US 12,135,450 B2
Method of manufacturing a display using a film-based lightguide and diffusely reflective release liner
Jose Romero, Chicago, IL (US); Anthony Nichol, Minneapolis, MN (US); Eric Blair, Naples, FL (US); and Zane Coleman, Elmhurst, IL (US)
Assigned to Azumo, Inc., Chicago, IL (US)
Filed by AZUMO, INC., Chicago, IL (US)
Filed on Jun. 9, 2021, as Appl. No. 17/343,558.
Application 17/343,558 is a continuation in part of application No. PCT/US2019/065525, filed on Dec. 10, 2019.
Claims priority of provisional application 62/777,838, filed on Dec. 11, 2018.
Prior Publication US 2021/0294021 A1, Sep. 23, 2021
Int. Cl. G02F 1/1335 (2006.01); F21V 8/00 (2006.01); H04N 9/31 (2006.01)
CPC G02B 6/0065 (2013.01) [G02B 6/0051 (2013.01); G02F 1/1335 (2013.01); G02F 1/133524 (2013.01); H04N 9/3152 (2013.01); H04N 9/3194 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of manufacturing a display comprising:
forming a front illumination film-based lightguide comprising
a core layer formed from a polymer film with a first refractive index and having lateral edges and opposing faces with a thickness not greater than 0.5 millimeters therebetween,
a plurality of light extraction features on or within the core layer defining a light emitting region of the front illumination film-based lightguide,
a pressure sensitive adhesive layer with a second refractive index less than the first refractive index, and
a diffusely reflective release liner removably and optically coupled to the pressure sensitive adhesive layer, the pressure sensitive adhesive layer is positioned between the core layer and the diffusely reflective release liner in the light emitting region;
coupling light from at least one light source into the front illumination film-based lightguide such that light from the at least one light source propagates by total internal reflection through the core layer, is extracted from the core layer by the plurality of light extraction features, passes through the pressure sensitive adhesive layer, diffusely reflects from the diffusely reflective release liner, and passes back through the pressure sensitive adhesive layer and core layer out of the front illumination film-based lightguide in the light emitting region;
analyzing the light exiting the light emitting region from the at least one light source for defects;
removing the diffusely reflective release liner from the front illumination film-based lightguide after analyzing the light exiting the light emitting region; and
optically coupling the core layer to a reflective spatial light modulator using the pressure sensitive adhesive layer after removing the diffusely reflective release liner.