CA1279783C - Totally internally reflecting thin, flexible film - Google Patents

Totally internally reflecting thin, flexible film

Info

Publication number
CA1279783C
CA1279783C CA000521320A CA521320A CA1279783C CA 1279783 C CA1279783 C CA 1279783C CA 000521320 A CA000521320 A CA 000521320A CA 521320 A CA521320 A CA 521320A CA 1279783 C CA1279783 C CA 1279783C
Authority
CA
Canada
Prior art keywords
film
light
conduit
structured surface
smooth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA000521320A
Other languages
French (fr)
Inventor
Sanford Cobb, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Co
Original Assignee
Minnesota Mining and Manufacturing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Minnesota Mining and Manufacturing Co filed Critical Minnesota Mining and Manufacturing Co
Application granted granted Critical
Publication of CA1279783C publication Critical patent/CA1279783C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/10—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/002—Refractors for light sources using microoptical elements for redirecting or diffusing light
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S23/00—Arrangements for concentrating solar-rays for solar heat collectors
    • F24S23/10—Prisms
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/12—Reflex reflectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V2200/00—Use of light guides, e.g. fibre optic devices, in lighting devices or systems
    • F21V2200/40—Use of light guides, e.g. fibre optic devices, in lighting devices or systems of hollow light guides
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/36—Mechanical coupling means
    • G02B6/38—Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807—Dismountable connectors, i.e. comprising plugs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/40—Solar thermal energy, e.g. solar towers

Abstract

Abstract of the Disclosure A thin, flexible film made of a transparent polymeric material including a structured surface and an opposite smooth surface, wherein light striking either surface, within certain angular ranges, is totally internally reflected. The structured surface includes a linear array of miniature substantially right angled isosceles prisms arranged side-by-side to form a plurality of peaks and grooves. In addition, the perpendicular sides of the prisms make an angle of approximately 45° with the smooth surface, and when the film is curled the smooth surface lies in a smooth continuous arcuate curve without materially affecting the performance of the film. Because of the film's flexibility and its ability to totally internally reflect light, it may be utilized in a variety of ways, for example, as a collector of solar energy or as a light conduit. The performance of the film may be manipulated to permit controlled light leakage.

Description

~.~79~83 A TOTALLY INTERNALLY REFLEC'TING TEIIN, FLEXIBLE FILM

Technical Field and sackground Art _.
The present invention relateæ to a thin, flexible film made of a transparent material having a structured surface on one side and a smooth surface opposite the structured surface on the other side, one aspect of which is that the combination of surfaces may totally internally reflect light.
It is well known, to those skilled in the art to form thin, flexible films structured on one side to deflect light, as illustrated in U.S. Patent No. 2,248,638.
In addition, mirrors have been used to reflect light and the making of mirrors is also well known to those skilled in the art as described in, for example, U.S. Patent No.
2,723,919. However, there are limitations associated with the use of mirrors. Commercially available mirrors, even when new, have limited reflectivities that normally range from about 75~ to about 95%, and, when, with the passing of 20 time, the reflective coating becomes tarnished, the efficiency decreases.
The principle of total internal reflection has been recognized by optical engineers, as an alternative to mirrors, for many decades for reflectors and luminairs, as 25 illustrated in U.S. Patent Nos. 2,175,Q67 and 4,26G,220.
Its application can be found in various optical instruments, for example, the porro prism6 in certain binoculars, the amici roo$ p~isms used in certain types of per~scop0~, and the roof prisms used ln certain types of 30 single len~ reflex cameras. ~owever, such devices are massive and bulky.
The present invention affords an improved thin, flexible ~ilm made of a transparent material having a structured surface on one side which will achieve total 35 internal reflectlon so that light, incident within certain angular ranges, is totally lnternally reflected. In addition, since the improved film requires no coating, it . ! . .

~, .

g~3 is capable o maintaining its efficiency over long periods of time. Finally, because o the film's ~lexlbility, it can be formed into a variety of shapes and utilized in several ways.
Disclosure of the Invention . . _ .
The present invention provides a novel thin, flexible film made of a suitable transparent materialt 10 which has a structured surface on one side and a smooth surface opposite the structured surface on the other side.
The structured surface consists of a linear array of miniature substantially right angled isosceles prisms arranged side-by-side to form a plurality of peaks and 15 grooves. When the film is in a planar position, the perpendicular sides of each prism make an angle of approximately 45 with the smooth surface opposite the structured surface. In addition, when the 11m i~ curled or arched, the smooth surface lies in a smooth continuous 20 arcuate curve and incident light striking the concave side of the film, within certain angular ranges, is totally internally reflected.
The ability to maintain reflectivity when the smooth surface lies in an arcuate curve results in the film 25 being able to be utili~ed in a variety of ways. For example, the flexibility of the film allows it to be used as a concentrator of solar energy when applied onto a trough.
A particular advantage of the film's flexibility 30 is that it can be formed into a conduit or optical tunnel having a va~iety of cross-sectional shapes with the linear array of right angled isosceles prisms disposed parallel, orthogonally, or at any angle to the axis of the conduit.
However, lisht will only be totally internally reflected 35 and transported along the conduit if it is properly directed into the conduit. Further, the performance of the conduit can be manipulated so that the conduit acts as an illuminator by permitting a controlled amount of light leakage.

~.~7~3 srief Description o:E the Drawin~s The present invention will be more fully described with reerence to the accompanying drawings 5 wherein like refersnce numerals identify corresponding components, and:
Figures lA and lB are enlarged perspective views of the film of the present invention;
Figure 2 is a schematic end view of the film of the pre~ent invention;
Figure 3 i8 an inverted end view of Figure 2;
Figure 4 is an exaggerated view similar to Figure 2 depicting the film when it is curled into a smooth continuous arcuate curve;
Figure 5 is an exaggerated view similar to Figure 3 depicting the film when it is curled into a smooth continuous arcuate curve;
Figure 6 is a perspective view of a parabolic solar energy concentrating trough utilizing the film of the 20 present invention;
Figure 7.is a perspective view of a light conduit utilizing the film of the present invention; and Figure 8 is a schematic end view of the film of the-present invention having rounded peaks to permit light 25 leakage.
Detailed Description Referring to Figures lA and 1~ of the drawings, the thin, flexible fil~ ~ the present lnvention, generally 30 designated 10, is compris~d of a transparent polymeric material having a structurad surface 12 on one side and a smooth surface 14 opposite the structured surface on the other side. Incident light striking either of the surfaces 12 or 14, within certain angular ranges, will be totally 35 internally reflected at the other surface, as illustrated in Figure 2. The light will be totally internally reflected when the light refracted by the first surface strikes the second surface at an angle, with respect to the .
~' " ' ' ~ -.

~ 3 ~4_ normal, greater than the critical angle. This critical an~le, in air~ is defined as the arc sine of the reciprocal of the index of refraction of the material. In addition, a significant portion of the incident light striking either of the surfaces 12 or 14, outside those angular ranges, will be transmitted and the remainder will be reflected, as illustrated in Figure 3. In either situation, thece is negligible absorption of light by the material.
The structured surface 12 includes a linear array of miniature ~ubstantially right angled isoceles prisms 16 arranged side-by-side in parallel relationship to form a plurality of peaks 17 and grooves 18 running the length of the film 10, as illustrated in Figures 2 and 3.
15 The perpendicular sides 20 make an angle alpha ( a), of approximately 45, with the adjacent smooth surface 14 when the film is in a planar position. In addition, when the film 10 is curled such that the smooth surface 14 lies in a continuous arcuate curve, the angle alpha ( a~ varies from 45 and the sides 20 curve due to compression or tension, as illustrated in Figures 4 and 5. It has besn ound that these conditions do not significantly affect the performance of the film l~ in many applications.
The particular material used for the film 10 may 25 vary~ but it is intended that the material be normally flexibl~, and yet may not have sufficient strength to be self supportiny ln particular applications. The flexibility of the film 1~ can best be defined as the ability to be curled so that the ~mooth surface 14 is a 30 smooth continuous arcuate curve having no discernable discontinuities, such as kinks, fractures, segments, or the like. It is, however, essential that the materlal be transparent, and preferably homoyeneous and i~otropic.
Useful polymeric materials for this purpose are 35 commercially available, for example, acrylics and polycarbonates having nomlnal indices of refraction of 1. 493 and 1. 586, respectively. Other useful polymers are polypropylene, polyurethane, polystyrene, polyvinyl ~7~7~- 5 -chloride and the like. The particular polymeric material selected is not significant to the invention hereof, so long as it provid~s the desoribed function. Normally, the manufacturers of this product will select the best commercially available polymeric material based upon price, application and manufacturing process. However, polycarbonates are of particular interest because of their high indices o refraction and physical properties.
There are several ways to continuously mass produce the film of the present invention which are well known to those skilled in the art, for example as illustrated in U.S. Patent Nos. 3,6~9,346, 4,244,683, 4,576,850 and U.~. Patent Application No. GB2,127,344A, published April 11, 1984. In addition, previous methods lS for mass producing rigid sheets have also included compression molding, casting or calendering. The particular manufacturing proces~ is not essential to the present invention, and is a matter o~ choice based upon economics and availability~
The thickness of the ~ilm is essential to the present invention because the performance and appllcability of the film are dependent upon its flexibility so that the film 10 m~y be curled into a variety of shapes, such as tubular or cylindrical. An approximation for the minimum cylindrical diameter D to which a particular film having a thickne~s T, as mea~ured fro~ the smooth surfac~ 14 to the valley of the groaves 18, may be curled is determined by the equation: D~T C, where C is a constant associated with the modulus of elasticity of the particular material. When 30 the prisms 16 are micro in size, at least 40 per 2.5 cm, and the ~llm 10 has a particular thickness T, it may be curled such that the smooth surface 14 will lie in a smooth continuous arcuate curve while maintaining total internal reflection. It has been determined that an acrylic ilm having prisms micro in size has a constant C of about 200 associated therewith. ~or example, a 0.38 mm thick acrylic film having about 70 prisms per 2.5 cm will exhibit ., .

~783 sufficient flexibility to be capable of being easily curled into a cyl~nder having a minimum diameter of approximately 7.6 cm, while maintaining a smooth continuous arcuate 5 surface without breaking. In addition, such a film will be rigid and self-supporting enough to easily maintain its shape when curled into a cylinder having a diameter of approximately 45.7 cm. Thi~ ability to maintain reflectivity results in the film being able to be utilized 10 in a variety of ways, and eliminates the prior requirement that the optically active surface be rigidly maintained in planar configuration as taught by U.S. Patent No.
~,260,220.
As illustrated in Figure lA, a light ray A
1~ incident on the smooth surface 14, at an angle I1 made with the normal N to the smooth surface 14, is refracted and totally internally reflected at the structured surface 12.
The light ray A and the normal N both lie in a plane that is perpendicular to the direction P in which the linear 20 array of prisms 16 of the structured sur~ace 12 lie. Light ray A will be totally internally reflected and emerge as reflected light ray A' still lying in that same plane.
Similarly, another light ray B, incident on the smooth surface 14 at an angle I2 in a plane not perpendicular to the direetion P, is illustrated. The incident light ray B
is internally reflected and emerges as light ray B' in another plane defined by the incoming light ray B and the prism direction P.

~pplication and Use Several of the various applications and uses of the film 10 of the present invention will now be described.
For example, the film 10 may be attached to a parabolic trough 30 made of a hard rigid material which supports the film 10 to form a concentrator of solar energy, as illustrated in Figure 6. Thus, solar energy S incident upon the smooth surface 14 is totally internally reflected and emer~e6 focused on the llnear target 32.

a3 The ~ost promising and revolutionary use of the film 10 is ~ts ability to be formed into a tubular light conduit 40, whereby the smooth surface 14 lies in a smooth continuous arcuate curve, as illustrated in Figure 7.
Further, as lllustrated in Figures 4 and 5, the conduit 40 may be formed with the structured surface 14 on the inner concave surface or on the outer convex surface. Thus, light can be directed into the conduit 40, as illustrated in Figure 7, by a light source L-S, and a predetermined portion of the light, dependant upon the size and placement of the light source, will be contained by internal reflection and will emerge from the other end when the prisms 16 are disposed parallel to the axis of the conduit The performance of the conduit 40 may be manipulated by adding diffusing particles, or by incorporating windows or imperfections, such as non-optically smooth prism sides and/or non-optically sharp 20 corner~ or peaks, so that the l;ght conduit 40 acts as an illuminator by permitting controlled light leakage. To permit controlled light leakage, the peaks 17, which are normally razor sharp for light transportation, may be blunted or rounded as illustrated in Figure 8. The amount 25 of light leaka~e per reflection is of the order r/p, where r is the approximate radius of the round peak 17' of the prisms 16' and p is the groove perlod. Thus, by varying the radius r of the peaks 17', light leakage can be controlled. It is preferred that this be accomplished 30 without any post-production or conversion operation, which for example may require additional or specialized dies or tooling, or by varyin~ parameters in the manufacturing process. This has proved both effective and economical by varying the following parameters to control replication and 35 the rounding of the peaks: ~1) die temperature; (2) die pressure; (3) line speed; (4) tooling temperature;
(5) cooling rate; (6) polymer dopants, etc. If the manufacturing process is other than extrusion, other parameters may apply.

' ` ' ~7~83 -8-While a preferred embodiment of the present invention has been described so as to enable one skilled in the art to p~actice the techniques o~ the present invention, the preceding description is intended to be exemplary and should not be used to limit the scope of the invention. The scope of the ;nvention should be determined only by reference to the following claims.

: 25 ,,

Claims (15)

1. A thin, flexible film formed of a transparent polymeric material, comprising a structured surface on one side and a smooth surface opposite said structured surface on the other side, said structured surface includes a linear array of miniature substantially right angled isosceles prisms arranged side-by-side to form a plurality of peaks and grooves, the perpendicular sides of said prisms make an angle of approximately 45° with said smooth surface opposite said structured surface, so that when said film is curled said smooth surface lies in a smooth continuous arcuate curve.
2. The film defined in claim 1, wherein said isosceles prisms are micro in size, at least 40 per 2.5 cm.
3. The film defined in claim 1, wherein the film does not have sufficient strength to be self-supporting.
4. The film defined in claim 1, wherein said transparent polymeric material is polycarbonate.
5, The film defined in claim 1, wherein said transparent polymeric material is acrylic.
6. The film defined in claim 1, wherein incident light striking the smooth surface within certain angular ranges is totally internally reflected.
7. The film defined in claim 1, wherein incident light striking the structured surface within certain angular ranges is totally internally reflected.
8. The film defined in claim 1, wherein said film has a thickness of approximately 0.38 mm and about 70 prisms per 2.5 cm so that when said film is curled said smooth surface lies in a smooth continuous arcuate curve without any discernable discontinuities.
9. The film defined in claim 1, wherein said peaks are rounded to permit controlled light leakage defined in accordance with the ratio r/?, where r is the approximate radius of the round peaks and ? is the groove period.
10. The film defined in claim 9, wherein said transparent polymeric material further includes light diffusing particles.
11. A light conduit for transporting light, comprising a thin, flexible film of a transparent polymeric material including a structured surface on one side and a smooth surface opposite said structured surface on the other side, said structured surface having a linear array of miniature substantially right angled isosceles prisms arranged side-by-side to form a plurality of peaks and grooves, the perpendicular sides of said prisms make an angle of approximately 45° with said smooth surface opposite said structured surface, and said film is formed into a tubular configuration so that said smooth surface lies in a smooth continuous arcuate curve, whereby light entering the conduit, within certain angular ranges, is totally internally reflected as it travels along the conduit.
12. The light conduit defined in claim 11, wherein the corners of said prisms of said structured surface are not optically sharp, so that the light conduit acts as an illuminator by allowing some of the light entering said conduit to escape through the film without being totally internally reflected.
13. The light conduit defined in claim 11, wherein the perpendicular sides of said prisms of said structured surface are not optically smooth, so that the light conduit acts as an illuminator by allowing some of the light entering said conduit to escape through the film without being totally internally reflected.
14. The light conduit defined in claim 11, wherein said peaks are rounded to permit controlled light leakage defined in accordance with the ratio r/?, where r is the approximate radius of the round peaks and ? is the groove period.
15. The light conduit defined in claim 11, wherein said transparent polymeric material further includes light diffusing particles.
CA000521320A 1985-11-21 1986-10-24 Totally internally reflecting thin, flexible film Expired - Lifetime CA1279783C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US79986985A 1985-11-21 1985-11-21
US799,869 1985-11-21

Publications (1)

Publication Number Publication Date
CA1279783C true CA1279783C (en) 1991-02-05

Family

ID=25176971

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000521320A Expired - Lifetime CA1279783C (en) 1985-11-21 1986-10-24 Totally internally reflecting thin, flexible film

Country Status (12)

Country Link
US (1) US4906070A (en)
EP (1) EP0225123B1 (en)
JP (7) JP2670518B2 (en)
KR (1) KR950003434B1 (en)
AR (1) AR245987A1 (en)
AU (1) AU582283B2 (en)
BR (1) BR8605708A (en)
CA (1) CA1279783C (en)
DE (1) DE3688123T2 (en)
ES (1) ES2003516A6 (en)
HK (1) HK47595A (en)
MX (1) MX168138B (en)

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US4906070A (en) 1990-03-06
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