Abstract: A light collimating and diffusing film and a method for making the film are provided. The film includes a plastic layer having a first side and a second side opposite the first side and at least a first peripheral edge. The first side has a first textured surface, wherein between 7 to 20 percent of slope angles on the first textured surface proximate a first axis has a value between zero and five degrees. The first axis is substantially parallel to the first peripheral edge. The plastic layer collimates light propagating therethrough.

Abstract: A light diffusing film for a back light display is described. The light diffusing film includes a unitary film consisting essentially of polycarbonate and a uniformly dispersed anti-static material in an amount sufficient to impart anti-static properties to the film. The anti-static material may comprise a fluorinated phosphonium sulfonate. The film may additionally include at least one textured surface for the low scattering of light. Alternatively, the film may additionally include a uniformly dispersed acrylic bulk scattering additive of particles having a mean particle size of from about 3 to about 10 microns and present in an amount from about 2 to about 7 percent by weight percent for the high scattering of light.

Abstract: Disclosed herein is an embossing system, methods for its use, and articles produced therefrom. In one embodiment, the embossing system comprises: an embossing apparatus, a coating zone, and a curing zone. The embossing apparatus is capable of producing an embossed film. The coating zone is capable of disposing a coating onto the surface features, wherein the coating comprises a well depth that is equal to or greater than one-half of the average height of the surface features. In one embodiment, a film making process comprises: heating a polymer, embossing the polymer to form an embossed film, disposing a coating on the embossed film, and curing the coating.

Abstract: In one embodiment, the process for forming a multilayer film comprises disposing a supportive layer adjacent to an imprinting layer to form a multilayer film and imprinting microstructures in the imprinting layer as the multilayer film passes between a heated roller and a compression roller. The multilayer film is free of a removable carrier layer. The supportive layer has a supportive layer glass transition temperature that is greater than or equal to about 15° C. higher than the imprinting layer glass transition temperature and/or the supportive layer has a supportive layer melting temperature that is greater than or equal to about 15° C. higher than an imprinting layer melting temperature. The imprinting temperature is lower than the supportive layer melting temperature.

Abstract: Disclosed herein is a defect detection apparatus comprising a first light source that emits light in a direction parallel to an apex of prismatic structures disposed on a mold; wherein an angle between a central axis of a beam of light emitted by the first light source and a vertical taken at the first light source is about 20 to about 90 degrees; a second light source that emits light in a direction perpendicular to the apex of the prismatic structures disposed on the mold; wherein an angle between a central axis of a beam of light emitted by the second light source and a vertical taken at the second light source is less than 45 degrees; a sample holder for holding the mold; a camera placed directly above the sample holder; and translational stages for supporting the camera and the sample holder.

Abstract: Disclosed herein is a method comprising inspecting a mold for a defect; determining a type of defect present on the mold; sorting the mold by type of defect present; treating the mold with a cleaning process that is suitable to remove the defect; and pressing the mold against a polymeric film to produce a series of defect free light management films; wherein the yield of light management films manufactured from the mold is higher than the yield of light management films that are produced from a comparative mold that has not been treated with the cleaning process.

Abstract: A system for the inspection of and a process for the correction of defects in a microreplicated optical display film manufacturing process. The process steps of manufacturing a master, a plurality of shims from the master, and a multiplicity of display films from each shim are integrated with a systemic defect identification and correction process. Each primary manufacturing step has its own inspection system and correction process where defect information for that step of the process is fed back and analyzed; and from that analysis the subprocess is adjusted to eliminate or reduce the detected defect. The systemic defect is identified as to its source and then fed back and analyzed in the correction step of the respective subprocess in order to cure the root of the defect.

Abstract: A system and a method for detecting defects in a light-management film are provided. The system includes a first light source configured to emit light onto a first side of the film in a first predetermined region of the film. The system further includes a second light source configured to emit light onto a second side of the film in the first predetermined region of the film. The system further includes a first camera configured to receive a first portion of light reflected from the first predetermined region of film from the first light source and a second portion of the light propagating through the film from the second light source. Finally, the system includes a signal-processing device openably coupled to the first camera configured to detect a defect in the first predetermined region of the film based on at least one of the first and second portions of light.

Abstract: Disclosed herein are copolyester embossed film and methods of making the same. In one embodiment, the film making process comprises forming a substrate film, wherein the substrate film comprises a copolyester stilbene polymer, embossing the substrate film to form an embossed film, and cross-linking the embossed film. In another embodiment, the process comprises forming a substrate film, embossing the substrate film to form an embossed film, and cross-linking the embossed film. The substrate film comprises a copolyester comprising repeating units derived from stilbene dicarboxylic acid, 1,4 cyclohexane dicarboxylic acid, and 1,4-cyclohexane dimethanol.

Abstract: In one embodiment, the film making process can comprise: introducing a plastic melt to a nip between a calendar roll and a resilient roll, passing the plastic melt between the calendar roll and the resilient roll to produce the film, and controlling a roughness of the film by actively cooling an external surface of the resilient roll. In another embodiment, the film making process can comprise: introducing a plastic melt having a melt temperature to a nip between a calendar roll and a resilient roll, passing the plastic melt between the calendar roll and the resilient roll to produce the film, and adjusting a roughness of the film at a constant production rate and a constant nip pressure.

Abstract: A light collimating and diffusing film and a method for making the film are provided. The film includes a plastic layer having a first side and a second side opposite the first side and at least a first peripheral edge. The first side has a first textured surface, wherein between 7 to 20 percent of slope angles on the first textured surface proximate a first axis has a value between zero and five degrees. The first axis is substantially parallel to the first peripheral edge. The plastic layer collimates light propagating therethrough.

Abstract: In one embodiment, a brightness enhancement film comprises: a diffusing film comprising a front surface and a back surface, a coating on the front surface, and light redirecting structures disposed in the coating. The brightness enhancement film is capable of collimating light, and wherein, without the coating, the diffusing film would be capable of spread light passing through the back surface. In another embodiment, the brightness enhancement film comprises: a diffusing film comprising a front surface and a back surface, a coating on the front surface, and light redirecting structures disposed in the coating. The diffusing film has a stress retardation gradient of less than or equal to 50 nm/in, wherein an interval for calculation of the stress retardation gradient is less than 1 inch. The brightness enhancement film is capable of collimating light.

Abstract: A light management film includes a first layer with a thermoplastic resin and a particular phosphonium sulfonate salt, and a second layer formed from a curable composition and having a refractive index of at least 1.5. The light management film exhibits reduced static electricity build-up and reduced dust attraction, making it easier to handle during fabrication of display devices such as the flat panel displays of laptop computers.

Abstract: A method of inspecting a light-management film comprises reflecting light from an overhead light source off a first side of the light-management film and examining the light-management film for defects; directing transmission light from a backlight source through a second side of the light-management film to the first side and examining the light-management film for defects; reflecting light from the overhead light source off the second side of the light-management film and examining the light-management film for defects; directing transmission light from the backlight source through the first side of the light-management film to the second side and examining the light-management film for defects; and measuring a location of each of the examined defects in the light-management film.

Abstract: A brightness enhancement film comprises a base film, wherein a stress retardation gradient of the base film is calculated to be less than or equal to 50 nanometers per inch, wherein a first surface of the base film is textured, and wherein a light-redirecting structure is disposed on a first surface of the base film.

Abstract: In one embodiment, the extrusion process can comprise: feeding a thermoplastic polycarbonate resin to an extruder; heating the resin to a temperature sufficient to attain a melt viscosity of less than or equal to about 300 Pa.s; extruding the heated resin; and passing the extruded resin through a gap between two solid metal calendering rolls to produce a film. The film has a birefringence of less than or equal to about 50 nm.

Abstract: A system and a method for detecting defects in a light-management film are provided. The system includes a first light source configured to emit light onto a first side of the film in a first predetermined region of the film. The system further includes a second light source configured to emit light onto a second side of the film in the first predetermined region of the film. The system further includes a first camera configured to receive a first portion of light reflected from the first predetermined region of film from the first light source and a second portion of the light propagating through the film from the second light source. Finally, the system includes a signal-processing device operably coupled to the first camera configured to detect a defect in the first predetermined region of the film based on at least one of the first and second portions of light.

Abstract: A light collimating and diffusing film and a method for making the film are provided. The film includes a plastic layer having a first side and a second side opposite the first side and at least a first peripheral edge. The first side has a first textured surface, wherein between 7 to 20 percent of slope angles on the first textured surface proximate a first axis has a value between zero and five degrees. The first axis is substantially parallel to the first peripheral edge. The plastic layer collimates light propagating therethrough.

Abstract: An apparatus and method for quantitatively measuring ripple and distortion levels in a transparent sheet (or film) material is provided. The apparatus includes a light source for projecting light beams onto a screen. A frame assembly is positioned intermediate to the light source and is adapted to hold the transparent sheet material at a predetermined angle and distance from the screen. The light beams pass though the transparent sheet material and projects an image onto the screen. The process includes digitally capturing the image and generating parameter signals from the digital image. The parameter signals are used in a model to quantitatively assign a value to the level of ripple and distortion present in the transparent sheet material.

Abstract: In one embodiment, an extrusion process can comprise: feeding a thermoplastic polycarbonate resin to an extruder; heating the resin in the extruder to a melt temperature that is above a glass transition temperature of the resin, thereby producing a melt of the thermoplastic polycarbonate resin; extruding the melted resin downwardly through an extrusion nozzle orifice having a slot configuration; passing the melted resin downwardly into a gap between two calendering rolls at least one of which has a highly polished surface, and wherein the calendering rolls are maintained at a roll temperature of less than the glass transition temperature; and cooling the thermoplastic polycarbonate resin film to below its glass transition temperature as the thermoplastic polycarbonate resin film advances through the gap.