Thin film high definition dimensional image display device and methods of making same

Abstract

A high definition thin lens dimensional image display device and methods of manufacturing the same. The thin lens dimensional image display device generally includes a lens array on a first surface of a film, such as a lenticular lens array or a fly's eye lens array, with a printed imaged either printed directly on a second planar surface of the film, or on a separate substrate that is laminated thereto. The resulting display device offers a lower cost display device having greater flexibility for a wider variety of applications than traditional image display devices, without compromising image quality. Processes for manufacturing the display device include printing on a pre-fabricated thin lens web, inline printing of an image and patterning of the lens array, and inline printing of a substrate and application of a coating to the substrate which is subsequently patterned or embossed.

What is claimed is: 
     
         1 . Flexible packaging for displaying a dimensional image comprising:
 a substrate;   a lens array, the lens array including a plurality of lenses; and   a dimensional image layer viewable through the lens array,   wherein the dimensional image layer and the lens array define a light steering optical layer having a thickness of about one to about ten mils.   
     
     
         2 . The flexible packaging of  claim 1 , wherein the lens array comprises a preformed lens material having a first surface including the plurality of lenses, and a flat second surface, and wherein the flat second surface of the lens material is laminated to the substrate. 
     
     
         3 . The flexible packaging of  claim 2 , wherein the dimensional image layer is printed on at least a portion of the flat second surface of the lens material, the substrate, or both. 
     
     
         4 . The flexible packaging of  claim 1 , wherein the substrate comprises a polymeric film, and wherein at least a portion of a first surface of the polymeric film is embossed to form the lens array thereon. 
     
     
         5 . The flexible packaging of  claim 4 , wherein the dimensional image layer is printed on at least a portion of the second surface of the polymeric film opposite the lens array. 
     
     
         6 . The flexible packaging of  claim 5 , further comprising a laminate applied over at least a portion of dimensional image layer. 
     
     
         7 . The flexible packaging of  claim 1 , wherein the lens array comprises a coating applied to a first surface of the substrate, and wherein at least a portion of the coating is patterned to form the plurality of lenses. 
     
     
         8 . The flexible packaging of  claim 7 , wherein the dimensional image layer is printed on the first surface of the substrate before the coating is applied. 
     
     
         9 . The flexible packaging of  claim 1 , the flexible packaging comprising a packaging wrapper, a packing tube, a sticker, or a label. 
     
     
         10 . The flexible packaging of  claim 1 , wherein the plurality of lenses comprises at least one lenticular lens, one fly's eye lens, or both. 
     
     
         11 . The flexible packaging of  claim 1 , wherein the thickness of the light steering optical layer is from about one to about five mils. 
     
     
         12 . A method of making flexible packaging for displaying dimensional images comprising:
 providing a substrate;   providing a lens array material having a plurality of lenses formed on at least a portion of a first surface;   printing a dimensional image layer on at least a portion of first surface of the substrate, a second substantially planar surface of the lens array material, or both; and   bonding the first surface of the substrate to the second substantially planar surface of the lens array material,   wherein the dimensional image layer and the lens array define a light steering optical layer having a thickness of about one to about ten mils.   
     
     
         13 . The method of  claim 12 , wherein the dimensional image layer is printed on at least a portion of the first surface of the substrate, and the lens array material is bonded to the first surface of the substrate having the dimensional image layer thereon. 
     
     
         14 . The method of  claim 12 , wherein the plurality of lenses comprises at least one lenticular lens, one fly's eye lens, or both. 
     
     
         15 . A method of making flexible packaging for displaying dimensional images comprising:
 providing a flexible film;   applying a dimensional image layer to at least a portion of a first surface of the flexible film, a second surface of the flexible film, or both; and   patterning the second surface of the flexible film to form a lens array on at least a portion of the second surface, the lens array including a plurality of lenses;   wherein the dimensional image layer and the lens array define a light steering optical layer having a thickness of about one to about ten mils.   
     
     
         16 . The method of  claim 15 , wherein the flexible film comprises a polymeric film, and wherein patterning the second surface of the flexible film includes embossing at least a portion of the second surface to form the lens array. 
     
     
         17 . The method of  claim 15 , wherein patterning the second surface of the substrate comprises:
 applying a coating to at least a portion of the second surface of the flexible film; and   curing the coating.   
     
     
         18 . The method of  claim 17 , wherein applying a coating comprises:
 printing the coating on at least a portion of the second surface of the flexible film to form the lens array.   
     
     
         19 . The method of  claim 17 , wherein applying a dimensional image layer comprises printing the dimensional image layer on at least a portion of the first surface of the flexible film before application of the coating, after application of the coating, or both. 
     
     
         20 . The method of  claim 15 , wherein the plurality of lenses comprises at least one lenticular lens, one fly's eye lens, or both.