Wire Grid Polarizer Mold Bridge Structure
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Solution Overview
Problem
The manufacturing process of wire grid polarizers with fine pitches is prone to defects, leading to reduced productivity and economic efficiency due to the small pitch interval, which can deteriorate the optical characteristics of display devices.
Innovation Solution
A master mold with embossed bridge portions is used to connect embossed portions separated by debossed portions, allowing liquid resin to flow and fill the mold correctly, preventing defects caused by capillary phenomena and resin spread anisotropy, and improving the manufacturing process of wire grid polarizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a polarizer with fine pitch (100 nm or less) is used to achieve high optical performance in visible light region, then optical characteristics are improved, but manufacturing defects occur more frequently
Solution Approach 1:
The mold part is segmented into embossed portions, debossed portions, and embossed bridge portions. The embossed bridge portions connect adjacent embossed portions that are separated by debossed portions, creating a segmented structure that prevents manufacturing defects while maintaining fine pitch precision of 100 nm or less
Solution Approach 2:
The embossed bridge portions act as intermediary structures between adjacent embossed portions. These bridge portions facilitate proper liquid resin flow and filling during manufacturing, preventing defects caused by capillary phenomena and resin spread anisotropy, thereby ensuring reliable manufacturing of fine pitch polarizers
2Ease of manufacture
If liquid resin is coated in the first direction to form embossed grid bridge portions, then resin filling is improved, but capillary phenomena and spread anisotropy cause defects
Solution Approach 1:
The mold structure incorporates local quality variations through embossed bridge portions at specific locations. These localized embossed structures modify resin flow characteristics in critical areas, preventing capillary phenomena and spread anisotropy defects while maintaining ease of manufacture through controlled resin filling
Solution Approach 2:
The embossed bridge portions are designed in advance to counteract capillary phenomena and resin spread anisotropy. By pre-configuring these bridge structures, the mold prevents defect formation before they occur during the resin coating process, ensuring manufacturing precision while maintaining ease of manufacture
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
The solution effectively prevents defects during the manufacturing process, enhancing the optical characteristics and product quality of wire grid polarizers, thereby improving the overall efficiency and quality of display devices.
Implementation Method 1
preventing defects caused by capillary phenomena and resin spread anisotropy
Data Source
AI summary
A master mold for manufacturing a wire grid polarizer includes a mold substrate and a mold part disposed on the mold substrate, in which the mold part includes a plurality of embossed portions extending in a first direction substantially in parallel with one another, a plurality of debossed portions, at least some of which are disposed between adjacent embossed portions, extending in the first direction and separating adjacent embossed portions, and an embossed bridge portion arranged in a second direction intersecting the first direction and connecting the plurality of embossed portions separated by the debossed portions. A wire grid polarizer and a method of manufacturing a wire grid polarizer are also disclosed.