Nanowire polarizers by guided self-assembly of block copolymers

Abstract

Wire-grid polarizers (WGPs) are currently limited by their wafer-scale manufacturing methods to sizes of approximately 12 to 18 in. For large-size displays, a new method for the production of large-area WGPs is required. Large-area WGPs were simulated using the finite-difference-time-domain method, and a scaleable method for their production based on a block copolymer (BCP)-nanostructured template was implemented. The nanostructured template is globally aligned through the use of a cylinder-forming liquid crystal (LC) diblock copolymer, which is first aligned on a rubbed polyimide substrate. A surface-relief template is produced using the differential dry etch rates of the cylinder-forming component and LC polymer matrix component of the BCP. The template is metalized to produce a WGP. Polarizers of arbitrary size with polarization efficiency up to 0.6 have been made in close agreement with calculated values for idealized structures. The choice of the cylinder-forming polymer is critical to the degree of alignment of the template, and the thermal stability of the LC polymer matrix is critical to the stability of the template during etching.