MULTIDOMAIN LIQUID CRYSTAL DISPLAY AND METHOD FOR MANUFACTURING THEREOF Field of Invention
The invention is related to the field of electronics and can be used for manufacture information displays, in particular, liquid crystal (LC) indicators, screens, panels etc.
Prior Art
The drawback of the majority of liquid crystal displays is a strong dependence of their transmission on the angle of light incidence [S.T.Wu, C.S.Wu, SID Digest 27, 763 (1996).] and, as a result, decrease of contrast and even inversion of transmission levels at some observation angles. To improve these characteristics of displays a set of retardation plates is used in many cases [N.Yamagishi, H.Watanabe, K.Yokoyama. 'Japan Display 89', 316 (1989)], which increases the cost of the device and does not resolve the problem of color inversion.
Multi-domain LC displays, in which a single pixel contains areas with various orientations of the liquid crystal in the plane of substrates [M.Schadt, Proc.SID'97, 24.1 (1997)] are the most envisaging further development from the above point of view In details this design is described by [A.Takeda et al, SID 98 DIGEST, 1077 (1998)] and [Y.Koike et al., Proceedings of 1DW97, 159(1997)]. It comprises two substrates supplied with patterned electrodes, on which protrusions with the slopes in opposite directions, are deposited photolithographically Protrusions are designed to pretilt the liquid crystal molecules from the normal to the substrate. The room between the substrates is filled with the homeotropically aligned liquid crystal possessing negative dielectric anisotropy. In the OFF state the LC molecules are aligned perpendicularly to the substrates except the protrusions areas, on which slopes the molecules are inclined to the angle equal to that formed by the substrate and the protrusion. This pretilt is not high and has negligible contribution into optical properties of the device in the OFF state. Therefore in crossed polarizers the device does not transmit the light. When potential difference is applied to the substrates this pretilt is sufficient to direct molecular reorientation in opposite directions within the
pixel area. This results in domain formation and leads to equilibration of the angular dependence of the optical parameters. Low brightness (about 30% of a conventional display) is the drawback of such device. It is caused by the fact that protrusions take more than 30%o of the area as well as special protrusions pattern is to be used to obtain 4-domain variant of such device, and the said pattern reduces the overall brightness. Besides this, two additional technological operations of photolithography are involved to make such display.
There are devices [N.A.Konovalov, A.A.Minko. A.A.Muravski, S.Ye.Yakovenko, WO 98/57222, dd. 21.04.98] and [V.A.Konovalov, A.A.Muravski, S.Ν. Timofeev, S.Ye.Yakovenko, WO 00/08521,dd. 17.02.00], that comprise two substrates supplied with patterned electrodes, on which dielectric elements (either having the form of protrusions, or by filling the wells in the substrate) are formed photolithographically. The room between the substrates is filled with homeotropically aligned liquid crystals possessing negative dielectric anisotropy. In the OFF state the molecules are aligned perpendicularly to the substrates. When potential difference is applied to the electrodes on the opposite substrates, there appears an electric field on the interface between the dielectric deviating element and the liquid crystal appears, and that electric field does not coincide with the liquid crystal director field and has the component perpendicular to the director field. The direction of this component is governed by the pattern of the deviating dielectric elements. The amplitude of this field is sufficient to reorient the liquid crystal in opposite directions resulting in formation of various domains within the pixel area and in equilibration of the optical characteristics of the device. In contrast to the device having zigzag protrusions [Y.Koike et al], in this case the dielectric elements occupy only 5-10% of the surface and the brightness of the device is increased. The pattern of the dielectric elements is capable of producing 2-, 4-domain devices with any reasonable pixel shape. The drawback of this method of manufacturing liquid crystal display is the presence of additional photolithographic operations to produce the dielectric elements, which increases the complexity and the cost of the device.
The technical decision [S.-C. Lien, R.A.John, Patent USA Νo.5.309.264.] is the closest to the proposed devices and method, in that decision various LC domains within the pixel area are formed by joint action of the protrusions having slopes in the
different directions, which are formed photolithographically on the substrate of color filters, and the fringe field of the pixel, which arises after electric field is applied and is caused by the electrode pattern. The protrusions act as elements pretilting LC director away from the normal to the substrate. The room between the substrates is filled with the homeotropically aligned liquid crystal possessing negative dielectric anisotropy. Liquid crystal molecules are aligned perpendicularly to the surface of the substrates and in the OFF state the device does not transmit the light (polarizers are crossed). Only on the slopes of the protrusions the liquid crystal molecules are inclined from the normal to the angle equal to that formed by the slope and the substrate. The liquid crystal molecules on the protrusions are pretilted in different directions. The pretilt is small that is why it has negligible effect on the optical parameters of the device in the OFF state. Within the pixel area the protrusions are oriented in such a way that the LC molecules pretilt due to their slopes coincides with that due to the fringe field at the long sides of the electrodes which arises when the electric field is applied to the electrodes (the pixel has elongated shape). In the device described above the joint action of the fringe electric field and protrusions results in the LC molecules reorientation in different directions with respect to the long axes of the protrusions within the pixel area. The drawback of this device is not equal area of different domains. Although the method is capable of producing 4 domains (this number is considered to be optimal to equilibrate the optical properties in various viewing directions) due to difference in their area, it is difficult to achieve good equilibration. Besides, additional photolithographic operation is required in this method to deposit protrusions on the top of the electrode on the color filter substrate. This makes technologic process more complicated and increases the cost of the device.
Summary of the Invention
The object of the present invention is to design less sophisticated and less expensive displays possessing similar wide viewing angle as the Icnown ones and to propose simpler method of their manufacturing.
To achieve the object in a multidomain display comprising two parallel substrates with the faced to each other surfaces having pixel array, and that pixel array consists
of electrically conductive, insulating and planarizing layers, aligning and protective coatings, with active matrix elements as well as relief placed at least on one of the said surfaces and liquid crystal filling the room between the said surfaces, such relief is made as at least one set of closely placed to each other parallel alternating protrusions and grooves of arbitrary cross-section and orientation.
Parallel protrusions and grooves have the height differential in the range 0.01 - 3 μm and the pitch of their displacement does not exceed 15 μm.
The said relief can be made in one of the layers below the electrode, e.g. in the insulating layer separating the gate, or in the coating planarizing the active matrix elements.
Alternatively, the said relief can be made in one of the layers placed on the top of the electrode, e.g. in the coating protecting the active matrix elements from the environment.
Relief can be made in color filters and/or in the black matrix within the pixel area.
Such proposed device can be supplied with any additional design providing equilibration of its optical properties under various viewing angles. For example, in addition to the relief the pixel electrode can be patterned to distort the electric field, which appears when potential difference is applied to the electrodes on the opposite substrates. Alternatively, an additional relief can be formed to pretilt the liquid crystal and/or to distort the electric field between the opposite electrodes. Alternatively, material of the aligning layer at least on one of the said substrates is made to pretilt the liquid crystal.
To achieve the above object in the method of manufacturing of the proposed device, which includes formation of the pixel array comprising active matrix elements on one of the said parallel substrates, formation of the electrically conductive electrodes, insulating and planarizing layer, aligning, planarizing and protective coatings on the surfaces of the said substrates faced to each other as well as formation of the active
matrix elements as well as of relief at least on one of the said surfaces and filling the room between the said surfaces with a liquid crystal, in the proposed method of manufacturing liquid crystal display the said relief is made as at least one set of closely placed to each other parallel alternating protrusions and grooves of arbitrary cross-section and orientation, the said protrusions and grooves are placed so closely, that under the potential difference applied to the opposite electrodes the said liquid crystal reorients parallel to the protrusions and grooves.
Parallel protrusions and grooves can be made with the height differential in the range 0.01 - 3 μm and can be displaced with the pitch not exceeding 15 μm
The said relief can be made within the process of display manufacturing. It can be made in one of the layers below, or on the top of the electrode, either in the insulating layer separating the gate, or in the coating planarizing the active matrix elements, or in the coating protecting the active matrix elements from the environment, as well as in color filters and/or made of the black matrix material while forming the last.
The proposed method can be accomplished with additional technological operations providing equilibration of its optical properties under various viewing angles. For example, the pixel electrode can be patterned to distort the electric field, which appears when potential difference is applied to the electrodes on the opposite substrates. Alternatively, an additional relief can be formed to pretilt the liquid crystal and/or to distort the electric field between the opposite electrodes. Alternatively material of the aligning layer at least on one of the said substrates is made to pre-tilts the liquid crystal.
Aligning coatings on the faced to each other surfaces of the substrates can be for homeotropic alignment with the liquid crystal, which fills the room between the said substrates, having negative dielectric anisotropy and in the absence of electric field being aligned perpendicularly to the substrates.
The surfaces of the substrates faced to each other are supplied with electrodes. When the potential difference is applied between the electrodes, an electric field appears
between them. The said electric field reorients the liquid crystal parallel to the substrates. Due to minimization of the internal distortion energy (see [P. de Gennes, The physics of liquid crystals. Clatedon Press, Oxford, 1974, Chap.3.] for explanations) the liquid crystal tends to align parallel to the protrusions and grooves of the relief. Due to the non-uniformity of the electric field, on the opposite sides of the pixel electrode the liquid crystal molecules are reoriented by the electric field in opposite directions along the relief. Hence, within the pixel area two domains are formed with different liquid crystal orientation. Thus the multidomain structure is formed to equilibrate optical properties of the liquid crystal display under various viewing angles. In contrast to the known designs [WO 98/57222, WO 00/08521, S.-C. Lien], in the proposed device and method of its manufacturing the domains are formed due to different mechanisms. Consequently, there is no need to distort either electric field or the liquid crystal director field. Therefore, no additional layers are required. The desired domain structure can be obtained not by depositing additional layers on the top of the electrode, but by patterning one of the intermediate layers (e.g. insulators), which are in any case produced during the liquid crystal display manufacturing. The material properties of such patterned layer and its position in the whole design are irrelevant to the desired effect.
Therefore, the proposed method has fewer processing operations and consequently displays manufactured in this way have simpler design. Orientation of the protrusions and grooves governs the plain of the liquid crystal reorientation under electric field. Therefore, making the profile with different orientation of the grooves within the pixel area one can obtain 2-, 4- and multidomain devices for any actual pixel shape.
In the case of low electric field, in contrast to the Icnown designs [[A.Takeda, Y.Koike, WO 98/57222, WO 00/08521, S.-C. Lien], where the relief elements deviate the electric field applied to the opposite electrodes from the liquid crystal director field (or vice versa), in the proposed design these two fields are coincident. When electric field exceeds the threshold for the particular liquid crystal value, liquid crystal director field is distorted (it deviates from the normal to the substrate) and in the known design the liquid crystal reorients in the direction of the electric field deviation from the liquid crystal director field. In the proposed design only at this moment direction of the preferred orientation of the liquid crystal in the plane of the
substrates appears. This is caused by the fact of absence of the liquid crystal director field distortions, when liquid crustal is aligned parallel to the closely and parallel placed protrusions and grooves. Any other orientation of the liquid crystal (aligned in the substrate plane) relative to the relief creates the wave-like distortion of the liquid crystal director. From the point of view of the elasticity theory of the liquid crystals [P. de Gennes], its free surface energy density in the case of sinusoidal distortion is described by formula
Fs = 1/4K (h/2)2 q3 sin2* Θ (1)
Where K is the elastic constant of the liquid crystal, h and q are the height differential and wave vector of the relief, Θ is the angle between the liquid crystal director and the direction of the grooves.
This energy is minimized when Θ=0, i.e. when the liquid crystal is parallel to the grooves of the relief. From formula (1) one can see that the energy difference between the states with the liquid crystal parallel and perpendicular to the relief grooves increases with the increase of the height differential h and with the decrease of the relief period λ"2π/q. We established experimentally, that 10 μm period and 1 μm of height differential is sufficient to provide stable and reproducible orientation of the liquid crystal parallel to the grooves, while its initial alignment was homeotropic. In combination with other external factors, such as fringe field, or with a certain surface profile of the relief, the minimum of the surface energy can be achieved for the liquid crystal orientation in the plane of the substrates deviating from the grooves direction (i.e. for Θ ≠ 0). Such deviation of the liquid crystal orientation Θ can be as big as 45°.
As it is clear from the summary of the invention, the proposed design is applicable also for planar alignment of the liquid crystal. In contrast with the Icnown design [WO 00/08521], planar aligning layers should be not rubbed, but the liquid crystal orientation is governed by the surface profile, which in this case is also made of the sets of closely displaced alternating parallel protrusions and grooves. Liquid crystals with positive dielectric anisotropy are used in such devices. One can also deposit homeotropic aligning layer on one substrate, and planar aligning layer on another one. In such a case liquid crystal with any sign of dielectric anisotropy can be used.
Examples of the devices according to the present invention and variants of the design are shown in the figures.
Brief Description of the Drawings
Fig.l schematically shows the proposed device in the absence of the driving voltage. Fig.2 shows the top view and cross-section of the fragment of one of the substrates of the proposed device - the substrate with the active matrix - mufactured according to the present invention. Dashed lines show the vias in the insulating layer, which separates the crossing electrodes.
In a big scale Fig.3 shows the dielectric layer and Fig.4 shows the planarizing layer. Fig.5 shows the top view and cross-section of the fragment of another substrate made with the known method - the substrate with the color filters, and Fig.6 shows the top view and cross-section of the fragment of the substrate made according to the present invention. Dashed lines delineate the borders of the pixels. Letters R,G,B denote the colors of the filters: red, green and blue respectively.
Fig.7 shows the top view and cross-section of the fragment of the substrate with the color filters and the black mask, made according to the present invention. Dashed lines delineate the borders of the pixels. Letters R,G,B denote the colors of the filters: red, green and blue respectively.
Fig.8-10 show the examples of the relief variants: in fig.8 - with various number of the sets of parallel protrusions and grooves, in Fig.9 - with various orientation of the grooves, Fig.10 shows combination of the relief with the slits in the pixel electrodes.
Detailed Description of the Inventions
Multidomain liquid crystal display (see Fig.l) comprises two parallel substrates 1 and 2 and nematic liquid crystal 3, which fills the room between the substrates. On the surfaces of the substrates faced to each other the pixels are placed, which pixels include conductive 4, planarizing 5 layers, aligning 6 and protective 7 coatings.
On the substrate 1 in the example of the proposed device (Fig.2) the pixel matrix is placed, comprising active elements 8, conductive column electrodes 9, conductive row electrodes 10 and conductive pixel electrodes 11, insulating 12 and planarizing 5
layers. Relief 13 having a form of a set of closely displaced parallel alternating protrusions and grooves of arbitrary cross-section and orientation is shown in a big scale in Fig.3 (being made in the insulating layer 12) and Fig.4 (being made in planarizing layer 5). Dashed lines show vias 14 in the insulating layer 12, which separates crossing electrodes 9 and 10.
On another substrate 2 of the proposed device (see Fig.6) color filters 15 are displaced. Dashed lines delineate the borders of the pixels. Letters R,G,B denote the colors of the filters: red, green and blue respectively. Comparing Fig.5 - the substrates made according to the known method - with Fig.6 - the substrates made according to the invention - one can see that conductive layers 4 and aligning layers 6 repeat the relief 13 made in color filters 15.
To increase the contrast, black mask 16 is made around color filters 15. In the device according to the present invention on the substrate 2 relief 13 can be made of the black mask material on the top of the color filters 15. (see Fig.7).
In general, relief can have arbitrary shape. The obligatory requirement is the presence , of the sets of parallel protrusions and grooves. In contrast to the case shown in Fig.3- 7, where within each pixel only one set of parallel grooves and protrusions is displaced, there can be four, or more of such sets, as it is shown in fig.8. Protrusions can have various orientation relative to the pixel edges, as it is shown in Fig.9. The relief of parallel grooves, which governs the liquid crystal orientation, can be combined with other Icnown multidomain designs, e.g. with the slits 17 in .pixel electrodes 11 [T.Sugiura, Journal of SID, 1, 341 (1993).], as it is shown in Fig.10.
The proposed method of manufacturing multidomain liquid crystal display can be described as following.
Two parallel substrates 1 and 2 (see Fig.l) are taken as a starting material. On one of the substrates a matrix of active elements is placed comprising the active elements 8, column electrodes 9, row electrodes 10 and pixel electrodes 11 (at least one of the substrates should be transparent). Relief can be made, for example, on the active
matrix substrate either after deposition of the insulating coating 12, or after planarization of the substrate (Fig.3,4).
In the first case before gates are made insulating coating is deposited on the substrate and vias 14 are fabricated photolithographically in it to provide electric contact between the active elements 8, column electrodes 9 and pixel electrodes 11 (Fig.3). While designing photomask for the said vias formation the relief pattern is prepared simultaneously. Then, in the same process with the vias 14 the relief 13 is formed in the insulating coating having the form of parallel grooves within the pixel area. (Fig.3).
In the second case, right before making pixel electrodes the substrate is planarized by the Icnown method [H.C.Huang, Y.T.Wong, C.T.Nguyen, H.S.Kwok, , SID 96 DIGEST, 685 (1996)]. This is done by depositing the planarizing layer 5 which may be also polished if required. Then vias 14 are formed photolithographically in this layer, which vias provide electric contact between active elements 8 and pixel electrodes 11 (Fig.4). Simultaneously, with the same photomask, as it was described above, relief 13 is formed in the planarizing layer as grooves (holes) having the form of parallel lines within the pixel area (Fig.4). All subsequent layers made in the process of manufacturing liquid crystal display reproduce relief 13.
Relief can be made on the color filter substrate too. Color filters are made by one of the known methods [T.Sugiura]: photolithographic, or etching.
According to the first variant the colored layer should be photosensitive (either due to formation of the polymer structure, or due to radical polymerization). First, colored photoresist is deposited on the substrate and is covered with oxygen protective layer. It is exposed through the photomask and non-exposed parts are removed in the developer. The set of color filters 15 remains on the substrate. This procedure is repeated to obtain filters of other colors (Fig.5-6).
According to the etching method colored layer should not be necessarily photosensitive. Colored polyimide is deposited on the substrate and the required single color filter pattern 15 is formed photolithographically. This operation is
repeated for other color filters (fig.5-6). In both methods either dyes, or pigments can be used as coloring species. It is essential, that color filter of each pixel is not continuous as it is implied usually (see Fig.5), but patterned (Fig.6). This pattern produces a relief on the flat surface of the substrate. For example, in Fig.6 each color filter having primary rectangular shape of the pixel is divided into parallel protrusions, crossing the pixel parallel to the short side.
Within the present method for the liquid crystal display manufacturing black mask can be deposited around color filters to increase the contrast. As well as color filters black mask can be made of colored polyimide and can be produced by similar methods on the top of color filters, or on the active matrix substrate at any stage. In such a case relief 13 on the pixel can be made simultaneously with patterning of the black mask 16, as it is shown in Fig.7.
In general, relief can have arbitrary shape. The obligatory requirement is the presence of the sets of parallel protrusions and grooves. In contrast to the case shown in Fig.3 - 7, where within each pixel only one set of parallel grooves and protrusions is displaced, there can be four, or more of such sets, as it is shown in fig.8. Protrusions can have various orientation relative to the pixel edges, as it is shown in Fig.9. The relief of parallel grooves, which governs the liquid crystal orientation, can be combined with other known multidomain designs, e.g. with the slits 17 in .pixel electrodes 11 [S.-C. Lien], as it is shown in Fig.10.
During the next technological operation transparent conductive layer 4 is deposited on both substrates (Fig.1-7), and pixel electrodes 11 are formed of the layer 4 on the active matrix substrate (Fig.2). These electrodes are made in electric contact with active elements 8. Aligning layer 6 (Fig.1-7) is deposited on the top of the conductive layer to provide homeotropic alignment of the liquid crystal. Spacers (not shown in the figures) are displaced, if required, across the display area and the substrates are overlaid with aligning color filters 15 with pixel electrodes 11.
This sandwich is sealed and the room between the substrates is filled with the liquid crystal 3 possessing negative dielectric anisotropy. Polarizers (not shown) are attached from outside.
The liquid crystal can be both chiral or non-chiral. To provide high contrast the liquid crystal spontaneous pitch should meet the following requirement d/p<0,5 (where d - is the liquid crystal layer thickness, p - is its spontaneous pitch.
Liquid crystal doped with a dichroic dye can be also used in the proposed method of manufacturing display. In such a case display can operate without polarizers and show information due to light absorption by dye molecules. Appropriate dyes can have dichroic ratio either bigger, or smaller that one, and both chiral and non-chiral liquid crystals are applicable.
Devices made with the proposed method can operate in reflective mode as well. In such a case one of the substrates and the electrode deposited on it are non-transparent (reflective). Image is obtained with the help of one polarizer.
The proposed device operates as following.
In the state without electric field liquid crystal molecules are aligned perpendicularly to the substrates across the whole display area (see Fig.l). Although relief 13 of one of the substrates distorts surface alignment of the liquid crystal, but this distortion has alternating character and remains on the microlevel. Because of this and also because of weak anchoring of the liquid crystal with the surface, these distortions do not exhibit themselves in optical properties of the liquid crystal device and in crossed polarizers it does not transmit the light. In electric field liquid crystal 3 reorients parallel to the substrates, and to minimize its surface distortions produced by the relief 13, liquid crystal simultaneously orients parallel or almost parallel to the grooves of the relief. With the electrode geometry shown in Fig.2 at the edges of the pixel electrodes 11 the molecules reorient with their bottom end towards the pixel center, i.e. in opposite directions at the opposite edges. Thus domains with different (including opposite) orientation of the liquid crystal within the pixel area are formed. Under various viewing angles different domains have different transmission and transmission of the whole pixel equals some average value. This explains how inversion of gray levels of the liquid crystal device under various observation angles
is reduced. The effect is similar to that observed in the known devices [WO 98/57222, WO 00/08521, S.-C. Lien].
The proposed methods was used to fabricate the substrates shown in Fig.2-6 and the liquid crystal display was assembled. The substrate thiclcness was 1 mm. The transparent electrode 4 was made of Indium Tin Oxide 70 nm thick with the surface resistivity 200 Ohm/α. The matrix described in [E.Kaneko, Liquid clystal TV dispays (KTK Scientific publishing, Tokyo), Chap.7] was made at the active matrix substrate. Insulating layer 12 pattern and the pattern of the pixel electrodes 11 are correspond to Fig.2,3, insulating layer having the thiclcness of 2 μm. Both substrates were covered with homeotropic aligning coating 6 AL-655 (JSR) 80 nm thick. On one of the substrates conventional plastic ball spacers with 3-4 μm diameter were deposited. The substrates were overlaid with the aligning coatings faced to each other and sealed with epoxy-based glue, like UHU plus endfest 300. The room between the substrates was filled with the liquid crystal MLC-6608 with negative dielectric anisotropy. Polarizers were attached to the outside faces of the glass substrates being aligned at 45° to the pixel edges and crossed to each other. Thus the manufactured device in the ON state forms 2 domains within each pixel with the liquid crystal oriented perpendicular to the long pixel sides and transmits 90-95%) of light in crossed polarizers (the light passing through the device in parallel polarizers is taken for 100% level).
The above analysis evidences that one can use traditional technology of manufacturing liquid crystal display and without any additional technological operations one can manufacture a device with wide viewing angle. The number of domains, their geometry and proportions can be easily varied by the relief pattern. In transmission mode such multidomain device is only 5-10% less bright that conventional monodomain devices. This drawback is insignificant for desk-top displays.
The scope of the claimed invention is not limited by the given examples.