CN108646460A - Realize the high density pel array device and preparation method thereof that emergent light polarizes entirely - Google Patents

Abstract

The invention provides a high-density pixel array device for realizing full polarization of outgoing light and a manufacturing method thereof. The packaging structure is a laminated structure, including a color filter layer, a polarization splitting film layer and a dot matrix LED light source array. The polarized light-splitting film layer in this structure is prepared by hot embossing technology. The specific steps are: firstly, a hard blank is used to prepare a stamper, and then the polymer substrate is embossed and molded. After curing, the stamper is separated from the embossed mold. Right-angle prism array film layer pattern, then vapor-deposit a layer of light-splitting film on the slope of the polymer prism, and then insert another embossed prefabricated same film layer pattern, and finally attach it on the light-emitting side of the prism at intervals of a right-angle side length For the upper half-wave plate, attach the upper polarizer at the corresponding position. The invention realizes high-density pixel display with matching polarization characteristics and pixel aperture ratio and its backlight integration structure, ensures the display effect, and at the same time makes the device structure thinner, and its manufacturing method also proves its practicability and feasibility.

Description

High-density pixel array device for realizing full polarization of outgoing light and manufacturing method thereof

technical field

The invention relates to a high-density pixel array device for realizing full polarization of outgoing light and a manufacturing method thereof.

Background technique

The development of display technology has been roughly divided into four generations: CRT (glass picture tube display) as the first generation display technology, PDP and LCD as the second generation, OLED as the third generation, and laser as the fourth generation. Among them, due to reasons such as large size, CRT monitors cannot meet our requirements for updating the times, and are gradually far away from people's lives. The display technology we are talking about now is more reflected in the flat panel display (FPD) technology that started from the second generation technology. Due to the advantages of light weight, thin thickness, small size, and no radiation, flat panel display (FPD) devices have become the current development direction of display technology. Flat panel display technologies mainly include: liquid crystal display (LCD), organic light emitting diode display (OLED), LED display, etc.

In order to obtain higher-density pixel display, one of the mainstream technologies is to use the recently developed LCOS technology, which uses reflective liquid crystal display technology that combines MOS device integration technology on Si wafers with LCD technology to achieve high-density pixels. show. The resolution of OLED displays is mainly determined by the planar source evaporation shadow mask process to achieve high-density pixel display. In addition, the light-emitting diodes are arranged in a matrix, and the distance between adjacent light-emitting diodes is less than 1mm. This method greatly increases the pixel density of the LED display.

A liquid crystal display device mainly includes three parts, namely an array substrate, a color filter and a backlight source.

The liquid crystal display device is a non-luminous display device, which needs a backlight source to achieve the display function. The performance of the backlight will directly affect the image quality of the LCD. Since the backlight is a surface light source, the backlight module converts the light emitted by the point light source or the line light source into a surface light source through diffuse reflection. The high density of the liquid crystal display device The pixel aperture ratio is low, resulting in partial energy loss, and the existing high-density pixel structure cannot achieve polarization multiplexing, and the backlight energy loss is obvious. Polarized light used as a backlight source can make the display effect of the liquid crystal display device better, but the polarization multiplexing method of the polarized light device used as the backlight source has not yet been developed, and the complexity of the traditional structure is not conducive to its application. Based on this, this patent proposes a new type of high-density array device. Before the white light passes through the filter, a polarization splitting film layer is placed on the light source, and the white light is decomposed into polarized light by using the polarization splitting film layer to realize polarization. 1. A high-density pixel display that matches the pixel aperture ratio and its backlight integration structure, and its manufacturing method is described, which ensures the display effect and makes the device structure thinner at the same time.

Contents of the invention

In view of this, the object of the present invention is to provide a high-density pixel array device and its manufacturing method for realizing full polarization of outgoing light, so as to ensure the color saturation, color gamut and light energy utilization rate of liquid crystal display.

To achieve the above object, the present invention adopts the following technical solutions:

A high-density pixel array device that realizes full polarization of outgoing light, characterized in that it includes a color filter layer arranged from top to bottom, a polarization splitting film layer and a dot matrix LED light source array; the color filter layer includes base, black matrix frame, color pixel structure array; the polarized light-splitting film layer includes a high light-transmitting polymer isosceles right-angle prism combination, a light-splitting film, a half-wave plate and a periodically arranged polarizer; the polymer isosceles The right-angle prism combination is composed of several pixel units; the pixel unit is composed of two sets of polarized beam splitting units and one set of polarizers arranged periodically.

Further, the manufacturing method of the polarized light-splitting film layer includes the following steps:

Step S1: making the pressing film blank into a pressing film with an isosceles right-angled triangle cross section; using methods such as electron beam lithography, reactive ion etching technology, or nanosphere etching technology to make the pressing molding blank into an isosceles cross section Right-angled triangular stamper, the cross-sectional dimensions of each isosceles right-angled triangle of the stamper are all equal, with the length of 1 right-angled side vacated for every group of 2, each group interval, the right-angled triangular prism body is connected according to the right-angled side The planes where the slopes of each isosceles right triangle in the section are located are parallel to each other in space. The transparent material for making the stamper blank has strong hardness, including but not limited to Si, SiO2, silicon nitride, diamond, etc.;

Step S2: Select a transparent polymer material as the substrate, coat the substrate with a layer of the same polymer film with an additive manufacturing process, heat it to a high elastic state, and then press the isosceles right triangle die according to the vertical downward direction. The pressure extrudes the polymer film to make it instantly deformed, and forms a film layer opposite to the pressed film with a cross-section of an isosceles right-angled triangle array, and finally it is cured in the form of heat or light; the manufacturing process includes spin coating, spraying, etc. Ink printing, casting, evaporation, etc.;

Step S3: using graphic transfer technology, the stamper is separated from the film layer, that is, the blank pattern is transferred to the substrate, and a film layer pattern containing an array of isosceles right-angled triangular prisms is made, and the shape of the pattern is consistent with the mold; in each group Polarizers are set at the vacant positions of the right-angle prisms; the preparation method of the polarizers is to use a polymer compound polyvinyl alcohol film with a network structure as a substrate, and then impregnated with iodine with strong dichroism, which is stabilized by boric acid aqueous solution reduction. After that, it is stretched 4~5 times in one direction;

Step S4: Make a mask plate, block the right-angled sides of each isosceles right-angled triangle and the position of the polarizer, and attach a layer of high-transparency material on two adjacent triangular slopes by evaporation or spin coating;

Step S5: Repeat steps S2 and S3 to pre-fabricate another polymer film layer pattern containing a rectangular prism array with exactly the same shape, and align the triangular slopes of the two film layer patterns to make them fit together accurately and firmly. Finally, a half-wave plate is pasted on the light-emitting surface of one of the two polarization splitting units. The size of the half-wave plate needs to cover, but not exceed, the length of the right-angled side of the triangle in the cross section.

Further, the dot matrix LED light source array includes LED lamp beads, a substrate structure and secondary optical elements arranged on the LED lamp beads.

Further, the polarized light-splitting film layer has at least three polarized light-emitting surfaces, and the light-emitting surface of the polarized light-splitting unit not covered by a half-wave plate is the first polarization surface, and the outgoing light of the first polarization surface is transmitted through the light-splitting film. P light; the light output surface of the polarization splitting unit containing a half-wave plate is the second polarization plane, and the outgoing light at the second polarization plane is converted by the half-wave plate from the S light reflected by the light-splitting film to generate P light; only the polarizer covers The light exit plane at the unit is the third polarization plane, and the exit light of the third polarization plane is the P light converted by the polarizer.

Further, no more than two sets of dot matrix LED lamp beads and secondary optical elements are installed for every three sets of polarization splitting units; The group is located below the polarization beam splitting unit that is not coated with a beam splitting film. The width of the substrate structure of a single LED bead is less than or equal to twice the right-angled side of the isosceles right-angled triangle of the polarization beam splitting film layer. The dot matrix LED is used as the incident light source of the system, and the center of its light-emitting optical axis is aligned with the center of the right-angled prism. The unit size of a single light-emitting chip of a dot matrix LED is smaller than the aperture of the secondary optical element, and is also smaller than the sub-pixel width of the color filter layer. The dot matrix LED chips can also be replaced by Mini-LED chips and Micro-LED chips, and the structure size can be further reduced. Dot matrix LED light sources are preferably blue light, ultraviolet light and other light sources, and the center wavelength is between 100 nm and 490 nm.

Further, the light emitting surface of the polarization splitting unit is correspondingly covered with filters of different primary colors, which are sequentially arranged on the light emitting surface of the unit in the order of red, green, and blue to form a color filter layer. That is, each polarization splitting unit forms a sub-pixel point, that is, a pixel point of one color in the three primary colors, and three polarization splitting units form a complete pixel unit group. The material of these color filters has high transmittance for the color wavelength corresponding to the sub-pixel, and quantum dots, phosphors, color photosensitive glue, etc. can be used, but not limited to this. In this structure, the dot matrix LED light source is preferred For blue light, ultraviolet light and other light sources, if necessary, add a blue sub-pixel color filter film layer. The material of the color filter can also be colored glass, color light-blocking material, etc. In this structure, the dot matrix LED light source is preferably a white light broad-spectrum light source covering the visible light band.

Further, the thickness of the color filter layer is ≤3 μm, the thickness of the polarization splitting film is ≤7 μm, and the thickness of the backlight source depends on the actual use of the LED wick.

Further, the manufacturing process of the polymer material prism is not limited to the thermal embossing process, extrusion molding and injection molding can also be used to form the prism array on the substrate at one time; the ultraviolet imprinting process can be used to stamp the substrate on the substrate In the last molding, the polymer material prisms after molding are connected to each other to form an array;

The process flow of UV imprinting is as follows:

In the first step, the monomer-coated substrate and transparent stamper are loaded into the alignment machine, vacuum-fixed in their respective chucks, and the contact is started after the optical alignment of the substrate and stamper is completed;

In the second step, the polymer in the embossed area is polymerized and cured by UV exposure of the stamper;

The third step to the fifth step are the same as step S3 to step S5.

Further, along the direction of light propagation, the light emitted by the LED dot matrix will be collected and shaped by the secondary optical element. The secondary optical element can be a reflector coated with a reflective film on the inner surface, or a refractor with a free-form surface , the half-angle of light collection is greater than 60 degrees, and the LED light energy is collected as much as possible and emitted in a directional manner. The outgoing light of the secondary optical element is an illumination spot that fills the light-emitting surface and has high illuminance uniformity.

Further, the spectroscopic film is prepared and formed on the slope of one of the two opposite right-angle prisms, each spectroscopic film forms an angle of 45° with the direction of the substrate surface, and the spatial positions of each spectroscopic film are parallel to each other, preferably by evaporation. The preparation process is as follows:

The first step is degreasing and cleaning with acetone or alcohol;

The second step, surface treatment, corona discharge treatment, ultraviolet irradiation treatment, etc.;

The third step, bottom surface coating/hardening treatment, spraying with spray gun;

The fourth step, vacuum evaporation process, the evaporation metal is aluminum, gold, etc.;

The fifth step, surface coating/hardening treatment, requires surface coating treatment or overcoating.

Further, the material for making the high transparency material includes but not limited to zinc sulfide, silicon dioxide, titanium dioxide, and Ta2O5.

Compared with the prior art, the present invention has the following beneficial effects:

The novel high-density array device of the present invention realizes high-density pixel display with matching polarization characteristics and pixel aperture ratio and its backlight integration structure, which ensures the display effect and makes the device structure thinner, and its manufacturing method also proves its practicability and feasibility.

Description of drawings

FIG. 1 is a schematic structural view of a high-density pixel array device for realizing full polarization of outgoing light in the present invention;

Fig. 2 is the stamper schematic diagram that the present invention makes high light transmittance polymer rectangular prism array;

Fig. 3 is a combination diagram of a high light-transmitting polymer rectangular prism embossed in an embodiment of the present invention;

4 is a schematic diagram of a color filter layer in an embodiment of the present invention;

Fig. 5 is the schematic diagram of the polarization splitting thin film layer in an embodiment of the present invention;

6 is a schematic structural view of a direct-lit dot-matrix LED backlight in an embodiment of the present invention;

Fig. 7 is the trend figure of optical path in rectangular prism array in one embodiment of the present invention;

FIG. 8 is a diagram showing the direction of the optical path in the structural system of a high-density pixel array device with fully polarized outgoing light in an embodiment of the present invention;

Fig. 9 is a combination diagram of a high light-transmitting polymer rectangular prism bonded to a substrate in an embodiment of the present invention;

Fig. 10 is a schematic structural diagram of a high-density pixel array device with fully polarized outgoing light attached to a substrate in an embodiment of the present invention;

Fig. 11 is a schematic diagram of a polarized light-splitting film layer bonded to a substrate in an embodiment of the present invention;

Fig. 12 is the stamper schematic diagram of making the high light transmittance polymer rectangular prism array which saves the prism array;

Fig. 13 is a combination diagram of a high light-transmitting polymer right-angle prism embossed in an embodiment of the present invention;

Fig. 14 is a schematic structural diagram of a high-density pixel array device that realizes the full polarization of the outgoing light of the saving prism array in an embodiment of the present invention;

Fig. 15 is a schematic diagram of the polarization splitting film layer saving the prism array in an embodiment of the present invention;

FIG. 16 is a process flow diagram of a polarization splitting film that saves a prism array in an embodiment of the present invention;

The reference signs therein explain:

1-color filter layer; 10-black matrix frame; 11-red quantum dot film; 12-green quantum dot film; 13-color film substrate; 22-light-splitting film; 23-half-wave plate; 24-light incident surface of polarized light-splitting film layer; 25-light-emitting surface of polarized light-splitting film layer; 26-polarizer; 3-direct type point Array LED backlight; 30-substrate structure; 31-LED lamp bead; 32-secondary optical element; 4-light source light; 5-S light; 6-P light; 7-first pressing mold; 8-second pressing mold.

Detailed ways

The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

Please refer to Figure 1, the present invention provides a high-density pixel array device with fully polarized outgoing light, which is characterized in that it includes a color filter layer, a polarization splitting film layer and a dot matrix LED light source array from top to bottom;

The color filter layer includes a substrate, a black matrix frame, and a color pixel structure array; the polarized light-splitting film layer includes a polymer isosceles rectangular prism combination with high light transmittance, a light-splitting film, a half-wave plate, and periodically arranged polarizers. sheet; the polymer isosceles right-angle prism combination is composed of several pixel units; the pixel unit is composed of two sets of polarization beam splitting units and a set of polarizers set periodically.

In an embodiment of the present invention, further, the manufacturing method of the polarization splitting film layer includes the following steps:

Step S1: making the pressing film blank into a pressing film with an isosceles right-angled triangle cross section; using methods such as electron beam lithography, reactive ion etching technology, or nanosphere etching technology to make the pressing molding blank into an isosceles cross section Right-angled triangular stamper, the cross-sectional dimensions of each isosceles right-angled triangle of the stamper are all equal, with the length of 1 right-angled side vacated for every group of 2, each group interval, the right-angled triangular prism body is connected according to the right-angled side The planes where the slopes of each isosceles right triangle in the section are located are parallel to each other in space. The transparent material for making the stamper blank has strong hardness, including but not limited to Si, SiO2, silicon nitride, diamond, etc.;

Step S2: Select a transparent polymer material as the substrate, coat the substrate with a layer of the same polymer film with an additive manufacturing process, heat it to a high elastic state, and then press the isosceles right triangle die according to the vertical downward direction. The pressure extrudes the polymer film to make it instantly deformed, and forms a film layer opposite to the pressed film with a cross-section of an isosceles right-angled triangle array, and finally it is cured in the form of heat or light; the manufacturing process includes spin coating, spraying, etc. Ink printing, casting, evaporation, etc.;

Step S3: adopt pattern transfer technology, separate stamper and film layer, be about to transfer blank pattern on substrate, make the film layer pattern that contains will isosceles right triangle prism array, the shape of pattern is consistent with mold; Polarizers are set at the vacant positions of the right-angle prisms; the preparation method of the polarizers is to use a polymer compound polyvinyl alcohol film with a network structure as a substrate, and then impregnated with iodine with strong dichroism, which is stabilized by boric acid aqueous solution reduction. After that, it is stretched 4~5 times in one direction;

Step S4: Make a mask plate, block the right-angled sides of each isosceles right-angled triangle and the position of the polarizer, and attach a layer of high-transparency material on two adjacent triangular slopes by evaporation or spin coating;

Step S5: Repeat steps S2 and S3 to pre-fabricate another polymer film layer pattern containing a rectangular prism array with exactly the same shape, and align the triangular slopes of the two film layer patterns to make them fit together accurately and firmly. Finally, a half-wave plate is pasted on the light-emitting surface of one of the two polarization splitting units. The size of the half-wave plate needs to cover, but not exceed, the length of the right-angled side of the triangle in the cross section.

In an embodiment of the present invention, further, the dot matrix LED light source array includes LED lamp beads, a substrate structure and secondary optical elements arranged on the LED lamp beads.

In an embodiment of the present invention, further, the polarized light-splitting film layer has at least three polarized light exit surfaces, and the light-exit surface of the polarization light-splitting unit not covered by the half-wave plate is the first polarization surface, and the exit surface of the first polarization surface The emitted light is transmitted through the splitting film and emitted as P light; the light output surface of the polarization splitting unit containing a half-wave plate is the second polarization plane, and the outgoing light at the second polarization plane is converted by the half-wave plate from the S light reflected by the splitting film to generate P Light; only the light exit surface of the unit covered by the polarizer is the third polarization plane, and the outgoing light of the third polarization plane is P light converted by the polarizer.

In an embodiment of the present invention, further, no more than 2 sets of dot matrix LED lamp beads and secondary optical elements are provided for every three sets of polarization splitting units; The other group is located under the polarization beam splitting unit without a beam splitting film. The width of the substrate structure of a single LED bead is less than or equal to twice the right-angled side of the isosceles right-angled triangle of the polarization beam splitting film layer. The dot matrix LED is used as the incident light source of the system, and the center of its light-emitting optical axis is aligned with the center of the right-angled prism. The unit size of a single light-emitting chip of a dot matrix LED is smaller than the aperture of the secondary optical element, and is also smaller than the sub-pixel width of the color filter layer. The dot matrix LED chips can also be replaced by Mini-LED chips and Micro-LED chips, and the structure size can be further reduced. Dot matrix LED light sources are preferably blue light, ultraviolet light and other light sources, and the center wavelength is between 100 nm and 490 nm.

In an embodiment of the present invention, further, the light-emitting surface of the polarization splitting unit is correspondingly covered with filters of different primary colors, which are sequentially arranged on the light-emitting surface of the unit in the order of red, green, and blue to form a color filter filter. Floor. That is, each polarization splitting unit forms a sub-pixel point, that is, a pixel point of one color in the three primary colors, and three polarization splitting units form a complete pixel unit group. The material of these color filters has high transmittance for the color wavelength corresponding to the sub-pixel, and quantum dots, phosphors, color photosensitive glue, etc. can be used, but not limited to this. In this structure, the dot matrix LED light source is preferred For blue light, ultraviolet light and other light sources, if necessary, add a blue sub-pixel color filter film layer. The material of the color filter can also be colored glass, color light-blocking material, etc. In this structure, the dot matrix LED light source is preferably a white light broad-spectrum light source covering the visible light band.

In an embodiment of the present invention, further, the thickness of the color filter layer is ≤3 μm, the thickness of the polarization splitting film is ≤7 μm, and the thickness of the backlight source depends on the actual use of the LED wick.

In an embodiment of the present invention, further, the manufacturing process of the polymer material prism is not limited to the thermal embossing process, extrusion molding and injection molding can also be used to form the prism array on the substrate at one time; UV embossing can be used Printing process, using a stamper to form on the substrate at one time, and the formed polymer material prisms are connected to each other to form an array;

The process flow of UV imprinting is as follows:

In the first step, the monomer-coated substrate and transparent stamper are loaded into the alignment machine, vacuum-fixed in their respective chucks, and the contact is started after the optical alignment of the substrate and stamper is completed;

In the second step, the polymer in the embossed area is polymerized and cured by UV exposure of the stamper;

The third step to the fifth step are the same as step S3 to step S5.

Further, along the direction of light propagation, the light emitted by the LED dot matrix will be collected and shaped by the secondary optical element. The secondary optical element can be a reflector coated with a reflective film on the inner surface, or a refractor with a free-form surface , the half-angle of light collection is greater than 60 degrees, and the LED light energy is collected as much as possible and emitted in a directional manner. The outgoing light of the secondary optical element is an illumination spot that fills the light-emitting surface and has high illuminance uniformity.

In an embodiment of the present invention, further, the dichroic film is prepared and formed on the slope of one of the two relative right-angle prisms, each dichroic film is at an angle of 45° to the direction of the substrate surface, and the spatial position of each dichroic film is Parallel to each other, the preparation process of evaporation is preferably used, and the process is as follows:

The first step is degreasing and cleaning with acetone or alcohol;

The second step, surface treatment, corona discharge treatment, ultraviolet irradiation treatment, etc.;

The third step, bottom surface coating/hardening treatment, spraying with spray gun;

The fourth step, vacuum evaporation process, the evaporation metal is aluminum, gold, etc.;

The fifth step, surface coating/hardening treatment, requires surface coating treatment or overcoating.

Further, the material for making the high transparency material includes but not limited to zinc sulfide, silicon dioxide, titanium dioxide, and Ta2O5.

In order to allow those skilled in the art to better understand the technical solutions of the present invention, the present invention will be described in detail below in conjunction with the accompanying drawings.

Example 1

Figure 1 shows the structure of such a high-density pixel array device that realizes full polarization of outgoing light, including: a color filter layer 1, a polarization splitting film layer 2, and a direct-type dot matrix LED backlight located under the polarization splitting film layer 3. In the first initial structure shown in Figure 1, the structure of the color filter layer 1 is as shown in Figure 4, and the structure of the direct-type dot matrix LED backlight 3 is as shown in Figure 6; the structure of the polarization splitting film layer 2 As shown in FIG. 5 , the polarization splitting film layer 2 is composed of a high light-transmitting polymer rectangular prism array 21 , a splitting film 22 , a half-wave plate 23 and a polarizing plate 26 . The polymer right-angle prism array 21 of the polarization splitting film layer can be made of a light-transmitting polymer material. Since the backlight source uses a blue LED, the polymer material is required to have a transmittance of ≥ 90% for light with a wavelength between 380-480nm. , The material can be a polymer material such as polymethyl acrylate, polyacrylate, polyurethane, silicone resin, polystyrene, styrene acrylonitrile copolymer, polymethylisoprene, transparent polyamide. High light transmission polymer material prism is a solid light transmission material. Its shape is a cube formed by fitting two prisms (polymer rectangular prisms). The thickness can be adjusted as needed. It can be produced by heat embossing. The process flow chart is shown in Figure 16, and the specific implementation steps are as follows:

The first step is mold preparation. Using methods such as electron beam lithography, reactive ion etching technology or nanosphere etching technology, the stamper blank is made into a stamper 7 whose cross section is an isosceles right triangle as shown in Figure 2, each of the stamper 7 The cross-sectional dimensions of the isosceles right-angled triangles are all equal, and the length of one right-angled side is vacated in each group of two, and the length of one right-angled side is vacated in each group, and the right-angled triangular prisms are connected according to the right-angled sides to form an array. The planes of the inclined planes are all parallel to each other in space. Die blanks are usually made of Si, SiO2, silicon nitride, diamond and other materials. These materials have many excellent properties: high Knoop hardness, large compressive strength, and high tensile strength can reduce the deformation and wear of the die; high thermal conductivity and low thermal expansion coefficient make the thermal deformation of the die during heating very small. In addition, repeated imprinting will pollute the stamper, and it is necessary to clean the stamper with strong acid and organic solvents, which requires the material of the stamper to be an inert material that is resistant to corrosion.

The second step is embossing. Select a transparent polymer material as the substrate, and use additive manufacturing processes on the substrate, including spin coating, inkjet printing, casting, evaporation, etc., to coat a layer of the same polymer film, put it into the imprinting machine and heat it to high In the elastic state, the polymer substrate is heated above its glass transition temperature, which reduces the stickiness of the polymer substrate and increases fluidity during the molding process. Then press the right-angled triangle die 7 made in the first step to extrude the polymer film according to the vertical downward pressure, under a certain pressure, make it deform instantly (but the temperature is too high and it is not necessary, because it will increase the molding cycle, However, there is no significant improvement in the molded structure, and it may even bend the polymer and cause damage to the mold). And form a film layer opposite to the stamper 7 with a cross-section of an array of isosceles right triangles. Then lower the temperature to around the solidification point of the polymer. Finally it is cured in the form of heat or light.

The third step is pattern transfer and polarizer production. Using pattern transfer techniques such as etching, peeling, and vibration, the stamper is separated from the film layer, that is, the blank pattern is transferred to the substrate, and a film layer pattern containing a right-angle prism array is produced. The shape of the pattern is consistent with the mold. A polarizer is placed at the vacant position of each group of right-angle prisms. The preparation method of the polarizer is to use a polymer compound polyvinyl alcohol film with a network structure as a substrate, and then impregnated with iodine with strong dichroism. After the boric acid aqueous solution is reduced and stabilized, it is uniaxially stretched 4 to 5 times.

The fourth step is the preparation of spectroscopic film. Make a mask, cover the right-angled side of each isosceles right-angled triangle, and attach a layer of spectroscopic film on the inclined surface of the triangle by evaporation or spin coating, as shown in Figure 3. The material of the spectroscopic film has high transparency, including but not limited to zinc sulfide, silicon dioxide, titanium dioxide, Ta2O5, etc.

The fifth step is the fitting of the section body. Repeat the second and third steps to prepare another polymer film layer pattern with the same shape and rectangular prism array in advance, align the triangular slopes of the two film layer patterns to make them fit together accurately and firmly, and finally A half-wave plate is pasted on the light-emitting surface of one of the two polarization splitting units, and the size of the half-wave plate needs to cover, but not exceed, the length of the right-angled side of the triangle in the cross section.

Example 2

Figure 10 shows a schematic structural view of the high-density pixel array device that is bonded to the substrate and realizes full polarization of the outgoing light, including: a color filter layer 1, a polarization splitting film layer 2, and a directly below the polarization splitting film layer Dot matrix LED backlight 3. In the first initial structure shown in Figure 10, the structure of the color filter layer 1 is as shown in Figure 4, and the structure of the direct-type dot matrix LED backlight 3 is as shown in Figure 6; As shown in FIG. 11 , the polarized light-splitting film layer 2 is composed of a substrate 20 , a high light-transmitting polymer rectangular prism array 21 , a light-splitting film 22 , a half-wave plate 23 and a polarizing plate 26 . The high light-transmitting polymer rectangular prism array 21 of the polarization splitting film layer can be made of a light-transmitting polymer material. Since the backlight source adopts a blue LED, the polymer material is required to be transparent to light with a wavelength between 380-480nm. Overrate ≥ 90%, the material can be polymer materials such as polymethyl acrylate, polyacrylate, polyurethane, silicone resin, polystyrene, styrene acrylonitrile copolymer, polymethylisoprene, transparent poly amides. The polymer material prism is a solid light-transmitting material. Its shape is a cube formed by fitting two prisms, and then attaching a layer of substrate respectively. The thickness can be adjusted as needed. It can be produced by heat embossing. The process flow chart is shown in Figure 16, and the specific implementation steps are as follows:

The first step, compression mold preparation, with the first step of embodiment 1;

The second step, embossing process, with the second step of embodiment 1;

The 3rd step, pattern transfer and polarizer are made, with the 3rd step of embodiment 1;

The 4th step, spectroscopic film preparation, with the 4th step of embodiment 1;

In the fifth step, the polymer rectangular prism array obtained by embossing is bonded to the substrate. First, a layer of adhesive is coated on the upper surface of the cuboid substrate, and then the bottom surface of the previously embossed polymer material prism is neatly bonded to the cuboid substrate. As shown in Figure 9.

The sixth step is to prepare the polarizing and spectroscopic thin film layer. Repeat the second, third, and fifth steps to make another identical polymer film layer pattern, and make the triangular slopes of the two film layer patterns face each other so that they are firmly and accurately fitted together to form a polymer rectangular prism Combination, and finally on the light-emitting side of the combination of polymer right-angle prisms, the upper half-wave plate is attached to the length of the right-angled side of the triangle at every interval. The size of the half-wave plate needs to cover but not exceed the right-angled side of the triangle.

Example 3

Figure 1 shows the structure of this high-density pixel array device with fully polarized outgoing light, including: a color filter layer 1, a polarization splitting film layer 2, and a direct-type dot matrix LED backlight 3 located under the polarization splitting film layer . In the first initial structure shown in Figure 1, the structure of the color filter layer 1 is as shown in Figure 4, and the structure of the direct-type dot matrix LED backlight 3 is as shown in Figure 6; the structure of the polarization splitting film layer 2 As shown in FIG. 5 , the polarizing light-splitting complex film layer 2 is composed of a high light-transmitting polymer rectangular prism array 21 , a light-splitting film 22 , a half-wave plate 23 and a polarizing plate 26 . The polymer right-angle prism array 21 of the polarization splitting film layer can be made of a light-transmitting polymer material. Since the backlight source uses a blue LED, the polymer material is required to have a transmittance of ≥ 90% for light with a wavelength between 380-480nm. , The material can be a polymer material such as polymethyl acrylate, polyacrylate, polyurethane, silicone resin, polystyrene, styrene acrylonitrile copolymer, polymethylisoprene, transparent polyamide. High light transmission polymer material prism is a solid light transmission material. Its shape is a cube formed by fitting two prisms (polymer rectangular prisms). The thickness can be adjusted as needed. It can be made by UV embossing. The process flow chart is shown in Figure 16, and the specific implementation steps are as follows:

The process flow of UV imprinting is as follows:

In the first step, the monomer-coated substrate and the transparent stamper 7 are loaded into the alignment machine, vacuum-fixed in their respective chucks, and the contact is started after the optical alignment of the substrate and the stamper 7 is completed;

In the second step, the polymer in the embossed area is polymerized and cured through ultraviolet exposure of the stamper 7;

The process of the third step to the fifth step is the same as the third step to the fifth step of embodiment 1.

Example 4

Figure 14 shows the structure of this high-density pixel array device that saves the full polarization of the outgoing light of the prism array, including: a color filter layer 1, a polarization splitting film layer 2, and a direct-type dot matrix located under the polarization splitting film layer LED backlight 3. In the first initial structure shown in Figure 14, the structure of the color filter layer 1 is shown in Figure 4, and the structure of the direct-type dot matrix LED backlight 3 is shown in Figure 6; the polarization splitting of the prism array is saved The structure of the film layer 2 is shown in FIG. 15 . The polarizing and beam-splitting film layer 2 is composed of a high light-transmitting polymer rectangular prism array 21 , a light-splitting film 22 , a half-wave plate 23 and a polarizer 26 . The polymer right-angle prism array 21 of the polarization splitting film layer can be made of a light-transmitting polymer material. Since the backlight source uses a blue LED, the polymer material is required to have a transmittance of ≥ 90% for light with a wavelength between 380-480nm. , The material can be a polymer material such as polymethyl acrylate, polyacrylate, polyurethane, silicone resin, polystyrene, styrene acrylonitrile copolymer, polymethylisoprene, transparent polyamide. High light transmission polymer material prism is a solid light transmission material. Its shape is a cube formed by fitting two prisms (polymer rectangular prisms). The thickness can be adjusted as needed. It can be produced by heat embossing. The process flow chart is shown in Figure 16, and the specific implementation steps are as follows:

The first step is mold preparation. The cross-section of the die blank is made into two isosceles right-angled triangle dies 8 inserted in every spaced position, as shown in FIG. 12 , and other parts are similar to those of Embodiment 1.

Second step, embossing process, is similar with embodiment 1;

The 3rd step, pattern transfer and polarizer are made similar with embodiment 1;

The fourth step, the preparation of spectroscopic film, as shown in Figure 13, the process is similar to that of Example 1;

The fifth step is to prepare the polarizing and spectroscopic thin film layer. Attach a half-wave plate to the light-emitting surface without the polymer prism and the light-emitting surface to the left of the light-emitting surface. The size of the half-wave plate needs to cover, but not exceed, the length of the right-angled side of the cross-sectional triangle. Other parts are similar with embodiment 1.

The above descriptions are only preferred embodiments of the present invention, and all equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope of the present invention.

Claims (10)

1. A high-density pixel array device that realizes full polarization of outgoing light, characterized in that: it includes a color filter layer arranged from top to bottom, a polarization splitting film layer and a dot matrix LED light source array; The color filter layer includes a substrate, a black matrix frame, and a color pixel structure array; the polarized light-splitting film layer includes a polymer isosceles rectangular prism combination with high light transmittance, a light-splitting film, a half-wave plate, and periodically arranged polarizers. sheet; the polymer isosceles right-angle prism combination is composed of several pixel units; the pixel unit is composed of two sets of polarization beam splitting units and a set of polarizers set periodically. 2. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 1, wherein the method for manufacturing the polarization splitting film layer comprises the following steps: Step S1: the laminated film blank is made into a laminated film whose cross section is an isosceles right triangle; Step S2: Select a transparent polymer material as the substrate, coat the substrate with a layer of the same polymer film with an additive manufacturing process, heat it to a high elastic state, and then press the isosceles right triangle die according to the vertical downward direction. Extrude the polymer film under pressure to deform it instantaneously, and form a film layer opposite to the pressed film with a cross-section of an isosceles right triangle array, and finally cure it in the form of heat or light; Step S3: Using graphic transfer technology, the stamper is separated from the film layer, that is, the blank pattern is transferred to the substrate, and a film layer pattern containing a rectangular prism array is made. The shape of the pattern is consistent with the mold; the space between each group of rectangular prisms is Set the polarizer at the out position; Step S4: Make a mask plate, block the right-angled sides of each isosceles right-angled triangle and the position of the polarizer, and attach a layer of high-transparency material on two adjacent triangular slopes by evaporation or spin coating; Step S5: Repeat steps S2 and S3 to pre-fabricate another polymer film layer pattern containing a rectangular prism array with exactly the same shape, and align the triangular slopes of the two film layer patterns to make them fit together accurately and firmly. Finally, a half-wave plate is pasted on the light-emitting surface of one of the two polarization splitting units. The size of the half-wave plate needs to cover, but not exceed, the length of the right-angled side of the triangle in the cross section. 3. A high-density pixel array device for realizing full polarization of outgoing light according to claim 1, characterized in that: the dot matrix LED light source array includes LED lamp beads, a substrate structure and two LED lamp beads secondary optics. 4. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2, wherein the polarization splitting film layer has at least three polarized light exit surfaces, and there is no half-wave plate The light output surface of the covered polarization beam splitting unit is the first polarization plane, and the output light of the first polarization plane is transmitted through the beam splitting film and emitted as P light; The output light at the position is converted by the half-wave plate from the S light reflected by the dichroic film to generate P light; the light output surface at the unit covered only by the polarizer is the third polarization plane, and the output light of the third polarization plane is converted by the polarizer For the P light. 5. A high-density pixel array device for realizing full polarization of outgoing light according to claim 3, characterized in that: no more than two sets of dot matrix LED lamp beads and secondary optical elements are provided for every three sets of polarization splitting units; When setting up two groups of light sources, one group needs to be located under the polarization beam splitting unit that has been coated with a beam splitting film, and the other group is located under the polarization beam splitting unit that has not been coated with a beam splitting film. 6. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2, wherein the light exit surface of the polarization splitting unit is correspondingly covered with filters of different primary colors, according to the red , green, and blue are sequentially arranged on the light-emitting surface of the unit to form a color filter layer. 7 . The method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2 , wherein the thickness of the color filter layer is ≤3 μm, and the thickness of the polarization splitting film is ≤7 μm. 8. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2, characterized in that: the method for preparing the polarizer is to use a polymer compound polyvinyl alcohol with a network structure The film is used as a substrate, and then impregnated with iodine with strong dichroism, and after being stabilized by boric acid aqueous solution, it is uniaxially stretched 4 to 5 times. 9. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2, characterized in that: the manufacturing material of the stamper blank includes but is not limited to Si, SiO2, silicon nitride, diamond. 10. A method for manufacturing a high-density pixel array device that realizes full polarization of outgoing light according to claim 2, wherein the high-transparency material includes but is not limited to zinc sulfide, silicon dioxide, titanium dioxide, Ta2O5.