# Patent

## Title
Wire grid polarizer with bordered sections

## Abstract

A wire grid polarizer comprising a transparent substrate having a first surface. Multiple separate and discrete sections of wire grids can be disposed over the first surface and attached to the substrate, with a border between the sections including an opaque mask material. The mask material can be disposed over the first surface of the substrate. The mask material can be a material different than the wire grid material. The mask material can extend over or under a portion of an edge of the wire grid.

## Background
CLAIM OF PRIORITY
This is a continuation-in-part of U.S. patent application Ser. No. 13/430,945, filed on Mar. 27, 2012, which claims priority to U.S. Provisional Patent Application No. 61/487,061, filed on May 17, 2011; all of which are hereby incorporated herein by reference in their entirety.


FIELD OF THE INVENTION
The present application is related generally to wire grid polarizers, and especially wire grid polarizers with separate pixels or functionality sections.
BACKGROUND
Polarized light can improve vision systems and can be used in televisions, computer projectors, medical vision systems, military vision equipment, etc. It can be beneficial to have adjacent polarizing sections, such as adjacent wire grid polarizers, that have a difference in angular orientation of the wires between the different sections. This can allow the light to be polarized in a different direction through different sections. This difference can be used to provide real-time, multiple views of an object. For example, see U.S. Pat. Nos. 6,075,235 and 7,375,887. Although the different polarization due to different wire grid angles is helpful, it would be beneficial to have more real-time views of an object than can be provided by adjacent wire grid polarizers with different wire grid angles.
It is beneficial for a wire grid polarizer to have high transmission of one polarization Tp and low transmission of another polarization Ts. Some structural characteristics of wire grid polarizers, such as a decreased wire height h, increases both Tp, which is usually desirable, and Ts, which is usually undesirable. Other structural characteristics of wire grid polarizers, such as increased wire height h, decreases both Tp, which is usually undesirable, and Ts, which is usually desirable. Thus, there can be a trade-off between optimization of Tp and optimization of Ts. It would be beneficial to optimize for both Tp and Ts.
Polarizers optimized for one wavelength, or range of wavelengths, may not be suitable for polarization of another wavelength, or range of wavelengths. Objects appear differently under different wavelengths of light. For example, visible, ultraviolet, and infrared light emanating from an object, or even different wavelengths within visible, ultraviolet, or infrared can be detected and compared for analysis of the object. It would be beneficial to have a polarizer optimized for each of these wavelengths or wavelength ranges.
Alignment of adjacent polarizing sections can be difficult. Misalignment can adversely affect the image. Edges, and especially corners, of polarizing sections can have distorted wires that may distort the image. It would be beneficial to have a way of improving alignment of polarizing sections and to reduce or remove the distortion of wire grid polarizer section edges.
SUMMARY
It has been recognized that it would be advantageous to have improved alignment of separate polarizer sections and a reduction or elimination of light distortion caused by defects in the edges of sections. The present invention is directed to a wire grid polarizer having multiple sections or pixels that satisfies these needs.
The wire grid polarizer comprises a substrate which is transparent to incoming light and having a first surface. Multiple separate and discrete sections of wire grids can be disposed over the first surface and attached to the substrate. A border between the sections can include a mask material, disposed over the first surface of the substrate, which is opaque to incoming light, and is a material different than the wire grid material. The mask material can extend over or under a portion of an edge of the wire grid.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top view of a wire grid polarizer having multiple functionality sections or pixels, with a border between the sections, in accordance with an embodiment of the present invention;
FIG. 2 is a schematic cross-sectional side view of one aspect of the wire grid polarizer of FIG. 1, with the mask material disposed between the wires and the substrate, taken along line 2-2 in FIG. 1, in accordance with an embodiment of the present invention;
FIG. 3 is a schematic cross-sectional side of view one aspect of the wire grid polarizer of FIG. 1, with the mask material disposed over the wires, taken along line 2-2 in FIG. 1, in accordance with an embodiment of the present invention;
FIG. 4 is a schematic top view of a wire grid polarizer having multiple functionality sections or pixels, with a curved border between the sections, in accordance with an embodiment of the present invention;
FIG. 5 is a schematic top view of a wire grid polarizer having multiple functionality sections or pixels, with a border between the sections, and wherein corners between sections of the wire grid are substantially free of mask material, in accordance with an embodiment of the present invention;
FIG. 6 is a schematic top view of a wire grid polarizer having multiple functionality sections or pixels, with a border between the sections, and wherein a diameter of intersecting junctions of the mask material is less than a diameter of mask material between longitudinal lengths of the sections, in accordance with an embodiment of the present invention.



DETAILED DESCRIPTION
As illustrated in FIGS. 1-3, wire grid polarizers 10, 20, and 30 are shown comprising a substrate 11 which is transparent to incoming light and having a first surface 11f and multiple separate and discrete sections 14 of wire grids disposed over the first surface 11f and attached to the substrate 11. The wire grids of each section can include an array of substantially parallel, elongated wires 13 configured for polarization of incoming light. “Configured for polarization of incoming light” can mean that the wires 13 have a pitch that is less than half the wavelength of incoming light and a length longer than a wavelength of incoming light, or the light for which polarization is desired. “Configured for polarization of incoming light” can also include other wire characteristics such as wire height, wire width, wire material(s), etc, selected for polarization of the light.
Typically, there may be many separate and discrete sections 14, even thousands, but there may also be only a few. The polarizers described herein can have at least four separate and discrete sections 14 in one aspect, at least 10 separate and discrete sections 14 in another aspect, at least 100 separate and discrete sections 14 in another aspect, or at least 1000 separate and discrete sections 14 in another aspect.
A wire grid characteristic of at least one of the sections 14 can be different from a wire grid characteristic of at least one other section. The different characteristic can be a difference in wire material; a difference in coating on top of the wires; a difference in thin film between the wires and the substrate; a difference in substrate between the wires; a difference in number of layers of separate wires; a difference in angular orientation; a difference in wire cross-sectional shape wherein at least one shape is non-rectangular; a difference in pitch of at least 10 nanometers; a difference in wire width of at least 10 nanometers; and/or a difference in wire height of at least 10 nanometers. Different wire grid characteristics of different sections are described more fully in U.S. patent application Ser. No. 13/430,945. The above characteristics can be used in different sections for improved analysis of an image by allowing substantial differences in light characteristics transmitted through each section 14. Shown on wire grid polarizer 10 of FIG. 1 are different sections 14a-c. Each section 14a-c can represent a different characteristic. The different sections are represented by lines having a different angular orientation, but this different angular orientation of the lines is merely representative of a difference between the sections, and does not necessarily indicate a difference in angular orientation of the wires 13.
Also shown in FIG. 1 are two sections 14d that have six sides and two of the sides 15 of each section 14d are aligned parallel with wires of the wire grid in that section. In this section 14d, the lines do indicate the direction of the wires. This alignment of wires with the side 15 of the section 14d can be beneficial for reduced distortion of the light, especially in locations where there would have been sharp, corners (such as  ̃90° for example).
A border between the sections can include a mask material 12. The mask material 12 can be disposed over the first surface 11f of the substrate 11. The mask material 12 can be opaque to incoming light. The phrase “opaque to incoming light” means opaque to light for which polarization is desired, and such light can be ultraviolet, visible, or infrared, or other wavelengths of the electromagnetic spectrum, depending on the desired application. Thus, if the polarizer is used for polarization of ultraviolet light, the mask material 12 may be opaque to ultraviolet light, but might not necessarily be opaque to infrared light which might also be impinging on the polarizer.
The mask material 12 can be a material different than the wire grid material. The mask material can have a slower differential etch rate than the wires 13. The mask material 12 can be chemically resistant to chemicals used for etching the wire grids. In one aspect, the mask material 12 can comprise carbon, copper, gold, titanium, silicon, and/or tungsten. The mask material can comprise chemical compounds including the previous elements, such as for example titanium oxide, titanium nitride, silicon oxide, silicon nitride, etc. The mask material can have a thickness of between 5 and 50 nanometers.
The mask material 12 can extend over or under a portion of an edge of the wire grid. As shown on wire grid polarizer 20 of FIG. 2, the mask material 12 can extend under a portion of the wires 13b. As shown on wire grid polarizer 30 of FIG. 3, the mask material 12 can extend over a portion of the wires 13b. If the mask material 12 extends over a portion of the wires 13b, the mask material may be primarily on top of the wires. Alternatively, as shown in FIG. 3, the mask material 12 can extend between 31 the wires 13b. Whether the mask material remains primarily on top of the wires 13b or extends between 31 the wires 13b depends on the material used for the mask 12, the process of application of the mask 12, and spacing between the wires 13b. 
As shown in FIGS. 2-3, wires 13a towards the center of the section tend to be relatively uniform in shape and height. Wires 13b near the edge of the section tend to be relatively distorted. The opaque mask 12 can prevent light from being transmitted through the distorted wires 13b, and thus undesirable distortion of light passing through polarizer edges can be avoided.
As shown in FIGS. 2-3, the wires can be divided into two groups or portions. The portion of the edge of the wire grid 13b having mask material 12 extending over or under defines an opaque wire grid section 21b (i.e. light can be blocked by the mask material 12 and thus not transmit through the polarizer in this section 21b). A portion of the wire grid 13a having no mask material 12 extending over or under the wire grid defines a transmissive wire grid section 21a (due to the absence of mask material 12, light can transmit through the polarizer in this section 21a). For some applications, it will be desirable to maximize the transmissive wire grid section 21a. For other applications, it is not necessary to maximize the transmissive wire grid section 21a, and thus the opaque wire grid section 21b can be relatively larger. An area of the transmissive wire grid section 21a divided by an area of the opaque wire grid section 21b can be greater than 1 in one aspect, between 2 and 1000 in another aspect, or between 1 and 1000 in another aspect.
Some applications may require a curved border to the wire grid sections 14, and may require a partial or total surrounding of one section 14 by another. A wire grid polarizer 40 with curved borders of the sections 14e-f is shown in FIG. 4. The mask 12 can define the boundaries.
It can be difficult to manufacture properly shaped wires in corners of the sections, resulting in undesirable distortion of light in the corners. One alternative for handling this problem, as shown on wire grid polarizer 50 of FIG. 5, is to have mask material 12 only disposed along a portion of longitudinal and/or lateral lengths of the sections 14 (or longitudinal lengths of the borders), and have corners 51 between the sections 14 of wire grid that are substantially free of mask material. These corners 51 can be substrate 11 that is free of any material on top, wires from the sections, overlapping wires from different sections, or a combination of the above. Removal of the mask 12 from the corners can avoid image problems associated with an abrupt corner. The mask material 12 can be disposed along at least 80% of longitudinal and/or lateral lengths of the sections in one aspect




  
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Shown on wire grid polarizer 60 in FIG. 6 is another method for resolving the problem of distorted wires 13 at corners of the polarizer. The mask 12 can be narrowed to a smaller diameter or width at or near the corners or intersecting junctions 61 of mask material 12. A diameter d2 of intersecting junctions of the mask material divided by a diameter d1 of mask material between longitudinal lengths of the sections can be between 0.1 and 0.9 in one aspect




  
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How to Make:

Wire grid polarizers with multiple functionality sections 14 can be made by masking off certain sections while leaving other sections uncovered. For example, a resist or oxide can be patterned to leave a section or multiple sections open, and other section(s) covered or masked off. Metal can be applied through sputter to the open sections. The metal can be patterned and etched. Coatings can be added if desired. The resist or oxide can be removed or lifted off. The sections that had the original wire grids can then be masked off, new sections can be opened and the procedure of adding wires can be repeated, but with different characteristics, for the new, opened, sections. This process can be repeated for as many different sections with different wire characteristics as desired.
As another example, if all wires will be made of the same metal, then the metal can first be applied to a substrate. A resist or oxide can be patterned to leave a section or multiple sections open. The metal can be patterned and etched. Coatings can be added if desired. The resist or oxide can be removed or lifted off. The sections that had the original wire grids can then be masked off, and new sections can be opened, and the procedure of adding wires can be repeated, but with different characteristics, for the new, opened, sections.
This process of masking certain sections, while forming the wires in other sections, then masking different sections, can result in misalignment of the sections. For some applications, it is especially undesirable if adjacent sections overlap. The mask material 12 of the present invention can allow for distinct boundaries between the sections. The mask material 12 can be applied, such as by chemical vapor deposition for example, then patterned. The pattern can be squares, such as sections 14a-c in FIG. 1, 6-sided structures, such as section 14d in FIG. 1, curved sections, such as section 14e in FIG. 4, or other shapes. The wires may be applied to the different sections as described above. Misalignment of the wire grid sections can be masked by the mask material 12. Also, distortion of the wires 13b at edges and/or corners can also be masked or blocked by the mask material 12. Alternatively, the wires may be applied to the different sections as described above, then the mask may be applied, such as by chemical vapor deposition for example, then patterned to open up the sections.

## Claims

1. A wire grid polarizer device, comprising:
a substrate which is transparent to incoming light and having a first surface;
at least four separate and discrete sections of wire grids (wire grid sections) disposed over the first surface and attached to the substrate;
the wire grids of each wire grid section including an array of substantially parallel, elongated wires configured for polarization of incoming light;
a wire grid characteristic of at least one of the wire grid sections is different from a wire grid characteristic of at least one other wire grid section;
a border between the wire grid sections including a mask material;
the mask material disposed over the first surface of the substrate;
the mask material is opaque to incoming light and is a material different than a wire grid material of at least one of the wire grid sections;
the mask material extends over or under a portion of an edge of at least one of the wire grid sections;
the portion of the edge of the wire grid having mask material extending over or under the edge of at least one of the wire grid sections defines an opaque wire grid section;
a portion of at least one of the wire grid sections having no mask material extending over or under the wire grid defines a transmissive wire grid section;
an area of the transmissive wire grid section divided by an area of the opaque wire grid section is greater than 1.

2. The polarizer of claim 1, wherein the transmissive wire grid section divided by the opaque wire grid section is between 2 and 1000.

3. The polarizer of claim 1, wherein the border is curved.

4. The polarizer of claim 1, wherein at least two of the wire grid sections have at least six sides and at least two of the sides of each wire grid section are aligned parallel with wires of the wire grid in that section.

5. The polarizer of claim 1, wherein the mask material has a thickness of between 5 and 50 nanometers.

6. The polarizer of claim 1, wherein the mask material is disposed partially between the substrate and the wires of at least one of the wire grid sections.

7. The polarizer of claim 1, wherein the mask material is chemically resistant to chemicals used for etching at least one of the wire grid sections.

8. The polarizer of claim 1, wherein the mask material comprises carbon, copper, gold, titanium, silicon, tungsten, or combinations thereof.

9. The polarizer of claim 1, wherein:
the mask material is disposed along at least 80% of longitudinal lengths of the wire grid sections; and
corners between the wire grid sections are substantially free of mask material.

10. The polarizer of claim 1, wherein a diameter of intersecting junctions of the mask material divided by a diameter of mask material between longitudinal lengths of the wire grid sections is between 0.1 and 0.9.

11. The polarizer of claim 1, wherein the wire grid sections include at least 1000 separate and discrete sections.

12. The polarizer of claim 1, wherein the different characteristic is
a difference in wire material;
a difference in coating on top of the wires;
a difference in thin film between the wires and the substrate;
a difference in substrate between the wires;
a difference in number of layers of separate wires; or
combinations thereof.

13. The polarizer of claim 12, wherein the different structure also includes at least one of the following:
a difference in angular orientation;
a difference in wire cross-sectional shape wherein at least one shape is non-rectangular;
a difference in pitch of at least 10 nanometers;
a difference in wire width of at least 10 nanometers; or
a difference in wire height of at least 10 nanometers.

14. A wire grid polarizer device, comprising:
a substrate which is transparent to incoming light and having a first surface;
at least 10 separate and discrete sections of wire grids (wire grid sections) disposed over the first surface and attached to the substrate;
the wire grids of each wire grid section including an array of substantially parallel, elongated wires configured for polarization of incoming light;
a border between the wire grid sections including a mask material;
the mask material disposed over the first surface of the substrate;
the mask material is opaque to incoming light and is a material different than a wire grid material of the wire grids; and
the mask material extends over or under a portion of an edge of at least one of the wire grid sections.

15. The polarizer of claim 14, wherein
the portion of the edge of the wire grid having mask material extending over or under the edge of at least one of the wire grid sections defines an opaque wire grid section;
a portion the edge of at least one of the wire grid sections having no mask material extending over or under the wire grid defines a transmissive wire grid section;
an area of the transmissive wire grid section divided by an area of the opaque wire grid section is between 2 and 1000; and
a wire grid characteristic of at least one of the wire grid sections is different from a wire grid characteristic of at least one other wire grid section and the different characteristic is:
a difference in wire material;
a difference in coating on top of the wires;
a difference in thin film between the wires and the substrate;
a difference in substrate between the wires;
a difference in number of layers of separate wires;
a difference in angular orientation;
a difference in wire cross-sectional shape wherein at least one shape is non-rectangular;
a difference in pitch of at least 10 nanometers;
a difference in wire width of at least 10 nanometers;
a difference in wire height of at least 10 nanometers; or
combinations thereof.

16. The polarizer of claim 14, wherein the mask material is chemically resistant to chemicals used for etching the wire grids and the mask material comprises carbon, copper, gold, titanium, silicon, tungsten, or combinations thereof.

17. A wire grid polarizer device, comprising:
a substrate which is transparent to incoming light and having a first surface;
at least 100 separate and discrete sections of wire grids (wire grid sections) disposed over the first surface and attached to the substrate;
the wire grids of each section including an array of substantially parallel, elongated wires configured for polarization of incoming light;
a wire grid characteristic of at least one of the wire grid sections is different from a wire grid characteristic of at least one other wire grid section;
a border between the wire grid sections including a mask material;
the mask material disposed over the first surface of the substrate;
the mask material having a thickness of between 5 and 50 nanometers;
the mask material is opaque to incoming light and is a material different than a wire grid material of at least one of the wire grid sections;
the mask material extends over or under a portion of an edge of at least one of the wire grid sections;
the portion of the edge of the wire grid having mask material extending over or under the edge of at least one of the wire grid sections defines an opaque wire grid section;
a portion of at least one of the wire grid sections having no mask material extending over or under the wire grid defines a transmissive wire grid section;
an area of the transmissive wire grid section divided by an area of the opaque wire grid section is between 1 and 1000.

18. The polarizer of claim 17, wherein:
the mask material is disposed along at least 90% of longitudinal lengths of the wire grid sections; and
corners between the wire grid sections of the wire grid are substantially free of mask material.

19. The polarizer of claim 17, wherein a diameter of intersecting junctions of the mask material divided by a diameter of mask material between longitudinal lengths of the sections is between 0.2 and 0.8.

20. The polarizer of claim 17, wherein the different characteristic is:
a difference in wire material;
a difference in coating on top of the wires;
a difference in thin film between the wires and the substrate;
a difference in substrate between the wires;
a difference in number of layers of separate wires; or
combinations thereof.