KR20070022092A - Thermoplastic Optical Devices with High Vertex Sharpness - Google Patents

Abstract

The present invention relates to an element of an image generating apparatus and an element forming apparatus, the method comprising providing a first layer and a second layer. The method also includes extruding the first layer and the second layer, wherein the second layer has a melt flow at least 10% greater than the melt flow of the second layer. Furthermore, the method includes forming a plurality of optical elements on the surface of the second layer.

Description

Thermoplastic Optical Device with High Vertex Sharpness {THERMOPLASTIC OPTICAL FEATURE WITH HIGH APEX SHARPNESS}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention generally relates to an image generating apparatus, and more particularly to a component for improving light efficiency of a light valve image generating apparatus.

Light valves are widely used in display technology. For example, display panels refer to only a few home appliances, but are becoming popular in many home appliances such as televisions, computer monitors, point of sale displays, personal digital assistants and electronic cinemas.

Many light valves are based on liquid crystal (LC) technology. Some LC technologies are the basis for light propagation through LC devices (panels), while others are based on two times the light traversing the panels after being reflected off the far surface of the panel. .

LC materials are used to selectively rotate the axis of liquid crystal particles. As is well known, by applying a voltage across the LC panel, the direction of the LC fine particles can be controlled and the polarity state of the reflected light can be selectively changed. As such, by selectively switching transistors in the array, the LC medium can be used to modulate light into image information. This modulation can be used to provide light in the dark state in certain image elements (pixels) and light in the others, so that the polarity state controls the state of the light. Accordingly, the image is generated to form an image or “picture” by the LC panel and optics by selective polarity conversion on the screen.

In many LCD devices, light from the source is selectively polarized in a particular orientation before being tilted on the LC layer in that particular orientation. The LC layer may have a voltage applied selectively to orient the particles of material in any manner. And the polarity of the inclined light in the LC layer is selectively changed when traversing through the LC layer. Light in one linear polarity is propagated by the polarizer (sometimes referred to as an analyzer) to light in the bright state, while light in the orthogonal polarity is reflected or absorbed by the analyzer as light in the dark state.

While LCD devices are commonly used in the field of displays and microdisplay consumer electronics, there are certain disadvantages associated with known devices, their components, and methods of manufacturing the same. For example, with known structures, the efficiency of light propagation to the final image generating surface is worse and results in poor image quality.

Accordingly, there is a need for a method and apparatus for overcoming the disadvantages of the known apparatus as described above.

According to the illustrated embodiment, a method of forming an element of an image generating apparatus includes providing a first layer and a second layer. The method also extrudes a first layer into a second layer, the second layer having a melt flow at least 10% greater than the melting of the first layer. Further, the method includes forming a plurality of optical elements on each surface of the first and second layers. In addition, the first and second layers have substantially the same optical properties.

According to the illustrated embodiment, the optical component has a first layer and a second layer. The first layer and the second layer have substantially the same optical properties. The element includes a plurality of optical elements composed of at least a portion of the first layer and the second layer.

1 is a cross-sectional view illustrating an LCD including a backlight device according to an embodiment of the present invention;

2A is a schematic diagram illustrating a redirecting element in accordance with one embodiment of the present invention;

2B is a cross-sectional view illustrating the redirecting element along line 2b-2b;

3 illustrates a redirecting layer according to an embodiment of the present invention;

4 is a cross-sectional view schematically illustrating an apparatus for forming an aiming layer according to an embodiment of the present invention;

5 is a cross-sectional view illustrating another redirecting element including at least one other layer in accordance with one embodiment of the present invention.

In addition to the conventional meaning and content of the embodiments described herein, the following terms are defined. It is to be emphasized that the terminology provided is for the purpose of supplementing their ordinary meanings only, and are not intended to be limiting.

1. As used herein, "transparent" means the ability to allow radiation to pass through without significant diffusion or absorption in the material. According to the illustrated embodiment, a "transparent" material is defined as a material having a spectral transmission greater than 90%.

2. As used herein, the term "light" means visible light.

3. As used herein, the term "polymer film" means a film comprising a polymer, and as used herein, the term "polymer" means a homopolymer, a copolymer and a polymer mixture.

4. As used herein, the terms "optical gain", "on-axis gain" or "gain" refer to the ratio of output light intensity in a particular direction, and the particular direction is often It can be normal to the plane of the film divided by the input light intensity. That is, the optical gain, on-axis gain, and gain are used to measure the efficiency of the redirecting film and can be used to compare the performance of the optical redirecting film.

5. As used herein, the term “curved surface” indicates a three-dimensional feature in a film having curvature in at least one plane.

6. As used herein, the term “wedge shaped feature” refers to an element comprising one or more inclined surfaces, which surfaces may consist of a combination of planar and curved surfaces.

7. As used herein, the term “optical film” refers to a relatively thin polymer film that alters the characteristics of propagated incident light. For example, the redirecting optical film of this embodiment provides an optical gain (output / input) of 1.0 or greater.

It is to be emphasized again that the referenced predicate is not intended to be limited to any embodiment in which it is intended to supplement the ordinary meaning of each term and has the features described by one or more reference terms.

In the following detailed description, for purposes of explanation, and not by way of limitation, embodiments that describe particular details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the following description may benefit from other embodiments that depart from the specific details described herein. In addition, description of the well-known apparatus and method is abbreviate | omitted so that description of this invention may not be obscured. Such methods and apparatus have been described clearly for those skilled in the art to practice this embodiment. Wherever possible, the same reference numerals are used throughout the same features.

For clarity and as described in connection with this embodiment, the light redirecting layer has a first layer and a second layer. The first layer has a smooth lower surface, thereby diffusing light so that recycling of the light redirecting film does not fail. The first layer also has an upper surface on which a plurality of optical elements are formed. On its upper surface, a second layer is arranged. The second layer is made of substantially the same optical material as the first layer and has different physical properties from the first layer. As will be clearer from the description of the invention, the second layer is, among other advantages, in such a way that the optical element uniformly crosses the surface of the light redirecting layer, with the molding pattern being copied to a high degree, It can be made to have desirable optical properties.

According to one embodiment of the invention, a manufacturing method for manufacturing an optical device comprises extruding a first layer to a second layer, wherein the first layer is at least 10% greater than the melt flow of the second layer. Has a melt flow. The illustrated method allows for the formation of features and the formation of desirable features in a more uniform manner on the top surface. Furthermore, due to the nature of the first layer, low pressure may be applied to implement complete replication of the final redirecting layer. Among other advantages, this provides more uniformity to the final product and smoothes the lower surface of the first layer.

1 illustrates an image generating apparatus 100 having an extruded composite layer light redirecting polymer layer 105 in accordance with one embodiment of the present invention. In this embodiment, the light source 101 connects light to the light path 102, which has a diffuse reflecting layer 103 disposed over at least one side illustrated. Light source 101 typically includes a cold cathode fluorescent bulb (CCFB), an ultra high pressure (UHP) gas lamp, a light emitting diode (LED) array, or an organic LED array. It should be noted that this is for illustrative purposes only and other sources suitable for providing light to the display device may be used.

Light from the light passage 102 propagates to the selective diffuser 104, which diffuses the light, preferably to provide more uniform illumination across the display surface (not shown), sometimes printed into the light passage or It conceals certain features to be embossed and reduces moire interference. As will be described in more detail herein, light is passed through the light diffusing layer 104 and then incident on the light redirecting film 105 and gathered into a narrower cone compared to the light incident on the film. The light redirecting layer 105 is oriented as illustrated so that the individual optical elements are on the side proximate the LC panel 106.

Another device, such as another diffuser or reflective polarizer (not shown), may be disposed between the light redirecting layer 105 and the LC panel 106. Other polarizers (sometimes referred to as analyzers) may also be included in the structure of the LC display 100. Since the devices of multiple displays 100 are well known to those skilled in the art of LC play, many of the descriptions are omitted so as not to obscure the description of the following embodiments.

2A is a schematic diagram illustrating an optical element 201 that may be disposed on the top surface of a light redirecting layer (eg, layer 105) according to one embodiment. Of course, this is only one of the plurality of similar elements of the light redirecting layer 105. In one embodiment, the device 201 is in the form of a curved wedge having a curved surface 202 and a flat surface 203. Curved surface 202 may have one, two, and three axis curvatures to allow light to be redirected in one or more directions, as described in more detail herein. Two surfaces 202 and 203 meet at the ridge 204. As illustrated, the ridge 204 is a linear apex formed where the surfaces 202 and 203 of the device 201 meet.

It should be noted that the shape of the device 201 is illustrative, and various types of devices other than the curved wedge shape may be used. Preferably, other types of devices than those illustrated in FIG. 2A have useful types of vertices and side surfaces 202 and 203 that can redirect light and recycle light so that the light is also provided in a predetermined example. As described in connection with the disclosed embodiments. Of course, to reduce the land area and to realize a substantially uniform structure, it is desirable to provide a skin layer as described herein.

FIG. 2B is a cross-sectional view illustrating the element 201 of FIG. 2A at lines 2B-2B. As will be described in more detail herein, the device 201 consists of a first layer 205 and a second layer 206 disposed thereon. The first layer 205 is made of a material having a relatively high refractive index with respect to the medium in which it is disposed (eg air). This relatively high refractive index is desirable for refracting light to aim at or recycle it. Device 201 has a side surface 207 and ridges 204. Of course, the second layer 206 disposed over the first layer has substantially the same surface. According to the illustrated embodiment, the second layer 206 is made of a material that is substantially optically identical to the material of the first layer 205. However, as described in more detail herein, certain physical properties of the second layer 206 are different from the first layer 205. For example, the first layer 205 and the second layer 206 are made of a material having substantially the same refractive index n _r , each having a light transmission / unit thickness of at least 85% transmission and of similar coloration. It has a haze characteristic.

Ultimately, the combination of these properties allows optical transitions from one layer to another, substantially free of undesirable reflections, providing uniformity of replication and improving optical characteristics.

As will be described in more detail herein, the first layer 205 is polycarbonate and the other layer is a polycarbonate layer having certain optical properties that are substantially the same as the first layer. In this embodiment, the second layer has a thickness of approximately 100 micrometers at approximately 2 μm and the first layer has a thickness of approximately 10 to approximately 200 micrometers. In some embodiments, the second layer has a thickness that is approximately 10% of the average height of the light member.

These surfaces 202 and 203 preferably provide an interface of 45 ° to the surrounding medium, which may be air or other film (not shown). Of course, it should be noted that this is not essential and the interface may be different than 45 °. Also preferably, the feature of the device has a cross section indicating an angle that includes 90 ° from the feature of the highest point (peak). It should be noted that the land (as opposed to the point), where appropriate, is the highest point (eg, as illustrated in FIG. 26), and that the angle included therein is measured at the intersection of the side portion 207.

As illustrated in the examples, a 90 ° peak angle is preferred because it produces the highest on-axis brightness on the light redirecting film. It should be noted that angles of approximately 88 ° to 92 ° can be used to produce similar results and to reduce losses in on-axis brightness. Furthermore, when the angle of the vertex is about 85 ° or less or 95 ° or more, the on-axis brightness for the light redirecting film is reduced.

As mentioned above, one structural advantage of the device 201 is to substantially aim the light with a relatively low angle of incidence with respect to the sides 202 and 203, and to substantially light the light with a relatively high angle. Is the ability to redirect. As a result, irregularly polarized light 208, incident on surface 203 at a relatively high angle, is refracted towards surface 203 and provided to LC panel 106 in a larger aiming condition. However, light 209 having a relatively low angle of incidence is reflected by light 306 and eventually returns towards light path 103. Ultimately, some of this light 209 may again be incident on device 101 or its diffuse reflector 103, and may be irregular to improve efficiency and thus improve performance of image generating apparatus 100. It can be recycled as polarized diffused light, such that light exiting the light redirecting film exits a cone that is narrower than light entering the light redirecting film. As can be readily predicted, in device 201, light 209 may be undesirable in on-axis observation of the LC display, due to the relatively low angle of incidence. That is, although not reflected as illustrated, the light 209 will excel outside the acceptance of the LC panel 106 or other element of the image generating display. The loss of light will have a detrimental effect on light efficiency from the light source 101 to the image generating surface (not shown). In the end, this will adversely affect the quality of the image, especially when viewed almost on-axis.

In addition to the geometrically relevant preferred features of the side surfaces 202 and 203 of the device 201, the width of the vertices or lands 210 also affects the light efficiency propagated from the light source 101 to the LC panel 106. And accordingly will affect the quality of the image provided by the image generating device. In the end, the width 210 of the vertex is a point formed by ideally concentrating two sides 202 and 203 together. However, by known methods, there are manufacturing limitations that sometimes interfere with true points. Alternatively, land 210 that is flat or round will result. Such lands do not substantially affect optically incident light thereon. For example, light 211 is lost due to a defect in optical power in land 210. Accordingly, it is desirable to minimize the width 304 as much as possible. Stated a bit differently, it is desirable to minimize the contribution to vertex 204 to the surface area of device 201. The larger the surface area portion from the vertex, the smaller the efficiency of the device 201 is in the redirecting light to the normal to the plane of the film.

Furthermore, it is useful to maintain uniformity in the size of the width 210 across a layer of a plurality of elements smaller than a certain deviation. This uniformity is desirable for the quality of the image because of the naked eye's exceptional ability to search for differences greater than approximately 75 μm. According to one embodiment, the width or land 210 has a size of approximately 0.25 μm to approximately 75 μm and has a deviation of approximately ± 0.5 μm across a layer of a plurality of devices. It should be noted that the size provided is for illustration only. For example, if not small, width 210 may be approximately 0.20 μm. Further, the width 210 may be larger than 0.75 μm, but the optical characteristics of the on-axis brightness of the element 201 are substantially impaired as the width reaches 3.0 μm. Finally, it should be noted that the structure of the device 201 may have more rounded ridges and defined intersections smaller than those illustrated in FIG. 2B. Optionally, the structure is as wide as possible 210.

3 is a schematic diagram illustrating a portion of a redirecting layer 300 according to one embodiment of the present invention. The redirecting layer 300 has a plurality of elements 201 described in connection with the embodiment of FIGS. 2A and 2B. This element is formed from the first layer 205 and the second layer as described above. That is, the redirecting layer 300 has a substrate, a plurality of devices 201 formed from the first layer, and a skin layer formed from the second layer 206. As will be described in detail herein, the skin layer 206 is composed of a plurality of devices 201 having a uniform width 210 and having surfaces 202 and 203 on one surface 302 above the layer 300. To make another surface 301 that is fabricated, smooth and on the opposite side of layer 302.

In the embodiment of Figures 2A-3, elements 201 are curved wedge-shaped elements that are irregularly arranged and arranged in parallel with each other. This allows the ridges 204 to be generally aligned in the same direction. In turn, it is desirable for the layer to have ridges generally aligned such that the layers are redirected substantially in one direction (eg, image plane axis) to produce a higher axial gain in the liquid crystal backlight structure of the illustrated embodiment. Optionally, surfaces 202 and 203 have some curvature. This bend may be in the plane of layer 300, in a plane perpendicular to plane 300, or on both sides. Accordingly, it may be useful to have the device 201 with a curve in the plane of the film so that the devices can aim light in one or more directions.

As will be appreciated, the curvature of the ridge 204 is part of an arc smooth smooth curve, such as a circle or an ellipse. The radius of the bend is the fraction of the circle as illustrated. The radius of curvature determines how much light the layer 300 provides is redirected in each direction and how much molar and axial brightness it has. In addition, the wedge-shaped element 201 on the light redirecting component 300 has a pitch or angular orientation that is variable relative to the size, pitch or angular orientation of the pixel or other repeating element, so that the moire interference pattern is passed through the LCD panel. Do not identify it.

In the illustrated embodiment, the optical elements 201 are oriented irregularly with respect to each other so that the pixels in the liquid crystal display are spaced apart to reduce or substantially eliminate any interference. Such "randomization" includes the size, shape, location, depth, angle or density of an optical element. This may obviate the need for the diffuser layer to impair moor and similar effects. In addition, at least some of the individual optical elements may be classified and aligned across the surface of the film, and at least some of each of the classified optical elements have different size or morphological features, which vary across the film. Collectively generating average size or morphological properties for each classification to obtain average characteristic values beyond the mechanical tolerances for any single optical element and to ensure that pixels are spaced apart in the liquid crystal display to eliminate moulding and interference do. In addition, at least some of the individual optical elements can be oriented at different angles with respect to each other to customize the ability of the film to be reoriented / redirected along two different axes.

4 is a schematic cross-sectional view of an apparatus 400 used to form a light redirecting layer in accordance with one embodiment of the present invention. The apparatus 400 has a nip 401 for extruding the first material 402 and the second material 403. The first material 402 is on the first side and the second material 403 is on the other side of the nip 401. The coextruded layers 402 and 403 are then subjected to pressure by the first roller 405 and the second roller 406. The first roller 405 is in contact with the first layer 402 and forms a substantially smooth surface 301 of the layer 300, as described above. The second roller 406 has a patterned surface (not shown) that forms a pattern of the plurality of elements 201 of one embodiment. After passing through the rollers 405, 406, a layer 407 is formed. This layer 407 has the features of layer 300 of this embodiment, which can be used as the light redirecting layer.

The first layer 402 is, as illustrated, a material having various desirable properties from the standpoint of manufacture and optical performance. For example, the first layer 402 is substantially transparent, provides UV stability, has hardness that can be accommodated in display appliances, has a relatively high physical modulus, and is extruded. It may be a monomer or a multi-layer. Further, the first layer 402 may be made of a material having the optical properties as described above and substantially the same optical properties as the optical properties of the second layer 403.

In the illustrated embodiment, the first layer 402 is a durable polycarbonate with a high optical transmission value (eg, transparent). The durability of such polycarbonates may allow the light redirecting layer of the illustrated embodiment to lower top scratching than known light redirecting films made of weaker and brittle materials such as UV cured polyacrylates. Polycarbonates are useful by grade for other household appliances and some are formulated to provide high temperature resistance, dimensional stability, increase environmental stability, and lower melt viscosity. The ultimate feature is a useful feature for the second material 403. Preferably, as described in more detail herein, the melt flow rate of the second layer 403 is approximately at least 10% greater than the melt flow rate of the first layer 402 during manufacture.

In another embodiment, the first layer 402 includes an olefin repeat unit. Polyolefins are low cost and have good strength and surface properties. In another embodiment of the present invention, the substrate comprises cellulose acetate. Illustrative polymers include polyesters (eg PET and PEN) and molded polyolefins such as polypropylene and polyethylene, polystyrene, acetate and vinyl.

Thermoplastics are useful because they are inexpensive and easy to manufacture. UV curable materials often suffer from low environmental stability and need to be coated on preformed substrates. In addition to the complexity of manufacturing, UV coatings are susceptible to curling and other detrimental situations.

The second material 403 forms a second layer (eg, second layer 206) or skin layer according to one embodiment. The second material is chosen in terms of its preferred manufacturing, in particular for its viscosity at the extrusion point. For this reason, the difficulty which is harmful to a known manufacturing method and the resulting optical film makes it highly replicable to a layer and makes it impossible to form a pattern (for example, the pattern of an optical element). In many known methods, it is essential to apply a significant amount of pressure (eg, 13.8 MPa to 20.7 MPa) to copy the pattern. The high pressure used in this known method results in unevenness across the patterned side and causes roughness of the back side. In all respects, the amount of useful layers is lower than intended. Furthermore, high pressure increases repair on the device 400.

In contrast, the pressure is applied by the rollers 404 and 405 using the second material 403 to provide an excellent pattern, while reducing in some embodiments by 25% compared to the reference pressure of known techniques. . That is, the second material 403 is easily moldable due to its flexibility at the extrusion temperature. This results in features such as vertices or ridges, and the lateral surface has uniformity and dimensions across the layers described above. Furthermore, the backside or smooth surface (eg 301) has a relatively low roughness, which adversely affects recycling properties. In some embodiments, the roughness of the smooth surface is 50 nanometers or less.

In the illustrated embodiment, the second material 402 has substantially the same optical properties as the first material 403. For example, the refractive index of the second material 402 is in the order of approximately ± 0.1 to approximately ± 0.3 of the refractive index of the first material. Usually, the refractive indices of the first and second materials are substantially the same. As described above, refractive index matching improves the light efficiency propagated to the LC panel or image panel by reducing reflection.

One way to match the second layer to the refractive index of the first layer is to have TiO ₂ with an average particle size of 30 nanometers or less. This TiO ₂ is polymerized in situ prior to extruding layer 403 and used to increase the refractive index of the polymer element.

It should be noted that TiO ₂ dispersed in the bulk polymer has a higher propagation rate, lower color, and higher refractive index can be produced compared to the bulk polymer of the layer. Preferably, the nanoparticles significantly increase the refractive index because they can affect the refractive index without significantly altering the diffusive properties of the optical device. As illustrated, the refractive index of the optical element is varied by at least approximately 0.02 from the base polymer in the case of polycarbonate. This increase in refractive index increases the performance of the optical element and increases the refractive index by 0.02, yielding an optical benefit. Preferably, the refractive index of the optical element is varied by at least 0.1 from the base polymer. The nano-TiO ₂ added to the second layer is adapted to minimize the predetermined internal reflection at the interface between the two layers, matching the refractive index of the second layer to substantially match the refractive index of the first layer.

It should be noted that refractive indices that match the first and second materials are desirable for redirecting light and recycling light or are useful in home appliances where reflection and total internal reflection are minimized. However, substantial matching of the refractive indices is not necessary to carry out all embodiments. That is, it is clear from the viewpoint of the embodiment that the refractive index differs considerably between the two layers. In essence, the quality and high degree of uniformity of the features formed in the relatively low pressure extrusion process of this embodiment will also benefit the highly differing refractive index layers.

In this illustrated embodiment, the second material 403 has a melt flow rate of approximately at least 10% greater than the first material 402 measured by the ASTM D1238 melt flow surface at 300 ° C. In addition, the melt flow rate of the second material 403 may be approximately 200% to 300% greater than the flow rate of the first material measured in the same standard. In one embodiment, the second material 403 is a polycarbonate layer having a flow melt flow rate of approximately 60 g / 10 min to approximately 90 g / 10 min. As illustrated, the first layer 402 is a polycarbonate having a melt flow rate of approximately 5 g / 10 min to approximately 55 g / 10 min.

In the illustrated embodiment, the refractive index of the first material (first layer 205) is approximately 1.59 to approximately 1.69. As can be seen, the larger the refractive index of the device 201, the light is redirected towards the normal to the film surface.

5 is a cross-sectional view illustrating an optical element 501 according to another embodiment. The element 501 is substantially the same as the structure of the element 201 described previously, and the details of this structure and fabrication are not repeated. It should be noted, however, that layers 205 and 206 may differ in form and function from those previously described.

The optical element 501 consists of a first layer 205, a second layer 206, and a third layer 502, which is extruded in the manner previously illustrated. Layer 502 may have other optical properties with desirable chemical, optical, electrical, or physical properties. For example, layer 502 alters or enhances their physical or chemical properties, particularly along the surface of a film or device. Such layers or coatings include, for example, improving physical preservation or strength of slip formulations, low backside attachment materials, conductive layers, antistatic coatings or films, barrier layers, flame retardants, UV stabilizers, abrasion resistant, optical coatings or films or devices. And a substrate to be made. Layer 502 may also be used to improve release from the patterned roll, thereby improving the replication and quality of the light redirecting film. In addition, layer 502 may be an antistatic coating or film. Such coatings or films include, for example, V ₂ O ₅ , and salts, carbon or other conductive metal layers of sulfonic acid polymers.

In addition, layer 502 is positioned between layers 205-206 to provide adhesion between the layers or for other physical or optical purposes.

Finally, it should be noted that, in many cases, the material intended to be used as the optical element can be expensive. A preferred aspect of this embodiment is the ability to provide only a thin layer of expensive material to form the intended structure. For example, layer 206 may be made of an expensive material as compared to layer 205. As such, significant cost savings can be realized by only requiring a thin layer.

Claims (33)

In the method of forming the element of the image generating device, Providing a first layer and a second layer, Extruding the first layer and the second layer, such that the second layer has a melt flow rate that is at least 10% greater than the melt flow rate of the first layer; Forming a plurality of optical elements on each surface of the first and second layers such that the first layer and the second layer have substantially the same optical properties; Device Formation Method. The method of claim 1, And forming at least a third layer over or below the second layer. Device Formation Method. The method of claim 1, The optical property is at least one of an index of refraction, coloration, haze and light propagation Device Formation Method. The method of claim 1, Applying pressure to the first layer and the second layer to form a plurality of optical elements on a predetermined side of the device; Device Formation Method. The method of claim 1, The second layer has a melt flow rate that is about 200% to about 300% greater than the flow rate of the first layer Device Formation Method. The method of claim 1, At least one of the plurality of optical elements has a first side and a second side each oriented at about 45 ° with respect to the peripheral medium Device Formation Method. The method of claim 6, The surrounding medium is air Device Formation Method. The method of claim 6, The first and second layers have substantially the same refractive index, and the peripheral medium has a refractive index less than that of the first and second layers. Device Formation Method. The method of claim 1, Each of the plurality of optical elements having a vertex having a width of approximately 0.25 μm to approximately 0.75 μm Device Formation Method. The method of claim 9, The width of the vertex across the layer is approximately ± 0.5 μm Device Formation Method. The method of claim 1, Each of the plurality of optical elements is substantially wedge shaped Device Formation Method. The method of claim 10, The layer is a light redirecting layer Device Formation Method. The method of claim 1, The image generating device is a liquid crystal display device Device Formation Method. The method of claim 1, Each of the plurality of optical elements having at least one curved side and a ridge Device Formation Method. The method of claim 5, wherein The second layer has a melt flow rate of approximately 60 g / 10 min to approximately 90 g / 10 min. Device Formation Method. The method of claim 5, wherein The first layer has a melt flow rate from approximately 5 g / 10 min to approximately 55 g / 10 min Device Formation Method. In the optical component, With the first layer, A second layer of material having substantially the same optical properties as the first layer and having a melt flow at least 10% greater than the melt flow of the first layer, A plurality of optical elements forming at least a portion of the first layer and the second layer Optical components. The method of claim 17, The plurality of optical elements are optical redirecting elements Optical components. The method of claim 17, The optical property is at least one of an index of refraction, color scheme, opacity and light propagation Optical components. The method of claim 17, Further comprising at least a third layer above or below the second layer Optical components. The method of claim 17, The second layer has a melt flow rate that is about 200% to about 300% greater than the flow rate of the first layer Optical components. The method of claim 17, The optical property is at least one of an index of refraction, color scheme, opacity and light propagation Optical components. The method of claim 17, At least one of the optical elements has a first side and a second side, each oriented at approximately 45 ° with respect to the peripheral medium Optical components. The method of claim 23, The narrow angle between the first and second sides is approximately 90 ° Optical components. The method of claim 1, Each of the plurality of optical elements having a vertex having a width of approximately 0.25 μm to approximately 0.75 μm Optical components. The method of claim 9, The width of the vertex across the layer of the optical component is approximately ± 0.5 μm Optical components. The method of claim 18, Each of the plurality of optical elements has a substantially curved ridge Optical components. The method of claim 27, The ridge forming an elliptical arc Optical components. The method of claim 17, Said first layer having a first thickness and said second layer having a second thickness substantially less than said first thickness Optical components. The method of claim 29, The second thickness is less than 10% of the average height of the optical element Optical components. The method of claim 17, The first layer is made of a first material and the second layer is made of a second material Optical components. The method of claim 17, The second layer has a melt flow rate of approximately 60 g / 10 min to approximately 90 g / 10 min. Optical components. The method of claim 17, The first layer has a melt flow rate from approximately 5 g / 10 min to approximately 55 g / 10 min Optical components.

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