Abstract: A method for making wire grid optical elements by preferentially depositing material on a substrate is disclosed. Material can be preferentially deposited by directing an electromagnetic interference pattern on to a substrate to selectively heat areas of the substrate coincident with the interference pattern maxima. The substrate can then be exposed to gas phase material that is capable of preferentially accumulating on surfaces based on surface temperature.

Abstract: A curable slurry for forming ceramic microstructures on a substrate using a mold. The slurry is a mixture of a ceramic powder, a fugitive binder, and a diluent. The ceramic powder has a low softening temperature in a range of about 400° C. to 600° C. and a coefficient of thermal expansion closely matched to that of the substrate. The fugitive binder is capable of radiation curing, electron beam curing, or thermal curing. The diluent promotes release properties with the mold after curing the binder or quick and complete burn out of the binder during debinding.

Abstract: A retroreflective article that has a layer of optical elements and a multilayer reflective coating disposed on the optical elements. The reflective coating reflects light back into the optical elements so that it can be returned toward the light source. The multilayer reflective coating has multiple polymer layers and has layers that possess different refractive indices.

Abstract: An apparatus for molding and aligning microstructures on a patterned substrate using a microstructured mold. A slurry containing a mixture of a ceramic powder and a curable fugitive binder is placed between the microstructure of a stretchable mold and a patterned substrate. The mold can be stretched to align the microstructure of the mold with a predetermined portion of the patterned substrate. The slurry is hardened between the mold and the substrate. The mold is then removed to leave microstructures adhered to the substrate and aligned with the pattern of the substrate. The microstructures can be thermally heated to remove the binder and optimally fired to sinter the ceramic powder.

Abstract: A molding composition is provided that includes an inorganic component, an organic binder component, and a debinding catalyst. The molding composition is capable of lowering the sintering temperature, for example, when the molding composition is used to make ceramic microstructures such as barrier ribs for plasma display panels.

Abstract: Birefringent optical films have a Brewster angle (the angle at which reflectance of p-polarized light goes to zero) which is very large or is nonexistent. This allows for the construction of multilayer mirrors and polarizers whose reflectivity for p-polarized light decreases slowly with angle of incidence, are independent of angle of incidence, or increase with angle of incidence away from the normal. As a result, multilayer films having high reflectivity (for both planes of polarization for any incident direction in the case of mirrors, and for the selected direction in the case of polarizers) over a wide bandwidth, can be achieved.

Abstract: Disclosed are thermal transfer elements and processes for patterning organic materials for electronic devices onto patterned substrates. These donor elements and methods are particularly suited for making organic electroluminescent devices and displays. The donor elements can include a substrate, and optional light-to-heat conversion layer, and a single or multicomponent transfer layer that can be imagewise transferred to a receptor to form an organic electroluminescent device, portions thereof, or components therefor, The methods offer advantages over conventional patterning techniques such as photolithography, and make it possible to fabricate new organic electroluminescent device constructions.

Abstract: Disclosed are thermal transfer elements and processes for patterning solvent-coated layers and solvent-susceptible layers onto the same receptor substrate. These donor elements and methods are particularly suited for making organic electroluminescent devices and displays. The donor elements can include a substrate, an optional light-to-heat conversion layer, and a single or multicomponent transfer layer that can be imagewise transferred to a receptor to form an organic electroluminescent device, portions thereof, or components therefor. The methods offer advantages over conventional patterning techniques such as photolithography, and make it possible to fabricate new organic electroluminescent device constructions.

Abstract: A thermal transfer donor element is disclosed that includes a substrate, a transfer layer, a light-to-heat conversion layer disposed between the substrate and the transfer layer, and an underlayer disposed between the substrate and the light-to-heat conversion layer. The underlayer manages heat flow between layers of the donor element during imaging. For example, the underlayer can increase heat transport from the light-to-heat conversion layer to the substrate to prevent overheating. The underlayer can also be used to insulate the substrate from heat generated in the light-to-heat conversion layer or to increase heat flow to the transfer layer during imaging. Managing heat flow using an underlayer can improve transfer properties and/or reduce defect formation during imaging.

Abstract: A thermal transfer donor element is provided which comprises a support, a light-to-heat conversion layer, an interlayer, and a thermal transfer layer. When the above donor element is brought into contact with a receptor and imagewise irradiated, an image is obtained which is free from contamination by the light-to-heat conversion layer. The construction and process of this invention is useful in making colored images including applications such as color proofs and color filter elements.

Abstract: A thermal transfer element for forming a multilayer device may include a substrate and a multicomponent transfer unit that, when transferred to a receptor, is configured and arranged to form a first operational layer and a second operational layer of a multilayer device. In at least some instances, the thermal transfer element also includes a light-to-heat conversion (LTHC) layer that can convert light energy to heat energy to transfer the multicomponent transfer unit. Transferring the multicomponent transfer unit to the receptor may include contacting a receptor with a thermal transfer element having a substrate and a multicomponent transfer unit. Then, the thermal transfer element is selectively heated to transfer the multicomponent transfer unit to the receptor according to a pattern to form at least first and second operational layers of a device.

Abstract: A transflector is described which increases efficiency and brightness under both ambient and supplemental lighting conditions in visual display applications. In one embodiment, the transflector includes a reflective polarizing element that reflects one polarization of light and transmits the other. In an alternate embodiment, the transflector includes a reflective polarizing element and a diffusing element such that the transflector diffusely reflects light of one polarization and transmits the other. The transflector is useful for both reflective and transflective liquid crystal displays.

Abstract: Diffusely reflective articles manufactured from optical bodies including continuous and disperse phases are disclosed along with methods of manufacturing such articles. Also disclosed are underdrawn continuous/disperse phase optical bodies that are particularly well-suited to post-forming operations. The articles, methods and optical bodies of the present invention preferably allow for post-forming of the optical bodies while retaining desired levels of diffuse reflectivity in the articles formed from the optical bodies.

Abstract: A method for molding and aligning microstructures on a patterned substrate using a microstructured mold. A slurry containing a mixture of a ceramic powder and a curable fugitive binder is placed between the microstructure of a stretchable mold and a patterned substrate. The mold can be stretched to align the microstructure of the mold with a predetermined portion of the patterned substrate. The slurry is hardened between the mold and the substrate. The mold is then removed to leave microstructures adhered to the substrate and aligned with the pattern of the substrate. The microstructures can be thermally heated to remove the binder and optimally fired to sinter the ceramic powder.

Abstract: A retroreflective article that has a layer of optical elements and a multilayer reflective coating disposed on the optical elements. The reflective coating reflects light back into the optical elements so that it can be returned toward the light source. The multilayer reflective coating has multiple polymer layers and has layers that possess different refractive indices.

Abstract: The present invention provides a thermal transfer donor element that includes a transfer layer comprising a fully or partially crosslinked material. The crosslinked transfer layer can be imagewise transferred from the donor element to a proximate receptor by imaging the donor element with radiation that can be absorbed and converted into heat by a light-to-heat converter included in the donor element. The heat generated during imaging is sufficient to effect transfer of the crosslinked transfer layer.

Abstract: A thermal mass transfer donor element is provided that includes a thermal transfer layer and a light-to-heat conversion layer, wherein the light-to-heat conversion layer has at least two regions exhibiting different absorption coefficients. The thermal transfer donor elements provided can improve imaging performance by increasing transfer sensitivity and decreasing imaging defects.

Abstract: A plasticizer-containing layer can be used in a thermal transfer element to facilitate transfer to a receptor for the formation of a variety of articles. In one method, a receptor is brought into contact with a thermal transfer element that includes a transfer unit having at least one layer with a binder composition and a plasticizer. A portion of the transfer unit is thermally transferred to the receptor. This thermal transfer can be accomplished using, for example, a thermal print head or radiative (e.g., light or laser) thermal transfer. After transfer, the binder composition and the plasticizer (in the portion of the transfer unit that is transferred to the receptor) are reactively coupled.

Abstract: A method for making retroreflective articles that have a layer of optical elements and a multilayer reflective coating disposed on the optical elements. The reflective coating reflects light back into the optical elements so that it can be returned toward the light source. The multilayer reflective coating has at least one polymer layer made by condensing a curing a pre-polymer vapor.

Abstract: An improved electronic display that includes components selected to enhance display performance. The improved display includes an active substrate that has a plurality of thin film transistors and a plurality of thermally transferred color filters that include a colorant in a crosslinked binder. The active substrate can also include a black matrix. Other components in the improved display such as a liquid crystal material, spacers, and bottom polarizer, can be selected to enhance display performance characteristics such as brightness, power consumption, response time, weight, and thickness. The invention also provides a method of forming a color filter substrate for displays including the steps of thermally mass transferring a plurality of color filters and crosslinking the plurality of color filters after transfer. Before the crosslinking step, the plurality of color filters can be inspected and removed for reworking of the substrate.