CA2217974A1

CA2217974A1 - Optical film to simulate beveled glass

Info

Publication number: CA2217974A1
Application number: CA002217974A
Authority: CA
Inventors: John A. Futhey; Douglas C. Sundet
Original assignee: Individual
Current assignee: 3M Co
Priority date: 1995-04-25
Filing date: 1996-03-11
Publication date: 1996-10-31
Also published as: US5840407A; EP0823061A1; WO1996034302A1; AU5174096A; JPH11504434A

Abstract

A transparent optical film (30) made of a polymeric material has a first smooth surface (32) and a second structured surface (34) for providing a simulated beveled appearance. The structured surface (34) of the film is formed of a plurality of spaced parallel grooves, each groove being formed by a first facet which is substantially perpendicular to the first smooth surface and a second facet which makes an angle between 1 to 60 degrees with the first smooth surface. The film may be affixed to glass, the adhesive applied to the first smooth surface (32) or the second structured surface (72), to simulate beveled glass. Further, a leaded glass appearance or beveled mirror appearance may be simulated by vapor coating the optical film .

Description

W 096/34302 PCTrUS96/02561 OPTICAL FILM TO SIMULATE BEVELED GLASS

Field of the Invention The present invention generally relates to microstructured transparent optical film. In particular, the present invention relates to improvements in ~ microstructured ll~1spa,e-ll optical films applied to glass or mirrors for decorative purposes. The optical film, when applied to glass or mirrors, refracts the ll ~ ed light to give the appeh, ~ce of cut beveled glass.

Back~round of the Invention Cut beveled glass is used for decorative purposes in a variety of applic~tiQn.~, for example, in windows, doors and tables. Cut beveled glass, however, is c~cllsi~e due to the sul~sL~llial labor required. For glass m~mlf~ctllrers~ it is necçss~y to use thicker, and therefore more c ,~ensi.~e, glass when m~mlf~ctl-ring cut beveled glass to ensure the outside edge of the bevel meets minimllm standards of thi~ness .MoreovPr~ it is v:rtu~11y impossib!c .for ,~yp,~l CO~u;;~ , of gla~ to cut z bevel ~n a pane of glass. Therefore, it would be desirable for consumers and glass m~mlf~-,tllrers to produce high quality ~imlll~tecl beveled glass that was easy and inexpensive to produce the beveled effect in the glass. Further, it would be desirable if the beveled effect could be produced without removing the glass from its frame and the beveled effect could be removed or rh~nge~l when desired.
Telllpered glass is widely used in bllil~1in~.~ for both commercial and r~ nti~l applic~tion~ Telllpeled glass is hard and brittle, however, and is ~liffiClllt to m~f~.hine a bevel on the edge of the glass. Therefore, it is also desirable to be able to produce an inexpensive ~imlll~tec~ beveled edge for tempered glass.
U.S. Patent Number 4,192,905 to Scheibal describes a transparent strip of polymeric material used to imitate a beveled edge. The Ll~spal elll strip has a wedged-shaped cross-section, the wedge shape having an angle similar to a beveled edge. The Ll~llspalel,L strip has adhesive on one side for affixing the strip to the glass, thereby producing a beveled edge appearance. While the wedge-shaped strip may beplaced with the thinner edge on the outside edge of the glass, it produces a sharp ridge on the inner edge of the strip. If the wedge-shaped strip is place with the thicker edge on the outside edge of the glass, however, inrident light is refracted in the opposite dile~;Lioll as colllpa,ed to real beveled glass.
Microstructured Lla,lspalt;l,L optical film has been used on glass, mirrors, vehicles, signs, ceilings and other surfaces for decorative purposes. For example, col,llnonly-~ignecl U.S. Patent Number 3,908,056 to Anderson describes an optically decorative web that produces a real or virtual image which image is other than that of an actual surface ofthe strip. The Anderson optically decorative web co",~lises a strip of opaque or Ll ansl)a, e"L polymeric material having a series of ridges and grooves on one side and a smooth surface on the other side. Examples of real or virtual images produced by the optically decorative web Anderson discloses are metallic or Llal,s~a,e"L
concave or convex surfaces, an arched ceiling which would be concave, giving thesensation of being in a room having a domed ceiling, a metallic strip on an automobile, m~ ling on furniture, or the appea~lce of a semicylindrical glass or met~llic bar 1~ çYt~n~lin~ across a glass panel.
Cut or textured glass shapes, having beveled edges, are frequently assembled together in decorative paLLe",s using lead or brass came. The process of cutting the glass shapes and asse",l~ lg the shapes using the lead came is e~ si~e and requires con~ rable skill and time. The process to create dirrele"L textures on glass varies, depending on the texture. For example, glue chip texture is achieved by the application of animal glue to the sandblasted surface of glass. The glue is exposed to heat and allowed to dry, thereby chipping the surface of the glass to produce the textured surface.

2~ S~lmm~ry ofthe Invention To overcome the limitations in the prior art described above, and to overcome other limitations that will become appa,e"l upon reading and underst~ntling the present specific~tion, the present invention provides a L~lsl)alellL optical film for providing a sim~ te~l beveled appearance. The polymeric film has a first smooth surface and a second structured surface. The structured surface has a plurality of spaced parallel grooves, each groove being formed by a first facet, which is subst~nfi~lly perp~n~iclll~r to the smooth surface, and a second facet, which makes an angle with the smooth W 096134302 PCTnUS96/02561 surface such that light rays entering the smooth surface behave similarly to light rays entering the actual cut beveled glass. The present invention further provides a polymeric film having a first portion and a second portion, the first portion having a structured surface ~im~ ting beveled glass and the second portion ~imlll~ting textured glass.

BriefDescli~,Lion ofthe Drawin~s The present invention will be more fully described with reference to the accolllp~lyillg drawings wherein like reference numerals identify corresponding colllponellls, and:
Figure 1 is a top view of a sheet of beveled glass;
Figure 2 is an enlal~ed sectional view of the beveled portion of cut beveled glass taken along line 2-2 of Figure 1 used to describe the behavior of the refracted light rays;
Figure 3 is a side cross-sectional view of a first embodiment of the present invention, where the film is affixed to the glass with the grooved side away from the glass;
Figure 4 is a side view of the grooves of the film for the first embodiment;
Figure 5 is a side cross-sectional view of a second embodiment of the present invention, where the film is affixed to the glass with the grooved side facing the glass;
Figure 6 is a side view of the grooves of the film for the second embodiment to help describe the behavior of refracted light rays;
Figure 7 is a side cross-sectional view of the present invention oriented on glass to produce a ~imlll~tecl V-groove;
Figure 8 is a graph showing the nP!ceSS~ y di~;l ence in refractive indices between the film and air to achieve a deflection angle nec~ss,., y to .~imlll~te various bevel angles;
Figure 9 is a graph showing the nec~ss~ry dirrelellce in refractive indices between the film and the adhesive to achieve a deflection angle necessaly to simlll~te various bevel angles;

CA 022l7974 l997-lO-09 W 096/34302 PCTrUS96/02561 Figure 10 is a side cross-sectional view of a beveled mirror to help describe the behavior of reflected and refracted light rays;
Figure 11 is a side cross-section~l view of the present invention applied to a mirror, the film of the present invention having grooves facing away from the S mirror;
Figure 12 is a side cross-sectional view ofthe present invention applied to a mirror, the film of the present invention having grooves facing the mirror;Figures 13a is a top view of another embodiment of the present invention, the film having a first portion ~im~ finp beveled glass and a second portion ~imlll~fing textured glass; and Figure 13b is an enlarged sectional view taken along line 13b-13b of Figure 13a.

Detailed Description of a Preferred Embodiment To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparenL upon reading and undel~ li.)g the present sperifir,~tic~n, the present invention provides an optical film for applic~tiQn to a sheet of glass that ~imlll~tes the appe~nce of beveled glass. Moreover, the present invention provides a simple, econc~mic~l way to customize doors, windows, mirrors and other glass objects by applying ~imlll~ted beveled and/or textured shapes made from embossed or molded polymers over existing glass surfaces. Figure 1 shows a , e~ ~. .g, .1;~. sheet of beveled glass 2, having bevel 4 on the edges of glass 2. Beveled glass 2 has a center portion 6, where a perprn~lic li~r ray of light is not refracted at the glass/air interface. At bevel 4, however, inri~lrnt light enLeling the glass at the bottom ofthe bevel is refracted as it exits glass 2. Rerelling to Figure 2, a cross-sectional view of bevel 4 at the edge of glass 2 is shown. Bevel 4 is cut at an angle ~ to bottom surface 12 of glass 2. Angle ~3 varies depending on the desired effect of the bevel and the use of the beveled glass, although it typically is in the range of S to 4~ degrees. For rx~n plr, in Figure 2, bevel 4 is used as decorative edging on a sheet of glass, and angle ~ is 10 degrees. When light ray 20 enters glass 2 from bottom surface 12, the deflection angle of light ray 20 as it exits the glass mr.~il lm may be measured from a normal to bottom surface 12 of glass 2. The refractive index of air and glass are represented by nl and n2, CA 022l7974 l997-lO-09 W 096t34302 PCTrUS96/02561 _5_ respectively. Typical numbers for the refractive indices of air and glass, respectively, are:
n,= 1.0 n2= 1.5 Using these p~ ~I-~;Lers and Snell's law:
nlsin(~3+~)=n2sin~3 r the de-flection angle ~ may be d~;Le~ ed to be applox;~ Ply 5 degrees.
To produce an optical film that will give the appe~ ~1ce of cut beveled glass when applied to a sheet of glass, the film must be optically clear. Further, the facets bending inr.i~1Pnt light, thereby producing the beveled appe~ce must be sufflciently small such that they will not be evident to a casual observer. Examples of suitable materials to produce the optical film of the present invention include cellulose acetate butyrate, polycarbonate, meLhyl...c;~ rrylate, polyvinylchloride and polystyrene.
Rt;rt;llhlg to Figure 3, a cross-sectional view of a portion of a sheet of glass with the optical film ofthe present invention applied to it is shown. Optical film 30 has smooth, planar first side 32 and second side 34 opposite first side 32. Second side 34 of optical film 30 has a plurality of prism grooves, preferably running parallel to the length of film 30. The grooved preferably are equally spaced. Optical film 30 is applied to the surface of glass 50 by Ll~ulsl)alt;llL adhes*e 40. Preferably, adhesive 40 is a pres~ure sensitive adhesive, such as SCW-100 Ll~llsrer adhesive, Scotch brand 666 double coated tape and Scotch brand VHB ll~ rel adhesive, all m~mlf~ctllred by Minnesota Mining and M~mlf~r,tllring Conlp~ly, St. Paul, MN. In a plerelled embodiment, adhesive 40 is applied to optical film 30 with a removable liner to produce an optical tape for easy application to a sheet of glass. In such an embodiment, the liner is removed and the optical tape is positioned over the area of the glass where the beveled effect is desired.
Referring to Figure 4, the grooves and the facets ~lPfining the grooves will now be described. On second side 34 of optical film 30, a plurality of prism grooves 60 are defined by first subst~nti~lly perpendicular facet 62 and second facet 64. First facet 62 is subst~nti~lly perpendicular to planar first side 32 of optical film 30 and is defined by draft angle a. Draft angle a is theoretically zero degrees for an optimal ~ 30 beveled effect. In practice, however, draft angle a is greater than zero degrees for m~nllf~r,tllring ease, and pl~;rel~bly falls in the range between zero and seven degrees.
The angle ~ that defines second facet 64 is critical to the quality of the bevel effect W 096/34302 PCTrUS96/02561 produced by the optical film. To sim~ te the optical qualities of cut beveled glass, light rays entering perp~nrlic ll~r to planar first side 32 of optical film 30 and exiting second facet 64 must behave similarly to light rays that enter the planar side of cut beveled glass and exit out the beveled portion of the glass. Because the geometries of the cut beveled glass and the second facet 64 of optical film 30 are similar and because both glass and the polymeric materials used for the optical film have indices of refraction around 1.5, f, angle ~ must be similar to the bevel angle in glass. As shown in Figure 2, it is desirable for light rays to be deflected 5 degrees from the perpPntlic ll~r when exiting the optical film to ~imlll~te a 10 degree bevel. Thus, to produce an exit angle of 5 degrees from the perpPntliclll~r for light rays e.l~e~ g perpendicular to the first planar side 32 of optical film 30, angle ~ must also be appro~illla~ely 10 degrees. The pitch 66 of the grooves, the rli~t~nr,e between peaks ofthe grooves, plc;relably is sllffisi~ntly small such that an observer from a ~liet~nr.e cannot discern the individual grooves. If the pitch 66 ofthe grooves is too small, however, the film exhibits diffractive sc~lle~ g and color. As the groove spacing is made smaller, the color introduced by diffraction is .. ,.x;,.. ;,~d This can PnhAn~ e the decorative effect of the film, but ~liminich~ the clarity of an object viewed through the bevel. Preferably, the pitch 66 of grooves 60 will range between five and 5oo~lm and more plert;l~bly, between 50 and 250 ~m. For purposes of providing color by diffraction, however, the preferable pitch is between one and ten ~m.
In the embodiment of the present invention shown in Figure 3, the grooves of the optical film are exposed to the Pl~m~nt~ This exposure can cause problems, as the peaks of the grooves are somewhat fragile and are prone to scratches that can eventually degrade the quality of the beveled appearance. Moreover, thegrooves can fill with water, oil, dirt and other matter which can also degrade the optical quality of the beveled effect. Referring to Figure 5, the cross-section of another embodiment of the present invention is shown which avoids the above-mentioned concerns. Optical film 70iS made of a substantially transparent polymeric material, preferably having a high index of refraction. Some pl er~ ;d polymeric m~tPri~1~ include polycarbonate, with an index of refraction of appl~ atelyl.60 and polystyrene, with an index of refraction of appl~x;" ,;.IP.1Y 1.59 -1.60. Optical film 70 has a first surface 72 that has a plurality of parallel grooves 76, preferably running the length of optical film 70, each groove 76 being defined by a first facet 78 and a second facet 79. Optical W 096/34302 PCTrUS96/02561 film 70 has a subst~nti~lly planar second surface 74 opposite first surface 72. Second surface 74 is the surface exposed to the el~m~ntc thereby providing a surface that is easily cleaned and protecting the peaks of the grooves. First facet 78 is subs~ lly pe l.e~ ic~ r to second surface 74, with a draft angle, as described for the previous S embodiment, of between zero and seven degrees from the perpen~ r. Second facet 79 is defined by angle ~, as will later be described.
Optical film 70 is affixed to glass 90 by adhesive 80. Adhesive 80 is subst~nti~lly~ lsp-clll and preferably has a low index of refraction. Some examples of adhesives to be used include silicone based adhesives such as Dow Corning Q2-7406, 280A, X2 - 7735, General Electric PSA 590, PSA 600, and PSA 610, which are polydimethyl siloxane based silicone pressure sensitive adhesives having an index of refraction app~ -alely between 1.40 to 1.43. A p-crc-~cd adhesive is a polydiorganosilf-x~ne polyurea se~ ed copolymer-based composition. The composition is prepared as follows: Polydi...cll,ylsiloxane ~ mine (molecular weight 37,800) was fed at a rate of 7.92 g/min (0.000420 amine equivalents/min) into the first zone of a Leistritz (Leistritz Col ~o, alion, .All~nd~le, NJ) 8 zone, 18 mm ~1;A ~ I ~ r 720 mm length co-rotating twin screw extruder having double start fully inte,...~l,;.,g screws ope,ali"g at 250 rev~ llltinn~ per minute. Silicate resin (SR-545, available from General Electric Silicone Products Division, Waterford, NY, the toluene from this solution as supplied having previously been evaporated) was fed at a rate of 9.1 g/min to the third zone of the extruder. A Illi~lu. c of 30.65 parts methylenedicyclohexylene-4,4'-diisocyanate, 18.15 parts isocyanatoethyl meth~rylate, and 51.20 parts DAROCURETM
1173 (a photo;";~ or, available from EM Industries, H~wlhollle~ NY) was fed at a rate of O.154 g/min (0.000541 isocyanate equivalents/min) into the seventh zone. The tclllpcl al.lre profile of the each of the 90 mm long zones was: zones 1 through 5 -40~C; zones 6 and 7 - 60~C; zone 8 - 120~C; and endcap - 160~C. The reslllting pressure-sensitive adhesive was extruded at 160~C through a die and collected.
The pl erel I cd adhesive has an index of refraction of 1.43 . Adhesive 80 must fill the grooves, leaving enough excess thickness for good adhesion. Therefore, a less viscous adhesive is preferable, as it flows better into the grooves, thereby ~l;",;"z.l;"~ any air pockets in the grooves. The p~erclled adhesive has a lower viscosity before W curing and may be l~min~ted to the grooves before curing to better fill the W 096/34302 PCTrUS96/02561 grooves without air ellll ~Illent. In one embodiment, after adhesive 80, a pressure sensitive adhesive, is applied to optical film 70, a removable liner is applied to the other side of adhesive 80 to form an optical tape.
While the absolute values of the index of refraction of the polymeric material used for the optical film and index of refraction of the adhesive or air are not critical, the di~elelllial of the values of the indices of refraction of the two is critical to produce the desired beveled effect. Figres 8 and 9 are graphs showing the deflection angle ~ with respect to the di~el enlial in refractive indices between the optical film and air for a groove/air int~ ce, such as the embodiment shown in Figure 3, and between the optical film and adhesive for an embodiment where the grooves face the glass, such as the embodiment shown in Figure 5. Figures 8 and 9 lepl~:selll the relationship when the polymeric material has a refractive index of 1.6. The deflection angle is subst~nti~lly the same for a range of refractive indices for the polymeric m~tPri~l, although as the refractive index approaches lower values, such as 1.3, the deflection angle gets smaller, and conversely, as the refractive index approaches larger values, such as 3.0, the deflection angle gets larger.
Figure 8iS a graph showing the necess~ry di~erellLial in refractive indices b~lweel the optical film and air to produce desired deflection angles ~. The nec~ss~ry di~elenlial is dependent on the physical angle ~3 of the grooves in the optical film, as shown by lines 170,172 and 174 which represent the relationship between the dirre;lelllial and exit angle ~ for physical angles ~3 of 5, 15 and 25 degrees, respectively.
Figure 9 is a graph showing the n.~c~sS~ . y difrelenlial in refractive indices between the optical film and adhesive to produce desired d~flecti~ n angles ~. The nece~.y di~erenlial is dependent on the physical angle ~1 of the grooves in the optical film, as shown by lines 180, 182 and 184, which represent the relationship between the di~el~ ial and exit angle ~ for physical angles ~3 of 15, 30 and 45 degrees, respectively.
For loY~mple, for a physical angle ~ of thirty degrees in an embodiment with adhesive on the grooved side of the optical film, to obtain an exit angle ~ of five degrees, the di~el ~ ial between the refractive index of the film and the refractive index ofthe adhesive would need to be appl~imately 0.155. Thus, if a polymeric m~teri~l t having an index of refraction of 1.60 is used for the optical film, an adhesive having a W 096/34302 PCTrUS96/02561 _g _ refractive index of 1.445 would produce an exit angle of five degrees. Similarly, to obtain an exit angle of three degrees, a di~-c;-llial of ap~ xi~alely 0.09 would be nt~ceSSh~y. Thelerole, line 182 of Figure 9 shows that dirrele.-lials between 0.1 and 0.35 will produce exit angles between three and eleven degrees for a physical angle of thirty degrees. Those sWlled in the art will readily recognize that the relationship between the . physical angle ~3, the refractive index of the optical film and the refractive index of the adhesive can be varied to obtain the desired exit angle to t~m~ te the exit angle from beveled glass having various physical angles.
R~rt;..i- g to Figure 6, optical film 70 has a first grooved surface with second facet 79 defined by angle ~ and has an index of refraction of n2 and a second planar surface 74 at the film/air interface. The index of refraction of air is cleeign~ted by nl and the adhesive, n3. To produce an adequate beveled appearance with the adhesive applied to the first grooved surface of the optical film, the relationship between the indices of refraction of the polyrneric material and adhesive, and the physical angle ~
dt-fining the grooves is ~ignifit ~nt Rere-ling back to Figure 6, light ray 100 is refracted both at the adhesive/film interface as well as at the film/air interface. Snell's law at the first refraction, at the adhesive/film interface, is:
n3sin ~3 = n2 sin a where a is the inte.".t-tl;~l~ angle as shown. Snell's law at the second refraction, at the film/air interface, is:
n2 sin( ~3 - a ) = nl sin ~
Co---l,i- i--g the two equations and el;l~ A~ g the intermetli~te angle a gives the following r.ol~fion~hir between the physical angle ~3 defining the grooves, and the indices of refraction of the air, film and adhesive:

sin ~ ( n3 sin ~) _ n3 sin ~ cos ~ = n' sin SZ7 n2 n2 n2 - where ~ is the angle of deflection of light ray 100 from a normal to the second planar surface of the optical film. The above relationship shows that as the difference between the index of refraction of the polymeric material of the film and the index of refraction of the adhesive gets larger, the physical angle ~ can get smaller.

To produce a high quality beveled appearance with a particular bevel angle, the angle of deflection ~ of a light ray entering the bottom of the glass should be similar to or the same as the angle of deflection in cut beveled glass. Further, to have a reasonable groove structure, that is, the physical angles are not so high that m~mlf~ctllring the grooves and filling them with adhesive is not too .lifficl~lt and the tape can be reasonably thin, the dirr~ l,Lial between the indices of refraction of the polymeric material of the optical film and the adhesive must be substantial. As shown in Figure 2, for a bevel angle of 10 degrees, the angle of deflection ~ is appl~x;~ ely 5 degrees.
Polymeric material such as polycarbonate, poly~lyl el1e or some hybrid of either of these and other polymers will have an index of refraction of appl ox; " ,~1 ~ly 1.57. The aforçm~ntioned silicone adhesives have an index of refraction of a~p, u~hn~Lely 1.42.
Using these pararneters, the physical angle ~ d~.fining the grooves will be appro;~i",aLely 28 degrees. This physical angle allows the tape to be reasonably thin. For example, if the groove pitch is 5 mils, or .1270 millimeters, then the groove depth would be 2.65 mils, or .0673 mill;",~;le~ :i, and the total tape thi~~~ness could be app.~-X;lllhl~ly 5 mils, or .1270 millimet~rs While the above C~.~ullplE ~im~ ted a 10 degree bevel angle, a range of bevel angles can be cimlll~ted by varying the physical angle ~3 def ning the grooves within the range of one to 60 degrees. In the embodiment with the grooves exposed, it is more preferable to have the physical angle ~3 in the range of 3 and 30 degrees and even more pr~re. ~le to have the physical angle ~ in the range of 7 and 20 degrees. In the embodiment with the planar side of the optical film exposed, it is more preferable to have the physical angle ~3 in the range of 10 and S5 degrees and even more preferable to have the physical angle ~t in the range of 23 and 38 degrees.
In an embodiment where the adhesive is applied to the optical film and a strippable liner is applied to the adhesive to form an optical tape, it is desirable for the optical tape to be repositionable upon application to the glass for a short period of time to precisely align the glass and tape. One method of applying the optical tape to produce the repositionable property is to first apply a mixture of water, poly~ ro~yl alcohol and liquid d~L~l~ellL, such as a liquid dishwashing d~;Le~e~L, such as Joy, m~mlf~ctllred by Procter & Gamble, Cin~inn~ti~ OH, in an appl.~lll~Le ratio of 40:20: 1.
After ~le~ning the surface of the glass, the surface is wet with the liquid mixture. The W 096/34302 PCTrUS96/02561 liner is removed from the adhesive and the optical tape is placed on the wet glass. The liquid allows the optical tape to be easily slid around the surface of the glass until it is precisely in a desired location. The liquid will evaporate over time, such as overnight, and the optical tape will be p~ n~ y bonded to the glass. This method further reduces visua1 flaws, such as ellLl ~ped air between the bond lines, when the film is affixed to the glass.
While the present invention has been described to produce a beveled edge appe~ ~ce on glass, the film also may be used to ~im~ te a V-groove cut into glass. Figure 7 shows the pl~c~om~nt of two strips of optical film to create a V-groove cut effect. First optical film 110 and second optical film 112 are placed ~qdj~cçnt along their lengthwise direction, with grooves also running along the length of the film.
Optical film 110 has the outer edge of its sim~ ted bevel ~dj~c~nt the outer edge of the ~imllls~ted bevel of optical film 112 to create a V-groove appearance. Film 110 and 112 are affixed to glass 114 by adhesive 116.
Films with microstructured s ~ cçs can also be used with .. i.. ored surfaces to create a beveled appe~ce. When the l-~-s,~c;--L optical film desc-ibed above is bonded to the surface of a mirror with the smooth side of the film affixed to the mirror, however, the film has a hazy appearance. Figures 11 and 12 show embo-ii,.,~.,l~
ofthe present invention for application to .-li-.oled surfaces. Figure 10 shows a cross-ser,tit n~i view of a beveled mirrored surface. At mirrored surface 124 of mirror 120, light ray 128 is reflected, the angle of inc;d~nce al equal to the angle of reflection a2.
Light ray 128 is refracted at beveled edge 122 having a physical angle of ~, with an angle of deflection of ~. The behavior of light ray 128 with respect to beveled edge 122 and mirrored surface 124 can be described by the following equations:
c~ = 2 a + ~ (Equation 1) nl sin ( ~3 + ~ ) + n2 sin ~; (Equation 2) a = ~t; and (Equation 3) cs = 2~ + ~ (Equation 4) In Figure 11, optical film 130 is applied to mirror 132 by adhesive 134.
Mirror 132 has mirrored surface 136. To improve the beveled appe~lce ofthe W Og6/34302 PCTrUS96/02561 transparent optical film, the grooved side of optical film 130 is vapor coated with a highly reflective metal 138, such as ~lllmimlm or silver. Thus, light rays 140 appro~rhin~ optical film 138 are rPflected at surface 138, the angle of in~ i~1pnce equaling the angle of reflection, thereby creating a beveled al~pe~ce. The angle of inci~lPn~e and angle of reflection are each equal to the physical angle ~ . Another advantage of the vapor coat layer is that the adhesive beneath the vapor coat layer is invisible from view.
Figure 12 shows a similar embodiment as Figure 11, except the grooves ofthe optical film are facing the lllhloled surface. Optical film 150 is applied to mirror 152 by adhesive 154. The grooved side of optical film 150 is vapor coated with highly reflective metal 158. Light ray 160is re.flected at vapor coat layer 158 and refracted at planar side 159 of optical film 160. The behavior of light ray 160 with respect to the embodiment of Figure 12is governed by Equations 1-4, shown above. In an embodiment with the grooved side of optical film 150 facing the mirrored surface, h(swever, the vapor coating is not necess~ry, although it is pl~r~lled. In an embodiment where film 150 is not vapor coated, the optical effect of applying film 150 to mirror 152 is the appearance of a bevel with a larger angle than would appear if the same film were applied to glass, such as in Figure 5, due to the double refraction of the light rays after they reflect offthe surface of mirror 152.
Rerellhlg to Figure 13a and 13b, a top view and a cross-sectional view of another embodiment ofthe present invention is shown. Figure 13a shows film 200 ~imlll~ting a cut glass shape, in Figure 13a, a square, made of a polymeric material, such as plasticized polyvinyl chloride, polycarbonate, cellulose acetate butyrate, and eLllyl...~ rylate. Film 200 has first side 206 and a second side opposite first side 206. Film 200 has a first portion having random textured surface 202 and second portion having structured surface 204~iml-l,qting a beveled edge. Random textured surface 202iS preferable on the second side opposite first side 206. Structured surface 204 may either be on the first side or the second side of film 200. Structured surface 204 has a plurality of prism grooves and facets oriented such that light rays entering pel~ lic~ r to planar side 206 of film 200 are refracted similarly to cut beveled glass.
A more det~iled description of structured surface 204iS given in conjunction with Figures 3-5 . When structured surface 204iS on the second side of film 200, as shown in Figure 13b, film 200 may be affixed to glass, not shown, with adhesive on first side 206, W 096134302 PCTnUS~6102561 similar to the embodiment shown in Figure 3. When structured surface 204 is on first side 206 of film 200, film 200 is affixed to glass with adhesive on structured surface 204, similar to the embodiment shown in Figure 5. When the adhesive in on structured surface 204, it is p~erel~ble to orient structured surface 204 facing the glass and textured surface 202 away from the glass.
Textured surface 202 may be any of a variety of textures typically found on textured glass. Some c,.~l~lcs of textures include ripple glass, having high and low spots of rippled or wormy texture, l-~- "" ,~ ed glass, characterized by its circular ha,l~lel t;d h~lpl e~ions on the surface, moss glass, having a fine gravelly texture, flemish glass, having wide high and low spots, glue chip glass, having fern-like texture and baroque, having a surface with raised wildly swirled texture. Textured surface 202 may be fabricated using a photochemical engraving process on a die, and embossing ormolding the po1ymer in the die. Another method is by electroplating a piece of glue chip glass to obtain a mirror image ofthe glass. The ele~Ll.,r~,lll,ed ~l~ll~el is used to emboss a sheet of llleLllyh~lt~,th~-'.rylate with the glue chip pattern. To add the microstructured grooves to the ~im~ ted glass, a channel is milled into the methylmeth~crylate around the pelhlleler and strips of microstructured film are inselled into the milled channel so that the s ~rf~ces are ~li necl The fabricated master then is ele.,LloplaLed to obtain a sLalllpel. This process produces a one-piece ~l~llpel by parqueting several pieces together. The ~L~ll~er then can be used to emboss or mold the ~imlll~ted beve1ed and textured glass.
The present invention can also ~imlll~te the appearance of leaded windows, where cut glass shapes having beveled edges are assembled together using lead or brass came. This decorative pattern is ~imlll~ted by affixing the polymeric ~imlll~ted cut glass shapes, as shown in Figures 13a and 13b, on the glass and affixing mircostructured stripping with a vapor coat layer to the glass to ~imlll~te lead or brass came. Referring back to Figure 3, first side 32 of optical film 30 can be vapor coated with a highly reflective metal, such as ~lllminllm or silver, to create the leaded appearance. Alternatively, lere"ing back to Figure 11, grooved side of optical film 130 can be vapor coated to produce the leaded appearance using reflective metal 138.Figure 12 shows yet another embodiment of ~imlll~ted lead came, where the grooved side optical film 150 is vapor coated with metal 158.

Although a pler~ d embodiment has been illustrated and described for the present invention, it will be appreciated by those of ordinary skill in the art that any method or app~lus which is calculated to achieve this same purpose may be ed for the specific configurations and steps shown. This applic~tion is inten-ied S to cover any adaptations or variations of the present invention. Therefore, it is allirc:~lly int~n-led that this invention be limited only by the appended claims and the equivalents thereo~

Claims

Claims:

1. A transparent optical film for providing a simulated beveled appearance, said film comprising a polymeric film having a first smooth surface and a second structured surface, said second structured surface being formed of a plurality of spaced parallel grooves, each said groove being formed by a first facet which issubstantially perpendicular to said first smooth surface and a second facet which makes an angle between 1 to 60 degrees with said first smooth surface.

2. The transparent optical film according to claim 1, further comprising a layer of adhesive applied to said first smooth surface.

3. The transparent optical film according to claim 1, further comprising a layer of adhesive applied to said second structured surface.

4. The transparent optical film according to claim 2, wherein said second facet makes an angle between 3 and 30 degrees with said first smooth surface.

5. The transparent optical film according to claim 2, wherein said second facet makes an angle between 7 and 20 degrees with said first smooth surface.

6. The transparent optical film according to claim 2, wherein the index of refraction of said polymeric film is between 1.35 and 1.65.

7. The transparent optical film according to claim 3, wherein said second facet makes an angle between 10 and 55 degrees with said first smooth surface.

8. The transparent optical film according to claim 3, wherein said second facet makes an angle between 23 and 38 degrees with said first smooth surface.

9. The transparent optical film according to claim 3, wherein the index of refraction of said polymeric film is between 1.5 and 1.65 and the index of refraction of said adhesive is between 1.3 and 1.45.

10. The transparent optical film according to claim 3, wherein the index of refraction of said polymeric film is between 0.1 and 0.5 greater than the index of refraction of said adhesive.

11. The transparent optical film according to claim 1, wherein said second structured surface is coated with a reflective material.

12. The transparent optical film according to claim 1, wherein said first smooth surface is coated with a reflective material.

13. A window with a simulated beveled portion, said window comprising:
a pane of glass;
a polymeric film having a first smooth surface and a second structured surface said second structured surface being formed of a plurality of spaced parallel grooves, each said groove being formed by a first facet which is substantially perpendicular to said first smooth surface and a second facet which makes an angle between 1 to 60 degrees with said first smooth surface; and a layer of adhesive for affixing said polymeric film to said pane of glass in portions of said glass for simulating a beveled appearance.

14. A mirror with a simulated beveled portion, said mirror comprising:
a first mirrored portion having a reflective surface;
a polymeric film having a first smooth surface and a second structured surface, said second structured surface being formed of a plurality of spaced parallel grooves, each said groove being formed by a first facet which is substantially perpendicular to said first smooth surface and a second facet which makes an angle between 1 to 60 degrees with said first smooth surface and being coated with a reflective material; and a layer of adhesive for affixing said polymeric film to said mirror in second portions of said mirror for simulating a beveled appearance.

15. A film for providing a simulated beveled glass and textured glass appearance, said film comprising a polymeric film having a first portion and a second portion, said first portion having a smooth surface and a structured surface, said structured surface being formed of a plurality of spaced parallel grooves, each said groove being formed by a first facet which is substantially perpendicular to said smooth surface and a second facet which makes an angle between 1 to 60 degrees with said smooth surface, said second portion having a textured surface structure and a smooth surface.

16. The film according to claim 15, further comprising a layer of adhesive applied to said smooth surface of said first portion and said second portion.

17. The film according to claim 15, further comprising a layer of adhesive applied to said structured portion of said first portion and said smooth surface of said second portion.