Wire Grid Polarizer Manufacturing via Polymer Mold Patterning
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Solution Overview
Problem
Liquid crystal display apparatuses face reduced light efficiency and visibility due to polarizers that absorb light, particularly when wire grid patterns include metals like aluminum, leading to decreased reflectivity and visibility.
Innovation Solution
A method of manufacturing a polarizer involving the formation of metal layers on a substrate, followed by the creation of a lattice pattern using a polymer layer and a mold, with a light blocking mask to control exposure, allowing for the patterning of adhesion, hard, and metal layers to form a polarizer with reduced reflectivity and improved visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal layer is used in the wire grid pattern of the polarizer, then the polarizer can effectively block light components perpendicular to the transmitting axis, but the reflectivity of the polarizer increases and visibility of the liquid crystal display apparatus decreases
Solution Approach 1:
The patent applies composite materials by combining metal layers with dielectric layers (such as silicon oxide, silicon nitride, or organic dielectric materials) to create a multilayer structure. This composite approach maintains the light blocking performance of the metal while the dielectric layers reduce reflectivity and improve visibility. The alternating metal-dielectric structure allows the polarizer to effectively block perpendicular light components while minimizing harmful reflections that affect display visibility.
2Reliability
If a metal layer is used in the wire grid pattern of the polarizer, then the polarizer can effectively block light components perpendicular to the transmitting axis, but light efficiency of the liquid crystal display apparatus decreases
Solution Approach 1:
The patent uses composite materials consisting of metal layers combined with dielectric layers to create a polarizer structure that reduces light absorption. The dielectric layers have lower absorption coefficients compared to metals, so their inclusion in the multilayer structure reduces overall light energy loss while maintaining the necessary light blocking performance for polarization functionality.
3Manufacturing precision
If a complex patterning process is used to form the wire grid pattern, then the polarizer can achieve precise lattice structure, but the manufacturing complexity and number of process steps increase
Solution Approach 1:
The patent applies preliminary action by forming a sacrificial polymer layer with the desired lattice pattern before depositing the metal and dielectric layers. This pre-formed polymer template guides the subsequent patterning processes, allowing the metal and dielectric layers to be deposited conformally and then selectively removed. This approach simplifies the overall manufacturing process by establishing the lattice structure early, avoiding the need for complex step-by-step patterning of each layer.
Solution Approach 2:
The patent uses a polymer layer as an intermediary element to transfer the lattice pattern to the metal and dielectric layers. The polymer layer acts as a sacrificial template that is easily patterned and removed, leaving behind the desired lattice structure in the functional layers. This intermediary approach simplifies the manufacturing process by decoupling the pattern formation from the material deposition, allowing for easier and more precise lattice pattern creation.
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 method enhances light efficiency and visibility in liquid crystal display apparatuses by minimizing light absorption and reflectivity, thereby improving the overall performance of the display.
Implementation Method 1
forming an adhesion layer on a portion of the hard mask
Implementation Method 2
disposing a light blocking mask over a portion of the mold; radiating light towards the mold and the light blocking mask to expose a first portion of the lattice pattern to the light
Data Source
AI summary
A method of manufacturing a polarizer, the method including: forming a metal layer on a substrate; forming a hard mask on the metal layer; forming an adhesion layer on a portion of the hard mask; forming a polymer layer on the hard mask and the adhesion layer; pressing a mold on the polymer layer to form a lattice pattern in association with the polymer layer; removing the mold and a portion of the lattice pattern; and patterning the adhesion layer, the hard mask, and the metal layer using a remaining portion of the lattice pattern as a mask.