Method of manufacturing a wire grid polarizer

• US 8,927,056 B2
• Filed: 10/16/2006
• Issued: 01/06/2015
• Est. Priority Date: 10/17/2005
• Status: Active Grant

• Current Assignee: Asahi Kasei Kabushiki Kaisha
• Original Assignee: Asahi Kasei Kabushiki Kaisha
• Inventors: Yamaki, Hiroshi, Sato, Yusuke, Namatame, Takuji, Kawazu, Yasuyuki
• Primary Examiner(s): Turocy, David
• Assistant Examiner(s): Miller, Michael G
• Application Number:
  US11/580,842
• Publication Number:
  US 20070087549A1
• Time in Patent Office: 3,004 Days
• Field of Search: 427162-169, 4272481-2557
• US Class Current: 427/163.1
• CPC Class Codes: G02B 5/3058 comprising electrically conductive elements, e.g. wire grids, conductive particles

Abstract

A dielectric layer 2 is formed on a region including grid-shaped convex portions 1a of a resin substrate 1 having the grid-shaped convex portions 1a with pitches of 80 nm to 120 nm on its surface, and metal wires 3 are formed on the dielectric layer 2. It is thereby possible to obtain a wire grid polarizer having a microstructural concavo-convex grid with pitches of the level of 120 nm or less that has not been implemented.

Claims

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

forming a dielectric layer on a region including grid-shaped convex portions of a resin substrate having grid-shaped convex portions and concave portions on a surface thereof; and

forming metal wires on one side faces of the convex portions of the dielectric layer by using oblique vapor deposition from one side face of the convex portions in which the metal wires are formed by depositing metal in the direction of an about 30°

or less angle formed between the normal of the plane of the substrate and a source of vapor deposition within a plane perpendicularly intersecting a longitudinal direction of a grid of the grid-shaped convex portions, wherein the grid-shaped convex portions of the resin substrate have pitches 150 nm or less and a height 0.5 time to 2.0 times the pitches of the grid-shaped convex portions and the aspect ratio (a ratio being the ratio of the height (H₃) to the width (w₃), of the metal wires ranges from 2 to 5.

2. The method of manufacturing a wire grid polarizer according to claim 1, wherein the step of forming the dielectric layer, the dielectric layer is formed to cover the grid-shaped convex portions of the resin substrate and at least part of side faces of the portions.

3. The method of manufacturing a wire grid polarizer according to claim 1, wherein pitches of the grid-shaped convex portions on the surface of the resin substrate are less than or equal to 120 nm.

4. The method of manufacturing a wire grid polarizer according to claim 1, wherein the resin substrate is prepared by performing uniaxial drawing on a drawing target member with a concavo-convex grid with pitches of 100 nm to 100 μ

m on its surface, in the direction substantially parallel to a longitudinal direction of the concavo-convex grid, with a width of the drawing target member made free in the direction substantially perpendicular to the longitudinal direction.

5. The method of manufacturing a wire grid polarizer according to claim 1, wherein a grid shaped convex portion is applied to a resin substrate by transferring a microstructual concavo-convex grid to the resin substrate, using a mold that is made by performing uniaxial drawing on a drawing target member with a concavo-convex grid with pitches of 100 nm to 100 μ

m on its surface, in the direction substantially parallel to a longitudinal direction of the concavo-convex grid, with a width of the drawing target member made free in the direction substantially perpendicular to the longitudinal direction.

6. The method of manufacturing a wire grid polarizer according to claim 1, wherein the resin substrate is shaped using a mold having grid-shaped convex portions.

7. The method of manufacturing a wire grid polarizer according to claim 1, wherein the grid-shaped convex portions have a height 1.0 time to 2.0 times the pitches of the grid-shaped convex portions.

8. The method of manufacturing a wire grid polarizer according to claim 1, wherein the dielectric layer has a thickness ranging from 2 nm to 200 nm.

9. The method of manufacturing a wire grid polarizer according to claim 1, wherein the metal wires have a height ranging from 120 nm to 200 nm.

10. The method of manufacturing a wire grid polarizer according to claim 1, wherein a height difference between a convex portion peak and a concave portion valley ranges from 100 nm to 300 nm.

11. The method of manufacturing a wire grid polarizer according to claim 1, wherein the grid-shaped convex portions of the resin substrate have pitches of 80 nm or more.