Pre-stacked optical films

Abstract

Pre-aligned optical layers are stacked and arranged such that an adhesive layer, which is stacked onto the optical layers, contacts at least the uppermost layer and lowermost layer. The resulting subassemblies can be assembled into an optical display without individual handling of the layers, which reduces installation time and manufacturing costs.

1 . An optical subassembly for use in an optical display, the optical subassembly comprising: 
 a plurality of stacked optical films having an uppermost film and a lowermost film, each of the uppermost and lowermost films having at least first and second edges; and    first and second adhesive layers contacting the uppermost and lowermost films of the stack on the first and second edges of the uppermost and lowermost films to hold the stack together as a unit, so that the stack can be assembled into an optical display without individual handling of the optical films of the stack.    
     
     
         2 . The optical subassembly of  claim 1  and further comprising: 
 at least one intermediate film between the uppermost and lowermost films of the stack.    
     
     
         3 . The optical subassembly of  claim 2  wherein the two edges of the optical films are staggered.  
     
     
         4 . The optical subassembly of  claim 2  wherein the optical films are configured such that each optical film contacts the first and second adhesive layers.  
     
     
         5 . The optical subassembly of  claim 1  wherein third edges of the optical films are staggered.  
     
     
         6 . The optical subassembly of  claim 1  wherein at least one optical film includes voids to allow the first adhesive layer to contact the lowermost film.  
     
     
         7 . The optical subassembly of  claim 1  further comprising a protective cover sheet.  
     
     
         8 . The optical subassembly of  claim 2  wherein the at least one intermediate film between the uppermost and lowermost films of the stack is selected from the group consisting of a turning film, a prismatic film, a reflective polarizer, a diffuser, and combinations of any of them.  
     
     
         9 . The optical subassembly of  claim 2  wherein the at least one intermediate film between the uppermost and lowermost films of the stack is two prismatic films.  
     
     
         10 . The optical subassembly of  claim 1  wherein the each of the first and second adhesive layers have two major sides and have an adhesive on each of the two major sides.  
     
     
         11 . The optical subassembly of  claim 1  wherein the each of the first and second adhesive layers have two major sides, wherein one of the major sides is black and the other major side is white or silver.  
     
     
         12 . The optical subassembly of  claim 1  wherein the first and second edges have a length and the first and second adhesive layers contact the length of the first and second edges.  
     
     
         13 . The optical subassembly of  claim 1  wherein each of the uppermost and lowermost films has four edges and first, second, third, and fourth adhesive layers contacting the uppermost and lowermost films of the stack on the four edges of the uppermost and lowermost films.  
     
     
         14 . The optical assembly of  claim 13  wherein the first, second, third, and fourth adhesive layers are a unitary adhesive layer having a shape of a frame.  
     
     
         15 . The optical subassembly of  claim 1  and further comprising: 
 a light guide stacked under the lowermost film which is configured to allow the first and second adhesive layers to contact the light guide.    
     
     
         16 . An optical film package comprising in combination: 
 a light guide; and    an optical subassembly of  claim 1 .    
     
     
         17 . The optical film package of  claim 16  wherein the adhesive layer has a portion of a frame-type shape.  
     
     
         18 . An optical display comprising in combination: 
 a backlight unit;    a display panel unit; and    an optical film subassembly of  claim 1  positioned between the backlight unit and the display panel unit.    
     
     
         19 . The optical display of  claim 18  wherein the backlight unit further comprises: 
 a light guide; and    at least one light source.    
     
     
         20 . The optical display of  claim 18  wherein the adhesive layers secure the optical film subassembly to the display panel unit.