Abstract:
A liquid crystal display has liquid crystal containerizing micro-cavities monolithically integrally formed as part of a thin film transistors substrate thereof where mouths of the micro-cavities are sealed shut by material of a capping layer and where the capping layer is patterned to have relatively thicker regions and comparatively thinner or devoid of capping material regions interposed between the thicker regions for thereby providing the capping layer with improved flexibility, the relatively thicker regions being disposed over the mouths of the microcavities.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to and the benefit of Korean Patent Application No. 10-2013-0109368 filed in the Korean Intellectual Property Office on Sep. 11, 2013, the entire contents of which application are incorporated herein by reference. 
       BACKGROUND 
       [0002]    (a) Field 
         [0003]    The present disclosure of invention relates to a liquid crystal display and a manufacturing method thereof. 
         [0004]    (b) Description of Related Technology 
         [0005]    The liquid crystal display (LCD) is one of the more widely used of the flat or otherwise thin panel displays. A typical LCD includes two spaced apart panels provided with field-generating electrodes such pixel electrodes and a common electrode, and a liquid crystal (LC) material layer interposed therebetween. 
         [0006]    The LCD produces images by applying voltages to the field-generating electrodes to generate an electric field passing through the LC layer, which then determines orientations of LC molecules in the LC layer and thereby adjusts polarization of incident light. The adjusted polarization is used to control degree of luminance of passed through and/or reflected light rays. 
         [0007]    A relatively new technology for containerizing the LC material includes forming a micro-cavity that is integrally provided as part of the cell unit of a corresponding pixel and filling the cavity with liquid crystal fluid. This technology typically includes the manufacturing steps of forming a sacrificial layer composed of an organic material and the like, forming a supporting member (roof member) on the sacrificial layer, removing the sacrificial layer to leave a space under stood the roof member, and filling the empty space formed through the removal of the sacrificial layer with liquid crystal through a liquid crystal injection hole. This monolithically integrated process has various advantages over the more traditional method of gluing an upper panel non-monolithically to a lower panel. 
         [0008]    Here, after injecting the liquid crystal, the liquid crystal injection hole may be capped (sealed closed) with a coating material and the like. However, that leaves the capping material in direct contact with the liquid crystal fluid at the mouth of the microcavity, such that there is a danger of contamination of the liquid crystal by the capping material or impurities disposed thereon. 
         [0009]    It is to be understood that this background of the technology section is intended to provide useful background for understanding the here disclosed technology and as such, the technology background section may include ideas, concepts or recognitions that were not part of what was known or appreciated by those skilled in the pertinent art prior to corresponding invention dates of subject matter disclosed herein. 
       SUMMARY 
       [0010]    The present disclosure of invention provides a liquid crystal display structured for reducing contamination of a liquid crystal (LC) thereof by capping mouths of corresponding LC-containerizing micro-cavities with a patterned capping layer, and a manufacturing method thereof. 
         [0011]    An exemplary embodiment provides a liquid crystal display including: a substrate; a thin film transistor disposed on the substrate; a pixel electrode connected to a terminal of the thin film transistor; a lower insulating layer disposed to face the pixel electrode; a roof layer disposed on the lower insulating layer; and a capping layer disposed on the roof layer, wherein a plurality of microcavities each having a respective liquid crystal injection holes are each being formed between the pixel electrode and the roof layer, the microcavities including liquid crystal materials, the capping layer being patterned to include a first region and a second region, where the liquid crystal injection holes being covered by capping material forming the capping layer in the first region, and the capping layer being opened at the second region corresponding to the roof layer and wherein the first region and the second region extend in parallel to one another. 
         [0012]    The first region and the second region may extend in a linear manner. 
         [0013]    The first region may overlap positions of the respective liquid crystal injection holes 
         [0014]    The capping layer may be patterned to have a plurality of spaced apart capping regions separated from each other by interposed ones of the second regions. 
         [0015]    The capping material forming the first region of the capping layer may include an organic material or an inorganic material. 
         [0016]    The capping material may include polyimide or polyacrylate. 
         [0017]    The liquid crystal display may further include a lower insulating layer disposed between the microcavity and the roof layer, and a common electrode disposed between the micro-cavity and the lower insulating layer. 
         [0018]    A liquid crystal injection holes forming region may be disposed between the microcavities, and a first region of the patterned capping layer covers the liquid crystal injection hole forming region. 
         [0019]    The liquid crystal injection hole forming region may be extended in a direction that is parallel to a gate line connected to the thin film transistor. 
         [0020]    The liquid crystal display may further include an overcoat layer disposed on the capping layer, wherein the overcoat layer covers a boundary of the first region and the second region. 
         [0021]    The present disclosure of invention also provides a method for manufacturing a liquid crystal display, including: forming a thin film transistor on a substrate; forming a pixel electrode to be connected to a terminal of the thin film transistor; forming a sacrificial layer on the pixel electrode; forming a lower insulating layer on the sacrificial layer; forming a roof layer on the lower insulating layer; forming a plurality of micro-cavities having a corresponding one or more liquid crystal injection holes by removing the sacrificial layer; injecting a liquid crystal material into the micro-cavities; forming a donor substrate including a support layer, a light-to-heat conversion layer disposed below the support layer, and a transfer layer disposed below the light-to-heat conversion layer; selectively disposing the donor substrate on the roof layer so as to thereby allow part of the transfer layer to cover the liquid crystal injection holes for example by using a laser-induced thermal imaging (LITI) method, and thus forming the patterned capping layer. 
         [0022]    The patterned capping layer may be formed to include a first region and a second region, the liquid crystal injection holes being covered by capping material forming the capping layer in the first region, and the capping layer being opened at the second region corresponding to the roof layer. 
         [0023]    The first region and the second region may be formed to be extended in a parallel manner. 
         [0024]    The first region and the second region may be formed to be extended in a linear manner. 
         [0025]    The first region may be formed to overlap an edge of the microcavity. 
         [0026]    The patterned capping layer may be formed to include a plurality of spaced apart capping regions separated from each other with corresponding second regions therebetween. 
         [0027]    The method further includes forming a common electrode between the sacrificial layer and the lower insulating layer. 
         [0028]    A liquid crystal injection hole forming region is disposed between the micro-cavities, and a first region of the capping layer is formed to cover the liquid crystal injection hole forming region. 
         [0029]    The liquid crystal injection hole forming region is formed to be extended in a direction that is parallel to a gate line connected to the thin film transistor. 
         [0030]    The method further includes forming an overcoat layer on the capping layer, wherein the overcoat layer is formed to cover a boundary of the first region and the second region. 
         [0031]    According to the exemplary embodiments of the present disclosure of invention, a degree of exposure of the injected liquid crystal material with a fluidic form of the capping material is reduced by using the laser-induced thermal imaging (LITI) method to thereby rapidly form the capping layer that covers the liquid crystal injection holes through the laser-induced thermal imaging (LITI) method, thereby minimizing danger of contamination of the liquid crystal by a fluidic form of the capping material. Additionally, the capping layer is made more flexible by virtue of it being patterned to have the thinned second regions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]      FIG. 1  shows a top plan view of a liquid crystal display according to an exemplary embodiment of the present disclosure. 
           [0033]      FIG. 2  shows a cross-sectional view with respect to a line II-II of  FIG. 1 . 
           [0034]      FIG. 3  shows a cross-sectional view with respect to a line III-III of  FIG. 1 . 
           [0035]      FIG. 4  to  FIG. 16  show cross-sectional views of a method for manufacturing a liquid crystal display according to an exemplary embodiment in accordance with the present disclosure of invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Exemplary embodiments in accordance with the present disclosure of invention will now be described in more detail with reference to the accompanying drawings. However, the present disclosure is not limited to the exemplary embodiments used herein and may be implemented in other forms. In addition, exemplary embodiments introduced herein are disposed to make disclosed contents thorough and complete, and to sufficiently transfer the spirit of the present teachings to those skilled in the art. 
         [0037]    In the drawings, the thickness of layers, films, panels, regions, etc., are exaggerated for clarity. It will be understood that when a layer is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening them may also be present. Like reference numerals designate like elements throughout the specification. 
         [0038]      FIG. 1  shows a top plan view of a liquid crystal display according to an exemplary embodiment.  FIG. 2  shows a cross-sectional view with respect to a line of  FIG. 1 .  FIG. 3  shows a cross-sectional view with respect to a line of  FIG. 1 . 
         [0039]    Referring to  FIG. 1  to  FIG. 3 , a gate line  121  and a storage electrode line  131  are formed on an insulating substrate  110  formed of a light-passing material such as a transparent glass or a plastic. The gate line  121  includes a gate electrode  124  branching therefrom. The storage electrode line  131  is mainly extended in a horizontal direction of the drawing, and transfers a predetermined voltage such as a common voltage (Vcom). The storage electrode line  131  includes a pair of vertical portions  135   a  substantially extended to be perpendicular to the gate line  121   a , and a horizontal portion  135   b  connecting ends of the pair of vertical portions  135   a  to each other. The storage electrodes  135   a  and  135   b  wrap about a transparent pixel electrode  191 . 
         [0040]    A gate insulating layer  140  is formed on the gate line  121  and on the storage electrode line  131   
         [0041]    A first semiconductive layer portion  151  is positioned at a lower portion of a data line  171 , and a second semiconductive layer portion  154  is positioned at a lower portion of opposed source/drain electrodes having a channel portion defined therebetween such that a thin film transistor (Q) is formed on the gate insulating layer  140 . 
         [0042]    A plurality of ohmic contacts may be formed on each of the semiconductor layers  151  and  154 , and between the data line  171  and the respective source/drain electrode, but they are omitted in the drawings to avoid illustrative clutter. 
         [0043]    Data conductors  171 ,  173 , and  175  including a source electrode  173 , the data line  171  connected with the source electrode  173 , and a drain electrode  175  are formed on each of the semiconductive layer portions  151  and  154  and on the gate insulating layer  140 . 
         [0044]    The gate electrode  124 , the source electrode  173 , and the drain electrode  175  form parts of the thin film transistor (Q) together with the semiconductive layer portion  154 , where the channel of the thin film transistor Q is formed on the semiconductive layer portion  154  between the source electrode  173  and the drain electrode  175 . 
         [0045]    A first interlayer insulating layer  180   a  is formed on the data conductors  171 ,  173 , and  175 , and an exposed portion of the semiconductive layer portion  154 . The first interlayer insulating layer  180   a  may include an inorganic insulating material, such as a silicon nitride (SiNx) and a silicon oxide (SiOx), or an organic insulating material. 
         [0046]    A color filter  230  and a light blocking member ( 220   a  and  220   b ) are formed on the first interlayer insulating layer  180   a.    
         [0047]    In one embodiment, the light blocking member ( 220   a  and  220   b ) has a lattice or matrix structure having respective openings corresponding to light controlling regions (aperture regions) used for displaying a desired image. The light blocking member (e.g., black matrix) may be formed of an opaque and/or reflective material suitable for preventing light from being transmitted therethrough. The color filter  230  is formed within the opening of the light blocking member ( 220   a  and  220   b ). The light blocking member ( 220   a  and  220   b ) includes a horizontal light blocking member portion  220   a  formed to extend in a direction parallel to the gate line  121  and a vertical light blocking member portion  220   b  formed to extend in a direction parallel to the data line  171 . 
         [0048]    The color filter  230  may display one of primary colors, such as the three primary colors red, green, and blue. However, the colors are not limited to red, green, and blue, and the color filter  230  may also display one among a cyan-based color, a magenta-based color, a yellow-based color, and a white-based or clear color. The color filter  230  may be formed of a material displaying different colors for each adjacent pixel. 
         [0049]    A second interlayer insulating layer  180   b  covering the color filter  230  and the light blocking member  220  is formed on the color filter  230  and the light blocking member  220 . The second interlayer insulating layer  180   b  may include an inorganic insulating material, such as a silicon nitride (SiNx) and a silicon oxide (SiOx), or an organic insulating material. Contrary to the illustration in the cross-sectional view of  FIG. 2 , in a case where a surface step is generated due to a difference in thickness between the color filter  230  and the light blocking member  220 , the second interlayer insulating layer  180   b  includes a planarized organic insulating material, so that it is possible to decrease or remove the step. 
         [0050]    A contact hole  185  through which the drain electrode  175  is exposed is formed in the color filter  230 , the light blocking member  220 , and the interlayer insulating layers  180   a  and  180   b.    
         [0051]    The pixel electrode  191  is positioned on the second interlayer insulating layer  180   b . The pixel electrode  191  may be formed of a transparent conductive material such as ITO or IZO. 
         [0052]    An entire general shape of the pixel electrode  191  may be a quadrangle as illustrated, and may include in its details a cross-shaped stem portion including a horizontal stem portion  191   a  and a vertical stem portion  191   b  crossing the horizontal stem portion  191   a . Further, the pixel electrode  191  is divided into four sub-regions by the horizontal stem portion  191   a  and the vertical stem portion  191   b , and each sub-region includes a plurality of micro-branch portions  191   c . Also, the pixel electrode  191  may further include an outer stem portion surrounding an outer side of the pixel electrode  191 . 
         [0053]    The micro-branch portion  191   c  of the pixel electrode  191  forms an angle of approximately 40 degrees to 45 degrees with respect to the gate line  121  or the horizontal stem portion  191   a . The micro-branch portions of the adjacent two sub regions may be orthogonal to each other. A width of the micro-branch portion is gradually increased, or intervals between the micro-branch portions  191   c  may be different from each other. 
         [0054]    The pixel electrode  191  includes an extended portion  197  connected at a lower end of the vertical stem portion  191   b  and having a wider area than that of the vertical stem portion  191   b , is physically and electrically connected with the drain electrode  175  through the contact hole  185  at the extended portion  197 , and receives a data voltage from the drain electrode  175 . 
         [0055]    The description of the aforementioned thin film transistor Q and pixel electrode  191  is one example, and a structure of the thin film transistor and a design of the pixel electrode may be modified in order to achieve various design goals such as to differently improve side visibility. 
         [0056]    A lower alignment layer  11  is formed on the pixel electrode  191 , and the lower alignment layer  11  may be a vertical alignment layer. The lower alignment layer  11  can be formed inclusive of at least one of generally-used materials such as polyamic acid, polysiloxane, or polyimide used for the a liquid crystal alignment layer. 
         [0057]    An upper alignment layer  21  is positioned at a portion facing the lower alignment layer  11 , and a microcavity  305  is formed between the lower alignment layer  11  and the upper alignment layer  21 . A liquid crystal material including liquid crystal molecules  310  is injected in the microcavity  305  through a mouth of the microcavity which is referred to here as the liquid crystal injection hole  307 . The microcavity  305  may be formed along a column direction, that is, a vertical direction, of the pixel electrode  191 . An alignment material forming the alignment layers  11  and  21  and the liquid crystal material including the liquid crystal molecules  310  may be injected into the microcavity  305  by using capillary force. 
         [0058]    The microcavities  305  are distributed along a horizontal direction and along sidewalls of a trough like region referred to here as the liquid crystal injection holes forming region  307 FP which is positioned at a portion overlapping the gate line  121 , and may be plural along the direction in which the gate line  121  is extended. Each of the plurality of formed microcavities  305  may correspond to a respective pixel area, and the pixel area may correspond to an aperture region controlling light passing therethrough for accordingly displaying a desired image. 
         [0059]    A common electrode  270  and a lower insulating layer  350  are positioned on the upper alignment layer  21 . The common electrode  270  receives the common voltage (Vcom), and generates an electric field together with the pixel electrode  191  to which the data voltage is applied to determine a direction in which the liquid crystal molecules  310  positioned within the microcavity  305  between the two electrodes are inclined. The common electrode  270  forms a capacitor with the pixel electrode  191  to maintain the received voltage even after the thin film transistor is turned off. The lower insulating layer  350  may be formed of a silicon nitride (SiNx) or a silicon oxide (SiOx). 
         [0060]    In the present exemplary embodiment, it is described that the common electrode  270  is monolithically integrated formed on top of the microcavity  305 . But in another exemplary embodiment, the common electrode  270  may be formed at a lower portion of the microcavity  305 , so that liquid crystal driving according to a horizontal electric field mode is possible. 
         [0061]    A roof layer  360  is positioned on the lower insulating layer  350 . The roof layer  360  serves to make a support so that the microcavity  305 , which is a space between the pixel electrode  191  and the common electrode  270 , is formed. The roof layer  360  may include a photoresist or other organic materials. 
         [0062]    An upper insulating layer  370  is positioned on the roof layer  360 . The upper insulating layer  370  may be in contact with an upper surface of the roof layer  360 . The upper insulating layer  370  may be formed of a silicon nitride (SiNx) or a silicon oxide (SiOx). 
         [0063]    The capping layer  390  may be disposed in the liquid crystal injection holes forming region  307 FP and may cover the corresponding liquid crystal injection holes  307  of the respective microcavities  305  that during manufacture exposed by the liquid crystal injection holes along the sidewalls of the trough-forming region  307 FP. The capping layer  390  is patterned so as to be differentiated into a first region  390   a  of a raised nature and a second region  390   b  of a reduced or devoid nature (essentially devoid of the capping material). The first region  390   a  includes the liquid crystal injection hole forming region  307 FP and overlaps an edge of the microcavity  305 . In other words, the first region  390   a  represents a part for a capping material to cover and seal closed the liquid crystal injection holes  307 . The second region  390   b  is not covered by the capping material (or has a substantially reduced amount of such material) and does not have corresponding liquid crystal injection holes  307 . That is, the capping layer  390  is patterned so as not to be disposed in an entire region of an upper side of the upper insulating layer  370  but rather to have thinned or devoid portions which allow for flexibility. 
         [0064]    The first region  390   a  of the capping layer  390  is disposed in a lengthy (elongated) manner in a direction in which the trough-like, liquid crystal injection hole forming region  307 FP is extended at a part that corresponds to the interior sidewalls of the liquid crystal injection hole forming region  307 FP. The first region  390   a  includes a plurality of capping regions that are spaced apart from each other by the interposition of second regions  390   b  therebetween. As shown in  FIG. 1 , the first region  390   a  and the second region  390   b  can be linearly extended in a direction in which the gate line  121  is extended in a parallel manner. 
         [0065]    The capping layer  390  includes an organic material or an inorganic material. The capping layer  390  may include a polyimide or a polyacrylate. 
         [0066]    An overcoat layer  395  formed with an inorganic layer or an organic layer can be disposed on the capping layer  390 . The overcoat layer  395  protects the liquid crystal molecules  310  injected into the microcavity  305  from external impacts and flattens (provides improved planarity to) the layer. The overcoat layer  395  can be an organic material or an inorganic material. The organic material can be polymethylmethacrylate (PMMA), polystyrene (PS), polymer derivatives having phenol groups, acryl polymers, imide polymers, arylether polymers, amide polymers, fluorine polymers, p-xylene polymers, vinyl alcohol polymers, and a material that is a combination thereof. When the overcoat layer  395  is an inorganic material, it can be a material made of a silicon oxide (SiOx), a silicon nitride (SiNx), aluminum oxide (Al2O3), titanium oxide (TiO2), tantalum oxide (Ta2O5), hafnium oxide (HfO2), zirconium oxide (ZrO2), or a combination thereof. 
         [0067]    As shown in  FIG. 3 , a partition wall portion (PWP) is formed between the sets of microcavities  305  neighboring one another in the horizontal direction. The partition wall portion (PWP) can be formed in a direction in which the data line  171  is extended, and it can be covered by the roof layer  360 . The lower insulating layer  350 , the common electrode  270 , and the roof layer  360  are disposed in the partition wall portion (PWP), which forms a partition wall, and thus partitions or defines the separation between respective sets of the microcavities  305 . There is provided a partition wall structure such as the partition wall portion (PWP) between the sets of the microcavities  305  so when the insulation substrate  110  is bent, less stress is generated and a change of a cell gap is much reduced. 
         [0068]    A polarizer (not shown) is disposed at a bottom of the insulation substrate  110  and a top of the upper insulating layer  370 . The polarizer can include a polarization element for generating polarization and a tri-acetyl-cellulose (TAG) layer for acquiring durability, and depending on the exemplary embodiment, directions of transmissive axes of an upper polarizer and a lower polarizer can be perpendicular or parallel. 
         [0069]    Referring to  FIG. 4  to  FIG. 16 , a method for manufacturing the above-described liquid crystal display according to an exemplary embodiment will now be described. The exemplary embodiment to be described below is an exemplary embodiment of a manufacturing method and is changeable into other forms consistent with the present teachings. 
         [0070]      FIG. 4  to  FIG. 16  show cross-sectional views of a method for manufacturing a liquid crystal display according to an exemplary embodiment in accordance with the present teachings.  FIGS. 4 ,  6 ,  8 ,  10 ,  11 ,  13 ,  15 , and  16  sequentially show cross-sectional views with respect to a line II-II of  FIG. 1 .  FIGS. 5 ,  7 ,  9 ,  12 , and  14  show cross-sectional views with respect to a line III-III of  FIG. 1 . 
         [0071]    Referring to  FIG. 1 ,  FIG. 4 , and  FIG. 5 , to form a general switching element on the substrate  110 , a gate line  121  extended in the horizontal direction is formed on the substrate, a gate insulating layer  140  is formed on the gate line  121 , semiconductive layer portions  151  and  154  are formed on the gate insulating layer  140 , and a source electrode  173  and a drain electrode  175  are formed. In this instance, a data line  171  connected to the source electrode  173  can be formed to cross the gate line  121  and be extended in the vertical direction. 
         [0072]    A first interlayer insulating layer  180   a  is formed on the data conductors  171 ,  173 , and  175  including the source electrode  173 , the drain electrode  175 , and the data line  171  and the exposed semiconductive layer portion  154 . 
         [0073]    A color filter  230  is formed at a position that corresponds to a pixel area on the first interlayer insulating layer  180   a , and a light blocking member  220  is formed in boundary areas of the color filter  230 . 
         [0074]    A second interlayer insulating layer  180   b  is formed on the color filter  230  and the light blocking member  220  to cover them, and the second interlayer insulating layer  180   b  is formed to have a contact hole  185  extending therethrough for electrically and physically connecting the pixel electrode  191  and the drain electrode  175 . 
         [0075]    A pixel electrode  191  is formed on the second interlayer insulating layer  180   b , and a sacrificial layer  300  is formed on the pixel electrode  191 . As shown in  FIG. 5 , an opening (OPN) is formed in the sacrificial layer  300  in a direction that is parallel to the data line  171 . The opening (OPN) is filled with the common electrode  270 , the lower insulating layer  350 , the roof layer  360  material, and the upper insulating layer  370  to thereby form a partition wall portion (PWP) as shown in  FIG. 7 . 
         [0076]    Referring to  FIG. 6  and  FIG. 7 , a common electrode  270 , a lower insulating layer  350 , and a roof layer  360  are sequentially formed on the sacrificial layer  300 . The roof layer  360  can be eliminated from a region that corresponds to the light blocking member  220  disposed between the pixel areas neighboring in the vertical direction by an exposure and development process. The roof layer  360  exposes the lower insulating layer  350  at the region that corresponds to the light blocking member  220 . In this instance, the common electrode  270 , the lower insulating layer  350 , and the roof layer  360  fill the opening (OPN) of the vertical light blocking member  220   b  and form the partition wall portion (PWP). 
         [0077]    Referring to  FIG. 8  and  FIG. 9 , an upper insulating layer  370  is formed to cover the roof layer  360  and the exposed lower insulating layer  350 . 
         [0078]    Referring to  FIG. 10 , the upper insulating layer  370 , the lower insulating layer  350 , and the common electrode  270  are dry-etched to partially remove the upper insulating layer  370 , the lower insulating layer  350 , and the common electrode  270  and thereby form a liquid crystal injection holes forming region  307 FP. In this instance, the upper insulating layer  370  may have a structure for covering a side of the roof layer  360 , and without being restricted to this, it is also possible to have the side of the roof layer  360  exposed to the outside by removing the upper insulating layer  370  covering the side of the roof layer  360 . 
         [0079]    Referring to  FIG. 11  and  FIG. 12 , the sacrificial layer  300  is selectively removed where exposed through the liquid crystal injection holes forming region  307 FP by for example performing an oxygen ( 02 ) ashing process or a wet etching process. In this instance, a corresponding microcavity  305  having a liquid crystal injection hole  307  is formed. The microcavity  305  is an empty space from which the sacrificial layer  300  has been eliminated. 
         [0080]    Referring to  FIG. 13  and  FIG. 14 , an alignment material is injected (e.g., absorbed by surface capillary action) through the liquid crystal injection hole  307  to form alignment layers  11  and  21  on the pixel electrode  191  and the common electrode  270 . In detail, the alignment material including a solid content and a solvent is injected through the liquid crystal injection hole  307  and a bake process is then performed to selectively remove the solvent while leaving the solidified alignment material adhered to the interior surfaces of the microcavity  305 . 
         [0081]    A liquid crystal material including liquid crystal molecules  310  is next injected into the microcavity  305  through the liquid crystal injection hole  307  for example by using an inkjet method. 
         [0082]    Referring to  FIG. 15 , a donor substrate  500  including a support layer  510 , a light-to-heat conversion layer  520  disposed below the support layer  510 , and a transfer layer  390   p  below the light-to-heat conversion layer  520  are disposed as shown relative to the in-process substrate. 
         [0083]    The support layer  510  may include a material with high optical transmittance such as a transparent polymer material, for example, glass, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyethylene (PE), or polycarbonate (PC). 
         [0084]    The light-to-heat conversion layer  520  converts incident light into heat, and it may include a metal material with a great absorption rate, for example, chromium (Cr), molybdenum (Mo), titanium (Ti), tungsten, aluminum oxide, aluminum sulfide, or an alloy thereof. Further, a light absorbing layer  120  may include carbon (C) or an infrared dye. 
         [0085]    The transfer layer  390   p  becomes selectively separated from the support layer  510  by local development of thermal energy when locally subjected by the light-to-heat conversion layer  520  to such thermal energy, and is thus locally and selectively transferred to the substrate portion that is its transfer target. The transfer layer  390   p  can include a capping material. 
         [0086]    As shown in  FIG. 15 , a donor substrate  500  is disposed to face the liquid crystal display according to the present exemplary embodiment. Patterned laser beams can be irradiated along the position that corresponds to a first region  390   a  of the capping layer by using a laser-induced thermal imaging (LITI) method. The patterned laser beams correspond to the part in which the liquid crystal injection hole forming region  307 FP is formed. On the other hand, the laser beams are not irradiated to the portions corresponding to the so-called, second regions (e.g., devoid or substantially thinner regions)  390   b  of the capping layer. 
         [0087]    Referring to  FIG. 16 , the laser-induced thermal imaging (LITI) method is applied to cover the liquid crystal injection hole forming region  307 FP and form the patterned capping layer  390 . When laser energy is applied to the light-to-heat conversion layer  520  by the laser-induced thermal imaging (LITI) method, the light-to-heat conversion layer  520  is expanded, the transfer layer  390   p  is expanded, and the transfer layer  390   p  is separated from the support layer  510  of the donor substrate  500  so the transfer layer  390   p  is transferred to cover the liquid crystal injection hole  307  of the liquid crystal display and the liquid crystal injection hole forming region  307 FP. The laser-induced thermal imaging (LITI) method rapidly forms the capping layer  390  comparing with a coating and a curing after the coating. Therefore, the LITI method may reduce a danger of contamination of the liquid crystal. 
         [0088]    Here, a first region  390   a  of the capping layer  390  can be formed such that the transfer layer  390   p  may be transferred to overlap an edge of where the liquid crystal injection hole(s)  307  are present. Further, the reduced or zero thickness second regions  390   b  can be interposed between adjacent ones of the first regions  390   a  so as to subdivide the capping layer  390  into a plurality of relatively thick capping regions in the first regions  390   a  and substantially thinner or devoid second regions  390   b  so as to thereby provide for improved flexibility and/or stress relief. 
         [0089]    While the present disclosure of invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the present teachings are not limited to the disclosed embodiments, but, on the contrary, they are intended to cover various modifications and equivalent arrangements included within the spirit and scope of the present teachings.