PATENT DOCUMENT

Publication Number: US-11921368-B2
Application Number: US-202117482231-A
Country: US
Kind Code: B2

Title: Electronic devices having antiglare films with transparent apertures

Abstract:
An electronic device may be provided with a display. The display may be overlapped by an antiglare film. The antiglare film may have a rough surface to diffuse incident light, thereby reducing glare. Additionally, the antiglare film may have a smooth portion that forms a transparent window and allows light to pass through undiffused. The electronic device may include a light-based component, such as a camera, that receives undiffused light through the transparent window. By overlapping the light-based component with the transparent window, the light-based component may receive the light in an unimpeded manner, thereby making more accurate measurements of the light. The display may have one or more display layers, such as opaque masking layers or polarizers, with openings that are aligned with the transparent window. The light-based component may receive the light through these openings so that the light is not absorbed or polarized before reaching the component.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a housing; 
 a light-based component in the housing; and 
 an antiglare film having a smooth portion that overlaps the light-based component and a rough portion that surrounds the smooth portion, wherein the antiglare film comprises:
 a substrate, and 
 a coating layer on the substrate, wherein the rough portion is a first distance from the substrate along a thickness direction of the substrate, wherein the smooth portion is in the coating layer and is a second distance from the substrate along the thickness direction of the substrate that is less than the first distance, wherein the rough portion and the smooth portion are formed in a single layer, and wherein a difference between the first distance and the second distance is between 50 microns and 250 microns. 
 
 
     
     
       2. The electronic device defined in  claim 1  wherein the light-based component is selected from the group consisting of: a camera, an ambient light-sensor, and a proximity sensor. 
     
     
       3. The electronic device defined in  claim 1  further comprising:
 a display overlapped by the rough portion of the antiglare film. 
 
     
     
       4. The electronic device defined in  claim 3  wherein the display includes a polarizer layer and an opaque masking layer, wherein the polarizer layer and the opaque masking layer respectively have first and second openings that overlap the light-based component, and wherein the light-based component receives light through the smooth portion of the antiglare film, the first opening, and the second opening. 
     
     
       5. The electronic device defined in  claim 4  wherein the first opening has a first center, the second opening has a second center, the smooth portion has a third center, and the first, second, and third centers are aligned. 
     
     
       6. The electronic device defined in  claim 4  wherein the first opening transmits at least 60% of light incident on the first opening and wherein the second opening transmits at least 50% of light incident on the second opening. 
     
     
       7. The electronic device defined in  claim 4  wherein the display includes a display layer having a third opening and wherein the light-based component extends into the third opening. 
     
     
       8. The electronic device defined in  claim 1  wherein the rough portion of the antiglare film comprises protruding surface structures having peaks and valleys, and wherein the peaks of the protruding surface structures are separated from the valleys by at least 0.1 microns. 
     
     
       9. The electronic device defined in  claim 8  wherein the smooth portion has a first diameter between 1 mm and 20 mm. 
     
     
       10. The electronic device defined in  claim 9  further comprising:
 a polarizer with an opening, wherein the opening has a second diameter, and wherein an absolute value of a difference between the first diameter and the second diameter is less than 2 mm. 
 
     
     
       11. The electronic device defined in  claim 1  wherein the coating layer comprises resin and wherein the substrate is a soft-mold substrate. 
     
     
       12. An electronic device comprising:
 a display having an active area defined by an array of pixels and having an inactive area; 
 a light-based component overlapped by the inactive area; and 
 an antiglare portion having a transparent window through which the light-based component receives ambient light, wherein the antiglare portion has a first surface, an opposing second surface, and a third surface between the first surface and the second surface, the first surface is a first distance from the second surface along a thickness direction of the antiglare portion and the third surface is a second distance from the second surface along the thickness direction of the antiglare portion that is less than the first distance, a difference between the first distance and the second distance is between 50 microns and 250 microns, the first surface has a first roughness, the third surface has a second roughness that is less than the first roughness, the transparent window includes the third surface, and the first, second and third surfaces form a portion of a single layer. 
 
     
     
       13. The electronic device defined in  claim 12  wherein the light-based component is a camera. 
     
     
       14. The electronic device defined in  claim 13  wherein the antiglare portion has a rough surface that diffuses light and wherein the transparent window comprises a smooth surface that allows light to pass through undiffused. 
     
     
       15. The electronic device defined in  claim 14  further comprising:
 a first housing portion, wherein the display and the camera are in the first housing portion; and 
 a second housing portion that is configured to rotate relative to the first housing portion. 
 
     
     
       16. The electronic device defined in  claim 15  further comprising a keyboard in the second housing portion. 
     
     
       17. The electronic device defined in  claim 14  wherein the display comprises:
 a first display layer having a first opening; and 
 a second display layer having a second opening, wherein the camera receives light through the first opening, the second opening, and the transparent window. 
 
     
     
       18. An electronic device comprising:
 a housing; 
 a display in the housing, wherein the display has an active area and an inactive area, and wherein the display comprises:
 a first display layer with a first window, and 
 a second display layer with a second window; 
 
 an antiglare film that overlaps the display, wherein the antiglare film comprises resin, the antiglare film has a single layer with a rough portion and a smooth portion that forms a transparent window, the single layer has a first surface and an opposing second surface, the rough portion and the smooth portion are formed in the second surface, the rough portion is a first distance from the first surface along a thickness direction of the antiglare film, the smooth portion is a second distance from the first surface along the thickness direction of the antiglare film, the second distance is less than the first distance, and a difference between the first distance and the second distance is between 50 microns and 250 microns; and 
 a light-based component overlapped by the inactive area of the display, wherein the light-based component has an aperture that is aligned with the first window, the second window, and the transparent window. 
 
     
     
       19. The electronic device defined in  claim 18  wherein the first display layer is a polarizer layer and the second display layer is an opaque masking layer.

Description:
BACKGROUND 
     This relates generally to electronic devices, and, more particularly, to electronic devices with antiglare films. 
     Electronic devices such as laptop computers, cellular telephones, and other equipment are sometimes provided with displays. In some devices, displays are covered with antiglare films, which reduces/prevents glare when a user views the displays. 
     It can be challenging to incorporate desired functionality into devices such as these. For example, it may be difficult to incorporate light-based devices such as light sensors and cameras into a device with a display covered by an antiglare film, as the antiglare film may diffuse light incident on the light sensors and cameras. 
     SUMMARY 
     An electronic device may be provided with a display. The display may have a display cover layer. The display cover layer may overlap liquid crystal display layers or display layers of other display technologies. An antiglare film may be provided over the display cover layer or otherwise overlap the display to reduce or eliminate glare by diffusing light incident on the film. 
     The display may have an active area with pixels and an inactive area without pixels (or with dummy pixels). Light-based components, such as cameras, ambient light sensors, image sensors, or other light sensors may be provided under the display cover layer and/or other display layers in the inactive area. 
     A transparent window may be formed in the antiglare film in the inactive area. One or more of the light-based components may be mounted in the electronic device in alignment with the transparent window. A polarizer layer may overlap the active and inactive areas of the display, and a masking layer may overlap the inactive area of the display. An opening in the polarizer, an unpolarized portion, or other window of the polarizer, as well as an opening or window in the masking layer, may be aligned with the transparent window. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic diagram of an illustrative electronic device in accordance with an embodiment. 
         FIG.  2    is a perspective view of an illustrative electronic device having a keyboard, a display, and a transparent window in an inactive portion of the display for underlying light-based components, such as light sensors, in accordance with an embodiment. 
         FIG.  3    is a perspective view of an illustrative electronic device having a display and a transparent window for light-based components, such as light sensors, in accordance with an embodiment. 
         FIG.  4    is a cross-sectional side view of a portion of an illustrative antiglare film with a transparent window in accordance with an embodiment. 
         FIG.  5    is a cross-sectional side view of a portion of an illustrative display in an electronic device having a transparent opening in an antiglare film, an opening in a polarizer, and an opening in a masking layer overlapping a light-based component in accordance with an embodiment. 
         FIG.  6    is a schematic of illustrative steps for forming an antiglare film with a transparent opening in accordance with an embodiment. 
         FIG.  7 A  is a front view of an illustrative sheet of molds used to form antiglare films with transparent openings in accordance with an embodiment. 
         FIG.  7 B  is a perspective view of an illustrative roll of molds used to form antiglare films with transparent openings in accordance with an embodiment. 
         FIG.  8    is a flowchart of illustrative steps used to form antiglare films with transparent openings in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     An illustrative electronic device of the type that may be provided with one or more light-based devices under a display with an antiglare film is shown in  FIG.  1   . Electronic device  10  may be a computing device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, a device embedded in eyeglasses or other equipment worn on a user&#39;s head, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, equipment that implements the functionality of two or more of these devices, or other electronic equipment. 
     As shown in  FIG.  1   , electronic device  10  may have control circuitry  16 . Control circuitry  16  may include storage and processing circuitry for supporting the operation of device  10 . The storage and processing circuitry may include storage such as nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive) and volatile memory (e.g., static or dynamic random-access-memory). Processing circuitry in control circuitry  16  may be used to control the operation of device  10 . The processing circuitry may be based on one or more microprocessors, microcontrollers, digital signal processors, baseband processors, power management units, audio chips, application specific integrated circuits, etc. 
     Input-output circuitry in device  10  such as input-output devices  12  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. Input-output devices  12  may include buttons, joysticks, scrolling wheels, touch pads, key pads, keyboards, microphones, speakers, tone generators, vibrators, light-emitting diodes for components such as status indicators, data ports, etc. A user can control the operation of device  10  by supplying commands through input-output devices  12  and may receive status information and other output from device  10  using the output resources of input-output devices  12 . 
     Input-output devices  12  may include one or more displays such as display  14 . Display  14  may be a touch screen display that includes a touch sensor for gathering touch input from a user or display  14  may be insensitive to touch. A touch sensor for display  14  may be based on an array of capacitive touch sensor electrodes, acoustic touch sensor structures, resistive touch components, force-based touch sensor structures, a light-based touch sensor, or other suitable touch sensor arrangements. 
     Input-output devices  12  may also include sensors  18 . Sensors  18  may include a capacitive proximity sensor, a light-based proximity sensor, a camera, an ambient light sensor, a light-based fingerprint sensor, a fingerprint sensor based on a capacitive touch sensor, a magnetic sensor, an accelerometer, an image sensor, a force sensor, a touch sensor for a button or track pad, a temperature sensor, a pressure sensor, a compass, a microphone, a visible digital image sensor (visible-light camera), an infrared digital image sensor (infrared-light camera), and/or other sensors, and/or multiple sensors mentioned in the list above. 
     Sensors  18  may be used to gather user commands (e.g., commands that direct control circuitry  16  to take action), may be used to gather information on the environment surrounding device  10  (e.g., information on ambient light levels, ambient temperature, ambient atmospheric pressure, etc.), and may be used in performing biometric authentication operations (e.g., using a fingerprint sensor, using visible and/or infrared cameras, using voice recognition, etc.). After a user has been authenticated using biometric authentication operations and/or after entering a password or supplying other information to device  10 , control circuitry  16  may provide the user with access to the features of device  10  (e.g., circuitry  16  may allow the user to make telephone calls, access stored information in storage in device  10 , send text messages or email messages, etc.). In some cases, it may be desirable to incorporate one or more sensors  18  under a portion of display  14 . An example of a device with a sensor under a portion of a display is shown in  FIG.  2   . 
     As shown in  FIG.  2   , electronic device  10  may be a portable computer or other electronic equipment that has a display, such as display  14 . Display  14  may be mounted in upper housing portion  20 . The housing of electronic device  10 , which is defined by upper housing portion  20  and lower housing portion  22 , may be formed from a unitary piece of material (e.g., metal, plastic, glass, or fiber composite materials) or may be formed from multiple structures that have been mounted together using adhesive, fasteners, and/or other attachment mechanisms. For example, upper housing portion  20  and lower housing portion  22  may be formed from frame members and other internal supports to which external plates, housing sidewalls, bezel structures, and other structures are mounted. 
     Because housing portion  20  may be used to house display  14 , housing portion  20  may sometimes be referred to as a display housing. Display housing  20  may be attached to housing portion  22  (sometimes referred to as a main unit or base housing) using hinge structures, so that display housing  20  may rotate relative to main housing  22  around hinge axis  24 . Device  10  may include ports for removable media, data ports, keys such as keyboard  26 , input devices such as track pad  28 , microphones, speakers, sensors, status indicators lights, etc. as desired. 
     Display  14  may have an active portion and an inactive portion (also referred to as the active area and inactive area, respectively, herein). Inactive portion  15  of display  14  may have a rectangular ring shape or other suitable shape and may form a border around the periphery of display  14 , as shown by the dashed line in  FIG.  2   . In other words, inactive portion  15  may surround the active region of display  14 , either partially or entirely. However, inactive portion  15  may be adjacent to a single portion of the active area of display  14 , if desired. 
     Image pixel array elements such as liquid crystal image pixels, organic light-emitting diode image pixels, or other active image pixel structures may be used in the active portion of display  14  to present images to a user of device  10 . Inactive portion  15  is generally devoid of image pixel elements and does not participate in forming images for a user. To hide unsightly internal components from view, internal components in inactive portion  15  may be blocked from view using an opaque masking layer such as a layer of ink. 
     To ensure that users of electronic device  10  do not experience glare when viewing display  14  and inactive area  15 , electronic device  10  may include an antiglare film that overlaps both the active area of display  14  and inactive area  15 . The antiglare film may diffuse light that is incident on the film, thereby reducing unsightly reflections. 
     Device  10  may have components that are formed in inactive device region  15 . To accommodate components that require light, such as cameras, image sensors, ambient light sensors, infrared light-emitting diodes for providing illumination, optical proximity sensors having an infrared light-emitting diode and a corresponding infrared light detector for detecting emitted infrared light that has reflected from an external object, and/or other light-based components, window  22  may be formed in inactive area  15 . Window  22  may include a transparent window in the antiglare film, an opening in the opaque masking layer, and/or openings in other display layers of display  14 . These windows and openings may be aligned with the underlying light-based components to allow light to pass to the components unimpeded by the overlying layers. 
     Although  FIG.  2    shows display  14  on one surface of upper housing portion  20 , this is merely illustrative. Display  14  may be formed on multiple surfaces of upper housing portion  20  and/or may be formed on or more surfaces of lower housing portion  22 , if desired. In one example, keyboard  26  and/or touch pad  28  may be formed from one or more displays in lower housing portion  22 . 
     Device  10  is not limited to a single window  22 . There may be any suitable number of windows  22  in display  14  (e.g., at least one, at least two, at least three, at least four, two, four, fewer than ten, 3-7, etc.). In general, there may be any suitable number of windows  22  in display  14 , and these windows may be used in transmitting emitted and/or received visible light, infrared light, and/or other light. 
     Although  FIG.  2    has shown electronic device  10  as a device having a display and keyboard in separate housing portions, which may be a device such as a laptop computer, this is merely illustrative. Another example of electronic device  10  is shown in  FIG.  3   . 
     As shown in  FIG.  3   , electronic device  10  may be a portable electronic device such as a handheld device (e.g., a cellular telephone or tablet computer) having opposing front and rear faces. In the example of  FIG.  3   , device  10  may include a display, such as display  14 , mounted in housing  21  on the front face of device  10 . Configurations in which display  14  is mounted in other portions of an electronic device may be used, if desired. 
     Device  10  may have opening/window  22  in a portion of display  14  (such as in inactive area  15 ) to allow light to reach underlying components, such as cameras, image sensors, ambient light sensors, or other light-based components. Window  22  may include a transparent window in an antiglare film that overlaps display  14 , an opening in an opaque masking layer of display  14 , and/or an opening or unpolarized region in a polarizer in display  14 . 
     As discussed above in connection with  FIG.  2   , opening/window  22  may be formed in inactive area  15  of display  14 . Alternatively or additionally, opening/window  22  may be partially or fully surrounded by the active area of display  14  (i.e., partially or fully surrounded by pixels of display  14 ). Additionally, device  10  is not limited to a single window  22 . Device  10  may have any desired number of windows that overlap the inactive area and/or the active area of display  14 . 
     Housing  21 , which may sometimes be referred to as an enclosure or case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of any two or more of these materials. Housing  21  may be formed using a unibody configuration in which some or all of housing  21  is machined or molded as a single structure or may be formed using multiple structures (e.g., an internal frame structure, one or more structures that form exterior housing surfaces, etc.). 
     Display  14  may be protected using a display cover layer such as a layer of transparent glass, clear plastic, sapphire, or other clear layer. Display  14  may be a liquid crystal display, may be an electrophoretic display, may be an organic light-emitting diode display or other display with an array of light-emitting diodes, may be a plasma display, may be an electrowetting display, may be a display based on microelectromechanical systems (MEMs) pixels, or may be any other suitable display. Illustrative configurations in which display  14  is a liquid crystal display may sometimes be described herein as an example. 
     Regardless of the configuration of electronic device  10  and the one or more displays  14 , it may be desirable to include an antiglare film that overlaps display  14 . Antiglare films may diffuse light incident on display  14 , thereby reducing or eliminating the glare seen by a user of electronic device  10  when viewing the display. It may be desirable to apply these antiglare films over both the active and inactive areas of displays  14  to maintain consistent appearances across the two areas. However, if optical components are included under display  14  in the active area or inactive area, light incident on the optical components may be diffused by the overlying antiglare films, thereby negatively impacting any measurements taken by the optical components. Therefore, window  22  may include an opening in the antiglare film that overlaps display  14 . An example of an antiglare film having a transparent opening is shown in  FIG.  4   . 
     As shown in  FIG.  4   , antiglare film  30  may include substrate  32  and coating layer  34 . Substrate  32  may be an optically clear substrate and may be formed from any desired material, such as thermoplastic copolyester (TPC), polyethylene terephthalate (PET), polycarbonate (PC), or triacetate (TAC). However, these materials are merely illustrative. Any material may be used for substrate  32 , as desired. 
     Coating layer  34  may be formed from resin or other transparent material. For example, coating layer may be formed from UV curable resin, or resin curable using other methods, such as visible light, infrared light, electron beam processes, or thermal processes. However, these materials are merely illustrative. Coating layer  34  may be formed from any desired material. 
     Coating layer  34  may have rough surface  36 , which may have protruding surface structures, such as nanostructures. The protruding surface structures may have peaks and valleys. The peaks may be portions of the protruding surface structure that are a maximum height above substrate  32 , which the valleys may be portions of the protruding surface structures that are a minimum height above substrate  32 . The protruding surface structures may be at least 0.1 microns in height, less than 0.2 microns in height, between 0.1 and 0.2 microns in height, less than 1 micron in height, greater than 0.2 microns in height, or any other desired height. Rough surface  36  may have an RMS surface roughness of 100 nm to 1 micron or other suitable value. 
     Height H a  may be the distance between the valleys and peaks of the protruding surface structures. Height H a  may be at least 0.05 microns, less than 20 microns, at least 0.1 microns, less than 5 microns, between 0.05 microns and 20 microns, between 0.1 and 5 microns, or any other desired height. 
     As shown in  FIG.  4   , light  40  may be incident on rough surface  36 . The protruding surface structures on rough surface  36  may diffuse and reflect light  40  as it is incident on rough surface  36 . A first portion of the light may reflect as diffusely reflected light  42 , and a second portion of the light may be transmit as diffusely transmitted light  44 . This diffusely reflected light (e.g., diffusely reflected light  42 ) may reduce glare when applied over an electronic device display or over other portions of an electronic device. 
     Antiglare film  30  may also have transparent aperture  22 , which may allow light to pass through undiffused. This may allow light-based components, such as cameras, image sensors, proximity sensors, ambient light sensors, or other components, to measure ambient light more accurately than if the light were diffused prior to reaching the light-based components. Transparent aperture  22  in antiglare film  30  may be formed from smooth surface  38  of coating layer  34 . As shown in  FIG.  4   , smooth surface  38  may allow light  46  to pass through antiglare film  30  as undiffused light  48 . In this way, antiglare film  30  may have transparent window  22 , which may allow for light to pass undiffused to underlying optical components. 
     Transparent aperture  22  (i.e., smooth surface  38 ) may have a diameter D a . Diameter D a  may at least 1 mm, less than 20 mm, between 1 mm and 20 mm, at least 2 mm, less than 5 mm, between 2 mm and 5 mm, or any other desired diameter. 
     Height H b  may be the distance between a lower surface of coating layer  34  (i.e., the surface adjacent to substrate  32 ) and smooth surface  38 . Height H b  may be at least 0 microns, may be less than 250 microns, may be less than 50 microns, may be at least 10 microns, may be between 0 microns and 250 microns, may be between 0 microns and 50 microns, or may be any other desired height. 
     Height H 0  may be the distance between smooth surface  38  and the bottom of the valleys in rough surface  36 . Height H 0  may be less than 250 microns, greater than −250 microns (e.g., if smooth surface  38  is higher than the valleys in rough surface  36 ), greater than −50 microns, less than 50 microns, between −250 microns and 250 microns, between −50 microns and 50 microns, or any other desired height. 
     Although antiglare film  30  is described as a film on substrate  32 , this is merely illustrative. Coating layer  34  may be formed directly on a portion of electronic device  10 , such as a display cover layer (e.g., a cover glass) or a housing wall. Alternatively or additionally, portions of electronic device  10  may be directly patterned to form an antiglare portion (i.e., antiglare portion  30 ) and a transparent window. Antiglare film/antiglare portion  30  may be formed in any desired manner. 
     By having rough surface  36  and smooth surface  38 , antiglare film  30  can reduce or eliminate glare for a user of an electronic device by diffusing light incident on rough surface  36 , while ensuring that any light-based components can receive undiffused light through smooth surface  38 . In this way, underlying light-based components may make more accurate measurements given the undiffused light than if the components received diffused light. An example of antiglare film  30  over a display and an underlying light-based component is shown in  FIG.  5     
     As shown in  FIG.  5   , display  14  may be a liquid crystal display with color filter substrate  50  (also referred to as upper substrate  50  herein) and thin-film transistor substrate  52  (also referred to as lower substrate  52  herein). Although not shown in  FIG.  5   , a backlight may emit light that proceeds through display  14  and illuminates color filters on color filter substrate  50 . Thin-film transistor substrate  52  may control a liquid crystal layer that selectively allows light to pass through to color filter substrate  50 , thereby changing which color filters of color filter substrate  50  are illuminated. This, in turn, may change the light and image outputted by display  14 . Although a liquid crystal display is shown in  FIG.  5   , this is merely illustrative. Any desired display may be used, such as an organic light-emitting diode display or another type of light-emitting diode display. In cases where display  14  is a non-liquid crystal display, substrates  50  and  52  may be upper and lower display substrates, respectively. Upper display substrate  50  and lower display substrate  52  are not limited to being color filter and thin-film transistor substrates. 
     Front polarizer  55  may be formed on an upper surface of color filter substrate  50 , and rear polarizer  62  may be formed on a lower surface of thin-film transistor layer  52 . Front polarizer  55  and rear polarizer  62  may polarize light emitted by the display backlight before and after the light has passed through the display layers of display  14  to ensure that only desired light is emitted by display  14 . Generally, front polarizer  55  and rear polarizer  62  may be formed on any desired surface within display  14 . 
     As shown in  FIG.  5   , black masking layer  54  (also referred to as opaque masking layer  54  and masking layer  54  herein) may be interposed between thin-film transistor layer  52  and color filter layer  50 . Black masking layer  54  may be patterned in the region over thin-film transistor layer  52  (e.g., the active area AA of display  14 ) to allow light to selectively pass through, or may be absent from the active area. Black masking layer  14  may be provided in the inactive area IA of display  14  to ensure that components in inactive area IA are not visible from the exterior of display  14  and to match the appearance of display  14  when display  14  is off. 
     Although black masking layer  54  is shown between color filter layer  50  and thin-film transistor layer  52 , this is merely illustrative. Black masking layer  54  may be provided in any desired location within display  14 , such as over upper polarizer  55 , or between upper polarizer  55  and color filter layer  50 . 
     In  FIG.  5   , antiglare film  30 , which was described above in connection with  FIG.  4   , may be formed over upper polarizer  55 . As described, antiglare film  30  may include substrate  32 , which may be in contact with upper polarizer  55 . Coating layer  34 , which may include rough surface  36  and smooth surface  38 , may be formed on substrate  32 . Substrate  32  may serve as a cover layer for display  14 , and be formed from a material such as plastic, glass, or ceramic, or display  14  may include an optional display cover layer between substrate  32  and the other display layers. Antiglare film  30  may diffuse light incident on rough surface  36  to reduce or eliminate glare when display  14  is viewed by a user of device  10 . 
     Light-based component  56  may be in inactive area IA of display  14 . In particular, light-based component  56  may be in opening  58  in thin-film transistor layer  52 . However, the location of light-based component is merely illustrative. Light-based component  56  may be in any desired location, such as in the active area AA of display  14 . Moreover, opening  58  may extend through multiple display layers, including thin-film transistor layer  52 , black masking layer  54 , color filter layer  50 , and/or upper polarizer  55  if desired. Alternatively, opening  58  may be absent, and light-based component may be formed behind one or more transparent layers of display  14 . 
     Regardless of the position of light-based component  56 , antiglare coating  30  may have a transparent window  22  to ensure that light that reaches light-based component  56  is not diffused prior to reaching light-based component  56 . As shown in  FIG.  5   , transparent window  22  may include smooth surface  38 , which may allow light to pass through undiffused. As discussed above in connection with  FIG.  4   , smooth surface  38  may have diameter D a , which may be greater than 1 mm, less than 20 mm, between 1 mm and 20 mm, greater than 2 mm, less than 5 mm, between 2 mm and 5 mm, or any other desired diameter. 
     Other layers of display  14  may also have openings or transparent portions to allow light to reach light-based component  56  in an unimpeded manner. For example, black masking layer  54  may have opening  60 , and upper polarizer  55  may have opening  61 . Opening  60  may be formed from a patterned opening in black masking layer  54  (e.g., opening  60  may be an absence of masking material that is surrounded by masking material), or may be a window within black masking layer  54  (i.e., window  60  may be formed in layer  54 , and may be a removal of some material, or a bleached portion of the layer). Opening/window  60  may have diameter D b . Opening  61  may be formed from a patterned opening in upper polarizer  55  (e.g., opening  61  may be an absence of polarizer material that is surrounded by polarizer material), or opening  61  may be an unpolarized window in upper polarizer  55  (e.g., opening  61  may be bleached portion of polarizer  55  that includes polarizer material but does not polarize light as it passes through opening  61 ). Opening  61  may have diameter D c . Although methods of forming openings  60  and  61  have been described, they are merely illustrative. Any desired method may be used to form openings  60  and  61 . 
     Openings  60  and  61  may allow light to reach light-sensing component  56  unimpeded. In particular, opening  60  in black masking layer  54  may transmit at least 50%, at least 75%, less than 95%, or at least 60% of light incident on opening  60  through the opening. Opening  61  in upper polarizer  55  may transmit at least 60%, at least 80%, less than 95%, or at least 70% of light incident on opening  61  through the opening. However, these light transmissions of openings  60  and  61  are merely illustrative. In general, openings  60  and  61  may have any desired light transmission to ensure that light-based component  56  can receive sufficient light to make accurate measurements, produce accurate images, or perform other desired functions. 
     Opening  61  in upper polarizer  55  may also allow light to pass through without polarizing the light. For example, opening  61  (or transparent polarizer window  61 ) may have an extinction ratio (p-polarized/s-polarized or s-polarized/p-polarized, as desired) of less than 5:1, less than 10:1, less than 2:1, 5:1, or other desired extinction ratio. In this way, light may pass through opening  61  without being polarized, allowing underlying light-based component  56  to perform accurate ambient light measurements. 
     Transparent aperture  22 , polarizer opening  61 , and black masking layer opening  60  may all be aligned with light-based component  56 . For example, light-based component  56  may have an aperture through which light is received, and transparent aperture  22 , polarizer opening  61 , and black masking layer opening  60  may all be alighted with the aperture of light-based component  56 . In particular, the centers of transparent aperture  22 , polarizer opening  61 , black masking layer opening  60 , and the aperture of light-based component  56  may all be aligned within a tolerance of less than 0.5 mm, less than 0.25 mm, less than 0.3 mm, or greater than 0.1 mm. However, these tolerances are merely illustrative. The centers of transparent aperture  22 , polarizer opening  61 , black masking layer opening  60 , and the aperture of light-based component may all be aligned within a tolerance of any desired value. 
     Although openings  60  and  61  are shown in  FIG.  5    as through openings, this is merely illustrative. Generally, any of the display layers in display  14  may have windows, which may be through openings, openings that extend partially through the layer, bleached portions of the layer, or other transparent or semi-transparent regions. For example, polarizer  55  may have window  61  and opaque masking layer  54  may have window  60 . 
     Transparent aperture diameter D a  may be greater than the aperture of light-based component  56 . For example, transparent aperture diameter D a  may be at least 0.1 mm greater, at least 0.2 mm greater, less than 0.5 mm greater, or any other desired diameter greater than the aperture of light-based component  56 . In one example, diameter D a  may be at least 3 mm, at least 4 mm, 3.8 mm, or at least 2.5 mm, while diameter D b  (which may have the same diameter as the aperture of light-based component  56  within 0.1 mm, within 1 mm, or other desired value) may be at least 2 mm, at least 2.5 mm, 2.0 mm, or at least 1.5 mm. However, these diameters are merely illustrative. Any desired diameters may be used for diameter D a  and diameter D b . 
     Opening  61  in upper polarizer  55  may have diameter D c , which may be greater than opening  60  in black masking layer  54 . For example, diameter D c  may be at least 0.1 mm greater, at least 0.2 mm greater, less than 0.5 mm greater, or any other desired diameter greater than diameter D b . Diameter D c  may be greater than 1 mm, less than 20 mm, between 1 mm and 20 mm, greater than 2 mm, less than 5 mm, between 2 mm and 5 mm, or any other desired diameter. 
     Moreover, diameter D c  may be smaller than or larger than diameter D a . Generally, an absolute value of a difference between diameter D a  and diameter D 0  may be less than 0.5, less than 1.0, less than 1.5, greater than 0.75, or less than 2.0. However, this is merely illustrative. Diameters D a  and D c  may have any desired difference. 
     In one example, diameter D a  may be 3.8 mm and diameter D c  may be 3.0 mm. In another example, diameter D a  may be 3.3 mm and diameter D c  may be 4.6 mm. However, these examples are merely illustrative that diameter D a  may be greater or less than diameter D c  within the ranges previously discussed. Diameters D a  and D c  may have any desired values. 
     Although antiglare film  30  has been described as being used with a liquid crystal display with openings in various display layers, this is merely illustrative. Antiglare film  30  may be applied over any portion of electronic device  10 , such as housing walls with openings for light-based components. Moreover, although antiglare film  30  has been described as a film that is applied over a portion of electronic device  10 , this is merely illustrative. Any desired portion of electronic device  10 , such as a cover glass over a display or a housing wall may be coated or laminated with an antiglare coating (i.e., antiglare coating  30 ), or may be directly patterned into rough and smooth portions to form an antiglare portion of the device (i.e., antiglare portion  30 ). 
     Alternatively or additionally, antiglare film  30  may be applied over non-liquid crystal displays, such as organic light-emitting diode display, microLED displays, or any other desired displays. Moreover, any desired number of displays in display  14  (e.g., no display layers, all display layers, or some display layers) may have openings aligned with transparent window  22  in antiglare film  30 , as desired. Additionally, one or more display layers of display  14  shown in  FIG.  5    may be omitted. For example, front polarizer  55 , rear polarizer  62 , black masking layer  54 , and/or one or both substrates  50  and  52  may be omitted from the stack shown in  FIG.  5   . Regardless of the display or other structure underlying antiglare film  30 , a method of forming antiglare film  30  is shown in  FIG.  6   . 
     As shown in  FIG.  6   , master  64  may be made. Master  64  may be a hard material, such as glass or metal. In general, however, master  64  may be made of any desired material. Master  64  may have rough surface  65  and smooth surface  67 . In one example, master  64  may initially be completely smooth and rough surface  65  may be created using acid etching (e.g., using hexafluorosilicic acid), creating microcracks using chemical etching, followed by polishing (e.g., using hydrofluoric acid or sodium hydroxide), or sandblasting. However, these methods of creating master  64  are merely illustrative. In general, master  64  may be formed using any desired method. 
     After master  64  has been formed, resin  34  and substrate  32 , which together form antiglare film  30 , may be applied over master  64 . Resin  34  may be UV curable resin, or resin curable using other methods, such as visible light, infrared light, electron beam processes, or thermal processes. Although layer  34  has been described as being formed from using resin, this is merely illustrative. In general, any desired material may be used to form coating layer  34 . 
     Substrate  32  may be a soft mold substrate, such as thermoplastic copolyester (TPC), polyethylene terephthalate (PET), polycarbonate (PC), or triacetate (TAC). However, these materials are merely illustrative. In general, substrate  32  may be formed from any desired material. 
     While resin  34  and substrate  32  are on master  64 , resin  34  may be cured. For example, if resin  34  is formed from UV curable resin, UV light may be used to cure resin  34 . If resin  34  is curable by other processes, any desired process may be used to cure resin  34 . 
     After resin  34  has been cured, antiglare film  30  may be removed from master  64 . Antiglare film  30  may have substantially the same characteristics as those described above in connection with  FIG.  4   , including substrate  32 , coating layer  34 , rough surface  36 , and smooth surface  38  (which may in turn form transparent window/aperture  22  over an underlying optical component). Antiglare film  30  may then be applied to an electronic device display or other desired object. 
     Although the process of  FIG.  6    has been described with respect to making a single antiglare film  30 , multiple antiglare films may be made at a time, if desired. For example,  FIG.  7 A  shows master portions  68  on substrate  66 . Resin and a substrate, such as resin  34  and substrate  32  may be applied across substrate  66 , thereby forming multiple antiglare films when the resin is cured. Substrate  66  may have any desired number of master portions  68 , such as at least 12 portions, at least 16 portions, at least 14 portions, or any other desired number. Substrate  66  with master portions  68  may be used in sheet-by-sheet formation of antiglare films. 
       FIG.  7 B  shows alternative manufacturing equipment. In  FIG.  7 B , master portions  68  are on roller  70 . Roller  70  may be used in a roll-to-roll process in which resin and substrates, such as resin  34  and substrate  32 , are unwound from a first roll to be patterned by roller  70 . While in contact with or after contacting roller  70 , the resin may be cured, thereby forming a plurality of antiglare films. Roller  70  may have nay desired number of master portions  68 , such as at least 12 portions, at least 16 portions, at least 14 portions, or any other desired number. However, whether the equipment of  FIG.  7 A ,  FIG.  7 B , or other desired equipment is used, a flowchart showing steps used in forming antiglare film  30  is shown in  FIG.  8   . 
     As shown in  FIG.  8   , at step  72 , an ultraviolet curable resin may be patterned onto a substrate. The ultraviolet curable resin may correspond with resin/coating layer  34  of  FIG.  4   , and the substrate may correspond with substrate  32  of  FIG.  4   . The substrate may be a soft mold substrate, such as thermoplastic copolyester (TPC), polyethylene terephthalate (PET), polycarbonate (PC), or triacetate (TAC). However, the substrate is not limited to a soft mold substrate, and any desired substrate may be used, if desired. 
     At step  74 , the ultraviolet curable resin may be patterned with a pattern roller. For example, roller  70  of  FIG.  7 B  may be used to pattern the ultraviolet curable resin into antiglare film portions with rough surfaces and smooth surfaces, such as antiglare film  30  with rough surface  36  and smooth surface  38 . However, the use of a pattern roller is merely illustrative. A patterned substrate, such as substrate  66  of  FIG.  7 A  may be used to produce sheets of antiglare films. In general, any desired method of patterning the resin may be used. 
     At step  76 , the ultraviolet resin may be cured with ultraviolet light. As a result, the finished antiglare film may have smooth and patterned regions, as shown in  FIG.  4   . The smooth regions may allow light to pass through unimpeded. Therefore, the smooth regions may overlap underlying light-based components in electronic devices to ensure that light reaches the light-based components unimpeded and undiffused. 
     Although steps  72 - 76  have been described as using ultraviolet resin and using ultraviolet light to cure the resin, this is merely illustrative. In general, any desired material may be used on an underlying substrate to form antiglare film  30 . For example, resin curable using other methods, such as visible light, infrared light, electron beam processes, or thermal processes, may be used. Alternatively, other materials may be used to form coating layer  34  of antiglare film  30 , if desired. 
     The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20210922
Publication Date: 20240305
Grant Date: 20240305
Priority Date: 20210922
Inventors: LU, ZHIJIAN
QI, JUN
LI, XIANGTONG
ZHU, XINYU
Assignee: APPLE INC
CPC Classifications: [{"code": "G02F1/133502", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B1/11", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/133512", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/133528", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/133502", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02F1/133502", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B5/0215", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/0289", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B1/11", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/133512", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/133528", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 85571695