Wire Grid Reflective Polarizer Alignment on Curved Substrates
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Solution Overview
Problem
The adhesion of a wire grid film to a curved substrate in reflective polarizing optical elements can lead to cracks and haze, deteriorating the appearance of the element.
Innovation Solution
A reflective polarizing optical element is designed with a substrate having a curved surface portion and a wire grid film where the angle between the extending direction of the wires and the short diameter of the substrate is within 45°, and a manufacturing apparatus is used to align and adhere the film to minimize stretching and tilting, ensuring a parallel relationship.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire grid film is adhered to a curved substrate, then polarization beam splitting function is achieved, but appearance deteriorates due to cracks and haze
Solution Approach 1:
The patent applies asymmetry by deliberately orienting the wire grid film at a specific angle (45° or less) relative to the short diameter of the curved substrate. This asymmetric orientation optimizes the balance between maintaining polarization functionality and minimizing appearance defects such as cracks and haze, rather than using a symmetric or arbitrary alignment.
Solution Approach 2:
The patent changes the critical parameter of wire grid orientation angle relative to the substrate's short diameter. By controlling this angular parameter to be 45° or less, the patent transforms the adhesion process to reduce stress concentration and minimize appearance deterioration while preserving the polarization beam splitting function.
2Shape
If wire grid film is stretched during adhesion to curved surface, then film conforms to substrate shape, but polarization characteristics deteriorate
Solution Approach 1:
The patent uses asymmetric orientation of the wire grid film relative to the substrate geometry. By aligning the wire grid at a specific angle (45° or less) to the short diameter, the patent creates an optimal configuration that reduces differential stretching across the film while maintaining conformity to the curved surface, thereby preserving polarization characteristics.
Solution Approach 2:
The patent controls the orientation angle parameter of the wire grid film as a critical factor. By setting this parameter to 45° or less relative to the short diameter, the patent minimizes the stretching effect during adhesion to the curved surface, thus maintaining both shape conformity and polarization performance.
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 configuration reduces the risk of deterioration in appearance and maintains optimal polarization characteristics by minimizing stretching and tilting of the wire grid film, enhancing the durability and performance of the optical element.
Implementation Method 1
a wire grid film for a polarization beam splitter having a wire grid structure
Data Source
AI summary
A reflective polarizing optical element includes: a substrate including a curved surface portion having a surface forming a curved surface, the curved surface portion having, in a plan view in an optical axis direction, when the curved surface portion has a shape surrounded by a plurality of arcs each forming a part of the same circle in the plan view, and by a line connecting ends of adjacent arcs among the plurality of arcs, a short diameter that is defined by the shortest diameter among diameters passing through a center point of the circle; and a reflective polarizing film for a polarization beam splitter having a wire grid structure, which is to be adhered to the curved surface portion so that an angle formed between an extending direction of wires in the reflective polarizing film and an extending direction of the short diameter of the substrate falls within 45°.