United States Patent [191
`Konno et al.
`
`[54] LIGHT-DIFFUSING SHEET MEMBER
`
`[75] Inventors: Teruaki Konno, Tokyo; Koichi
`Sawada; Masahiro Kilamnra, both of
`Osaka, all of Japan
`
`[73] Assignee: Keiwa Shoko Kabushiki Kaisha,
`Osaka, Japan
`
`[21] Appl. No.: 658,314
`[22] Filed:
`Jun. 5, 1996
`
`Related US. Application Data
`
`[63] Continuation of Ser. No. 954,304, Sep. 30, 1992, abandoned.
`[30]
`Foreign Application Priority Data
`
`[JP]
`[JP]
`[JP]
`
`Jun. 22, 1919
`Oct. 9, 1991
`Jan. 13, 1992
`[51] Int. Cl.6
`[52] US. Cl.
`[58] Field of Search
`
`Japan ............................. .. 4-042936 U
`Japan
`3-082CD8 U
`Japan
`4-000679 U
`G02B 5/02
`359/599; 359/452
`3591599, 452,
`359/453, 455. 456, 460; 354/452
`
`US005706134A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,706,134
`Jan. 6, 1998
`
`2721885 11/1978
`2925647 12/1980
`3625767 2J1987
`56-139189 3/1980
`55-120001
`9/1980
`55-120002
`9/1980
`62-116201
`7/1987
`62-169105
`7/1987
`62-201729 12/1987
`63-41101
`3/1988
`63-177884 11/1988
`63-291001 11/1988
`2-120702 5/1990
`2-214822
`8/1990
`2-221926
`9/ 1990
`1585338 211981
`2054119 2J198l
`
`..
`
`359/599
`
`................................... .. 359/599
`
`Japan ................................... .. 359/599
`Japan ................................... .. 359/599
`Japan .
`Japan ................................... .. 359/599
`United Kingdom .
`United Kingdom .
`
`U1‘ HER PUBLICATIONS
`
`Patents Abstracts of Japan, P-735, Jul. 26. 1988. V01.
`12/No. 266.
`
`Primary Examiner—Jon W. Henry
`Attorney, Agent, or Firm-Marshall, O’Toole, Gerstein,
`Murray & Borun
`
`[56]
`
`References Cited
`
`[57]
`
`ABSTRACT
`
`U.S. PATENT DOCUMENTS
`2294930 9/1942 Palmquist.
`3,269,835 8/1966 Flint
`3,491,237
`1/1970 'Iillett
`3,612,650 10/1971 Miyaho
`3,655,263 4/1972 Holfman et a1. .
`3,726,583 4/1973 Fujisaki et al.
`3,984,176 10/1976 Hirai et al. .
`3,994,086 11/1976 Mizouchi .
`
`
`4,068,922 4,989,933
`
`1/1978 Dotsko 2/1991 Duguay .... ..
`5,170,285 12/1992 Shibasaki
`
`359/5/99
`.... .. 250/71
`359/452
`
`359/452
`
`.
`
`359/452
`385/901
`359/599
`
`FOREIGN PATENT DOCUMENTS
`
`2503663 8/1975 Germany.
`
`A light diffusing sheet member used as a diifusing plate of
`a liquid crystal display by which light transmitted from a
`light source is uniformly di?used so that the luminance of a
`screen of a light dilfusing plate liquid crystal display portion
`is su?icient and a user can easily look at characters. graphics
`and the like displayed on the screen from diiferent angles. A
`light diifusing sheet member comprises a base material sheet
`and a light di?’using layer applied on the top face of the base
`mataial sheet, and beads mixed therein. The beads have
`di?erent sizes, and include particles buried in a synthetic
`resin and particles which at least partially project from the
`synthetic resin.
`
`4 Claims, 5 Drawing Sheets
`
`‘ "\ .0‘ b.0000.‘
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`2
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`VIZIO EX. 1023
`K.J. Pretech Ex. 1023
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`VIIO EX. 1023
`K.J. Pretech Ex. 1023
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`Pretech_000888
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`

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`US. Patent
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`Jan. 6, 1998
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`Sheet 1 of 5
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`5,706,134
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`US. Patent
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`Jan. 6, 1998
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`Sheet 2 of 5
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`US. Patent
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`Jan. 6, 1998
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`Sheet 3 of 5
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`US. Patent
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`Jan. 6, 1998
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`Sheet 4 of 5
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`5,706,134
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`Pretech_000892
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`

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`US. Patent
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`Jan. 6, 1998
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`Sheet 5 of 5
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`5,706,134
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`Pretech_000893
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`

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`5,706,134
`
`1
`LIGHT-DIFFUSING SHEET MEMBER
`
`This is a continuation of US. application Ser. No.
`07/954,304. ?led Sep. 30, 1992. now abandoned.
`
`FIH.D AND BACKGROUND OF THE
`INVENTION
`The present invention relates to a light diffusing sheet
`member which uniformly diffuses light, and more particu
`larly to a light diffusing sheet member for use as a light
`di?’using plate that uniformly diffuses light transmitted from
`a light source which is the back light of a liquid crystal panel
`in a liquid crystal display.
`In a prior art liquid crystal display 10 as shown in FIG. 6,
`light irradiated by a ?uorescent tube 11, which is a back
`light, passes through a guide plate 12. ‘The ?uorescent tube
`11 is provided on the backside of a liquid crystal panel. On
`the bottom face of the guide plate 12 is provided a re?ecting
`portion which consists of a metal deposition layer, which is
`formed by deposition of a metal such as silver or aluminum.
`The light guided upwardly is uniformly diffused and passed
`by a ditfusing plate 13 provided above the guide plate 12,
`and is then guided to a liquid crystal display unit 14 provided
`above the di?’using plate 13.
`Conventionally, the diffusing plate 13 comprises a light
`diffusing sheet member wherein a resin such as polycarbon
`ate which is melted and extruded on the surface of a base
`material is ?nished by means of a pressing and cooling roll
`(so-called mat roll) or the like having many ?ne concave and
`convex portions impressed on its surface so that the resin has
`?ne concave and convex portions on its surface, or the resin
`is heated and pressurized by means of a pressing roll having
`many ?ne convex portions on its surface so that the resin has
`many ?ne concave and convex portions (embossed).
`(1) Japanese Utility Model Publication No. 2648111991
`discloses a light di?‘using sheet member in which a light
`diffusing layer is ai?xed to the surface of a polyester ?lm or
`the like, the light diifusing layer containing light diffusing
`materials such as titanium oxide, calcium carbonate, talc,
`silica powder, glass beads and the like.
`(2) Japanese Unexamined Utility Model Publication No.
`11201/1991 discloses a light diffusing sheet member in
`which light is uniformly irradiated from a light source to the
`outside through a sheet body irrespective of the distance
`from the light source by means of a pattern display having
`a difference in the distribution of density caused by a minute
`material group for light re?ection such as aluminum powder
`or silver powder which is provided on the light irradiation
`face of the sheet body on the light source side.
`However, the light diffusing sheet member used as a
`diffusing plate of a liquid crystal display according to the
`prior art has the following drawbacks.
`According to the light diffusing sheet member in publi
`cation No. 26481/1991, a light diffusing material is af?xed
`to the ?lm surface so that uniform light diffusion cannot
`fully be performed
`According to the light di?’using sheet member in publi
`cation No. 11201/1991, it is necessary that the difference in
`distribution be set great when the distance from the light
`source is increased. Accordingly. the structure is compli
`cated and costs are increased.
`In both of the above light diifusing sheet members, the
`luminance of the screen of a liquid crystal display portion is
`not su?icient. Consequently, it is hard or impossible to read
`characters, graphics and the like displayed on the screen.
`depending on the viewing angle.
`
`2
`It is an object of the present invention to provide a light
`diffusing sheet member wherein light is uniformly diffused
`and more particularly to a light di?’using sheet member used
`as a diffusing plate which uniformly diffuses light transmit
`ted from a light source in a liquid crystal display, so that the
`luminance of a screen of a light di?=using plate liquid crystal
`display portion is su?icient and a user can easily look at
`characters, graphics and the like displayed on the screen
`from dilferent angles.
`
`SUMMARY OF THE INVENTION
`
`The present invention has been made in consideration of
`the above-mentioned problems and object. and comprises a
`light diffusing sheet member characterized in that a light
`dilfusing layer is formed on the surface of a base material
`sheet, the light diffusing layer being a synthetic resin layer
`having beads mixed therein.
`The base material sheet is transparent and the light
`diffusing layer is a transparent synthetic resin layer having
`transparent beads mixed therein.
`The light diffusing layer has beads mixed therein. the
`beads having diiferent sizes.
`The beads include particles buried in the synthetic resin
`layer and particles which at least partially project from the
`synthetic resin layer.
`The beads cover almost the entire surface of the base
`material sheet.
`A metal deposition layer is formed on the back of the base
`material sheet.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The foregoing and other objects. features and advantages
`of the present invention will become more apparent upon a
`reading of the following detailed description and the
`drawings, wherein:
`FIG. 1(a) is a partially enlarged sectional view showing a
`light di?‘using sheet member according to a ?rst embodi
`ment of the present invention;
`FIG. 1(b) is a blowup of a portion of FIG. 1(a);
`FIG. 2 (a) is a sectional view showing the light diffusing
`sheet member according to the ?rst embodiment of the
`present invention;
`FIG. 2 (b) is a sectional view showing a light diffusing
`sheet member according to a second embodiment of the
`present invention;
`FIGS. 3 (a) and 3 (b) are sectional views showing
`variations of the light ditfusing sheet member in accordance
`with the present invention;
`FIG. 4 (a) is a partial sectional view illustrating the state
`of light diffusion performed by the light diifusing sheet
`member according to the ?rst embodiment of the present
`invention;
`FIG. 4 (b) is a partial sectional view illustrating the state
`of light diffusion performed by the light diifusing sheet
`member according to the second embodiment of the present
`invention;
`FIG. 5 is a perspective view showing an application of the
`light diffusing sheet member in accordance with the present
`invention;
`FIG. 6 is a sectional view showing the structure of a liquid
`crystal display according to the prior art; and
`FIGS. 7 (a) and 7 (b) are plan views showing the
`distribution pattern of head particles on the diffusing layer of
`
`25
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`3
`the light diffusing sheet member in accordance with the
`present invention.
`
`5,706,134
`
`20
`
`25
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`30
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`35
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`40
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`4
`from 5:95 to 95:5. Some of the beads are totally embedded
`and others are partially embedded. The ratio of the number
`of totally embedded beads or particles to the partially
`embedded beads or particles is in the range from 1:99 to
`99:1; preferably in the range from 5:95 to 95:5.
`With the light diffusing sheet member having the above
`mentioned structure, light A (FIG. 4 (0)) is transmitted from
`below the base material sheet 2 of the light diffusing sheet
`member 1, passes through the base material sheet 2, and into
`a layer having the particles 4a and 4b so as to be uniformly
`di?‘used by the particles as shown in FIG. 4 (a) (see an arrow
`B). The particles 4a are completely buried in the synthetic
`resin 5 of the light diffusing layer 3 (see FIG. 1 (b)). The
`particles 4b are partially buried in the synthetic resin 5 and
`at least partially project from the synthetic resin 5.
`With reference to FIG. 2 (a), the light diffusing sheet
`member of the second embodiment has the same structure as
`that of the ?rst embodiment except that there is provided a
`metal deposition layer 6 which is formed by depositing a
`metal such as silver or aluminum on the bottom face of a
`base material sheet 2.
`Referring to the light diffusing sheet member having the
`above—mentioned structure of the present invention (see
`FIG. 4 (b)). light C transmitted through the side of the base
`material sheet 2 of a light diffusing sheet member 1 is
`re?ected by the metal deposition layer 6 formed on the
`bottom face of the base material sheet 2 and an interface
`between the base material sheet 2 and a light diffusing layer
`3 formed on the top face of the base material sheet 2. guided
`to the light di?’using layer 3 and then uniformly diifused in
`the same manner as in the ?rst embodiment shown in FIG.
`4 (0).
`According to one manner of use. an adhesive layer 7 may
`be provided on the bottom face of the base material sheet 2
`as shown in FIG. 3 (a) and a printing portion 8 may be
`provided on the adhesive layer 7 as shown in FIG. 3 (b) so
`that patterns such as characters can be displayed. In addition,
`a release paper can be removably a?xed to the adhesive
`layer 7 so as to attach the light di?using sheet member 1 to
`an object. Those skilled in the art can easily understand the
`foregoing.
`Furthermore, a synthetic resin layer having bead particles
`such as silica or carbon mixed therein may be applied on
`cloth, nonwoven fabric. a compound base material sheet
`formed by a?ixing a vinyl chloride resin sheet to cloth, or the
`like. In this case, there can be provided an excellent light
`diffusing sheet which can widely be used as an antire?ection
`sheet.
`
`DEI‘AEED DESCRIPTION OF THE
`INVENTION
`Preferred embodiments of the present invention are be
`described in detail with reference to the ?gures of the
`accompanying drawings.
`In FIG. 1 (a), the reference numeral 1 denotes a light
`di?using sheet member which essentially comprises a trans
`parent base material sheet 2 and a light ditfusing layer 3
`applied thereon.
`Preferable examples of the base material sheet 2 include
`a transpuent glass substrate and a synthetic resin ?lm such
`as polyethylene terephthalate (PET). polycarbonate (PC) or
`a transparent acrylic resin having a thickness of about 20 to
`300 pm. There can be used any base material sheet which is
`transparent. does not inhibit light from passing and has
`elasticity, durability and the like, according to the use of the
`sheet.
`The light diffusing layer 3 is formed by a synthetic resin
`5 (FIG. 1A) and the like as a base layer. There are mixed, in
`the synthetic resin 5 base layer, one or more kind(s) of bead
`particles 4 such as a urethane resin, a vinyl chloride resin, an
`acrylic resin or glass.
`In considmation of light diffusing effects, the ratio of the
`beads particles 4 to the synthetic resin 5 is suitably 30 to
`90% by weight. If the ratio is smaller than 30% by weight.
`desirable light di?using effects cannot be obtained. If the
`ratio is greater than 90% by weight. the adhesion of the bead
`particles 4 to the synthetic resin 5 is poor so that the beads
`particles 4 easily come off.
`In order to obtain good light diffusing effects, the size of
`the bead particles 4 is suitably about 1 to 50 pm. In addition,
`it is preferred that two or more kinds of beads having
`different sizes are mixed. In consideration of working
`properties, strength and light di?‘using effects, it is preferred
`that the synthetic resin 5 include an acrylic resin as a main
`agent having bead particles mixed therein, and a resin of a
`two-liquid hardening type using an isocyanate synthetic
`resin as a hardening agent and having a thickness of about
`15 to 20 um (including no beads particles). However, there
`can be used other kinds of bead particles and synthetic resins
`by which desirable light diffusing effeds may be obtained
`The light di?’using layer 3 having beads particles may
`properly be applied on the top face of the base material sheet
`2 by a known blade roll coating method or the like.
`It is always required that particles 40 and particles 4b be
`mixed in the synthetic resin 5 so that light transmitted
`throng! the base material sheet 2 is uniformly di?used
`through the light diffusing layer 3. As shown in FIG. 1 (b),
`the particles 40 are completely buried in the synthetic resin
`5. and the particles 4b are partially buried in the synthetic
`resin 5 and at least partially project from the synthetic resin
`5. The ratio of particles to be mixed can suitably be changed
`according to the desired light diffusing ratio. The bead
`particles 4 may be distributed over the surface of the base
`material sheet 2 as shown in FIG. 7 (a), and may cover
`almost the entire surface of the base material sheet 2 as
`shown in FIG. 7 (b). In the latter case with greater density
`of the bead particles. light to be transmitted can be di?’used
`more uniformly.
`As mentioned above and as shown in the drawings,
`relatively large size and small size beads are provided. The
`ratio of the number of small size beads to the large size beads
`is in the range from 1:99 to 99:1; preferably in the range
`
`45
`
`EXAMPIEI
`5 Parts by weight of “PTC LN hardening agent”
`(manufactured by DAINICHI SEIKA KABUSHIKI
`KAISHA) as a hardening agent was mixed with 100 parts by
`weight of a coating main agent (“RUB coating agent"
`manufactured by DAINICHI SEIKA KABUSHIKI
`KAISHA) containing au'ylic beads (having a size of 5 to 40
`pm) as a resin of a two-liquid hardening type. The mixture
`thus prepared was applied at a thickness of 15 to 20 pm
`(including no beads) on the top face of a polyethylene
`terephthalate (PET) sheet (“PET T-lOO” manufactured by
`DIAPHOYL KABUSI-lll? KAISHA) as a base material
`having a thickness of 100 pm by a known blade roll coating
`method.
`The results of characteristic tests of a sheet member thus
`prepared are as follows:
`
`60
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`Optical characteristics:
`
`5
`
`light transmittance
`
`l-[aae
`
`Surface re?ectance:
`
`Surface electric resistance
`
`Surface hardness
`
`88.9%
`(by as K 7105 A method)
`84.9(%)
`(by us K 7105)
`10.7%
`(by as K 7105 A method)
`10“(Q)
`(by us K 6911)
`Pencil hardness
`(not less than 4H)
`(by as K 5400)
`
`EXAMPLE 2
`5 Parts by weight of "PTC LN hardening agent”
`(manufactured by DAINICHI SEIKA KABUSHIKI
`KAISHA) as a hardening agent was mixed with 100 parts by
`weight of a coating main agent (“RUB coating agent”
`manufactured by DAINICHI SEIKA KABUSHIKI
`20
`KAISHA) containing acrylic beads (having a size of 30 to 40
`pm) as a resin of a two-liquid hardening type. The mixture
`thus prepared was applied at a thickness of 15 to 20 um
`(including no beads) on the top face of a vinyl chloride sheet
`(“hard vinyl chloride sheet” manufactured by RIKEN
`25
`VINYL KOGYO KABUSHlKI KAlSHA) as a base mate
`rial having a thickness of 0.1 mm by a known blade roll
`coating method.
`The results of characteristic tests given to a sheet member
`thus prepared are as follows:
`Surface hardness:
`Pencil hardness (not less than 4 H) (by JIS K 5400)
`Taber’s abrasion resistance test (not greater than 10'3 g)
`(by ASTM D 1044)
`Adhesion:
`There was used a label having an adhesion of 1200 gf/25
`mm or more to a stainless plate.
`At?x:
`40° C., 40 g/cm2 >04 hr.
`Evaluation:
`There was con?rmed the presence of adhesion after
`release at an angle of 90°—no adhesion)
`Surface re?ectance: not greater than 10% (by HS K 7105 A
`method)
`According to the light diffusing sheet member having the
`above-mentioned structure of the present invention, a light
`diffusing layer is formed on the surface of a transparent base
`material sheet. The light di?‘using layer is a transparent
`synthetic resin layer having transparent beads mixed therein.
`The beads have different sizes and include particles buried
`in the synthetic resin layer and particles which at least
`partially project from the synthetic resin layer.
`Thus, light transmitted from below the base material
`sheet passes through the base material sheet and then
`through the light di?°using layer. Consequently, the light is
`uniformly di?used by the bead particles mixed in the light
`di?’using layer.
`Accordingly, if the light di?’using sheet member of the
`present invention is used as a di?’using plate provided on the
`back of a liquid crystal panel in a liquid crystal display, light
`transmitted from a light source can be di?’used more uni
`formly than in the prior art. Thus, there can be provided a
`light di?cusing sheet member as a di?’using plate by which
`the luminance of a screen of a light diffusing plate liquid
`crystal display portion is su?icient and a user can view
`characters. graphics and the like displayed on the screen
`from different angles.
`
`50
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`5,706,134
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`6
`In case a metal deposition layer is formed on the back of
`the base material sheet of the light diifusing sheet member
`according to the present invention, light transmitted through
`the side of the base material sheet is re?ected by a metal
`deposition face and an interface between the base material
`sheet and the light diifusing layer and is guided to the light
`di?using layer so as to be diffused uniformly.
`On the back of the liquid crystal panel in the liquid crystal
`display, the light diffusing sheet member can function as a
`re?ecting plate, a guide plate and a di?'using plate according
`to the prior art.
`For example. in case the light dilfusing sheet member of
`the present invention is placed on or a?ixed to the front
`interior member of a car 20. in particular a top face 22 of a
`dash board 21 as shown in FIG. 5, light A transmitted
`through a front glass 24 is irregularly re?ected.
`Consequently, the front interior member of the car 20, in
`particular the dash board, is mirrored in the front face of the
`front glass so that it is possible to prevent a driver's view
`from being interrupted.
`In order to prevent the light of lighting equipment from
`being re?ected by the display portion of a transparent liquid
`crystal panel of a clock or a digital meter of a car, a srreen
`of a word processor or a computer, and the like, so that the
`display portion or screen is hard to look at. the light di?’using
`sheet member of the present invention can be used on the
`surface of a member which should prevent light from being
`re?ected, for example, can be a?ixed to the surfaces of
`members around a CRT (Cathode Ray Tube) of OA devices
`or the like. Thus, remarkable etfects can be obtained.
`Although the present invention has fully been described
`by way of example with reference to the accompanying
`drawings, it is to be understood that various changes and
`modi?cations will be apparent to those skilled in the art.
`However, unless such changes and modi?cations depart
`from the scope of the invention, they should be construed as
`being included therein.
`What is claimed is:
`1. A light-diffusing sheet member comprising a transpar
`ent base material sheet and a light-di?using layer formed on
`the surface of said base material sheet and made of a
`transparent synthetic resin layer having transparent beads
`mixed therein;
`wherein said ligrt-ditfusing layer has beads of ditferent
`particle sizes, the ratio of said beads to said synthetic
`resin layer is 30 to 90% by weight, and said light
`ditfusing layer has some of said beads buried therein
`and other of said beads projecting partially therefrom.
`2. A light-diifusing sheet member according to claim 1,
`wherein said beads comprise small beads and large beads in
`the quantity ratio of from 1:99 to 99:1.
`3. Alightdi?‘using sheet member according to claims 1 or
`2, wherein said beads comprise the buried beads and the
`partially projected beads in the quantity ratio of from 1:99 to
`991.
`4. A light-diifusing sheet member comprising a base
`material sheet and a light-di?‘using layer formed on the
`surface of said base material sheet and made of a synthetic
`resin layer having beads mixed therein;
`wherein said light-diffusing layer has beads of di?’erent
`particle sizes. and said light-dilfusing layer has some of
`said beads buried therein and other of said beads
`projecting partially therefrom, said light-di?using sheet
`member further comprising a metal deposition layer
`formed on the back of said base material sheet.
`
`* * ill
`
`it!
`
`it‘
`
`Pretech_000896
`
`

`
`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`
`PATENT NO. :
`
`5,706,134
`
`DATED
`
`:
`
`January 6, 1998
`
`INVENTOR(S) :
`
`TERUAKI KONNO, ET AL.
`
`It is certi?ed that error appears in the above-identi?ed patent and that said Letters Patent is hereby
`
`corrected as shown below:
`
`On the title page, under
`[30] Foreign Application Priority Data, the data for the first application should
`
`read Jun. 22, 1992 [JP] Japan .......... .. 4-042936 U
`
`[56] Refefen?es Cited, the eighth reference listed, should be corrected to
`
`read -— 3,994,086 11/1976 Mizuochi ——.
`
`Signed and Sealed this
`Eighteenth Day of May, 1999
`
`AI‘H’SIlrlg 01/!(‘81'
`
`A cling Comm/winner of I’menrx uml Trademark
`
`Q. 'I‘ODI) DICKINSON
`
`Pretech_000897