Flexible Wire Grid Polarizer with Etch Stop Rib
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Solution Overview
Problem
Existing wire grid polarizers (WGPs) face challenges in flexibility due to cracking or delamination when bent, stretched, or compressed, limiting their application in curved optical devices.
Innovation Solution
The development of a flexible wire grid polarizer (WGP) comprising a flexible substrate with an array of wires, each including a flexible rib and a polarizing rib, along with an etch stop rib. This configuration enhances flexibility and reduces cracking, delamination, and collapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wire grid polarizer is made flexible to enable use in curved optical devices, then adaptability is improved, but cracking and delamination occur during bending, stretching, or compression
Solution Approach 1:
The wire grid polarizer is segmented into discrete wires or ribs separated by spacing, allowing each element to independently deform during bending or stretching. This segmentation prevents continuous stress propagation that would cause cracking in rigid structures, enabling flexibility while maintaining structural integrity of individual wire elements
Solution Approach 2:
The patent employs thin film structures for the wire grid polarizer layers, which inherently provide flexibility. The thin film nature allows the structure to bend and deform without the rigid support needed by thick structures, enabling conformal mounting on curved surfaces while reducing the risk of cracking and delamination through controlled thin-film mechanics
2Adaptability or versatility
If the wire grid polarizer is stretched to conform to curved surfaces, then adaptability is improved, but delamination of WGP materials occurs
Solution Approach 1:
The patent modifies physical parameters including wire spacing, wire thickness, and layer configuration to optimize stretchability. By adjusting these parameters, the structure can accommodate tensile deformation without exceeding adhesion limits, preventing delamination while enabling stretching to conformal geometries
3Adaptability or versatility
If the wire grid polarizer is compressed to fit curved geometries, then adaptability is improved, but collapse of wires or ribs occurs
Solution Approach 1:
The patent incorporates curved or arched wire geometries rather than straight lines, allowing the structure to naturally accommodate compressive forces through geometric curvature. This pre-curving enables the wires to flex and conform to compressed geometries without collapsing, as the curved shape distributes compressive stress along the arc rather than concentrating it at straight-line contact points
Data Source
AI summary
A wire grid polarizer (WGP) can include a flexible substrate. The flexible substrate might be desirable for WGP flexibility or to aid in further processing of the WGP. Wires of the WGP can include flexible ribs to minimize or avoid defects such as cracks in the WGP. An etch stop layer in the wires can allow formation of the flexible ribs without delamination of a reflective portion of the wires. The WGP embodiments herein can have improved flexibility, stretchablility, compressibility, or combinations thereof with reduced cracking, collapse, and delamination of wires or ribs.