Method for manufacturing stamp and method for manufacturing wire grid polarizer using the stamp

Patent metadata

Field	Value
Publication number	US-9868634-B2
Application number	US-201514682501-A
Country	US
Kind code	B2
Filing date	Apr 9, 2015
Priority date	Jan 8, 2015
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

A method for manufacturing at least one stamp may include preparing a mold that includes mold protrusions, wherein the mold protrusions extend parallel to each other in a plan view of the mold and include a first mold protrusion. The method may further include providing resin on the mold, wherein the resin partially covers the mold protrusions without completely covering the mold protrusions, and wherein a side of the resin is at an angle with respect to the first mold protrusion in a plan view of a structure that includes the mold and the resin. The method may further include curing the resin to form cured resin. The method may further include forming a stamp that includes the cured resin.

First claim

What is claimed is:

1. A method for manufacturing at least one stamp, the method comprising:
preparing a mold that includes mold protrusions, wherein the mold protrusions extend parallel to each other in a plan view of the mold and include a first mold protrusion;
providing first resin on the mold, wherein the first resin partially covers the mold protrusions without completely covering the mold protrusions, and wherein a first side of the first resin is at a first angle with respect to the first mold protrusion in a plan view of a structure that includes the mold and the first resin;
curing the first resin to form first cured resin;
forming a first stamp that includes the first cured resin;
providing second resin on the mold, wherein the second resin partially covers the mold protrusions without completely covering the mold protrusions, wherein a first side of the second resin is at a second angle with respect to the first mold protrusion in a plan view of a structure that includes the mold and the second resin, and wherein the second angle is unequal to the first angle;
curing the second resin to form second cured resin;
forming a second stamp that includes the second cured resin; and
rotating the mold before providing the second resin on the mold.

2. The method of claim 1 , wherein the first side of the first resin is longer than a second side of the first resin in a plan view of the first resin, and wherein the first side of the second resin is longer than a second side of the second resin in a plan view of the second resin.

3. The method of claim 1 , wherein an area of the first cured resin in a plan view of the first cured resin is equal to an area of the second cured resin in a plan view of the second cured resin.

4. The method of claim 1 , wherein a difference between the second angle and the first angle is equal to 90 degrees.

5. The method of claim 1 , wherein the first angle is an acute angle, and wherein the second angle is an obtuse angle.

6. The method of claim 1 , wherein the first angle is an acute angle or an obtuse angle.

7. The method of claim 1 , wherein the first resin is positioned between two portions of the first mold protrusion in the plan view of the structure that includes the mold and the first resin.

8. The method of claim 1 , wherein the first resin is positioned between two arcs of the mold in a plan view of a structure that includes the mold and the first resin.

9. A method for manufacturing at least one wire grid polarizer, the method comprising:
preparing a mold that includes mold protrusions, wherein the mold protrusions extend parallel to each other in a plan view of the mold and include a first mold protrusion;
providing first resin on the mold, wherein the first resin partially covers the mold protrusions without completely covering the mold protrusions, and wherein a first side of the first resin is at a first angle with respect to the first mold protrusion in a plan view of a structure that includes the mold and the first resin;
curing the first resin to form first cured resin;
forming a first stamp that includes the first cured resin;
pressing the first stamp on first mask material for forming a first mask;
etching a first metal film through the first mask to form wires of a first wire grid polarizer;
providing second resin on the mold, wherein the second resin partially covers the mold protrusions without completely covering the mold protrusions, wherein a first side of the second resin is at a second angle with respect to the first mold protrusion in a plan view of a structure that includes the mold and the second resin, and wherein the second angle is unequal to the first angle;
curing the second resin to form second cured resin;
forming a second stamp that includes the second cured resin;
pressing the second stamp on second mask material for forming a second mask; and
etching a second metal film through the second mask to form wires of a second wire grid polarizer; and
rotating the mold before providing the second resin on the mold.

10. The method of claim 9 , wherein the first side of the first resin is longer than a second side of the first resin in a plan view of the first resin, and wherein the first side of the second resin is longer than a second side of the second resin in a plan view of the second resin.

11. The method of claim 10 , wherein a length of a wire of the wires of the second wire grid polarizer is substantially equal to a length of the first side of the first resin.

12. The method of claim 9 , wherein a first side of the first cured resin is longer than a second side of the first cured resin in a plan view of the first cured resin, wherein a length of the first side of the first cured resin is equal to a length of a wire of the wires of the second wire grid polarizer, wherein a first side of the second cured resin is longer than a second side of the second cured resin in a plan view of the second cured resin, and wherein a length of the second side of the second cured resin is equal to a length of a wire of the wires of the first wire grid polarizer.

13. The method of claim 9 , wherein a first side of the first cured resin is longer than a second side of the first cured resin in a plan view of the first cured resin, and wherein a wire of the wires of the second wire grid polarizer is shorter than the first side of the first cured resin and is longer than the second side of the first cured resin.

14. The method of claim 9 , wherein the mold includes a silicon member.

15. The method of claim 9 , wherein the first resin is positioned between two arcs of the first mold protrusion in the plan view of the structure that includes the mold and the first resin.

16. The method of claim 9 , wherein the first mask includes the first mask material and a resistance layer, and wherein the resistance layer is positioned between the first mask material and the first metal film.

Assignees

• Samsung Display Co Ltd

Inventors

• Lee Dae Young
• Cho Hyun Bin
• Kim Eun Jung
• Jo Gug Rae

Classifications

• B81C99/009 Primary

  Manufacturing the stamps or the moulds · CPC title

• B29L2011/0066

  Optical filters · CPC title

• G02B27/286

  for controlling or changing the state of polarisation, e.g. transforming one polarisation state into another (G02B5/3083 takes precedence; light guide coupling means utilising polarising elements G02B6/34) · CPC title

• B29C59/002

  Component parts, details or accessories; Auxiliary operations · CPC title

• B29C33/42

  characterised by the shape of the moulding surface, e.g. ribs or grooves · CPC title