Method and device for preparing polarization layer of controllable polarizer

Abstract

The present application discloses a method and apparatus for preparing a polarizing layer of a controllable polarizer, relating to the technical field of optical device manufacturing. The method comprises: 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 laminating the PVA film in an electrolytic cell; turning on 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; cutting off the power source when the deposition layer reaches a preset deposition thickness, demolding the deposition layer attached to the PVA film, and obtaining a PVA film-deposition layer composite to constitute the polarizing layer of the polarizer. The present application utilizes a comb-shaped metal grid to form a polarizer with fixed-direction linear polarization. Compared with existing PVA dyeing solutions, the metal itself has zero transmittance, and no light is emitted in the blocked area, thus preventing uncontrolled light emission from interfering with image quality. The required linear polarization and transmittance can be designed according to actual needs.

Description

Technical Field

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

[0002] Polarizers, a key component of liquid crystal displays (LCDs), achieve optical modulation of liquid crystal molecules through polarization-selective light transmission. Traditional polarizers use polyvinyl alcohol (PVA) as the polarizing layer. After being dyed with iodine or dye molecules, they are mechanically stretched in a fixed direction to align the molecules, forming a single light transmission axis (linear skewness > 99.98%). Triacetyl cellulose (TAC) film is laminated on both sides of the PVA layer to protect against water and oxygen corrosion, supplemented by a pressure-sensitive adhesive (PSA) and a release film to form a multi-layer structure. This process relies on mechanical stretching technology to achieve molecular orientation. In theory, the orthogonal front and rear polarizers can completely block backlight, resulting in a transmittance close to zero, thus supporting high-contrast displays (e.g., black-state brightness < 0.1 cd / m²).

[0003] The iodine-dying process used in conventional iodine-based polarizers can achieve high linear polarization and a practical transmittance of approximately 40%. However, its core drawback lies in the insufficient chemical stability of the iodine molecules. The iodine-polyvinyl alcohol complex in the PVA layer is susceptible to dissociation in hot and humid environments, resulting in polarization degradation and uncontrolled light emission that interferes with image quality.

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

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

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

[0007] To achieve the above objectives, the present application proposes a method and device for preparing a polarization layer of a controllable polarizer, the method comprising:

[0008] Laminating the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template;

[0009] Installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell;

[0010] 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;

[0011] 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 demoulded to obtain a PVA film-deposited layer composite body that constitutes the polarizing layer of the polarizer.

[0012] In one embodiment, the steps of preparing the prefabricated comb-shaped metal grid template include:

[0013] Using quartz glass as the substrate of the prefabricated comb-shaped metal grid template;

[0014] sputtering a chromium film layer on the surface of the quartz glass based on the grid specifications of a prefabricated comb-shaped metal grid template;

[0015] The chromium film is etched by laser etching technology to form a comb-shaped grid pattern on the chromium film layer on the surface of the quartz glass, 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 to the positive electrode of the power supply;

[0016] 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.

[0017] In one embodiment, the design of the grid specifications of the prefabricated comb-shaped metal grid template includes:

[0018] 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 strips and the width of the transparent area between two adjacent opaque metal strips.

[0019] In one embodiment, laminating the PVA film to the grid surface of the prefabricated comb-shaped metal grid template includes:

[0020] 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.

[0021] In one embodiment, the step of installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell includes:

[0022] 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 robotic arm or a hoisting device;

[0023] 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;

[0024] A cathode plate is pre-installed on the inner wall of the electrolytic cell and connected to the negative electrode of the power supply;

[0025] The electrolyte is injected into the electrolytic tank until the prefabricated comb-shaped metal grid template is submerged.

[0026] In one embodiment, the step of turning on the power 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:

[0027] In the initial stage of deposition, a low current density is used to induce metal ions to form nucleation points on the surface of the PVA film, 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;

[0028] 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.

[0029] In one embodiment, the step of inducing metal ions to form nucleation points on the surface of the PVA film by using a low current density in the initial stage of deposition includes:

[0030] The electrolyte temperature is kept stable by a temperature control module, metal ions are replenished by an automatic titration system to maintain a stable metal ion concentration, and redox potential detection and regular filtration are performed to remove suspended particles; the temperature control module includes at least a titanium plate heat exchanger and a temperature sensor, the titanium plate heat exchanger is located in the circulation pipe 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 the outlet of the liquid storage tank to monitor the temperature; the automatic titration system includes at least a metering pump, a mother liquor 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 liquor storage tank, and is used to inject the metal ion mother liquor into the circulation loop, and the detection unit is integrated in the electrolytic cell outlet pipe to detect the metal ion concentration.

[0031] In one embodiment, the step of increasing the current density to a target value to form a deposition layer on the surface of the PVA film during the main deposition phase includes:

[0032] 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 rate.

[0033] In one embodiment, the step of cutting off the power supply when the deposited layer reaches a preset deposition thickness, performing a demolding process on the deposited layer attached to the PVA film, and obtaining a PVA film-deposited layer composite to form the polarizing layer of the polarizer comprises:

[0034] When the deposited 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;

[0035] 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;

[0036] The PVA film-deposition layer composite is cleaned to remove electrolyte residue.

[0037] In addition, to achieve the above-mentioned purpose, the present application also proposes a device for preparing a polarization layer of a controllable polarizer, wherein the device for preparing a polarization layer of a controllable polarizer comprises:

[0038] A laminating module is used to laminate the polyvinyl alcohol (PVA) film onto the grid surface of the prefabricated comb-shaped metal grid template;

[0039] A template installation module is used to install the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell;

[0040] an electrolytic deposition module, configured to connect a power source 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;

[0041] 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 to form a polarizing layer of the polarizer.

[0042] One or more technical solutions proposed in this application have at least the following technical effects:

[0043] The present application proceeds through the following steps: 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 laminating the PVA film in an electrolytic cell; 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; cutting off the power supply when the deposition layer reaches a preset deposition thickness, and demolding the deposition layer attached to the PVA film to obtain a PVA film-deposition layer composite constituting the polarizing layer of the polarizer, thereby solving the problems of poor material stability and process ceiling effect faced by traditional polarizer technology due to reliance on dyeing and stretching processes. Compared with the prior art, the present application utilizes a comb-shaped metal grid to form a polarizer with fixed-direction linear polarization. Since the transmittance of the metal itself is zero, no light is emitted in the blocked area, thereby avoiding uncontrolled light emission interfering with the image quality, and the required linear polarization degree and transmittance can be designed according to actual needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0045] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0046] Figure 1 A schematic flow chart of Example 1 of the method for preparing a polarizing layer of a controllable polarizer of the present application;

[0047] Figure 2 A schematic flow chart of a second embodiment of the method for preparing a polarizing layer of a controllable polarizer of the present application;

[0048] Figure 3 A schematic structural diagram of a third embodiment of the method for preparing a polarizing layer of a controllable polarizer of the present application;

[0049] Figure 4 A schematic flow chart of a fourth embodiment of the method for preparing a polarizing layer of a controllable polarizer of the present application;

[0050] Figure 5 A schematic diagram of a process for preparing a polarizing layer of a controllable polarizer according to a fifth embodiment of the present invention;

[0051] Figure 6 A schematic flow chart of Example 6 of the method for preparing a polarizing layer of a controllable polarizer of the present application;

[0052] Figure 7 This is a schematic diagram of the module structure of the polarization layer preparation device of the controllable polarizer according to an embodiment of the present application.

[0053] The purpose, features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0054] It should be understood that the specific embodiments described herein are merely used to explain the technical solutions of the present application and are not intended to limit the present application.

[0055] In order to better understand the technical solution of the present application, a detailed description will be given below in conjunction with the accompanying drawings and specific implementation methods.

[0056] The main solution of the embodiment of the present application is: to adhere the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template; to install the prefabricated comb-shaped metal grid template adhered to the PVA film in an electrolytic cell; to turn on the power supply so that a deposition layer with the same shape as the grid surface of the prefabricated comb-shaped metal grid template is formed on the surface of the PVA film; to cut off the power supply when the deposition layer reaches a preset deposition thickness, and to demold the deposition layer attached to the PVA film to obtain a PVA film-deposition layer complex that constitutes the polarizing layer of the polarizer.

[0057] Because the existing traditional polarizer technology relies on the dyeing and stretching process, it faces the problems of poor material stability and process ceiling effect.

[0058] The present application provides a solution that uses a comb-shaped metal grid to form a polarizer with fixed-direction linear polarization. Since the transmittance of the metal itself is zero, no light is emitted in the blocked area, thus preventing uncontrolled light from interfering with the image quality. The required linear polarization and transmittance can be designed according to actual needs.

[0059] Based on this, the present invention provides a method for preparing a polarization layer of a controllable polarizer, referring to Figure 1 , Figure 1 Schematic diagram of the process of the first embodiment of the method for preparing the polarizing layer of the controllable polarizer of the present application.

[0060] In this embodiment, the method for preparing the polarization layer of the controllable polarizer includes steps S10 to S40:

[0061] Step S10, laminating a polyvinyl alcohol (PVA) film to a grid surface of a prefabricated comb-shaped metal grid template;

[0062] It should be noted that the purpose of laminating the PVA film is to ensure close molecular-level contact between the PVA film and the grid surface of the prefabricated comb-shaped metal grid template, providing a uniform micro-area electric field distribution for subsequent electrochemical precipitation and achieving precise replication of the metal grid. Furthermore, it is necessary to maintain a high degree of cleanliness on the grid surface of the prefabricated comb-shaped metal grid template, such as by using plasma cleaning to remove surface organic matter and particles or ultrapure water ultrasonic treatment to avoid pinholes in the deposited layer.

[0063] Step S20, installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell;

[0064] It should be noted that the prefabricated comb-shaped metal grid template bonded to the PVA film should be stably fixed and accurately aligned in the electrolytic cell, such as the template being parallel to the cathode (cell body) to ensure uniformity of the electric field distribution, or the verticality of the template suspension bracket should be calibrated by a laser alignment system.

[0065] Step S30, 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;

[0066] It should be noted that the metal ions in the electrolyte (such as Fe³⁺, Mg 2+ Cr +5 The prefabricated comb-shaped metal grid template has a higher electric field strength in the raised area of the comb-shaped grid, which induces the metal ions to preferentially reduce and deposit at the corresponding position of the PVA film, accurately replicating the template grid.

[0067] Step S40 , 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 that constitutes a polarizing layer of the polarizer.

[0068] It should be noted that after the deposited layer reaches a preset thickness, the PVA film-deposited layer complex is completely separated from the template through physical or chemical methods to ensure that the deposited layer structure is intact and has no residue, thereby forming the final polarizing functional layer.

[0069] This application innovates the traditional polarizer process through an electrochemical manufacturing method to achieve a high-precision, long-life, green, and flexible polarization layer. Its shading 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 the shading area can achieve no light transmission and the light-transmitting area has a unique transmission direction, lateral light leakage can be achieved, thereby improving display quality.

[0070] Further, refer to Figure 2 The second 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 2 The example diagram shown further refines the preparation steps of the "prefabricated comb-shaped metal grid template" in step S10, including steps A201 to A204:

[0071] Step A201, using quartz glass as a substrate for the prefabricated comb-shaped metal grid template;

[0072] 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.

[0073] Step A202: 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;

[0074] It should be noted that high-purity chromium can be sputtered on the surface of quartz glass using a magnetron sputtering coating machine to form a chromium film. The required chromium film thickness can be adjusted by sputtering time and power. It can be used to prepare micron-level patterns, such as comb grids, and the uniformity of the film layer can be detected using the four-point probe method.

[0075] Step A203: using laser etching technology to etch the chromium film to form a comb-shaped grid pattern on the chromium film layer on the surface of the quartz glass, and making the grid circuit electrically connected, and welding a lead to the edge of the prefabricated comb-shaped metal grid template for connection to the positive electrode of the power supply;

[0076] It should be noted that a collector bar can be designed at the end of the comb-shaped grid to ensure electrical connectivity of the entire pattern. The leads can be welded to the collector bar at the edge of the template, and the spacing between the welding points can be set to 10 mm.

[0077] Step A204: performing a surface passivation treatment on the comb-shaped grid pattern on the etched quartz glass surface to form an anti-oxidation protection layer to obtain a prefabricated comb-shaped metal grid template.

[0078] It should be noted that surface passivation treatment is performed through chemical passivation or physical passivation process to improve oxidation resistance.

[0079] This embodiment provides a highly stable prefabricated comb-shaped metal grid template preparation solution for the mass production of controllable metal grid polarizers through precise parameter control and multi-technology integration.

[0080] Further, refer to Figure 3 The third embodiment of the method for preparing the polarization layer of the controllable polarizer of the present application provides a structural schematic diagram based on the above Figure 3 As shown in the example figure, 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 by the preset transmittance of the polarization layer of the polarizer, wherein the grid specifications include at least the width of the opaque metal strip and the width of the transparent area between two adjacent opaque metal strips.

[0081] Specifically, the width of the opaque metal strip can be set to a, the width of the transparent area between two adjacent opaque metal strips is set to b, the preset transmittance of the polarizing layer is T=b / (a+b)*100%, and the preset transmittance is obtained by adjusting the values of a and b.

[0082] Furthermore, the step of "sticking the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template" in step S10 is further refined, including sticking the PVA film to the grid surface of the prefabricated comb-shaped metal grid template through a vacuum adsorption device, and laying a fluororubber strip along the edge of the PVA film to form a closed annular sealing ring.

[0083] It should be noted that the PVA film and the prefabricated comb-shaped metal grid template are first pretreated, wherein the PVA film is activated by plasma treatment and destatic treatment, and the prefabricated comb-shaped metal grid template is ultrasonically cleaned; on the vacuum adsorption platform, the PVA film is transferred to the top of the prefabricated comb-shaped metal grid template through the optical alignment system, and the position deviation is fed back in real time for dynamic compensation to ensure the alignment error. After the wrinkles on the PVA film surface are eliminated in the primary adsorption stage, molecular-level contact is achieved in the high-pressure adsorption stage, and gradient adsorption and exhaust are used to avoid residual microbubbles during the vacuum adsorption process that cause pinholes in the deposition layer; a fluororubber strip is laid on the edge of the PVA film (such as exceeding the effective area by 5mm) to form a closed ring seal to prevent the electrolyte from penetrating into the sealing interface and corroding the metal grid.

[0084] Further, refer to Figure 4 The fourth 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 4 The example diagram shown further refines the step of "installing the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell" in step S20, including steps A401 to A404:

[0085] Step A401: adjusting the position of the insulating ceramic fixture in the electrolytic cell, and vertically suspending the prefabricated comb-shaped metal grid template laminated with the PVA film in the center of the electrolytic cell body by a robotic arm or a hoisting device;

[0086] 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 at its lower edge 100 mm above the bottom of the cell by a robotic arm to reserve the flow of electrolyte. The horizontal offset of the template is controlled by the cell wall guide groove limiter.

[0087] Step A402: Lead the lead wire out from the edge of the prefabricated comb-shaped metal grid template and connect it to the positive electrode of the power supply through the insulating sleeve on the top of the electrolytic cell;

[0088] It should be noted that the lead wire may be made of corrosion-resistant and low-resistance platinum wire.

[0089] Step A403: pre-install a cathode plate on the inner wall of the electrolytic cell and connect it to the negative electrode of the power supply;

[0090] 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.

[0091] Step A404: injecting electrolyte into the electrolytic cell until the prefabricated comb-shaped metal grid template is submerged.

[0092] It should be noted that the electrolyte can be FeCl3 acidic solution, and other metal ions such as Mg 2 + , Cr +5 The electrolyte circulation management system consists of at least an acid-resistant liquid storage tank, a multi-stage filtration system to remove suspended particles, closed-loop control of ion concentration, and automatic refilling of the electrolyte by detecting metal ion concentration. The electrolyte is perfused to a preset liquid level, such as 20 mm, above the template-PVA complex consisting of the PVA membrane and the prefabricated comb-shaped metal grid template.

[0093] 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 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" in step S30, including steps A501 to A502:

[0094] Step A501: In the initial stage of deposition, metal ions are induced to form nucleation points on the surface of the PVA film using a low current density, and a circulation pump is activated to stabilize the electrolyte flow rate and eliminate concentration polarization; the circulation pump is installed outside the electrolytic cell and connected to the liquid storage tank and the liquid inlet at the bottom of the cell body to form a closed circulation path;

[0095] It should be noted that in the initial stage of deposition, power is applied at a low current density for a certain period of time to allow metal ions to form uniform nucleation points on the surface of the PVA film, thereby avoiding dendrite growth caused by high current; low current density reduces concentration polarization, allowing metal ions to be uniformly adsorbed on the surface of the PVA film to form dense nuclei, and low electric field strength limits the ion migration rate to avoid preferential orientation and the formation of dendrites; the circulation pump is installed on the external circulation pipeline, responsible for extracting the electrolyte from the tank body, and then returning it to the tank body after filtering and temperature adjustment. The outlet of the circulation pump is connected to the porous distributor at the bottom of the electrolytic cell to ensure uniform inflow of the electrolyte, and 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, so that the electrolyte flows from bottom to top, evenly covering the template, eliminating concentration polarization through forced convection, and ensuring the uniformity of nucleation in the initial stage of deposition.

[0096] Step A502: In the main deposition phase, the current density is increased to a target value to form a deposition layer on the surface of the PVA film.

[0097] It should be noted that the current density can be further increased in stages until it stabilizes at the target value, and the current can be reduced in stages after the deposited layer reaches the preset target thickness to prevent film peeling caused by sudden power outages. In addition, pulse current can be used to suppress edge effects, and auxiliary cathode shielding rings can be installed around the template to absorb excess edge current. If the edge thickness exceeds a certain percentage of the center area, a pulsed reverse current is initiated to correct the effect.

[0098] This embodiment regulates the generation of the metal ion deposition layer by means of stage current setting and pulse current, thereby effectively improving the stability and yield of the generated product.

[0099] Furthermore, 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 includes: maintaining the electrolyte temperature stable through a temperature control module, replenishing metal ions through an automatic titration system to maintain a stable metal ion concentration, and performing redox potential detection and regular filtration to remove suspended particles; the temperature control module includes at least a titanium plate heat exchanger and a temperature sensor, the titanium plate heat exchanger is located in the circulation pipe 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 includes at least a metering pump, a mother liquor 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 liquor storage tank, and is used to inject the metal ion mother liquor into the circulation loop, and the detection unit is integrated in the electrolytic cell outlet pipe to detect the metal ion concentration.

[0100] Specifically, the electrolyte temperature at the temperature control module position is used to ensure the stability of ion mobility. Large temperature fluctuations will cause changes in nucleation density and deterioration of thickness uniformity. For example, an external circulation cooling system is used, and a titanium plate heat exchanger and a temperature sensor in the tank are used to adjust the temperature. Metal ion concentration detection can be performed by online ICP-OES (inductively coupled plasma emission spectrometer) at preset time intervals to detect Fe³⁺ and Cr 6+ The concentration of metal ions, such as Fe 3+ When the concentration is lower than 2.75 mol / L, start the metering pump to inject FeCl3 mother liquor, adjust the pump speed according to the concentration deviation to keep the metal ion concentration stable; control the Cr 6+ / Cr 3+ proportion to ensure the stability of the sediment layer composition; the suspended particle filtration system controls large volume particles in the electrolyte to prevent nucleation point contamination.

[0101] This embodiment monitors the temperature, concentration, redox potential, and particle count in the electrolytic cell to adjust the electrolyte state in real time, thereby effectively reducing the defect rate of the deposited layer.

[0102] Furthermore, 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 includes: real-time monitoring of the thickness of the deposition layer by a laser interferometer thickness gauge and real-time monitoring of the transmittance by an ultraviolet spectrophotometer, and adjusting the current density and metal ion concentration based on the deposition layer thickness and transmittance monitoring data to control the deposition rate.

[0103] 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 on the surface of the deposited layer and the reference beam; the optical fiber probe is integrated into the tank body to detect the transmittance online, and cross-verify with the laser thickness measurement data to eliminate the error of a single sensor; for the adjustment of current density, the forward pulse current can increase the deposition rate, and the reverse pulse can inhibit the growth of dendrites; Fe is detected by ICP-OES 3+ Cr 6+ The metal ion concentration.

[0104] Specifically, the thickness and transmittance of the deposited layer are acquired in real time, and the Kalman filter is used to eliminate noise. The thickness consistency and transmittance stability of the deposited layer are maintained by adjusting the current density and metal ion concentration to control the deposition rate. When the thickness of the deposited layer exceeds the limit, an overthickness warning is issued, triggering the current to pause and start reverse etching. When the metal ion concentration is lower than the target concentration, such as Fe 3+ When the concentration is lower than the target concentration of 2.75 mol / L, a concentration compensation alarm is issued and the titration is accelerated.

[0105] This embodiment achieves precise control of the deposition speed and thickness of the polarization layer of the controllable polarizer through the coordinated detection of current density and dynamic response to changes in the electrolyte state, such as temperature fluctuations and ion consumption, by a laser interferometer thickness gauge and an ultraviolet spectrophotometer.

[0106] Further, refer to Figure 6 The sixth 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 6 The example diagram shown further refines the step of "cutting off the power supply when the deposited layer reaches a preset deposition thickness, demolding the deposited layer attached to the PVA film, and obtaining a PVA film-deposited layer composite to form a polarizing layer of the polarizer" in step S40, including steps A601 to A603:

[0107] Step A601, when the deposited 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;

[0108] It should be noted that when the deposition layer reaches the preset deposition thickness, the current is reduced in a gradient to avoid film peeling caused by sudden power failure; after cutting off the power, the electrolyte circulation pump is turned off, the valve is locked to prevent backflow, and the electrolyte is filtered to a storage tank for recycling.

[0109] Step A602, 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;

[0110] It should be noted that the thermal expansion includes infrared radiation to 80-100°C and liquid nitrogen spray (-50 degrees Celsius) spraying for 3 seconds to form temperature difference stress, and the expansion difference between quartz and chromium produces shear stress; the chemical assistance includes spraying of a release agent, such as perfluoropolyether oil, which is left to stand for 2 minutes after spraying, and then supercritical CO2 is used to clean and remove residues.

[0111] Step A603: Clean the PVA film-deposition layer complex to remove electrolyte residue.

[0112] Specifically, after the PVA film-deposition layer composite is demoulded, it is subjected to primary cleaning by ultrasonic and acid cleaning, and then alkaline neutralization is performed, such as rinsing with NAOH solution for 1 minute to neutralize the acid residue, and then deep cleaning is performed by rinsing with ultrapure water. After the deep cleaning is completed, a drying process is performed, such as vacuum drying, at a temperature of 50°C and a vacuum degree of 10 -1 Pa, time 30 minutes, to prevent PVA thermal deformation, and infrared drying, wavelength 3-5μm, intensity 1kW / m², quickly remove the surface water film.

[0113] In addition, the PVA film-deposited layer obtained by electroforming in this application has extremely high replication accuracy, and electroforming can even replicate metal wires and high-precision metal meshes (ultrafine metal meshes) below 0.5μm; the thickness, hardness, toughness and strength of the deposited metal can be adjusted by changing the electroplating conditions and the composition and method of the plating solution; multi-layer electroplating, alloy electroplating, and composite electroplating methods can also be used to obtain physical properties that cannot be obtained by other processing methods.

[0114] It should be noted that the above examples are only used to understand the present application and do not constitute a limitation on the method for preparing the polarization layer of the controllable polarizer of the present application. More simple transformations based on this technical concept are all within the scope of protection of the present application.

[0115] Furthermore, the present application also provides a device for preparing a polarization layer of a controllable polarizer, please refer to Figure 7 , the polarization layer preparation device of the controllable polarizer includes:

[0116] The laminating module 10 is used to laminate the polyvinyl alcohol (PVA) film onto the grid surface of the prefabricated comb-shaped metal grid template;

[0117] A template installation module 20 is used to install the prefabricated comb-shaped metal grid template attached to the PVA film in the electrolytic cell;

[0118] The electrolytic deposition module 30 is used to turn 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;

[0119] The demoulding module 40 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 to form a polarizing layer of the polarizer.

[0120] The device for preparing the polarization layer of a controllable polarizer provided in this application, which adopts the method for preparing the polarization layer of a controllable polarizer in the above-mentioned embodiment, can solve the technical problems of poor material stability and process ceiling effect faced by traditional polarizer technology due to its reliance on dyeing and stretching processes. Compared with the existing technology, the beneficial effects of the device for preparing the polarization layer of a controllable polarizer provided in this application are the same as the beneficial effects of the method for preparing the polarization layer of a controllable polarizer provided in the above-mentioned embodiment, and the other technical features of the device for preparing the polarization layer of a controllable polarizer are the same as the features disclosed in the above-mentioned embodiment method, and are not further described here.

[0121] It should be understood that the various parts disclosed in this application can be implemented using hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any one or more embodiments or examples in a suitable manner.

[0122] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

[0123] The flow charts and block diagrams in the accompanying drawings illustrate the possible architecture, functions and operations of the systems, methods and computer program products according to various embodiments of the present application. In this regard, each box in the flow chart or block diagram can represent a module, program segment or a part of code, and the module, program segment or a part of code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order than that marked in the accompanying drawings. For example, two boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flow chart and the combination of the boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs the specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0124] The modules described in the embodiments of the present application may be implemented in software or hardware, wherein the name of a module does not necessarily limit the unit itself.

[0125] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0126] 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 cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of such features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme in which A and B are satisfied at the same time. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0127] The above description is only part of the embodiments of the present application and does not limit the patent scope of the present application. All equivalent structural transformations made by using the contents of the present application specification and drawings under the technical concept of the present application, or direct / indirect application in other related technical fields are included in the patent protection scope of the present application.

Claims

1. A method for preparing a polarizing layer of a controllable polarizer, characterized in that: The method comprises: Laminating a polyvinyl alcohol (PVA) film to a grid surface of a prefabricated comb-shaped metal grid template; wherein the preparation steps of the prefabricated comb-shaped metal grid template include: using quartz glass as a substrate for 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; etching the chromium film using a laser etching technique to form a comb-shaped grid pattern on the chromium film layer on the surface of the quartz glass, and ensuring electrical connectivity of the grid circuits; welding a lead to the edge of the prefabricated comb-shaped metal grid template for connection to a positive power supply; and performing a surface passivation treatment on the comb-shaped grid pattern on the etched surface of the quartz glass to form an anti-oxidation protective layer, thereby obtaining the prefabricated comb-shaped metal grid template. The step of laminating the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template comprises: laminating the PVA film to the grid surface of the prefabricated comb-shaped metal grid template by a vacuum adsorption device, and laying a fluororubber strip along the edge of the PVA film to form a closed annular sealing ring; 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 having 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 that constitutes a polarizing layer of the polarizer; 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 robotic 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; injecting electrolyte into the electrolytic tank until the prefabricated comb-shaped metal grid template is submerged; 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, a low current density is used to induce metal ions to form nucleation points on the surface of the PVA film, 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.

2. The method for preparing a polarizing layer of a controllable polarizer according to claim 1, wherein: 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 strips and the width of the transparent area between two adjacent opaque metal strips.

3. The method for preparing a polarizing layer of a controllable polarizer according to claim 2, wherein: 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 replenished by an automatic titration system to maintain a stable metal ion concentration, and redox potential detection and regular filtration are performed to remove suspended particles; the temperature control module includes at least a titanium plate heat exchanger and a temperature sensor, the titanium plate heat exchanger is located in the circulation pipe 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 the outlet of the liquid storage tank to monitor the temperature; the automatic titration system includes at least a metering pump, a mother liquor 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 liquor storage tank, and is used to inject the metal ion mother liquor into the circulation loop, and the detection unit is integrated in the electrolytic cell outlet pipe to detect the metal ion concentration.

4. The method for preparing a polarizing layer of a controllable polarizer according to claim 3, wherein: The step of increasing the current density to a target value to form a deposition layer on the surface of the PVA film during the main deposition phase includes: 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 rate.

5. The method for preparing a polarizing layer of a controllable polarizer according to claim 4, wherein: The step of cutting off the power supply when the deposited layer reaches a preset deposition thickness, performing demoulding on the deposited layer attached to the PVA film, and obtaining a PVA film-deposited layer composite to form a polarizing layer of the polarizer comprises: When the deposited 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.

6. A device for preparing a polarization layer of a controllable polarizer, characterized in that: The controllable polarizer preparation device comprises: The laminating module is used to laminat e the polyvinyl alcohol (PVA) film on the grid surface of the prefabricated comb-shaped metal grid template; the laminating module is also used for the preparation steps of the prefabricated comb-shaped metal grid template, including: 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; etching the chromium film using laser etching technology to form a comb-shaped grid pattern on the chromium film layer on the surface of the quartz glass, and making the grid circuit electrically connected, and The edge of the comb-shaped metal grid template is welded with a lead for connecting to 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; the laminating module is further used to laminarize the polyvinyl alcohol (PVA) film to the grid surface of the prefabricated comb-shaped metal grid template, including: laminating the PVA film to the grid surface of the prefabricated comb-shaped metal grid template by a vacuum adsorption device, and laying a fluororubber strip along the edge of the PVA film to form a closed annular sealing ring; A template installation module is used to install the prefabricated comb-shaped metal grid template laminated with the PVA film in the electrolytic cell; the template installation module is also used in the steps of installing the prefabricated comb-shaped metal grid template laminated with the PVA film in the electrolytic cell, including: adjusting the position of the insulating ceramic fixture in the electrolytic cell, and vertically suspending the prefabricated comb-shaped metal grid template laminated with the PVA film in the center of the cell body of the electrolytic cell by a robotic arm or a lifting device; leading the lead wire from the edge of the prefabricated comb-shaped metal grid template and connecting it to the positive pole of the power supply through the insulating sleeve on the top of the electrolytic cell; pre-installing a cathode plate on the inner wall of the electrolytic cell and connecting it to the negative pole of the power supply; and injecting electrolyte into the electrolytic cell until the prefabricated comb-shaped metal grid template is submerged. An electrolytic deposition module is configured to be powered on 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; the electrolytic deposition module is further configured 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 by powering on the module, wherein the steps of: inducing metal ions to form nucleation points on the surface of the PVA film by using a low current density in an initial deposition stage, and starting a circulation pump to stabilize the electrolyte flow rate and eliminate concentration polarization; the circulation pump is installed outside the electrolytic cell, connecting a liquid storage tank to a liquid inlet at the bottom of the cell body to form a closed circulation path; in a main deposition stage, increasing the current density to a target value to form a deposition layer on the surface of the PVA film; 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 to form a polarizing layer of the polarizer.

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