Reflecting light polarizer made of coated non-linear surfaces

A reflecting light polarizer having improved polarizing efficiency, comprising:

• a first mating surface having a saw tooth shaped cross section;
• a second mating surface having a saw tooth shaped cross section;
• and
• a polarizing coating disposed between the first mating surface and the second mating surface;
• wherein a first light polarization is transmitted through the reflecting light polarizer and a second light polarization is reflected by the reflecting light polarizer.

A reflecting light polarizer having improved polarizing efficiency, comprising:

• a first mating surface comprising a plurality of first planar segments and a plurality of second planar segments, the second planar segments being interposed between adjacent ones of the first planar segments;
• a second mating surface comprising a plurality of third planar segments and a plurality of fourth planar segments, the fourth planar segments being interposed between adjacent ones of the third planar segments;
• a polarizing coating disposed between the first planar segments and the third planar segments;
• a mirror coating disposed between the second planar segments and the fourth planar segments;
• wherein a first light polarization is transmitted through the reflecting light polarizer and a second light polarization is reflected by the reflecting light polarizer.

A method of manufacturing a reflecting light polarizer having improved polarizing efficiency, comprising the steps of:

• (a) depositing a first polarizing coating on at least one mating surface of a plurality of plates;
• (b) securing together the plurality of plates with the first polarizing coating disposed between the mating surfaces of adjacent plates;
• (c) cutting the secured plurality of plates along at least one first cross section to form a plurality of plate sections, each of the plate sections having at least one cross sectional surface;
• (d) applying a second polarizing coating to a plurality of the cross sectional surfaces;
• (e) securing together the plurality of plate sections, wherein the cross sectional surfaces of adjacent plate sections are mated together and the polarizing coating is disposed between the cross sectional surfaces being mated;
• and
• (f) cutting the plurality of plate sections along at least one second cross section.

A method of manufacturing a reflecting light polarizer having improved polarizing efficiency, comprising the steps of:

• (a) molding a first plate having a first mating surface;
• (b) molding a second plate having a second mating surface;
• (c) depositing a polarizing coating to at least one of the first mating surface and the second mating surface;
• and
• (d) securing the first mating surface to the second mating surface.

A method of manufacturing a reflecting light polarizer having improved polarizing efficiency, comprising the steps of:

• (a) extruding a first plate having a first mating surface;
• (b) extruding a second plate having a second mating surface;
• (c) depositing a polarizing coating to at least one of the first mating surface and the second mating surface;
• and
• (d) securing the first mating surface to the second mating surface.