their coextrusion.In general, second optical layers, cortex and or the vitrifacation transition temperature Tg of spendable non-optical layers be lower than, or be not higher than the about temperature more than 40 ℃ of the first optical layers glass transition temperature.Second optical layers, cortex and or the glass transition temperature of spendable non-optical layers be lower than the glass transition temperature of first optical layers.

Conventional blooming

Conventional blooming can comprise the polymeric optical films that for example contains at the polarization by reflection element described in the above-mentioned document.Find that these polymeric optical films can be often wetting or for example be adhered on the adjacently situated surfaces of a LCD of making of smooth glass.Because two air-polymer interfaces have been eliminated, so transmission has increased, will cause the formation of speck.In addition, polymeric optical films can show Newton ring, and it is the colour circle that has that can see owing to interfere between the very near surface, two intervals.Form the optical property that speck and these two kinds of phenomenons of Newton ring all can the impact polymer blooming and be placed with the optical property of the device of this blooming.

In addition, the little point defect on the blooming also is that the consumer pays close attention to.These shortcomings can hinder attractive in appearance or hinder and check and repairing.In addition, other the non-smooth films and the unit that install in the display for example can be imprinted on the blooming, make the surperficial defective of film.And under temperature cycles, polymeric optical films can warpage (for example, described film bends, and temporarily or for good and all presents uneven shape).In addition, blooming is used for display (for example LCD), when when being different from the view of normal direction (be light incide the plane of blooming with the angles of 90 degree) basically, blooming has shown colored appearance, and these colors can be different everywhere on display.This colour inhomogeneous be that the non-homogeneous spectrum that sees through of because wide incident visual angle (being 50 degree or less with respect to the blooming plane for example) causing to small part.

Existing blooming is carried out some improved trials, solved at least a portion of these problems.For example, outermost layer (for example, cortex) is carried out embossing, reduce wetting and formation Newton ring.Yet embossing is handled and can be formed more uneven surfaces outward appearance again.At least on high incident angle, can see embossing texture user in some cases.In addition, in the manufacture process of blooming, the embossing operation requires to adopt accurate knurling tool and additional step.Embossing also can influence the homogeneity of bed thickness, causes inhomogeneous on the color.

Particle-containing layer

Discovery adds particle being arranged in the particle-containing layer that the polarization by reflection element plays the light path of inclined to one side light, and some useful optics or mechanical properties can be provided.These advantages comprise and for example reduce or eliminate wetting and Newton ring and color is covered or homogenising.

Under the situation of reflection multilayer polarizer, shown in Fig. 2～7, particle-containing layer 132 (one or more layers) for example can be, one deck cortex 128 (Fig. 2,3 and 4), two-layer cortex 128 (Fig. 5 and 7), or be arranged on coating 134 (Fig. 6) on the polarization by reflection element first type surface 136.Part or even all particle can both protrude from layer.

Example shown in Fig. 2～7 can change, so as with other the polarization by reflection element for example continuously/disperse phase reflective polarizer, cholesterol reflective polarizer and wire grid reflective polarizer together use.Particle-containing layer (one or more layers) can be the single cortex of polarization by reflection element, the inside non-optical layers in the polarization by reflection element, the perhaps coating on the polarization by reflection element.

Figure 10 and 11 has illustrated another embodiment of the present invention, and wherein monolayer of particles 132 is positioned on the surface 105 on polarization by reflection element 102 upper stratas 104, and a face coat is provided on the polarization by reflection element.For the purposes of the present invention, " individual layer " is meant that thickness is about the layer of 1 particle 132 thickness, and it is positioned on layer 104 the surface 105 or near surface.

Under some situation, part particle 132 is embedded in the layer 104, and all the other particles 132 protrude from layer 104, and perhaps part is exposed to layer 104 outside.Under other situation, all particles 132 can both be embedded in fully or be embedded in the layer 104 substantially, still can provide rough surface.

Particle 132 in the top layer on a polarization by reflection element 102 can according to they occupy the layer 104 surface percentage characterize.In order to realize the desired performance that reduces Show Color of polarization by reflection element, and reduce wetting, can require particle 132 occupy layer 104 exposing surface at least about 10%.Can also require particle 132 occupy the layer 104 exposing surface at least about 20%.

Increase particle 132 and occupy the long-pending percentage of layer 104 exposing surface, bias light for example can be provided or comprise the attendant advantages of luminance gain of the optical display of the polarization by reflection element 102 that particle 132 is arranged in the layer 104.But, increase luminance gain, comprise that light source is preferably carried on the surface of particle 132, and particle 132 preferably occupies the long-pending at least one major part (that is, greater than 50%) of layer 104 exposing surface, more preferably from about 60% or more, preferred more about 70% or more, even more preferably from about 90% or more.

As described in embodiment, the monolayer of particles in the top layer on a polarization by reflection element or other distributions of particle can augmentativity to depart from the normal direction broad angular field of view for example under some situation, at least about the luminance gain in ± 30 degree.In addition, the distribution of individual layer and other diffuse components also can reduce or eliminate the visible color unevenness of multi-layer optical film reflective polarizer off-axis.Preferably, compare, use the gain of the blooming of particle-containing layer not reduce basically with the same blooming that does not have particle.(for example, 632.8nm) or wavelength coverage, the minimizing of gain preferably is not more than 5%, more preferably no more than 3%, even preferably is not more than 2% again for interested wavelength.

Particle does not preferably absorb the light that the polarization by reflection element sees through in fact, and it is depolarized.The light quantity that sees through blooming does not preferably reduce substantially.More preferably, the light quantity with polarization state that the polarizer that preferentially is reflected sees through does not reduce basically, for example uses second polarizer to measure.

The surface energy prevention of roughening or the blooming on minimizing wetting other adjacent base materials of blooming or the film are because the quality of roughened surface can stop or reduce the ability that blooming is adhered to adjacent smooth surface.The surface energy of roughening also stops or reduces the order of severity of Newton ring (for example, because two coloured rings that the very near smooth surfaces in interval are interfered formation).The quality on the surface of roughening also can be reduced in the homogeneity of the spacing between blooming and the contiguous smooth surface.

The needs to lining (diaphragm before being used for using) can also be reduced or exempt in the surface of roughening.Because little cut is no longer visible.And, the blooming work that do not influence in fact that the surface of roughening usually can hidden existence and on smooth surface visible defects (for example, gel, mold deposit, depression, mold line, cut).Because film and the smooth substrate for example friction factor between the interior glass of LC module are lower, the wearing quality of film also can be improved in the surface of roughening, and can reduce the possibility that temperature variation causes the film warpage.In some cases, the surface energy of roughening opposing or shelter the impression that causes by contiguous film, base material and other object surfaces features.

Compare with the film through embossing, the rough surface of blooming also can improve the THICKNESS CONTROL of film.This point can cause better color homogeneity above the film.Film is carried out the skin-friction coefficient that roughening can significantly reduce film.The friction factor (for example by ASTM D1894 measure) that the blooming that contains the particle top layer is arranged can be do not contain the particle top layer blooming friction factor 50% or still less, 25% or still less, even 10% or still less.Use particle-containing layer can make average surface roughness increase to 3 times or more, 10 times or more, even 25 times or more.Average surfaceness can for example be used, and Wyko interferometer (Wyko company, Tuscon Arizona, Roughness/ step tester's model RS 104048) is measured.

In order to make top layer (one or more layers) roughening of blooming, can select its refractive index particle the same or different with the other materials on top layer.Select such particle, it can keep shape at blooming between the normal operating period, thereby keeps wanting the advantage of roughening.Particle can be added in one or two cortex of reflecting polarizing layer, and the coating that perhaps contains particle can cover on one or two surface of reflecting polarizing layer.The surface texturisation on top layer (one or more layers) is subjected to coating of particles and size-grade distribution, and alignment conditions is used for forming the polymkeric substance on top layer (one or more layers) and extrudes or the influence of coated conditions.

Particle in the particle-containing layer also can rise diffuse component (for example, diffuse component) effect, as shown in Figure 2.These particle-containing layers can be positioned on the surface of a polarization by reflection element or it is inner, and can together form with the polarization by reflection element, perhaps cover the polarization by reflection element and, and also have extra play (one or more layers).

When the diffusion of using particle/diffusive properties, particle can be positioned at particle-containing layer, protrudes from the surface of layer, perhaps is in this two states.Diffusion/the diffuse properties that contains the film of particle can originate from volume diffusion, surface diffusion or the two combination.When the diffuse properties of using them and when being positioned at cortex, particle preferably is provided in the cortex on only first type surface of blooming.In the layer on two first type surfaces of blooming particle is arranged, film just can see through the light with the polarization state that can otherwise be reflected, describe as described in 09/199602 as the patented claim of the common transfer of the U.S., its name is called " mattress reflector of selective transmission ", and its content is with reference to being incorporated into this.

Because the light in certain wavelength coverage is uneven (non-homogeneous transmitted spectrum) by the transmission of reflective polarizer, color can be formed in the optical devices that reflective polarizer is housed.In addition, the transmitted spectrum of a reflective polarizer can spatially change, so even also can observe different colors on display under the same visual angle.Transmitted spectrum can change when the visual angle changed.The complex pattern of the color that clean effect changes with visual angle and screen position with regard to the generation meeting.

If desired, the particle in the particle-containing layer can make the light generation diffusion by the polarization by reflection element, forms the blooming of the non-homogeneous less and integral color lighter (for example, the film of hidden color) of color.After light preferably fully passes through the polarization by reflection element at least in part, diffusion has taken place in this light, see that with special angle the observer of film not only can see with the light without diffusion of single angle by the polarization by reflection element, and, because diffusion also can be seen with the light of other angles by the polarization by reflection element.The spectrum of seeing is average on an angular range, than the spectrum level and smooth (forming less color) of the situation that diffusion does not take place.Like this, the spectrum seen of observer is with the combination of different angles by the spectrum of polarization by reflection element.So just hidden the color of the specific light transmission spectrum that on observer's angle, can see.

Particle and the difference of refractive index that contains the layer of particle can influence some factors, for example normal angle of blooming gain (using the tolerance of the brightness value of the increase that blooming obtains under the bias light display condition) and the average amount of color that is obtained by diffusion.Usually, the normal angle gain reduces with the difference increase of particle with the refractive index of the layer that contains particle.Different therewith, the average amount of color then increases with the difference of the refractive index of particle and particle-containing layer, because the difference of bigger refractive index causes bigger scattering.So just can select the material of particle and the layer that contains particle, obtain desired combination property at least based on the difference of particle with the refractive index of the material of the layer that contains particle.Particle and contain the difference of refractive index between the layer of particle and for example be generally in 0～0.12 scope.

In order to obtain the effect of diffusion (for example scattering), the refractive index of particle can be different from the refractive index (volume diffusion) of other materials of particle-containing layer.In addition, the refractive index of particle also can be suitable with the refractive index of other materials of particle-containing layer, in the case, only is that rough surface provides desired diffusion (surface diffusion).The volume diffusion of particle-containing layer (one or more layers) (for example scattering) performance depends on that many factors comprise, for example the particle density in the refractive index of other parts of particle refractive index, particle-containing layer, coating of particles and orientation and the layer.

The surface diffusion performance of particle-containing layer (one or more layers) depends on that many factors comprise, for example coating of particles and size-grade distribution, alignment conditions, be used for forming superficial layer (one or more layers) polymkeric substance (one or more), extrude or coated conditions.The diffuse properties of film is volume diffusion, surface diffusion, perhaps the result of volume and surface diffusion.

Under some situation, may need basic similar with layer 104 of the refractive index of particle 132, feasible diffused light by goods mainly is surface diffusion but not volume diffusion.For example, particle 132 and the index difference of layer between 104 about 0.2 or littler, preferred about 0.1 or littler, more preferably from about 0.05 or littler.When surface diffusion was required feature, particle 132 was preferably optically transparent for the light of interested wavelength.

When brightness improves film, for example available from the BEF film of the 3M company in Sao Paulo, the Minnesota State, when being used for LCD, when the visual angle increased, light intensity sharply descended at a narrow angular range usually.Particle can make to fall suddenly in the intensity of this angular range and become level and smooth, makes it become milder transformation.In addition, when non-smooth film when for example the BEF film contacts with the reflective polarizer film close, their can stamp a bad pattern on reflective polarizer film.And particle can reduce or eliminate the picture on surface that can see that is imprinted on the polarizer film.

Blooming also can together use with absorptive polarizers or with the absorptive polarizers layer, for example, at WO95/17691, among WO 99/36813 and the WO 99/36814 description is arranged, and its full content is with reference to being incorporated into this.In this embodiment, particle-containing layer can hidden as mentioned above color.

The order of severity that the dark status color of conventional reflection/absorptive polarizers is leaked can use conventional dichroic polarizer to observe, and this dichroic polarizer is orientated extremely can absorb and preferentially is reflected/polarized light that absorptive polarizers sees through.Add that particle-containing layer generally can reduce this this color and leak.

The suitable material of particle comprises for example inorganic oxide and polymkeric substance, they substantially can not be miscible, and in the particle-containing layer process, can not cause in the material of layer harmful reaction (degraded) takes place, can thermal degradation under processing temperature, the remarkable light in interested wavelength or wavelength coverage not.The example of suitable material (for example comprises silicon dioxide, sodium silicoaluminate, aluminium oxide, liquid crystal polymer; the Vectra TM liquid crystal polymer of buying from the Benjamin Eastman chemicals Products Co., Ltd of Tennessee State Kingsport;), amorphous polystyrene, glass, styrene acrylonitrile copolymer, talcum, crosslinked granules of polystyrene or compound matter (for example, the Zeeospheres of 3M company of polystyrene copolymer, aluminium oxide and silicon dioxide ^TM, Sao Paulo, the Minnesota State) or the combination of these materials.

The particle mean size of particle is usually in 0.1～20 micron scope for example.Usually, the particle mean size of particle is in 0.3～10 micron scope.Under some situation at least, preferably use granule, because just can in unit volume, add more particle like this, often form surface more coarse or more even roughness or more light diffusion center.

Although can use the particle of Any shape, spherical particle is being preferred in some cases, especially because this can help improving the effect and the gain of hidden color.For surface diffusion, spheric grain is compared with other shapes, and every particle can produce a large amount of rat effects, and the arrangement of aspherical particle in membrane plane is to make the thickness direction of its shortest main shaft at film.

Amounts of particles in the particle-containing layer usually depends on such factor, for example desired blooming performance, the refractive index of the other materials of the type of the type of the polymkeric substance that in particle-containing layer, uses and composition, particle and composition and particle and particle-containing layer (for example polymkeric substance (one or more)) poor.Granule content in the particle-containing layer for example is at least 0.01 volume %, is benchmark with the cumulative volume of the material that is used for preparing particle-containing layer.Granule content is less can not to have much influences to the character of film.For organic granular, polymer beads especially, granule content generally is not more than about 25 volume %.For inorganic particle, content generally is about 0.01-10 volume %, usually is 0.05～5 volume %, is benchmark with the cumulative volume of the material that is used for preparing particle-containing layer.

Can make and in many ways particle be added particle-containing layer (one or more layers).For example, particle can be in extruder and the polymer mixed of particle-containing layer.Then particle-containing layer (one or more layers) and optical layers coextrusion can be formed blooming.Particle can be with the polymer mixed of additive method and particle-containing layer, and described method comprises, for example, before extruding in mixer or other devices composite grain and polymkeric substance.

In other method, particle also can be added in the monomer of the polymkeric substance that is used for forming particle-containing layer.For example, as under the situation of particle-containing layer, particle can add in the reaction mixture that contains the carboxylate that is used for forming polyester and diol monomer at polyester.Particle should be unable to influence polymerization process or speed by catalytic degradation reaction for example, chain termination or with monomer reaction.Zeeospheres for example ^TMThis particle is appropriate to add and is used for forming in the monomer of polyester particle-containing layer.Mix with the monomer that is used for preparing polyester as fruit granule, it should not comprise acidic-group or phosphorus.

Under some situation, use above-mentioned any method, with particle and polymer manufacture masterbatch.This masterbatch can join in the more heteropolymer in extruder or mixer with selected ratio then, and preparation has the film of the granule content that requires.

On a reflective polarizer, provide in the another kind of method on the top layer that comprises particle, can be to preformed polarization by reflection element with the top layer precursor deposition.The top layer precursor can be any material that is suitable for forming coating on the polarization by reflection element, comprises monomer, oligomer and polymeric material.For example, the top layer precursor can be the above-mentioned any polymkeric substance of first and second optical layers and non-optical layers or the precursor of these polymkeric substance of being used for, and also can be the material of sulfo-polyurethane, sulfo-polyester, fluorinated acrylate and acrylate and so on.

Particle can provide with premixed slurry, solution or the dispersion that contains the top layer precursor.Another way that can supply is particle to be separated with the top layer precursor provide.For example, precursor at first is coated on the polarization by reflection element, and particle just can be deposited on this precursor, for example, scatter or otherwise deposit by landing, injection, waterfall type, so that obtain other distribution forms of desired particle individual layer or particle in the top layer or on the top layer.Precursor just can be cured then, and is dry or otherwise process, and forms desired top layer, and this top layer retains particle in desired mode.The relative scale of top layer precursor and particle can change according to many factors, comprises the form on coarse top layer of for example desired formation and the character of precursor.

In some embodiment at least, in the stent process of the reflection multilayer polarizing coating that is used for making orientation, it is to be fixed in the tenter clip to be that the part (for example 30%) of the total polymer of system film is arranged, and it can not be orientated fully.This non-oriented material trims as " edge contour of stenter ".Described " edge contour of stenter " can contain the particle of polymeric material.These particles can be for example to come from interior the staining and/or back stent processing and formation of tenter clip.

Particle is added the cortex of blooming or other contain the particle non-optical layers, can shelter the particle that to introduce when using recycle " edge contour of stenter " or other recycled materials.The light diffusion of rough surface and particle can hidden edge contour by stenter be stained or the outward appearance of the particle that back stent processing is introduced.Adding particle in these cortexes can recycling better " edge contour of stenter " and discarded film fragment, and this just can greatly save cost, and more effectively utilizes material.

Or spendable overlayer

Under some situation at least, extrude when having the film that contains the particle cortex, can in the outlet of extruder mould, gather the material that contains particle.Described material comes off from mould outlet sometimes, forms defective in film.Have been found that in containing of blooming 100 to form overlayer 105 (or multilayer) on the particle cortex 104, just can reduce or eliminate the defective of gathering and producing thereupon on mould, as shown in figure 14.Usually, select tectal thickness and material like this, make that because the endocorpuscular existence of particle-containing layer, overlayer has rough surface when being orientated (for example stretching).Before the orientation, overlayer can be with or without the surface of roughening.

Overlayer can with shown in Fig. 1,2,3,5,6 and 7 or above-mentioned any cortex that contains particle combine.Contain particle cortex and overlayer and can provide above-mentioned any advantage or performance as " top layer " together.Suitable material comprises the described polymeric material that is used to form cortex (one or more layers), comprises for example polyester (for example copolyesters of PEN and polyethylene terephthalate).In some embodiment, use that at least a identical polymkeric substance forms overlayer in first optical layers, second optical layers or the cortex.

Use overlayer can reduce blooming (with respect to there not being tectal same film) surfaceness (for example Rq), but this surfaceness is general still big than the surfaceness that does not contain the similar blooming that the particle cortex forms.

Other layer and coatings

The layer or the coating of difference in functionality also can be added on film of the present invention and the optical devices, are used for changing or improving their physics or chemical property, especially film or the character on the apparatus surface.If use the surface of roughization of particle-containing layer blooming, generally no longer provide other layer and coating so on the particle-containing layer, unless described layer or coating also are coarse.Suitable other layer or coating can be for example low viscosity back lining materials, conductive layer, antistatic coating or film, restraining barrier, fire retardant, UV stabilizing agent, high-abrasive material, optical coating, and the base material that is intended to improve the mechanical integrity or the intensity of film or device.Other layers or coating have description at for example WO 97/01440 among WO99/36262 and the WO 99/36248, and its content is with reference to being incorporated into this.

Display embodiment

Blooming can be used in many kinds of display systems and other purposes, comprises that transmission (for example bias light), reflection and Transflective (transflective) show.For example, Fig. 8 has illustrated the sectional view of a schematic bias light display system 200 of the present invention, comprises display medium 202, bias light 204, polarizer 208 and one or adoptable reverberator 206.The observer is positioned at a side of the display device 202 opposite with bias light 204.

Display medium 202 is by being shown to the observer through the light that penetrates from bias light 204 with information or image.

An example of display medium 202 is LCD (LCD), and it only sees through a kind of light of polarization state.Because the LCD display medium is Polarization-Sensitive, best is that what bias light 204 was supplied is the light of the polarization state of energy transmission display device 202.

The bias light 204 that supply is used to observe the light of display system 200 comprises light source 216 and light guide 218.Though light guide 218 shown in Figure 8 has rectangular section usually, bias light can use the light guide of any suitable shape.For example, light guide 218 can be a wedge shape, flute profile, false wedge shape guides, or the like.Main consideration is that light guide 218 can receive the light and the ejaculation of sending from light source 216.As a result, light 218 just can pass through rear reflector (for example, available reverberator 206), and derivation mechanism and miscellaneous part are finished the function that needs.

Reflective polarizer 208 is bloomings, it comprise one deck polarization by reflection element 210 and at least one deck contain particle 214 the layer 212.Reflective polarizer 208 part of light as a setting provides, and its effect is basic seeing through from the light of a kind of polarization state of light guide 218 ejaculations, and fundamental reflection is from the light of other polarization states of light guide 218 ejaculations.Polarization by reflection element 208 can be for example the reflection multilayer polarizer, continuously/disperse phase reflective polarizer, cholesterol reflective polarizer or wire grid reflective polarizer.Though shown particle-containing layer 212 is positioned on the polarization by reflection element, particle-containing layer (one or more layers) for example can be provided with on the polarization by reflection element or be inner, as mentioned above.

In one embodiment, utilized diffusion (for example scattering) character of particle-containing layer 212.In this embodiment, particle-containing layer polarization by reflection element 210 and the light of accepting bias light 204 surperficial opposing preferably.Lip-deep cortex or coating.

Embodiment

The material of polymkeric substance that is used to form these embodiment is available from following supplier: available from naphthalene two dimethyl phthalates and the terephthalic acid (TPA) (Decatur of Amoco, the Alabama), available from Hoechst Celanese (Dallas, Texas) dimethyl terephthalate (DMT), available from the ethylene glycol of Union Carbide (Charleston, West Virginia), available from BASF (Charlotte, the North Carolina) 1, the 6-hexanediol.

" gain test instrument " is used to test the some films among these embodiment." gain test instrument " can use a photometer and suitable bias light to make, and a polarizer is placed between the two, so that only bias light polarization part can be by photometer measurement.Suitable some luminosity is in respect of Minolta LS-100 and LS-110 (Minolta company limited, Ramsey, New Jersey).The gain absolute value that records depends on that the bias light of use and sample are for the orientation of bias light and the size of sample.Gain definitions is the normal axis brightness of tester when having reflective polarizer in light path, is not had the value after the normal axis brightness normalization of reflective polarizer in the light path.The bias light of Shi Yonging obtains from Landmark in an embodiment, and polarizer is that a high contrast shows polarizer, and its orientation is to make polarizer pass through the major axis alignment that axle is aimed at bias light.Sample is inserted in the tester, and the axle that passes through of the sample of make suring aligns with the axle that passes through of high contrast polarizer.It is enough big that sample size is wanted, and can cover whole bias light.

The smooth glass of the clean face of a slice that the side that contains the particle top layer of film is being pasted on the diffuse background radiant top of monochromatic green (about 540nm) is placed, measured Newton ring.With hand with film smooth on glass after, just can see that Newton ring (if exist) is some bright fringess and dark fringe.Result's judgement grade is 1 (cannot see Newton ring)-4 (seeing Newton ring clearly).

It is similar to Newton ring to have measured wetting measuring method.The different white light sources that are to use.When reflective polarizer be attached on glass after, have speck, just said wetting phenomena.The grade of measurement result is 1 (not observing wetting)-4 (sees clearly wetting).

Use Wyko interferometer (Wyko company, Tuscon Arizona, Roughness/Step Tester model RS 104048) amplifying under 100 times of conditions, measure mean roughness Rq.

Measured the friction factor of polyethylene terephthalate film according to ASTM № D1894.

Unevenness is that a kind of blooming of quality when using polarizer film to form volume of having described is for measurement.The rolling difference just illustrates defectiveness on the film, and cupping, pimple and gauffer are for example arranged on the film.Generally speaking, if the friction factor between the adjacent membranes surface is enough low in the volume, just almost there are not or seldom have these rolling defectives.

Comparative Examples 1 and 2 and embodiment 1-23

Use first optical layers that forms by (PEN) multipolymer to make the reflection multilayer polarizer film, described multipolymer contains carboxylate subunit that is formed by 90 moles of % naphthalene two dimethyl phthalates and 10 moles of % dimethyl terephthalate (DMT) and the glycol subunit that is formed by 100 moles of % ethylene glycol subunits, and limiting viscosity is 0.48dL/g.Refractive index is about 1.633.

Formed second optical layers by (PEN) multipolymer, described multipolymer contains carboxylate subunit that is formed by 55 moles of % naphthalene two dimethyl phthalates and 45 moles of % dimethyl terephthalate (DMT) and the glycol subunit that is formed by 95 moles of % ethylene glycol and 5mol% hexanediol, and limiting viscosity is 0.53dL/g.Refractive index is about 1.610.

Use the polyester identical to form cortex with second optical layers.Except Comparative Examples and embodiment 12, one deck cortex comprises amorphous state polystyrene as particle, and (Styron 663, Dow chemicals company, Midland, Michigan State, 1.59), the W-210 Zeeospheres (Minnesota State refractive index:, the 3M company of St.Paul, refractive index: 1.53, particle mean size: 2.5 microns, remove than 5 microns big particles), silicon dioxide (Aerosil ^TM, Ox50, Dugussa company, Dublin, Ohio, refractive index 1.48,0.3 micron of particle mean size), or these materials make up with the consumption shown in the table 1.During optic test, this single skin that comprises particle will make the light of bias light by containing before the particle optical layers remainder by blooming in the orientation on the upper surface of blooming.Do not comprise particle in Comparative Examples 1 and 2 cortexes.All comprise particle in two cortexes on the two sides of embodiment 12 first and second optical layers laminate.

Table 1 Comparative Examples 1 and 2 and composition and the result of embodiment 1-23

Embodiment	Polystyrene (wt.%)	??Zeeo- ?spheres ?(wt.％)	Gain	Newton ring	Wetting	Friction factor	????Rq ???(nm)	Unevenness
									Comparative Examples 1	??????-	????-	???1.538	???4	???4	???＞5	????15	?????-
??????1	????20.00	????-	???1.524	???1	???1	???0.4	????428	?????-
									??????2	????10.00	????-	???1.530	???1	???1	???0.4	????219	?????-
??????3	????5.00	????-	???1.534	???1	???1	???0.7	????157	?????-
									??????4	????2.50	????-	???1.536	???1	???1	???1.15	?????88	?????-
??????5	????1.25	????-	???1.536	???-	???-	????-	?????54	?????-
									??????6	?????-	????0.15	???1.541	???3	???1	???0.35	?????47	?????-
??????7	?????-	????0.30	???1.540	???2	???1	???0.33	?????71	?????-
									??????8	?????-	????0.60	???1.538	???2	???1	???0.3	?????97	?????-
??????9	?????-	????1.20	???1.531	???2	???1	????-	????132	?????-
									??????10	?????-	????3.00	???1.511	???1	???1	???0.35	????232	?????-
??????11	????2.50	????0.30	???1.540	???1	???1	???0.3	????106	?????-
									??????12	????5 a	?????-	???1.526	???-	???-	???0.7	????211	?????-
Comparative Examples 2	?????-	?????-	???1.554	???4	???3	????-	?????-	Difference
									??????13	????2.50	?????-	???1.548	???2	???1	????-	?????-	Good
??????14	????3.75	?????-	???1.551	???2	???1	????-	?????-	Good
									??????15	????5.00	?????-	???1.551	???1	???1	????-	?????-	Good
??????16	????5.00	????0.15	???1.546	???1	???1	????-	?????-	Outstanding
									??????17	????3.75	????0.15	???1.550	???1	???1	????-	?????-	Outstanding
??????18	????2.50	????0.15	???1.552	???2	???1	????-	?????-	Outstanding
									??????19	????3.75	?????-	???1.545	???2	???1	???0.15	?????-	Good
??????20	????3.75	?????-	???1.551	???1	???1	???0.30	?????-	Outstanding

????21	-	????1.00	???1.551	???3	???1	-	?-	Outstanding
									????22	-	????2.00	???1.552	???2	???1	-	?-	Outstanding
????23	-	????3.00	???1.542	???1	???1	-	?-	Outstanding

^aProvide particle in two cortexes with this percent.

Above-mentioned coPEN adopts a charging/multiple stratification system coextrusion, forms a multilayer film, and 893 first and second optical layers that replace are arranged, and on every surface of first and second optical layers that these replace a cortex is arranged.The thickness of single first and second optical layers is about 50-120nm, and the thickness of two cortexes is about 12 microns.The film of extruding about 20 seconds of heating in being filled with 154 ℃ the stenter of hot-air then, is carried out the uniaxial tension orientation with 6: 1 draw ratios, makes thick about 125 microns reflective polarizer.

Table 1 has shown the normal angle gain, Newton ring of these embodiment, wetting, friction factor and unevenness.As seen eliminating to soak generally needs small quantities of particles, needs more particle but eliminate Newton ring.Other tests comprise that thickness measure and middle layer lamination it seems the influence that not existed by cortex (one or more layers) endoparticle.Compare with the blooming of Comparative Examples, have the gain of the blooming that contains the particle cortex to there is no significantly and reduce.

Specifically be that Zeeospheres is arranged ^TMSample form uniform isotropy outward appearance.Polystyrene sample is laterally having a shot-like particle with the about 50 microns places of draw direction on about 1mm length.

Comparative Examples 3 and 4 and embodiment 24-26

Make the reflection multilayer polarizer film in the described identical mode of the foregoing description, different is that first optical layers is made with PEN (PEN), is used for the amounts of particles in the polarizer of embodiment 24-26 and the thickness variation as shown in table 2 of type and cortex.

Table 2 Comparative Examples 3 and 4 and composition and the result of embodiment 24-26

Embodiment Comparative Examples 3	Particle-	The volume % 0.0 of particle	Polarizer gross thickness (μ m) 12.5	Skin thickness (μ m) 125	Normal angle increases 1.580	The p-polarization is by the standard deviation 400-650nm 8.4% of attitude
							????24	?Zeeosphe	????2.5	????12.5	????125	???1.578	?????6.2％
Comparative Examples 4	????-	????0.0	????25	????125	???1.555	?????8.3％
							????25	Zeeosphe	????5.0	????25	????125	???1.569	?????4.3％
????26	??PS/EM b	???10.0	????25	????125	???1.570	?????3.2％

^bThe solid-state spheric grain of polystyrene and ethyl acetate copolymer (refractive index 1.53,2.5 microns of mean diameters)

Embodiment 24,25 and 26 has presented significant color in the LC display hidden.The p polarization of 400-650nm adopts with the light source on 60 ° of angular alignment blooming surfaces and measures by the standard deviation of attitude, and described blooming forms (for example embodiment 24-26) by containing the particle cortex.The light of Lambda19 spectrophotometer (Perkin Elmer Corp., Norwalk, the Connecticut) observation of integrating sphere through film is equipped with in use.This Experimental design and bias light display are optically similar, and for example as shown in Figure 8, the observer observes with the angle with respect to 60 ° on blooming plane.

The spectrum (bright line) that the blooming of the spectrum (concealed wire) of the blooming of Comparative Examples 4 and embodiment 26 is arranged among Fig. 9.The spectrum of embodiment 26 bloomings is much even in the 400-650nm wavelength coverage.

Embodiment 27

Claim that with comprising sfi in the sulfo-polyurethane matrix diameter is that the superficial layer of 4 microns polystyrene spheres covers the similar reflection multilayer polarizer film of reflection multilayer polarizer film with Comparative Examples 1 and 2.Polystyrene spheres premixed formation is contained 69 weight % water, 20% according to United States Patent (USP) 5,756,633 and 5,929, the 160 sulfo-urethane resins of making, 1%Triton X-100 (Union Carbide Chem.and Plastics Co., Danbury, Connecticut) and the top layer precursor of 10% polystyrene spheres.The refractive index of polystyrene spheres and sulfo-urethane resin is respectively in 1.51～1.56 scope.

This precursor is spread on the reflective polarizer films by hand.Just formed the top layer of surperficial roughening after the water evaporation, stayed the polystyrene ball portion and be embedded in the resin matrix.

Observation shows that ball is individual layer and is distributed on the surface, top layer, and the ball that exposes accounts for the surface, top layer less than 100%.

Referring to Figure 12, what the figure shows is to compare the optical property aspect luminance gain with the same reflection multilayer polarizing coating that does not have this top layer.These results are to use above-mentioned gain test instrument to obtain.

Line A and B represent not contain respectively the luminance gain of the reflection multilayer polarizing coating on particle top layer in each angular field of view when 0 degree and 90 degree uses, second polarizer.Line C and D represent respectively to have the reflection multilayer polarizing coating that contains the particle top layer luminance gain in each angular field of view when 0 degree and 90 degree uses, second polarizer.As shown in the figure, for the angular field of view to about ± 30 ° from normal direction, the top layer has increased luminance gain, being included in gain increase 2-3 radix point on the normal angle.

Embodiment 28

The top layer of embodiment 27 is formed on continuously/and diffusion reflects on the polarizer mutually.A slice trilamellar membrane forms and has carried out stretch orientation with coetrusion.Two-layer 52 weight %PEN multipolymers (the glycol subunit that has 70 moles of % naphthoic acid esters and 30 moles of % benzoic ether subunits and 100mol% to form), the 45 weight % syndiotactic polystyrene multipolymer (Questra of comprising of outside by ethylene glycol ^TMMA405, Dow chemicals company, Midland, Michigan State), 3 weight % styrene maleic anhydride copolymer (Dylark ^TM332, Nova chemicals company, Monacha, Pennsylvania).Central stratum is a copolyesters, 80mol% is arranged to benzoic ether subunit and 100 moles of glycol subunits that % is formed by ethylene glycol between benzoic ether and 20 moles of %.The thickness of each layer is approximately equal.

Use charger and forging die that this is three-layer co-extrudedly gone out to the cast wheel of cooling to form sheet material.Use a machine-direction oriented machine will cast sheet longitudinally stretch orientation to draw ratio be about 1.25: 1, use stenter with sheet in the horizontal stretch orientation to draw ratio be 1: 4.9.The about 170mm of thickness of the alignment films of carrying.

Observation shows that ball is individual layer and is distributed on the surface, top layer, and the ball that exposes accounts for the surface, top layer less than 100%.

Referring to Figure 13, what the figure shows is to compare the optical property aspect luminance gain with the same reflection multilayer polarizing coating that does not have this top layer.These results are to use above-mentioned gain test instrument to obtain.

Continuous/diffusion that does not contain the particle top layer that line A and B represent respectively to use second polarizer at 0 degree and 90 degree mutually reflective polarizer film in the luminance gain of each angular field of view.Line C and D represent respectively when 0 degree and 90 degree use second polarizer, to have contain the particle top layer continuous/diffusion mutually reflective polarizer films in the luminance gain of each angular field of view.As shown in the figure, use blooming to keep the normal incidence luminance gain, and how the explanation blooming can control the light output to display preferably.

Comparative Examples 5 and embodiment 29 and 30

Using by limiting viscosity is that first optical layers that the PEN of 0.48dL/g forms is made the reflection multilayer polarizer film.And form second optical layers with (PEN) multipolymer, this multipolymer contains from the carboxylate subunit of 55mol% naphthalene two dimethyl phthalates and 45 moles of % dimethyl terephthalate (DMT) formation and from 95mol% ethylene glycol and 5 moles of glycol subunits that the % hexanediol forms, and limiting viscosity is 0.53dL/g.The thickness of first and second optical layers respectively is about 50-120nm.

On film and face that cast wheel contacts, use (PEN) multipolymer to form first cortex, described multipolymer contains from the carboxylate subunit of 75mol% naphthalene two dimethyl phthalates and 25 moles of % dimethyl terephthalate (DMT) formation and from 95mol% ethylene glycol and 5 moles of glycol subunits that the % hexanediol forms, and limiting viscosity is 0.53dL/g.Use same polyester to be formed on the back side of film as second optical layers.Except Comparative Examples 5, the second cortexes comprise W-210 Zeeospheres as particle (3M company, Sao Paulo, the Minnesota State, refractive index: 1.53, average grain size: 2.5 microns, remove greater than 5 microns particle).Thick about 12 microns of cortex.

For embodiment 30, form coverlay containing on second cortex of particle, this coverlay is used with the first cortex identical materials and is made.Coated film is stretching thick forward about 6.8 microns.

Embodiment	Particle in the cortex	Cover thickness (mm) before the stretch orientation	The roughness of alignment films (Rq)
				Comparative Examples 5	Do not have	Do not have	????17
???29	5 weight % Zeeospheres TM	Do not have	????516
				???30	5 weight % Zeeospheres TM	????????6.8	????317

Use charger and forging die that each layer is coextruded to the multilayer film that is formed with 892 layers of first and second optical layers that replaces on the chilled cast wheel, on two surfaces of the first and second optical layers laminate that replace a cortex is arranged all.For embodiment 29 and 30, the cortex on the contact cast wheel face of film contains Zeeospheres ^TMIn embodiment 30, containing formation one deck overlayer on the particle cortex.Heating will be cast the sheet stretch orientation with about 6: 1 draw ratios after about 20 seconds in filling with the stenter of 154 ℃ hot-air, and the thickness of alignment films is about 125mm.

Embodiment 29 and 30 does not observe Newton ring and wetting.Thickness measure and middle layer lamination are not subjected to have in the cortex influence of particle existence, are not contained the influence that has overlayer to exist on the particle cortex yet.For same stretch orientation condition, the gain of corticated blooming does not reduce substantially on the particle-containing layer.For example, the gain of Comparative Examples #5 is 1.548, and the gain of embodiment 30 is 1.541.

Not will be understood that the present invention is subject to above-mentioned specific embodiment, should be understood that the present invention covers all aspects of the invention described in the appended claims.Those of ordinary skill in the industry can understand that method and many kinds of various changes, equivalence can be applicable to structure of the present invention after having read this instructions.

Claims (40)

1. blooming, it comprises:

The polarization by reflection element, the light of this element fundamental reflection first polarization state, and the light of basic transmission second polarization state,

Be positioned at the top layer on the polarization by reflection element, it be in the same light path of polarization by reflection element in, the structure on this top layer and arrangement make its transmissive light, top layer contain many coarse particles of top layer outside surface that make,

Use the gain of the optical devices of described blooming, with use the top layer in do not have the gain of optical devices of the same blooming of many particles to compare, significantly do not reduce.

2. blooming as claimed in claim 1 is characterized in that at least some particulate fractions embed the top layer, and partly protrudes from the top layer.

3. blooming as claimed in claim 1 is characterized in that basic all described many particles monolayer alignment on the outside surface on top layer.

4. blooming as claimed in claim 1 is characterized in that basic all described many particles all embed in the top layer.

5. blooming as claimed in claim 1 is characterized in that the difference of refractive index of all the other materials on described particle and top layer is not more than about 0.2.

6. blooming as claimed in claim 1 is characterized in that described particle roughly is spherical.

7. blooming as claimed in claim 1 is characterized in that described polarization by reflection element and top layer form co-extruded films.

8. blooming as claimed in claim 1 is characterized in that described top layer includes the film that covers on the polarization by reflection element.

9. blooming as claimed in claim 1, it is characterized in that described polarization by reflection element contains first and second materials, at least a in first and second materials is birefringent, first and second materials are for the big light that must be enough to fundamental reflection first polarization state of difference of the refractive index of the first polarization state light, and first and second materials are little as to be enough to the light of basic transmission second polarization state for the difference of the refractive index of the second polarization state light.

10. blooming as claimed in claim 9 is characterized in that described polarization by reflection element includes multi-layer optical film, and many birefringence first optical layers and many second optical layers are alternately arranged in this blooming.

11. blooming as claimed in claim 9 is characterized in that described first material is positioned at second material.

12. blooming as claimed in claim 1 is characterized in that described polarization by reflection element comprises birefringence cholesterol material.

13. blooming as claimed in claim 1 is characterized in that described many particles comprise at least a material that is selected from compound substance, glass, talcum and their potpourri of amorphous polymer, aluminium oxide, silicon dioxide, aluminium oxide and silicon dioxide.

14. blooming as claimed in claim 1 is characterized in that comparing with the same blooming that does not have particle in the top layer when described blooming is placed into another contiguous surface, its trend that forms Newton ring reduces.

15. blooming as claimed in claim 1 when it is characterized in that described multi-layer optical film is placed into another contiguous surface, is compared with the same multi-layer optical film that does not have particle in the top layer, wetting trend takes place reduce.

16. blooming as claimed in claim 1, it is characterized in that using described blooming optical devices gain with use the top layer in do not have the gain of optical devices of the same blooming of described many particles to compare, reduce being no more than 3%.

17. blooming as claimed in claim 16, it is characterized in that described blooming can make visible light transmissive polarization by reflection element, and then see through the top layer, it is more more even significantly than the situation of the same blooming that does not have many particles to see through the light intensity of back on the 400-650nm scope.

18. optical devices, it comprises:

Light source and the described blooming of claim 1.

19. optical devices as claimed in claim 18 is characterized in that described top layer is positioned at the polarization by reflection element and accepts from light source on the back side on surface of light.

20. optical devices as claimed in claim 18 is characterized in that described top layer comprises the top layer of polarization by reflection element.

21. optical devices as claimed in claim 18 is characterized in that described top layer comprises the coating on the polarization by reflection element surface.

22. optical devices as claimed in claim 18 is characterized in that having at least the described many particles of a part to protrude from the top layer.

23. optical devices as claimed in claim 18, it is characterized in that described polarization by reflection element and top layer see through visible light, seeing through the light intensity of back on the scope of 400-650nm does not have the situation of same polarization by reflection element of many particles more even significantly than the top layer.

24. optical devices as claimed in claim 18 is characterized in that described light source comprises bias light.

25. optical devices as claimed in claim 18, it also comprises display medium.

26. optical devices as claimed in claim 25 is characterized in that described display medium comprises the liquid crystal display medium.

27. optical devices as claimed in claim 25 is characterized in that described polarization by reflection element and top layer are between light source and display medium.

28. optical devices as claimed in claim 27 is characterized in that described top layer is between polarization by reflection element and display medium.

29. a method of making blooming, it comprises:

Form the fundamental reflection first polarization state light and see through the polarization by reflection element of the second polarization state light substantially;

Form the top layer on first first type surface of polarization by reflection element, described top layer comprises many coarse particles of top layer outside surface that make,

Use this blooming optical devices gain with use the top layer in do not have the gain of optical devices of the same blooming of described many particles to compare, significantly do not reduce.

30. method as claimed in claim 29 is characterized in that described formation polarization by reflection element and forms the top layer comprising coextrusion polarization by reflection element and top layer.

31. method as claimed in claim 29, it also comprises does not have the top layer of particle to be arranged on second first type surface of polarization by reflection element at least one.

32. method as claimed in claim 29 is characterized in that described formation top layer comprises:

Many particles are mixed with the monomer that is used for forming the top layer polymkeric substance,

In the presence of many particles, make monomer polymerization, form the top layer polymkeric substance,

Use at least a portion top layer polymkeric substance and many particles to form the top layer.

33. method as claimed in claim 29 is characterized in that described formation top layer comprises:

The top layer polymkeric substance that will contain many particles places on the polarization by reflection element.

34. method as claimed in claim 29 is characterized in that described formation top layer comprises:

The top layer polymkeric substance is placed on the polarization by reflection element,

Many particles are placed the top layer polymkeric substance that is arranged on the polarization by reflection element.

35. a blooming, it comprises:

The polarization by reflection element, the light of this element fundamental reflection first polarization state, and see through the light of second polarization state substantially,

Be positioned at the particle-containing layer on the polarization by reflection element, it be in the same light path of polarization by reflection element in, the structure of particle-containing layer and arrangement make that its can transmitted light, contain many coarse particles of blooming outside surface that make in the particle-containing layer,

Use this blooming optical devices gain with use particle-containing layer in do not have the gain of optical devices of the same blooming of many particles to compare, significantly do not reduce.

36. blooming as claimed in claim 35, it also comprises the overlayer that is positioned on the particle-containing layer, and wherein the many particles in the particle-containing layer make tectal outside surface roughening.

37. blooming as claimed in claim 35, it is characterized in that described polarization by reflection element contains first and second materials, at least a in first and second materials is birefringent, first and second materials are for the big light that must be enough to fundamental reflection first polarization state of difference of the refractive index of the first polarization state light, and first and second materials are little as to be enough to see through substantially the light of second polarization state for the difference of the refractive index of the second polarization state light.

38. blooming as claimed in claim 37 is characterized in that described polarization by reflection element comprises multi-layer optical film, has many birefringent first optical layers and many second optical layers alternately to arrange in this blooming.

39. blooming as claimed in claim 37 is characterized in that described first material is in second material.

40. blooming as claimed in claim 35 is characterized in that described polarization by reflection element comprises birefringence cholesterol material.

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