阅读说明：本技术 带小面的微结构化表面、光学膜和方法 (Faceted microstructured surface, optical film and method ) 是由 克里斯托弗·J·德克斯 特里·D·彭 肯尼斯·A·爱泼斯坦 戴维·J·兰姆 于 2018-01-08 设计创作，主要内容包括：本发明公开了一种微结构化表面、光学膜和方法,包括：基本上随机布置的多个小面,每个小面相对于微结构化表面的平面限定至少一个倾斜度,多个小面的至少一个倾斜度限定倾斜度大小累积分布,倾斜度大小累积分布在20度附近的变化率基本上小于在60度附近的变化率,其中倾斜度大小分布在10度附近的变化率小于约0.5％/度,并且所述倾斜度大小分布在20度附近的变化率小于约1％/度。(The invention discloses a microstructured surface, an optical film and a method, comprising: a plurality of facets arranged substantially randomly, each facet defining at least one slope with respect to a plane of the microstructured surface, the at least one slope of the plurality of facets defining a slope magnitude cumulative distribution, the slope magnitude cumulative distribution having a rate of change about 20 degrees substantially less than a rate of change about 60 degrees, wherein the slope magnitude distribution has a rate of change about 10 degrees less than about 0.5%/degree and the slope magnitude distribution has a rate of change about 20 degrees less than about 1%/degree.)

1. A microstructured surface comprising:

a plurality of facets arranged substantially randomly, each facet defining at least one slope with respect to a plane of the microstructured surface, the at least one slope of the plurality of facets defining a slope magnitude cumulative distribution having a rate of change about 20 degrees substantially less than a rate of change about 60 degrees, wherein the rate of change of the slope magnitude distribution about 10 degrees is less than about 0.5%/degree and the rate of change of the slope magnitude distribution about 20 degrees is less than about 1%/degree.

2. A microstructured surface comprising:

a plurality of facets arranged substantially randomly, each facet comprising a substantially flat central portion defining a slope with respect to a plane of the microstructured surface, the slopes of the plurality of facets defining a slope magnitude cumulative distribution, a rate of change of the slope magnitude cumulative distribution of slopes less than about 10 degrees being less than about 1%/degree, a rate of change of the slope magnitude cumulative distribution of slopes less than about 30 degrees being less than about 2%/degree.

3. A microstructured surface comprising a plurality of substantially randomly arranged prism structures, each prism structure comprising a plurality of facets intersecting at a peak, a central portion of each facet defining an azimuthal angle relative to a normal direction to a plane of the microstructured surface and a polar angle relative to the normal direction to the plane of the microstructured surface, a difference in distribution of the azimuthal angle between 0 degrees and 360 degrees being less than about 20%, less than about 5% of the polar angles of the facets of the plurality of prism structures being less than about 10 degrees, and a maximum of the distribution of the polar angles being between about 10 degrees and 60 degrees, such that for substantially collimated light incident along the normal direction, the microstructured surface has a first total optical transmittance for collimated light incident from a peak side of the microstructured surface and a second substantially lower total optical transmittance for collimated light incident on an opposite side of the microstructured surface A second total optical transmission, and such that for substantially collimated light incident from the opposite side of the microstructured surface along a direction oblique to the normal direction, the microstructured surface has a third total optical transmission that is greater than the second total optical transmission.

4. A microstructured surface comprising:

a plurality of facets arranged substantially randomly and defining a plurality of slopes relative to a plane of the microstructured surface such that a surface percentage/solid angle in degrees squared of a gradient of about zero is from about 0.0005% to about 0.01%, wherein the surface percentage/solid angle in degrees squared of a gradient of about zero is from about 0.001% to about 0.006%.

5. A microstructured surface comprising:

a plurality of facets arranged substantially randomly and defining a plurality of slopes relative to a plane of the microstructured surface, less than about 0.010%/cube corner in square having a gradient magnitude of less than about 10 degrees and more than about 0.008%/cube corner in square having a gradient magnitude of about 50 degrees.

6. An optical film, comprising:

a microstructured surface comprising a plurality of prism structures, the microstructured surface defining a reference plane and a thickness direction perpendicular to the reference plane;

wherein the plurality of prism structures comprise a plurality of facets, each facet having a facet normal direction that forms a polar angle with respect to the thickness direction and an azimuth angle along the reference plane,

wherein the microstructured surface has a substantially uniform surface azimuthal distribution of the plurality of facets, an

Wherein the microstructured surface has a surface polar angle distribution of the plurality of facets having an off-axis peak polar angle distribution, wherein the off-axis peak polar angle distribution is at least twice as high as the on-axis polar angle distribution, wherein the plurality of prism structures are irregularly distributed across the microstructured surface, wherein the microstructured surface has a facet surface azimuthal distribution that is substantially uniform at a resolution comprising at least 10,000 facets.

7. An optical film, comprising:

a microstructured surface comprising a plurality of prism structures, the microstructured surface defining a reference plane and a thickness direction perpendicular to the reference plane;

wherein the plurality of prism structures comprise a plurality of facets, each facet having a facet normal direction that forms a polar angle with respect to the thickness direction and an azimuth angle along the reference plane,

wherein the microstructured surface is characterized by substantially uniform azimuthal transmission for collimated light, and

wherein the microstructured surface is characterized by a polar angle transmission having an off-axis peak polar angle transmission for collimated light, wherein the off-axis peak polar angle transmission is at least twice as high as the on-axis polar angle transmission, and wherein the plurality of prism structures are irregularly distributed across the microstructured surface.

8. A method, comprising:

preparing an electroplating solution comprising a metal template, wherein the metal template has a crystal geometry corresponding to an irregular prism structure; and

electroplating a metal layer from the electroplating solution onto a substrate, wherein the metal layer comprises irregular ridges corresponding to a microstructured surface having irregular prism structures, the microstructured surface defining a reference plane and a thickness direction perpendicular to the reference plane, wherein the irregular prism structures comprise planar facets each having a facet normal direction that forms a polar angle with respect to the reference plane and an azimuthal angle along the reference plane, and wherein the irregular prism structures are distributed across the optical film such that collimated light optical transmission characteristics of the microstructured surface approximate collimated light optical transmission characteristics of a polymerized surface of pyramidal prism structures.

Background

Display systems, such as Liquid Crystal Display (LCD) systems, are used in a variety of applications and commercially available devices, such as, for example, computer monitors, Personal Digital Assistants (PDAs), mobile phones, miniature music players, and thin LCD televisions. Many LCDs include a liquid crystal panel and an extended area light source (commonly referred to as a backlight) for illuminating the liquid crystal panel. Backlights typically include one or more lamps and a plurality of light management films such as, for example, light guides, mirror films, light redirecting films (including brightness enhancing films), retarder films, light polarizing films, and diffuser films. Diffuser films are typically included to hide optical defects and improve the brightness uniformity of the light emitted by the backlight. The diffusion membrane may also be used in applications other than display systems.

Disclosure of Invention

In accordance with embodiments of the present disclosure, an optical article may include an optical film having a microstructured surface having prism structures randomly distributed across a reference plane. The irregular prism structures may include flat facets that are at polar angles and azimuthal angles with respect to the reference plane. The prism structures may be distributed and oriented such that the collimated light optical transmission characteristic of the microstructured surface approximates the collimated light optical transmission characteristic of the polymerized pyramidal prism structures.

In another embodiment, an optical film can include a microstructured surface comprising a plurality of prism structures, the microstructured surface defining a reference plane and a thickness direction perpendicular to the reference plane; wherein the plurality of prism structures comprises a plurality of facets, each facet having a facet normal direction that forms a polar angle with respect to the thickness direction and an azimuthal angle along the reference plane, and wherein the microstructured surface has a substantially uniform distribution of surface azimuthal angles of the plurality of facets, and wherein the microstructured surface has a distribution of surface polar angles of the plurality of facets off-axis peak polar angle distributions.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

Drawings

In the drawings, like numbering represents like elements. Dotted lines represent optional or functional components, while dashed lines represent components outside the views.

Fig. 1 is an illustration of an optical article comprising an optical film on a substrate.

Fig. 2A is an illustration of an optical article comprising an optical film having a microstructured surface.

Fig. 2B is an illustration of a top view of a facet of a prism structure.

Fig. 2C is an illustration of a side view of a planar facet of a prism structure.

FIG. 3 illustrates an exemplary process for forming an optical film.

FIG. 4 is an exemplary method for generating light transmission information for an optical film by collimated light transmission.

Fig. 5A, 6A, and 7A are conoscopic plots of light intensity at polar and azimuthal angles for samples 1, 2, and 3, respectively, of the optical films disclosed herein.

Fig. 5B, 6B, and 7B are graphs of the average polar angle tilt (x-axis) of the normalized polar angle transmission profile (y-axis).

FIG. 8A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film with a pyramidal hexagonal packing array.

FIG. 8B is a plot of the average polar angle slope (x-axis) of the normalized polar angle transmission distribution (y-axis).

FIG. 9A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film having a prismatic waffle-like grid.

FIG. 9B is a plot of the average polar angle slope (x-axis) of the normalized polar angle transmission distribution (y-axis).

FIG. 10A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film with an array of partial spheres.

FIG. 10B is a plot of the average polar angle slope (x-axis) of the normalized polar angle transmission distribution (y-axis).

Fig. 11A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film having irregular prisms with rounded peaks.

FIG. 11B is a plot of the average polar angle slope (x-axis) of the normalized polar angle transmission distribution (y-axis).

Fig. 12A is a conoscopic representation of confocal tilt data for polar and azimuthal angles of a sample optical film.

Fig. 12B is a graph of tilt frequency (y-axis) versus polar angle (x-axis).

FIG. 13 is a table of modeled cone gain versus various cone structure parameters.

FIG. 14A is a graph illustrating light intensity at a polar angle relative to a planar major surface of an inverted pyramidal structure and an azimuthal angle along a major surface of the pyramidal structure.

Fig. 14B is a plot of normalized luminance for a range of surface polar angles for sample 5 and the simulated pyramidal structures.

Fig. 15A and 15B are composite AFM images of samples 6A and 6B, respectively, including the above facet analysis.

Fig. 16A and 16B are composite AFM images of samples 7A and 7B, respectively, including the above facet analysis.

Fig. 17A is a composite AFM image of sample 8 including the facet analysis described above.

Fig. 17B is a composite AFM image of sample 9 including the facet analysis described above.

Fig. 18A and 18B are composite AFM images of optical films having irregular prisms with rounded peaks including facet analysis described above.

FIG. 19 is a composite AFM image of an optical film with a pyramidal hexagonal packing array including facet analysis described above.

FIG. 20 is a composite AFM image of an optical film with a partially sphere packed array including facet analysis described above.

FIG. 21 is a composite AFM image of an optical film with an array of pyramidal prisms including the facet analysis described above.

FIG. 22 is a graph of coverage area as a percentage of total surface area for a flat faceted core region for six optical film examples. Samples 6-9 exhibited significantly higher surface area coverage than the irregular prismatic, partially spherical, and hexagonal pyramidal optical films.

Fig. 23A and 23B are graphs of power spectral density versus spatial frequency along two orthogonal in-plane directions (y and x, respectively).

Fig. 24A is a graph of facet azimuthal distribution of an optical film, the facet azimuthal distribution indicating surface area coverage of the facet portion at various azimuthal angles.

FIG. 24B is a graph of a gradient azimuthal distribution of a flat-faceted optical film, the gradient azimuthal distribution representing surface area coverage of the gradient portion at various azimuthal angles.

Fig. 25A-25B are two-dimensional distribution plots of gradient/facet distributions based on AFM data from optical films of the present disclosure.

Fig. 26A-26D are two-dimensional distribution plots of the gradient/facet distribution of AFM data based on optical films having irregular prisms (26D), partial spheres (26A), hexagonal pyramids (26B), and pyramidal prisms (26C).

Fig. 27A is a graph of the cumulative distribution of gradient sizes for the optical film disclosed in sample 10, the optical film disclosed in sample 11, and the irregular prismatic optical film.

FIG. 27B is a graph of the gradient size distribution of sample 10, sample 11, and irregular prismatic optical film.

Fig. 27C is a graph showing a cumulative facet slope magnitude distribution of the optical film.

FIG. 27D is a plot of facet tilt angle distributions of tilt angle versus normalized frequency for sample 6, sample 7, and irregular prisms.

Fig. 27E is a graph of the gradient magnitude cumulative distribution of the optical film described above.

Fig. 27F is a graph of coverage of a flat facet core region with a slope greater than 20 degrees.

Fig. 27G is a graph of coverage of a flat facet core region without any slope limitation.

Fig. 27H and 27I are graphs of facet azimuthal and gradient azimuthal distributions.

Fig. 27J is a graph of cumulative facet tilt angle distribution for the optical film described above.

Fig. 27K and 27L are graphs of the magnitude of the gradient of the normalized frequency in%/solid angle in degrees squared.

Fig. 28-36 relate to the same analysis as discussed with respect to fig. 15-22 above, but with a broader curvature constraint.

Fig. 37 is a micrograph of an exemplary optical film as described herein.

Detailed Description

The microstructured film may include microstructures having angled sides to collimate light by refracting light at certain incident angles and reflecting light back into the film at other incident angles for further processing. To promote consistent brightness across the surface of the microstructured film, the microstructures can be patterned to have surfaces oriented at a variety of angles. In some cases, the microstructures can be elongated prismatic microstructures having flat sides angled in opposite directions. For example, two films of elongated prismatic microstructures may be stacked at a perpendicular angle to collimate light along respective uniaxial axes. The surface of the film having these microstructures may be covered by angled sides. However, due to the limited azimuthal distribution of the side angles, the patterned structure of these films may not spatially distribute light uniformly over the entire surface. In other cases, the microstructures may have a circular or elliptical base profile with a radial surface that distributes light in all directions. For example, the microstructures may be spherical lenses or pyramids. However, the circular profile of these circular base microstructures may not substantially cover the surface of the film in which they are used, leaving flat or unstructured areas between the circular base microstructures. In addition, microstructured films having regular microstructure patterns can have negative effects, such as moire effects.

The present disclosure includes an optical film having a micro-structured surface for collimating light. The microstructured surface includes an irregularly distributed plurality of prism structures including a plurality of facets angled with respect to a reference plane of the microstructured surface. While the prism structures may be individually irregular or random, the facets of the prism structures may be sized, angled, and distributed such that the surface azimuthal distribution of the facets may be substantially uniform along the reference plane, while the surface polar angular distribution of the facets may fall substantially within the polar angular range associated with peak transmission of light normally incident to the reference plane. Such a facet distribution can result in a microstructured surface optical profile approximating that of a pyramidal optical profile, such as that of a collection of pyramidal prism structures having an equivalent base angle distribution, while covering substantially the entire major surface with prism structures. The use of an interconnecting facet surface can result in substantially the entire surface of the optical film being covered by the microstructured surface. The irregular distribution of prism structures can reduce the moire effect that occurs in patterned or regular films.

Fig. 1 is an illustration of an optical article 100 including an optical film 110 on a substrate 120. The optical film 110 includes a microstructured surface 111 and a planar major surface 112 that is coupled to a substrate 120. Substrate 120 includes a bottom major surface 121. Light 131 generated by light source 130 can refract through substrate 120 at bottom major surface 121 and exit at microstructured surface 111. Light 131 exiting optical article 100 may be substantially collimated (i.e., exit microstructured surface 111 in a direction substantially perpendicular to bottom major surface 121).

The microstructured surface 111 can be configured to generate collimated light from non-collimated light produced by the light source 130 and processed through the optical article 100. Factors that affect the collimation of light at the microstructured surface 111 can include, for example: the refractive index of optical film 110, the refractive index of the medium contacting microstructured surface 111, and the angle of incident light on microstructured surface 111. Factors that affect the angle of incident light on the microstructured surface 111 can include, for example: the refractive index of the substrate 120, the refractive index of the medium between the bottom major surface 121 of the substrate 120 and the light source 130, and the angle of incident light emitted from the light source 130.

In some examples, optical article 100 may polarize and collimate light from light source 130. As described in further detail below, the optical film 110 can be a collimating film and the substrate 120 can be a reflective polarizer. By combining the collimating optical film described herein with a reflective polarizer, the optical article is operable to increase the degree of collimation and brightness in a single backlight film.

Fig. 2A is an illustration of an optical article 200 (such as the optical article 100 described above), the optical article 200 including an optical film 210 having a microstructured surface 211. The optical article 200 may be used in an optical device that also includes a light source (such as light source 130) and a light gating device (such as a liquid crystal display device). The optical article 200 may be used to direct light from a light source to a light gating device. Examples of light sources include electroluminescent panels, light guide assemblies, and fluorescent or LED backlights. The light source may produce non-collimated light. Depending on the configuration of the microstructured surface 211, the optical article 200 can be used as a brightness enhancement film, a uniformity film, a turning film, or an image directing film (a refracted beam redirection product). The optical system in which the optical article 200 is used may be an optical display, backlight, or similar system, and may include other components, such as a liquid crystal panel and additional polarizers and/or other optical films or components.

Optical film 210 can be attached to substrate 220 at planar major surface 212. In this embodiment, the optical article 200 includes two layers: a substrate 220 and an optical film 210. However, the optical film 210 may have one or more layers. For example, in some cases, the optical article 200 can have only a single layer of the optical film 210, the optical film 210 including the microstructured surface 211 and the bottom major surface 212. In some cases, optical film 200 can have many layers. For example, in some cases, the substrate 220 may be composed of multiple different layers. When the optical article 200 includes multiple layers, the constituent layers can be coextensive with each other, and each pair of adjacent constituent layers includes a tangible optical material and has major surfaces that completely coincide with each other, or are in physical contact with each other over at least 80% or at least 90% of their respective surface areas.

The substrate 220 may have a composition suitable for use in optical products designed to control light flow. Factors and characteristics useful as substrate materials may include sufficient optical clarity and structural strength such that, for example, substrate 220 may be assembled into or used within a particular optical product, and may have sufficient temperature and aging resistance such that the performance of the optical product is not affected over time. The particular chemical composition and thickness of the substrate 220 for any optical product can depend on the requirements of the particular optical product being constructed, for example, balancing the needs for strength, transparency, temperature resistance, surface energy, adhesion to the microstructured surface, the ability to form a microstructured surface, and the like. The substrate 220 may be uniaxially or biaxially oriented.

Substrate materials that may be used for the substrate 220 include, but are not limited to: styrene-acrylonitrile, cellulose acetate butyrate, cellulose acetate propionate, cellulose triacetate, polyethersulfone, polymethylmethacrylate, polyurethane, polyester, polycarbonate, polyvinylchloride, polystyrene, polyethylene naphthalate, a copolymer or blend based on naphthalene dicarboxylic acids, polycycloolefin, polyimide, and glass. Optionally, the substrate material may contain mixtures or combinations of these materials. In one embodiment, the substrate 220 may be multilayered or may contain a dispersed phase suspended or dispersed in a continuous phase. For some optical products, such as brightness enhancing films, examples of desirable substrate materials may include, but are not limited to, polyethylene terephthalate (PET) and polycarbonate.

Some substrate materials may be optically active and may be used as polarizing materials. The polarization of light passing through the film can be achieved, for example, by including a dichroic polarizer in the film material that selectively absorbs passing light, or by including a reflective polarizer in the film material that selectively reflects passing light. Light polarization can also be achieved by including inorganic materials (such as oriented mica platelets) or by a discontinuous phase dispersed in a continuous film (such as droplets of light modulating liquid crystals dispersed in a continuous film). Alternatively, the film may be prepared from ultra-thin layers of different materials. The polarizing material in the film can be oriented in a polarizing orientation, for example, by employing methods such as stretching the film, applying an electric or magnetic field, and coating techniques.

Examples of polarizing films include those described in U.S. Pat. nos. 5,825,543 and 5,783,120, each of which is incorporated herein by reference. The use of these polarizer films in combination with brightness enhancing films is described in U.S. Pat. No. 6,111,696, which is incorporated herein by reference. Second examples of polarizing films useful as substrates are those described in U.S. patent No. 5,882,774, also incorporated herein by reference. Commercially available films are multilayer films sold under the trade name DBEF (reflective polarizing brightness enhancement film) from 3M company. The use of such multilayer polarizing optical films in brightness enhancing films is described in U.S. Pat. No. 5,828,488, which is incorporated herein by reference. The substrates listed herein are not exclusive and other polarizing and non-polarizing films can be used as substrates for the optical products of the present invention, as will be appreciated by those skilled in the art. These substrate materials can be combined with any number of other films (including, for example, polarizing films) to form a multilayer structure. A short list of additional substrate materials may include those films described in U.S. patents 5,612,820 and 5,486,949, among others. The thickness of a particular substrate may also depend on the optical product requirements described above.

In some examples, optical article 200 can be a free-floating film or a backlight film, and substrate 220 can be a reflective polarizer. Optical film 210 can be attached to substrate 220 at bottom major surface 212 with microstructured surface 211 facing a display component, such as a liquid crystal display. Optical film 210 can be "above" substrate 220 in a film stack of a system in which optical article 200 is used relative to the path of light traveling through the system. An optical article 200 having a reflective polarizer and a collimating optical film can provide both collimating and brightness enhancing properties in the same film.

The optical film 210 can directly contact the substrate 220 or be optically aligned with the substrate 220 at the bottom major surface 212 and can have a size, shape, and thickness that allow the microstructured surface 211 to direct or concentrate the flow of light. The optical film 210 may be integrally formed with the substrate 220 or may be formed from one material and attached or laminated to the substrate 220.

Optical film 210 may have any suitable refractive index. Factors for selecting the index of refraction may include, but are not limited to, the direction of light incident into optical film 210, the surface characteristics of microstructured surface 211, and the desired direction of light exiting microstructured surface 211. For example, in some cases, optical film 210 can have a refractive index in a range from about 1.4 to about 1.8, or from about 1.5 to about 1.7. In some cases, optical film 210 may have a refractive index of not less than about 1.5, or not less than about 1.55, or not less than about 1.6, or not less than about 1.65, or not less than about 1.7.

The optical film 210 may have a composition suitable for use in optical products designed to control light flow. Materials that may be used for optical film 10 include, but are not limited to: poly (carbonate) (PC); syndiotactic polystyrene and isotactic Polystyrene (PS); C1-C8 alkylstyrene; alkyl-containing, aromatic-containing, and aliphatic ring-containing (meth) acrylates, including poly (methyl methacrylate) (PMMA) and PMMA copolymers; ethoxylated and propoxylated (meth) acrylates; multifunctional (meth) acrylates; acrylic acid modified epoxy resin; an epoxy resin; and other ethylenically unsaturated materials; cyclic olefins and cyclic olefinic copolymers; acrylonitrile Butadiene Styrene (ABS); styrene-acrylonitrile copolymer (SAN); an epoxy resin; poly (vinylcyclohexane); PMMA/poly (vinyl fluoride) blends; poly (phenylene ether) alloys; a styrene block copolymer; a polyimide; polysulfones; poly (vinyl chloride); poly (dimethylsiloxane) (PDMS); a polyurethane; an unsaturated polyester; poly (ethylene) including low birefringence polyethylene; poly (propylene) (PP); poly (alkyl terephthalates), such as poly (ethylene terephthalate) (PET); poly (alkyl naphthalates), such as poly (ethylene naphthalate) (PEN); a polyamide; an ionomer; vinyl acetate/polyethylene copolymers; cellulose acetate; cellulose acetate butyrate; a fluoropolymer; poly (styrene) -poly (ethylene) copolymers; PET and PEN copolymers, including polyolefinic PET and PEN; and poly (carbonate)/aliphatic PET blends.

Optical film 210 can include a microstructured surface 211. Microstructured surface 211 can represent a structured surface for transmitting substantially collimated light from optical article 200. The microstructured surface 211 can be configured to refract light contacting the microstructured surface 211 at one or more particular ranges of angles of incidence and reflect light outside of these one or more ranges. The one or more ranges may depend on, for example, the refractive index of optical film 210 and any substance (such as air) contacting microstructured surface 211. Fig. 4 is an SEM image of an exemplary optical film, such as optical film 210, having a microstructured surface, such as microstructured surface 211. For reference purposes, the microstructured surface 211 can define a base plane having an x-axis 241 and a y-axis 242 perpendicular to the x-axis 241, and can define a thickness direction along a z-axis 243 perpendicular to the base plane.

The microstructured surface 211 can include a plurality of prism structures 230. The prism structures 230 can represent the configuration of the microstructured surface 211 that characterizes the desired function of the optical film 210 with prism structures 230, such as collimating light. In general, the prism structures 230 are capable of redirecting light by, for example, refracting a portion of the incident light and recycling a different portion of the incident light. The prism structures 230 may be designed to redirect light incident on the facets 231 of the prism structures 230 in a desired direction, such as in the positive z-direction. In some examples, the prism structures 230 may redirect light in a direction substantially parallel to the z-axis 243 and perpendicular to a reference plane formed by the x-axis and the y-axis. The prism structures 230 can cover substantially all of the microstructured surface 211 of the optical film 210, such as greater than 90% of the surface area of the microstructured surface 211.

The prism structures 230 of the microstructured surface 211 may be substantially irregularly or randomly arranged across the microstructured surface 211. The substantially irregular or random arrangement may include a spatial distribution of prism structures 230 across the microstructured surface 211 that is locally unpatterned or irregularly patterned, but may exhibit a particular characteristic, range of characteristics, or likelihood of characteristics in the polymer. For example, as the plurality of prism structures 230 increases, the average characteristics of the plurality of prism structures 230 may exhibit less deviation; however, the first spatial region of the prism structures 230 and the second spatial region of the prism structures 230 may not have similar characteristic distributions.

The discontinuities, such as protrusions, on the microstructured surface 211 of the optical article 200 may be offset in profile from the average centerline through the prism structures 230 such that the sum of the areas encompassed by the surface profile above the centerline is equal to the sum of the areas below the line that is substantially parallel to the (microstructured) collimating surface of the article. The height of the prism structures 230, as measured by optical or electron microscopy, can be about 0.2 to 100 microns over a representative characteristic length of the surface (e.g., 1cm-30 cm). The average centerline may be planar, concave, convex, non-spherical, or a combination thereof. The prism structures 230 may have a pitch defined as the farthest distance between two intersecting facets. The pitch of the prism structures 230 may not exceed 250 microns and may vary from 0 microns (cross) to 250 microns. The pitch may be related to factors such as the base angle 233 of the facets 231 on the prism structures 230 and the height of the prism structures 230. In some examples, the height and spacing may be selected to mitigate sparkle. Sparkle refers to an optical artifact that appears as a grainy texture (texture unevenness) consisting of small areas of bright and dark brightness that appear as a random pattern. The position of the bright and dark regions may vary with the viewing angle, making the texture particularly noticeable and objectionable to a viewer. To minimize sparkle, the prismatic structures 230 may have a height of less than about 100 microns and preferably less than 20 microns-30 microns, may have very little periodicity, may not form microimages of adjacent structures, or any combination of these properties.

The plurality of prism structures 230 may include a plurality of facets 231. Each prism structure 230 may include a plurality of facets 231 that intersect at a peak 237. Each facet 231 may represent a surface of the prism structure 230 and the microstructured surface 211 that defines at least one degree of tilt relative to a reference plane formed by the x-axis 241 and the y-axis 242, each facet 231 and the corresponding degree of tilt forming a non-zero base angle 233.

At least one slope of the plurality of facets 231 may define a slope magnitude distribution and a slope magnitude cumulative distribution. The slope magnitude distribution may represent a normalized frequency of the slope angle (such as the base angle 233). The slope magnitude cumulative distribution can represent the cumulative normalized frequency of the slope angles (such as base angle 233) for each degree on the microstructured surface 211. The cumulative slope magnitude distribution may include a rate of change representing a change in the cumulative normalized frequency of the slope angles. In some examples, the rate of change of the slope magnitude cumulative distribution of slopes less than about 10 degrees may be less than about 1%/degree, while the rate of change of the slope magnitude cumulative distribution of slopes less than about 30 degrees may be less than about 2%/degree. See, e.g., fig. 27A. In some examples, the rate of change of the slope magnitude cumulative distribution at 20% may be substantially less than the rate of change of the slope magnitude cumulative distribution around 60 degrees. See, e.g., fig. 27D. In some examples, the rate of change of the slope magnitude cumulative distribution may be less than about 0.5%/degree around 10 degrees, and the rate of change of the slope magnitude cumulative distribution may be less than about 1%/degree around 20 degrees. See, e.g., fig. 27B.

The microstructured surface 211 can define a plurality of slopes relative to a reference plane. In some examples, about 10% of the microstructured surface has a slope of less than about 10 degrees and about 15% of the microstructured surface has a slope of greater than about 60 degrees. See, e.g., fig. 27A. In some examples, about 80% of the structured surface has a slope of between about 30 degrees and about 60 degrees. See, e.g., fig. 27A.

Each facet 231 may have a surface area and a facet normal direction representing an average surface direction of the facet 231. The surface area of each facet 231 may represent an area through which light passing through the optical film 210 may contact the facet and be refracted at a lower angle of incidence or reflected at a higher angle of incidence. In examples where the facets 231 are curved, the facet normal direction may be the normal direction of an average degree of curvature, a tangent to a curvature, a plane across the peak of the facet 231, or other functional surface representing the average refractive surface of the facet 231.

The facets 231 may cover substantially all of the microstructured surface 211. In some examples, facets 231 may cover greater than 90% of microstructured surface 211. The surface coverage of the microstructured surface 211 may be expressed as a microstructured surface percentage per cube angle in degrees squared for a particular gradient size range or limit. In some examples, less than 0.010%/cube corner in square of microstructured surface 211 has a gradient magnitude of about 10 degrees, while less than 0.008%/cube corner in square of microstructured surface 211 has a gradient magnitude of about 30 degrees. See, e.g., fig. 27K. In some examples, less than about 0.008%/cube angle in square degrees of microstructured surface 211 has a gradient magnitude of about 10 degrees, while less than 0.007%/cube angle in square degrees of microstructured surface has a gradient magnitude of about 30 degrees. In some examples, the microstructured surface 211 with a gradient size of about zero per cube angle in degrees squared is about 0.0005% to about 0.01%. In some examples, the microstructured surface 211 with a gradient magnitude of about zero per solid angle in degrees squared is about 0.001% to about 0.006%. In some examples, less than about 0.010%/cube corner in square degrees of microstructured surface 211 has a gradient magnitude of less than about 10 degrees, and greater than about 0.008%/cube corner in square degrees of microstructured surface 211 has a gradient magnitude of about 50 degrees. See, e.g., fig. 27L. In some examples, such as examples in which the percent planar portion of the microstructured surface is greater than about 10%, less than 0.010% of the structured surface per cube corner in square has a gradient magnitude of about 10 degrees.

A sub-plurality of the plurality of prism structures 230 may include facets 231 having a substantially planar central portion surrounded by a substantially curved peripheral portion. In some examples, less than about 20% of the planar central portion of the facets have a slope of less than about 40 degrees and less than about 10% of the structured surface 211 has a slope of less than about 20 degrees.

The facets 231 may be substantially planar. The substantial flatness may be represented or determined by, for example, a radius of curvature or an average curvature of the flat facets 231 (such as a radius of curvature ten times as large as the average height of the prism structures 230). In some examples, certain portions (such as greater than 30%) of the facets 231 of the microstructured surface 211 can be substantially flat.

The plurality of prism structures 230 may include a plurality of peaks 237 formed at the intersection of two facets 231. The two facets 231 forming the peak 237 may have an associated apex angle 232. Each peak 237 may have an associated radius of curvature that represents the angular sharpness of the peak. For example, the peaks 237 may have a radius of curvature that is less than one tenth of the average height of the prism structures 230. The peaks 237 may be substantially defined or sharp such that the surface area of the peaks 237 does not contribute significantly to the microstructured surface 211. In some examples, the surface area of the plurality of peaks 237 is less than 1% of the total surface area of microstructured surface 211. Microstructured surface 211 with defined peaks 237 can increase the surface area of facets 231, increase the optical gain for a desired transmission range transmitted from optical film 210, and reduce the paraxial transmission angle due to wet-out.

Fig. 2B is an illustration of a top view of facets 231 of prism structures 230. The facet normal direction 234 may form an azimuthal angle 235 with an x-axis 241 (as shown) or a y-axis 242. Azimuth 235 may represent the orientation of facet 231 along a reference plane formed by x-axis 241 and y-axis 242. Facet 231 may be oriented within a substantially omnidirectional angular range (such as 0 to 2 pi radians) at azimuth 235.

Fig. 2C is an illustration of a side view of the planar face 231 of the prism structure 230. The facet normal direction 234 may form a polar angle 236 with the z-axis 243. Azimuth angle 236 may represent the orientation of planar facet 231 normal to a reference plane formed by x-axis 241 and y-axis 242. The face 231 may be oriented within substantially a full polar angle quadrant of the polar angle 236, such as 0 to pi/2 radians.

Microstructured surface 211 can have a surface normal distribution of facets 231. The surface normal distribution of a facet may represent the normal distribution of the facet 231, such as the probability or concentration of the facet 231 having a particular polar 235 or azimuthal 236 angle. The surface normal distribution of the facet 231 includes a surface polar angle distribution of the facet 231 and a surface azimuthal angle distribution of the facet 231.

The surface polar angle distribution represents a normal distribution of the facet 231 at a particular polar angle 236. In some examples, the surface polar angle distribution may be expressed as a percentage of facets within a range of polar angles. For example, substantially all (such as greater than 90%) of the facets 231 may have a polar angle within a particular range of polar angles. The particular polar angle range may include a polar angle range that produces substantially collimated light, such as within five degrees of the z-axis 243. In some examples, substantially all of the facets 231 may have a polar angle 236 of approximately 45 degrees, such as 90% of the facets 231 having a polar angle 236 between 40 degrees and 50 degrees. In some examples, the surface polar angle distribution may be represented as a probability of a flat facet 231 having a particular polar angle 236.

The surface polar angle distribution of the plurality of facets 231 may include a peak polar angle distribution associated with a polar angle or polar angle range representing the peak distribution of the plurality of facets 231. The peak pole distribution may be off-axis; that is, the peak polar angle distribution can be substantially non-perpendicular to the reference plane of microstructured surface 211. In some examples, the surface polar angle distribution has an off-axis peak polar angle distribution that is at least twice as high as the on-axis polar angle distribution.

Prism structures 230 can be distributed across optical film 210, and their facets oriented across microstructured surface 211 such that the surface polar angle distribution of the facets increases the optical gain of optical film 210 for a particular polar angle range. In some examples, the surface polar angle distribution may be configured to form a polar angle transmission distribution, where the polar angle transmission distribution expresses the transmission of axially collimated light through the microstructured surface 211 as an intensity distribution within a polar angle of 0 to pi/2. The polar angle transmission distribution can be correlated to the collimated light transmission characteristics of the polymerized cone microstructure. For example, at a particular refractive index, the pyramidal microstructures can distribute light having a peak brightness at a particular polar angle, and the peak brightness can be a particular ratio that is higher (such as twice as high) than the on-axis polar angle transmission. The surface polar angle distribution of the microstructured surface 211 can include substantially all facets within a polar angle range that generate collimated light from light at a particular incident angle associated with peak brightness. In some examples, the polar angle range is selected for peak brightness of light with an incident angle between 32 and 38 degrees. Facets 231 may be oriented within a range of polar angles 236 (such as 30 to 60 degrees) such that light transmitted from microstructured surface 211 is substantially collimated.

The surface polar angle distribution of the facets 231 may have peaks

The surface azimuth distribution represents the distribution of facets 231 at a particular polar angle. For example, at high sample capacities, 1/360 for substantially all flat facets, such as between 0.1% and 0.5%, or between 0.25% and 0.3%, may have azimuth angles between particular angles. The prism structures 230 can be distributed across the optical film 210 and their flat facets oriented across the microstructured surface 211 such that the surface azimuthal distribution of facets 231 can produce a uniform azimuthal transmission distribution, where azimuthal transmission distribution represents the transmission of light through the microstructured surface 211 at an azimuthal angle. The azimuthal transmission of light may be correlated to the collimated light transmission characteristics of the polymerized pyramidal microstructures. For example, a pyramidal microstructure can distribute light uniformly across an omnidirectional angular range. The surface azimuthal distribution of the facets 231 may be uniform within a particular angular resolution across the full 360 degrees. In some examples, the angular resolution is selected based on manufacturing accuracy. The aggregate surface area or number of facets 231 may be substantially the same for each azimuth angle 235, and the azimuth angles 235 may generally be rotationally symmetric. In some examples, at a particular facet 231 sample volume or resolution (such as greater than 10,000 flat facets), the aggregate surface area and number of facets 231 may be evaluated to be substantially the same, as there may be local variations in azimuth 235.

While the prism structures 230 may be irregularly distributed and oriented across the optical film 210, the polymerization of the flat facets 231 of the prism structures 230 results in a microstructured surface 211 having a surface area that is uniformly distributed over an omnidirectional angular range on a reference plane to uniformly distribute light and having a limited polar angular range to substantially collimate light.

FIG. 3 illustrates an exemplary process 300 for forming an optical film, such as optical film 210. Prior to fabricating the optical film, a microreplication tool can be created that has structured surface characteristics that correspond to the microstructured surface of the optical film, such as microstructured surface 211. Alternatively, a microreplication tool having a structured surface characteristic corresponding to the microstructured surface of the optical film can be provided or selected based on the desired microstructured surface of the optical film.

In step 310, a substrate may be provided to serve as a foundation upon which a metal layer may be electroplated. The substrate may take one of a variety of forms (e.g., sheet, plate, or cylinder). For example, a cylinder may be used to produce a continuous roll of product. The substrate may be made of metal, and exemplary metals include nickel, copper, and brass; however, other metals may also be used. The substrate may have an exposed surface ("substrate surface") upon which one or more electrodeposited layers may be formed in subsequent steps. The substrate surface may be smooth and flat, or substantially flat. The curved outer surface of a smooth polished cylinder can be considered substantially flat, particularly when considering a small local area near any given point on the surface of the cylinder.

In step 320, plating conditions for plating the surface of the substrate may be selected. The composition of the electroplating solution (such as the type of metal salt used in the solution) as well as other process parameters (such as current density, plating time, and substrate movement speed) may be selected such that the electroplated layer is not formed to be smooth and planar, but rather has a major surface that is structured and characterized by irregular, planar faceted features, such as features corresponding to the desired prism structures 230. The choice of current density, plating time, and base exposure (such as substrate travel speed) can determine the size and density of the irregular features. The selection of a metal template (such as the type of metal salt used in the electroplating solution) may determine the geometry of the feature. For example, the type of metal salt used in the electroplating process may determine the geometry of the deposited metal structures, and thus, the shape of the prism structures (such as prism structures 230) on the microstructured surface (such as microstructured surface 211).

In step 330, a metal layer may be formed on the base surface of the substrate using an electroplating process. Before this step begins, the base surface of the substrate may be primed or otherwise treated to promote adhesion. The metal to be electroplated may be substantially the same as the metal comprising the surface of the substrate. For example, the electroplated layer formed in step 330 may also be made of copper if the substrate surface comprises copper. To form the metal layer, the electroplating process may use an electroplating solution. The electroplating process can be performed such that the surface of the electroplated layer has a microstructured surface with irregular surfaces corresponding to microstructured surface 211. The metal may not adhere uniformly to the microstructured surface of the roll, forming ridges. The microstructured surface of the optical film replicates peaks or valleys, etc. relative to the microstructured surface of the roll. The location and arrangement of the deposited metal structures on the microstructured roll is random. The structured features and roughness of a representative first major surface can be seen in the SEM image of the optical film of fig. 36, which was microreplicated from the surface of the electroplated layer made according to step 330.

After completing step 330, the substrate having one or more electroplated layers may be used as an original tool to form the optical diffusion film. In some cases, the structured surface of the tool (which may include the structured surface of the electroplated layer or layers generated in step 330) may be passivated or otherwise protected with a second metal or other suitable material. For example, if one or more of the electroplated layers consists of copper, the structured surface may be electroplated with a thin coating of chromium. The thin coating of chromium or other suitable material is preferably thin enough to substantially preserve the topography of the structured surface.

One or more replica tools can be made by microreplicating the structured surface of the original tool, and then one or more replica tools can be used to make the optical film, rather than using the original tool itself to make the optical diffuser film. A first replica made from the original tool will have a first replica structured surface that corresponds to the structured surface but is an inverted version of the structured surface. For example, the protrusions in the structured surface correspond to cavities in the first replica structured surface. A second replica can be made from the first replica. The second replica will have a second replica structured surface that corresponds to the structured surface of the original tool and is a non-inverted version of the structured surface.

After the structured surface tool is made, for example, in step 330, an optical film (e.g., optical film 210) having the same structured surface (whether inverted or not with respect to the original tool) can be made in step 340 by microreplication from the original tool or a replica tool. The optical film may be formed from the tool using any suitable process including, for example, embossing a preformed film, or casting and curing a curable layer on a carrier film. For example, the optical film 210 having the microstructured surface 211 can be prepared by: (a) preparing a polymerizable composition; (b) depositing a polymerizable composition onto the master negative structured surface of the structured surface tool formed in step 330 in an amount sufficient to fill the cavities of the master; (c) filling the cavity by moving a bead of polymerizable composition between a substrate (such as substrate 220) and a master; and (d) curing the polymerizable composition. In the above embodiments, the optical film 210 and the substrate 220 may be separate layers that are bonded together. Another method may include replicating the mold directly onto an extruded or cast substrate material, resulting in a monolithic substrate 220 and optical film 210.

Examples

Light transmission characterization

Samples (sample 1, sample 2, and sample 3) of the optical films according to the present disclosure were fabricated according to the techniques described herein (including fig. 3 described above). The tool was made using a method similar to that disclosed in U.S. patent application 2010/0302479 entitled Optical Article. Optical films are made using a tool through a casting and curing process such as described in U.S. patent 5,175,030. The resin used in the casting and curing process is a resin suitable for optical use. Comparative examples of optical films having (1) pyramidal hexagonal packing arrays, (2) prismatic waffle grids, (3) partial sphere packing arrays, and (4) irregular prisms with rounded peaks are also provided.

The optical films are tested with collimated light transmission probes to determine optical properties of the optical films, such as polar angle transmission profiles and azimuthal angle transmission profiles. FIG. 4 is an exemplary method for producing light transmission information for an optical film by collimated light transmission. An optical probe with axially collimated LED light was placed in front of the microstructured surface of the optical film and aligned to a polar and azimuthal angle of 0 degrees. The detector is placed behind the flat major surface of the optical film. Axially collimated light from the light probe is processed through the optical film and the angular scattering of the source light due to the structured surface of the optical film is measured on a detector. The base angles of the facets of the microstructured surface can be determined using collimated light transmission, the base angles corresponding to the polar angle range of the surface polar angle distribution of the microstructured surface.

Surface characterization

Four samples (sample 6A/B, sample 7A/B, sample 8, and sample 9) of optical films according to the present disclosure were made according to the techniques described herein (including fig. 3 and examples 1-3 above). The invention also provides the following comparative examples: (1) optical films having irregular prisms with rounded peaks, (2) optical films having a hexagonal packing array of pyramids, (3) optical films having a partial sphere packing array, and (4) optical films having an array of pyramidal prisms. AFM images of the samples were taken and used for image analysis, as will be described below.

AFM images were analyzed for flatness and angular orientation. Code is written to add facet analysis functionality to the inclination analysis tool. The facet analysis function is configured for identifying a core area of the facet for analyzing the flatness and orientation of the facet of the sample. The pre-filter height map is chosen to minimize noise (e.g., medium 3 for AFM and fourier low pass for confocal microscopy) and the height map is shifted so that zero height is the average height.

The gCURVATURE and tcURVATURE are computed at each pixel. The gcurvature at the pixel is to use the following three points: surface curvatures calculated in the gradient direction for the height of Z (x, y), Z (x-dx, y-dy), and Z (x + dx, y + dy), where (dx, dy) is parallel to the gradient vector and the magnitude of (dx, dy) is Sk/Skdivosor, where Sk is the core roughness depth and Skdivosor is a unitless parameter set by the user. The size of (dx, dy) may be rounded to the nearest pixel and set to a minimum value, such as 3 pixels. tcurvature is the same as gcurvature except that the curvature is calculated using a direction transverse to the gradient rather than parallel to the gradient.

A binary map of the flat facets is obtained using the threshold value for each pixel. These thresholds include: (1) max (gcurvature) < rel _ curvecutoff/R, where R ═ min (crosslinking _ period)/2, and crosslinking _ period and ycrossing _ period are average distances between zero-crossing points in the x and y directions, respectively; and (2) gslope < facetslope _ cutoff.

Image processing steps may be applied to clean the binary image. The image processing step may include: etching, removing facets smaller than N pixels, dilation twice, etching, where N ceil (r minfacetcoeff) pixels, r is the size of (dx, dy) in pixels, and ceil is a function rounded to the nearest integer. An image is then generated and the statistics and distribution of the facet regions are calculated.

Examples 1, 2 and 3

Fig. 5A, 6A, and 7A are conoscopic plots of light intensity at polar and azimuthal angles for samples 1, 2, and 3, respectively, of the optical films disclosed herein. Each sample showed an off-axis and centered polar transmission profile over a range of polar angles, as well as an azimuthal transmission profile that was substantially uniform over the entire range.

Fig. 5B, 6B, and 7B are graphs of the average polar angle slope (x-axis) of the normalized polar angle transmission profile (y-axis). As observed in fig. 5B, 6B, and 7B, for the three samples, each sample had a concentrated polar angle range of peak polar angle transmission angles and polar angles. It is also reported as the ratio of the peak polar angle transmission angle to the on-axis (0 degree) polar angle. Significant peak polar angle transmission angles and high ratios of peak polar angle transmission to on-axis polar angle transmission may indicate a cone transmission profile and may be correlated with a substantially uniform surface azimuthal distribution of facets and a concentrated off-axis surface polar angle distribution of facets.

Comparative example 1 pyramidal hexagonal packing array

FIG. 8A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film with a pyramidal hexagonal packing array. Each cone may have curved sides and a hexagonal base and may be arranged in a patterned array, such as the patterned array of fig. 19. High relative brightness at certain azimuths indicates a non-uniform azimuthal transmission distribution associated with a non-uniform surface azimuthal distribution, such as patterned hexagonal peaks of pyramids. Fig. 8B is a graph of the average polar angle slope (x-axis) of the normalized polar angle transmission profile (y-axis). The samples have highly concentrated polar angle transmission profiles and very high peak polar transmission angles relative to the on-axis polar angle.

Comparative example 2 prism grid

FIG. 9A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film having a prismatic waffle-like grid. Each planar prismatic face may be oriented at one of four right angles. High relative brightness at certain azimuthal angles indicates a non-uniform azimuthal transmission distribution associated with a non-uniform azimuthal distribution, such as four right angles of a prism. Fig. 9B is a graph of the average polar angle slope (x-axis) of the normalized polar angle transmission profile (y-axis). Multiple peak polar transmission angles indicate non-uniform prism surfaces, while high on-axis polar angles indicate surfaces that are fairly flat or rounded at the prism apex.

Comparative example 3 partial sphere

FIG. 10A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film with an array of partial spheres. Each partial sphere may include rounded sides having a high on-axis polar angle component. Fig. 10B is a graph of the average polar angle slope (x-axis) of the normalized polar angle transmission profile (y-axis). The sample had a high on-axis polar transmission profile.

Comparative example 4 rounded irregular prism

Fig. 11A is a conoscopic plot of light intensity at polar and azimuthal angles for a sample optical film having irregular prisms with rounded peaks. The irregular prisms may have curved sides that meet at rounded peaks, such as in fig. 18A and 18B. FIG. 11B is a graph of the average polar tilt (x-axis) of the normalized polar angle transmission profile (y-axis). The peak polar angle transmission angle of the sample is close to the on-axis transmission angle, and a low ratio of peak polar angle transmission to on-axis polar angle transmission may indicate rounded peaks between prism surfaces.

Example 4

A fourth sample film (sample 4) as disclosed herein was prepared according to fig. 3 and the method described above. Fig. 12A is a conoscopic representation of confocal tilt data for polar and azimuthal angles of a sample optical film. In this embodiment, the polar and azimuthal angles may be related to the polar and azimuthal angles, respectively, of the planar facets of the optical film. As seen in fig. 12A, the slope distribution is highest at a particular polar angle range and is substantially evenly distributed across the azimuthal range. The peak polar angular distribution angle is substantially constant across azimuth. Fig. 12B is a graph of tilt frequency (y-axis) versus polar angle (x-axis). The polar angle distributions of the respective opposite azimuths are substantially correlated, thereby indicating a substantially uniform azimuthal distribution.

Example 5

The optical cone structure is modeled for determining optical characteristics of the optical cone structure. The optical cone structure simulates, for example, refraction and fresnel reflection at the surface of the optical cone structure. FIG. 13 is a table of modeled cone gain versus various cone structure parameters. The plurality of cones is modeled for evaluating cone gain versus cone structure parameters relative to gain obtained in the optical film. Factors that vary across the cone include, for example, the structural index (index), the protrusion surface fraction, the protrusion aspect ratio (height versus radius), and the surface roughness, which is characterized by the width of the gaussian distribution of the surface normal relative to the surface normal of the geometric cone. Fig. 14A is a chart showing light intensity at polar angles relative to a planar major surface of an inverted pyramidal structure and azimuthal angles along a major surface of the pyramidal structure.

The optical properties of a sample of the optical film (sample 5) were compared to the optical properties of the pyramidal structure model. Fig. 14B is a graph of normalized luminance for the range of surface polar angles for sample 5 and the simulated pyramidal structures. As seen in fig. 14A, the polar angle plot of the brightness of the optical film has an azimuthally smooth appearance. As also seen in fig. 13 and 14B, the collimated light optical transmission characteristics (such as measured optical gain) of the optical film are substantially comparable to the collimated light optical transmission characteristics (such as simulated optical gain) of the simulated pyramidal structures.

Examples 6 to 9 and comparative examples 5 to 8

Fig. 15A and 15B are composite AFM images of samples 6A and 6B, respectively, including the above facet analysis. Fig. 16A and 16B are composite AFM images of samples 7A and 7B, respectively, including the above facet analysis. Fig. 17A is a composite AFM image of sample 8 including the facet analysis described above. Fig. 17B is a composite AFM image of sample 9 including the facet analysis described above. Fig. 18A and 18B are composite AFM images of optical films having irregular prisms with rounded peaks including facet analysis described above. FIG. 19 is a composite AFM image of an optical film with a pyramidal hexagonal packing array including facet analysis described above. FIG. 20 is a composite AFM image of an optical film with a partially sphere packed array including facet analysis described above. The contour may represent a faceted surface within the curvature parameters. FIG. 21 is a composite AFM image of an optical film with an array of pyramidal prisms including the facet analysis described above. The contour may represent a faceted surface within the curvature parameters.

FIG. 22 is a graph of coverage area as a percentage of total surface area for a flat faceted core region for six optical film examples. Samples 6-9 exhibited significantly higher surface area coverage than the irregular prismatic, partially spherical, and hexagonal pyramidal optical films.

Fig. 23A and 23B are graphs of power spectral density versus spatial frequency along two orthogonal in-plane directions (y and x, respectively). The film topography can be defined relative to a reference plane along which each optical film extends. Using the x, y plane as a reference plane, the topography of each structured surface can be described as the height relative to the reference plane for the x and y components. Fig. 23A and 23B show the degree of spatial irregularity or randomness of the prism structure on the surface of each optical film. As seen in fig. 23A and 23B, both the x-average and y-average power spectral densities steadily decrease as the x-direction and y-direction spatial frequencies of samples 6A/B and 7A/B, respectively, of the present disclosure decrease. In contrast, optical films with pyramidal prisms exhibit high periodicity and patterning, as do optical films with hexagonal packed array cones, as observed by multiple and high peaks in power spectral density.

Fig. 24A is a graph of facet azimuthal distribution of an optical film, the facet azimuthal distribution indicating surface area coverage of the facet portion at various azimuthal angles. FIG. 24B is a graph of a gradient azimuthal distribution of a flat-faceted optical film, the gradient azimuthal distribution representing surface area coverage of the gradient portion at various azimuthal angles. Each graph plots percent coverage of the film at periodic azimuth angles. As seen in fig. 24A, both the pyramidal prisms and the hexagonal pyramids exhibited non-uniform azimuthal distributions of the facet portions, whereas the optical films of the present disclosure exhibited coverage over a narrower range. As seen in both fig. 24A and 24B, the two optical films of the present disclosure exhibit a substantially uniform azimuthal distribution of the faceted surfaces throughout the azimuthal range with little local variation in surface coverage.

Fig. 25A-25B are two-dimensional distribution plots of gradient/facet distributions based on AFM data from optical films of the present disclosure. Fig. 26D and 26A-26C are two-dimensional distribution plots of gradient/facet distribution of AFM data based on optical films having irregular prisms (26D), partial spheres (26A), hexagonal pyramids (26B), and pyramidal prisms (26C). For each figure, the x-axis is the x-direction slope and the y-axis is the y-direction slope. The arctangent of the slope is taken to obtain the slope angle in degrees. Each concentric ring represents 10 degrees. As seen in fig. 25A and 25B, the optical films of the present disclosure exhibit a uniform surface azimuthal distribution and an off-axis, concentrated surface polar angular distribution, similar to that shown in the conoscopic plots of examples 1-3 above and generally related to azimuthal and polar angular transmission distributions. In contrast, fig. 26D shows the distribution of surface polar angles closer to the polar angle on the axis. Fig. 26A shows a polar angle distribution of the diffusion surface with a high on-axis concentration. Fig. 26B shows a highly concentrated surface polar angle distribution. FIG. 26C shows a non-uniform surface azimuthal distribution.

Fig. 27C is a graph showing a cumulative facet slope magnitude distribution of the optical film. Samples 6-9 had a more compact gradient size distribution compared to other optical films.

FIG. 27D is a plot of facet tilt angle distributions of tilt angle versus normalized frequency for sample 6, sample 7, and irregular prisms. The irregular prisms have a bimodal slope angle distribution, while samples 6 and 7 have a significant peak distribution.

Fig. 27E is a graph of the gradient magnitude cumulative distribution of the optical film described above. Samples 6-9 have a higher gradient size than part of the sphere and irregular prisms.

Fig. 27F is a graph of coverage of a flat facet core region with a slope greater than 20 degrees. Samples 6-9 have significantly higher coverage of flat facets with slopes greater than 20 degrees compared to hexagonal pyramids, partial spheres, and irregular prisms.

Fig. 27G is a graph of coverage of a flat facet core region without any slope limitation. Samples 6-9 have significantly higher coverage of flat facets with a degree of tilt greater than 20 degrees compared to hexagonal pyramids, partial spheres, and irregular prisms.

Fig. 27H and 27I are graphs of facet azimuthal and gradient azimuthal distributions. Samples 6 and 7 show a substantially uniform azimuthal slope distribution over the entire azimuthal range.

Fig. 27J is a graph of cumulative facet tilt angle distribution for the optical film described above. Samples 6 and 7 have a more compact tilt angle (or gradient size) distribution than the irregular prisms.

Fig. 27K and 27L are graphs of the magnitude of the gradient of the normalized frequency in%/solid angle in degrees squared. For the gradient size between 35 and 65, samples 6-9 had high surface coverage as indicated by the high%/solid angle in degrees squared.

Fig. 28-36 relate to the same analysis as discussed above with respect to fig. 15-22, but with a broader curvature constraint.

Examples 10 and 11

Fig. 27A is a graph of the cumulative distribution of gradient sizes for the optical film disclosed in sample 10, the optical film disclosed in sample 11, and the irregular prismatic optical film. In this embodiment, the irregular prism optics may have a lower slope than either of samples 10 and 11. FIG. 27B is a graph of the gradient size distribution of sample 10, sample 11, and irregular prism optical film. The peak gradient normalized frequency is at a lower gradient magnitude.

Various embodiments of the present invention have been described. These and other embodiments are within the scope of the following claims.