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WO2025012837A1 - Film de commande de lumière et son procédé de fabrication - Google Patents

Film de commande de lumière et son procédé de fabrication Download PDF

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Publication number
WO2025012837A1
WO2025012837A1 PCT/IB2024/056730 IB2024056730W WO2025012837A1 WO 2025012837 A1 WO2025012837 A1 WO 2025012837A1 IB 2024056730 W IB2024056730 W IB 2024056730W WO 2025012837 A1 WO2025012837 A1 WO 2025012837A1
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WO
WIPO (PCT)
Prior art keywords
control film
light
light control
layer
light transmissive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IB2024/056730
Other languages
English (en)
Inventor
Raymond J. Kenney
Daniel J. Schmidt
Caleb T. NELSON
David Scott Thompson
Benjamin J. FORSYTHE
Jeffrey A. Boettcher
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Publication of WO2025012837A1 publication Critical patent/WO2025012837A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0273—Diffusing elements; Afocal elements characterized by the use
    • G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/0257—Diffusing elements; Afocal elements characterised by the diffusing properties creating an anisotropic diffusion characteristic, i.e. distributing output differently in two perpendicular axes
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B2207/00—Coding scheme for general features or characteristics of optical elements and systems of subclass G02B, but not including elements and systems which would be classified in G02B6/00 and subgroups
    • G02B2207/123—Optical louvre elements, e.g. for directional light blocking
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/08—Simple or compound lenses with non-spherical faces with discontinuous faces, e.g. Fresnel lens
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/003—Light absorbing elements
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133509—Filters, e.g. light shielding masks

Definitions

  • a light control film having a structured first major surface opposite a second major surface.
  • the structured first major surface includes a plurality of structures extending in a thickness direction of the light control film separated by one or more grooves.
  • Each structure includes one or more side surfaces.
  • Each groove has one or more substantially planar landings joining the corresponding structures.
  • Each of the one or more side surfaces makes an angle of greater than about 60 degrees with an adjacent landing of the one or more landings.
  • At least 80% of the one or more side surfaces and the one or more landings are coated with a first light transmissive layer having a first average thickness of greater than about 0.005 microns and including a plurality of first inorganic particles at a volume loading of greater than about 5%. At least 70% of the first light transmissive layer on each of the one or more side surfaces and at most 30% of the first light transmissive layer on the one or more landings is coated with a cover layer.
  • the first light transmissive layer coated on the one or more side surfaces has an arithmetic average surface roughness Ra2.
  • the first light transmissive layer coated on the one or more landings has an arithmetic average surface roughness Ra1, such that Ra1 > Ra2.
  • a method of making a light control film including providing a substantially light transmissive film having a structured first major surface and an opposing second major surface, the structured first major surface having a plurality of structures separated by one or more grooves extending in a thickness direction of the light control film, each structure having one or more side surfaces, each groove having one or more substantially planar landings joining the corresponding structures, each of the one or more side surfaces making an angle with an adjacent landing of the one or more landings of greater than about 60 degrees; coating the structured first major surface with a light transmissive layer, the light transmissive layer covering at least 80% of each of the plurality of structures and the one or more grooves and including a plurality of first inorganic particles at a volume loading of greater than about 5%; coating the light transmissive layer with a cover layer so that at least 80% of the light transmissive layer is covered by the cover layer; and etching the cover layer using a directional first etching process to remove more than about
  • a light control film including a light transmissive body having a plurality of structures extending in a thickness direction of the light control film separated by one or more grooves, each structure having one or more side surfaces, each groove having one or more substantially planar landings joining the corresponding structures; a first light transmissive layer having a first average thickness of greater than about 0.005 microns and coated on at least 80% of the plurality of structures and the one or more landings, the light transmissive layer including a plurality of first inorganic particles comprising a first inorganic material; a light absorbing layer having an average thickness of greater than about 0.05 microns and coated on at least 70% of the light transmissive layer on the one or more side surfaces and on at most 30% of the light transmissive layer on each of the one or more landings; and a planarizing overcoat covering the light absorbing layer and substantially planarizing the structured first major surface.
  • a second light transmissive layer is disposed between the planarizing overcoat and the light absorbing layer, the second light transmissive layer including the first inorganic material and having a second average thickness that is less than about 20 nm.
  • FIGS.1A-1C provide side, cross-sectional views of a light control film, in accordance with an embodiment of the present description
  • FIGS.2A-2B provide additional details for a light control film, in accordance with an embodiment of the present description
  • FIGS.3A-3B present contrasting top and side profile views of a light control film, respectively, in accordance with an embodiment of the present description
  • FIG.4 provide details on the structure of a light control film, including angles and widths of various features, in accordance with an embodiment of the present description
  • FIGS.5A-5B show embodiments of light transmissive and cover layers of a light control film, in accordance with an embodiment of the present description
  • FIGS.6A-6D illustrate display systems including a light control film, in accordance with an embodiment of the present description
  • FIG.7 illustrates a method of making a light control film, in accordance with an embodiment of the present description
  • FIG.8 includes a microscope image of a light control film, in accordance with an embodiment of the present description
  • Etch stops also known as etch masks or hard masks
  • Etch stops are ubiquitous in microelectronics manufacturing where they allow for termination of an etching process to a controlled depth. Etch stops can function in wet and/or dry etching processes.
  • the etch stops for dry etching are typically inorganic coatings (e.g., oxides or nitrides or metals) and would typically comprise a continuous inorganic layer, as opposed to a layer of discrete inorganic nanoparticles.
  • the layer-by-layer (LbL) coating method (a liquid phase coating method) is used to deposit dry etch stops comprising inorganic oxide particles and oppositely charged polymers, or two oppositely charged inorganic oxide particles.
  • LbL deposition involves the sequential assembly of at least two different materials with binding groups, which are complementary to each other (e.g., oppositely charged functional groups or H-bond donor and acceptors groups, etc.).
  • This coating method can provide very high loadings of inorganic particles (of various shapes and sizes), for example loadings of greater than or equal to 25 wt%, greater than or equal to 50 wt%, greater than or equal to 75 wt%, greater than or equal to 90 wt%, or greater than or equal to 99 wt%, as can be measured by thermogravimetric analysis (TGA), for example.
  • TGA thermogravimetric analysis
  • very high-volume loadings of inorganic particles can be achieved, for example loadings of greater than or equal to 10 vol%, greater than or equal to 25 vol%, greater than or equal to 50 vol%, greater than or equal to 75 vol%, as can be measured by scanning electron microscopy (SEM) and/or transmission electron microscopy (TEM), for example.
  • SEM scanning electron microscopy
  • TEM transmission electron microscopy
  • the coatings may also be porous, especially when spherical nanoparticles are used. It is unexpected that a porous and/or organic-containing composite coating could function as an effective dry etch stop.
  • Relevant inorganic materials for the etch stops of the present description may include metal oxide nanoparticles such as silicon dioxide (silica), aluminum oxide (alumina), zirconium oxide (zirconia), titanium dioxide (titania), and the like.
  • metal oxide nanoparticles such as silicon dioxide (silica), aluminum oxide (alumina), zirconium oxide (zirconia), titanium dioxide (titania), and the like.
  • Other relevant metal oxides include clay platelets, such as aluminosilicates (e.g., montmorillonite, vermiculite, and the like) or lithium magnesium silicates (e.g., LAPONITE ® ).
  • Still more relevant inorganic materials include MXenes, as well as sulfide or nitride particles. Metal nanoparticles and platelets are also in scope.
  • organic binder materials possess binding groups (e.g., charged functional groups) on their unmodified surfaces, while others may require surface modification.
  • Relevant organic binder materials for the etch stops of this invention include charged polymers (i.e., polyelectrolytes). These polymers can be water soluble or can be water insoluble, but stable in water as emulsions, dispersions, or suspensions. The polymers must possess binding groups (e.g., charged functional groups), either as part of the polymer backbone or side chains, or through surface modification by a charged surfactant.
  • Typical negatively charged groups may include, for example, carboxylate, sulfonate, phosphate, or phosphonate groups, while typical positively charged groups may include, for example, primary, secondary, or tertiary amines, and quaternary ammonium groups, or phosphonium or sulfonium groups, for example.
  • LbL-deposited etch stops Compared to classic dry etch stops deposited via vacuum deposition, LbL-deposited etch stops have the benefit of not requiring a vacuum chamber. Vacuum chambers require time for pump down and also can complicate web handling.
  • a light control film includes a structured first major surface opposite a second major surface.
  • the structured first major surface may include a plurality of structures extending in a thickness direction (e.g., a z-direction) of the light control film separated by one or more grooves (e.g., channels or valleys extending between adjacent structures).
  • each structure of the plurality of structures may include one or more side surfaces.
  • each groove may have one or more substantially planar landings (i.e., planar surfaces extending between) joining the corresponding structures.
  • each of the one or more side surfaces may make an angle of greater than about 60 degrees, or greater than 65 degrees, or greater than 70 degrees, or greater than about 75 degrees, or greater than about 80 degrees, or greater than about 85 degrees, with an adjacent landing of the one or more landings.
  • degrees refer to the magnitude of the angle, no matter the relative direction of the angle relative to the substantially planar landing. That is, as an example, an angle of 85 degrees would be considered equivalent to an angle of -85 degrees if only magnitude is considered.
  • one side surface may be at an angle of 85 degrees to the landing and leaning to the right, which an adjacent side surface may be at an angle of 85 degrees but leaning to the left.
  • at least 80%, or at least 85%, or at least 90%, or at least 95% of the one or more side surfaces and the one or more landings may be coated with a first light transmissive layer having a first average thickness of greater than about 0.005 microns.
  • the first light transmissive layer may include a plurality of first inorganic particles at a volume loading of greater than about 5%.
  • the volume loading of the first inorganic particles may be at a volume loading of from about 5% to about 95%, or from about 5% to about 80%, or from about 5% to about 70%, or from about 7% to about 70%, or from about 10% to about 70%.
  • the inorganic particles in the light transmissive layer may be spherical, aspherical, oblong, or platelets, or any other appropriate shape.
  • the particles may be non-aggregated, individual particles, loose aggregates of individual particles, or permanent aggregates of primary particles.
  • the particles may be amorphous, crystalline, or semi-crystalline.
  • the first inorganic particles may be sputtered particles which enter a vapor phase as atoms or small atom clusters which may then be redeposited as an integral material layer.
  • typical primary/individual particle diameters may range from about 1 nm to about 190 nm, or from about 1 nm to about 75 nm, or from about 1 nm to about 50 nm.
  • the longest dimension would typically range from about 4 nm to about 3000 nm, or from about 4 nm to about 1000 nm, or from about 4 nm to about 500 nm, or from about 4 nm to about 250 nm, or from about 4 nm to about 75 nm.
  • they may be fully or partially exfoliated with aspect ratios less than about 3000:1, or less than about 1000:1, or less than about 500:1, or less than about 250:1, or less than about 50:1. In some embodiments, platelets may have an aspect ratio greater than about 5:1.
  • the particle size (e.g., diameter or longest dimension) of the inorganic particles in the light transmissive layer can be measured by scanning electron microscopy (SEM) or transmission electron microscopy (TEM), for example.
  • the particle size distribution of the inorganic particles in the light transmissive layer may be, for example, monodisperse, polydisperse, multimodal (e.g., bimodal, or trimodal).
  • the light transmissive layer may have an average thickness in a range of between about 0.005 microns and about 0.500 microns, or between about 0.01 microns and about 0.400 microns, or between about 0.03 microns and about 0.300 microns.
  • At least 70%, or at least about 75%, or at least about 80%, or at least about 85%, or at least about 90%, or at least about 95% of the first light transmissive layer on each of the one or more side surfaces, and at most 30%, or at most about 25%, or at most about 20%, or at most about 15%, or at most about 10%, or at most about 5% of the first light transmissive layer on the one or more landings, may be coated with a cover layer.
  • the cover layer may have an average thickness of greater than about 0.05 microns.
  • the light absorbing cover layer may have an average thickness of greater than about 0.05 microns, or greater than about 0.1 microns, or greater than about 0.15 microns, or greater than about 0.2 microns, or greater than about 0.25 microns, or greater than about 0.3 microns, or greater than about 0.35 microns, or greater than about 0.4 microns, or greater than about 0.45 microns, or greater than about 0.5 microns, or greater than about 0.55 microns, or greater than about 0.6 microns, or greater than about 0.65 microns, or greater than about 0.7 microns, or greater than about 0.75 microns, or greater than about 1.0 microns, or greater than about 1.25 microns, or greater than about 1.5 microns, or greater than about 2 microns, or greater than about 2.5 microns, or greater than about 3 microns.
  • the cover layer may have an average thickness of less than about 2000 nm, or less than about 1500 nm, or less than about 1000 nm, or less than about 500 nm, or less than about 400 nm, or less than about 300 nm, or less than about 200 nm, or less than about 100 nm, or less than about 50 nm.
  • the cover layer may be a multilayer coating with core clad structure (i.e., may include a core layer disposed between a first cladding layer and a second cladding layer, as described in US Patent No.11,550,183, which is hereby included by reference).
  • the first light transmissive layer may be coated on the one or more side surfaces and may have an arithmetic average surface roughness Ra2. In some embodiments, the first light transmissive layer coated on the one or more landings may have an arithmetic average surface roughness Ra1. In some embodiments, Ra1 may be greater than Ra2 (i.e., the surface of the first light transmissive layer coated on the one or more landings may be rougher than the surface of the first light transmissive layer coated on the one or more side surfaces).
  • the surface roughness of the light transmissive layer on the landings may be affected more readily by a directional etching process than the surface roughness of the light transmissive layer on the side surfaces (e.g., the “direction” of the directional etching process may be more orthogonal to the landings than to the side surfaces).
  • Ra2 may be greater than zero.
  • the one or more side surfaces i.e., the side surfaces themselves, not the light transmissive layer on top of them
  • the one or more landings may have an arithmetic surface roughness less than about Ra1/10, or less than about Ra1/25, or less than about Ra1/50. Stated another way, the light transmissive layer on top of the landings may have a roughness Ra1, while the landings themselves are smoother (e.g., about Ra1/10 or less).
  • the one or more side surfaces may include a first side surface and a second side surface connected by a substantially planar top surface that is substantially parallel to the one or more landings.
  • the planar top surface may also be coated with a cover layer, and the planar top surface may have an arithmetic average surface roughness substantially the same as the first light transmissive layer coated on the one or more landings.
  • the one or more side surfaces may include a first side surface and a second side surface meeting at a peak (e.g., a triangular prism).
  • the plurality of structures may include linear structures extending substantially across a width direction of the light control film (e.g., an y-direction) and arranged along an orthogonal length direction (e.g., a x-direction) of the light control film.
  • each linear structure may be separated from each adjacent linear structure by a groove.
  • the plurality of structures comprises a plurality of posts arranged along a width direction and an orthogonal length direction of the light control film.
  • at least a portion of the posts in the plurality of posts may be substantially surrounded by the one or more landings.
  • the one or more side surfaces may include a single side surface (e.g., a continuous, external side surface of a cylindrical post) or may include multiple side surfaces (e.g., such as the sides of a triangular pyramid post or a rectangular prism post).
  • the light control film may further include a second light transmissive layer disposed on at least a portion of the cover layer.
  • the second light transmissive layer may include the first inorganic material.
  • the source of this second light transmissive layer may be redeposition during a selective etch step composed of nonvolatile etch byproducts from the first light transmissive layer.
  • the second light transmissive layer may have a second average thickness less than the first average thickness of the first light transmissive layer. In some embodiments, the second average thickness may be less than about 20 nm, or less than about 10 nm, or less than about 5 nm. In some such embodiments, the second light transmissive layer may be discontinuous.
  • At least one of the first light transmissive layer and the cover layer may be porous (e.g., having a plurality of pores). In some such embodiments, a volume fraction of the pores is greater than 0.2, or greater than 0.3, or greater than 0.4, or greater than 0.5, or greater than 0.6, or greater than 0.7. In some embodiments, at least one of the light transmissive and cover layers may be physically discontinuous including a plurality of spaced apart islands. In some embodiments, the cover layer may be light absorbing.
  • the cover layer may absorb light at one more wavelengths in the ultraviolet light range (i.e., 100-400 nm) and/or the visible light range (i.e., 400-700 nm) and/or the infrared light range (i.e., 700 nm – 1 mm).
  • the light absorbing cover layer may include a plurality of light absorbing particles.
  • the light absorbing particles may include one or more of a dye, a pigment, and a carbon black.
  • the light absorbing cover layer may have an optical density, at one or more wavelengths from 100 nm to 1 mm of greater than about 0.1, or greater than about 0.2, or greater than about 0.4, or greater than about 0.6, or greater than about 0.8, or greater than about 1, or greater than about 1.1, or greater than about 1.2, or greater than about 1.3, or greater than about 1.4, or greater than about 1.5, or greater than about 2, or greater than about 2.5, or greater than about 3, or greater than about 3.5, or greater than about 4, or greater than about 4.5, or greater than about 5, or greater than about 5.5, or greater than about 6.
  • the optical density is less than about 3.0, or less than about 2.5, or less than about 2.0.
  • the optical density is between 0.5 and 2.5, or between 1.0 and 2.0 or between 1.2 and 1.8.
  • optical density shall be defined as -log10(T), where T is the optical transmission of the film, and T is defined as I t /I o , where I o is the intensity of incident light and I t is the intensity of the transmitted light (light passing through the medium).
  • T is the optical transmission of the film
  • I t is the intensity of incident light
  • I t is the intensity of the transmitted light (light passing through the medium).
  • the optical density is calculated as -log10(0.01) which is equal to an optical density of 2.0.
  • a layer-by-layer (LbL) coating method the same method that can be used to deposit the etch stop, is used to deposit the cover layer.
  • the cover layer would comprise at least one material with a first binding group and a second material with a second binding group, the first binding group and second binding group having complementary interactions.
  • the first material is a polymer binder (e.g., a polyelectrolyte).
  • the polymer binder may be the same polymer binder present in the etch stop or may be a different polymer.
  • the second material would typically be a light-absorbing pigment, dye, or a carbon black comprising binding groups complementary to those in the first material.
  • Suitable pigments include, for example, ionically-modified pigment nanoparticles commercially available as inkjet pigment colorants under the trade designation CAB-O-JET from Cabot Corporation (Boston, MA) such as black, cyan, magenta, and/or yellow pigments, or inkjet pigments from the BONJET Black Series from Orient Corporation of America (Cranford, NJ).
  • pigments or other wavelength-selective light absorbing particles may be functionalized either by being covalently surface modified or non-covalently surface modified, for example, with an ionic surfactant.
  • dyes/pigments include phthalocyanines, cyanine, transition metal dithioline, squarylium, croconium, quinones, anthraquinones, iminium, pyrylium, thiapyrylium, azulenium, azo, perylene and indoanilines. Many of these dyes and pigments can exhibit visible and/or infrared light absorption as well. Further, many different types of visible dyes and colorants may be used such as acid dyes, azoic coloring matters, coupling components, diazo components.
  • Basic dyes include developers, direct dyes, disperse dyes, fluorescent brighteners, food dyes, ingrain dyes, leather dyes, mordant dyes, natural dyes and pigments, oxidation bases, pigments, reactive dyes, reducing agents, solvent dyes, sulfur dyes, condense sulfur dyes, vat dyes.
  • organic pigments may belong to one or more of monoazo, azo condensation, insoluble metal salts of acid dyes and disazo, naphthols, arylides, diarylides, pyrazolone, acetoarylides, naphthanilides, phthalocyanines, anthraquinone, perylene, flavanthrone, triphendioxazine, metal complexes, quinacridone, polypyrrole etc.
  • Suitable dyes for the cover layer could include, for example, acid dyes or basic dyes; some specific examples include, without limitation, Acid Orange 12, Acid Blue 25, Eriochrome Black T, Lissamine Green B, Acid Fuchsin, Alizarin Blue Black B, Acid Blue 80, Acid Blue 9, Brilliant Blue G, Water Soluble Nigrosin, Methylene Blue, Crystal Violet, Safranin, Basic Fuchsin, and combinations thereof. Note that dyes with just one or a few charged functional groups, for example, may not be suitable as a material for layer-by-layer deposition directly; however, such dyes can be ion exchanged into layer-by-layer coatings as disclosed in WO2023/047204 (Schmidt et al.).
  • the light absorbing material in the light-absorbing cover layer may comprise individual dye molecules, aggregates of dye molecules, and/or pigment particles, for example.
  • the pigment or carbon black particles in the light-absorbing cover layer may be spherical, aspherical, oblong, or platelets, for example.
  • the particles may be non-aggregated, individual particles, or they may be loose aggregates of individual particles, or they may be permanent aggregates of primary particles.
  • the particles may be amorphous, crystalline, or semi-crystalline. In the case of spherical particles, typical primary/individual particle diameters range from 1 nm to 190 nm, more preferably from 5 nm to 100 nm.
  • the longest dimension would typically range from 4 nm to 3000 nm, or from 4 nm to 1000 nm, or from 4 nm to 500 nm, or from 4 nm to 250 nm, or from 4 nm to 75 nm.
  • they may be fully or partially exfoliated with aspect ratios less than 3000:1, less than 1000:1, less than 500:1, less than 250:1, or less than 50:1. Platelets would typically have an aspect ratio greater than 5:1.
  • the particle size (e.g., diameter or longest dimension) of the particles in the cover layer can be measured by scanning electron microscopy (SEM) or transmission electron microscopy (TEM), for example.
  • the particle size distribution of the particles in the cover layer may be, for example, monodisperse, polydisperse, bimodal, or multimodal (e.g., bimodal or trimodal). Various embodiments may include mixtures of the different types of particles described above.
  • the light control film may further include a planarizing overcoat covering, and substantially planarizing, the structured first major surface.
  • a refractive index of the planarizing overcoat may be substantially the same as a refractive index of the plurality of structures.
  • the refractive index of the planarizing overcoat may be different from the refractive index of the plurality of structures by a value of less than 0.05, or less than 0.04, or less than 0.03.
  • a refractive index of the planarizing overcoat may be different from a refractive index of the plurality of structures by greater than about 0.07, or greater than about 0.09, or greater than about 0.1, or greater than about 0.13, or greater than about 0.15, or greater than about 0.2, or greater than about 0.25.
  • the first inorganic particles of the first light transmissive layer may include one or more of silicon dioxide, titanium dioxide, zirconium dioxide, aluminum oxide, and clay platelets.
  • the clay platelets may include silicates.
  • the silicates may include one or more of aluminum silicates and magnesium silicates.
  • the first inorganic particles of the first light transmissive layer may be dispersed in a polymeric binder at the weight loading of greater than about 15%.
  • one of the polymeric binder and the plurality of first inorganic particles may include a plurality of positively charged ionic groups (i.e., ionic, or ionizable group), and the other one of the polymeric binder and the plurality of first inorganic particles may include a plurality of negatively charged ionic groups.
  • the polymeric binder may include one or more of poly(ethylenimine) (PEI), poly(allylamine hydrochloride), polyvinylamine, chitosan, polyaniline, polyamidoamine, poly(vinylbenzyltrimethylamine), polydiallyldimethylammonium chloride (PDAC), poly(dimethylaminoethyl methacrylate), poly(methacryloylamino)propyl-trimethylammonium chloride, poly(vinyl sulfate), poly(vinyl sulfonate), poly(acrylic acid) (PAA), poly(methacrylic acid), poly(styrene sulfonate), dextran sulfate, heparin, hyaluronic acid, carrageenan, carboxymethylcellulose, alginate, sulfonated tetrafluoroethylene based fluoropolymers, poly(vinylphosphoric acid), poly(vinylphosphoric acid
  • any binder in the first light transmission layer may be at a weight loading of not greater than about 20%, or not greater than about 15%, or not greater than about 10%, or not greater than about 5%, or not greater than about 4%, or not greater than about 3%, or not greater than about 2%, or not greater than about 1%.
  • the first light transmission layer does not include any binder.
  • the first light transmissive layer may further include a plurality of second inorganic particles.
  • the second inorganic particles may include one or more of silicon dioxide, titanium dioxide, zirconium dioxide, aluminum oxide, and clay platelets.
  • the clay platelets may include silicates.
  • the silicates may include one or more of aluminum silicates and magnesium silicates.
  • one of the plurality of first inorganic particles and the plurality of second inorganic particles may include a plurality of positively charged ionic groups, and the other one of the plurality of first inorganic particles and the plurality of second inorganic particles may include a plurality of negatively charged ionic groups.
  • a display system may include any of the light control films described herein, or similar embodiments, and a display configured to form an image to a viewer.
  • the light control film may be disposed between the viewer and the display.
  • the display may include an LCD or OLED display.
  • a display system may include any of the light control films described herein, or similar embodiments, an LCD display panel configured to form an image to a viewer, and a backlight.
  • the light control film may be disposed between the light LCD display panel and the backlight.
  • the display system may further include a multilayer optical film which is optically coupled to the light control film.
  • the multilayer optical film may be disposed between the light control film and the backlight.
  • a display system may include any of the light control films described herein, or similar embodiments and an OLED display configured to display an image to a viewer.
  • the OLED display may include a circular polarizer.
  • the light control film may be disposed between the OLED display and the viewer.
  • the display system may further include a plurality of optically functional layers optically coupled to each other. In some such embodiments, substantially no airgap exists between any adjacent optically functional layers.
  • a method of making a light control film includes providing a substantially light transmissive film having a structured first major surface and an opposing second major surface, the structured first major surface including a plurality of structures separated by one or more grooves extending in a thickness direction of the light control film, each structure including one or more side surfaces, and each groove having one or more substantially planar landings joining the corresponding structures, each of the one or more side surfaces making an angle with an adjacent landing of the one or more landings of greater than about 60 degrees, or greater than about 65 degrees, or greater than about 70 degrees, or greater than about 75 degrees, or greater than about 80 degrees, or greater than about 85 degrees; coating the structured first major surface with a light transmissive layer, the light transmissive layer covering at least 80%, or at least 85% or at least 90%, or at least 95% of each of the plurality of structures and the one or more grooves and including a plurality of first inorganic particles at a volume loading of greater than about 5%; coating the light transmissive layer
  • the method of making a light control film may result in the light transmissive layer coated on the one or more landings and the one or more side surfaces having respective arithmetic average surface roughnesses Ra1 and Ra2, such that Ra1 > Ra2.
  • Ra2 may be greater than zero.
  • the method of making a light control film may further include covering and substantially planarizing the structured first major surface with a planarizing overcoat.
  • a light control film includes a light transmissive body having a plurality of structures extending in a thickness direction (e.g., a z- direction) of the light control film separated by one or more grooves, a first light transmissive layer, a light absorbing layer, and a planarizing overcoat.
  • each structure may have one or more side surfaces.
  • each groove may have one or more substantially planar landings joining the corresponding structures.
  • the first light transmissive layer may have a first average thickness of greater than about 0.005 microns and may be coated on at least 80% of the plurality of structures and the one or more landings.
  • the light transmissive layer may include a plurality of first inorganic particles including a first inorganic material.
  • the light absorbing layer may have an average thickness of greater than about 0.05 microns and may be coated on at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 95% of the light transmissive layer on the one or more side surfaces and on at most 30%, or at most 25%, or at most 20%, or at most 15%, or at most 10%, or at most 5% of the light transmissive layer on each of the one or more landings.
  • the planarizing overcoat may cover the light absorbing layer and may substantially planarize the structured first major surface.
  • a second light transmissive layer is disposed between the planarizing overcoat and the light absorbing layer.
  • the second light transmissive layer may include the first inorganic material and may have a second average thickness that is less than about 20 nm, or less than about 10 nm, or less than about 5 nm.
  • the second light transmissive layer may be discontinuous.
  • a refractive index of the planarizing overcoat may be substantially the same as the plurality of structures.
  • the refractive index of the planarizing overcoat may be different from the refractive index of the plurality of structures by a value of less than 0.05, or less than 0.04, or less than 0.03. In some embodiments, a refractive index of the planarizing overcoat may be different from a refractive index of a material of the first major surface by greater than about 0.07.
  • the light control film may be bonded to an adhesive.
  • the adhesive may be a pressure sensitive adhesive.
  • the adhesive may be at least one of an acrylic adhesive, a synthetic rubber adhesive, a natural rubber adhesive, and a silicone adhesive. In some such embodiments, the adhesive may have a haze value of at least 10%.
  • light control film 300 may include a light transmissive body 10 having a structured first major surface 11 opposite a second major surface 12.
  • the structured first major surface 11 may include a plurality of structures 10a extending in a thickness direction of the light control film (e.g., the z-direction of FIG.1A) separated by one or more grooves 28.
  • each structure 10a may include one or more side surfaces 30a, 30b (collectively side surfaces 30).
  • each groove 28 may have one or more substantially planar landings 25 joining the corresponding adjacent structures 10a.
  • each of the one or more side surfaces 30a, 30b may make an angle ⁇ 1, ⁇ 2 with an adjacent landing 25 or with the second major surface 12.
  • the angle ⁇ 1, ⁇ 2 may be greater than about 60 degrees, or greater than about 65 degrees, or greater than about 70 degrees, or greater than about 75 degrees, or greater than about 80 degrees, or greater than about 85 degrees.
  • angles ⁇ 1 and ⁇ 2 may be substantially identical in magnitude but may be opposing in sign (i.e., each angle may be inclined toward the other angle, as shown in FIG. 1A). In some embodiments, angles ⁇ 1 and ⁇ 2 may be about 90 degrees (i.e., substantially orthogonal to landing 25 or to second major surface 12). In some embodiments, at least 80% of the one or more side surfaces 30a, 30b and the one or more landings 25 may be coated with a first light transmissive layer 40 having a first average thickness, h, of greater than about 0.005 microns.
  • first light transmissive layer 40 may have an average thickness in a range of between 0.005 microns and 0.500 microns, or from 0.01 microns to 0.400 microns, or from about 0.03 microns to about 0.300 microns.
  • at least 70% of first light transmissive layer 40 on each of the one or more side surfaces 30a, 30b and at most 30% of the first light transmissive layer 40 on the one or more landings 25 may be coated with a cover layer 50. Stated another way, cover layer 50 may cover more of side surfaces 30a, 30b than it covers the one or more landings 25.
  • the first light transmissive layer 40 coated on the one or more side surfaces 30a, 30b may have an arithmetic average surface roughness Ra2, and the first light transmissive layer 40 coated on the one or more landings 25 may have an arithmetic average surface roughness Ra1.
  • Ra1 may be greater than Ra2.
  • the average surface roughness Ra2 of side surfaces 30 e.g., 30a, 30b
  • Ra2 may be greater than zero.
  • the one or more side surfaces 30, 30a, 30b may have an arithmetic surface roughness within about 10% of Ra2 (i.e., they may have an average surface roughness substantially similar to Ra2).
  • the one or more landings 25 may have an arithmetic surface roughness less than about Ra1/10 (i.e., the first light transmissive layer 40 on top of the landings has roughness Ra1, while the landings 25 themselves, beneath the first light transmissive layer 40, are considerably smoother, less than about a tenth of Ra1).
  • one or more side surfaces 30a, 30b may include a first side surface 30a and a second side surface 30b connected by a substantially planar top surface 20.
  • the substantially planar top surface 20 may be substantially parallel to the one or more landings 25.
  • at most 30% of first light transmissive layer 40 on the planar top surface 20 may be coated with cover layer 50.
  • planar top surface 20 may have an arithmetic average surface roughness Ra2 substantially the same as the first light transmissive layer 40 coated on the one or more landings 25 (i.e., the average surface roughness of first light transmissive layer 40 on planar top surface 20 may be substantially the same as the average surface roughness of first light transmissive layer 40 on the one or more landings 25).
  • first light transmissive layer 40 may include a plurality of first inorganic particles 41 at a volume loading of greater than about 5%.
  • the first inorganic particles 41 may include one or more of silicon dioxide, titanium dioxide, zirconium dioxide, aluminum oxide, and clay platelets (e.g., the clay platelets may include silicates, including one or more of aluminum silicates and magnesium silicates).
  • light transmissive layer 40 may include a plurality of first inorganic particles 41 (FIG.1B) at a weight loading of greater than about 15%, or greater than about 20%, or greater than about 25%, or greater than about 30%, or greater than about 40%, or greater than about 50%, or greater than about 60%, or greater than about 70%, or greater than about 80%, or greater than about 90%, or greater than about 95%, or greater than about 96%, or greater than about 97%, or greater than about 98%, or greater than about 99%.
  • the first inorganic particles 41 of the light transmissive layer 40 may be dispersed in a polymeric binder 42 at the weight loading of greater than about 15%.
  • the first inorganic particles 41 are included at a weight loading of from about 15% to 99%, or from 20% to 80%, or from 25% to 70%.
  • the light transmissive layer may have a plurality of first inorganic particles 41 at a volume loading of from about 5% to 95%, or from about 5% to 80%, or from 5% to 70%, or from 10% to 70%.
  • the first inorganic particles 41 may include one or more of silicon dioxide, titanium dioxide, zirconium dioxide, aluminum oxide, and clay platelets (e.g., the clay platelets may include silicates, including one or more of aluminum silicates and magnesium silicates).
  • one of the polymeric binder 42 and the plurality of first inorganic particles 41 may include a plurality of positively charged ionic groups, and the other one of the polymeric binder 42 and the plurality of first inorganic particles 41 may include a plurality of negatively charged ionic groups.
  • Ionic groups can be inherently present on the surface of the inorganic particles; below the isoelectric point of the inorganic particle, the surface would possess a plurality of positively charged functional groups (i.e., net positive charge), while, above the isoelectric point, the surface would possess a plurality of negatively charged functional groups (i.e., net negative charge).
  • inorganic particles can be surface-functionalized or surface-modified to impart charged functional groups.
  • Surface functionalization/modification can be done with inorganic and/or organic materials.
  • An example material with inorganic surface modification is colloidal silica with an alumina surface, such as Nalco 1056 (available from Nalco Water, Naperville, IL).
  • silicon dioxide particles can be surface functionalized with an amino silane to impart positively charged amine groups to the surface.
  • the polymeric binder 42 may include one or more of poly(ethylenimine) (PEI), poly(allylamine hydrochloride), polyvinylamine, chitosan, polyaniline, polyamidoamine, poly(vinylbenzyltriamethylamine), polydiallyldimethylammonium chloride (PDAC), poly(dimethylaminoethyl methacrylate), poly(methacryloylamino)propyl- trimethylammonium chloride, poly(vinyl sulfate), poly(vinyl sulfonate), poly(acrylic acid) (PAA), poly(methacrylic acid), poly(styrene sulfonate), dextran sulfate, heparin, hyaluronic acid, carrageenan, carboxymethylcellulose, alginate, sulfonated tetrafluoroethylene based fluoropolymers, poly(vinylphosphoric acid), poly(
  • first light transmission layer 40 may contain a binder at a low weight loading.
  • any binder in first light transmission layer 40 may be at a weight loading of not greater than about 20%, or not greater than about 15%, or not greater than about 10%, or not greater than about 5%, not greater than about or 4%, or not greater than about 3%, or not greater than about 2%, or not greater than about 1%.
  • first light transmission layer 40 may not include any binder.
  • first light transmissive layer 40 may further include a plurality of second inorganic particles 43 (FIG.1C).
  • the second inorganic particles 43 may include one or more of silicon dioxide, titanium dioxide, zirconium dioxide, aluminum oxide, and clay platelets (e.g., the clay platelets may include silicates, including one or more of aluminum silicates and magnesium silicates).
  • one of the plurality of first inorganic particles 41 and the plurality of second inorganic particles 43 may include a plurality of positively charged ionic groups, and the other one of the plurality of first inorganic particles 41 and the plurality of second inorganic particles 43 may include a plurality of negatively charged ionic groups.
  • light control film 300 may further include a planarizing overcoat 90 covering, and substantially planarizing, structured first major surface 11.
  • a refractive index of the planarizing overcoat may be substantially the same as a refractive index of the plurality of structures. In some embodiments, the refractive index of the planarizing overcoat may be different from the refractive index of the plurality of structures by a value of less than 0.05, or less than 0.04, or less than 0.03. In some embodiments, a refractive index of the planarizing overcoat may be different from a refractive index of the plurality of structures by greater than about 0.07.
  • FIGS.2A-2B provide additional details for a light control film, such as the light control film 300 of FIG.1A. The following discussion addresses FIGS.1A-1C and 2A-2B as a whole and the figures should be reviewed in conjunction.
  • light control film 300 includes a light transmissive body 10 having a structured first major surface 11 opposite a second major surface 12.
  • the structured first major surface 11 may include a plurality of structures 10a extending in a thickness direction of the light control film separated by one or more grooves 28.
  • each structure 10a may include one or more side surfaces 30a, 30b (collectively side surfaces 30) and a planar top 20.
  • each groove 28 may have one or more substantially planar landings 25 joining the corresponding adjacent structures 10a.
  • a first light transmissive layer 40 may substantially cover the one or more side surfaces 30/30a/30b, landings 25, and a substantially planar top surface 20.
  • a cover layer 50 may substantially cover at least the one or more side surfaces 30/30a/30b.
  • cover layer 50 may have an average thickness of greater than about 0.05 microns, or greater than about 0.1 microns, or greater than about 0.15 microns, or greater than about 0.2 microns, or greater than about 0.25 microns, or greater than about 0.3 microns, or greater than about 0.35 microns, or greater than about 0.4 microns, or greater than about 0.45 microns, or greater than about 0.5 microns, or greater than about 0.55 microns, or greater than about 0.6 microns, or greater than about 0.65 microns, or greater than about 0.7 microns, or greater than about 0.75 microns, or greater than about 1.0 microns, or greater than about 1.25 microns, or greater than about 1.5 microns, or greater than about 2 microns, or greater than about 2.5 microns, or greater than about 3 microns.
  • the cover layer may have an average thickness of from about 0.05 microns to 1.5 microns, or from about 0.10 microns to 1.0 microns, or from about 0.50 microns to 1.2 microns, or from about 0.20 microns to 0.50 microns.
  • the light absorbing cover layer 50 may have an optical density of greater than about 0.1, or greater than about 0.2, or greater than about 0.4, or greater than about 0.6, or greater than about 0.8, or greater than about 1, or greater than about 1.1, or greater than about 1.2, or greater than about 1.3, or greater than about 1.5, or greater than about 2, or greater than about 2.5, or greater than about 3, or greater than about 3.5, or greater than about 4, or greater than about 4.5, or greater than about 5, or greater than about 5.5, or greater than about 6.
  • the optical density is less than about 3.0, or less than about 2.5, or less than about 2.0. In some embodiments the optical density is between 0.5 and 2.5, or between 1.0 and 2.0 or between 1.2 and 1.8.
  • the cover layer may be light absorbing.
  • the light absorbing cover layer may include a polyelectrolyte.
  • the light absorbing cover layer may include a plurality of light absorbing particles (e.g., the light absorbing particles may contain one or more of a dye, a pigment, and a carbon black).
  • FIG.2B is an SEM micrograph of a sample of a light control film according to the present description (i.e., an actual image showing an embodiment similar to the embodiment described in FIG.1 and FIG.2A).
  • FIG.2B shows light transmissive body 10 and a portion of one of the plurality of structures 10a (along the right side of the image).
  • First light transmissive layer 40 is a thin layer on side surfaces 30/30a/30b, landings 25, and a planar top surface 20 (although planar top surface is not visible in this micrograph).
  • a cover layer 50 covers the first light transmissive layer 40 on the one or more side surfaces 30/30a/30b, but substantially does not cover landings 25 (or planar top surface 20).
  • FIGS.3A and 3B presents contrasting top and side profile views of a light control film respectively, such as the embodiment of light control film 300 shown in FIG.1.
  • the plurality of structures 10a may include linear structures extending substantially across a width direction of the light control film (e.g., along the x-direction shown in FIG.3A) and arranged along an orthogonal length direction of the light control film (e.g., extending along the y-direction).
  • each linear structure 10a may be separated from each adjacent linear structure by a groove 28.
  • first light transmissive layer 40 covers and is visible over the landings 25 and substantially planar tops 20 of the structures but is covered by cover layer 50 on the one or more side surfaces 30/30a/30b.
  • a type of louver film may be created with areas of light transmission (landings 25 and planar tops 20) alternating with areas of light blocking/absorbing (side surfaces 30/30a/30b).
  • the one or more side surfaces 30/30a/30b may be substantially vertical (e.g., oriented along the y-direction shown in FIG.3B) and, because they are covered by cover layer 50, these substantially vertical, light blocking/absorbing “walls” can be used to direct light through the light control film 300 (e.g., to columnize or otherwise direct the light being transmitted).
  • FIG.4 provide details on the structure of a light control film, including angles and widths of various features, according to an embodiment of the present description. In particular, FIG.4 is provided to illustrate how the structure of the light control film may be modified/adjusted to meet the design of a light control film which meets a specific set of requirements.
  • light control film 300 in FIG.4 which share like numbers with elements of other figures herein shall be assumed to have the same function unless otherwise specified. Accordingly, these elements may not be described again in this discussion.
  • the performance of a light control film depends on the specific arrangement and configuration of the elements of the light control film. Changes in the angles of the “walls” in a louver film, the spacing between adjacent louvers, the “period” of the louvers, the depth of the channel between louvers, and the shape of the channels and walls which make up the light control film are all things that can be adjusted to change the performance of the light control film.
  • the configurations of the “walls” created by the cover layer 50 on the side surfaces 30/30a/30b define how the light control film performs.
  • the orientation of cover layer 50 may, for example, depend on the angles ⁇ 1 and ⁇ 2 of side surfaces 30a, 30b.
  • the height h c of the cover layer 50 may also have an effect on the performance (i.e., the length in the z-direction, or thickness direction of the light control film 300, of the space defined between the “walls” of the cover layer 50 may determine the amount of columnizing done as light passes through the space).
  • h c may be about 5 microns, or about 10 microns, or about 15 microns, or about 20 microns, or about 30 microns, or about 40 microns, or about 50 microns, or about 60 microns, or about 75 microns, or about 100 microns, or about 150 microns, or about 200 microns, or about 250 microns.
  • cover layer 50 on side surfaces 30 may not extend all the way to planar top surface 20.
  • the pitch, p1, or the distance between ends of one structure 10a and an adjacent one, including the landing 25 and planar top 20, and the widths of the structures 10a, landings 25, and planar tops 20 may also have effects on the performance of light control film 300.
  • p1 may be about 20 microns, or about 30 microns, or about 40 microns, or about 50 microns, or about 60 microns, or about 75 microns, or about 100 microns, or about 150 microns, or about 200 microns, or about 250 microns.
  • a typical structure 10a may have a first width w1 near the base of the structure and a second width w2 near the top of the structure.
  • w1 and w2 may be substantially equal (e.g., within about 10% of each other).
  • w1 may be greater than w2.
  • the “channels” formed between adjacent structure 10a may have width w3 near the base of the channel (near landing 25) and width w4 near the top of the channel.
  • “top” shall mean a surface or space higher on the page in the z-direction shown, and “bottom” shall mean a surface or lower on the page in the z-direction.
  • w3 and w4 may be substantially equal (e.g., within about 10% of each other). In some other embodiments, w4 may be greater than w3. In some embodiments, it may be advantageous for the planarizing overcoat to be symmetric with the transmissive layer. In such an embodiment, w3 may be about equal to w2 and w1 may be about equal to w4. All of these features discussed herein affect the “channels” they define, and the shape, size, spacing, and orientation of these channels can be used to control the “cutoff angle” of the channels (i.e., the angle beyond which light passing through light control film 300 is blocked.
  • FIGS.5A-5B show representations of embodiments of the light transmissive and cover layers of a light control film, such as light control film 300 of FIG.1A.
  • FIGS.5A-5B are schematic drawings and not intended to be accurate to scale or proportion.
  • Each of FIGS.5A and 5B may represent an embodiment of one of the first light transmissive layer 40 (shown here as 40’) or cover layer 50 (shown here as 50’).
  • at least one of the first light transmissive layer 40’ and cover layer 50’ may be porous comprising a plurality of pores 40’a, 50’a.
  • pores 40’a, 50’a may be created by interstitial spaces between particles within the first light transmissive layer 40’ and/or cover layer 50’.
  • a volume fraction of the pores may be greater than 0.2, or greater than 0.3, or greater than 0.4, or greater than 0.5, or greater than 0.6, or greater than 0.7.
  • an average size of pores 40’a, 50’a may be less than about 50 nm, or less than about 40 nm, or less than about 30 nm, or less than about 20 nm, or less than about 10 nm, or less than about 5 nm, or less than about 1 nm.
  • pores 40’a, 50’a may be at least partially filled with the material of planarizing overcoat (such as overcoat 90 of claim 1).
  • FIG.5B shows a representation of an embodiment of either a light transmissive layer 40” or a cover layer 50” (shown in both a top view and a side cutaway view) which is physically discontinuous and which includes a plurality of spaced apart islands 40”a, 50”a separated by gaps 41”a, 51”a.
  • FIGS.6A-6D illustrate display systems including a light control film, such as light control film 300 of FIG.1A. Like-numbered elements in FIGS.6A through 6D shall be assumed to have the same function unless specifically stated otherwise herein, and therefore descriptions of these shared elements may not be repeated.
  • display system 400 may include a light control film 300 disposed above a display 70 configured to form an image 71.
  • the light control film 300 may be disposed between the viewer 80 and display 70.
  • the light control film 300 in some embodiments, may be disposed between and include transparent substrate layers 72 and 73.
  • the display system may include optional cover glass layer 76 which may or may not be optically coupled to the surface of the display system 70.
  • the coupling layer may comprise an optically clear adhesive (not shown) disposed between the surface of the display 70 and cover window or cover glass 76.
  • the light control assembly 305 may be disposed above the display with an airgap between the light control assembly and the cover glass 76 and/or display 70.
  • the display assembly can be any type of display, such as an LCD display, OLED display, micro-LED display, etc.
  • the light control film is optically coupled to the display or cover glass using an optically clear adhesive.
  • the light control film assembly may be optically coupled to the display 70 and/or cover glass 76 with a self-wetting optically clear and repositionable removable adhesive layer.
  • display system 401 may include a light control film assembly 306 disposed behind an LCD display 70 having configured to form an image 71 on an emission plane of display 70.
  • the light control film assembly 306 may be disposed between LCD display 70 and a backlight 100.
  • the light control assembly 306 may include light control film 300 and a reflective polarizer 77.
  • the light transmissive body 10 of light control film 300 may be disposed on a substrate 72 (e.g., a polycarbonate substrate).
  • the planarization layer 90 may be bonded to reflective polarizer 77 with a first adhesive layer 78a (e.g., a UV cross-linked adhesive).
  • the opposite side of the reflective polarizer 77 i.e., the side opposite planarization layer 90
  • the first adhesive layer 78a and second adhesive layer 78b may include the same material (e.g., same adhesive).
  • a first brightness enhancement film 105 may separate backlight 100 and the light control assembly 306.
  • a second brightness enhancement film 106 may be paired with first brightness enhancement film 105 (e.g., crossed prism films).
  • first brightness enhancement film 105 e.g., crossed prism films.
  • the two crossed brightness enhancement films may be optically coupled with an adhesive.
  • display system 401 may include a cover glass 76 which may or may not be optically coupled to the surface of the display system 70.
  • a coupling layer may comprise an optically clear adhesive (not shown) disposed between the surface of the display 70 and cover glass 76.
  • display 70 may be disposed between the viewer 80 and light control film assembly 306.
  • FIG.6C shows an integrated display system 402 with an OLED assembly 700 and light control film assembly 307.
  • light transmissive body 10 of light control film 300 is disposed on a substrate 72 (e.g., a polycarbonate substrate).
  • the planarization layer 90 may bonded to cover glass 76 (e.g., a glass or plastic pane) with an optically clear adhesive 85.
  • light control film assembly 307 may be bonded to OLED assembly 700 with an optically clear adhesive 84.
  • optically clear adhesive 84 may be optically bond/optically couple substrate 72 and a polarizer 83 (e.g., a circular polarizer).
  • OLED assembly 700 may include OLED display 70 with OLED emission layer 71a.
  • a thin film encapsulation layer 81 may, in some embodiments, be disposed over OLED emission layer 71 and seal the OLED emissive layer 71 against air, moisture, or other environmental factors.
  • OLED assembly 700 may include an in-cell touch sensor layer 82 and an optically clear adhesive 88 which may optically bond the in-cell touch layer 82 to polarizer layer 83 (e.g., a circular polarizer).
  • polarizer layer 83 e.g., a circular polarizer
  • light control film 300 may be disposed between viewer 80 and OLED display 70.
  • the optically clear adhesive layers shown in the embodiments of Figures 6A - 6C may have any useful thickness.
  • the optically clear adhesive may have a thickness of from about 10 microns to about 400 microns, or from about 10 microns to about 300 microns, or from about 10 microns to about 150 microns, or from about 25 microns to about 125 microns, or from about 50 microns to about 100 microns.
  • adhesive layer 85 may have a haze level from about 0.1% to about 70%, or from about 0.1% to about 60%, or from about 0.1% to about 55%, or from about 0.1% to about 50%, or from about 0.1% to about 40%, or from about 2% to about 30%, or from about 5% to about 20%.
  • adhesive layer 95 may be an optically clear adhesive.
  • an optically clear adhesive layer used to bond the cover glass to the display systems 400, 401 and 402 may include laminating adhesives which have the properties of pressure sensitive adhesives.
  • optically clear adhesive layers may be a liquid applied adhesive, applied by any suitable method, which is cured to a polymeric state after bonding of two layers.
  • a laminating adhesive may have additional reactive functionality which can be reacted in a secondary curing process.
  • the display systems 400, 401, and 402 may be a curved display system 407 such as that represented in FIG.6D.
  • curved display system 407 may be curved along at least one direction (e.g., curved along the x-axis of FIG.6B).
  • light control film 300 and light control film assemblies 305 may be a curved light control film 307, also represented by the schematic drawing of FIG.6D.
  • curved light control film 307 may be curved along at least one direction (e.g., the x-axis as shown in FIG. 6D).
  • FIG.7 illustrates an embodiment of a method of making a light control film, according to the present description.
  • the method includes the steps of: (A) providing a substantially light transmissive film 10 including a structured first major surface 11 and an opposing second major surface 12, the structured first major surface 11 including a plurality of structures 10a separated by one or more grooves 28 extending in a thickness direction of the light control film 10 (e.g., the z-direction shown in FIG.7), each structure 10 including one or more side surfaces 30/30a/30b, each groove 28 having one or more substantially planar landings 25 joining the corresponding structures, each of the one or more side surfaces 30/30a/30b making an angle with an adjacent landing 25 of the one or more landings 25, or with the second major surface 12, of greater than about 60 degrees; (B) coating the structured first major surface 11 with a light transmissive layer 40, the light transmissive layer 40 covering at least 80% of each of the plurality of structures 10a and the one or more grooves 28 and a plurality of first inorganic particles (e.g., first inorganic particles 41 of FIGS.
  • the method of making a light control film may further include covering and substantially planarizing the structured first major surface with a planarizing overcoat 90 (not shown in FIG.7 but shown in at least FIG.1A).
  • FIG.8 includes a TEM micrograph of an embodiment of a light control film having a first light transmissive layer 40 and a second light transmissive layer 45, according to the present description. The microscope image of FIG.8 shows a close-up view of an area of light control film 300 shown in the dashed rectangle region in the bottom half of the figure.
  • light control film 300 may include a light transmissive body 10 with structures 10a separated by one or more grooves 28, a first light transmissive layer 40, a light absorbing layer 50, a planarizing overcoat 90.
  • light transmissive body 10 may have a plurality of alternating linear first 20 and second 30 facets extending along a first direction (e.g., the y-axis shown in FIG.3A) and arranged along a different second direction (e.g., the x-axis of FIG.3A).
  • first light transmissive layer 40 may have a first average thickness of greater than about 0.005 microns, or greater than about 0.01 microns, or greater than about 0.02 microns, or greater than about 0.03 microns, or greater than about 0.04 microns, or greater than about 0.05 microns, or greater than about microns, 0.08 microns, or greater than about 0.1 microns, or greater than about 0.15 microns, or greater than about 0.2 microns and coated on at least 80%, or at least 85%, or at least 90%, or at least 95% of each of the first 20 and second 30 facets.
  • the light transmissive layer 40 may include a plurality of first inorganic particles (e.g., particles 41 of FIGS.1B and 1C) including a first inorganic material (e.g., Si).
  • first inorganic material e.g., Si
  • light absorbing layer 50 may have an average thickness of greater than about 0.05 microns, or greater than about 0.1 microns, or greater than about 0.15 microns, or greater than about 0.2 microns, or greater than about 0.25 microns, or greater than about 0.3 microns, or greater than about 0.35 microns, or greater than about 0.4 microns, or greater than about 0.45 microns, or greater than about 0.5 microns, or greater than about 0.55 microns, or greater than about 0.6 microns, or greater than about 0.65 microns, or greater than about 0.7 microns, or greater than about 0.75 microns, or greater than about 1.0 microns, or greater than about 1.25 microns, or greater than about 1.5
  • planarizing overcoat 90 covers light absorbing layer 50 and substantially planarizes structured first major surface 11.
  • a second light transmissive layer 45 (shown in electron micrograph as a faint line between cover layer 50 and overcoat 90) may be disposed between planarizing overcoat 90 and light absorbing layer 50.
  • second light transmissive layer 45 may include the first inorganic material and may have a second average thickness that is less than the first average thickness. In some embodiments, the second average thickness may be less than about 20 nm, or less than about 10 nm, or less than about 5 nm..
  • FIGS.9A-9D illustrate various alternate embodiments of a light control film, according to the present description.
  • FIG.9A shows an alternate embodiment of a light control film 308 where the one or more side surfaces 30 of the structures 10a of light transmissive body 10 include a first side surface 30a and a second side surface 30b, but there is no substantially planar top surface joining side surfaces 20a and 30b. That is, in this embodiment, the first side surface and the second side surface meet at and form a peak 35 (e.g., of a triangular linear prism).
  • a peak 35 e.g., of a triangular linear prism
  • FIGS.9B, 9C, and 9D show alternate views of an embodiment of a light control film 308 where the structures 10a (shown as dashed lines, as structures 10a would not be visible covered by light transmissive layer 40) are embodied as a plurality of posts arranged along a width direction (e.g., the Y-direction of FIG.9B) and an orthogonal length direction (e.g., the X- direction) of light control film 309.
  • the posts in the plurality of posts may be substantially surrounded by the one or more landings 25.
  • the landings 25 may be found between adjacent posts/structures 10a in grooves 28 which may extend in both the width and length direction.
  • Each of the side surfaces 30 of the posts/structures 10a may be substantially covered in cover layer 50 (but landings 25 or planer tops 20 may be substantially uncovered by cover layer 50).
  • FIG.9C shows a cross-sectional view of light control film 309 where the cross-section is taken at the plane marked AA in FIG.9B.
  • the one or more side surfaces 30 may be substantially orthogonal to the second major surface 12 of light transmissive body 10.
  • Structures/posts 10a may, in some embodiments, be in the shape/form of rectangular prisms (as seen in FIGS.9B and 9D) but may also be any appropriate shape, including, but not limited to, a cylinder or a triangular prism.
  • FIG.9D provides an additional perspective view of an embodiment of light control film 309 featuring posts 10a which are rectangular prisms arranged in a regular, two- dimensional array of posts 10a.
  • the arrangement of posts 10a may be irregular (e.g., random) across the length and width directions.
  • the cover layer 50 may substantially cover the substantially vertical sides 30 of posts/structures 10a but substantially planar landings 25 and substantially planar tops 20 may be substantially uncovered by cover layer 50. Examples Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight.
  • Photomer 6010 Aliphatic urethane diacrylate obtained under the tradename PHOTOMER 6010 from IGM Resins (Charlotte, NC) SR602 Ethoxylated (10) bisphenol A diacrylate obtained from Sartomer (Exton, PA) SR601 Ethoxylated (4) bisphenol A diacrylate obtained from Sartomer TMPTA Trimethylolpropane triacrylate obtained from Cytec Industries (Woodland Park, NJ) PEA (ETERMER 2010) Phenoxyethyl acrylate obtained under the trade designation ETERMER 2010 from Eternal Chemical Co., Ltd., Kaohsiung, Taiwan Darocur 1173 2-Hydroxy-2-methylpropiophenone photoinitiator obtained under the trade designation DAROCUR 1173 from BASF (Florham Park, NJ) TPO Diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide photoinitiator obtained under the trade designation DAROCUR
  • Paul, MN PDAC Polydiallyldimethylammonium chloride obtained under the trade designation DEHYQUART CC6 from BASF SiO 2 -5nm Anionic silicon dioxide nanoparticles with average particle size of 5 nm and ammonia stabilized, obtained under the trade designation NALCO 2326 from Nalco Water, Naperville, IL. SiO 2 -44nm Anionic silicon dioxide nanoparticles with average particle size of 44 nm and ammonia stabilized, obtained under the trade designation NALCO DVSZN004 from Nalco Water. TiO 2 Anionic titanium dioxide nanoparticles, tetramethylammonium stabilized in water, obtained from 3M (St. Paul, MN).
  • EXPCB Anionic, surface-modified carbon black dispersion obtained from Cabot Corp., Boston, MA CR3090 Anionic, styrene-acrylic emulsion obtained under the tradename CARBOSET CR-3090 from Lubrizol.
  • Table 1 Composition of Resin A used to make clear channel film Material Parts by Weight Photomer 6010 60 SR602 20 SR601 4.0 TMPTA 8.0 PEA (Etermer 2010) 8.0 Darocur 1173 0.35 TPO 0.10 I1035 0.20
  • a “cast-and-cure” microreplication process was carried out with Resin A and the tool described above.
  • the line conditions were: resin temperature 150 ⁇ F, die temperature 150 ⁇ F, coater IR 120 ⁇ F edges/130 ⁇ F center, tool temperature 100 ⁇ F, and line speed 70 fpm. Fusion D lamps, with peak wavelength at 385 nm, were used for curing and operated at 100% power.
  • the resulting microstructured film comprised a plurality of protrusions/ribs separated by channels/valleys.
  • the base layer was PET film (3M, St. Paul, MN), having a thickness of 2.93 mils (74.4 microns).
  • the side of the PET film that contacts the resin was primed with a thermoset acrylic polymer (Rhoplex 3208 available from Dow Chemical, Midland, MI).
  • the land layer of the cured resin had a thickness of 8 microns.
  • the protrusions of the microstructured film are a negative replication of the grooves of the tool.
  • the protrusions have a wall angle of 1.5 degrees resulting in the protrusions being slightly tapered.
  • the channels of the microstructured film are a negative replication of the uncut portions of the tool between the grooves.
  • a PDAC coating solution was made with 0.32% solids DEHYQUART CC6 and 0.14 wt% of TMAOH (2.38% solids) in deionized (DI) water.
  • a PEI coating solution was made with 0.1% solids LUPASOL WF in DI water without any added salt or pH adjustment. Multiple different anionic metal oxide particles were used for etch stops.
  • a SiO 2 -5 nm coating solution was made with 1.0% solids NALCO 2326, 48 mM TMACl, and 2.7 wt% of TMAOH (2.38% solids) in DI water, while a SiO 2 -44 nm coating solution was made with 1.0% solids NALCO DVSZN004, 48 mM TMACl, and 2.7 wt% of TMAOH (2.38% solids) in DI water.
  • a TiO 2 coating solution was made with 1.0% solids TiO 2 , 65 mM TMACl, and 0.76 wt% of TMAOH (2.38% solids) in DI water.
  • a VMT clay coating solution was made with 1.0% solids MICROLITE 963A+ in DI water without any added salt or pH adjustment.
  • the apparatus comprises pressure vessels loaded with the coating solutions.
  • Spray nozzles with a flat spray pattern (from Spraying Systems, Inc., Wheaton, Illinois) were mounted to spray the coating solutions and rinse water at specified times, controlled by solenoid valves.
  • the pressure vessels (Alloy Products Corp., Waukesha, WI) containing the coating solutions were pressurized with nitrogen to 30 psi, while the pressure vessel containing deionized (DI) water was pressurized with air to 30 psi.
  • DI deionized
  • Flow rates from the coating solution nozzles were each 10 gallons per hour, while flow rate from the DI water rinse nozzles were 40 gallons per hour.
  • the substrate to be coated (9”x10”) was adhered at the edges with epoxy (Scotch-Weld epoxy adhesive, DP100 Clear, 3M Company, St. Paul, MN) to a glass plate (12” x 12” x 1/8” thick) (Brin Northwestern Glass Co., Minneapolis, MN), which was mounted on a vertical translation stage and held in place with a vacuum chuck.
  • the polycation (e.g., PDAC) solution was sprayed onto the substrate while the stage moved vertically downward at 76 mm/sec.
  • the DI water was sprayed onto the substrate while the stage moved vertically upward at 102 mm/sec.
  • the substrate was then dried with an airknife at a speed of 3 mm/sec.
  • the polyanion (e.g., silica nanoparticle) solution was sprayed onto the substrate while the stage moved vertically downward at 76 mm/sec.
  • Another dwell period of 12 sec was allowed to elapse.
  • the DI water was sprayed onto the substrate while the stage moved vertically upward at 102 mm/sec.
  • the substrate was then dried with an airknife at a speed of 3 mm/sec.
  • the Cation solution was 2.5% solids SC72 with 200 mM NaCl and 0.1% PL92 in DI water.
  • the Cover Layer Core Anion solution was 2.5% solids EXPCB with 50 mM NaCl and 0.1% PL92 in DI water.
  • the Cover Layer Clad Anion solution was 4.0% solids CR3090, 0.5% solids EXPCB with 50 mM NaCl and 0.1% PL92 in DI water.
  • the light-absorbing coating construction comprised six bilayers of Cation/Cover Layer Clad Anion, denoted as (Cation/Cover Layer Clad Anion) 6 , followed by four bilayers of Cation/Cover Layer Core Anion, denoted as (Cation/Cover Layer Core Anion) 4 , followed by six bilayers of Cation/Cover Layer Clad Anion, denoted as (Cation/Cover Layer Clad Anion) 6 , for a total of sixteen bilayers.
  • Microstructured film was threaded through the coating line.
  • the coating solutions were separately coated onto the microstructured film with a #4 Mayer Rod fed from a liquid delivery manifold at a flow rate of about 200 mL/min at each coating station.
  • the Cation solution was 1.0% solids SC72 with 200 mM NaCl and 0.1% PL92 in DI water.
  • the Cover Layer Core Anion solution was 1.0% solids EXPCB with 50 mM NaCl and 0.1% PL92 in DI water.
  • the light-absorbing coating construction comprised six bilayers of Cation/Cover Layer Core Anion, denoted as (Cation/Cover Layer Core Anion) 6 . Thickness of the LbL coating, determined by analyzing an SEM image of the coating on a sidewall of the clear channel film with ImageJ software, was 422 ⁇ 36 nm.
  • RIE Light Absorbing Cover Layer Reactive ion etching
  • a first treatment time of 150 seconds was completed on all samples by moving the film through the chamber at a rate of 2 ft/min.
  • a second treatment time was applied to the same surface by moving the same section of film through the chamber at a rate of 1 ft /min. Together, this resulted in a full treatment time of 450 seconds.
  • the RF power and the gas supply were stopped, and the chamber was returned to atmospheric pressure.
  • Intermediate treatment times from 150 to 450 s were collected from the gradient etch time down the length of the sample. Additional information regarding materials and processes for applying cylindrical RIE and further details around the reactor used can be found in US8460568 B2.
  • %Transmission %Transmission
  • %T %Transmission
  • BYK Garnier-Gard Plus instrument
  • SEM Scanning Electron Microscopy
  • Samples were freeze fractured with liquid nitrogen. Imaging was done with a Hitachi S4700 Field Emission microscope. Coating thickness values were determined using ImageJ software, a Java-based image processing program developed at the National Institutes of Health. SEM was used to measure thickness of the light transmissive layer (i.e., etch stop) and the light-absorbing cover layer.
  • Method to Backfill Resin A was heated to 65°C in an oven.
  • TEM Transmission Electron Microscopy
  • the powder samples were analyzed using a TA Instruments Discovery Thermogravimetric Analyzer (TGA) in HiRes mode.
  • TGA TA Instruments Discovery Thermogravimetric Analyzer
  • the sample was subjected to a heating profile ranging from room temperature ( ⁇ 30 °C) to 700 °C in a nitrogen atmosphere, with a heating rate of 20.0 °C/min and a resolution setting of 4.0. Under these conditions, the instrument heats the sample until weight loss is detected, at which point the temperature stabilizes until weight loss diminishes, and then heating recommences.
  • the atmosphere was then switched to air and the HiRes heating ramp was continued to 800° C.
  • the weight% residue at 800° C was taken as the weight % of inorganic particles (e.g., metal oxide) in the coating samples.
  • inorganic particles e.g., metal oxide
  • Porosity (i.e., volume % air) of the LbL etch stop coatings was measured with an in situ spectroscopic ellipsometry method, similar to what was reported in Lee et al. JACS 2009 Vol.131 p. 671-679.
  • the spectroscopic ellipsometer was an M-2000 instrument and the software was WVASE32, both purchased from J.A. Woollam Co., Inc. (Lincoln, NE).
  • LbL etch stop coatings deposited on silicon wafers using the “Method to Coat a Layer-by-Layer Etch Stop (Light Transmissive Layer) – Batch” were placed in a custom-made quartz cell with windows perpendicular to the incident and reflected light from the ellipsometer at a measurement angle of 70 degrees. Measurements were taken in ambient air and in a DI water environment (ambient). Etch stop coatings were modeled as Cauchy layers. Porosity was calculated using the Lorentz-Lorenz mixing rule for refractive indices.
  • Volume % of inorganic particles in the LbL etch stop coatings was calculated from the weight % values determined in the “Method for Determining Weight% of Inorganic Particles in LbL Etch Stop Coatings” and the porosity values determined in the “Method for Determining Porosity of LbL Etch Stop Coatings”, assuming a density of SiO 2 to be 2.05 g/cc, density of TiO 2 to be 3.90 g/cc, and density of PDAC polymer to be 1.00 g/cc.
  • Refractive index of the LbL Etch Stop Coatings was determined using a Filmetrics (San Diego, CA) F10-AR reflectometer with hardcoat (HC) mode for coatings deposited on glass plates using the “Method to Coat a Layer-by-Layer Etch Stop (“Light Transmissive Layer”) – Batch”.
  • Method for Measuring the Luminance Profile from a Diffuse Light Source A sample of film was placed on a Lambertian light source. When the light transmissive regions are tapered, the film is positioned such that the widest portion of the tapered regions are closer to the light source.
  • An Eldim L80 conoscope (Eldim S.A., Herouville-Saint-Clair, France) was used to detect light output in a hemispheric fashion at all polar and azimuthal angles simultaneously. After detection, a cross section of transmission (e.g., brightness) readings were taken in a direction orthogonal to the direction of the louvers (denoted as a 0 ⁇ orientation angle), unless indicated otherwise.
  • Relative transmission i.e., brightness of visible light is defined as the percentage of on- axis luminance, at a certain viewing angle, between a reading with film and a reading without the film.
  • the Lambertian light source consisted of diffuse transmission from a light box having the baseline luminance profile depicted in FIG.6 of WO 2019/118685 A1 (Schmidt et al.).
  • the light box was a six-sided hollow cube measuring approximately 12.5 cm x 12.5 cm c 11.5 cm (L x W x H) made from diffuse polytetrafluoroethylene (PTFE) plates of approximately 6 millimeters (mm) thickness.
  • PTFE diffuse polytetrafluoroethylene
  • One face of the box was chosen as the sample surface.
  • the hollow light box had a diffuse reflectance of approximately 0.83 measured at the sample surface (e.g., approximately 83%, averaged over the 400-700 nm wavelength range).
  • the box was illuminated from within through an approximately 1 cm circular hole in the bottom of the box (opposite the sample surface, with the light directed toward the sample surface from inside).
  • the illumination was provided using a stabilized broadband incandescent light source attached to a fiber-optic bundle used to direct the light (Fostec DCR-II with a 1 cm diameter fiber bundle extension from Schott-Fostec LLC, Marlborough, MA and Auburn, NY).
  • CE1 No Etch Stop Step 1 A microstructured film was prepared as described in “Method for Cast-and-Cure Microreplication to Make Clear Channel Film.” Step 2: The microstructured film was coated with a light absorbing LbL coating as described in “Method to Coat a Light Absorbing Cover Layer - Continuous.” Step 3: The light absorbing layer was etched as described in “Method to Selectively Remove the Light Absorbing Cover Layer.” (See FIG.10, SEM image of CE1 after Step #3).
  • Step 4 The structured film of Step 3 was backfilled as described in “Method to Backfill.”
  • Step 1 A microstructured film was prepared as described in “Method for Cast-and-Cure Microreplication to Make Clear Channel Film.”
  • Step 2 A layer-by-layer etch stop was applied on the microstructured film as described in “Method to Coat a Layer-by-Layer Etch Stop (Light Transmissive Layer) – Continuous” using a PDAC coating solution as the Cation and SiO 2 -5 nm coating solution as the Anion.”
  • Step 3 The microstructured film was coated with a light absorbing LbL coating as described in “Method to Coat a Light Absorbing Cover Layer - Continuous.”
  • Step 4 The light absorbing layer was etched as described in “Method to Selectively Remove the Light Absorbing Cover Layer.” (See FIG.11, SEM image of E
  • Step 5 The structured film of Step 4 was backfilled as described in “Method to Backfill.”
  • Step 1 A microstructured film was prepared as described in “Method for Cast-and-Cure Microreplication to Make Clear Channel Film.”
  • Step 2 A layer-by-layer etch stop was applied on the microstructured film as described in “Method to Coat a Layer-by-Layer Etch Stop (Light Transmissive Layer) – Continuous” using a PDAC coating solution as the Cation and SiO 2 -44 nm coating solution as the Anion.”
  • Step 3 The microstructured film was coated with a light absorbing LbL coating as described in “Method to Coat a Light Absorbing Cover Layer - Continuous.”
  • Step 4 The light absorbing layer was etched as described in “Method to Selectively Remove the Light Absorbing Cover Layer.” (See FIG.12, SEM image
  • Step 5 The structured film of Step 4 was backfilled as described in “Method to Backfill.”
  • Step 1 A microstructured film was prepared as described in “Method for Cast-and-Cure Microreplication to Make Clear Channel Film.”
  • Step 2 A layer-by-layer etch stop was applied on the microstructured film as described in “Method to Coat a Layer-by-Layer Etch Stop (Light Transmissive Layer) – Continuous” using a PDAC coating solution as the Cation and TiO 2 coating solution as the Anion”
  • Step 3 The microstructured film was coated with a light absorbing LbL coating as described in “Method to Coat a Light Absorbing Cover Layer - Continuous.”
  • Step 4 The light absorbing layer was etched as described in “Method to Selectively Remove the Light Absorbing Cover Layer.” (See FIG.13, SEM image of EX3 after Step #4).
  • Step 5 The structured film of Step 4 was backfilled as described in “Method to Backfill.”
  • EX 4 LbL Etch Stop – (PEI/VMT)6 Step 1: A microstructured film was prepared as described in “Method for Cast-and-Cure Microreplication to Make Clear Channel Film.”
  • Step 2 A layer-by-layer etch stop was applied on the microstructured film as described in “Method to Coat a Layer-by-Layer Etch Stop (Light Transmissive Layer) – Batch” using a PEI coating solution as the Cation and VMT coating solution as the Anion.”
  • Step 3 The microstructured film was coated with a light absorbing LbL coating as described in “Method to Coat a Light Absorbing Cover Layer - Batch.”
  • Step 4 The light absorbing layer was etched as described in “Method to Selectively Remove the Light Absorbing Cover Layer.” (See FIG.14, SEM image of EX4 after Step #4).
  • the light absorbing cover layer does not extend to the level of the bottom horizontal surface of the microstructured film. This can be explained by the etching of the polymer resin on both the the top and bottom horizontal surfaces. In the Examples, on the other hand, at the tops of the ridges, the light absorbing cover layer does not reach the same level as the horizontal surface of the microstructured film.
  • the etch stop i.e., light transmissive layer 40, e.g., see FIG.1A
  • the etch stop i.e., light transmissive layer 40, e.g., see FIG.1A
  • the light absorbing cover layer does approximately reach the same level of the etch stop (i.e., the light transmissive layer).
  • Table 4 Thickness, refractive index, wt% inorganic particles, porosity, and vol% inorganic particles in the LbL etch stops (i.e., “light transmissive layers”) of EX1-EX3.
  • the luminance profile was measured using the “Method for Measuring the Luminance Profile from a Diffuse Light Source”. Data for CE1 and EX1 are shown in Table 5 below.
  • substantially equal will mean about equal where about is as described above. If the use of “substantially parallel” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially parallel” will mean within 30 degrees of parallel. Directions or surfaces described as substantially parallel to one another may, in some embodiments, be within 20 degrees, or within 10 degrees of parallel, or may be parallel or nominally parallel.
  • substantially aligned will mean aligned to within 20% of a width of the objects being aligned. Objects described as substantially aligned may, in some embodiments, be aligned to within 10% or to within 5% of a width of the objects being aligned. All references, patents, and patent applications referenced in the foregoing are hereby incorporated herein by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control.

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Abstract

L'invention concerne un film de commande de lumière qui a une première surface principale structurée comprenant des structures séparées par une ou plusieurs rainures et ayant des surfaces latérales. Chaque rainure a un ou plusieurs paliers joignant des structures adjacentes. Chacune des surfaces latérales forme un angle supérieur à environ 60 degrés avec un palier adjacent. Au moins 80% des surfaces latérales et des paliers sont revêtus d'une première couche de transmission de lumière comprenant des particules inorganiques à une charge de volume supérieure à environ 5%. Au moins 70% de la première couche de transmission de lumière sur chacune des surfaces latérales et au plus 30% de la première couche de transmission de lumière sur les paliers sont revêtus d'une couche de recouvrement. La première couche de transmission de lumière appliquée sur les surfaces latérales a une rugosité de surface moyenne Ra2, et la première couche de transmission de lumière appliquée sur les paliers a une rugosité de surface moyenne Ra1, où Ra1 > Ra2.
PCT/IB2024/056730 2023-07-12 2024-07-10 Film de commande de lumière et son procédé de fabrication Pending WO2025012837A1 (fr)

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Publication number Priority date Publication date Assignee Title
US8234998B2 (en) 2006-09-08 2012-08-07 Massachusetts Institute Of Technology Automated layer by layer spray technology
US8460568B2 (en) 2008-12-30 2013-06-11 3M Innovative Properties Company Method for making nanostructured surfaces
WO2019118685A1 (fr) 2017-12-13 2019-06-20 3M Innovative Properties Company Film de commande de lumière à haute transmission
US10926289B2 (en) 2015-10-12 2021-02-23 3M Innovative Properties Company Layer-by-layer coating apparatus and method
WO2021090129A1 (fr) * 2019-11-08 2021-05-14 3M Innovative Properties Company Système optique comprenant un film de commande de lumière et une lentille de fresnel
US11550183B2 (en) 2018-08-01 2023-01-10 3M Innovative Properties Company High transmission light control film
WO2023047204A1 (fr) 2021-09-24 2023-03-30 3M Innovative Properties Company Films microstructurés revêtus, leurs procédés de fabrication, et procédés de fabrication de films de commande de lumière

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US8234998B2 (en) 2006-09-08 2012-08-07 Massachusetts Institute Of Technology Automated layer by layer spray technology
US8460568B2 (en) 2008-12-30 2013-06-11 3M Innovative Properties Company Method for making nanostructured surfaces
US10926289B2 (en) 2015-10-12 2021-02-23 3M Innovative Properties Company Layer-by-layer coating apparatus and method
WO2019118685A1 (fr) 2017-12-13 2019-06-20 3M Innovative Properties Company Film de commande de lumière à haute transmission
US11550183B2 (en) 2018-08-01 2023-01-10 3M Innovative Properties Company High transmission light control film
WO2021090129A1 (fr) * 2019-11-08 2021-05-14 3M Innovative Properties Company Système optique comprenant un film de commande de lumière et une lentille de fresnel
WO2023047204A1 (fr) 2021-09-24 2023-03-30 3M Innovative Properties Company Films microstructurés revêtus, leurs procédés de fabrication, et procédés de fabrication de films de commande de lumière

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KROGMAN ET AL.: "Automated Process for Improved Uniformity and Versatility of Layer-by-Layer Deposition", LANGMUIR, vol. 2007, no. 23, pages 3137 - 3141
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