Coupled Unit Wafer Structure for Large Reflective Polarizing Plates
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Solution Overview
Problem
The manufacturing of large dimension reflective polarizing plates for liquid crystal display panels is hindered by the limited size of master wafers, resulting in low optical efficiency due to the low optical efficiency of polarizing plates.
Innovation Solution
A method involving the creation of a relatively large planar area master wafer by coupling multiple unit wafers with patterned surfaces, using a coupling surface with low roughness and a photocurable or thermosetting resin to align and bond the wafers, and transferring the pattern to a resin layer for optical device production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional single master wafer is used, then manufacturing process is simple, but the area of the master wafer is limited
Solution Approach 1:
The master wafer is divided into multiple unit wafers that are manufactured separately and then coupled together. Each unit wafer can be produced using standard manufacturing processes, and the coupling of multiple unit wafers creates a large-area master wafer that overcomes the size limitations of traditional single wafers.
Solution Approach 2:
Multiple unit wafers are coupled together through their coupling surfaces to form a single large-area master wafer. The coupling part bonds the unit wafers together, merging them into a unified structure that maintains pattern alignment and achieves the desired large planar area.
2Loss of energy
If absorptive polarizing plate is used, then manufacturing is easier, but optical efficiency is low
Solution Approach 1:
The patent replaces absorptive polarizing plates with reflective polarizing plates that use wire grid structures. This substitution changes the polarization mechanism from absorption to reflection, significantly improving optical efficiency by reducing light energy loss while maintaining the ability to control polarized light.
3Loss of energy
If large dimension reflective polarizing plate is manufactured, then optical efficiency is improved, but manufacturing difficulty increases due to master wafer size limitation
Solution Approach 1:
The large-area master wafer is segmented into multiple unit wafers that are manufactured separately using standard processes, then coupled together. This segmentation allows the production of large dimension reflective polarizing plates without requiring a single oversized master wafer, thus maintaining ease of manufacture while achieving the desired large area.
Solution Approach 2:
The patent transitions from a two-dimensional single wafer to a three-dimensional coupled structure of multiple unit wafers. By stacking and coupling unit wafers together, the system achieves a large effective area that would be impossible with a single wafer of the same physical dimensions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of large dimension reflective polarizing plates with improved optical efficiency by overcoming the limitations of traditional master wafer size, enhancing the manufacturing process for liquid crystal display panels.
Implementation Method 1
a coupling part which couples adjacent unit wafers among the plurality of unit wafers on which the coupling surface is defined, to each other
Implementation Method 2
The coupling part may include a photocurable resin or a thermosetting resin
Data Source
AI summary
A master wafer includes: a plurality of unit wafers each including a pattern disposed thereon; a coupling surface defined on each of the unit wafers; and a coupling part which couples adjacent unit wafers among the plurality of unit wafers on which the coupling surface is defined, to each other.