Abstract:
A multi-function integrated polarizer/optical film structure and manufacturing method thereof solves the disadvantages of O type or E type polarizers that cannot simultaneously have high polarizing efficiency and high transmittance. The present invention utilizes optical design to a polarizer/optical film having a plurality of material layers on substrates. The present invention is a multi-function integrated polarizer/optical film structure and manufacturing method thereof, that allows an LCD image to have high polarizing efficiency, high transmittance, wide-angle, high contrast and super-film characteristics simultaneously.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a multi-function integrated: polarizer/optical film structure and manufacturing method thereof, and more particularly, to a structure that can utilize optical design coats, a different materials polarizer/optical film on a plurality of substrates to generate an image with high polarization, high transmittance, wide-angle and high contrast characteristics simultaneously and a manufacturing method thereof.  
         [0003]     2. Description of Related Art  
         [0004]     Liquid crystal displays (hereinafter referred to as LCD) use two-piece of polarizing films to produces a linearly polarized light achieve the effect of contrast. A backlight module of the LCD provides a primary light. The primary light is following liquid crystal twisted to generate the linearly polarized light when the primary light passes through a first polarization film. When the linearly polarized light has passed through a second polarization, it will generate the effect of contrast.  
         [0005]     In fact, to arrive viewer of the light is under 5% than the original light when the original light passed through the refraction, the reflection and the absorption of the multi-layer materials. A dichroic polarizer of the absorption rate and the transmittance is effect factors of brightness in the LCD. The polarizing film decides liquid crystal display contrast and viewing angle. The degree of polarization of contrast and light loss of viewing angle is adjudging the measurements parameter of the polarizing film. Thereof, the polarizing efficiency, the transmittance, the contrast and light loss will decide the displays effect of the LCD.  
         [0006]     Commercial polarizers typically use O iodine as the predominant type; its principle merit is high polarizing efficiency (99.9%) and transmittance (44%-46%). The main disadvantages of the O iodine polarizers is following aspects: (1) The O iodine polarizers have the acute of light loss in wide viewing, so the O iodine polarizers much with a wide-angle film to achieve a high contrasts performance; (2) The O iodine polarizers have poor temperature and humidity; (3) The O iodine polarizers mechanical properties is not strong, so the O iodine polarizers must have a protective film pasted onto it to strengthen the nature at the outside surface; (4) The O iodine polarizers can only pasted onto outside the monitor.  
         [0007]     Another type of polarizating film is the E liquid crystal polarizating film which a novel polarizer of the present. The E polarizating film mainly has a discotic liquid crystal with absorption when the light passes through the discotic liquid crystal, O polarization light is absorbed, but E polarization light can pass through, thereby achieving the linearly polarized light effect. The E polarizating film polarizing efficiency of the best optics effect at present is approximately 95% and the transmittance of between 40%-44%. The advantages of E polarizating film are: (1) its thickness is approximately only 0.3-0.8 micrometers; (2) it is produced in a liquid crystal cell and sited on the LCD.  
         [0008]     Opposed to the iodine series and the E type polarizating film, another coat type of polarizating film is a dye series polarizating film which it mainly is absorption carrier. The influence absorbency parameters of dye series polarizating film are: (1) its absorption coefficient of dye molecules; (2) its increased dye density and (3) its polarizating film thickness. The main advantages of the dye series polarizating film are: (1) its have good temperature and humidity; (2) it is have a diverse number of coat manner choices and (3) it is produced in a liquid crystal cell.  
         [0009]     At present iodine series polarizer technology of prior art can be found in U.S. Pat. No. 4,591,512, a method for making visible range dichroic polarizer material comprising a uniaxially stretched film of polyvinyl alcohol stained with iodine and treated with a borating solution containing a zinc salt. The mechanical properties, the temperature and humidity of the polarizer are not good. Besides the body of iodine polarizating film, it pasted a protect film with triacetyl cellulose (TAC) on the upper and lower side. Thereof, the present iodine series polarizating film thickness is approximately 200 micrometers  
         [0010]     The E type polarizer technology of prior art can be found in, for example, U.S. Pat. Nos. 6,583,284, 6,563,640, 6,174,394, 6,049,428 and 5,739,296. The above technology utilities coating manufacture to make polarizating film of the discotic liquid crystal with absorption effect on a surface of substrates. When passes the dry process, the polarizating film will become the E type polarizating film. The light is produced the E type polarized light when it passed through the E type polarizating film.  
         [0011]     Another type of polarizating film is the O type polarizating film. The O type polarizating film utilizes a dye coat on the surface of substrate to forming the polarizating film. The O type polarizer technology of prior art can be found in, for example, U.S. Pat. Nos. 5,812,264, 6,007,745 and 5,601,884.  
         [0012]     A conventional polarizing efficiency and transmittance curves schematic draw of the O type, polarizating film is shown in  FIG. 1A . The vertical axis coordinates is a polarizing efficiency and transmittance percent of O type polarizating film. The cross axis coordinates is a wavelength. The Figure is shows a curve distribute for polarizing efficiency  10  and transmittance  12  on different wavelength of the O type polarizating film.  
         [0013]     A conventional polarizing efficiency and transmittance curves schematic draw of the E type polarizating film is shown in  FIG. 1B . The vertical axis coordinates is a polarizing efficiency and transmittance a percent of E type polarizating film. The cross axis coordinates is a wavelength. The Figure is shows a curve distributes for polarizing efficiency  14  and transmittance  16  on different wavelength of the E type polarizating film.  
       SUMMARY OF THE INVENTION  
       [0014]     For eliminating the defects of the prior art, the applicant proposes a multi-function integrated polarizer and film structure and a manufacturing method thereof.  
         [0015]     The main objective of the present invention is provides a multi-function integrated polarizer/optical film structure and a manufacturing method. The multi-function integrated polarizer/optical film structure is a multi-layer film. The multi-layer film structure of the polarizing efficiency and transmittance is through by an optic and a system regulation design with advantage of the E type and the O type simultaneously. The multi-layer film using different dye series materials achieve the multi-function integrated polarizer and film structure with high polarizing efficiency and high transmittance.  
         [0016]     For achieving the objectives above, the present invention provides a manufacturing process for a manufacturing method of a multi-function integrated polarizer/optical film structure, comprises providing at least one substrate; and coating a polarizer/optical film on said substrate.  
         [0017]     The present invention further provides a multi-function integrated polarizer/optical film structure, comprising A multi-function integrated polarizer/optical film structure, comprises at least one substrate; and a polarizer/optical film having a plurality of material layers respectively coated on one side of said at least one substrate or opposite sides of said at least one substrate. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     The foregoing aspects and many of the attendant advantages of this invention will be more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:  
         [0019]      FIG. 1A  is a conventional polarizing efficiency and transmittance curves schematic draw of the O type polarizating film in accordance with the prior art;  
         [0020]      FIG. 1B  is a conventional polarizing efficiency and transmittance curves schematic draw of the E type polarizating film in accordance with the prior art;  
         [0021]      FIGS. 2   a - e  is a polarization film schematic drawing illustrating various types of the material by coat manner on a substrate in accordance with the present invention;  
         [0022]      FIGS. 3   a - p  is a schematics drawing for display unit using a multi-function integrated polarizer/optical film structure in accordance with the present invention; and  
         [0023]      FIG. 4  is a polarizing efficiency and transmittance curves schematic draw of the multi-function integrated polarizer/optic film in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0024]     An absorption rate and a polarizing efficiency for light is increase due to a two-superimposition polarizating film thickness greater than a single polarizating film when the light passed through therein, but a transmittance for light is decrease. The two-superimposition polarizating film problem includes a basic film itself and an optical axis position between films. The optical axis position deviation angle will be absorption parts of light intensity tend to a degree of transmittance for light.  
         [0025]     The present invention is combining two polarizers of low polarization light to single integrate polarization film with high polarizing efficiency and high transmittance for use a nonlinear optics.  
         [0026]      FIGS. 2   a - e  is a polarization film schematic drawing illustrating various types of the material by coat manner on a substrate in accordance with the present invention. A multi-function integrated polarizer/optical film structure is applied to a polarization film, a wide-angle film or a normal optic film as in FIG.  2   a . The structure comprises a polarizer/optical film  32  having a plurality of material layers respectively coated on one side of at least one substrate  30 . The structure is combining with two layers stack polarizer/optical film and a substrate for illustrates in this figure. Wherein the material layers of the polarizer/optical film are arranged on the same of the substrate and the material of substrate is a transmission substrate or a non-transmission substrate.  
         [0027]     The material layers of the polarizer/optical film  32  comprise a first polarizer/optical film  320  and a second polarizer/optical film  322 . The first polarizer/optical film and the second polarizer/optical film is constituted by various kinds of dye-type material layers, such as O-type film, E-type film, P-type film, S-type film and combination of above films. The combination type of the polarizer/optical film could such as O+O type, E+E type, O+E type, P+S type, P+O type, P+E type, S+O type or S+E type. The polarizer/optical film using the same or different dye-type materials is patterned by a coating manner.  
         [0028]     The first polarizer/optical film  320  is sitting one side of the substrate  30  and the second polarizer/optical film  322  is sitting another side as shown in  FIG. 2   b . The first polarizer/optical film  320  and second polarizer/optical film  322  are constituted by various kinds of dye-type material layers. The polarizer/optical films  34  of a plurality of material layers is sitting the same one of the substrate as shown in  FIG. 2   c . The polarizer/optical films  34  of a plurality of material layers using the same dye-type material or different dye-type material combined with the multi-function integrated polarizer/optical film structure.  
         [0029]     The  FIG. 2   d  is based on the  FIG. 2   c . The first polarizer/optical film  320  is sitting another of the substrate  30  and the second polarizer/optical film  322  is sitting of the polarizer/optical films  34  of a plurality of material layers as shown in  FIG. 2   d . The polarizer/optical films  34  of a plurality of material layers is sitting two side of the substrate as shown in  FIG. 2   e . The polarizer/optical films  34  of a plurality of material layers using the same dye-type material or different dye-type material combined with the multi-function integrated polarizer/optical film structure.  
         [0030]      FIGS. 3   a - p  is a schematics drawing for display unit using a multi-function integrated polarizer/optical film structure in accordance with the present invention. In this embodiment using two substrates illustrated but it is not limited. The display unit comprises at least of substrate. The at least of substrate is a first substrate  300  and a second substrate  302  as shown in  FIG. 3   a . The first substrate  300  and the second substrate  302  is transmission substrate or non-transmission substrate, wherein the first substrate  300  and the second substrate  302  is a vertical arrangement. The polarizer/optical films  34  of a plurality of material layers is sitting any side of the first substrate  300  and the second substrate  302 . The polarizer/optical films  34  of a plurality of material layers is using the same dye-type material or different dye-type material. The polarizer/optical films  34  of a plurality of material layers on the second substrate  302  is to face the first substrate  300 . A plurality of display fluid media  36  filled between on the first substrate  300  and the second substrate  302 . The display fluid medium is liquid crystal, electrophoresis, self-luminous object or other fluid medium for easy display.  
         [0031]     The first substrate  300  and the second substrate  302  is a vertical arrangement and is sitting for face-to-face as shown in  FIG. 3   b . The polarizer/optical films  34  of a plurality of material layers is sitting another side on the first substrate  300  and the second substrate  302  individually. The polarizer/optical films  34  of a plurality of material layers on the first substrate  300  is sitting to face one of the second substrate  302 . Another of the second substrate  302  is sitting the polarizer/optical films  34  of a plurality of material layers as shown in  FIG. 3   c.    
         [0032]     The polarizer/optical films  34  of a plurality of material layers on the first substrate  300  is sitting to face the polarizer/optical films  34  of a plurality of material layers as shown in  FIG. 3   d . One side of the first substrate  300  and the second substrate  302  is sitting the polarizer/optical films  34  of a plurality of material layers. Another side of the first substrate  300  and the second substrate  302  is sitting a third polarizer/optical film  38  as shown in  FIG. 3   e . One side of the second substrate  302  is only sitting the polarizer/optical films  34  of a plurality of material layers and is face-to-face the third polarizer/optical film  38  of the first substrate  300  as shown in  FIG. 3   f.    
         [0033]     The third polarizer/optical film  38  of the first substrate  300  is sitting face-to-face the second substrate  302  as shown in  FIG. 3   g . The polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and the second substrate  302 , wherein the polarizer/optical films  34  of a plurality of material layers of the first substrate  300  is face-to-face the polarizer/optical films  34  of a plurality of material layers of the second substrate  302  as shown in  FIG. 3   h . The polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and the second substrate  302 , wherein the polarizer/optical films  34  of a plurality of material layers of the first substrate  300  is face-to-face the second substrate  302 , Another side of the second substrate  302  is sitting third polarizer/optical film  38  as shown in  FIG. 3   i.    
         [0034]     One side of the first substrate  300  is sitting the polarizer/optical films  34  of a plurality of material layers and another side is sitting the third polarizer/optical film  38 . A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302  and another half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side, wherein the half of the polarizer/optical films  34  of a plurality of material layers of the second substrate  302  is face-to-face the third polarizer/optical film  38  of the first substrate  300  as shown in  FIG. 3   j.    
         [0035]     One side of the second substrate  302  is sitting the polarizer/optical films  34  of a plurality of material layers and another side is sitting the third polarizer/optical film  38 . A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and another half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side, wherein the half of the polarizer/optical films  34  of a plurality of material layers of the first substrate  300  is face-to-face the polarizer/optical films  34  of a plurality of material layers of the second substrate  302  as shown in  FIG. 3   k.    
         [0036]     A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302  and another half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. The half of the polarizer/optical films  34  of a plurality of material layers of any side of the first substrate  300  is face-to-face the half of the polarizer/optical films  34  of a plurality of material layers of any side of the second substrate  302  as shown in  FIG. 31 . A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. The polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302 . The half of the polarizer/optical films  34  of a plurality of material layers of any side of the first substrate  300  is face-to-face the polarizer/optical films  34  of the second substrate  302  as shown in  FIG. 3   m . A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300  and half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. The polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302 . The half of the polarizer/optical films  34  of a plurality of material layers of any side of the first substrate  300  is face-to-face the second substrate  302  as shown in  FIG. 3   n.    
         [0037]     A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302  and half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. The polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300 , wherein the half of the polarizer/optical films  34  of a plurality of material layers of any side of the second substrate  302  is face-to-face the polarizer/optical films  34  of a plurality of material layers of the first substrate  300  as shown in  FIG. 3   o . A half of the polarizer/optical films  34  of a plurality of material layers is sitting one side of the second substrate  302  and half of the polarizer/optical films  34  of a plurality of material layers is sitting of the another side. The polarizer/optical films  34  of a plurality of material layers is sitting one side of the first substrate  300 , wherein the half of the polarizer/optical films  34  of a plurality of material layers of any side of the second substrate  302  is face-to-face the first substrate  300  as shown in  FIG. 3   p.    
         [0038]     The multi-function integrated polarizer and film structure of the present invention has the characteristic and the advantage is following aspect: 
        (1) The multi-function integrated polarizer and film structure is have high polarization, high transmittance, high contract and wide viewing characteristic.     (2) The multi-function integrated polarizer and film structure is super-film structure.     (3) The multi-function integrated polarizer and film structure is produced inside (or outside) a liquid crystal cell.     (4) The multi-function integrated polarizer- and film structure is constituted by various kinds of material layers, such as O-type film, E-type film, P-type film, S-type film and combination of above films.     (5) The multi-function integrated polarizer and film structure is no limit for material cost, so could reduce product cost.     (6) The polarization and transmittance of the multi-function integrated polarizer and film structure is through by optic for design.     (7) The multi-function integrated polarizer and film structure is simply of manufacture and easy for combination with optic characteristic polarizating film.     (8) The multi-function integrated polarizer and film structure is having O type and E type polarized advantage and solving disadvantage of O and E type.     (9) The multi-function integrated polarizer and film structure is applied to the many kinds of substrate.        
 
         [0048]     A polarizing efficiency and transmittance curves schematic draw of the multi-function integrated polarizer and optic film is shows in  FIG. 4 . The vertical axis is a percent coordinates of polarizing efficiency and transmittance percent of the multi-function integrated polarizer and optic film. The cross axis coordinates is a wavelength. The Figure is shows a curve distributes for polarizing efficiency  18  and transmittance  20  on different wavelength of the multi-function integrated polarizer and optic film. The multi-function integrated polarizer and optic film with a high polarizing efficiency and a high transmittance is different for the O type and E-type polarization film of the prior art.  
         [0049]     The present invention provides a manufacturing process for the multi-function integrated polarizer and optic film. The multi-function integrated polarizer/optical film structure is applied on an optical design of a wide angle, a thin film, a high brightness, a high polarization value and a high transmittance value. The manufacturing process comprises providing at least one substrate, wherein said the at least one substrate is a transmission substrate or a non-transmission substrate. The multi-function integrated polarizer/optical film structure is coats on the at least one substrates. The step of coating is achieved by a manner of one of a slot-die coating, an extrusion coating, a Mayer rod coating and a blade coating. The multi-function integrated polarizer/optical film structure is patterned by said manner. The multi-function integrated polarizer/optical film has a plurality of material layers using the same or different dye-type materials. The multi-function integrated polarizer/optical film is coated on a thin film transistor (TFT) of a display by said manner.  
         [0050]     The multi-function integrated polarizer/optical film is using dye-type materials and constituted by various kinds of material layers, such as O-type film, E-type film, P-type film, S-type film and combination of above films. The multi-function integrated polarizer/optical film of the polarizing efficiency value and said transmittance value are designed via an optical parameter. An optical parameter equation for calculating said polarizing efficiency value is given by  
       Ep   =           T   ⁢           ⁢   0     -     T   ⁢           ⁢   90           T   ⁢           ⁢   0     +     T   ⁢           ⁢   90         .         
 
 The Ep is polarizing efficiency value; the T0 is a parallel transmittance of non-polarization through the multi-function integrated polarizer/optical film; and the T90 is a vertical transmittance of non-polarization through the multi-function integrated polarizer/optical film. 
 
         [0051]     An optical parameter equation for calculating said transmittance value is given by  
       T   =           T   ⁢           ⁢   0     +     T   ⁢           ⁢   90       2     .         
 
 The T is transmittance; the T0 is a parallel transmittance of non-polarization through the multi-function integrated polarizer/optical film; and the T90 is a vertical transmittance of non-polarization through the multi-function integrated polarizer/optical film. The polarizing efficiency value and the transmittance value of the multi-function integrated polarizer/optical film structure are obtained through a combination of a non-linear optically design and calculation. That is integrate two low effects polarizer films to a signal polarizer/optical film with high polarization and high transmittance simultaneously. 
 
         [0052]     The present invention of the polarizing efficiency and the transmittance is shows through by a nonlinear optics design and redistribute between each of the film. In fact, the polarizing efficiency and transmittance of the multi-function integrated polarizer/optical film is decides by the whole films. In addition, the designed of the polarizing efficiency and transmittance although is a fix value, but between the films combination has various change for different environment and the material ingredient. The polarizing efficiency and transmittance of the multi-function integrated polarizer/optical film is design by nonlinear optic and distributes combination. When the films superimposition, the films cannot eliminate needs transmittance but also enhance the whole of the polarizing efficiency.  
         [0053]     It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.