Wire Grid Polarizer Resin Template Metal Deposition
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Solution Overview
Problem
The high manufacturing cost of wire grid polarizers due to significant metal material consumption and waste during the evaporation magnetron sputtering process for forming metal thin films.
Innovation Solution
A wire grid polarizer is manufactured using a base substrate with resin protrusions and metal wires forming a grid pattern, where the metal wires cover the resin protrusions' surfaces for polarization, reducing metal material consumption through a single patterning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If evaporation magnetron sputtering process is used to form metal thin film, then wire grid polarizer can be formed, but significant metal material consumption and waste occur
Solution Approach 1:
The patent applies preliminary action by forming resin protrusions on the substrate before depositing the metal layer. These pre-formed resin structures serve as templates that guide metal deposition, ensuring metal is deposited only where needed for polarization functionality, thereby reducing overall metal material consumption and waste during the sputtering process.
Solution Approach 2:
The patent implements local quality by creating resin protrusions with specific geometries (spheres, cylinders, cones, or pyramids) at predetermined locations on the substrate. These localized resin structures concentrate the metal deposition in specific regions, providing polarization functionality only where required rather than covering the entire substrate, thus reducing metal material usage.
2Reliability
If metal target material is used for evaporation magnetron sputtering, then wire grid polarizer can be manufactured, but manufacturing cost increases
Solution Approach 1:
The patent employs cheap short-living objects by replacing expensive metal target materials with inexpensive resin materials for forming the structural framework. The resin protrusions serve as disposable templates that guide metal deposition but can be made from low-cost materials, significantly reducing the overall manufacturing cost while maintaining the necessary polarization performance.
Solution Approach 2:
The patent uses composite materials by combining resin and metal in a hierarchical structure. The resin provides the structural framework and positioning, while the metal coating provides the polarization functionality. This composite approach allows optimization of each material's role, reducing reliance on expensive metal while maintaining performance.
3Manufacturing precision
If patterning process is used to form wire grid pattern, then metal thin film can be patterned, but significant metal material is removed and wasted
Solution Approach 1:
The patent applies preliminary action by pre-forming resin protrusions with the desired wire grid pattern before metal deposition. This preliminary structuring eliminates the need for subsequent patterning processes that would require removing metal material. The metal is deposited conformally on the pre-formed resin structures, achieving precise patterning without material removal and waste.
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 method reduces the cost of manufacturing wire grid polarizers by utilizing less expensive resin materials and minimizing metal material usage, while maintaining effective light polarization properties.
Implementation Method 1
When light enters the wire grid polarizer 20, with the oscillation effect of free electrons on a surface of the metal, light oscillating parallel to an electrical field vector component of the wire grid is almost all reflected, whereas almost all light oscillating perpendicular to the electrical field vector component of the wire grid transmits.
Implementation Method 2
coating a polymer monomer on the surface of the base substrate; subjecting the polymer monomer at a position corresponding to the resin protrusions to a curing treatment
Data Source
AI summary
Disclosed are a wire grid polarizer and a manufacturing method thereof, and a display device, which relate to the display technical field. The manufacturing method of the wire grid polarizer includes: coating a polymer monomer on the surface of the base substrate; subjecting the polymer monomer at a position corresponding to the resin protrusions to a curing treatment; forming a pattern of the resin protrusions disposed on the surface of the base substrate with intervals being provided between the resin protrusions; forming a metal layer on the surface of the resin protrusions; and forming a pattern of wire grid formed of the metal wires disposed on the surface of the resin protrusions with intervals being provided between the metal wires by a single patterning process, such that each of the metal wires covers at least one surface for polarization of one resin protrusion.