Patent Document

BACKGROUND OF THE INVENTION 
     Polarizers play an important role in directing or rearranging light and are used in numerous applications from photography to liquid crystal displays (LCDs). Consumer demand for products that use polarizers has created an aggressive and competitive marketplace for manufacturers of large and small LCD devices, aircraft windows, medical imaging equipment, solar energy collectors and other applications not yet realized. In relation to LCDs, the performance of a polarizer determines not only the amount of transmitted light that reaches the viewer, but also the contrast of the viewing platform. The materials and costs related to manufacturing these polarizers result in a high cost to the buyer. In an effort to achieve an edge in the market, manufacturers are continually looking for lower cost polarizer components and construction and fabrication methods without sacrificing quality and performance. 
     “Absorptive” polarizers, i.e., a linear polarizer where the unwanted polarization states are absorbed by the device are known in the art. A typical “absorptive” polarizer is usually structured in layers comprised of two protective films, two sheets of triacetate cellulose (TAC), one layer of polyvinyl alcohol (PVA), an iodine complex, and several surface treatments and adhesive layers. The most common absorptive polarizer is a “wire grid” polarizer which consists of a plurality of a parallel array of metal wires on a transparent substrate, typically glass or clear polymer film, placed in a plane perpendicular to the incident beam. The grid consists of both a metal medium (the conductor) and a dielectric. How the wire grid polarizer affects light, depends on the size of the grid and the width and pitch of the conductor and dielectric mediums, as well as the thickness of the substrate. 
     Most polarizers are comprised of many layers which are susceptible to de-lamination caused by moisture and/or heat, as well as the aging process often associated with typical non-wire grid polarizers. The layers are produced utilizing chemical compounds which may have negative effects on the environment. In addition, the current manufacturing processes result in a very low production yield of approximately 70%. Therefore, there is a need for a polarizer with less environmental impact in the manufacturing process and a higher production yield. 
     In the second quarter of 2009, the largest market share of the global polarizer market is the thin film transistor liquid crystal display (TFT-LCD) sector at 95%. Of this, 57% of the TFT-LCD market was for LCD TV-use polarizers. Other uses within this sector are computer monitors, mobile phones, video game systems, navigation systems, projectors and many more. 
     Most polarizers are woefully inefficient and in an LCD application allow too much light to pass through, requiring the use of other layers to further reduce the amount of transmitted light. Therefore, there is also a need for a more efficient, durable and reliable polarizer that is capable of controlling the passage of light without the vulnerabilities and high costs associated with the use of multiple layers of films and substrates. 
     SUMMARY OF THE INVENTION 
     The polarizers and manufacturing processes described herein satisfy the above-described industry needs. According to the present invention, a mechanical polarizing device and the manufacturing process thereof are provided. The mechanical polarizer filters light in a highly efficient and economical manner equal to wire grid polarizers. The more economical, high performance, environmentally friendly mechanical polarizer device and manufacturing process described herein have significant benefits to manufacturers and consumers alike. 
     The polarizers produced according to the present invention are less expensive to produce and more effectively and efficiently control the transmittance of light, thereby eliminating the need for some of the additional layers within a liquid crystal device is provided. The polarizers and manufacturing processes described herein will accordingly reduce the manufacturing cost of liquid crystal devices, thus benefiting manufacturers and consumers. Further, a more efficient polarizer as described herein will also allow the use of a smaller or less intense back-light source which in turn will not only reduce the amount of heat generated by the device, but will also consume less energy, resulting in a device having overall greater energy efficiency and lower environmental impact (i.e., reduced carbon footprint). 
     The polarizer produced according to the present invention is produced with less toxic chemical elements than currently in use, thus reducing the overall environmental impact of polarizer production. The polarizers produced with the manufacturing processes described herein have no size limitations, unlike standard wire grid polarizers, and the process generates a higher quality and greater production yield. In addition, the polarizers produced as described herein are produced at a lower cost than a typical absorptive polarizer. In addition, the process produces a product with no or fewer adverse toxic impacts on the environment than current production methods. 
     Accordingly, the present invention addresses problematic issues relating to the standard polarizers currently in use by electronics manufacturers. 
    
    
     
       FIGURES 
       These and other features, aspects and advantages of the present invention will become better understood from the following description, appended claims, and accompanying figures where like numbers reference like elements and where: 
         FIG. 1  is a cross sectional view schematically showing a structure of a transparent layer, to which the invention is applied; 
         FIG. 2  is a cross sectional view schematically showing a structure of a non-transparent substrate layer applied to a transparent substrate with an adhesive, to which the invention is applied; 
         FIG. 3  is a cross sectional view showing a photoresist layer applied to a non-transparent layer to which the invention is applied; 
         FIG. 4  is a cross sectional view showing the unwanted non-transparent material removed from the non-transparent layer, with the photoresist layer still attached, to which the invention is applied; 
         FIG. 5 a    is a cross sectional view schematically showing a structure of a Channel Grid (Channel Grid Structure) type polarization element, to which the invention is applied; 
         FIG. 5 b    is a plan view schematically showing a structure of a Channel Grid (Channel Grid Structure) type polarization element, to which the invention is applied; 
         FIG. 6  is a cross sectional view schematically showing a structure of a Channel Grid Structure with a protective transparent substrate applied with an adhesive to complete the Channel Grid type polarization element, to which the invention is applied; 
         FIG. 7 a    is High Speed Roll to Roll Nano-Etching Polarizer Assembly and Manufacturing Process of the Channel Grid type polarization element, to which the invention is applied; and 
         FIG. 7 b    is High Speed Sheet Fed Nano-Etching Polarizer Assembly and Manufacturing Process of the Channel Grid type polarization element, to which the invention is applied. 
     
    
    
     DESCRIPTION 
     According to one embodiment of the invention, a process for manufacturing a Polarizer Device  100  is described. 
     Referring now to  FIG. 1 , according to one embodiment, first, the manufacturing process starts with selecting a First Transparent Layer  101 . The First Transparent Layer  101  is a film substrate which is substantially transparent for the desired use. A variety of suitable materials comprise polymeric materials such as plastic polymers, acrylate polymers, acrylics, acrylonitrile butadiene styrene, cellulose ethers, cellulose esters, thermoplastic elastomers, ethylene ethyl acrylate copolymers, ethylene vinyl alcohol copolymers, glass, thermoplastic resins, polyolefins, polyacrylics and polyacrylates, ionomers, linear long-chain diols, methyl methacrylate styrene copolymers, methacrylate butadiene-styrene copolymers, polycarbonates, polyether, polyketones, polyethylenes, poly sulfides, polysulfones, polylactones, polyurethanes, polyetherketones, polyamides, polyesters, polyarylene oxides, polyarylene sulfides, polyetherimides, polyethylene terephthalate, polyepichorohydrins, polytetrafluoroethylenes, polyacetals and silicones. 
     The choice of the First Transparent Layer  101  is made after considering economical and environmental impact, purpose of use, and the layers of the material on which the Polarizer Device  100  will be placed. 
     Referring now to  FIG. 2 , after the First Transparent Layer  101  is selected, the First Transparent Layer  101  is coated with a transparent adhesive  110 . Next, a Non-Transparent Material layer  102  is deposited on the First Transparent Layer  101 . The Non-Transparent Material  102  may be deposited on the First Transparent Layer  101  by one of, but not limited to the following methods: vacuum deposition, ambient air process, or pressure process methods. The Non-Transparent Material  102  may also be deposited onto the First Transparent Layer  101  using a plasma or sputtering method or the deposition may be solution coated. Preferably, the height of the Non-Transparent Material layer  102  is about 80 nm (i) or the height is optimized at a different measurement for different wave-lengths of light or other uses. However, 180 nm is the preferred optimal height for the polarizer in the visible light spectrum. 
     Examples of the Non-Transparent Material layer  102  include, but are not limited to aluminum, copper, gold, nickel, and/or silver, or other suitable conductive non-transparent materials. Conducting polymers may also be used including, but are not limited to polyacetylene, polyaniline and polythiophene. 
     An additional option is utilizing the process of depositing the Non-Transparent Material grid  106  directly on the First Transparent Layer  101  with Nano-Imprint Lithography or laser nano-fabrication. Current technology can produce 5 nm resolution, which is considered too large for chip manufacturing, but for the purpose of the present invention, a 60 nm resolution may be used to make the grid pattern, making the current resolution of nano-Imprint Lithography an appropriate application of the technology. Nano-Imprint Lithography or nano-fabrication saves several steps, simplifying the process by saving the time and complexity of installing the mask  103 , etching the Non-Transparent Material from the First Transparent Layer  101 , and thus the removal of etched material, as well as neutralizing the etching process and removing the photoresist  103 . 
     There are several photoresist materials including, but not limited to polymethyl methacrylate, polymethylglutarimide and Phenol formaldehyde resin which may be suitably used according to the present invention. A pre-made photoresist  103  or the use of Nano-Imprint Lithography will put a negative image of the grid pattern on the Non-Transparent Material layer  102 . This pattern  103  (showing holes in photoresist) will produce the grid dimensions that are needed to produce an economically viable etched Channel Grid Polarizer. (As seen in  FIG. 7 a   ). The photoresist will have an alternating 73 nm to 84 nm open gap (ii) and a 60 nm covered gap (iii). The gap can be from 73 nm to 84 nm and will give the polarizer a period of 124 nm to 144 nm (iv). This dimension is optimal for a visual light polarizer wavelenth between 400 nm to 700 nm The 180 nm Non-Transparent Material height and the 60 nm width will give a heighth to width ratio of 3 to 1. This ratio can be varied for different polarizing effects. By varying the ratio and dimensions this process can be utilzed to process different light in other wavelengths. 
     Nano-Imprint Lithography or Nano-Colloidal Lithography processes may also be used to place the grid pattern onto the substrate. In Nano-Imprint Lithography, the substrate with the Non-Transparent Material coating would be coated with a light sensitive chemical photoresist. Then a polarizer pattern would be shone onto the photoresist. The light provided from a UV, DUV, or mercury-vapor lamp, would be concentrated onto the uncured chemical resist. The light will harden the negative image on the substrate, by means of cross-linking the photoresist material. The portion that was not hardened may be washed off. This leaves the substrate ready for the next step in the process. 
     Laser nano-fabrication methods may be adapted to this process and used to print long continuous channel patterns at high speed which may in turn increase the quantity and volume of channel material produced. 
     With the photoresist pattern  103  in place on Non-Transparent Layer  102  the next step is to remove the unwanted Non-Transparent Material  104 . Several different methods may be chosen to remove the Non-Transparent Material to produce the Channel Grid Structure, including but not limited to the use of a variety of liquids to etch or break the bond of the Non-Transparent Material  104  from the substrate  101   a , such as acids and bases. 
     There are also other methods like reactive ion etching to remove the unwanted Non-Transparent Material  104 . 
     The different processes for Non-Transparent Material removal can be broken down into three major types. 
     Wet Etching. This includes such methods as Isotropic Etching, Anisotropic Etching, Electrochemical Etching, and HF Etching (also known as Hydrofluoric acid Etching), HF Vapor Etching 
     Dry Etching. This includes such methods as Vapor Etching, Plasma Etching, Reactive Ion Etching (RIE), Deep Reactive Ion Etching (DRIE), Ion Beam Etching, Argon Ion Beam Accelerator, Micro-Electro-Mechanical-Systems (MEMS), Nano-Electro-Mechanical-Systems (NEMS) 
     Mechanical Removal. This includes such methods as a modified process of Micro Machining, advancements in Nano Machining), Femtosecond Laser Nano-machining, and the use of Precision Focused or Interference Focused High Powered Lasers and Laser Arrays 
     The next step is to remove the photoresist  103  from the Polarizer Device  100  comprising the First Transparent Layer/Non-Transparent Material  101   a . This process is predicated on the type of photoresist  103  used in the process. Some need strong chemicals or solvents like acetone, or carbon tetrachloride. Others can be removed by radiation like strong UV, or Gama Rays or other methods. 
     The next step is to clean and remove any leftover Non-Transparent Material  104 , photoresist  103 , or cleaning solvents. This will be in preparation for installation of the adhesive  109  and protective substrate coating  108  on the Channel Grid Structure side of the film  107 . This protective substrate coating  108  will serve two purposes. First, it will secure the Channel Grid Structure  107  so it will not be damaged if it is struck or folded. Second, changes to the optical qualities of the Polarizer Device  100  may be made by using different refractive index properties on the protective film  108 . 
     The next step will be to test the Channel Grid Polarizer for proper polarization to the desired light frequency for which it is designed. This would be done before the film is rolled up onto the Take-up Reel  129 . A computer record will be kept of the quality of the Channel Grid Polarizer produced, on an inch-by-inch basis, before it is rolled up and onto the Take-up Reel  129 . In this way if a bad sector is found it may be removed when the film is cut up into sheets. Also, if it is determined that the Polarizer Device  100  being produced is not within specified limits the computer assembly line  109   a  will be automatically shut down after generating a critical exception alert identifying the type and severity of all of the problems that have been detected, the time they were detected and all the areas impacted. This alert will allow the root cause of the problem to be quickly and readily analyzed and corrective action taken immediately to localize and correct all issues and to recertify operation. Final approval by Manufacturing Quality Assurance will be required before restarting the production line. 
     Description of the Embodiments 
     Roll-Fed Process 
     This embodiment of the invention is the specification, design, development, assembly, fabrication, integration, testing and certification of a High Speed Roll-Fed Nano-Etching Production Facility ( FIG. 7 a   ), which will automate the entire thin film fabrication process. 
     The Nano-Etching Channel Grid Polarizer Device Production process will be setup either as a fully automated or semi-automated large-scale production line. 
     It will consist of multiple Reels, including, but not limited to: 
     a) A first Transparent Layer Supply Reel  124 ; 
     b) A first Adhesive Supply Reel  125 ; 
     c) A Non-Transparent layer Supply Reel  126 ; 
     d) A second Adhesive Supply Reel  127 ; 
     e) A second Transparent Layer Supply Reel  128 ; and 
     f) A Take-up Reel  129 . 
     And an integrated multiple Stage Assembly, Fabrication and Inspection production line consisting of the following staging, processing and inspection elements and areas: 
     A. Cleaning and Preparation Areas  111   a - e  (Each film must be cleaned and prepared for entry into the clean-room); 
     B. Thin film adhesive Application  112 ; 
     C. Non-Transparent Material Deposition Staging Area  113 ; 
     D. Photo Resist or Photo Lithography Etching Area  114 ; 
     E. Removal of Non-Transparent Material Area by Chemical Etching or Other Methods  115 ; 
     F. Final Removal of Photoresist, Cleaning of the Base Substrate and Preparation Area  116 ; 
     G. Thin film adhesive Application  117 ; 
     H. Sealing the top surface with a Clear Protective Substrate  118 ; and 
     I. Final Inspection and Trimming Area  119 . 
     The following paragraphs describe the various process stages in more detail: 
     (See  FIG. 7 a   ) Beginning with the thin film Supply Reel  124  feed First Transparent Layer  101  material ( FIG. 1 ) into the Nano-Etching Polarizer Production Line control roller  121  that will move the First Transparent Layer  101  to and through all of the processing stages needed to produce the Polarizer Device  100  ( FIG. 6 ) that will be subsequently fed to and deposited onto the Final Channel Grid Polarizer Take-Up Reel  129 . 
     1 st  Stage 
     From the main Thin film Supply Reel  123  to the Preparation and Cleaning Area  111   a  where the film is cleaned and polished in preparation to enter the Clean Room and application of adhesive  110 . 
     2 nd  Stage 
     From there, the First Transparent Layer  101  material is fed into thin film Adhesive Application Area  112  where it has adhesive  110  applied. This stage consists of the following processes: 
     A thin film adhesive is fed from supply reel  125  through Cleaning and Preparation area  111   b  where it is cleaned for access to the clean room area. Once inside the clean room the first layer of protective film  123   a  is removed from the adhesive thin film  110  and fed out to a waste area. The thin film adhesive  110  is applied to the First Transparent Layer  101  and the second protective layer  123   b  is removed and fed out to a waste area. 
     3 rd  Stage 
     From there, the film First Transparent Layer  101  with adhesive  110  is fed into the Non-Transparent Material Deposition Staging Area  113  where it has the Non-Transparent Thin film  102  applied. 
     This stage consists of the following processes; 
     A thin film Non-Transparent Layer  102  is fed from Supply Reel  126  through Cleaning and Preparation area  111   c  where it is cleaned for access to the clean room area where it is applied to the film First Transparent Layer  101  with adhesive  110  by pinch rollers  120   b  or another method. 
     4 th  Stage 
     From there, the device substrate  101   a  comprising the First Transparent Layer  101  with adhesive  110  and Non-Transparent Layer  102 — FIG. 2 ) is fed into the Photo Resist or Photo Lithography Etching Area  114  where a Photoresist or masking pattern  103  is applied to the top of the Non-Transparent Material layer  102  ( FIG. 3 ). The Photoresist pattern  103  will produce the desired elongated channel pattern. There are several ways to accomplish this: 
     (a) Have a pre-made mask pressed onto the Non-Transparent Material layer  102  as it passes by the roller, 
     (b) By using a laser type drum to imprint the pattern onto the Non-Transparent Material Layer  102  with electrical charges. 
     (c) or other methods 
     5 th  Stage 
     From there, the device substrate  101   a  (with Photoresist or masking pattern  103 ) will pass through the Removal of Non-Transparent Material Area by Chemical Etching or Other Methods  115  which will remove the unprotected Non-Transparent Material  104 . With the photoresist pattern  103  in place on the thin film substrate  101   a  ( FIG. 3 ), one of several different methods may be used to remove the Non-Transparent Material to produce the Channel Grid Structure  107  ( FIG. 4 ), including the use of a variety of chemicals to etch or break the bond of the unwanted Non-Transparent Material of the Non-Transparent Material Layer  102  or the method of ion etching to remove the unwanted Non-Transparent Material  104 . 
     Methods of removing Non-Transparent Material by chemical etching may include, but are not limited to: Ion Beam Etching, Argon Ion Beam Accelerator, Micro-Electro-Mechanical-Systems (MEMS), Nano-Electro-Mechanical-Systems (NEMS), HF Vapor Etching, Use of High Powered Lasers for Non-Transparent Material Removal, and/or other Non-Transparent Material Removal Methods. 
     6 th  Stage 
     From there, the Channel Substrate Assembly  107  ( FIGS. 5 a  and 5 b   ) will enter the Complete Removal of Photoresist, Cleaning of the Base Substrate and Preparation Area  116  where it will be cleaned of all acids, photoresist  103 , and any and all other foreign materials. 
     7 th  Stage 
     From there, Channel Grid Structure  107  is fed into thin film Adhesive Application Area  117  where it has adhesive  109  applied. This stage consists of the following processes; A thin film adhesive is fed from supply reel  127  through Cleaning and Preparation area  111   d  where it is cleaned for access to the clean room area. Once inside the clean room the first layer of protective film  123   b  is removed from the adhesive thin film  109  and fed out to a waste area. The thin film adhesive  109  is applied to the Channel Grid Structure  107  and the second protective layer  123   d  is removed and fed out to a waste area. 
     8 th  Stage 
     From there, the Channel Grid Structure  107  with adhesive is fed into Protective Substrate Bonding/Lamination Stage  118  where a second Transparent Layer  108  is applied to Channel Substrate Assembly  107  from the Protective Substrate Roll  128 . This stage consists of the following processes; 
     A second Transparent Layer  108  is fed from Supply Reel  128  through Cleaning and Preparation area  111   e  where it is cleaned for access to the clean room area, then it is applied onto the etched side of the Channel Grid Structure  107  with adhesive  109  by pinch rollers  120   c  or another method. The second Transparent Layer  108  may be comprised of the same material as the First Transparent Layer  101 , or in some other cases, it may be comprised of a different material to produce enhanced effects of the Channel Grid Polarizer. 
     9 th  Stage, 
     From there, the finished Polarizer Device  100  ( FIG. 6 ) is fed into Final Inspection and Trimming Stage  119  where it will be inspected for integrity and workmanship during which time any and all defects will be identified, numbered and tracked by its location on the roll from its first appearance to its end appearance. From there the Polarizer Device  100  may be stored on pallets for subsequent processing or cut into smaller sizes to remove any defects identified in the film during the Final Inspection and Trimming Stage  119  for ease of shipping and storage. 
     Description of Embodiments 
     Sheet Fed Process 
     This embodiment of the invention is the specification, design, development, assembly, fabrication, integration, testing and certification of a High Speed Sheet-Fed Nano-Etching Production Facility ( FIG. 7 b   ), which will automate the entire thin film fabrication process. 
     The Nano-Etching Channel Grid Polarizer Device Production process will be setup either as a fully automated or semi-automated large-scale production line. 
     It will consist of multiple Cartridges and Reels, including, but not limited to: 
     g) A thin film Supply Reel  124 ; 
     h) A thin film Adhesive Supply Reel  125 ; 
     i) A thin film Adhesive Supply Reel  127 ; 
     j) A finishing Protective Substrate Reel  128 ; 
     k) A Non-Transparent thin film Cartridge  133 ; and 
     l) A final Channel Grid Polarizer Take-up Cartridge  134  and an integrated multiple Stage Assembly, Fabrication and Inspection production line consisting of the following staging, processing and inspection elements and areas: 
     J. Cleaning and Preparation Areas  111   a - d  (Each film must be cleaned and prepared for entry into the clean-room); 
     K. Thin film adhesive Application  112 ; 
     L. Non-Transparent Material Deposition Staging Area  113 ; 
     M. 2. Photo Resist or Photo Lithography Etching Area  114 ; 
     N. 3. Removal of Non-Transparent Material Area by Chemical Etching or Other Methods  115 ; 
     O. 4. Final Removal of Photoresist, Cleaning of the Base Substrate and Preparation Area  116 ; 
     P. 5. Thin film adhesive Application  117 ; 
     Q. 5. Sealing the top surface with a Clear Protective Substrate  118 ; and 
     R. 6. Final Inspection and Trimming Area  119 . 
     The following paragraphs describe the various process steps in more detail: 
     (See  FIG. 7 b   ) From thin film Sheet Supply Reel  124 , feed Substrate Material  131  ( FIG. 1 ) into the Nano-Etching Polarizer Production Line control roller  121  that will move the Substrate Film  131  to and through all of the processing stages needed to produce the final polarizing film  130  that will be subsequently fed to and deposited onto the Final Channel Grid Polarizer Take-Up Cartridge  134 . 
     1 st  Stage 
     From the main Thin Film Sheet Supply Reel  124  to the Preparation and Cleaning Area  111   a  where the film is cleaned and polished in preparation to enter the Clean Room and application of adhesive  110 . 
     2 nd  Stage 
     From there, the thin film sheet Substrate Material  131  is fed into thin film Adhesive Application Area  112  where it has adhesive  110  applied. This stage consists of the following processes. 
     A thin film adhesive is fed from supply reel  125  through Cleaning and Preparation area  111   b  where it is cleaned for access to the clean room area. Once inside the clean room the first layer of protective film  123   a  is removed from the adhesive thin film  110  and fed out to a waste area. The thin film adhesive  110  is applied to the First Transparent Layer  101  and the second protective layer  123   b  is removed and fed out to a waste area. 
     3 rd  Stage 
     From there, the film Substrate Material  131  with adhesive  110  is fed into the Non-Transparent Material Deposition Staging Area  113  where it has the Non-Transparent Thin film  102  applied. 
     This stage consists of the following processes: 
     A thin film Non-Transparent Layer  102  is fed from Supply Cartridge  133  and is applied to the film Substrate Material  131  with adhesive  110 . 
     4 th  Stage 
     From there, the film Substrate Material  131   a  (consisting of Substrate Material  131  with adhesive  110  and Non-Transparent Layer  102 — FIG. 2 ) is fed into the Photo Resist or Photo Lithography Etching Area  114  where a Photoresist or masking pattern  103  is applied to the top of the Non-Transparent Material layer  102  ( FIG. 3 ). The Photoresist pattern  103  will produce the desired elongated channel pattern. There are several ways to accomplish this: 
     (a) a pre-made mask is pressed onto the Non-Transparent Material layer  102  as it passes by the roller; 
     (b) use a laser type drum to imprint the pattern onto the Non-Transparent Material Layer  102  with electrical charges; and 
     (c) other methods. 
     5 th  Stage 
     From there, the film substrate  131   a  (with Photoresist or masking pattern  103 ) will pass through the Removal of Non-Transparent Material by Chemical Etching or Other Methods Area  115  that will remove the unprotected Non-Transparent Material  104 . With the photoresist pattern  103  in place on the thin film substrate  131   a  ( FIG. 3 ) One of several different methods may be used to remove the Non-Transparent Material to produce the Channel Grid Structure  107  ( FIG. 4 ), including the use of a variety of chemicals to etch or break the bond of the unwanted Non-Transparent Material of the Non-Transparent Material Layer  102  or the method of ion etching to remove the unwanted Non-Transparent Material  104 . 
     Methods of removing Non-Transparent Material by chemical etching may include, but are not limited to: Ion Beam Etching, Argon Ion Beam Accelerator, Micro-Electro-Mechanical-Systems (MEMS), Nano-Electro-Mechanical-Systems (NEMS), HF Vapor Etching, Use of High Powered Lasers for Non-Transparent Material Removal, and/or other Non-Transparent Material Removal Methods. 
     6 th  Stage 
     From there, the Channel Substrate Assembly  107  ( FIGS. 5 a  and 5 b   ) will enter the Complete Removal of Photoresist, Cleaning of the Base Substrate and Preparation Area  116  where it will be cleaned of all acids, photoresist  103 , and any and all other foreign materials. 
     7 th  Stage 
     From there, Channel Grid Structure  107  is fed into thin film Adhesive Application Area  117  where it has adhesive  109  applied. This stage consists of the following processes; A thin film adhesive is fed from supply reel  127  through Cleaning and Preparation area  111   c  where it is cleaned for access to the clean room area. Once inside the clean room the first layer of protective film  123   b  is removed from the adhesive thin film  109  and fed out to a waste area. The thin film adhesive  109  is applied to the Channel Grid Structure  107  and the second protective layer  123   c  is removed and fed out to a waste area. 
     8 th  Stage 
     From there, the Channel Grid Structure  107  with adhesive is fed into Protective Substrate Bonding/Lamination Stage  118  where a protective substrate  108  is applied to Channel Substrate Assembly  107  from the Protective Substrate Roll  128 . 
     This stage consists of the following processes; 
     A thin film Transparent Substrate Layer  108  is fed from Supply Reel  128  through Cleaning and Preparation area  111   d  where it is cleaned for access to the clean room area, and then it is applied onto the etched side of the Channel Grid Structure  107  with adhesive  109  by pinch rollers  120   c  or another method. The protective layer  108  may be comprised of the same material as the substrate  131 , or in some other cases, it may be comprised of a different material to produce enhanced effects of the Channel Grid Polarizer. 
     9 th  Stage, 
     From there, the finished Channel Grid Polarizer  130  ( FIG. 6 ) is fed into Final Inspection and Trimming Stage  119  where it will be inspected for integrity and workmanship during which time any and all defects will be identified, numbered and tracked by its location on the roll from its first appearance to its end appearance. From there the Channel Grid Polarizer film  130  can be stored on pallets for subsequent processing or cut into smaller sizes to remove any defects identified in the film during the Final Inspection and Trimming Stage  119  for ease of shipping and storage. 
     Stages of the Sheet Fed Manufacturing Process 
     This manufacturing process starts with a film substrate  131 . This film substrate  131  can be a variety of different materials consisting of, all forms of plastic polymers, acrylate polymers, acrylics, acrylonitrile butadiene styrene, cellulose ethers, cellulose esters, thermoplastic elastomers, ethylene ethyl acrylate copolymers, ethylene vinyl alcohol copolymers, glass, thermoplastic resins, polyolefins, polyacrylics and polyacrylates, ionomers, linear long-chain diols, methyl methacrylate styrene copolymers, methacrylate butadiene-styrene copolymers, polycarbonates, polyether, polyketones, Polyethylenes, poly sulfides, polysulfones, polylactones, polyurethanes, polyetherketones, polyamides, polyesters, polyarylene oxides, polyarylene sulfides, polyetherimides, polyethylene terephthalate, polyepichorohydrins, polytetrafluoroethylenes, polyacetals and silicones. 
     The choice of the film substrate  131  will be made after considering economical and environmental impact, purpose of use, and the layers of the material on which the polarizer will be placed. 
     After a film substrate  131  is selected, the substrate film  131  would be coated with a transparent adhesive  110 . Then a Non-Transparent Material layer  102  would be deposited on the film substrate  131 . The deposition of the Non-Transparent Material may be one of but not limited to the following a vacuum deposition or an ambient air process or pressure process. It may also be deposited onto the film substrate  131  using plasma or sputtering Method. It may also be solution coated. The height of the Non-Transparent Material layer  102  should be 180 nm (i) or a different measurement for different wave-lengths of light or other uses. 180 nm is the optimal height for the polarizer in the visible light spectrum. 
     The deposition of the Non-Transparent Material can be, but is not limited to aluminum, copper, gold, nickel, and/or silver, or other suitable non-transparent materials. There are also conducting polymers that can be used such as, but are not limited to polyacetylene, polyaniline and polythiophene. 
     An additional option is utilizing the process of depositing the Non-Transparent Material grid  106  directly on the substrate  131  with a new form of Nano-Imprint Lithography or laser nano-fabrication. At this time the technology is only experimental. Currently the technology can only produce 5 nm resolution, which is still too large for chip manufacturing, but for this purpose the only requirement is a 60 nm resolution to make the grid pattern, making the current resolution of nano-Imprint Lithography more appropriate in this case. This would save several steps, simplifying the process by saving the time and complexity of installing the mask  103 , etching the Non-Transparent Material from the substrate  131 , and thus the removal of etched material, as well as neutralizing the etching process and removing the photoresist  103 . 
     There are several photoresist materials including but not limited to Poly methyl methacrylate, Polymethylglutarimide and Phenol formaldehyde resin. A pre-made photoresist  103  or the use of Nano-Imprint Lithography will put a negative of the grid pattern on the Non-Transparent Material layer  102 . This pattern  103  (showing holes in photoresist) will produce the grid dimensions that are needed to produce an economically viable etched Channel Grid Polarizer. (As seen in  FIG. 5 a   ) The photoresist will have an alternating 73 nm to 84 nm open gap (ii) and a 60 nm covered gap (iii). The gap can be from 73 nm to 84 nm and will give the polarizer a period of 124 nm to 144 nm (iv). This dimension is optimal for a visual light polarizer wavelength. Between 400 nm to 700 nm The 180 nm Non-Transparent Material height and the 60 nm width will give a height to width ratio of 3 to 1. This ratio can be varied for different polarizing effects. By varying the ration and dimensions this process can be utilized to process different light in other wavelengths. 
     There are also the processes of using Nano-Imprint Lithography or Nano-Colloidal Lithography to place the grid pattern onto the substrate. In Nano-Imprint Lithography, the substrate with the Non-Transparent Material coating would be coated with a light sensitive chemical photoresist. Then a polarizer pattern would be shined onto the photoresist. The light provided from a UV, DUV, or mercury-vapor lamp, would be concentrated onto the uncured chemical resist. The light will harden the negative image on the substrate, by means of cross-linking the photoresist material. The portion that was not hardened would be washed off. This would leave the substrate ready for the next step in the process. 
     Laser nano-fabrication methods may be adapted to this process and used to print long continuous channel patterns at high speed which may in turn increase the quantity and volume of channel material produced. 
     With the photoresist pattern  103  in place on Non-Transparent Layer  102  the next step is to remove the unwanted Non-Transparent Material  104 . Several different methods may be chosen to remove the Non-Transparent Material to produce the Channel Grid Structure, including but not limited to the use of a variety of liquids to etch or break the bond of the Non-Transparent Material  104  from the substrate  101   a , such as acids and bases. 
     There are also other methods like reactive ion etching to remove the unwanted Non-Transparent Material  104 . 
     The different processes for Non-Transparent Material removal can be broken down into three major types. 
     1. Wet Etching. This includes such methods as Isotropic Etching, Anisotropic Etching, Electrochemical Etching, and HF Etching (also known as Hydrofluoric acid Etching), HF Vapor Etching. 
     2. Dry Etching. This includes such methods as Vapor Etching, Plasma Etching, Reactive Ion Etching (RIE), Deep Reactive Ion Etching (DRIE), Ion Beam Etching, Argon Ion Beam Accelerator, Micro-Electro-Mechanical-Systems (MEMS), Nano-Electro-Mechanical-Systems (NEMS). 
     3. Mechanical Removal. This includes such methods as a modified process of Micro Machining, advancements in Nano Machining), Femtosecond Laser Nano-machining, and the use of Precision Focused or Interference Focused High Powered Lasers and Laser Arrays. 
     The next step is to remove the photoresist  103  from the film substrate/Non-Transparent Material  131   a . This process is predicated on the type of photoresist  103  used in the process. Some need strong chemicals or solvents like acetone, or carbon tetrachloride. Others can be removed by radiation like strong UV, or Gama Rays or other methods. 
     The next step is to clean and remove any leftover Non-Transparent Material  104 , photoresist  103 , or cleaning solvents. This will be in preparation for installation of the adhesive  109  and protective substrate coating  108  on the Channel Grid Structure side of the film  107 . This protective substrate coating  108  will serve two purposes. First, it will secure the Channel Grid Structure  107  so it will not be damaged if it is struck or folded. Second, changes to the optical qualities of the film  130  may be made by using different refractive index properties on the protective film  108 . 
     The next step will be to test the Channel Grid Polarizer for proper polarization to the desired light frequency for which it is designed. This would be done before the film  130  is received into the Take-up cartridge  134 . A computer record will be kept of the quality of the Channel Grid Polarizer produced, on an inch-by-inch basis, before it is rolled up and into the Take-up cartridge  134 . In this way if a bad sector is found it may be removed when the film is cut up into sheets. Also, if it is determined that the Channel Grid Polarizer film material  130  being produced is not within specified limits the computer assembly line  FIG. 7 b    will be automatically shut down after generating a critical exception alert identifying the type and severity of all of the problems that have been detected, the time they were detected and all the areas impacted. This alert will allow the root cause of the problem to be quickly and readily analyzed and corrective action taken immediately to localize and correct all issues and to recertify operation. Final approval by Manufacturing Quality Assurance will be required before restarting the production line. 
     Although the present invention has been discussed in considerable detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the scope of the appended claims should not be limited to the description of preferred embodiments contained herein.

Technology Category: 7