POLARIZER, METHOD OF MANUFACTURING THE SAME, AND DISPLAY DEVICE

• US 20180024399A1
• Filed: 01/31/2017
• Published: 01/25/2018
• Est. Priority Date: 07/19/2016
• Status: Active Grant

• Current Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Original Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Inventors: HAN, Kang Soo, KIM, Eun Jung, JO, Gug Rae
• Granted Patent: US 10,642,092 B2
• Time in Patent Office: Days
• CPC Class Codes: G02B 5/3058 comprising electrically conductive elements, e.g. wire grids, conductive particles
• CPC Class Codes: G02F 1/133388 with constructional differences between the display region and the peripheral region
• CPC Class Codes: G02F 1/133512 Light shielding layers, e.g. black matrix G02F1/136209 takes precedence
• CPC Class Codes: G02F 1/133528 Polarisers
• CPC Class Codes: G02F 1/133536 Reflective polarizers G02F1/13362 takes precedence
• CPC Class Codes: G02F 1/133538 with spatial distribution of the polarisation direction
• CPC Class Codes: G02F 1/133548 Wire-grid polarisers
• CPC Class Codes: G02F 1/133565 inside the LC elements, i.e. between the cell substrates
• CPC Class Codes: G02F 1/1339 Gaskets; Spacers; Sealing of cells
• CPC Class Codes: G02F 1/134309 characterised by their geometrical arrangement
• CPC Class Codes: G02F 1/136227 Through-hole connection of the pixel electrode to the active element through an insulation layer
• CPC Class Codes: G02F 1/1368 in which the switching element is a three-electrode device G02F1/136277 takes precedence
• CPC Class Codes: G02F 2201/121 common or background

Abstract

A polarizer including: a base layer including a first area and a second area enclosing the first area; a polarizing part disposed on the first area of the base layer and including a plurality of linear patterns spaced apart from each other; a dummy part disposed on the second area of the base layer and spaced apart from the polarizing part; and a hard mask residue part disposed on a portion of the second area of the base layer between the polarizing part and the dummy part and contacting the base layer. The polarizing part and the dummy part include a metal layer disposed on the base layer, and a hard mask layer disposed on the metal layer and comprising the same material as the hard mask residue part.

Claims

1. A polarizer comprising:

a base layer comprising a first area and a second area enclosing the first area;

a polarizing part disposed on the first area of the base layer, the polarizing part comprising a plurality of linear patterns spaced apart from each other;

a dummy part disposed on the second area of the base layer and spaced apart from the polarizing part; and

a hard mask residue part disposed on a portion of the second area of the base layer between the polarizing part and the dummy part and contacting the base layer,

wherein the polarizing part and the dummy part comprise;

a metal layer disposed on the base layer; and

a hard mask layer disposed on the metal layer and comprising the same material as the hard mask residue part.

2. The polarizer of claim 1, wherein the dummy part has a stripe shape extending along an edge of the polarizing part.

3. The polarizer of claim 1, wherein the dummy part surrounds the polarizing part in plan view.

4. The polarizer of claim 1, wherein the dummy part comprises a plurality of island dummy patterns disposed on the second area of the base layer and spaced apart from each other.

5. The polarizer of claim 1, wherein the dummy part comprises at least one linear dummy pattern having a width substantially the same as a width of one of the linear patterns.

6. The polarizer of claim 1, wherein a shortest gap between the polarizing part and the dummy part is greater than a width of a linear pattern of the linear patterns.

7. The polarizer of claim 1, wherein:

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

the hard mask layer comprises at least one of silicon oxide (SiO_x) and silicon nitride (SiN_x).

20. The polarizer of claim 1, wherein the dummy part comprises at least one linear dummy pattern having a slanted side surface.

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

preparing a base layer comprising a first area and a second area enclosing the first area;

forming a metal layer on the first area and the second area of the base layer;

etching the metal layer to form a first portion disposed on the first area and a second portion disposed on the second area and spaced apart from the first portion;

forming a hard mask layer on the first portion, the second portion, and a third portion of the base layer between the first portion and the second portion;

forming a resist layer on the hard mask layer;

pressing the resist layer by a mold to form a resist pattern thereon;

etching the hard mask layer by using the resist pattern as a first mask; and

etching the first portion and the second portion by using the etched hard mask layer as a second mask.

9. The method of claim 8, wherein:

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

the hard mask layer comprises at least one of silicon oxide (SiO_x) and silicon nitride (SiN_x).

10. The method of claim 8, wherein:

etching the hard mask layer comprises forming a hard mask residue part between the etched first portion and the etched second portion to contact the base layer; and

the hard mask residue part comprises the same material as the hard mask layer.

11. A display device comprising:

a first substrate comprising;

a first base layer comprising a first area and a second area enclosing the first area;

a first polarizing part disposed on the first area of the first base layer, the first polarizing part comprising a plurality of first linear patterns spaced apart from each other;

a first dummy part disposed on the second area of the first base layer and spaced apart from the first polarizing part; and

a first hard mask residue part disposed on a portion of the second area of the first base layer between the first polarizing part and the first dummy part and contacting the first base layer;

a second substrate facing the first substrate; and

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

wherein the first polarizing part and the first dummy part comprise;

a first metal layer disposed on the first base layer; and

a first hard mask layer disposed on the first metal layer and comprising the same material as the first hard mask residue part.

12. The display device of claim 11, further comprising a sealant interposed between the first substrate and the second substrate and overlapping the second area of the first base layer.

13. The display device of claim 12, wherein the first dummy part does not overlap the sealant.

14. The display device of claim 12, wherein the sealant is disposed relatively closer to an edge of the first base layer as compared to the first dummy part.

15. The display device of claim 11, wherein the first substrate further comprises:

a first protective layer disposed on the first base layer and covering the first polarizing part, the first dummy part, and the first hard mask residue part;

a thin film transistor disposed on the first protective layer and overlapping the first area of the first base layer;

an insulation layer disposed on the thin film transistor; and

a pixel electrode disposed on the insulation layer and overlapping the first area of the first base layer, and electrically connected to the thin film transistor.

16. The display device of claim 15, wherein:

the first substrate further comprises a pad disposed on the first protective layer and overlapping the second area of the first base layer, and electrically connected to the thin film transistor; and

a shortest horizontal gap between the pad and the first polarizing part is greater than a shortest horizontal gap between the first dummy part and the first polarizing part.

17. The display device of claim 11, wherein:

the second substrate comprises;

a second polarizing part disposed on one surface of a second base layer, the second polarizing part comprising a plurality of second linear patterns spaced apart from each other and overlapping the first area of the first base layer;

a second dummy part disposed on one surface of the second base layer and overlapping the second area of the first base layer and spaced apart from the second polarizing part; and

a second hard mask residue part disposed on one surface of the second base layer, the second hard mask residue part overlapping the second area of the first base layer, interposed between the second polarizing part and the second dummy part, and contacting one surface of the second base layer; and

the second polarizing part and the second dummy part comprise;

a second metal layer disposed on one surface of the second base layer; and

a second hard mask layer disposed on the second metal layer and comprising the same material as the second hard mask residue part.

18. The display device of claim 17, wherein the second substrate further comprises a second protective layer disposed on the second polarizing part, the second dummy part, and the second hard mask residue part.

19. The display device of claim 18, wherein the second substrate further comprises:

a light blocking member disposed on the second protective layer and overlapping the second area of the second base layer; and

a common electrode disposed on the light blocking member.