Polarizer edge rib modification

• US 8,922,890 B2
• Filed: 03/21/2012
• Issued: 12/30/2014
• Est. Priority Date: 03/21/2012
• Status: Active Grant

• Current Assignee: Moxtek (Polatechno Co.,Ltd.)
• Original Assignee: Moxtek (Polatechno Co.,Ltd.)
• Inventors: Bangerter, Vern, Larsen, Mitchell R.
• Primary Examiner(s): FONT, FRANK G
• Application Number:
  US13/425,865
• Publication Number:
  US 20130250411A1
• Time in Patent Office: 1,014 Days
• Field of Search: 359/485.05, 359/487.03
• US Class Current: 359/485.05
• CPC Class Codes: G02B 5/30 Polarising elements light-modulating devices with active elements G02F1/00
• CPC Class Codes: G02B 5/3058 comprising electrically conductive elements, e.g. wire grids, conductive particles
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

A polarizer having a first surface bordered by an edge, including a standard region and a rib modification region. The standard region can include ribs having a standard characteristic. The standard region can be configured to polarize incident light. The rib modification region can be disposed along at least a segment of the edge of the substrate between the edge and at least a portion of the standard region. The rib modification region can comprise modified ribs modified from the standard characteristic to have a different characteristic.

Claims

1. A polarizer comprising:

a substrate having a first surface bordered by an edge;

an array of parallel, elongated ribs disposed over at least a portion of the first surface of the substrate;

the array of ribs comprising a central standard region and a rib modification region;

the standard region;

covering a central portion of the first surface of the substrate;

including ribs having a standard characteristic; and

configured to polarize incident light; and

the rib modification region;

disposed along at least a segment of the edge of the substrate between the edge and at least a portion of the standard region; and

comprising modified ribs modified from the standard characteristic to have a different characteristic;

a transition region between the rib modification region and the standard region and wherein ribs in the transition region have a transitional characteristic between the rib modification region and the standard region.

2. The polarizer of claim 1, wherein the standard region covers at least 100 times more than the rib modification region of the first surface of the substrate.

3. The polarizer of claim 1, wherein the rib modification region comprises adjacent ribs fused together.

4. A polarizer comprising:

a substrate having a first surface bordered by an edge;

an array of parallel, elongated ribs disposed over at least a portion of the first surface of the substrate;

the array of ribs comprising a central standard region and a rib modification region;

the standard region;

covering a central portion of the first surface of the substrate;

including ribs having a standard characteristic; and

configured to polarize incident light; and

the rib modification region;

disposed along at least a segment of the edge of the substrate between the edge and at least a portion of the standard region; and

comprising modified ribs modified from the standard characteristic to have a different characteristic;

ribs in the rib modification region and ribs in the standard region comprise;

substrate ribs formed in the substrate and extending from the substrate;

metal wires and segmented dielectric ribs disposed over the substrate ribs; and

metal wires in the standard region comprise separate wires such that adjacent wires disposed over adjacent substrate ribs are physically separate one from another.

5. The polarizer of claim 4, wherein:

the different characteristic includes rib width;

metal wires in the rib modification region are at least 25% wider than any rib width of ribs in the standard region; and

wherein rib width is measured in a direction perpendicular to a rib height.

6. The polarizer of claim 4, wherein metal wires in the rib modification region comprise multiple adjacent metal wires fused together.

7. The polarizer of claim 4, wherein a majority of segmented dielectric ribs are substantially aligned with underlying substrate ribs in both the rib modification region and in the standard region.

8. The polarizer of claim 4, wherein:

gaps between ribs in the standard region comprise air and the gaps are substantially free of polymer; and

gaps between ribs in the rib modification region comprise polymer.

9. A polarizer comprising:

a substrate having a first surface bordered by an edge;

an array of parallel, elongated ribs disposed over at least a portion of the first surface of the substrate;

the array of ribs comprising a central standard region and a rib modification region;

the standard region;

covering a central portion of the first surface of the substrate;

including ribs having a standard characteristic; and

configured to polarize incident light; and

the rib modification region;

disposed along at least a segment of the edge of the substrate between the edge and at least a portion of the standard region; and

comprising modified ribs modified from the standard characteristic to have a different characteristic;

the standard region having a capillary action caused by channels between the wires; and

a capillary action of the rib modification region is substantially less than the capillary action of the standard region.

10. The polarizer of claim 9, wherein all ribs in the rib modification region are at least 25% shorter than all ribs in the standard region.

11. The polarizer of claim 9, wherein the rib modification region comprises ribs that include an irregular cross-sectional profile and the standard region comprises ribs that have a substantially rectangular cross-sectional profile.

12. The polarizer of claim 9, wherein:

ribs in the standard region comprise metal wires, dielectric ribs, or combinations thereof, disposed on top of substrate ribs; and

ribs in the rib modification region comprise substrate ribs having sides and a top that are substantially free other rib material.

13. The polarizer of claim 9, wherein:

the rib modification region comprises two rib modification regions extending along two different segments of the edge on opposing sides of the polarizer;

each rib modification region extends along at least 70% of the segment, wherein the segment is a substantially straight portion of the edge between two corners of the edge; and

the two segments are substantially perpendicular to the array of ribs in the standard region.

14. The polarizer of claim 9, wherein:

polarization contrast in the rib modification region is less than 10 and polarization contrast in the standard region is greater than 40; and

contrast is defined as transmission of desired polarization (T_p) divided by transmission of undesired polarization (T_s).

15. A method of making a polarizer, the method comprising:

providing a polarizer including an array of parallel, elongated ribs disposed over a substantial portion of a surface of a substrate;

modifying the ribs along at least a segment of an edge of the substrate forming a modified region having different characteristics than a standard region, such that a capillary action of the modified region is substantially less than a capillary action of the standard region, the capillary action of the standard region being caused by channels between the wires; and

wherein modifying comprises melting a metallic portion of the ribs, ablating and forming a rib-less region along at least a portion of the edge of the substrate, or combinations thereof.

16. A method of making a polarizer, the method comprising:

providing a polarizer including an array of parallel, elongated ribs disposed over a substantial portion of a surface of a substrate;

modifying the ribs along at least a segment of an edge of the substrate forming a modified region having different characteristics than a standard region, such that a capillary action of the modified region is substantially less than a capillary action of the standard region, the capillary action of the standard region being caused by channels between the wires, and wherein modifying the ribs comprises;

applying a resist over the ribs;

activating the resist in the modified region or degrading the resist in the standard region; and

removing the resist from the standard region.