发明内容：
[0003]We have developed a new family of dual-sided optical films in which extended prisms and extended lenslets are formed in opposite major surfaces of the film and in a one-to-one correspondence with each other, and these elements are configured to produce an output beam that is characterized in a plane of observation perpendicular to the prisms by sharp transitions or edges on both sides of the beam, and by a finite angular spread or width. The film is operable with a light guide having at least one major surface adapted to emit light preferentially at oblique angles, and the dual-sided film is disposed proximate the light guide and oriented so that the oblique light emitted from the major surface of the light guide enters the optical film through the prisms, and the dual-sided film converts the oblique light into the output beam with the sharp edges. Light sources may be disposed at opposite ends of the light guide to emit oblique light in two different directions, such that oblique light of one direction (originating from one light source) is converted by the dual-sided film into a first such sharp-edged output beam, and oblique light in the other direction (originating from the other light source) is converted by the dual-sided film into a second such sharp-edged output beam. The first and second sharp-edged output beams may overlap (including the limiting case where the nearest beam edges of the first and second output beams coincide), or may not overlap. The new dual-sided films can be used in systems to provide a low profile (thin) lighting device whose output beam has crisp, sharp beam edges, e.g. as would be provided by a conventional spotlight, but in a much thinner profile without the need for bulky lenses or baffles such as are used in spotlights, and with an emitting surface that is (typically) larger and more extended in-plane.
[0004]Some or all of the prisms on the dual-sided film are compound prisms, in which the two inclined surfaces of each compound prism each include a tip portion, a base portion, and an intermediate portion disposed between the tip portion and the base portion. Each compound prism also has a sharp vertex. The intermediate portion of each inclined surface of a given compound prism forms a first profile shape with the tip portion and a second profile shape with the base portion. Either the first profile shape is concave and the second profile shape is convex, or the first profile shape is convex and the second profile shape is concave. In some cases, the intermediate portion has a smaller angle of inclination than that of the tip portion and the base portion, such that the first profile shape is concave and the second profile shape is convex. In other cases, the intermediate portion has a larger angle of inclination than that of the tip portion and the base portion, such that the first profile shape is convex and the second profile shape is concave. When obliquely incident light is incident on the prism side of the film, an output beam emerges from the lenslet side of the film. In a plane of observation perpendicular to an elongation axis of the prisms, the output beam has an intensity distribution with a sharp left beam edge and a sharp right beam edge, these beam edges having 10%-to-90% transition angles of no more than 7, or 6, or 5, or 4, or 3, or 2 degrees.
[0005]The present application further discloses, inter alia, optical films having opposed first and second structured surfaces, the optical film including a plurality of extended prisms formed in the first structured surface, and a plurality of extended lenslets formed in the second structured surface, the prisms and lenslets being arranged in a one-to-one correspondence of lenslets to prisms. At least some of the prisms are compound prisms, each compound prism having two inclined surfaces that are compound, each such compound inclined surface of each compound prism having a tip portion, a base portion, and an intermediate portion disposed between the tip portion and the base portion. The compound prisms also each have a sharp vertex. The intermediate portion forms a first profile shape with the tip portion and a second profile shape with the base portion. Either the first profile shape is concave and the second profile shape is convex, or the first profile shape is convex and the second profile shape is concave.
[0006]For each compound inclined surface of each compound prism, at least one of the tip portion, the base portion, and the intermediate portion may be planar. Furthermore, the tip, base, and intermediate portions may all be planar. For each compound inclined surface of each compound prism, at least one of the tip portion, the base portion, and the intermediate portion may be curved. Furthermore, the tip portion, the base portion, and the intermediate portion may all be curved. The compound inclined surface of each compound prism may be continuously curved.
[0007]For each compound prism, the tip portions of its two inclined surfaces may intersect to form the sharp vertex, and the vertex may have a radius of curvature no more than 3 microns, or no more than 2 microns, or no more than 1 micron.
[0008]The prisms may extend along respective first elongation axes that are parallel to each other, and the lenslets may extend along respective second elongation axes that are parallel to each other. The first axes may be parallel to the second axes.
[0009]The prisms may have respective prism optical axes, and at least some of the compound prisms may be symmetrically shaped with respect to the prism optical axis. However, at least some of the compound prisms may not be symmetrically shaped with respect to their respective prism optical axes. For each prism-lenslet pair, the lenslet may have a focal point, and the prism may have a vertex that is disposed at or near the focal point.
[0010]The intermediate portion may have a smaller angle of inclination than that of the tip portion and the base portion, such that the first profile shape is concave and the second profile shape is convex. Alternatively, the intermediate portion may have a larger angle of inclination than that of the tip portion and the base portion, such that the first profile shape is convex, and the second profile shape is concave.
[0011]We also disclose optical systems that include such optical films in combination with a light guide having a major surface adapted to emit light preferentially at oblique angles, and the optical film may be disposed proximate the light guide and oriented so that light emitted from the major surface of the light guide enters the optical film through the first structured surface. In some cases, the optical film and the light guide may be non-planar. In some cases, the optical film and the light guide may be flexible. In some cases, the system may also include one or more light sources attached to the light guide. In some cases, the system may be or include a display, a backlight, a luminaire, a task light, or a general-purpose lighting module.
[0012]We also disclose optical systems that include a light guide, a first light source, and an optical film. The light guide has a major surface adapted to emit light. The first light source is configured to inject light into the light guide along a first direction. The optical film has opposed first and second structured surfaces, the first structured surface having a plurality of extended prisms formed therein, and the second structured surface having a plurality of extended lenslets formed therein, and the prisms and lenslets are arranged in a one-to-one correspondence of lenslets to prisms. The optical film is disposed proximate the light guide and oriented so that light emitted from the major surface of the light guide enters the optical film through the first structured surface and exits the second structured surface of the optical film, the light exiting the optical film forming a first output beam when the first light source is energized. The first output beam has a first intensity distribution as a function of angle θ, the first intensity distribution being characterized by a first left beam edge at an angle θLE1, a first right beam edge at an angle θRE1, a first baseline intensity Ibaseline1, and a first maximum intensity Imax1 and a first minimum intensity Imin1 between the first left and first right beam edges. The first left beam edge has a sharpness characterized by a transition angle ΔθLE1, and the first right beam edge has a sharpness characterized by a transition angle ΔθRE1, where ΔθLE1 and ΔθRE1 are measured from 10% to 90% intensity levels between Imax1 and Ibaseline1. The transition angle ΔθLE1 is no more than 7 degrees (or no more than or 6, or 5, or 5, or 4, or 3, or 2 degrees), the transition angle ΔθRE1 is no more than 7 degrees (or no more than 6, or 5, or 4, or 3, or 2 degrees), Imin1 is at least Ibaseline1+20%*(Imax1−Ibaseline1), and a first beam width equal to θRE1−θLE1 is at least 10 degrees.
[0013]At least some of the prisms in the optical film may be compound prisms whose two inclined surfaces are compound and whose vertex is sharp. Each compound inclined surface of each such compound prism has a tip portion, a base portion, and an intermediate portion disposed between the tip portion and the base portion. The intermediate portion forms a first profile shape with the tip portion and a second profile shape with the base portion, and either the first profile shape is concave and the second profile shape is convex, or the first profile shape is convex and the second profile shape is concave. The system may also include a second light source configured to inject light into the light guide along a second direction different from the first direction, and the light exiting the optical film forms a second output beam when the second light source is energized. The second output beam has a second intensity distribution as a function of angle θ, the second intensity distribution being characterized by a second left beam edge at an angle θLE2, a second right beam edge at an angle θRE2, a second baseline intensity Ibaseline2, and a second maximum intensity Imax2 and a second minimum intensity Imin2 between the second left and second right beam edges. The second left beam edge has a sharpness characterized by a transition angle ΔθLE2, and the second right beam edge has a sharpness characterized by a transition angle ΔθRE2, where ΔθLE2 and ΔθRE2 are measured from 10% to 90% intensity levels between Imax2 and Ibaseline2. The transition angle ΔθLE2 is no more than 7 degrees (or no more than 6, or 5, or 4, or 3, or 2 degrees), the transition angle ΔθRE2 is no more than 7 degrees (or no more than 6, or 5, or 4, or 3, or 2 degrees), Imin2 is at least Ibaseline2 +20%*(Imax2−Ibaseline2), and a second beam width equal to θRE2−θLE2 is at least 10 degrees.
[0014]The transition angles ΔθLE1, ΔθRE1, ΔθLE2, and ΔθRE2 may each be no more than 7 degrees, or no more than 6 degrees, or no more than 5 degrees, or no more than 4 degrees, or no more than 3 degrees, or no more than 2 degrees, and they may each be at least 1 degree or 2 degrees. The first minimum intensity Imin1 may be at least Ibaseline1+30%*(Imax1−Ibaseline1), or at least Ibaseline1+40%(Imax1−Ibaseline1), and the second minimum intensity Imin2 may be at least Ibaseline2+30%*(Imax2−Ibaseline2), or at least Ibaseline2+40%*(Imax2−Ibaseline2). The first beam width and the second beam width may each be at least 20 degrees, or at least 30 degrees, or in a range from 10 to 40 degrees. The angle θLE2 may be in a range from θLE1 to θRE1, such that the first and second output beams overlap. The first and second output beams may be spaced apart from each other, and may have nearest beam edges separated by at least 3 degrees.
[0015]The optical film and the light guide may be non-planar. The optical film and the light guide may be flexible. The first light source may be attached to the light guide. The optical film may be attached to the light guide. The system may be or include a display, a backlight, a luminaire, a task light, or a general-purpose lighting module.
[0016]Related methods, systems, and articles are also discussed.
[0017]These and other aspects of the present application will be apparent from the detailed description below. In no event, however, should the above summaries be construed as limitations on the claimed subject matter, which subject matter is defined solely by the attached claims, as may be amended during prosecution.
具体实施方式：
[0046]In the figures, like reference numerals designate like elements.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0047]An optical system 100 capable of utilizing the unique properties of the disclosed dual-sided optical films is shown in FIG. 1A. In this case, the optical system 100 is a display system, but other devices and applications, including ambient lighting devices such as luminaires or task lights, are also contemplated. The system 100 is shown in relation to a Cartesian x-y-z coordinate system so that directions and orientations of selected features can be more easily discussed. The system 100 includes a display panel 120, e.g., a liquid crystal display (LCD) panel, and a backlight 130 positioned to provide light to the display panel 120. The backlight 130 includes one or more light guides 150, one or more first light sources 134, and one or more second light sources 132. The backlight 130 also includes a dual-sided optical film 140, details of which are discussed further below. The x-y plane of the coordinate system is assumed to lie parallel to the plane of the film 140, which is also typically parallel to the plane of the light guide 150 and display panel 120.
[0048]The light sources 132, 134 are disposed on opposite ends of the light guide, and inject light into the light guide from opposite directions. Each of the light sources may emit light that is nominally white and of a desired hue or color temperature. Alternatively, each light source may emit colored light, e.g., light perceived to be red, green, blue, or another known non-white color, and/or may emit ultraviolet and/or infrared (including near infrared) light. The light sources may also be or comprise clusters of individual light emitting devices, some or all of which may emit non-white colored light, but the combination of light from the individual devices may produce nominally white light, e.g. from the summation of red, green, and blue light. Light sources on opposite ends of the light guide may emit light of different white or non-white colors, or they emit light of the same colors. The light sources 132, 134 can be of any known design or type, e.g., one or both may be or comprise cold cathode fluorescent lamps (CCFLs), and one or both may be or comprise one or more inorganic solid state light sources such as light emitting diodes (LEDs) or laser diodes, and one or both may be or comprise one or more organic solid state light sources such as organic light emitting diodes (OLEDs). The round shapes used to represent the light sources in the drawings are merely schematic, and should not be construed to exclude LED(s), or any other suitable type of light source. The light sources 132, 134 are preferably electronically controllable such that either one can be energized to an ON state (producing maximum or otherwise significant light output) while keeping the other one in an OFF state (producing little or no light output), or both can be in the ON state at the same time if desired, and both may be turned OFF during non-use. In many cases, the light sources 132, 134 do not need to satisfy any particular requirement with regard to switching speed. For example, although either or both light sources 132, 134 may be capable of repetitively transitioning between the OFF state and the ON state at a rate that is imperceptible to the human eye (e.g., at least 30 or 60 Hz), such a capability is not necessary in many embodiments. (For flicker-free operation, transition rates may be in a range from 50 to 70 Hz, or more; for two-sided operation, transition rates may be in a range from 100 to 140 Hz (or more) for the display panel (if any) and the light sources.) Thus, light sources that have much slower characteristic transition times between the ON and OFF states can also be used.
[0049]The light guide 150 includes a first light input side 150c adjacent to the first light source 134 and an opposing second light input side 150d adjacent to the second light source 132. A first light guide major surface 150b extends between the first side 150c and second side 150d. A second light guide major surface 150a, opposite the first major surface 150b, extends between the first side 150c and the second side 150d. The major surfaces 150b, 150a of the light guide 150 may be substantially parallel to each other, or they may be non-parallel such that the light guide 150 is wedge-shaped. Light may be reflected or emitted from either surface 150b, 150a of the light guide 150, but in general light is emitted from surface 150a and is reflected from surface 150b. In some cases, a highly reflective surface may be provided on or adjacent to the first surface 150b to assist in re-directing light out through the second surface 150a. Light extraction features 153, e.g., shallow prisms, lenticular features, white dots, haze coatings, and/or other features, may be disposed on one or both major surfaces 150b, 150a of the light guide 150. Exemplary light extraction features for the light guide are discussed below in connection with FIG. 2. The light extraction features 153 are typically selected so that light emitted from the major surface 150a propagates preferentially at highly oblique angles in air as measured in the x-z plane, rather than propagating at normal or near-normal propagation directions that are parallel to, or deviate only slightly from, the z-axis (again as measured in the x-z plane). For example, the light emitted from the surface 150a into air may have a peak intensity direction that makes an angle relative to the surface normal (z-axis) of 60 degrees or more, or 70 degrees or more, or 80 degrees or more, where the peak intensity direction refers to the direction along which the intensity distribution of the output beam in the x-z plane is a maximum.
[0050]The light guide 150 may have a solid form, i.e., it may have an entirely solid interior between the first and second major surfaces 150a, 150b. The solid material may be or comprise any suitable light-transmissive material, such as glass, acrylic, polyester, or other suitable polymer or non-polymer materials. Alternatively, the light guide 150 may be hollow, i.e., its interior may be air or another gas, or vacuum. If hollow, the light guide 150 is provided with optical films or similar components on opposite sides thereof to provide the first and second major surfaces 150a, 150b. Hollow light guides may also be partitioned or subdivided into multiple light guides. Whether solid or hollow, the light guide 150 may be substantially planar, or it may be non-planar, e.g., undulating or curved, and the curvature may be slight (close to planar) or great, including cases where the light guide curves in on itself to form a complete or partial tube. Such tubes may have any desired cross-sectional shape, including curved shapes such as a circle or ellipse, or polygonal shapes such as a square, rectangle, or triangle, or combinations of any such shapes. A hollow tubular light guide may in this regard be made from a single piece of optical film or similar component(s) that turns in on itself to form a hollow tube, in which case the first and second major surfaces of the light guide may both be construed to be provided by such optical film or component(s). The curvature may be only in the x-z plane, or only in the y-z plane, or in both planes. Although the light guide and dual-sided film may be non-planar, for simplicity they are shown in the figures as being planar; in the former case one may interpret the figures as showing a small enough portion of the light guide and/or optical film such that it appears to be planar. Whether solid or hollow, depending on the material(s) of construction and their respective thicknesses, the light guide may be physically rigid, or it may be flexible. A flexible light guide or optical film may be flexed or otherwise manipulated to change its shape from planar to curved or vice versa, or from curved in one plane to curved in an orthogonal plane.
[0051]The dual-sided optical film 140 is disposed between the display panel 120 and the light guide 150. The film 140 has opposed structured surfaces. On the structured surface that is oriented away from the light guide 150, lenslets 142 are formed.
[0052]Prisms 141 are formed on the opposite structured surface of the film 140, which is oriented towards the light guide 150. In this orientation, light emitted from the major surface 150a of the light guide 150 is incident on the prisms 141, which help to deviate the incident light. The incident light is deviated by and passes through the film 140 to provide an output light beam that emerges from the film 140. As described further below, the properties of the output beam are strongly influenced by which of the light sources 132, 134 is in an ON state. When one light source is ON, the output beam may subtend a first angular range. When the opposite light source is ON, the output beam may subtend a second angular range, which may or may not overlap with the first angular range. The prisms 141 are shown schematically in FIGS. 1A and 1B as having a simple V-shaped profile; however, some, most, or all of the prisms 141 may be compound prisms, the finer details of which are shown and described further below. The more complex prism shape can be used to provide output beams that have sharp beam edges on both sides thereof.
[0053]Both the prisms 141 and the lenslets 142 are typically linear, or, in cases where one or both are not precisely linear (e.g. not straight), they are otherwise extended or elongated along a particular in-plane axis. Thus, the lenslets 142 may extend along lenslet axes that are parallel to each other. One such axis is shown in FIG. 1B as axis 144, which is assumed to be parallel to the y-axis. The prisms 141 may extend along respective prism axes that are parallel to each other. The lenslet axes of elongation are typically parallel to the prism axes of elongation. Perfect parallelism is not required, and axes that deviate slightly from perfect parallelism may also be considered to be parallel; however, misalignment results in different amounts of registration between a given prism/lenslet pair at different places along their length on the working surface of the dual-sided film—and such differences in the degree of registration (regardless of whether the degree of registration is tailored to have precise alignment, or intentional misalignment, of the relevant vertices or other reference points, as discussed below) are desirably about 1 micron or less. In some cases, extraction features 153 on the major surface 150b of the light guide may be linear or elongated along axes that are parallel to the elongation axes of the lenslets and prisms of the film 140; alternatively, such elongated extraction features 153 may be oriented at other angles.
[0054]In the film 140 or pertinent portion thereof, there is a one-to-one correspondence of prisms 141 to lenslets 142. Thus, for each prism 141 there is a unique lenslet 142 with which the given prism primarily interacts, and vice versa. One some, or all of the lenslets 142 may be in substantial registration with their respective prisms 141. Alternatively, the film 140 may be designed to incorporate a deliberate misalignment or misregistration of some or all of the lenslets relative to their respective prisms. Related to alignment or misalignment of the prisms and lenslets is the center-to-center spacings or pitches of these elements. In the case of a display system, the pitch of the lenslets 142 and the pitch of the prisms 141 may be selected to reduce or eliminate Moire patterns with respect to periodic features in the display panel 120. The pitch of the lenslets 142 and the pitch of the prisms 141 can also be determined based upon manufacturability. As LCD panels are manufactured with different pixel pitches, it can be desirable to change the pitch of the optical film to accommodate the different pixel pitches of the LCD panel. Useful pitch ranges for the respective elements on the structured surface of the optical film 140 is about 10 microns to about 140 microns, for example, but this should not be interpreted in an unduly limiting way.
[0055]The system 100 can have any useful shape or configuration. In many embodiments, the display panel 120, the light guide 150, and/or the dual-sided optical film 140 can have a square or rectangular shape. In some embodiments, however, any or all of these elements may have more than four sides and/or a curved shape.
[0056]A switchable driving element 160 is electrically connected to the first and second light sources 132, 134. This element may contain a suitable electrical power supply, e.g. one or more voltage sources and/or current sources, capable of energizing one or both of the light sources 132, 134. The power supply may be a single power supply module or element, or a group or network of power supply elements, e.g., one power supply element for each light source. The driving element 160 may also contain a switch that is coupled to the power supply and to the electrical supply lines that connect to the light sources. The switch may be a single transistor or other switching element, or a group or network of switching modules or elements. The switch and power supply within the driving element 160 may be configured to have several operational modes. These modes may include two, three, or all of: a mode in which only the first light source 134 is ON; a mode in which only the second light source 132 is ON; a mode in which both the first and second light sources are ON; and a mode in which neither of the first and second light sources are ON (i.e., both are OFF).
[0057]A controller 170 couples to the switchable driving element 160 and to the display panel 120. The controller 170 may control or direct the driving element into one of its operational modes so as to selectively energize the light sources. Coupling between the controller 170 and the driving element 160 may be wired, or wireless, or some combination of wired and wireless. For example, a user may employ a mobile phone or other mobile wireless device to activate the driving element 160, and the mobile phone or other wireless device may be considered to be part of the controller 170. The controller 170 may also control the display panel 120 so that it displays a desired image or series of images. Image information may be provided from the controller 170 to the display panel 120 in any known manner. The image may be a still image, sequence of images, video stream, and/or rendered computer graphics, for example.
[0058]We describe in more detail below how the dual-sided optical film 140, when provided with compound prisms, can provide the backlight (or other optical system) with the capability to produce at least two different output beams, each such beam having an angular distribution with sharp edges on both sides of the beam. The number of output beams provided by the backlight or system depends on which light sources are energized by the driving element 160, and the characteristics or features of the output beams are controlled by design details of the lenslets and compound prisms.
[0059]FIG. 1B is a schematic perspective view of the back light 130 showing the light guide 150, the optical film 140, and the second light sources 132. Like elements between FIGS. 1A and 1B have like reference numerals, and need not be further discussed. The optical film 140 includes lenslets 142 oriented away from the light guide 150 and prisms 141 with prism peaks oriented toward the light guide 150. The axis of elongation 144 of the lenslets, which may also correspond to the axis of elongation of the prisms 141, is shown to be parallel to the y-axis. In the case of the prisms 141, the elongation axis runs parallel to the vertex of the prism. The film 140 is shown to be adjacent the light guide 150 but spaced slightly apart. The film 140 may also be mounted or held so that it is in contact with the light guide 150, e.g. the film 140 may rest upon the light guide 150, while still substantially maintaining an air/polymer interface at the facets or inclined side surfaces of the prisms 141 (with a physically thin but optically thick layer of air) so that their refractive characteristics can be preserved. Alternatively, a low refractive index bonding material may be used between the prisms 141 and the light guide 150 to bond the film 140 to the light guide. In this regard, nanovoided materials having an ultra low index (ULI) of refraction are known that can come somewhat close in refractive index to air, and that can be used for this purpose. See e.g. patent application publications WO 2010/120864 (Hao et al.) and WO 2011/088161 (Wolk et al.), which discuss ULI materials whose refractive index (n) is in a range from about n≈1.15 to n≈1.35. See also patent application publications WO 2010/120422 (Kolb et al.), WO 2010/120468 (Kolb et al.), WO 2012/054320 (Coggio et al.), and US 2010/0208349 (Beer et al.). Air gap spacing techniques, e.g. wherein an array of microreplicated posts is used to bond the two components together while substantially maintaining an air gap between them, may also be used. See e.g. patent application publication US 2013/0039077 (Edmonds et al.).
[0060]The disclosed dual-sided optical films and associated components may be provided in a variety of forms and configurations. In some cases, the dual-sided optical film may be packaged, sold, or used by itself, e.g. in piece, sheet, or roll form. In other cases, the dual-sided optical film may be packaged, sold, or used with a light guide whose output beam characteristics are tailored for use with the dual-sided film. In such cases, the dual-sided film may be bonded to the light guide as discussed above, or they may not be bonded to each other. In some cases, the dual-sided optical film may be packaged, sold, or used with both a light guide that is tailored for use with the dual-sided film, and one or more LED(s) or other light source(s) that are adapted to inject light into the light guide, e.g., from opposite ends thereof as shown generally in FIG. 1A. The dual-sided film, the light guide, and the light source(s) may be bonded, attached, or otherwise held in proximity to each other to form a lighting module, which may be large or small, rigid or flexible, and substantially flat/planar or non-flat/non-planar, and which may be used by itself or in combination with other components. A lighting system that includes a dual-sided optical film, a light guide, and one or more light source(s) may be adapted for any desired end use, e.g., a display, a backlight, a luminaire, a task light, or a general-purpose lighting module.
[0061]FIG. 2 shows a schematic perspective view of an exemplary light guide 250 that may be suitable for use with some or all of the disclosed dual-sided optical films. The light guide 250 may be substituted for the light guide 150 in FIG. 1A, and the properties, options, and alternatives discussed in connection with the light guide 150 will be understood to apply equally to the light guide 250. Cartesian x-y-z coordinates are provided in FIG. 2 in a manner consistent with the coordinates of FIGS. 1A and 1B. FIG. 2 shows in exaggerated fashion exemplary surface structure on the two major surfaces of the light guide 250, but other orientations of the structured surface(s) relative to the edges of boundaries of the light guide can be used. The light guide 250 includes a first major surface 250a from which light is extracted towards a dual-sided optical film, a second major surface 250b opposite the first major surface, and side surfaces 250d, 250c which may serve as light injection surfaces for the first and second light sources as discussed elsewhere herein. For example, one light source may be positioned along the side surface 250c to provide a first oblique light beam emitted from the light guide 250, and a similar light source can be positioned along the side surface 250d to provide a second oblique light beam emitted from the light guide 250. An oblique light beam in this regard refers to a light beam whose intensity distribution in the x-z plane has a peak intensity direction of 60 degrees or more, or 70 degrees or more, or 80 degrees or more relative to the surface normal (z-axis), as discussed above.
[0062]The rear major surface 250b of the light guide is preferably machined, molded, or otherwise formed to provide a linear array of shallow prism structures 252. These prism structures are elongated along axes parallel to the y-axis, and are designed to reflect an appropriate portion of the light propagating along the length of the light guide (along the x-axis) so that the reflected light can refract out of the front major surface 250a into air (or a tangible material of suitably low refractive index) at a suitably oblique angle, and onward to the dual-sided optical film. In many cases, it is desirable for the reflected light to be extracted from the front major surface 250a relatively uniformly along the length of the light guide 250. The surface 250b may be coated with a reflective film such as aluminum, or it may have no such reflective coating. In the absence of any such reflective coating, a separate back reflector may be provided proximate the surface 250b to reflect any downward-propagating light that passes through the light guide so that such light is reflected back into and through the light guide. The prism structures 252 typically have a depth that is shallow relative to the overall thickness of the light guide, and a width or pitch that is small relative to the length of the light guide. The prism structures 252 have apex angles that are typically much greater than the apex angles of prisms used in the disclosed dual-sided optical films. The light guide may be made of any transparent optical material, typically with low scattering such as polycarbonate, or an acrylic polymer such as Spartech Polycast material. In one exemplary embodiment, the light guide may be made of acrylic material, such as cell-cast acrylic, and may have an overall thickness of 1.4 mm and a length of 140 mm along the x-axis, and the prisms may have a depth of 2.9 micrometers and a width of 81.6 micrometers, corresponding to a prism apex angle of about 172 degrees. The reader will understand that these values are merely exemplary, and should not be construed as unduly limiting.
[0063]The front major surface 250a of the light guide may be machined, molded, or otherwise formed to provide a linear array of lenticular structures or features 254 that are parallel to each other and to a lenticular elongation axis. In contrast to the elongation axis of the prism structures 252, the lenticular elongation axis is typically parallel to the x-axis. The lenticular structures 254 may be shaped and oriented to enhance angular spreading in the y-z plane for light that passes out of the light guide through the front major surface, and, if desired, to limit spatial spreading along the y-axis for light that remains in the light guide by reflection from the front major surface. In some cases, the lenticular structures 254 may have a depth that is shallow relative to the overall thickness of the light guide, and a width or pitch that is small relative to the width of the light guide. In some cases, the lenticular structures may be relatively strongly curved, while in other cases they may be more weakly curved. In one embodiment, the light guide may be made of cell-cast acrylic and may have an overall thickness of 0.76 mm, a length of 141 mm along the x-axis, and a width of 66 mm along the y-axis, and the lenticular structures 254 may each have a radius of 35.6 micrometers, a depth of 32.8 micrometers, and a width 323 of 72.6 mm, for example. In this embodiment, the prism structures 252 may have a depth of 2.9 micrometers, a width of 81.6 micrometers, and a prism apex angle of about 172 degrees. Again, the reader will understand that these embodiments are merely exemplary, and should not be construed as unduly limiting; for example, structures other than lenticular structures may be used on the front major surface of the light guide.
[0064]As mentioned above, the lenticular structures 254 may be shaped and oriented to limit spatial spreading along the y-axis for light that remains in the light guide by reflection from the front major surface. Limited spatial spreading along the y-axis can also be achieved, or enhanced, with light sources that are collimated (including substantially collimated) in the plane of the light guide, i.e., the x-y plane. Such a light source may be a relatively small area LED die or dies in combination with one or more collimating lenses, mirrors, or the like. FIG. 2A shows the light guide 250 of FIG. 2 in combination with light sources 232a, 232b, 232c arranged along side surface 250d, and light sources 234a, 234b, 234c arranged along side surface 250c. These light sources may be substantially collimated, or the lenticular structures 254 may be shaped to limit spatial spreading of light along the y-axis, or both. In the figure, the light sources 232a, 232b, 232c are shown as being ON, and the other light sources are OFF. Due to the collimation of the light sources, the shape of the lenticular structures 254, or both, the light sources 232a, 232b, 232c illuminate respective stripes or bands 250-1, 250-2, 250-3 of the light guide 250. The bands may be distinct, with little or no overlap as shown in the figure, or they may overlap to some extent. Each of the light sources may be independently addressable, such that the light guide can be effectively subdivided or partitioned as a function of which light sources on each side of the light guide are turned ON. For example, only one of the bands 250-1, 250-2, 250-3 may be illuminated, or only two may be illuminated, or all of the bands may be illuminated. Light sources 234a, 234b, 234c, which are located on the opposite side of the light guide, may be aligned with their counterpart light sources at side surface 250d such that they illuminate the same respective bands 250-1, 250-2, 250-3; alternately, the light sources 234a, 234b, 234c may be shifted or staggered along the y-direction relative to the light sources at side surface 250d, such that they illuminate other bands which may or may not overlap with each other in similar fashion to bands 250-1, 250-2, 250-3. The light sources 232a, 232b, 232c, 234a, 234b, 234c may all emit white light, or light of a non-white color or wavelength, or the light sources may emit different colors. A given portion of the light guide 250, such as any of the bands 250-1, 250-2, 250-3, may thus function as an independent light guide, and may emit at least two different output beams as a function of whether only its associated light source(s) at one side surface (e.g. surface 250d) is ON, or whether only its associated light source(s) at the opposite side surface (e.g. surface 250c) is ON, or whether both such light sources are ON. When a dual-sided optical film is used with such a light guide, the spatially banded or striped output capability of the light guide is substantially transferred to the dual-sided optical film, such that, by energizing the appropriate light source(s), the disclosed sharp-edged output beam(s) can emerge from the dual-sided optical film over all (all stripes or bands), or only a portion (at least one but less than all stripes or bands), or none (no stripes or bands) of its output surface.
[0065]Turning now to FIG. 3, we see there a schematic side view of a lighting system 300 in the context of a coordinate system that is consistent with that of FIGS. 1A, 1B, and 2. System 300 may be the same as or similar to the backlight 130 of FIGS. 1A and 1B, except that the controller 170 in FIG. 3 is not coupled to any display panel, and the light guide 150 of FIG. 3 may have a design substantially as described in connection with light guide 250 of FIG. 2. Other than this, like elements are labeled with like reference numbers, and need not be discussed further. Furthermore, in FIG. 3, only the light source 134 is energized (ON), and the light source 132 is not energized (OFF). Due to the characteristics of the light guide 150, the characteristics of the optical film 140, and the interaction between the light guide and the optical film, light from the light source 134 produces a first output beam 310 emerging from the dual-sided optical film, the first output beam 310 having an angular distribution in the x-z plane characterized by sharp transitions or edges on both of its sides.
[0066]Light from the energized light source 134 enters the light guide 150 through the first side 150c. This light travels along the light guide 150 generally in the positive x-direction, the light reflecting from the major surfaces 150a, 150b to provide a first guided light beam 134-1. As the beam 134-1 propagates, some of the light is refracted or otherwise extracted from the major surface 150a to provide an oblique light beam 134-2, represented by obliquely oriented arrows representing a direction of maximum light intensity in the x-z plane. The oblique light beam 134-2 is typically emitted over substantially the entire surface area of the major surface 150a, i.e., not only in the geometric center of the major surface 150a but also at or near its edges and at intermediate positions in between, as indicated by the multiple oblique arrows. The oblique light beam 134-2 has a direction of maximum light intensity that is most closely aligned with the positive x-direction. The direction of maximum light intensity of the beam 134-2 may deviate from the positive x-direction by, for example, 30 degrees or less, or 20 degrees or less, or 15 degrees or less, or 10 degrees or less.
[0067]Because of the directionality of the oblique light beam 134-2, light from the light source 134 enters the dual-sided optical film 140 predominantly through only one inclined side surface of each of the prisms 141 on the lower structured surface of the film 140. However, such inclined side surface may be a compound surface having at least a distinct tip portion, base portion, and intermediate portion as described below. Refraction provided by such compound surfaces, in cooperation with reflection provided at the other inclined surface of the prisms, and in cooperation with refraction provided by the lenslets, causes light to emerge from the film 140 as the first output beam 310. The output beam 310 arises from the summation of individual output beams or “beamlets” emitted from each lenslet 142 across the film 140. Three such representative beamlets are illustrated in FIG. 3: a beamlet 310-0 emitted at or near the geometric center of the film 140, a beamlet 310-1 emitted at or near a first end or edge of the film 140, and a beamlet 310-2 emitted at or near a second end or edge of the film 140. In the illustrated embodiment, the angular spreads or widths of the individual beams or beamlets are nominally the same as the angular spread or width of the overall output beam 310, because the angular distributions of the beamlets may all be substantially the same. In other embodiments, the angular spread of the individual beams or beamlets may differ somewhat from that of the overall output beam 310.
[0068]If the first light source 134 is turned OFF and the second light source 132 is turned ON, the system 300 produces a second output beam, which is also characterized by an angular distribution with two sharp edges. The second output beam typically covers a different angular range than the first output beam, and the angular distributions of the two output beams may overlap or they may not overlap. FIG. 4A shows a typical second output beam that may be produced in a manner consistent with the first output beam of FIG. 3, with the same dual-sided optical film. FIG. 4B shows an alternative second output beam that may be produced by modifying the design of the dual-sided optical film.
[0069]Thus, in FIG. 4A, a lighting system 400a is shown in the context of a coordinate system consistent with that of FIG. 3. The system 400a may be the same as or similar to the lighting system 300, except that the light source 134 is not energized (OFF), and the light source 132 is energized (ON). Due to the characteristics of the light guide 150, the characteristics of the dual-sided optical film 140, and the interaction between the light guide and the optical film, light from the light source 132 produces a second output beam 410a emerging from the optical film, the second output bea