METHOD OF MANUFACTURING A POLARIZER AND A DISPLAY PANEL HAVING THE SAME

• US 20160116798A1
• Filed: 04/21/2015
• Published: 04/28/2016
• Est. Priority Date: 10/22/2014
• Status: Active Grant

• Current Assignee: Samsung Display Company Limited (Samsung Group)
• Original Assignee: Samsung Display Company Limited (Samsung Group)
• Inventors: LEE, Dae-Young, JO, Gug-Rae, CHO, Hyung-Bin, NAM, Jung-Gun, JANG, Dae-Hwan, HAN, Kang-Soo
• Granted Patent: US 9,885,906 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G02B 5/3058 comprising electrically conductive elements, e.g. wire grids, conductive particles
• CPC Class Codes: G02F 1/133528 Polarisers
• CPC Class Codes: G02F 1/133548 Wire-grid polarisers

Abstract

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.

Claims

1. A method of manufacturing a polarizer, the method comprising:

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.

2. The method of claim 1, wherein the adhesion layer comprises at least one of a rubber-based adhesive, an acryl-based adhesive, a vinyl ester-based adhesive, a silicon-based adhesive, and a urethane-based adhesive.

3. The method of claim 1, further comprising:

curing the lattice pattern via at least one of heat treatment and ultraviolet treatment.

4. The method of claim 1, wherein:

the metal layer comprises a first metal layer and a second metal layer;

the first metal layer is disposed between the second metal layer and the substrate; and

the second metal layer comprises at least one of molybdenum and titanium.

5. The method of claim 4, wherein the first metal layer comprises at least one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chrome (Cr), iron (Fe), and nickel (Ni).

6. A method of manufacturing a polarizer, the method comprising:

forming a metal layer on a substrate;

forming a hard mask on the metal layer;

forming an adhesion layer on the hard mask;

forming a polymer layer on the adhesion layer;

pressing a mold on the polymer layer to form a lattice pattern in association with the polymer layer;

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, the first portion being adjacent to the portion of the mask;

removing the mold and a second 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.

7. The method of claim 6, wherein the adhesion layer comprises at least one of a rubber-based adhesive, an acryl-based adhesive, a vinyl ester-based adhesive, a silicon-based adhesive, and a urethane-based adhesive.

8. The method of claim 6, wherein the lattice pattern is cured via at least one of heat treatment and ultraviolet treatment.

9. The method of claim 6, wherein:

the metal layer comprises a first metal layer and a second metal layer;

the first metal layer is disposed between the second metal layer and the substrate; and

the second metal layer comprises at least one of molybdenum and titanium.

10. The method of claim 9, wherein the first metal layer comprises at least one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chrome (Cr), iron (Fe), and nickel (Ni).

11. A display panel comprising:

a first substrate;

a second substrate facing the first substrate, the second substrate comprising a thin film transistor; and

a liquid crystal layer disposed between the first substrate and the second substrate,

wherein the first substrate comprises;

a first polarizer comprising a first metal pattern spaced apart from a second metal pattern, the first and second metal patterns being disposed in a light transmittance area of the first substrate; and

a black matrix disposed outside the light transmittance area of the first substrate.

12. The display panel of claim 11, wherein the black matrix comprises a black coloring agent and an organic material.

13. The display panel of claim 11, wherein a portion of the black matrix overlaps a portion of the first polarizer.

14. The display panel of claim 11, wherein:

a first surface of the first substrate faces the second substrate;

the first polarizer is disposed on a second surface of the first substrate, the second surface opposing the first surface of the first substrate.

15. The display panel of claim 11, wherein the first and second metal patterns comprise:

a first metal layer comprising at least one of molybdenum and titanium; and

a second metal layer disposed on the first metal layer, the second metal layer comprising at least one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chrome (Cr), iron (Fe), and nickel (Ni).

16. The display panel of claim 11, further comprising:

a second polarizer comprising a third metal pattern spaced apart from a fourth metal pattern, the third and fourth metal patterns being disposed in a light transmittance area of the second substrate.

17. The display panel of claim 16, further comprising:

a reflection pattern disposed outside the light transmittance area of the second substrate, the reflection pattern overlapping the thin film transistor.

18. The display panel of claim 17, wherein:

an insulation layer is disposed on the first polarizer; and

the black matrix is disposed on the insulation layer.

19. The display panel of claim 17, wherein the second polarizer and the reflection pattern comprise:

a first metal layer comprising at least one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chrome (Cr), iron (Fe), and nickel (Ni); and

a second metal layer comprising at least one of molybdenum and titanium.

20. The display panel of claim 17, wherein the second substrate further comprises:

an insulation layer covering the second polarizer and the reflection pattern.