Method and device for preparing polarization layer of controllable polaroid

Abstract

The invention discloses a method and device for preparing a polarization layer of a controllable polaroid, and relates to the technical field of optical device manufacturing, and the method comprises the steps: enabling a polyvinyl alcohol (PVA) film to be attached to the grid surface of a prefabricated comb-shaped metal grid template; the prefabricated comb-shaped metal grid template attached with the PVA film is installed in an electrolytic cell; switching on a power supply to form a deposition layer with the same shape as the grid surface of the prefabricated comb-shaped metal grid template on the surface of the PVA film; and when the deposition layer reaches a preset deposition thickness, cutting off a power supply, and carrying out demolding treatment on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer complex to form a polarization layer of the polaroid. Compared with an existing PVA dyeing scheme, the polarizer with the linear deflection in the fixed direction is formed through the comb-shaped metal grids, the transmittance of metal is zero, no light is emitted in a shielding area, the situation that uncontrolled light is emitted to interfere with the image quality is avoided, and the needed linear deflection and transmittance can be designed according to actual requirements.

Description

Technical Field

[0001] The present application relates to the technical field of optical device manufacturing, and particularly to a method and device for preparing a polarization layer of a controllable polarizer. Background Art

[0002] As a key component of a liquid crystal display (LCD), the core function of a polarizer is to achieve the optical modulation of liquid crystal molecules through polarization-selective light transmission. Traditional polarizers use polyvinyl alcohol (PVA) as the polarization functional layer. After being dyed with iodine-based or dye molecules and mechanically stretched in a fixed direction to align the molecules, a single light transmission axis is formed (linear polarization degree > 99.98%). Triacetyl cellulose (TAC) films are laminated on both sides of the PVA layer to block the erosion of water and oxygen, and a multilayer structure is formed with a pressure-sensitive adhesive (PSA) and a release film. This process relies on the mechanical stretching technology of molecular orientation. In theory, the front and rear polarizers placed orthogonally can completely block the backlight, that is, the transmittance approaches 0, thus supporting high-contrast display (such as black-state brightness < 0.1 cd / m²).

[0003] The iodine-based dyeing process of traditional iodine-based polarizers can achieve a high linear polarization degree and a practical transmittance of about 40%. However, its core defect lies in the insufficient chemical stability of iodine molecules. The iodine-polyvinyl alcohol complex in the PVA layer is easily dissociated under the influence of a humid and hot environment, resulting in the attenuation of the polarization degree, and there is uncontrolled light emission interfering with the image quality.

[0004] Therefore, a new method for preparing a polarizer is needed to solve the problems of poor material stability and process ceiling effect faced by traditional polarizer technologies due to their dependence on the dyeing and stretching process.

[0005] The above content is only used to assist in understanding the technical solution of the present application, and does not represent an admission that the above content is prior art. Summary of the Invention

[0006] The main purpose of the present application is to provide a method and device for preparing a polarization layer of a controllable polarizer, aiming to solve the technical problems of poor material stability and process ceiling effect faced by traditional polarizer technologies due to their dependence on the dyeing and stretching process.

[0007] To achieve the above purpose, the present application proposes a method and device for preparing a polarization layer of a controllable polarizer. The method includes: Laminating a polyvinyl alcohol (PVA) film to the grid surface of a prefabricated comb-shaped metal grid template; Installing the prefabricated comb-shaped metal grid template laminated with the PVA film in an electrolytic cell; Turning on the power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template; When the deposition layer reaches a preset deposition thickness, cut off the power supply, and perform a demolding process on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite to form the polarization layer of the polarizer.

[0008] In one embodiment, the preparation steps of the prefabricated comb-shaped metal grid template include: Use quartz glass as the substrate of the prefabricated comb-shaped metal grid template; Sputter a chromium film layer on the surface of the quartz glass based on the grid specifications of the prefabricated comb-shaped metal grid template; Use laser etching technology to etch the chromium film so that the chromium film layer on the surface of the quartz glass forms a comb-shaped grid pattern and makes the grid lines electrically connected. Weld leads at the edge of the prefabricated comb-shaped metal grid template for connecting to the positive pole of the power supply; Perform a surface passivation treatment on the comb-shaped grid pattern on the surface of the etched quartz glass, and form an antioxidant protective layer to obtain the prefabricated comb-shaped metal grid template.

[0009] In one embodiment, the design of the grid specifications of the prefabricated comb-shaped metal grid template includes: Determine the grid specifications of the prefabricated comb-shaped metal grid template through the preset transmittance of the polarization layer of the polarizer, wherein the grid specifications at least include the width of the opaque metal strip and the width of the light-transmitting area between two adjacent opaque metal strips.

[0010] In one embodiment, attaching the PVA film to the grid surface of the prefabricated comb-shaped metal grid template includes: Attach the PVA film to the grid surface of the prefabricated comb-shaped metal grid template through a vacuum adsorption device, and lay a fluororubber strip along the edge of the PVA film to form a closed ring-shaped sealing ring.

[0011] In one embodiment, the step of installing the prefabricated comb-shaped metal grid template attached with the PVA film in the electrolytic cell includes: Adjust the position of the insulating ceramic fixture in the electrolytic cell, and vertically suspend the prefabricated comb-shaped metal grid template attached with the PVA film in the center of the cell body of the electrolytic cell through a robotic arm or a hoisting device; Lead out the lead from the edge of the prefabricated comb-shaped metal grid template, and connect it to the positive pole of the power supply through the insulating bushing on the top of the electrolytic cell; Pre-install a cathode plate on the inner wall of the cell body of the electrolytic cell and connect it to the negative pole of the power supply; Inject the electrolyte into the electrolytic cell until it submerges the prefabricated comb-shaped metal grid template.

[0012] In one embodiment, the step of turning on the power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template includes: In the initial deposition stage, metal ions are induced to form nucleation points on the surface of the PVA film by a low current density, and a circulation pump is started to stabilize the electrolyte flow rate and eliminate concentration polarization; the circulation pump is installed outside the electrolytic cell, connecting the liquid storage tank and the inlet at the bottom of the cell body to form a closed circulation path; In the main deposition stage, the current density is increased to the target value to form a deposition layer on the surface of the PVA film.

[0013] In one embodiment, the step of inducing metal ions to form nucleation points on the surface of the PVA film by a low current density in the initial deposition stage includes: The electrolyte temperature is kept stable by a temperature control module, metal ions are supplemented by an automatic titration system to maintain the stability of the metal ion concentration, and redox potential detection and periodic filtration are carried out to remove suspended particles; the temperature control module at least includes a titanium plate heat exchanger and a temperature sensor. The titanium plate heat exchanger is located in the circulation pipeline between the liquid storage tank and the electrolytic cell for heating / cooling the electrolyte. The temperature sensors are distributed and embedded in the inner wall of the electrolytic cell and at the outlet of the liquid storage tank for monitoring the temperature; the automatic titration system at least includes a metering pump, a mother liquor storage tank and a detection unit. The metering pump is installed at the top inlet of the liquid storage tank and connected to the mother liquor storage tank for injecting the metal ion mother liquor into the circulation loop. The detection unit is integrated in the outlet pipeline of the electrolytic cell to detect the metal ion concentration.

[0014] In one embodiment, the step of increasing the current density to the target value in the main deposition stage to form a deposition layer on the surface of the PVA film includes: The thickness of the deposition layer is monitored in real time by a laser interferometry thickness gauge and the light transmittance is monitored in real time by an ultraviolet spectrophotometer. Based on the monitoring data of the deposition layer thickness and light transmittance, the current density and metal ion concentration are adjusted to control the deposition rate.

[0015] In one embodiment, the step of cutting off the power supply when the deposition layer reaches the preset deposition thickness and performing demolding treatment on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite constituting the polarization layer of the polarizer includes: When the deposition layer reaches the preset deposition thickness, the power supply is cut off, the electrolyte circulation is stopped and the electrolyte in the cell is drained; The PVA film is demolded from the prefabricated comb-shaped metal grid template by mechanical, thermal expansion or chemical assistance methods to obtain a PVA film-deposition layer composite; The PVA film-deposition layer composite is cleaned to remove the residual electrolyte.

[0016] In addition, to achieve the above object, the present application also proposes a device for preparing the polarization layer of a controllable polarizer, and the device for preparing the polarization layer of the controllable polarizer includes: A laminating module for laminating a polyvinyl alcohol (PVA) film onto the grid surface of a prefabricated comb-shaped metal grid template; A template installation module for installing the prefabricated comb-shaped metal grid template with the laminated PVA film into an electrolytic cell; An electrolytic deposition module for connecting a power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template; A demolding module for cutting off the power supply when the deposition layer reaches a preset deposition thickness and performing a demolding process on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite that constitutes the polarization layer of a polarizer.

[0017] One or more technical solutions proposed in this application have at least the following technical effects: In this application, a PVA film is laminated onto the grid surface of a prefabricated comb-shaped metal grid template; the prefabricated comb-shaped metal grid template with the laminated PVA film is installed in an electrolytic cell; a power supply is connected to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template; when the deposition layer reaches a preset deposition thickness, the power supply is cut off, and a demolding process is performed on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite that constitutes the polarization layer of a polarizer, solving the problems of poor material stability and process ceiling effect faced by traditional polarizer technologies due to their reliance on the dyeing and stretching process. Compared with the prior art, this application uses a comb-shaped metal grid to form a polarizer with linearly polarized light in a fixed direction. Since the transmittance of the metal itself is zero, no light is emitted in the occlusion area, avoiding the interference of uncontrolled light emission on the image quality, and the required linear polarization degree and transmittance can be designed according to actual needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings herein are incorporated into the specification and constitute a part of this specification, showing embodiments consistent with this application and used together with the specification to explain the principles of this application.

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, for those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0020] Figure 1 It is a schematic flowchart provided for Embodiment 1 of the method for preparing the polarization layer of the controllable polarizer of this application; Figure 2 It is a schematic flowchart provided for Embodiment 2 of the method for preparing the polarization layer of the controllable polarizer of this application; Figure 3Schematic structural diagram provided for the third embodiment of the preparation method of the polarization layer of the controllable polarizer of the present application; Figure 4 Schematic flow diagram provided for the fourth embodiment of the preparation method of the polarization layer of the controllable polarizer of the present application; Figure 5 Schematic flow diagram provided for the fifth embodiment of the preparation method of the polarization layer of the controllable polarizer of the present application; Figure 6 Schematic flow diagram provided for the sixth embodiment of the preparation method of the polarization layer of the controllable polarizer of the present application; Figure 7 Schematic module diagram of the device for preparing the polarization layer of the controllable polarizer in the embodiment of the present application.

[0021] The realization of the purpose, functional characteristics and advantages of the present application will be further described with reference to the embodiments and the accompanying drawings. Detailed implementation manners

[0022] It should be understood that the specific embodiments described herein are only used to explain the technical solutions of the present application and are not used to limit the present application.

[0023] To better understand the technical solutions of the present application, the following will be described in detail in combination with the drawings in the specification and the specific implementation manners.

[0024] The main solution of the embodiment of the present application is: laminating a polyvinyl alcohol (PVA) film to the grid surface of a prefabricated comb-shaped metal grid template; installing the prefabricated comb-shaped metal grid template with the laminated PVA film in an electrolytic cell; turning on the power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template; cutting off the power supply when the deposition layer reaches a preset deposition thickness, and performing a demolding treatment on the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite body constituting the polarization layer of the polarizer.

[0025] Since the traditional polarizer technology in the prior art relies on the dyeing and stretching process, it faces problems such as poor material stability and the ceiling effect of the process.

[0026] The present application provides a solution to utilize a comb-shaped metal grid to form a polarizer with linearly polarized light in a fixed direction. Since the transmittance of the metal itself is zero, no light is emitted in the blocking area, avoiding the interference of uncontrolled light emission on the image quality, and being able to design the required linear polarization degree and transmittance according to actual needs.

[0027] Based on this, the embodiment of the present application provides a method for preparing the polarization layer of a controllable polarizer, referring to Figure 1 , Figure 1 Schematic flow diagram of the first embodiment of the method for preparing the polarization layer of the controllable polarizer of the present application.

[0028] In this embodiment, the method for preparing the polarization layer of the controllable polarizer includes steps S10 to S40: Step S10: Attach a polyvinyl alcohol (PVA) film to the grid surface of a prefabricated comb-shaped metal grid template. It should be noted that the purpose of attaching the PVA film is to ensure molecular-level close contact between the PVA film and the grid surface of the prefabricated comb-shaped metal grid template, provide a uniform micro-region electric field distribution for subsequent electrochemical deposition, and achieve precise replication of the metal grid. In addition, it is necessary to maintain a high cleanliness of the grid surface of the prefabricated comb-shaped metal grid template, such as removing surface organic substances and particles by plasma cleaning or ultrasonic cleaning with ultrapure water, etc., to avoid pinholes in the deposited layer.

[0029] Step S20: Install the prefabricated comb-shaped metal grid template with the attached PVA film in an electrolytic cell. It should be noted that it is necessary to ensure that the prefabricated comb-shaped metal grid template with the attached PVA film is stably fixed and accurately aligned in the electrolytic cell, such as making the template parallel to the cathode (cell body) to ensure the uniformity of the electric field distribution, or calibrating the verticality of the template suspension bracket through a laser alignment system.

[0030] Step S30: Turn on the power supply to form a deposited layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template. It should be noted that metal ions (such as Fe³⁺, Mg 2+ , Cr +5 , etc.) in the electrolyte undergo directional migration under the drive of the electric field. The electric field intensity in the comb-shaped grid protrusion area of the prefabricated comb-shaped metal grid template is higher, inducing the metal ions to preferentially reduce and deposit at the corresponding positions of the PVA film, precisely replicating the template grid.

[0031] Step S40: When the deposited layer reaches the preset deposition thickness, cut off the power supply, and perform a demolding process on the deposited layer attached to the PVA film to obtain a PVA film - deposited layer composite that constitutes the polarization layer of the polarizer.

[0032] It should be noted that after the deposited layer reaches the preset thickness, the PVA film - deposited layer composite is completely separated from the template by physical or chemical methods to ensure that the structure of the deposited layer is undamaged and residue-free, forming the final polarization functional layer.

[0033] This application innovates the traditional polarizer process through an electrochemical manufacturing method, achieving a polarization layer with high precision, long life, green characteristics, and flexible compatibility. Its light-shielding area and light-transmitting area can strictly control the transmission and blocking of light, and the polarization degree can theoretically reach 100%. By controlling the specifications of the prefabricated comb-shaped metal grid, the transmittance of the polarizer can be controlled, and the transmittance can be flexibly designed according to display requirements. In addition, since no light can pass through the light-shielding area and the transmission direction in the light-transmitting area is unique, lateral light leakage can be avoided, improving the display image quality.

[0034] Further, referring to Figure 2 , the second embodiment of the preparation method of the polarization layer of the controllable polarizer in this application provides a process schematic diagram. Based on the above Figure 2 shown example diagram, the preparation steps of the "prefabricated comb-shaped metal grid template" in step S10 are further refined, including steps A201 to A204: Step A201, use quartz glass as the substrate of the prefabricated comb-shaped metal grid template; It should be noted that the surface roughness of the quartz glass should be lower than the detection standard, such as 0.5 nm. In addition, ultrasonic cleaning is required to remove organic pollutants.

[0035] Step A202, sputter a chromium film layer on the surface of the quartz glass based on the grid specifications of the prefabricated comb-shaped metal grid template; It should be noted that a high-purity chromium film can be sputtered on the quartz glass surface by a magnetron sputtering coating machine. The thickness of the required chromium film can be adjusted by the sputtering time and power, which can be used to prepare micron-scale patterns, such as comb-shaped grids, and the uniformity of the film layer can be detected by the four-point probe method.

[0036] Step A203, use laser etching technology to etch the chromium film so that the chromium film layer on the surface of the quartz glass forms a comb-shaped grid pattern and makes the grid lines electrically connected. Weld leads at the edge of the prefabricated comb-shaped metal grid template for connecting the positive pole of the power supply; It should be noted that a current collector bar can be designed at the end of the comb-shaped grid to ensure the electrical connection of the entire pattern. The leads can be welded to the current collector bar at the edge of the template, and the welding point spacing can be set to 10 mm.

[0037] Step A204, perform surface passivation treatment on the comb-shaped grid pattern on the surface of the etched quartz glass to form an antioxidant protection layer, and then obtain the prefabricated comb-shaped metal grid template.

[0038] It should be noted that surface passivation treatment is performed through chemical passivation or physical passivation processes to improve antioxidant properties.

[0039] In this embodiment, through precise parameter control and the integration of multiple technologies, a preparation scheme for a prefabricated comb-shaped metal grid template with high stability is provided for the mass production of controllable metal grid polarizers.

[0040] Further, referring to Figure 3 , the third embodiment of the method for preparing the polarization layer of the controllable polarizer in this application provides a structural schematic diagram. Based on the above Figure 3 shown example diagram, the design of the grid specifications of the prefabricated comb-shaped metal grid template includes: determining the grid specifications of the prefabricated comb-shaped metal grid template through the preset transmittance of the polarization layer of the polarizer, where the grid specifications at least include the width of the light-blocking metal strips and the width of the light-transmitting area between two adjacent light-blocking metal strips.

[0041] Specifically, the width of the light-blocking metal strips can be set as a, the width of the light-transmitting area between two adjacent light-blocking metal strips is set as b, and the preset transmittance T of the polarization layer is T = b / (a + b) * 100%. The preset transmittance is obtained by adjusting the values of a and b.

[0042] Further, the step of "attaching the PVA film to the grid surface of the prefabricated comb-shaped metal grid template" in step S10 is further refined, including attaching the PVA film to the grid surface of the prefabricated comb-shaped metal grid template through a vacuum adsorption device, and laying fluororubber strips along the edge of the PVA film to form a closed annular sealing ring.

[0043] It should be noted that first, the PVA film and the prefabricated comb-shaped metal grid template are pre-treated, where the activation of the PVA film is achieved through plasma treatment and static elimination treatment, and the prefabricated comb-shaped metal grid template is ultrasonically cleaned; on the vacuum adsorption platform, through the optical alignment system, the PVA film is transferred above the prefabricated comb-shaped metal grid template, and the position deviation is dynamically compensated by real-time feedback to ensure the alignment error. After eliminating the wrinkles on the PVA film surface in the primary adsorption stage, molecular-level contact is achieved in the high-pressure adsorption stage, and the gradient adsorption and air extraction method is used to avoid pinholes in the deposition layer caused by residual micro-bubbles during the vacuum adsorption process; for the edge of the PVA film (such as exceeding the effective area by 5 mm), fluororubber strips are laid to form a closed annular sealing ring to prevent the electrolyte from seeping into the sealing interface and corroding the metal grid.

[0044] Further, referring to Figure 4 , the fourth embodiment of the method for preparing the polarization layer of the controllable polarizer in this application provides a process schematic diagram. Based on the above Figure 4 shown example diagram, the step of "installing the prefabricated comb-shaped metal grid template with the attached PVA film in the electrolytic cell" in step S20 is further refined, including steps A401~A404: Step A401, adjusting the position of the insulating ceramic fixture in the electrolytic cell, and vertically hanging the prefabricated comb-shaped metal grid template bonded with the PVA film in the center of the cell body of the electrolytic cell by a mechanical arm or a hoisting device; Specifically, the horizontality of the insulating ceramic fixture in the electrolytic cell is calibrated by a laser positioning system, and the prefabricated comb-shaped metal grid template is suspended by a robotic arm at its lower edge at a height of 100 mm from the bottom of the cell to reserve electrolyte flow, and the horizontal offset of the template is controlled by the cell wall guide groove limiter.

[0045] Step A402, leading the lead wire out from the edge of the prefabricated comb-shaped metal grid template and connecting it to the positive electrode of the power supply through the insulating sleeve on the top of the electrolytic cell; It should be noted that the lead wire may be made of corrosion-resistant and low-resistance platinum wire.

[0046] Step A403, pre-installing a cathode plate on the inner wall of the electrolytic cell and connecting it to the negative electrode of the power supply; It should be noted that the material of the electrolytic cell can be polytetrafluoroethylene (PTFE) or polypropylene (PP); the cathode plate can use a titanium mesh cathode plate, and its surface is platinum-plated to enhance the catalytic activity. The installation position is on both sides of the inner wall of the cell body, and the cross-sectional area of ​​the copper busbar is designed based on the current density to ensure uniform current distribution.

[0047] Step A404, injecting electrolyte into the electrolytic cell until the prefabricated comb-shaped metal grid template is submerged.

[0048] It should be noted that the electrolyte can be FeCl 3 Acidic solution, other metal ions such as Mg can also be added 2 + ,Cr +5 The electrolyte circulation management system comprises at least an acid corrosion-resistant liquid storage tank, a multi-stage filtration system, a suspended particle removal system, a closed-loop control system for ion concentration, and automatic liquid replenishment by detecting metal ion concentration; the electrolyte is perfused to submerge the template-PVA complex composed of the PVA membrane and the prefabricated comb-shaped metal grid template to a preset liquid level height, such as 20 mm.

[0049] Further, refer to Figure 5 The fifth embodiment of the method for preparing the polarization layer of the controllable polarizer of the present application provides a flow chart based on the above Figure 5 The example diagram shown further refines the step of "turning on the power supply so that the surface of the PVA film forms a deposition layer with the same shape as the grid surface of the prefabricated comb-shaped metal grid template" in step S30, including steps A501~A502: Step A501, at the initial stage of deposition, induce metal ions to form nucleation sites on the surface of the PVA film through a low current density, and start the circulation pump to stabilize the electrolyte flow rate and eliminate concentration polarization; the circulation pump is installed outside the electrolytic cell, connecting the liquid storage tank and the liquid inlet at the bottom of the cell to form a closed circulation path; It should be noted that at the initial stage of deposition, a low current density is applied for a certain period of time to form uniform nucleation sites of metal ions on the surface of the PVA film, avoiding dendrite growth caused by high current; the low current density reduces concentration polarization, enabling metal ions to be evenly adsorbed on the surface of the PVA film to form dense nucleation sites, and the low electric field strength restricts the ion migration rate, avoiding the generation of preferred orientation and dendrite formation; the circulation pump is installed on the external circulation pipeline, responsible for pumping the electrolyte out of the cell, filtering and adjusting the temperature, and then returning it to the cell. The outlet of the circulation pump is connected to a porous distributor at the bottom of the electrolytic cell to ensure uniform inflow of the electrolyte. The inlet of the circulation pump is connected to the overflow port at the top of the electrolytic cell to extract the electrolyte to the liquid storage tank, making the electrolyte flow from bottom to top, evenly covering the template, and eliminating concentration polarization through forced convection to ensure the uniformity of nucleation at the initial stage of deposition.

[0050] Step A502, at the main stage of deposition, increase the current density to the target value to form a deposition layer on the surface of the PVA film.

[0051] It should be noted that the current density value can be further increased to the target value in stages and stabilized, and the current can be reduced in stages after the deposition layer reaches the preset target thickness to prevent the film layer from peeling off due to sudden power failure. In addition, pulsed current can be used to suppress the edge effect, and an auxiliary cathode shielding ring can be set around the template to absorb the excess current at the edge. If the edge thickness exceeds a certain proportion of the central area, pulsed reverse current is started for correction.

[0052] In this embodiment, the generation of the metal ion deposition layer is regulated by means of staged current setting and pulsed current, effectively improving the stability and yield of the generated products.

[0053] Further, the step of inducing metal ions to form nucleation sites on the surface of the PVA film by a low current density in the initial deposition stage includes: keeping the electrolyte temperature stable through a temperature control module, replenishing metal ions through an automatic titration system to maintain the stability of the metal ion concentration, and performing redox potential detection and periodically filtering to remove suspended particles; the temperature control module at least includes a titanium plate heat exchanger and a temperature sensor, the titanium plate heat exchanger is located in the circulation pipeline between the liquid storage tank and the electrolytic cell, and is used for heating / cooling the electrolyte, and the temperature sensor is distributed and embedded in the inner wall of the electrolytic cell and the outlet of the liquid storage tank for monitoring the temperature; the automatic titration system at least includes a metering pump, a mother liquor storage tank and a detection unit, the metering pump is installed at the top liquid inlet of the liquid storage tank and is connected to the mother liquor storage tank for injecting the metal ion mother liquor into the circulation loop, and the detection unit is integrated in the outlet pipeline of the electrolytic cell to detect the metal ion concentration.

[0054] Specifically, the electrolyte temperature is controlled by the temperature control module to ensure the stability of the ion mobility. A large temperature fluctuation will cause a change in the nucleation density and deterioration of the thickness uniformity. For example, an external circulation cooling system is adopted, and a titanium plate heat exchanger and in-tank temperature sensors are used to adjust the temperature; the metal ion concentration can be detected by online ICP-OES (Inductively Coupled Plasma Optical Emission Spectrometer) at preset time intervals to detect the concentrations of metal ions such as Fe³⁺, Cr 6+ etc. When the concentration of Fe 3+ is lower than 2.75 mol / L, the metering pump is started to inject the FeCl 3 mother liquor, and the pump speed is adjusted according to the concentration deviation to keep the metal ion concentration stable; the ratio of Cr 6+ / Cr 3+ is controlled by redox potential detection to ensure the stability of the composition of the deposited layer; the large-volume particulate matter in the electrolyte is controlled by a suspended particle filtration system to prevent the contamination of the nucleation sites.

[0055] In this embodiment, by monitoring data such as the temperature, concentration, redox potential, and particle number in the electrolytic cell, the state of the electrolyte is adjusted in real time, effectively reducing the defect rate of the deposited layer.

[0056] Further, the step of increasing the current density to the target value on the surface of the PVA film to form a deposited layer in the main deposition stage includes: monitoring the thickness of the deposited layer in real time by a laser interferometric thickness gauge and monitoring the light transmittance in real time by an ultraviolet spectrophotometer, and adjusting the current density and metal ion concentration based on the monitoring data of the deposited layer thickness and light transmittance to control the deposition rate.

[0057] It should be noted that based on the principle of laser interference, the film thickness is calculated by using the change of interference fringes between the reflected light from the surface of the deposited layer and the reference beam; and the fiber optic probe is integrated into the tank body to detect the light transmittance online and cross-verify with the laser thickness measurement data to eliminate the error of a single sensor; for the adjustment of the current density, the forward pulse current can increase the deposition rate, and the reverse pulse can inhibit the dendrite growth; the concentrations of metal ions such as Fe 3+ , Cr 6+ are detected by ICP-OES.

[0058] Specifically, the thickness and light transmittance of the deposited layer are acquired in real time, the noise is eliminated by using Kalman filtering, and the deposition rate is controlled by adjusting the current density and the metal ion concentration to maintain the consistency of the deposited layer thickness and the stability of the light transmittance; when the thickness of the deposited layer exceeds the limit, an over-thickness warning is given, the current is paused, and reverse etching is started; when the metal ion concentration is lower than the target concentration, such as when the Fe 3+ concentration is lower than the target concentration of 2.75 mol / L, a concentration compensation alarm is given and titration is accelerated.

[0059] In this embodiment, through the collaborative detection of a laser interferometer thickness gauge and an ultraviolet spectrophotometer, the current density and the dynamic response to the changes in the electrolyte state, such as temperature fluctuations, ion consumption, etc., the deposition rate and the deposition thickness of the polarization layer of the controllable polarizer are accurately regulated.

[0060] Furthermore, referring to Figure 6 , a process schematic diagram is provided in the sixth embodiment of the method for preparing the polarization layer of the controllable polarizer of the present application. Based on the above Figure 6 shown example diagram, the step of "when the deposited layer reaches the preset deposition thickness, cut off the power supply, and perform demolding treatment on the deposited layer attached to the PVA film to obtain a PVA film-deposited layer composite body constituting the polarization layer of the polarizer" in step S40 is further refined, including steps A601 to A603: Step A601, when the deposited layer reaches the preset deposition thickness, cut off the power supply, stop the electrolyte circulation, and drain the electrolyte in the tank; It should be noted that when the deposited layer reaches the preset deposition thickness, the current is reduced in gradients to avoid film layer peeling caused by sudden power off; after cutting off the power supply, the electrolyte circulation pump is closed, the valve is locked to prevent backflow, and the electrolyte is filtered into the storage tank for recycling.

[0061] Step A602, demold the PVA film from the prefabricated comb-shaped metal grid template by mechanical, thermal expansion or chemical assistance methods to obtain a PVA film-deposited layer composite body; It should be noted that the thermal expansion includes infrared radiation up to 80 - 100 °C, spraying with liquid nitrogen (-50 °C) for 3 seconds to form thermal stress, and shear stress is generated due to the expansion difference between quartz and chromium; the chemical assistance includes spraying a release agent, such as perfluoropolyether oil, and standing for 2 minutes after spraying, and then using supercritical CO 2 Clean and remove the residue.

[0062] Step A603, clean the PVA film - deposition layer composite to remove the electrolyte residue.

[0063] Specifically, after the PVA film - deposition layer composite is demolded, primary cleaning is carried out by ultrasonic and acid cleaning, and then alkaline neutralization is carried out, such as rinsing with a NAOH solution for 1 minute to neutralize the acid residue, and then deep cleaning by rinsing with ultrapure water. After the deep cleaning is completed, a drying process is carried out, such as vacuum drying at a temperature of 50 °C and a vacuum degree of 10 -1 Pa for 30 minutes to prevent thermal deformation of PVA, and infrared drying with a wavelength of 3 - 5 μm and an intensity of 1 kW / m² to quickly remove the surface water film.

[0064] In addition, the PVA film - deposition layer obtained by electroforming in this application has extremely high replication accuracy. Electroforming can even replicate metal wires and high - precision metal meshes (ultrafine metal meshes) with a size below 0.5 μm; the thickness, hardness, toughness, and strength of the deposited metal can be adjusted by changing the electroplating conditions, the components of the plating solution, and the method; multilayer electroplating, alloy electroplating, and composite electroplating methods can also be used to obtain physical properties that cannot be obtained by other processing methods.

[0065] It should be noted that the above examples are only for understanding this application and do not constitute a limitation on the method for preparing the polarization layer of the controllable polarizer in this application. Based on this technical concept, more simple transformations in various forms are within the protection scope of this application.

[0066] Furthermore, this application also provides a device for preparing the polarization layer of a controllable polarizer. Please refer to Figure 7 The device for preparing the polarization layer of the controllable polarizer includes: A bonding module 10 for bonding a polyvinyl alcohol (PVA) film to the grid surface of a pre - fabricated comb - shaped metal grid template; A template installation module 20 for installing the pre - fabricated comb - shaped metal grid template with the PVA film bonded thereon into an electrolytic cell; An electrolytic deposition module 30 for turning on the power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the pre - fabricated comb - shaped metal grid template; A demolding module 40 for cutting off the power supply when the deposition layer reaches a preset deposition thickness and performing a demolding process on the deposition layer attached to the PVA film to obtain a PVA film - deposition layer composite that constitutes the polarization layer of the polarizer.

[0067] The polarization layer preparation device of the controllable polarizer provided by the present application adopts the polarization layer preparation method of the controllable polarizer in the above-mentioned embodiment, and can solve the technical problems of poor material stability and process ceiling effect faced by the traditional polarizer technology due to its dependence on the dyeing and stretching process. Compared with the prior art, the beneficial effects of the polarization layer preparation device of the controllable polarizer provided by the present application are the same as those of the polarization layer preparation method of the controllable polarizer provided by the above-mentioned embodiment, and other technical features in the polarization layer preparation device of the controllable polarizer are the same as the features disclosed in the method of the above-mentioned embodiment, which will not be elaborated here.

[0068] It should be understood that the various parts disclosed in the present application can be implemented by hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in a suitable manner in any one or more embodiments or examples.

[0069] The above is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed in the present application can easily think of changes or substitutions, which should all be covered by the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

[0070] The flowcharts and block diagrams in the accompanying drawings illustrate the possible architectures, functions, and operations of systems, methods, and computer program products according to various embodiments of the present application. In this regard, each block in the flowchart or block diagram may represent a module, a program segment, or a part of code, and the module, program segment, or part of code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the blocks may occur in a different order than marked in the accompanying drawings. For example, two consecutive blocks shown may actually be executed substantially in parallel, and they may sometimes be executed in the reverse order, depending on the functions involved. It should also be noted that each block in the block diagram and / or flowchart, and the combination of blocks in the block diagram and / or flowchart, can be implemented by a dedicated hardware-based system for performing the specified functions or operations, or can be implemented by a combination of dedicated hardware and computer instructions.

[0071] The modules described in the embodiments of the present application can be implemented in software or in hardware. Wherein, the name of the module does not constitute a limitation to the unit itself in some cases.

[0072] It should be noted that if there are directional indications (such as up, down, left, right, front, back...) involved in the embodiments of the present invention, the directional indications are only used to explain the relative positional relationship and movement conditions between components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0073] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and should not be construed as indicating or implying their relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In addition, if "and / or" or "and / or" appears throughout the text, its meaning includes three parallel scenarios. Taking "A and / or B" as an example, it includes scenario A, or scenario B, or the scenario where both A and B are satisfied simultaneously. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on what can be achieved by those of ordinary skill in the art. When the combination of technical solutions results in contradictions or cannot be achieved, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0074] The above are only some embodiments of the present application, and do not limit the patent scope of the present application. Any equivalent structural transformation made under the technical concept of the present application by using the content of the specification and drawings of the present application, or directly / indirectly applied in other related technical fields, is included in the patent protection scope of the present application.

Claims

1. A method for preparing a polarization layer of a controllable polarizer, characterized in that: The method comprises: Laminating the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template; Installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell; Turning on the power supply to form a deposition layer on the surface of the PVA film with the same shape as the grid surface of the prefabricated comb-shaped metal grid template; When the deposited layer reaches a preset deposition thickness, the power supply is cut off, and the deposited layer attached to the PVA film is demolded to obtain a PVA film-deposited layer composite body constituting a polarizing layer of the polarizer.

2. The method for preparing a polarization layer of a controllable polarizer according to claim 1, characterized in that: The preparation steps of the prefabricated comb-shaped metal grid template include: Using quartz glass as the substrate of the prefabricated comb-shaped metal grid template; sputtering a chromium film layer on the surface of the quartz glass based on the grid specifications of the prefabricated comb-shaped metal grid template; The chromium film is etched by laser etching technology so that the chromium film layer on the surface of the quartz glass forms a comb-shaped grid pattern, and the grid circuit is electrically connected, and a lead is welded on the edge of the prefabricated comb-shaped metal grid template for connecting the positive electrode of the power supply; The comb-shaped grid pattern on the etched quartz glass surface is subjected to surface passivation treatment to form an anti-oxidation protective layer to obtain a prefabricated comb-shaped metal grid template.

3. The method for preparing a polarization layer of a controllable polarizer according to claim 2, characterized in that: The design of the grid specifications of the prefabricated comb-shaped metal grid template includes: The grid specifications of the prefabricated comb-shaped metal grid template are determined by the preset transmittance of the polarization layer of the polarizer, wherein the grid specifications at least include the width of the opaque metal strip and the width of the light-transmitting area between two adjacent opaque metal strips.

4. The method for preparing a polarization layer of a controllable polarizer according to claim 3, characterized in that: The PVA film is attached to the grid surface of the prefabricated comb-shaped metal grid template including: The PVA film is attached to the grid surface of the prefabricated comb-shaped metal grid template by a vacuum adsorption device, and a fluororubber strip is laid along the edge of the PVA film to form a closed annular sealing ring.

5. The method for preparing a polarization layer of a controllable polarizer according to claim 4, characterized in that: The step of installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell comprises: Adjust the position of the insulating ceramic fixture in the electrolytic cell, and vertically hang the prefabricated comb-shaped metal grid template bonded with the PVA film in the center of the cell body of the electrolytic cell by a mechanical arm or a hoisting device; Leading the lead wire out from the edge of the prefabricated comb-shaped metal grid template and connecting it to the positive electrode of the power supply through the insulating sleeve on the top of the electrolytic cell; A cathode plate is pre-installed on the inner wall of the electrolytic cell and connected to the negative electrode of the power supply; The electrolyte is injected into the electrolytic cell until the prefabricated comb-shaped metal grid template is submerged.

6. The method for preparing a polarization layer of a controllable polarizer according to claim 5, characterized in that: The step of turning on the power supply to form a deposition layer on the surface of the PVA film having the same shape as the grid surface of the prefabricated comb-shaped metal grid template comprises: In the initial stage of deposition, metal ions are induced to form nucleation points on the surface of the PVA film by low current density, and a circulation pump is started to stabilize the electrolyte flow rate and eliminate concentration polarization; the circulation pump is installed outside the electrolytic cell, connecting the liquid storage tank and the liquid inlet at the bottom of the cell body to form a closed circulation path; In the main deposition stage, the current density is increased to a target value to form a deposition layer on the surface of the PVA film.

7. The method for preparing a polarization layer of a controllable polarizer according to claim 6, characterized in that: The step of inducing metal ions to form nucleation points on the surface of the PVA film by low current density in the initial stage of deposition comprises: The electrolyte temperature is kept stable by a temperature control module, metal ions are supplemented by an automatic titration system to maintain a stable metal ion concentration, and redox potential detection and regular filtration to remove suspended particles are performed; the temperature control module includes at least a titanium plate heat exchanger and a temperature sensor, the titanium plate heat exchanger is located in a circulation pipeline between the liquid storage tank and the electrolytic cell, and is used to heat / cool the electrolyte, and the temperature sensor is distributed and embedded in the inner wall of the electrolytic cell and at the outlet of the liquid storage tank, and is used to monitor the temperature; the automatic titration system includes at least a metering pump, a mother liquid storage tank and a detection unit, the metering pump is installed at the liquid inlet at the top of the liquid storage tank, and is connected to the mother liquid storage tank, and is used to inject the metal ion mother liquid into the circulation loop, and the detection unit is integrated in the outlet pipeline of the electrolytic cell to detect the metal ion concentration.

8. The method for preparing a polarization layer of a controllable polarizer according to claim 6, characterized in that: The step of increasing the current density to a target value in the main deposition stage to form a deposition layer on the surface of the PVA film comprises: The thickness of the deposited layer is monitored in real time by a laser interferometer thickness gauge and the transmittance is monitored in real time by an ultraviolet spectrophotometer. Based on the monitoring data of the thickness of the deposited layer and the transmittance, the current density and the metal ion concentration are adjusted to control the deposition speed.

9. The method for preparing a polarization layer of a controllable polarizer according to claim 8, characterized in that: The step of cutting off the power supply when the deposited layer reaches a preset deposition thickness, demoulding the deposited layer attached to the PVA film, and obtaining a PVA film-deposited layer composite body constituting a polarizing layer of the polarizer comprises: When the deposition layer reaches a preset deposition thickness, the power supply is cut off, the electrolyte circulation is stopped, and the electrolyte in the tank is drained; Demolding the PVA film from the prefabricated comb-shaped metal grid template by mechanical, thermal expansion or chemical assistance to obtain a PVA film-deposition layer composite; The PVA film-deposition layer composite is cleaned to remove electrolyte residue.

10. A device for preparing a polarization layer of a controllable polarizer, characterized in that: The controllable polarizer preparation device comprises: A laminating module, used for laminating the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template; A template installation module, used to install the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell; An electrolytic deposition module, used for connecting a power source to form a deposition layer on the surface of the PVA film in the same shape as the grid surface of the prefabricated comb-shaped metal grid template; The demoulding module is used to cut off the power supply when the deposited layer reaches a preset deposition thickness, and demould the deposited layer attached to the PVA film to obtain a PVA film-deposited layer composite body to form a polarizing layer of the polarizer.

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