US20100302218A1 - Illumination devices and methods of fabrication thereof - Google Patents

Abstract

Illumination devices and methods of making same are disclosed. In one embodiment, a display device includes a light modulating array and a light guide configured to receive light into at least one edge of the light guide. The display device can also include a light turning layer disposed such that the light guide is at least partially between the turning layer and the array. The turning layer can comprise at least one light turning feature having at least one curved turning surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Application No. 61/182,594 filed on May 29, 2009, titled “ILLUMINATION DEVICES AND METHODS OF FABRICATION THEREOF,” and U.S. Provisional Application No. 61/292,783 filed on Jan. 6, 2010, titled “ILLUMINATION DEVICES AND METHODS OF FABRICATION THEREOF,” both of which are hereby expressly incorporated by reference in their entireties.
BACKGROUND
• 1. Field
• The field of the invention relates to electromechanical systems.
• 2. Description of the Related Art
• Electromechanical systems include devices having electrical and mechanical elements, actuators, transducers, sensors, optical components (e.g., mirrors), and electronics. Electromechanical systems can be manufactured at a variety of scales including, but not limited to, microscales and nanoscales. For example, microelectromechanical systems (MEMS) devices can include structures having sizes ranging from about a micron to hundreds of microns or more. Nanoelectromechanical systems (NEMS) devices can include structures having sizes smaller than a micron including, for example, sizes smaller than several hundred nanometers. Electromechanical elements may be created using deposition, etching, lithography, and/or other micromachining processes that etch away parts of substrates and/or deposited material layers or that add layers to form electrical and electromechanical devices. One type of electromechanical systems device is called an interferometric modulator. As used herein, the term interferometric modulator or interferometric light modulator refers to a device that selectively absorbs and/or reflects light using the principles of optical interference. In certain embodiments, an interferometric modulator may comprise a pair of conductive plates, one or both of which may be transparent and/or reflective in whole or part and capable of relative motion upon application of an appropriate electrical signal. In a particular embodiment, one plate may comprise a stationary layer deposited on a substrate and the other plate may comprise a metallic membrane separated from the stationary layer by an air gap. As described herein in more detail, the position of one plate in relation to another can change the optical interference of light incident on the interferometric modulator. Such devices have a wide range of applications, and it would be beneficial in the art to utilize and/or modify the characteristics of these types of devices so that their features can be exploited in improving existing products and creating new products that have not yet been developed.
SUMMARY
• The system, method, and devices of the invention each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of Certain Embodiments,” one will understand how the features of this invention provide advantages over other display devices.
• Various embodiments described herein comprise an illumination device including a substrate layer and a turning layer including light turning features coated with reflective layers configured to turn light propagating within the substrate toward a display.
• In one embodiment, an illumination apparatus comprises a light source, a light guide having a generally planar first surface, a generally planar second surface opposite the first surface, a first end and a second end, and a length defined between the first end and the second end, the light guide having an x-axis extending generally parallel to the first surface between the first end and second end, a z-axis extending generally normal to the first surface and the second surface, and a y-axis extending generally normal to the x-axis and the z-axis, wherein the light guide is positioned to receive light from the light source into the light guide first end, and wherein light received from the light source propagates through the light guide towards the second end. This embodiment, and certain other embodiments, can also include a plurality of light turning features disposed on the first surface and protruding from the first surface into the light guide towards the second surface. Each light turning feature can have at least one curvilinear turning edge disposed on a plane that is parallel with a plane defined by the x-axis and the z-axis wherein the at least one turning edge is configured to receive at least a portion of the light which is propagating towards the second end of the light guide and reflect at least a portion of the received light out of the second surface of the light guide.
• In one aspect, the portion of light reflected by the at least one curvilinear turning edge forms an “emission cone” of light that has an angular width. In another aspect, the at least one turning edge is configured to focus or disperse light propagating in the light guide incident on the turning surface. In yet another aspect, the at least one turning edge has a convex or concave shaped profile and x-axis and z-axis defined plane on which it is disposed. In one aspect, the surface of at least turning feature forms a frustum and the frustum can have sidewalls that are concave and/or convex relative to the light guide.
• In another embodiment, a display device comprises an array of light modulating elements, a light guide disposed over the array, the light guide having at least one edge configured to receive light into the light guide, and a turning layer disposed such that the light guide is at least partially between the turning layer and the array. The turning layer can have a first surface and a second surface opposite the first surface wherein the second surface is disposed between the first surface and the array. The turning lay can include a plurality of light turning features disposed on the first surface and protruding from the first surface into the turning layer towards the second surface, each light turning feature being configured to receive at least a portion of light which is propagating through the turning layer and reflect at least a portion of the receive light toward the array. Each light turning feature can have a light turning surface configured to focus or disperse the portion of light received and reflected toward the array.
• In one aspect, the curved light turning surface of each light turning feature extends from the first surface into the light guide and comprises a depression formed in the first surface. In another aspect, the curved light turning surface can be frustum shaped. In yet another aspect, each light turning feature has at least one sidewall wherein at least a portion of the sidewall is curved. In one aspect, the curved portion of the sidewall is concave or convex. In one aspect, each turning feature comprises an optical mask disposed on at least a portion of the sidewall and the optical mask can include a first reflective layer, a second layer, and a third partially reflective layer disposed respectively on the tapered sidewall, wherein the first layer is configured to receive light propagating within the turning layer and reflect at least a portion of the received light toward the array. In one aspect, the first, second, and third layers can be configured to absorb a portion of light incident on the turning layer.
• In one aspect, the device further comprises a processor that is configured to communicate with the array of light modulating elements, the processor being configured to process image data, and a memory device that is configured to communicate with the processor. In one aspect, the device further comprises a driver circuit configured to send at least one signal to the array of light modulating elements and can also include a controller configured to send at least a portion of the image data to the driver circuit. In another aspect, the device further comprises an image source module configured to send image data to the processor. In one aspect, the image source module comprises at least one of a receiver, transceiver, and transmitter. In one aspect, the device further comprises an input device configured to receive input data and to communicate the input data to the processor.
• In another embodiment, a method of making a light guide including turning features that are configured to focus or disperse light incident thereon comprises providing a substrate, depositing a layer of material over at least a portion of the substrate, coating the material with a layer of photoresist, exposing the photoresist to leave portions of the photoresist layer on the material, and etching the layer of material to produce one or more depressions having curved sidewalls. In one aspect, the layer of material comprises silicon oxy-nitride.
• In another embodiment, a method of making a turning film including turning features that are configured to focus or disperse light incident thereon comprises providing a substrate, depositing a layer of material over at least a portion of the substrate, coating the material with a layer of photoresist, exposing and processing the photoresist to leave portions of the photoresist on the layer of material, etching the layer of material to produce one or more depressions having curved sidewalls, removing the photoresist, electroplating the surface of the layer of material and the substrate to produce a surface relief, and using the surface relief to mold a turning film. In one aspect, the sidewalls are convex or concave. In another aspect, the layer of material and substrate form at least one frustum shaped turning feature and the frustum shaped turning feature can have sidewalls that are convex or concave.
• In another embodiment, a display device includes means for modulating light, means for guiding light disposed over the modulating means, the light guiding means being configured to receive light, and means for turning light disposed such that the light guiding means is at least partially between the light turning means and the modulating means. The turning means can include a plurality of light turning features configured to receive at least a portion of light received by the light guiding means and reflect at least a portion of the received light toward the modulating means, wherein each light turning feature is configured to focus or disperse the portion of light received and reflected toward the modulating means. Each light turning feature can comprise a depression formed in a surface of the light turning means.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is an isometric view depicting a portion of one embodiment of an interferometric modulator display in which a movable reflective layer of a first interferometric modulator is in a relaxed position and a movable reflective layer of a second interferometric modulator is in an actuated position.
• FIG. 2 is a system block diagram illustrating one embodiment of an electronic device incorporating a 3×3 interferometric modulator display.
• FIG. 3 is a diagram of movable mirror position versus applied voltage for one exemplary embodiment of an interferometric modulator ofFIG. 1.
• FIG. 4 is an illustration of a set of row and column voltages that may be used to drive an interferometric modulator display.
• FIGS. 5A and 5B illustrate one exemplary timing diagram for row and column signals that may be used to write a frame of display data to the 3×3 interferometric modulator display ofFIG. 2.
• FIGS. 6A and 6B are system block diagrams illustrating an embodiment of a visual display device comprising a plurality of interferometric modulators.
• FIG. 7A is a cross-section of the device ofFIG. 1.
• FIG. 7B is a cross-section of an alternative embodiment of an interferometric modulator.
• FIG. 7C is a cross-section of another alternative embodiment of an interferometric modulator.
• FIG. 7D is a cross-section of yet another alternative embodiment of an interferometric modulator.
• FIG. 7E is a cross-section of an additional alternative embodiment of an interferometric modulator.
• FIG. 8 is a cross-section of an embodiment of a display device having an illumination device and a reflective display.
• FIG. 9A is a top plan view of an embodiment of a display device having turning features disposed in a uniform pattern on a turning film.
• FIG. 9B is a top plan view of an embodiment of a display device having turning features disposed in a non-uniform pattern on a turning film.
• FIG. 9C is a cross-section of an embodiment of an illumination device having a turning film and a substrate.
• FIG. 9D illustrates certain dimensions of one embodiment of a turning feature rotationally.
• FIG. 10 is a cross-section of an embodiment of an illumination device illustrating several embodiments of light turning features.
• FIG. 11 is a cross-section of an embodiment of an illumination device including a substrate with light turning features.
• FIG. 12 is a cross-section of an embodiment of an illumination device having two turning films.
• FIG. 13 is a cross-section of an embodiment of an illumination device having two turning films, each turning film having light turning features, where at least some of the light turning features in each turning film are disposed vertically offset from those in the other turning film.
• FIG. 14 is a cross-section of an embodiment of an illumination device having light turning features configured in the shape of a truncated cone and a lens.
• FIG. 15 is a cross-section of an embodiment of another illumination device illustrating a turning film and a light guide with curved edges.
• FIG. 16 is a cross-section of an illumination device illustrating an embodiment that includes a light source providing light through an angled edge of a turning film and/or a light guide.
• FIG. 17A is a cross-section of an embodiment of an illumination device that depicts light turning features having multi-coated edges.
• FIG. 17B is a top plan view of an embodiment of an illumination device.
• FIG. 18 is a cross-section of an embodiment of an illumination device illustrating several examples of light turning features with multi-coated edges.
• FIG. 19A is a cross-section of a turning film during a step of one example of a process for forming interferometric stacks on a light turning feature.
• FIG. 19B is a cross-section of the turning film ofFIG. 19A in an intermediate process step.
• FIG. 19C is a cross-section of an embodiment of the turning film ofFIG. 19C resulting from further processing.
• FIG. 19D is a block diagram schematically illustrating one embodiment of a method of making the turning film ofFIG. 19C.
• FIGS. 20A-20E are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 20F is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 20E.
• FIGS. 21A-21H are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 21I is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 21H.
• FIG. 22A-22E are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 22F is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 22E.
• FIG. 23A-23J are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 23K is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 23J.
• FIG. 24A-24F are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 24G is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 24F.
• FIG. 25A-25G are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 25H is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 25G.
• FIG. 26A-26F are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 26G is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 26F.
• FIG. 27A-27C are schematic cross-sectional views illustrating steps in a process of manufacturing an illumination device.
• FIG. 27D is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 27C.
• FIG. 27E is a block diagram schematically illustrating one embodiment of a method of making the illumination device ofFIG. 27C.
• FIG. 28 is a cross-section of an embodiment of a turning film having tapered walls.
• FIG. 29A is a schematic of a cross-section of an embodiment of a turning film having a polygonal turning feature.
• FIG. 29B is a schematic of a cross-section of an embodiment of a turning film having a concave curvilinear turning feature.
• FIG. 29C is a schematic of a cross-section of an embodiment of a turning film having a convex curvilinear turning feature.
• FIG. 29D is a schematic of a cross-section of an embodiment of a turning film having a frustum shaped turning feature with concave sidewalls.
• FIG. 29E is a schematic of a cross-section of an embodiment of a turning film having a frustum shaped turning feature with convex sidewalls.
• FIG. 29F is a perspective view of the turning feature ofFIG. 29D.
• FIG. 29G is a perspective view of the turning feature ofFIG. 29F.
• FIG. 30A is a schematic of a cross-section of an embodiment of a turning film having a concave curvilinear turning feature with multi-coated edges.
• FIG. 30B is a schematic of a cross-section of an embodiment of a turning film having a convex curvilinear turning feature with multi-coated edges.
• FIG. 30C is a schematic of a cross-section of an embodiment of a turning film having a frustum shaped turning feature with concave sidewalls and multi-coated edges.
• FIG. 30D is a schematic of a cross-section of an embodiment of a turning film having a frustum shaped turning feature with convex sidewalls and multi-coated edges.
• FIGS. 31A-31E are schematics of cross-sectional views illustrating steps in a process of manufacturing a turning film having convex turning features.
• FIGS. 32A-32E are schematics of cross-sectional views illustrating steps in a process of manufacturing a turning film having a concave turning feature.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
• The following detailed description is directed to certain specific embodiments. However, the teachings herein can be applied in a multitude of different ways. In this description, reference is made to the drawings wherein like parts are generally designated with like numerals throughout. In certain illustrated embodiments, like numerals are used to designate generally corresponding parts; however, it will be understood that such designated parts can vary from embodiment to embodiment, for example as described herein.
• The embodiments may be implemented in any device that is configured to display an image, whether in motion (e.g., video) or stationary (e.g., still image), and whether textual or pictorial. More particularly, it is contemplated that the embodiments may be implemented in or associated with a variety of electronic devices such as, but not limited to, mobile telephones, wireless devices, personal data assistants (PDAs), hand-held or portable computers, GPS receivers/navigators, cameras, MP3 players, camcorders, game consoles, wrist watches, clocks, calculators, television monitors, flat panel displays, computer monitors, auto displays (e.g., odometer display, etc.), cockpit controls and/or displays, display of camera views (e.g., display of a rear view camera in a vehicle), electronic photographs, electronic billboards or signs, projectors, architectural structures, packaging, and aesthetic structures (e.g., display of images on a piece of jewelry). MEMS devices of similar structure to those described herein can also be used in non-display applications such as in electronic switching devices.
• Illumination devices can be used to provide light for reflective displays when ambient light is insufficient. In some embodiments, an illumination device comprises a light source and a light guide that receives the light from the light source. Often the light source may be positioned or offset relative to the display, and in such a position it may not provide sufficient or uniform light directly to the reflective display. Accordingly, an illumination device can also include light turning features that re-direct light from the light source towards the display, and such turning features can be included in a turning film positioned on the light guide. In some embodiments, turning features have reflective coatings configured to (better) reflect light propagating within the light guide and/or turning film towards the reflective display. The reflective coatings could appear shiny or bright, but they can be masked to a viewer by forming a dark coating (e.g., black mask) over the reflective coating to absorb light such that the turning features appear dark or black, resulting in improving contrast of the display. The black mask can include the reflective layer, and an absorber layer, and be configured as a “static” interferometric modulator configured to appear dark or black. The light guide and the turning film may be made from an inorganic material. To facilitate light propagating between the turning film and the light guide, the turning film may have an index of refraction that matched to the light guide. Embodiments disclosed herein relate to different configurations of illumination devices that include one or more reflective coatings on turning features. Additional embodiments disclosed herein relate to processes of forming illumination devices that include an inorganic light guide and/or inorganic turning film.
• One interferometric modulator display embodiment comprising an interferometric MEMS display element is illustrated inFIG. 1. In these devices, the pixels are in either a bright or dark state. In the bright (“relaxed” or “open”) state, the display element reflects a large portion of incident visible light to a user. When in the dark (“actuated” or “closed”) state, the display element reflects little incident visible light to the user. Depending on the embodiment, the light reflectance properties of the “on” and “off” states may be reversed. MEMS pixels can be configured to reflect predominantly at selected colors, allowing for a color display in addition to black and white.
• FIG. 1 is an isometric view depicting two adjacent pixels in a series of pixels of a visual display, wherein each pixel comprises a MEMS interferometric modulator. In some embodiments, an interferometric modulator display comprises a row/column array of these interferometric modulators. Each interferometric modulator includes a pair of reflective layers positioned at a variable and controllable distance from each other to form a resonant optical gap with at least one variable dimension. In one embodiment, one of the reflective layers may be moved between two positions. In the first position, referred to herein as the relaxed position, the movable reflective layer is positioned at a relatively large distance from a fixed partially reflective layer. In the second position, referred to herein as the actuated position, the movable reflective layer is positioned more closely adjacent to the partially reflective layer. Incident light that reflects from the two layers interferes constructively or destructively depending on the position of the movable reflective layer, producing either an overall reflective or non-reflective state for each pixel.
• The depicted portion of the pixel array inFIG. 1 includes two adjacentinterferometric modulators12aand12b.In theinterferometric modulator12aon the left, a movablereflective layer14ais illustrated in a relaxed position at a predetermined distance from anoptical stack16a,which includes a partially reflective layer. In theinterferometric modulator12bon the right, the movablereflective layer14bis illustrated in an actuated position adjacent to theoptical stack16b.
• The optical stacks16aand16b(collectively referred to as optical stack16), as referenced herein, typically comprise several fused layers, which can include an electrode layer, such as indium tin oxide (ITO), a partially reflective layer, such as chromium, and a transparent dielectric. Theoptical stack16 is thus electrically conductive, partially transparent and partially reflective, and may be fabricated, for example, by depositing one or more of the above layers onto atransparent substrate20. The partially reflective layer can be formed from a variety of materials that are partially reflective such as various metals, semiconductors, and dielectrics. The partially reflective layer can be formed of one or more layers of materials, and each of the layers can be formed of a single material or a combination of materials.
• In some embodiments, the layers of theoptical stack16 are patterned into parallel strips, and may form row electrodes in a display device as described further below. The movablereflective layers14a,14bmay be formed as a series of parallel strips of a deposited metal layer or layers (orthogonal to the row electrodes of16a,16b) to form columns deposited on top ofposts18 and an intervening sacrificial material deposited between theposts18. When the sacrificial material is etched away, the movablereflective layers14a,14bare separated from theoptical stacks16a,16bby a definedgap19. A highly conductive and reflective material such as aluminum may be used for thereflective layers14, and these strips may form column electrodes in a display device. Note thatFIG. 1 may not be to scale. In some embodiments, the spacing betweenposts18 may be on the order of 10-100 um, while thegap19 may be on the order of <1000 Angstroms.
• With no applied voltage, thegap19 remains between the movablereflective layer14aandoptical stack16a,with the movablereflective layer14ain a mechanically relaxed state, as illustrated by thepixel12ainFIG. 1. However, when a potential (voltage) difference is applied to a selected row and column, the capacitor formed at the intersection of the row and column electrodes at the corresponding pixel becomes charged, and electrostatic forces pull the electrodes together. If the voltage is high enough, the movablereflective layer14 is deformed and is forced against theoptical stack16. A dielectric layer (not illustrated in this Figure) within theoptical stack16 may prevent shorting and control the separation distance betweenlayers14 and16, as illustrated by actuatedpixel12bon the right inFIG. 1. The behavior is the same regardless of the polarity of the applied potential difference.
• FIGS. 2 through 5 illustrate one exemplary process and system for using an array of interferometric modulators in a display application.
• FIG. 2 is a system block diagram illustrating one embodiment of an electronic device that may incorporate interferometric modulators. The electronic device includes aprocessor21 which may be any general purpose single- or multi-chip microprocessor such as an ARM®, Pentium®, 8051, MIPS®, Power PC®, or ALPHA®, or any special purpose microprocessor such as a digital signal processor, microcontroller, or a programmable gate array. As is conventional in the art, theprocessor21 may be configured to execute one or more software modules. In addition to executing an operating system, the processor may be configured to execute one or more software applications, including a web browser, a telephone application, an email program, or any other software application.
• In one embodiment, theprocessor21 is also configured to communicate with anarray driver22. In one embodiment, thearray driver22 includes arow driver circuit24 and acolumn driver circuit26 that provide signals to a display array orpanel30. The cross-section of the array illustrated inFIG. 1 is shown by the lines1-1 inFIG. 2. Note that althoughFIG. 2 illustrates a 3×3 array of interferometric modulators for the sake of clarity, thedisplay array30 may contain a very large number of interferometric modulators, and may have a different number of interferometric modulators in rows than in columns (e.g., 300 pixels per row by 190 pixels per column).
• FIG. 3 is a diagram of movable mirror position versus applied voltage for one exemplary embodiment of an interferometric modulator ofFIG. 1. For MEMS interferometric modulators, the row/column actuation protocol may take advantage of a hysteresis property of these devices as illustrated inFIG. 3. An interferometric modulator may require, for example, a 10 volt potential difference to cause a movable layer to deform from the relaxed state to the actuated state. However, when the voltage is reduced from that value, the movable layer maintains its state as the voltage drops back below 10 volts. In the exemplary embodiment ofFIG. 3, the movable layer does not relax completely until the voltage drops below 2 volts. There is thus a range of voltage, about 3 to 7 V in the example illustrated inFIG. 3, where there exists a window of applied voltage within which the device is stable in either the relaxed or actuated state. This is referred to herein as the “hysteresis window” or “stability window.” For a display array having the hysteresis characteristics ofFIG. 3, the row/column actuation protocol can be designed such that during row strobing, pixels in the strobed row that are to be actuated are exposed to a voltage difference of about 10 volts, and pixels that are to be relaxed are exposed to a voltage difference of close to zero volts. After the strobe, the pixels are exposed to a steady state or bias voltage difference of about 5 volts such that they remain in whatever state the row strobe put them in. After being written, each pixel sees a potential difference within the “stability window” of 3-7 volts in this example. This feature makes the pixel design illustrated inFIG. 1 stable under the same applied voltage conditions in either an actuated or relaxed pre-existing state. Since each pixel of the interferometric modulator, whether in the actuated or relaxed state, is essentially a capacitor formed by the fixed and moving reflective layers, this stable state can be held at a voltage within the hysteresis window with almost no power dissipation. Essentially no current flows into the pixel if the applied potential is fixed.
• As described further below, in typical applications, a frame of an image may be created by sending a set of data signals (each having a certain voltage level) across the set of column electrodes in accordance with the desired set of actuated pixels in the first row. A row pulse is then applied to a first row electrode, actuating the pixels corresponding to the set of data signals. The set of data signals is then changed to correspond to the desired set of actuated pixels in a second row. A pulse is then applied to the second row electrode, actuating the appropriate pixels in the second row in accordance with the data signals. The first row of pixels are unaffected by the second row pulse, and remain in the state they were set to during the first row pulse. This may be repeated for the entire series of rows in a sequential fashion to produce the frame. Generally, the frames are refreshed and/or updated with new image data by continually repeating this process at some desired number of frames per second. A wide variety of protocols for driving row and column electrodes of pixel arrays to produce image frames may be used.
• FIGS. 4 and 5 illustrate one possible actuation protocol for creating a display frame on the 3×3 array ofFIG. 2.FIG. 4 illustrates a possible set of column and row voltage levels that may be used for pixels exhibiting the hysteresis curves ofFIG. 3. In theFIG. 4 embodiment, actuating a pixel involves setting the appropriate column to −V_bias, and the appropriate row to +ΔV, which may correspond to −5 volts and +5 volts respectively Relaxing the pixel is accomplished by setting the appropriate column to +V_bias, and the appropriate row to the same +ΔV, producing a zero volt potential difference across the pixel. In those rows where the row voltage is held at zero volts, the pixels are stable in whatever state they were originally in, regardless of whether the column is at +V_bias, or −V_bias. As is also illustrated inFIG. 4, voltages of opposite polarity than those described above can be used, e.g., actuating a pixel can involve setting the appropriate column to +V_bias, and the appropriate row to −ΔV. In this embodiment, releasing the pixel is accomplished by setting the appropriate column to −V_bias, and the appropriate row to the same −ΔV, producing a zero volt potential difference across the pixel.
• FIG. 5B is a timing diagram showing a series of row and column signals applied to the 3×3 array ofFIG. 2 which will result in the display arrangement illustrated inFIG. 5A, where actuated pixels are non-reflective. Prior to writing the frame illustrated inFIG. 5A, the pixels can be in any state, and in this example, all the rows are initially at 0 volts, and all the columns are at +5 volts. With these applied voltages, all pixels are stable in their existing actuated or relaxed states.
• In theFIG. 5A frame, pixels (1,1), (1,2), (2,2), (3,2) and (3,3) are actuated. To accomplish this, during a “line time” forrow1,columns1 and2 are set to −5 volts, andcolumn3 is set to +5 volts. This does not change the state of any pixels, because all the pixels remain in the 3-7 volt stability window.Row1 is then strobed with a pulse that goes from 0, up to 5 volts, and back to zero. This actuates the (1,1) and (1,2) pixels and relaxes the (1,3) pixel. No other pixels in the array are affected. To setrow2 as desired,column2 is set to −5 volts, andcolumns1 and3 are set to +5 volts. The same strobe applied to row2 will then actuate pixel (2,2) and relax pixels (2,1) and (2,3). Again, no other pixels of the array are affected.Row3 is similarly set by settingcolumns2 and3 to −5 volts, andcolumn1 to +5 volts. Therow3 strobe sets therow3 pixels as shown inFIG. 5A. After writing the frame, the row potentials are zero, and the column potentials can remain at either +5 or −5 volts, and the display is then stable in the arrangement ofFIG. 5A. The same procedure can be employed for arrays of dozens or hundreds of rows and columns. The timing, sequence, and levels of voltages used to perform row and column actuation can be varied widely within the general principles outlined above, and the above example is exemplary only, and any actuation voltage method can be used with the systems and methods described herein.
• FIGS. 6A and 6B are system block diagrams illustrating an embodiment of adisplay device40. Thedisplay device40 can be, for example, a cellular or mobile telephone. However, the same components ofdisplay device40 or slight variations thereof are also illustrative of various types of display devices such as televisions and portable media players.
• Thedisplay device40 includes ahousing41, adisplay30, anantenna43, aspeaker45, aninput device48, and amicrophone46. Thehousing41 is generally formed from any of a variety of manufacturing processes, including injection molding, and vacuum forming. In addition, thehousing41 may be made from any of a variety of materials, including but not limited to plastic, metal, glass, rubber, and ceramic, or a combination thereof. In one embodiment thehousing41 includes removable portions (not shown) that may be interchanged with other removable portions of different color, or containing different logos, pictures, or symbols.
• Thedisplay30 ofexemplary display device40 may be any of a variety of displays, including a bi-stable display, as described herein. In other embodiments, thedisplay30 includes a flat-panel display, such as plasma, EL, OLED, STN LCD, or TFT LCD as described above, or a non-flat-panel display, such as a CRT or other tube device. However, for purposes of describing the present embodiment, thedisplay30 includes an interferometric modulator display, as described herein.
• The components of one embodiment ofexemplary display device40 are schematically illustrated inFIG. 6B. The illustratedexemplary display device40 includes ahousing41 and can include additional components at least partially enclosed therein. For example, in one embodiment, theexemplary display device40 includes anetwork interface27 that includes anantenna43 which is coupled to atransceiver47. Thetransceiver47 is connected to aprocessor21, which is connected toconditioning hardware52. Theconditioning hardware52 may be configured to condition a signal (e.g. filter a signal). Theconditioning hardware52 is connected to aspeaker45 and amicrophone46. Theprocessor21 is also connected to aninput device48 and adriver controller29. Thedriver controller29 is coupled to aframe buffer28, and to anarray driver22, which in turn is coupled to adisplay array30. Apower supply50 provides power to all components as required by the particularexemplary display device40 design.
• Thenetwork interface27 includes theantenna43 and thetransceiver47 so that theexemplary display device40 can communicate with one ore more devices over a network. In one embodiment thenetwork interface27 may also have some processing capabilities to relieve requirements of theprocessor21. Theantenna43 is any antenna for transmitting and receiving signals. In one embodiment, the antenna transmits and receives RF signals according to the IEEE 802.11 standard, including IEEE 802.11(a), (b), or (g). In another embodiment, the antenna transmits and receives RF signals according to the BLUETOOTH standard. In the case of a cellular telephone, the antenna is designed to receive CDMA, GSM, AMPS, W-CDMA, or other known signals that are used to communicate within a wireless cell phone network. Thetransceiver47 pre-processes the signals received from theantenna43 so that they may be received by and further manipulated by theprocessor21. Thetransceiver47 also processes signals received from theprocessor21 so that they may be transmitted from theexemplary display device40 via theantenna43.
• In an alternative embodiment, thetransceiver47 can be replaced by a receiver. In yet another alternative embodiment,network interface27 can be replaced by an image source, which can store or generate image data to be sent to theprocessor21. For example, the image source can be a digital video disc (DVD) or a hard-disc drive that contains image data, or a software module that generates image data.
• Processor21 generally controls the overall operation of theexemplary display device40. Theprocessor21 receives data, such as compressed image data from thenetwork interface27 or an image source, and processes the data into raw image data or into a format that is readily processed into raw image data. Theprocessor21 then sends the processed data to thedriver controller29 or to framebuffer28 for storage. Raw data typically refers to the information that identifies the image characteristics at each location within an image. For example, such image characteristics can include color, saturation, and gray-scale level.
• In one embodiment, theprocessor21 includes a microcontroller, CPU, or logic unit to control operation of theexemplary display device40.Conditioning hardware52 generally includes amplifiers and filters for transmitting signals to thespeaker45, and for receiving signals from themicrophone46.Conditioning hardware52 may be discrete components within theexemplary display device40, or may be incorporated within theprocessor21 or other components.
• Thedriver controller29 takes the raw image data generated by theprocessor21 either directly from theprocessor21 or from theframe buffer28 and reformats the raw image data appropriately for high speed transmission to thearray driver22. Specifically, thedriver controller29 reformats the raw image data into a data flow having a raster-like format, such that it has a time order suitable for scanning across thedisplay array30. Then thedriver controller29 sends the formatted information to thearray driver22. Although adriver controller29, such as a LCD controller, is often associated with thesystem processor21 as a stand-alone Integrated Circuit (IC), such controllers may be implemented in many ways. They may be embedded in theprocessor21 as hardware, embedded in theprocessor21 as software, or fully integrated in hardware with thearray driver22.
• Typically, thearray driver22 receives the formatted information from thedriver controller29 and reformats the video data into a parallel set of waveforms that are applied many times per second to the hundreds and sometimes thousands of leads coming from the display's x-y matrix of pixels.
• In one embodiment, thedriver controller29,array driver22, anddisplay array30 are appropriate for any of the types of displays described herein. For example, in one embodiment,driver controller29 is a conventional display controller or a bi-stable display controller (e.g., an interferometric modulator controller). In another embodiment,array driver22 is a conventional driver or a bi-stable display driver (e.g., an interferometric modulator display). In one embodiment, adriver controller29 is integrated with thearray driver22. Such an embodiment is common in highly integrated systems such as cellular phones, watches, and other small area displays. In yet another embodiment,display array30 is a typical display array or a bi-stable display array (e.g., a display including an array of interferometric modulators).
• Theinput device48 allows a user to control the operation of theexemplary display device40. In one embodiment,input device48 includes a keypad, such as a QWERTY keyboard or a telephone keypad, a button, a switch, a touch-sensitive screen, a pressure- or heat-sensitive membrane. In one embodiment, themicrophone46 is an input device for theexemplary display device40. When themicrophone46 is used to input data to the device, voice commands may be provided by a user for controlling operations of theexemplary display device40.
• Power supply50 can include a variety of energy storage devices as are well known in the art. For example, in one embodiment,power supply50 is a rechargeable battery, such as a nickel-cadmium battery or a lithium ion battery. In another embodiment,power supply50 is a renewable energy source, a capacitor, or a solar cell, including a plastic solar cell, and solar-cell paint. In another embodiment,power supply50 is configured to receive power from a wall outlet.
• In some implementations control programmability resides, as described above, in a driver controller which can be located in several places in the electronic display system. In some cases control programmability resides in thearray driver22. The above-described optimization may be implemented in any number of hardware and/or software components and in various configurations.
• The details of the structure of interferometric modulators that operate in accordance with the principles set forth above may vary widely. For example,FIGS. 7A-7E illustrate five different embodiments of the movablereflective layer14 and its supporting structures.FIG. 7A is a cross-section of the embodiment ofFIG. 1, where a strip ofmetal material14 is deposited on orthogonally extending supports18. InFIG. 7B, the moveablereflective layer14 of each interferometric modulator is square or rectangular in shape and attached to supports at the corners only, ontethers32. InFIG. 7C, the moveablereflective layer14 is square or rectangular in shape and suspended from adeformable layer34, which may comprise a flexible metal. Thedeformable layer34 connects, directly or indirectly, to thesubstrate20 around the perimeter of thedeformable layer34. These connections are herein referred to as support posts. The embodiment illustrated inFIG. 7D has support post plugs42 upon which thedeformable layer34 rests. The movablereflective layer14 remains suspended over the gap, as inFIGS. 7A-7C, but thedeformable layer34 does not form the support posts by filling holes between thedeformable layer34 and theoptical stack16. Rather, the support posts are formed of a planarization material, which is used to form support post plugs42. The embodiment illustrated inFIG. 7E is based on the embodiment shown inFIG. 7D, but may also be adapted to work with any of the embodiments illustrated inFIGS. 7A-7C as well as additional embodiments not shown. In the embodiment shown inFIG. 7E, an extra layer of metal or other conductive material has been used to form abus structure44. This allows signal routing along the back of the interferometric modulators, eliminating a number of electrodes that may otherwise have had to be formed on thesubstrate20.
• In embodiments such as those shown inFIG. 7, the interferometric modulators function as direct-view devices, in which images are viewed from the front side of thetransparent substrate20, the side opposite to that upon which the modulator is arranged. In these embodiments, thereflective layer14 optically shields the portions of the interferometric modulator on the side of the reflective layer opposite thesubstrate20, including thedeformable layer34. This allows the shielded areas to be configured and operated upon without negatively affecting the image quality. For example, such shielding allows thebus structure44 inFIG. 7E, which provides the ability to separate the optical properties of the modulator from the electromechanical properties of the modulator, such as addressing and the movements that result from that addressing. This separable modulator architecture allows the structural design and materials used for the electromechanical aspects and the optical aspects of the modulator to be selected and to function independently of each other. Moreover, the embodiments shown inFIGS. 7C-7E have additional benefits deriving from the decoupling of the optical properties of thereflective layer14 from its mechanical properties, which are carried out by thedeformable layer34. This allows the structural design and materials used for thereflective layer14 to be optimized with respect to the optical properties, and the structural design and materials used for thedeformable layer34 to be optimized with respect to desired mechanical properties.
• Interferometric modulators are reflective elements that can be configured to reflect ambient lighting in daylight or well-lit environments to produce a display. When ambient light may not be sufficient, a light source can provide the required illumination, either directly or through a light guide that provides a propagation path from the light source to the display elements. In some embodiments, an illumination device provides light from a light source to the display elements. The illumination device can include a light guide and light turning features, which may be disposed in or on a turning film disposed on the light guide. In some embodiments the illumination device also includes a light source. The light guide can be a planar optical device disposed over and parallel to the display such that incident light passes through the light guide to the display, and light reflected from the display also passes through the light guide. In certain embodiments, the light source includes an optical device (for example, a light bar) that is configured to receive light from a point source (e.g., a light emitting diode) and provides light as a line source. Light entering the light bar may propagate along some or all of the length of the bar and exit out of a surface or edge of the light bar over a portion or all of the length of the light bar. Light exiting the light bar may enter an edge of a light guide and/or a turning film, and then propagate within the light guide and/or turning film such that a portion of the light propagates in a direction across at least a portion of the display at a low-graze angle relative to the surface of the light guide aligned with the display such that the light is reflected within the light guide by total internal reflection (“TIR”). In various embodiments, turning features in the light guide and/or turning film direct the light towards the display elements at an angle sufficient so that at least some of the light passes through the light guide to the reflective display. In any of the embodiments described herein, the turning features may include one or more coatings (or layers). The coatings can be configured to increase reflectivity of a turning feature and/or function as a black mask to improve contrast of the display as seen by a viewer. In certain embodiments, the coatings on the turning features may be configured as an interferometric stack having a reflective layer that re-directs light propagating within the light guide and/or turning film, a partially reflective absorber layer disposed between the reflective layer and the direction exposed to ambient light, and a layer disposed between the reflective layer and the absorber layer which defines an optical resonant cavity by its thickness.
• FIG. 8 illustrates a cross-sectional view of one embodiment of adisplay device800 that includes an illumination device configured to provide front light illumination to areflective display807. Thedisplay device800 includes aturning film801 shown inFIG. 8 as forming afirst side800aof thedevice800. The turning,film801 is disposed on alight guide803. In this embodiment, areflective display807 is disposed underneath thelight guide803 and defines asecond side800bof thedisplay device800. According to some embodiments, anoptical isolation layer805 may optionally be disposed between thereflective display807 and thelight guide803. Alight source809 may be disposed near thelight guide803 and turningfilm801 and configured to input light into at least one edge or surface of either, or both, the turningfilm801 and thelight guide803, illustrated inFIG. 8 as providing light into both the turning film810 and thelight guide803. Thelight source809 may comprise any suitable light source, for example, an incandescent bulb, a light bar, a light emitting diode (“LED”), a fluorescent lamp, an LED light bar, an array of LEDs, and/or another light source.
• In some embodiments, thereflective display807 comprises a plurality of reflective elements, for example, interferometric modulators, MEMS devices, NEMS devices, reflective spatial light modulators, electromechanical devices, liquid crystal structures, and/or any other suitable reflective display. The reflective elements may be configured in an array. In some embodiments, thereflective display807 includes a first planar side that is configured to modulate light incident thereon and a second planar side disposed opposite to the first planar side. The size of thereflective display807 can vary depending upon the application. For example, in some embodiments, thereflective display807 is sized to fit within a notebook computer casing. In other embodiments, thereflective display807 is sized to fit within or form part of a mobile phone or similar mobile device.
• In some embodiments, the turningfilm801 andlight guide803 can comprise any substantially optically transmissive material that allows light to propagate along the length thereof. For example, the turningfilm801 and thelight guide803 may each comprise one or more of the following materials: acrylics, acrylate copolymers, UV-curable resins, polycarbonates, cycloolefin polymers, polymers, organic materials, inorganic materials, silicates, alumina, sapphire, glasses, polyethylene terephthalate (“PET”), polyethylene terephthalate glycol (“PET-G”), silicon oxy-nitride, and/or other optically transparent materials. In some embodiments, the turningfilm801 and thelight guide803 comprise the same material and in other embodiments, the turning film and thelight guide803 comprise different materials. In some embodiments, the indices of refraction of theturning film801 and thelight guide803 may be close or equal to one another such that light may propagate successively through the two layers without being substantially reflected or refracted at the interface between the two layers. In one embodiment, thelight guide803 and theturning film801 each have an index of refraction of about 1.52. According to other embodiments, the indices of refraction of thelight guide803 and/or theturning film801 can range from about 1.45 to about 2.05. Thelight guide803 and turningfilm801 may be held together by an adhesive, which may have an index of refraction similar or equal to the index of refraction of one or both of the light guide and turning film. In some embodiments, thereflective display807 is laminated to thelight guide803 using a refractive-index matched pressure-sensitive adhesive (“PSA”) or similar adhesive.
• Both thelight guide803 and theturning film801 can include one or more turning features820. In some embodiments, thelight guide803 and theturning film801 each comprise a single layer. In other embodiments, thelight guide803 and/or theturning film801 comprise more than one layer. Thelight guide803 and theturning film801 can have differing thicknesses and/or other dimensions. In example embodiments, the turningfilm801 can have a thickness of between about 40 and about 100 microns, and thelight guide803 can have a thickness of between about 40 and about 200 microns. Uniformity of brightness across thedisplay device800 and efficiency of the display device may be affected by the thickness of thelight guide803 and of theturning film801.
• In some embodiments, the turningfilm801 can include one or more turning features820 disposed on or along thefirst side800aof thedisplay device800. In other embodiments, one or more turning features820 may be disposed on the side of theturning film801 and/orlight guide803 nearest to thereflective display807. The turning features820 depicted throughout the attached figures are schematic and exaggerated in size and spacing therebetween for clarity of illustration. The turning features820 can comprise one or more angled and/or curved surfaces configured to refract (or reflect) at least some of the light which is traveling through the light guide (e.g., at an oblique angle) away from thedisplay807 at the interface between the angled or curved surface of thefeature820 and the air, and redirect that light towards thereflective display807. In certain embodiments, the turning features can comprise a plurality of surface features or volume features. In some embodiments, the turning features820 comprise one or more diffractive optical elements, grooves, depressions, and/or pits. In certain embodiments, the turning features820 comprise holograms or holographic features. The holograms may include holographic volume or surface features. The size, shape, quantity, and pattern of the turning features820 may vary. In some embodiments, the turning features820 may be disposed along the length and width of theturning film801. In some embodiments, turning features820 are disposed on about 5% of the area of thefirst side800aof theturning film801.
• In some embodiments, the turning features820 are configured to receive light propagating along the length of theturning film801 and turn the light through a large angle, for example, between about 70-90°. The turning features820 can have one or more edges shaped such that they can reflect light incident on the edges from certain directions via total internal reflection (“TIR”) and cause the light to be turned toward thereflective display807 at a normal or near-normal angle of incidence (with respect to the display). The turning features820 illustrated and described herein may include a reflective coating which is selected and/or configured to increase light reflection properties (for example, reflective coatings as described in reference toFIGS. 17A,18,19C,20D,20E,21H, and others). The turning features820 may be molded, etched, or machined in theturning film801. In some embodiments, the turning features described herein may be molded, etched, or machined directly in thelight guide803 and aseparate turning film801 is not included, such that the light guide itself forms a turning film. In some embodiments, both thelight guide803 and theturning film801 include turning features820. Methods for forming turning features are described herein below in reference toFIGS. 19A-D,20A-F,21.
• Still referring toFIG. 8, in one embodiment, light811 emitted from thelight source809 enters thelight guide803 and/or theturning film801 along one or more edges or surfaces of the light guide and/or the turning film. A portion oflight811 propagates within thelight guide803 and turningfilm801 at shallow angles (e.g., not near-perpendicular to the reflective display807) and may generally remain within thelight guide803 and turningfilm801 by TIR. When light811 impinges on turningfeatures820, it may be turned at a perpendicular or near-perpendicular angle toward thedisplay807 allowing the light811 to break TIR and illuminate thedisplay807.Light811 that illuminates thereflective display811 may be reflected towards thefirst side800aand out of thedisplay deice800 towards a viewer. To maximize the brightness and efficiency of thedisplay807, the light turning features820 can be configured to reflect light at an angle normal to the display or close thereto.Light811 that does not at first reflect off of one of the turning features820 may continue to propagate through thelight guide803 and turningfilm801 and subsequently reflect off another of the turning features820 and be redirected towards thedisplay807, for example at a location further from thelight source809.
• In some embodiments, one or more optical isolation layers805 may be disposed between thelight guide803 and thereflective display807 to improve the optical performance of thedisplay800. Anoptical isolation layer805 may be disposed between thelight guide803 and an array of interferometric modulators to prevent light propagating through thelight guide803 at shallow angles from reaching the array, because such light would also be reflected from the display at a shallow angle and may not reach a viewer. According to some embodiments, theoptical isolation layer805 has an index of refraction substantially lower than thelight guide803 such that light traveling through thelight guide803 and striking theoptical isolation layer805 at an oblique or low grazing angle, for example, light traveling at a lower angle than the critical angle (which may be, for example, greater than 50° or 60°), will be reflected back into thelight guide803 and turningfilm801. Theoptical isolation layer805 can include, for example, silicon dioxide, fluorinated silicon dioxide, or another material with a suitable index of refraction.
• As shown inFIGS. 9A-10, the size, shape, pattern, and quantity of the turning features820 can vary. The quantity of turning features820 can vary from oneturning film801 to another and the density of turning features820 can vary from one portion of aturning film801 to another portion of the turning film. For example,FIG. 9A illustrates an embodiment having turning features820 disposed across aturning film801 in a uniform pattern. In another example,FIG. 9B illustrates an embodiment where the density of turning features820 is higher towards the middle or center of theturning film801 than near the edges of theturning film801. The quantity and pattern of turningfeatures820 can affect the total illumination efficiency of a display device and/or the uniformity of light extraction across a display device. An illumination efficiency of a display device can be determined, for example, by comparing the amount of light provided by a light source with the amount of light reflected from thereflective display807. Additionally, the quantity and pattern of turning features820 on a giventurning film801 may depend upon the size and/or shape of the turning features. In some embodiments, the turning features820 comprise between about 2% and 10% of the total top surface area of aturning film801 and/orlight guide803. In one embodiment, the turning features820 comprise about 5% of the total top surface area of aturning film801. In some embodiments, turning features820 are disposed about 100 microns from one another on aturning film801. In some embodiments, each turningfeature820 on aturning film801 can be substantially the same size and shape. In other embodiments, the turning features820 on aturning film801 may vary in size and/or shape. In some embodiments, aturning film801 comprises a plurality of turning features820 each having a generally different cross-sectional shape. In some embodiments, aturning film801 comprises a plurality of turning features820 each having a generally similar cross-sectional shape. In some embodiments, aturning film801 comprises a first group of turningfeatures820 each having a generally similar cross-sectional shape and a second group of turningfeatures820 each having a generally similar cross-sectional shape wherein the first group offeatures820 are differently shaped than the second group of turning features. In some embodiments, aturning feature820 may have a generally polygonal cross-sectional shape, for example, square, rectangular, trapezoidal, triangular, hexagonal, octagonal, or some other polygonal shape. In other embodiments, aturning feature820 may have a generally curvilinear cross-sectional shape. In some embodiments, aturning feature820 has an irregular cross-sectional shape. The cross-sectional shape of aturning feature820 may be symmetric or asymmetric. In some embodiments, the shape formed by the surface of a turning feature may resemble a cone, a frustum of a cone, a pyramid, a frustum of a pyramid, a prism, a polyhedron, or another three-dimensional shape. The shape of the turning features820 viewed from the top may vary. In some embodiments, the shape of the turning features820 viewed from the top may be polygonal, curvilinear, irregular, generally polygonal, generally curvilinear, square, triangular, rectangular, circular, round, or another shape.
• As shown inFIG. 9C, the turning features820 in a turning film801 (or in a light guide) can be configured to vary in depth and width. In one embodiment, turning features820 on aturning film801 each have a similar depth measured from the top of theturning film801 to the bottom of the turning features820. In other embodiments, aturning film801 comprises a plurality of turning features820 which may be of different depths. Similarly, the volume of each turningfeature820 can vary from turningfilm801 to turningfilm801 or from turningfeature820 to turning feature820 on a common turning film. In some embodiments, the volume, depth, or width of turning features820 on a giventurning film801 may vary depending on the distance from the turning feature to the light source. For example, in some embodiments, the number of turning features820 increases from the light input edge of theturning film801 towards the center of theturning film801 to facilitate uniform light extraction. In some embodiments, the width of each turningfeature820 is between about one micron and about six microns. In some embodiment, the width of each turningfeature820 is about two microns. The size and shape of each turningfeature820 can be varied by using different patterns, etching agents, process recipes, and/or different lithography and deposition conditions of theturning film801 and/orlight guide803. In one embodiment, a first set of turning features820 may be formed using a first timed etch and a differently shaped and/or sized set of turning features820 may be formed using a second timed etch.
• FIG. 9D illustrates additional examples of turning features820a,820bwhich are rotationally symmetrical. The turning features820a,820bmay comprise indentations in the material comprising the light guide and/or turning film. As illustrated, in some embodiments, feature820bmay take on a conical shape having an apex. In other embodiments, the cone may be truncated, removing the apex and creating a frustoconical shape, so as to create thestructure820a.820a′ shows a cross-sectional view of one exemplary implementation of thefeature820a.Example dimensions of 15 μm of width and 3.5 μm of depth are indicated in the cross-sectional view shown inFIG. 9D, but other sizes and shapes are also possible. A wide variety of other alternative configurations are also possible.FIG. 10 shows an embodiment comprising a plurality of variously-shaped turning features820. For example, components (e.g., layers) may be added, removed, or rearranged. Also, although the terms film and layers have been used herein, such terms as used herein include film stacks and multilayered structures. Such film stacks and multilayered structures can be adhered to other structures using adhesive, or can be formed on other structures using deposition or in other manners.
• FIGS. 11 and 12 illustrate cross-sectional views of a light guide803 (FIG. 11) and a turning film801 (FIG. 12) that include one or more light turning features820. In some embodiments, the light turning features820 include one or more edges that extend from a top side orsurface823 to a bottom side orsurface825 of theturning film801 orlight guide803. Such a configuration can also be referred to as “running through” theturning film801 and/orlight guide803. For example, inFIG. 11, light turning features820 are shown running through alight guide803. The light turning features820 may have similar cross-sectional shapes or different cross-sectional shapes. The light turning features820 may be formed using different etching agents and techniques, for example, timed etching. In some embodiments, the light turning features820 may be formed by standard wet or dry etching processes. In certain embodiments, the light turning features820 may be formed by sand blast processes.
• InFIG. 12, light turning features820 are shown running through a turning film that includes twolayers801a,801b.The two turning film layers801a,801bare disposed onlight guide803, but the turning features820 do not extend into thelight guide803 from the turning film layers801a,801b.In some embodiments, the turning features820 may be formed through a single ormultilayer turning film801 into alight guide803. In one embodiment, turning features820 can may be formed through a single ormultilayer turning film801 and extend through a single or multilayerlight guide803.
• In some embodiments, a turning film may include a plurality oflayers801a,801beach including turning one or more turning features820. Referring toFIG. 13, a turning film includes afirst layer801aand asecond layer801b.Thefirst layer801ais disposed on thesecond layer801bsuch that thesecond layer801bis disposed between thelight guide803 and thefirst layer801a.Thefirst layer801aand thesecond layer801bmay each include separate turning features820. The turning features820 may be offset from one another (e.g., laterally offset relative to the length or width of the film turning layers) such that aturning feature820 in thefirst layer801ais not disposed directly above anotherturning feature820 in thesecond layer801b. In other embodiments, the turning features820 in thefirst layer801amay overlap one or more turning features820 in thesecond layer801b. In some embodiments, the turning features820 in thefirst layer801ahave a height “h” (FIG. 13) such that the turning features run through the first layer but do not extend into thesecond layer801b.Similarly, the turning features820 in thesecond layer801bmay run through the second layer but do not extend into thefirst layer801a.In other embodiments, one or more turning features820 may be disposed in both thefirst layer801aand thesecond layer801bas illustrated inFIG. 12. In some embodiments, the turning features820 vary in shape, size, pattern, quantity, and/or volume from layer to layer or within a single layer. For example, in one embodiment, the turning features820 in afirst layer801aare each substantially the same size but vary in cross-sectional shape and the turning features820 in asecond layer801bare each differently sized and differently shaped from one another and the turning features820 in thefirst layer801a.
• In some embodiments, aturning film801 and/orlight guide803 can include additional features in addition to turning features820.FIG. 14 illustrates aturning film801 that includes a plurality of turning features820 having a first configuration. Theturning film801 includes an additional optical device,edge1400, which may be configured in different shapes and sizes to optimize performance and provide multiple operational advantages. One or more ofedges1400 may be included in addition to turning features820. The structure ofadditional edges1400 can vary depending upon application. In some embodiments,edge1400 is configured as a Fresnel lens. In some embodiments, an additional edge includes a micro lens.
• In some embodiments, the shape of one or more edges or sides of thelight guide803 and/or turningfilm801 can be configured to affect the introduction of light from a light source into theturning film801 and/orlight guide803.FIG. 15 illustrates an embodiment of alight guide803 and aturning film801 where the two layers have beveled or curved edges that are not perpendicular to the faces of thelight guide803 or turningfilm801. In some embodiments, such beveled or curved sides or edges of theturning film801 and/orlight guide803 may be employed to reduce or eliminate bright spots near the edges where light is introduced by a light source, and to increase the uniformity of light extraction across the display. Similarly, in some embodiments, providing unpolished edges or sides on thelight guide803 and/or turningfilm801 can serve to eliminate bright spots of light extraction by acting as a diffuser and reflector. In some embodiments, such beveled edges can be covered by a reflector when appropriate to recycle light propagating within theturning film801 and/orlight guide803.
• Turning now toFIG. 16, in some embodiments, one or more edges or surfaces of thelight guide803 and/or turningfilm801 may be angled relative to thefirst side800aand/orsecond side800bof the display device. In some embodiments, the edges of theturning film801 and thelight guide803 may be disposed at an angle of about 45° relative to thefirst side800aandsecond side800b.In other embodiments, the edges of theturning film801 and thelight guide803 may be disposed at an angle of between about 0° and about 90° relative to thefirst side800aandsecond side800b.In some embodiments, alight source809 may be configured to introduce light at an angle about normal to the angled edges of theturning film801 and thelight guide803 in order to increase the efficiency of the display device. In some embodiments, when light is introduced into thelight guide803 and/or turningfilm801 at an angle, the light propagates within thelight guide803 and turningfilm801 at shallow angles and more light is turned by the light turning features820.
• As discussed above, in some embodiments, turning features may turn light at the air/turning feature interface via TIR and direct the light towards one or more directions (e.g., towards a reflective display). For any of the embodiments described herein, a turning feature may include a reflective coating configured to provide desirable optical characteristics. The coating can include one or more layers. One of the layers may be an additional coating configured to increase the reflectivity of a turning feature. The reflective coating may be metallic. In some embodiments, some of the plurality of turning features may include a reflective coating and others may not. In certain embodiments, a portion (or portions) of a turning feature may be covered with a reflective coating and another portion (or portions) of the turning feature may not be covered with a reflective coating. Using a reflective coating can improve the efficiency of a display device because the reflective coatings can be configured to reflect substantially all of the light that encounters the coatings and redirect that light toward the display. Additionally, in some applications, it may be desirable to add or build additional layers or features on top of one or more turning features. In some embodiments, one or more cover layers, for example, anti-glare layers, anti-reflection layers, anti-scratch layers, anti-smudge layers, diffuser layers, color filtering layers, lenses, or other layers, may be added on top of one or more turning features. In some embodiments, conductive electrode plates may be added on top of a turning film including turning features. In one embodiment, a touch sensor may be added over one or more turning features. In embodiments where turning features rely solely on the air/feature interface to turn light, having additional layers on the turning features may complicate the desired optical functionality because adhesives or laminates may cover or partially cover one or more turning features and affect TIR characteristics of the light turning feature. However, when reflective coatings are disposed over turning features, one or more additional layers can be added over the turning features without affecting the light turning properties of the turning features because they no longer rely on the TIR properties of a material-air interface.
• Using reflective coatings on turning features can diminish the contrast of the display if no additional coatings are disposed between the reflective coatings and a viewer. Accordingly, additional layers may be deposited over the reflective coating to prevent reflection of light from the reflective coating towards a viewer. In one embodiment, additional layers may be deposited over the reflective coating to form a static interferometric stack that appears dark or black to a viewer in order to improve the contrast of the display device while reflecting light incident on the reflective coating side of the stack towards a reflective display. In some embodiments, a static interferometric stack may include a reflector layer deposited on the turning film or light guide, an absorber layer, and an optical resonant cavity defined by the reflector layer and the absorber layer. In some embodiments, the reflector layer is a partial reflector. In some embodiments, reflective coatings are covered by one or more dark or black coatings to form a black mask which prevents reflection of light towards a viewer from the reflective coating.
• FIG. 17A illustrates aturning film801 that includes turning features820 (note:FIG. 17A and the other figures herein are not drawn to scale). Aninterferometric stack1707 is formed over portions of certain surfaces of each turningfeature820. Aninterferometric stack1707 includes areflective layer1705 disposed on one or more portions of theturning feature820 surface. Theinterferometric stack1707 also includes an opticallyresonant layer1703 formed on top of thereflective layer1705, and anabsorber layer1701 disposed over the opticallyresonant layer1703. Theinterferometric stacks1707 can be configured to interferometrically reflect selected wavelengths of light. This reflected light is incident on theabsorber layer1701. Theabsorber layer1701 and theinterferometric stacks1707 are configured such that theabsorber layer1701 absorbs light of the reflected wavelength such that thestack1707 appears black or dark, which can increase the contrast of the display. In the embodiment illustrated inFIG. 17A, thereflective layer1705 is formed on the tapered sidewalls831 of each turningfeature820 but not the bottom833. In some embodiments, thereflective layer1705 may be formed on portions of the taperedsidewalls831 and/or certain lower portions or thebottoms833.
• In some embodiments, thereflector layer1705 includes a single layer and in other embodiments thereflector layer1705 includes multiple layers of material. In various embodiments, the thicknesses of theabsorber1701 andreflective layers1705 may be selected to control relative amounts of reflectance and transmittance of light. In some embodiments, both theabsorber1701 and reflective1705 layers may comprise metal, and both can be configured to be partially transmissive. According to certain embodiments, the amount of light substantially reflected or transmitted through thereflective layer1705 can be affected by varying the thickness and the composition of thereflective layer1705, whereas the apparent color of reflection is largely determined by the interference effect governed by the size or thickness of the opticallyresonant layer1703 and the material properties of theabsorber layer1701 that determine the difference in optical path length. In some embodiments, modulating the bottomreflective layer1705 thickness can modulate the intensity of the reflected color versus the overall reflectivity of theinterferometric stack1707.
• In some embodiments, the opticallyresonant layer1703 is defined by a solid layer, for example, an optically transparent dielectric layer, or plurality of layers. In other embodiments, the opticallytransparent layer1703 is defined by an air gap or combination of optically transparent solid material layer(s) and an air gap. In some embodiments, the thickness of the optically resonant layer1704 may be selected to maximize or minimize the reflection of one or more specific colors of the light incident on theabsorber1701 side of thestack1707. In various embodiments, the color or colors reflected by the opticallyresonant layer1703 may be changed by changing the thickness of the layer.
• Theabsorber layer1701 can comprise various materials, for example, molybdenum (Mo), titanium (Ti), tungsten (W), chromium (Cr), etc., as well as alloys, for example, MoCr. Theabsorber1701 can be between about 20 and about 300 Å thick. In one embodiment, theabsorber1701 is about 80 Å thick. Thereflective layer1705 may, for example, comprise a metal layer, for example, aluminum (Al), nickel (Ni), silver (Ag), molybdenum (Mo), gold (Au), and chromium (Cr). Thereflective layer1701 can be between about 100 Å and about 700 Å thick. In one embodiment, thereflective layer1701 is about 300 Å thick. The opticallyresonant layer1703 can comprise various optically resonant materials, for example, air, silicon oxy-nitride (SiO_xN), silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), titanium dioxide (TiO₂), magnesium fluoride (MgF₂), chromium (III) oxide (Cr₃O₂), silicon nitride (Si₃N₄), transparent conductive oxides (TCOs), indium tin oxide (ITO), and zinc oxide (ZnO). In some embodiments, any dielectric with an index of refraction (n) between 1 and 3 can be used to form a suitable spacer layer. In some embodiments, the opticallyresonant layer1703 is between about 500 Å and about 1500 Å thick. In one embodiment, the opticallyresonant layer1703 is about 800 Å thick.
• Aninterferometric stack1707 as shown inFIG. 17 can be configured to selectively produce a desired reflection output using optical interference. As discussed above, in some embodiments, this reflected output may be “modulated” by selection of the thickness and optical properties of the layers that form thestack1707. The color observed by a viewer viewing theabsorber layer1701 side of the stack will correspond to the frequencies which are substantially reflected out of theinterferometric stack1707 and which are not substantially absorbed or destructively interfered by one or more layers in thestack1707. As shown inFIG. 17B, theinterferometric stacks1707 depicted inFIG. 17A can be configured to appear dark or black to a viewer viewing theabsorber layer1701 side of theturning film801. In some embodiments, configuring the coated portions of the turning features820 to appear dark or black improves the contrast of the display device while providing other benefits discussed above (e.g., improved light turning functionality and easily building layers on top of the turning features820 without disrupting the turning functionality). Additionally, selectively coating only portions of the turning features820, for example, the side-walls, with interferometric stack layers can limit the total area of theturning film801 that appears dark to a viewer due to interferometric disruption.
• Turning now toFIG. 18, an embodiment of aturning film801 is depicted including various turning features820. Eachturning feature820 differs in size and cross-sectional shape. Additionally, each turning feature includes aninterferometric stack1707 covering at least a portion of theturning feature820 surface. As discussed above, turning features820 that includeinterferometric stacks1707 can vary in size, shape, quantity, and pattern depending on the application. For example, in some embodiments, some turning features820 on aturning film801 can be covered at least partially by aninterferometric stack1707 and other turning features820 on thefilm801 may not be covered by an interferometric stack. In other embodiments, each turningfeature820 can vary in shape and/or size but each turningfeature820 may be covered at least partially by aninterferometric stack1707. In some embodiments, each turningfeature820 can be covered at least partially by aninterferometric stack1707 but the coverage may vary from oneturning feature820 to another.
• Turning now toFIGS. 19A-19C, one method of forminginterferometric stacks1707 over turning features820 is depicted in three steps.FIG. 19A shows an embodiment of aturning film801 including turning features820 formed thereon. The turning features820 may be etched, molded, machined, or otherwise formed in or on theturning layer801 using known methods. In some embodiments, the turningfilm801 can include multiple layers. In one embodiment, the turning features820 are formed directly on a light guide or on aturning film801 that comprises a light guide.FIG. 19B shows an embodiment of aturning film801 with aninterferometric stack1707 deposited on theturning feature820 side of theturning film801. As discussed above, theinterferometric stack1707 may contain a plurality of layers configured to produce a desired reflection output using optical interference. In one embodiment, the interferometric stack includes areflective layer1701 deposited on theturning feature820 side of theturning film801, an opticallyresonant layer1703 deposited on thereflective layer1701, and anabsorber layer1707 deposited on the optically resonant cavity layer.
• Methods of depositing the layers of aninterferometric stack1707 are known to those of skill in the art and include, for example, physical vapor deposition, chemical vapor deposition, electro-chemical vapor deposition, plasma-enhanced chemical vapor deposition, and/or other deposition techniques. As shown inFIG. 19B, asingle interferometric stack1707 covers theentire turning feature820 surface of theturning film801. In some embodiments, theinterferometric stack1707 is configured to appear dark or black to a viewer and thus, theentire turning film801 shown inFIG. 19B would appear dark or black to viewer looking at the turning feature side of the turning film. In some embodiments, it is important to limit the coverage of theinterferometric stack1707 to one or more portions of theturning film801 surface. In one embodiment, one or moreinterferometric stacks1707 are disposed near or over only the turning features820. Theturning film801 inFIG. 19B can be processed further to limit the coverage of theinterferometric stack1707.
• FIG. 19C shows an embodiment of theturning film801 depicted inFIGS. 19A and 19B withinterferometric stacks1707 disposed only over portions of the turning features820. In some embodiments, the turningfilm801 depicted inFIG. 19C can be formed by polishing the turning feature side of theturning film801 depicted inFIG. 19B and thinning the opposite side. The turning feature side of theturning film801 may be polished until theinterferometric stack1707 is removed from surfaces other than the turning features820. Similarly, the opposite side of theturning film801 may be optionally thinned until theinterferometric stack1707 is removed from a portion of the turning features820, for example, a bottom portion. In one embodiment, the turningfilm801 depicted inFIG. 19B may be polished and/or thinned such that theinterferometric stack1707 is divided into separate interferometric stacks that cover only a portion or portions of the turning features820 resulting in aturning film801 similar to the turning film schematically depicted inFIG. 19C.
• FIG. 19D is a block diagram depicting amethod1920 of manufacturing the turning film shown inFIG. 19C, according to one embodiment.Method1920 includes providing a turning film having a first side and a second side opposite the first side, the turning film including turning features formed on the first side as illustrated inblock1921, depositing an interferometric stack on the first side of the turning film as illustrated inblock1923, polishing the first side of the turning film until the interferometric stack is removed from surfaces other than the turning features as illustrated inblock1925, and thinning the second side until the interferometric stack is removed from at least the bottom portion of each turning features as illustrated inblock1927.
• FIGS. 20A-20E illustrate an embodiment of another method of forminginterferometric stacks1707 over turning features820.FIG. 20A shows an embodiment of alight guide803 and aturning film801 disposed on thelight guide803. In some embodiments, adissolvable layer2001, for example, a photoresist coating or layer, can be formed or deposited over the turningfilm801 as shown inFIG. 20B. In some embodiments, a plurality of light turning features820 can then be formed in thedissolvable layer2001 and theturning film801 as shown inFIG. 20C. According to certain embodiments, the turning features820 can have varying shapes and sizes. In some embodiments, the turning features820 are formed by etching or embossing. In some embodiments, the turning features820 run through theturning film801 to thelight guide803. In other embodiments, the turning features820 are shallower and do not run through theturning film801.
• Turning now toFIG. 20D, aninterferometric stack1707 is formed over thedissolvable layer2001, the exposed portions of theturning film801, and the exposed portions of thelight guide803 shown inFIG. 20C, such that theinterferometric stack1707 covers theturning feature820 side of thelight guide803 and turningfilm801 stack. According to some embodiments, theinterferometric stack1707 includes an aluminum layer, a silicon dioxide layer, and a molybdenum-chromium alloy. In some embodiments, portions of the depositedinterferometric stack1707 are removed from the turning feature side of theturning film801 by stripping or dissolving thedissolvable layer2001.FIG. 20E shows an embodiment of thelight guide803 and turningfilm801 depicted inFIG. 20D with the portions of theinterferometric stack1707 removed from portions of theturning film801. In some embodiments, the turningfilm801 andlight guide803 shown inFIG. 20E can be used to efficiently turn light towards a reflective display while still allowing a viewer to see the reflection from the display through the two layers. In some embodiments, additional layers, for example, a cover, can be added to theturning film801 with adhesives or by lamination without sacrificing the light turning performance of the light turning features820.
• FIG. 20F is a block diagram depicting amethod2020 of manufacturing the illumination device shown inFIG. 20E, according to one embodiment.Method2020 includes the steps of providing a light guide with a light turning film disposed thereon as illustrated inblock2021, depositing a dissolvable layer over the turning film as illustrated inblock2023, etching one or more turning features in the dissolvable layer and turning film as illustrated inblock2025, depositing an interferometric stack over the dissolvable layer and exposed portions of the turning film and light guide as illustrated inblock2027, and removing the dissolvable layer as illustrated inblock2029.
• FIGS. 21A-21H illustrate an embodiment of a method of forminginterferometric stacks1707 over different portions of turning features820. As shown inFIGS. 20A-20C, according to one embodiment, the process begins by providing alight guide803, depositing aturning film801 onto thelight guide803, and then depositing adissolvable layer2001 over certain portions of theturning film801. In some embodiments, thelight guide803 and the turning film can comprise any optically transparent material. In one embodiment, thedissolvable layer2001 comprises a light-sensitive material, for example, a photoresist. In some embodiments, adissolvable layer2001ais deposited across an entire side or surface of theturning film801 and then portions of the photoresist layer are removed by etching. According to certain embodiments, thedissolvable layer2001ais selectively deposited on portions of theturning film801.
• Turning now toFIG. 21D-21E, in some embodiments, turning features820 may be formed in theturning film801 in portions of theturning film801 that are not covered by thedissolvable layer2001a.In certain embodiments, the turning features820 are formed by various etching processes including dry etch processes and/or wet etch processes. As discussed above, the turning features820 can vary at least in size, shape, quantity, and/or pattern. In some embodiments, after the turning features820 are formed in theturning film801, thedissolvable layer2001ais stripped or dissolved and anotherdissolvable layer2001bis added to certain portions of theturning film801 and/or thelight guide803. In some embodiments, thedissolvable layer2001bmay be a photoresist layer that is patterned over certain portions of theturning film801 and thelight guide803 by a spin-coat, expose, and develop process. In some embodiments, a photoresist layer can be deposited using known methods to leave a resist pattern that serves as a physical mask to cover surfaces that are desired to be protected from subsequent etching, implantation, lift-off, and/or deposition steps. As shown inFIG. 21E, portions of the turning features820 are exposed and other portions of the turning features820,light guide803, and turningfilm801 are covered by thedissolvable layer2001b.
• As shown inFIGS. 21F-21H, in some embodiments, aninterferometric stack1707 can be deposited layer by layer over adissolvable layer2001band the exposed portions of theturning film801. In one embodiment, theinterferometric stack1707 includes a reflective layer, an optically resonant layer, and an absorber layer. In some embodiments, a reflective layer and black coating layer may be deposited over thedissolvable layer2001band the exposed portions of theturning film801. In some embodiments, once theinterferometric stack1707 has been deposited, thedissolvable layer2001bmay be removed or lifted-off from the turningfilm801 and thelight guide803. When thedissolvable layer2001bis lifted-off, the layers deposited onto thedissolvable layer2001bcan also be removed. As shown inFIG. 21G, in some embodiments,interferometric stacks1707 may remain over certain portions of turningfeatures1707 and/or theturning film801 andlight guide803 after thedissolvable layer2001 is removed. Limitinginterferometric stack1707 coverage to certain portions of the turning features820 and/or turningfilm801 can be used to balance contrast concerns with the light turning benefits provided by a reflective layer included as part of the interferometric stacks1707. In some embodiments,interferometric stacks1707 are deposited over the side-walls of the turning features820 and are configured to appear as black or dark rings to a viewer. In other embodiments,interferometric stacks1707 are deposited over the entire surfaces of the turning features820 and appear as black or dark circles or dots to a viewer.
• In some embodiments, apassivation layer2101 can be added over aturning film801 that includesinterferometric stack1707 coated turning features820.FIG. 21H shows an embodiment where apassivation layer2101 has been added over the embodiment shown inFIG. 21G. In some embodiments, thepassivation layer2101 can include silicon dioxide, silicon oxy-nitride, aluminum oxide, and/or any optically transparent material. In some embodiments, thepassivation layer2101 includes more than one layer. In some embodiments, thepassivation layer2101 includes an anti-glare layer, an anti-reflection layer, an anti-scratch layer, an anti-smudge layer, a diffuser layer, a color filtering layer, and/or a lens. In some embodiments, additional layers can be added over thepassivation layer2101. In some embodiments, thepassivation layer2101 can comprise an adhesive or material used to couple an additional layer (not shown) with theturning film801.
• FIG. 21J is a block diagram depicting amethod2120 of manufacturing the illumination device shown inFIG. 21H, according to one embodiment.Method2120 includes the steps of providing a light guide atblock2121, disposing a turning film on one surface of the light guide atblock2123, depositing a first dissolvable layer on the turning film atblock2125, etching one or more turning features in the first dissolvable layer and turning film atblock2127, removing the first dissolvable layer atblock2129, depositing a second dissolvable layer over exposed portions of the light guide and portions of the turning film where a light turning feature is not formed atblock2131, depositing an interferometric stack over the second dissolvable layer and exposed portions of the turning film atblock2133, removing the second dissolvable layer atblock2135, and depositing a passivation layer over the turning film and turning features atblock2137.
• FIGS. 22A-22E illustrate another embodiment of a method of forminginterferometric stacks1707 over turning features820. The method depicted inFIGS. 22A-22E is similar to the method depicted inFIGS. 21A-21H except that adissolvable layer2001 is not deposited within the turning features820. As shown inFIG. 22C, aninterferometric stack1707 is then deposited directly onto the entire surface of each turningfeature820 and also onto thedissolvable layer2001. In some embodiments, thedissolvable layer2001 is then lifted-off or removed resulting in the embodiment shown inFIG. 22D. Because theinterferometric stack1707 inFIG. 22D covers the entire surface of each turningfeature820, the turning features appear as black or dark shapes to a viewer instead of rings. As discussed above, in some embodiments,interferometric stacks1707 can be added to the same portions of each turningfeature820 or different portions. Additionally, in some embodiments, turning features820 can vary in size, shape, quantity, and pattern and the coverage of these turning features820 byinterferometric stacks1707 can also vary. For example, in one embodiment, afirst turning feature820 may not be covered by aninterferometric stack1707, asecond turning feature820 may be completely covered by aninterferometric stack1707, and athird turning feature820 may be covered partially by one or moreinterferometric stacks1707. As discussed above, in some embodiments, a reflective layer and one or more dark coating layers may be deposited over turning features or portions of turning features.
• FIG. 22F is a block diagram depicting amethod2220 of manufacturing the illumination device shown inFIG. 22E, according to one embodiment.Method2220 includes the steps of providing a light guide atblock2221, disposing a turning film on one surface of the light guide atblock2223, depositing a dissolvable layer on the turning film atblock2225, etching one or more turning features in the dissolvable layer and turning film atblock2227, depositing an interferometric stack over the dissolvable layer and the light turning features atblock2229, removing the dissolvable layer atblock2231, and depositing a passivation layer over the turning film and turning features atblock2233.
• Turning now toFIGS. 23A-23J, an embodiment of a method of forming a reflective coating over turning features820 is shown. As shown inFIGS. 23A-23D, in some embodiments, the process begins by adding aturning film801 to alight guide803, applying adissolvable layer2001 in a particular pattern over the turningfilm801, etching turning features820 into theturning film801, and stripping thedissolvable layer2001 from the turningfilm801. Turning toFIG. 23E, in one embodiment, an electroplating process may start by applying aseed layer2301 over the turningfilm801 and the surfaces of the turning features820. The seed layer may comprise any suitable material, for example, copper or silver. In some embodiments, a stick layer (not shown) may optionally be added over the turningfilm801 and the turning features820. Examples of suitable stick layers include tantalum, titanium, and molybdenum. In some embodiments, once theseed layer2301 is added over the turningfilm801 and the turning features820, adissolvable layer2001 may be added over the turningfilm801 and the portions of the turning features820. In one embodiment, thedissolvable layer2001 includes a photoresist layer that is spin-coated, exposed, and developed. In some embodiments, thedissolvable layer2001 may be applied in a pattern to expose all, or certain portions, of the turning features820. In one embodiment, thedissolvable layer2001 is patterned to leave the sidewalls of one or more turning features820 exposed.
• Turning now toFIG. 23G and 23H, in certain embodiments, portions of theseed layer2301 that are not covered by thedissolvable layer2001 are electroplated and thedissolvable layer2001 is stripped or removed from the turningfilm801 and the turning features820. In some embodiments, portions of theseed layer2301 may then be etched or removed with another process resulting in theturning film801 andlight guide stack803 shown inFIG. 23I. In some embodiments, portions of theseed layer2301 that are not over turning features820 may be removed by etching or another process. In certain embodiments, portions of theseed layer2301 that have not been electroplated are removed by etching. In some embodiments, portions of theseed layer2301 that were electroplated may be removed using various methods known in the art. In some embodiments, once portions of theseed layer2301 have been removed, apassivation layer2101 can optionally be applied over the turningfilm801 and turning features820 as schematically depicted inFIG. 23J. Because the turning features820 rely on a reflective coating applied to at least a portion of the turning features820 surfaces to turn light instead of total internal reflection, an air pocket over the turning features820 does not necessarily have to be maintained.
• FIG. 23K is a block diagram depicting amethod2320 of manufacturing the illumination device shown inFIG. 23J, according to one embodiment.Method2320 includes the steps of providing a light guide atblock2321, disposing a turning film on one surface of the light guide atblock2323, depositing a first dissolvable layer on the turning film atblock2325, etching one or more turning features in the first dissolvable layer and turning film atblock2327, removing the first dissolvable layer atblock2329, depositing a seed layer over the dissolvable layer and the light turning features atblock2331, depositing a second dissolvable layer over portions of the seed layer atblock2333, electroplating exposed portions of the seed layer atblock2335, removing the second dissolvable layer atblock2337, etching portions of the seed layer that are not electroplated atblock2339, and depositing a passivation layer over the turning film and turning features atblock2341.
• FIGS. 24A-24F depict an embodiment of a method of forming turning features820 with a reflective coating on the side of alight guide803 opposite a reflective display. In some embodiments, a reflective display may include thelight guide803 and thus, thelight guide803 can be used both for light turning and as part of the reflective display assembly. In some embodiments, the process begins inFIGS. 24A and 24B by depositing aseed layer2301 onto alight guide803. Thelight guide803 may comprise any suitable material, for example, inorganic materials and/or organic materials. In some embodiments, theseed layer2301 may comprise any suitable material, for example, tantalum, titanium, and molybdenum. As shown inFIG. 24C, in one embodiment, adissolvable layer2001 may be added over theseed layer2301 in a pattern leaving certain portions of theseed layer2301 exposed. Turning toFIG. 24D, in some embodiments, the exposed portions of theseed layer2301 may be electroplated using known methods, resulting in anelectroplate layer2303 disposed over at least a portion of theseed layer2301. In some embodiments, thedissolvable layer2001 may then be removed and portions of theseed layer2301 that were not electroplated may be etched or otherwise removed resulting in thelight guide803,seed layer2301, andelectroplate2303 stack depicted inFIG. 24E. In some embodiments, thedissolvable layer2001 comprises a photoresist and the photoresist is removed using known methods.
• Turning toFIG. 24F, aturning film801 can then be added over thelight guide803 surrounding-theseed layer2301 portions andelectroplate portions2303. In some embodiments, thelight guide803 may comprise material that is index matched to thelight guide803. In some embodiments, thelight guide803 and theturning film803 have about the same index of refraction. In some embodiments, thelight guide803 and theturning film801 each have an index of refraction between about 1.45 and 2.05. In some embodiments, thelight turning film801 comprises the same material(s) as thelight guide803. In some embodiments, the surface or side of theturning film801 opposite thelight guide803 may be substantially planar. In some embodiments, additional layers (not shown), for example, a cover layer, may be added over the turningfilm801. One advantage of the embodiment shown inFIGS. 24A-24F is that it allows the use of only asingle dissolvable layer2001 mask instead ofmultiple dissolvable layer2001 masks.
• FIG. 24G is a block diagram depicting amethod2420 of manufacturing the illumination device shown inFIG. 24F, according to one embodiment.Method2420 includes the steps of providing alight guide2421, depositing a seed layer on one surface of thelight guide2423, depositing a dissolvable layer on theseed layer2425, etching one or more turning features in thedissolvable layer2427, electroplating exposed portions of theseed layer2429, removing thedissolvable layer2431, etching portions of the seed layer that are not electroplated2433, and depositing a turning film layer on the light guide over portions of the seed layer that are not electroplated2435.
• FIGS. 25A-25G show another embodiment of a method of forming turning features820 with a reflective coating on the side of alight guide803 opposite a reflective display. Referring toFIGS. 25A-25C, in some embodiments, the method includes providing alight guide803, depositing aseed layer2301 on one surface of thelight guide803, and adding adissolvable layer2001 over theseed layer2301. In some embodiments, thedissolvable layer2001 may be added in a certain pattern or it may be deposited over the entire surface of theseed layer2301 and have certain portions removed to create a desired pattern. ComparingFIG. 25C to 24C, it can be appreciated by those of skill in the art that thedissolvable layer2001 pattern can be used to create differently shaped voids defined by sides or surfaces of different portions of thedissolvable layer2001 and theseed layer2301. For example, in some embodiments, voids may be formed with generally trapezoidal cross-sectional shapes or inverted trapezoidal cross-sectional shapes. Turning toFIG. 25D, in some embodiments, exposed portions of theseed layer2301 may be electroplated, resulting in anelectroplate layer2303 that partially fills the voids shown inFIG. 25C. In some embodiments, thedissolvable layer2001 may then be removed and portions of theseed layer2301 that were not electroplated may be etched or otherwise removed resulting in thelight guide803,seed layer2301, andelectroplate2303 stack depicted inFIG. 25E. Turning toFIGS. 25F and 25G, in certain embodiments, aturning film801 may be added over thelight guide803 and surround theseed layer2301 portions and electroplate layers2303. In some embodiments, abuffering layer2501 may be added on top of theturning film801. In certain embodiments, thebuffering layer2501 may comprise varying materials or layers configured to protect theturning film801 from scratches or other damage.
• FIG. 25H is a block diagram depicting amethod2520 of manufacturing the illumination device shown inFIG. 25G, according to one embodiment.Method2520 includes the steps of providing a light guide atblock2521, depositing a seed layer on one surface of the light guide atblock2523, depositing a dissolvable layer on the seed layer atblock2525, etching one or more turning features in the dissolvable layer atblock2527, electroplating exposed portions of the seed layer atblock2529, removing the dissolvable layer atblock2531, etching portions of the seed layer that are not electroplated atblock2533, depositing a turning film layer on the light guide over portions of the seed layer that are not electroplated atblock2535, and depositing a buffering layer over the turning film layer atblock2537.
• Turning now toFIGS. 26A-26F, another embodiment of a method of forming turning features820 with a reflective coating on aturning film801 is shown. In some embodiments, the method begins with providing aturning film801 and forming turning features820 on at least one surface of theturning film801. In some embodiments, a light guide may be provided and turning features820 may be formed on the light guide using known methods. As shown inFIG. 26C, in some embodiments, aninterferometric stack1707 is deposited over the turningfeature820 side of theturning film801. In certain embodiments, a reflective coating is applied instead of an interferometric stack and a dark coating layer is applied over the reflective coating. In some embodiments, adissolvable layer2001 is then formed in a pattern covering certain portions of theinterferometric stack1707 as shown inFIG. 26D. In some embodiments, thedissolvable layer2001 includes a photoresist material. In certain embodiments, portions of theinterferometric stack1707 that are not covered by thedissolvable layer2001 are removed. In some embodiments, the portions of theinterferometric stack1707 that are not covered by thedissolvable layer2001 are etched away using known methods and thedissolvable layer2001 is then removed resulting in the embodiment shown inFIG. 26E. In some embodiments, anadditional layer2101, for example, a passivation layer or cover layer, may then be added over the turningfilm801 and the interferometric stacks1707. One of skill in the art will understand that there are numerous methods and processes to form reflective layers and/or interferometric stacks over turning features or portions of turning features on a substrate layer.
• FIG. 26G is a block diagram depicting amethod2620 of manufacturing the illumination device shown inFIG. 26F, according to one embodiment.Method2620 includes the steps of providing a turning film having a first side and a second side opposite the first side atblock2621, etching turning features in the first side atblock2623, depositing an interferometric stack over the first side of the turning film atblock2625, depositing a dissolvable layer over the sidewalls of the turning features atblock2627, etching exposed portions of the interferometric stack atblock2629, removing the dissolvable layer atblock2631, and depositing a passivation layer over the turning film and turning features atblock2633.
• As discussed above, turning films and light guides can comprise various materials. Light guides or turning films are commonly formed by organic materials such as polymers or plastics. Using plastics in the light guide and/or turning film, however, can limit the mechanical, environmental, and/or chemical robustness of an illumination device. Certain molded plastics, for example, acrylics, polycarbonates, and cyclooelfin polymers, have low scratch resistance, limited chemical resistance, and have limited lifetime, as their optical properties can degrade from exposure to environmental stress factors. In some cases, cleaning and/or exposure to ultraviolet rays, temperature, and humidity, can cause molded plastics to degrade over time. In some embodiments of the invention, inorganic materials, for example, silicates and alumina, can be used to form one or more layers of a display device to increase the robustness of an illumination device. For example, in some embodiments, a substrate, light guide, turning feature, or other layers of the device can comprise an inorganic material. In some embodiments, inorganic materials can also provide superior optical properties, for example, higher transparency and higher refractive indices, than those of organic materials. In some embodiments, an inorganic turning film can be formed on an inorganic light guide using the methods disclosed below.
• Turning now toFIGS. 27A-27C, one embodiment of a method of building an illumination device incorporating an inorganic light guide and turning film is depicted.FIG. 27A shows an embodiment of alight guide803 comprising an inorganic material. In some embodiments, thelight guide803 comprises an aluminosilicate or sapphire. In some embodiments, a mixture of high purity silane (SiH₄dilute in argon), nitrous oxide (N₂O), and ammonia (NH₃) gases may be mixed to form an illumination device comprising silicon oxy-nitride having a desired refractive index. In some embodiments, the refractive index of the silicon oxy-nitride can be adjusted to a desired level, for example, to match the index of thelight guide803. In certain embodiments, the refractive index of the silicon oxy-nitride can be adjusted to the desired level by adjusting the N₂O:NH₃molar ratio. In one embodiment, the N₂O:NH₃molar ratio may be adjusted by controlling the flow rates of the respective gases. Example refractive indices of materials used in some embodiments include indices ranging from about 1.46 to about 2.05 as the N₂O:NH₃molar ratio increases from 0 to 100%.
• Turning now toFIG. 27B, silicon oxy-nitride can be deposited on thelight guide803 to form aturning film801 which can be configured with an index of refraction matched to that of thelight guide803. In one embodiment, a silicon oxy-nitride material can be deposited on thelight guide803 using plasma enhanced chemical vapor deposition (“PECVD”). In some embodiments, turning features820 can then be formed in the surface of theturning film801 opposite thelight guide803, for example as illustrated inFIG. 27C. In one embodiment, the turning features820 can be etched to form sloped side-walls, for example using a photolithographically patterned mask layer and a suitable wet or dry etching method. Differently sized and shaped turning features820 can be formed in theturning film801 using various manufacturing methods. In some embodiments, the shape formed by the surface of aturning feature820 may comprise a cone, a frustum of a cone, a pyramid, a frustum of a pyramid, a prism, a polyhedron, or another three-dimensional shape. In some embodiments, additional coatings, for example, reflective coatings, interferometric stacks, and/or dark coatings may be added over the turning features820 or portions of the turning features.
• In some embodiments, an illumination device comprising an inorganic light guide and turning film can be made using a sol-gel precursor mixture to form the light turning film. In some embodiments, the sol-gel precursor mixture can comprise organosilicon and organotitanium compounds which, when combined, form mixtures of silicon oxide and titanium dioxide. In some embodiments, the index of refraction of the structure produced from a sol-gel precursor mixture can be adjusted by adjusting the ratios of the precursors and/or by applying heat treatment. In some embodiments, the index of refraction of a structure produced from a sol-gel precursor mixture can be adjusted to a level anywhere between about 1.4 to about 2.4. In some embodiments, the light guide can comprise glass (e.g., TFT substrate type or aluminosilicate) having a refractive index of about 1.52. In other embodiments, a light guide can comprise sapphire having a refractive index of about 1.77. In some embodiments, a sol-gel precursor mixture can comprise tetraethaoxysilane (TEOS or tetraethyl orthosilicate), titanium isopropoxide, solvents, for example, ethanol, isopropanol, or mixtures thereof, and can also include one or more additives, for example, hydrochloric acid, acetic acid, and titanium chloride.
• In one embodiment, a sol-gel precursor mixture is formed by hydrolyzing TEOS and titanium isopropoxide, at a ratio chosen to match the refractive index of the light guide, along with TiCl₄in an ethanol/IPA mixture with water at an acidic pH of about 1 (which can be obtained, for example, by addition of HCl), and aging the solution at about 40 C. In some embodiments, the sol-gel precursor mixture can then be coated over the light guide. In certain embodiments, turning features may be formed in the sol-gel precursor mixture layer by pressing a mold onto the gelled ceramic coating, ramping the temperature to increase cross-link density, and drying at about 110 C. In some embodiments, the turning film comprising the sol-gel mixture can be further processed by densifying the sol-gel precursor mixture between about 600 C and about 800 C, so that the final refractive index of the turning film matches the refractive index of the light guide.
• FIG. 27D is a block diagram depicting amethod2720 of manufacturing the illumination device shown inFIG. 27C, according to one embodiment.Method2720 includes the steps of providing a light guide comprising an inorganic material, the light guide having a known index of refraction atblock2721, mixing high purity silane, nitrous oxide, and ammonia to create a silicon oxy-nitride having the same index of refraction as the light guide atblock2723, depositing the silicon oxy-nitride on one surface of the light guide atblock2725, and etching turning features in the silicon oxy-nitride layer atblock2727.FIG. 27E is a block diagram depicting a method atblock2750 of manufacturing the illumination device shown inFIG. 27C, according to one embodiment.Method2750 includes the steps of providing a light guide comprising an inorganic material, the light guide having a known index of refraction atblock2751, mixing organosilicon and organotitanium compounds to form a sol-gel precursor having the same index of refraction as the light guide atblock2753, depositing the sol-gel precursor on one surface of the light guide atblock2755, and molding turning features in the sol-gel precursor layer atblock2757.
• Turning now toFIG. 28, a cross-sectional view of an embodiment of aturning film801 is depicted. In some embodiments, the turningfilm801 comprises silicon oxy-nitride and includes one ormore turning feature820. In some embodiments, the one or more turning features820 can be formed by an etching process. In one embodiment, the etching process uses an etching gas comprising a mixture of SiON etchant, for example, CF₄, and a mask material etchant, for example, O₂for photoresist. In some embodiments, the silicon oxy-nitride is pulled back from itsinitial profile2801 as it is removed during etching, resulting in one or more light turning features820 with tapered side walls. In some embodiments, the turningfilm801 can be disposed on alight guide803. In some embodiments, the turningfilm801 can have an index of refraction that is, or is about, the same as the index of refraction of thelight guide803. In some embodiments, a reflective layer (not shown), an interferometric stack (not shown), and/or a black or dark coating (not shown) can be disposed over portions of theturning film801 including portions of the turning features820.
• As indicated herein, in some embodiments turning films can include turning features having curvilinear cross-sectional shapes. In the absence of curved edges or sidewalls, each edge extracts light and produces an emission cone based on the collimation of the light propagating in the turning film. Turning features with curved edges can be configured to adjust the angular width of the illumination cone of light produced by the turning features. Thus, curved edges can be configured to focus (e.g., reduce the angular width of the emission cone) or to disperse (e.g., increase the angular width of the emission cone) light propagating inside the turning film. These configurations can allow for the optimization of the emission properties of the turning film for a variety of input light sources and other geometrical constraints.
• Adjusting (e.g., increasing or decreasing) the angular width of the illumination cone can enable embodiments of displays to have thinner front lights by abrogating the need for a diffusing isolation layer that is sometimes used to produce a uniform display. Additionally, in some embodiments, turning features having curved edges can be placed farther apart from one another than turning features with straight edges because each curved turning feature illuminates a larger area of the display due to the increased width of the illumination cone. Turning films configured with increased spatial separation between light turning features can also be configured such that the thickness of the turning film is decreased.
• FIG. 29A illustrates a cross-sectional view of one embodiment of aturning film2901athat includes aturning feature2920a.Theturning film2901ais illustrated with an x-axis extending generally parallel to a bottom surface of the turning film, a z-axis extending generally normal to the bottom surface and a top surface of the turning film, and a y-axis extending generally normal to the x-axis and z-axis.Turning feature2920ais v-shaped and includes aleft edge2921aand aright edge2923aconfigured to direct light towards the bottom of theturning film2901a.Also shown is a first ray of light2911aand a second ray of light2911a′. Bothlight rays2911a,2911a′ are propagating within theturning film2901aat the same angle relative to the top and bottom of the turning film and thelight rays2911a,2911a′ are offset or spaced apart from one another. Because theleft edge2921aof theturning feature2920ais at a constant angle relative to the top of theturning film2901a, thelight rays2911a,2911a′ reflect off of theleft edge2921aat the same angle towards the bottom of theturning film2901a(in this illustration, downward). Thus, the illumination cone of light produced by theturning feature2920ais collimated (e.g., the rays of light that form the cone are substantially parallel to one another) as the light travels away from theturning feature2920a.While only the cross-section of theprismatic turning feature2920ais shown inFIG. 29A, it should be understood by those of skill in the art that the in-plane distribution of the light turning features disclosed herein can be linear, curvilinear, etc., so that a variety of front light configurations can be implemented, for example, light bar sources or LED sources.
• FIG. 29B illustrates a cross-sectional view of another embodiment of aturning film2901bthat includes aturning feature2920b.Turning feature2920bincludes a leftcurved edge2921band a rightcurved edge2923b.Edges2921b,2923bform aturning feature2920bthat is concave relative to theturning film2901b.Curved edges2921b,2923bcan be disposed in the turning film in one or more planes that are at least substantially parallel to the illustrated x-z plane of the turning film. Also shown are rays of light2911b,2911b′ that are propagating within theturning film2901bat the same angles relative to the top and bottom of the turning film. Therays2911b,2911b′ are directed away from one another after reflecting off of theleft edge2921bbecause the edge is curved. Thus, thecurved turning feature2920bcan create an illumination cone of light with an angular width that is greater than the cone of light produced by theturning feature2920ashown inFIG. 29A (e.g., an illumination cone of light that is not collimated).
• FIG. 29C illustrates a cross-sectional view of another embodiment of a turning film2901cthat includes a turning feature2920c.Turning feature2920cincludes a leftcurved edge2921cand a rightcurved edge2923c.Edges2921c,2923cform a turning feature2920cthat is convex relative to the turning film2901c.Curved edges2921c,2923ccan be disposed in the turning film in one or more planes that are at least substantially parallel to the illustrated x-z plane of the turning film. Rays of light2911c,2911c′ are directed away from one another after reflecting off theleft edge2921cbecause the edge is curved. Similarly to the turning feature illustrated inFIG. 29B, this results in an illumination cone of light that has an angular width that is greater than the cone of light produced by theturning feature2920ashown inFIG. 29A (e.g., an illumination cone of light that is not collimated).
• FIG. 29D illustrates a cross-sectional view of another embodiment of aturning film2901dthat includes aturning feature2920d.Turning feature2920dincludes a leftcurved edge2921dand a rightcurved edge2923d.Turning feature2920dalso includes a substantiallystraight edge2925dbetween the left and right edges and disposed substantially parallel to the top and bottom of the turning film.Edges2921d,2923d,and2925dform aturning feature2920dwith sidewalls that are convex relative to theturning film2901dand disposed in the turning film in one or more planes that are at least substantially parallel to the illustrated x-z plane of the turning film. Rays of light2911d,2911d′ are directed away from one another after reflecting off theleft edge2921dbecause the edge is curved. Similarly to the turning features illustrated inFIGS. 29B and 29C this results in an illumination cone of light that has an angular width that is greater than the cone of light produced by theturning feature2920ashown inFIG. 29A (e.g., an illumination cone of light that is not collimated).
• FIG. 29E illustrates a cross-sectional view of another embodiment of aturning film2901ethat includes aturning feature2920e.Turning feature2920eincludes a leftcurved edge2921eand a rightcurved edge2923e.Turning feature2920ealso includes a substantiallystraight edge2925ebetween the left and right edges and disposed substantially parallel to the top and bottom of the turning film.Edges2921e,2923e,and2925eform aturning feature2920ewith sidewalls that are concave relative to theturning film2901eand disposed in the turning film in one or more planes that are at least substantially parallel to the illustrated x-z plane of the turning film. Rays of light2911e,2911e′ are directed away from one another after reflecting off theleft edge2921ebecause the edge is curved. Similarly to the turning features illustrated inFIGS. 29B and 29C this results in an illumination cone of light that has an angular width that is greater than the cone of light produced by theturning feature2920ashown inFIG. 29A (e.g., an illumination cone of light that is not collimated).
• FIG. 29F illustrates a perspective view of theturning feature2920dofFIG. 29D. The surfaces of theturning feature2920dform a truncated curvilinear shape or frustum having sidewalls that are concave relative to the space adjacent the turning feature.FIG. 29G illustrates a perspective view of theturning feature2920eofFIG. 29E. The surfaces of theturning feature2920eform a truncated curvilinear shape or frustum having sidewalls that are convex relative to the space adjacent the turning feature.
• As discussed above, turning features can be coated with reflective layers or coatings to provide desirable optical characteristics and additional layers can be deposited over the reflective coating to prevent the reflection of light from the reflective coating towards a viewer. In some embodiments, additional layers can be deposited over the reflective coating to form a static interferometric stack, or optical mask, that appears dark or black to a viewer in order to improve the contrast of the display device while reflecting light incident on the reflective coating side of the stack towards a reflective display.FIGS. 30A-30D illustrate embodiments of turning features3020 that have curved sidewalls or edges3021,3023 with reflective coatings3003 deposited over the curved sidewalls. An optically resonant layer3005 and absorber layer3007 can optionally be deposited over the reflective coating3003 to form an interferometric stack3009. The interferometric stacks3009 can be configured such that the absorber layers3007 absorb light of the reflected wavelength such that the stack3009 appears black or dark, which can increase the contrast of the display. As discussed above, the reflective coatings3003 and/or interferometric stacks3009 can be disposed over only a portion or portions of the surface of a turning feature3020 or they can be disposed over the entire surface of a turning feature.
• In some instances, frustum shaped turning features similar to turningfeature2920dofFIG. 29F and turningfeature2920eofFIG. 29G can be easier to manufacture or produce than the turning features shown inFIGS. 29B and 29C which do not have flat bottom edges. All of the turning features discussed herein can be manufactured, fabricated, or produced using plastic molding or by using the inorganic material system deposition and etching techniques discussed above. In some embodiments, a thin film front light can be manufactured using known film embossing techniques, for example hot or UV embossing, using a master mold tool produced by diamond turning techniques. A diamond tool can be machined so that its tip has a curved-wall cross-section and can be used to cut into a substrate (e.g., metals or alloys based on copper or nickel) to fabricate a mold with the desired curved sidewall grooves. In another example of making master tools, photolithography and etching techniques can be used to produce wafers with desired surface topography. Photolithography and etching can be used to produce a light guide by producing one or more turning features directly in a substrate, or such techniques can be used to produce a surface relief that can be used to produce turning films. By properly designing the lithography mask, turning features with concave and/or convex sidewalls or edges can be produced. For example, an etchant can be chosen that etches the photoresist material and another layer of material in order to control the curvature of the etching.
• FIGS. 31A-31E illustrate one example of a process for fabricating a turning film or light guide including convex turning features. As shown inFIG. 31A, a process for fabricating a turning film or light guide can begin by providing asubstrate3101. In some embodiments, thesubstrate3101 comprises silicon or silicon dioxide. With reference toFIG. 31B, a layer ofmaterial3103 can then be deposited on the substrate. As discussed below, the layer ofmaterial3103 can later be etched and can comprise, for example, silicon oxy-nitride, aluminum, and other suitable materials.
• Referring now toFIG. 31C, the layer ofmaterial3103 can then be coated with aphotoresist3105. After coating the layer ofmaterial3103, thephotoresist3105 can be exposed and patterned through a specially designed photolithographic mask and developed to leave portions of the coat ofphotoresist3105 on the layer ofmaterial3103. Turning now toFIG. 31D, the layer ofmaterial3103 can then be etched to produce curved sidewalls or edges. The etching process can be controlled to pull-back or etch certain portions of the photoresist in addition to thematerial3103 to produce curved sidewalls (edges). For example, thematerial3103 can be etched isotropically or with a combination of isotropic with anisotropic etching for tailoring the curved shape of the sidewalls. After etching, the photoresist layer can be removed resulting in a light guide or a surface relief that can be used to manufacture a turning film. When manufacturing a turning film, the surface relief can be electroplated to produce a mold that can be used to manufacture turning films that match the surface relief. As shown inFIG. 31E, with the surface relief replicated, a frontlight turning film3110 including convex turning features3120 can be tooled and embossed.
• FIGS. 32A-32E illustrate one example of a process for fabricating a turning film including concave turning features. As shown inFIG. 32A, a process for fabricating a turning film can begin by providing asubstrate3201. In some embodiments, thesubstrate3201 comprises silicon or silicon dioxide. With reference toFIG. 32B, a layer ofmaterial3203 can then be deposited on the substrate. As discussed below, the layer ofmaterial3203 can later be etched and can comprise, for example, silicon dioxide, aluminum, silicon nitride, and other suitable materials.
• Referring now toFIG. 32C, the layer ofmaterial3203 can then be coated with aphotoresist3205. After coating the layer ofmaterial3203, thephotoresist3205 can be exposed through a specially designed photolithographic mask and developed to leave portions of the coat ofphotoresist3205 on the layer ofmaterial3203. Turning now toFIG. 32D, the layer ofmaterial3203 can then be etched to produce curved sidewalls or edges. In some embodiments, thematerial3203 can be etched isotropically or with a combination of isotropic with anisotropic etching for tailoring the curved shape of the sidewalls. After etching, the photoresist layer can be removed and the surface relief can be replicated by electroforming the surface. As shown inFIG. 32E, with the surface relief replicated, afront light film3210 including aconvex turning feature3220 can be tooled and embossed.
• The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof.

Claims (32)

1. An illumination apparatus comprising:

a light source;

a light guide having a generally planar first surface, a generally planar second surface opposite the first surface, a first end and a second end, and a length defined between the first end and the second end, the light guide having an x-axis extending parallel to the first surface between the first end and second end, a z-axis extending normal to the first surface and the second surface, and a y-axis extending normal to the x-axis and the z-axis, wherein the light guide is positioned to receive light from the light source into the light guide first end, and wherein light received from the light source propagates through the light guide towards the second end; and

a plurality of light turning features disposed on the first surface and protruding from the first surface into the light guide towards the second surface, each light turning feature having at least one curvilinear turning edge disposed on a plane that is parallel with a plane defined by the x-axis and the z-axis, the at least one turning edge configured to receive at least a portion of the light which is propagating towards the second end of the light guide and reflect at least a portion of the received light out of the second surface of the light guide.

2. The illumination apparatus ofclaim 1, wherein the turning edge of the light turning feature is configured such that the portion of light reflected by the at least one curvilinear turning edge forms an emission cone of light that has an angular width.

3. The illumination apparatus ofclaim 2, wherein the at least one turning edge is configured to focus light that is propagating in the light guide and incident on the at least one turning edge.

4. The illumination apparatus ofclaim 2, wherein the at least one turning edge is configured to disperse light that is propagating in the light guide and incident on the at least one turning edge.

5. The illumination apparatus ofclaim 1, wherein the at least one turning edge has a convex shaped profile on the x-axis and the z-axis defined plane on which it is disposed.

6. The illumination apparatus ofclaim 1, wherein the at least one turning has a convex shaped profile on the x-axis and the z-axis defined plane on which it is disposed.

7. The illumination apparatus ofclaim 1, wherein the surface of at least one turning feature is frustum shaped.

8. The illumination apparatus ofclaim 7, wherein the frustum comprises concave sides.

9. The illumination apparatus ofclaim 7, wherein the frustum comprises convex sides.

10. A display device comprising:

an array of light modulating elements;

a light guide disposed over the array, the light guide having at least one edge configured to receive light into the light guide; and

a turning layer disposed such that the light guide is at least partially between the turning layer and the array, the turning layer having a first surface and a second surface opposite the first surface, wherein the second surface is disposed between the first surface and the array, wherein the turning layer further comprises a plurality of light turning features disposed on the first surface and protruding from the first surface into the turning layer towards the second surface, each light turning feature being configured to receive at least a portion of light which is propagating through the turning layer and reflect at least a portion of the received light toward the array, each light turning feature having a light turning surface configured to focus or disperse the portion of light received and reflected toward the array.

11. The device ofclaim 10, wherein the curved light turning surface of each light turning feature extends from the first surface into the light guide and comprises a depression formed in the first surface.

12. The device ofclaim 11, wherein the curved light turning surface is frustum shaped.

13. The device ofclaim 11, wherein each light turning feature has at least one sidewall and wherein at least a portion of the sidewall is curved.

14. The device ofclaim 13, wherein the curved portion of the sidewall is convex.

15. The device ofclaim 13, wherein the curved portion of the sidewall is concave.

16. The device ofclaim 13, wherein each turning feature comprises an optical mask disposed on at least a portion of the sidewall.

17. The device ofclaim 16, wherein the optical mask comprises a first reflective layer, a second layer, and a third partially reflective layer disposed respectively on the sidewall, wherein the first layer is configured to receive light propagating within the turning layer and reflect at least a portion of the received light toward the array.

18. The device ofclaim 17, wherein the first, second, and third layers are configured to absorb a portion of light incident on the turning layer.

19. The device ofclaim 10, further comprising:

a processor that is configured to communicate with the array of light modulating elements, the processor being configured to process image data; and

a memory device that is configured to communicate with the processor.

20. The device ofclaim 19, further comprising a driver circuit configured to send at least one signal to the array of light modulating elements.

21. The device ofclaim 20, further comprising a controller configured to send at least a portion of the image data to the driver circuit.

22. The device ofclaim 19, further comprising an image source module configured to send the image data to the processor.

23. The device ofclaim 22, wherein said image source module comprises at least one of a receiver, transceiver, and transmitter.

24. The device ofclaim 19, further comprising an input device configured to receive input data and to communicate the input data to the processor.

25. A method of making a light guide including turning features that are configured to focus or disperse light incident thereon, the method comprising:

providing a substrate;

depositing a layer of material over at least a portion of the substrate;

coating the material with a layer of photoresist;

exposing the photoresist to leave a pattern of portions of the photoresist on the layer of material; and

etching the layer of material to produce one or more depressions having curved sidewalls.

26. A method of making a turning film including turning features that are configured to focus or disperse light incident thereon, the method comprising:

providing a substrate;

depositing a layer of material over at least a portion of the substrate;

coating the material with a layer of photoresist;

exposing the photoresist to leave portions of the photoresist on the layer of material;

etching the layer of material to produce one or more depressions having curved sidewalls;

removing the photoresist;

electroplating the surface of the layer of material and the substrate to produce a surface relief; and

using the surface relief to mold a turning film.

27. The method ofclaim 26, wherein the sidewalls are convex.

28. The method ofclaim 26, wherein the sidewalls are concave.

29. The method ofclaim 26, wherein the layer of material and substrate form at least one frustum shaped turning feature.

30. The method ofclaim 29, wherein the frustum shaped turning feature comprises sidewalls that are convex.

31. The method ofclaim 29, wherein the frustum shaped turning feature comprises sidewalls that are concave.

32. A display device comprising:

means for modulating light;

means for guiding light disposed over the modulating means, the light guiding means being configured to receive light; and

means for turning light disposed such that the light guiding means is at least partially between the light turning means and the modulating means, wherein the turning means comprises a plurality of light turning features configured to receive at least a portion of light received by the light guiding means and reflect at least a portion of the received light toward the modulating means, wherein each light turning feature is configured to focus or disperse the portion of light received and reflected toward the modulating means, and wherein each light turning feature comprises a depression formed in a surface of the light turning means.

Images