Embedding Scattering Centers in Polymer Substrate to Yield Robust Hazy Film with High Optical Transmittance: Application to Virtual‐Reality Display

Abstract Flexible plastic film with embedded air gaps is introduced to reduce the screen‐door effect (SDE) in virtual‐reality (VR) displays. Silver chloride nanorods are used as an etching mask to implement wavelength‐scale patterns with high aspect ratio on the surface of polyethylene terephthalate (PET) film. The patterned PET is coated with a layer of highly viscous protective resin; this coating produces numerous air gaps in the valleys of the patterns, so the plastic film develops a haze. The resulting film has an average transmittance of 93.6% and an average haze of 88.6% in visible wavelengths (400–800 nm), as well as increased resistance to scratching. Consequently, the hazy film significantly reduces the SDE of a VR display, thereby reducing the SDE indices from 41% to 11% for red, from 19% to 0.8% for green, and from 14% to 0.7% for blue. The electromagnetic simulations provide evidence that the air‐trapped sites in the film can effectively scatter light to yield the increase in haze.