ARRAY SUBSTRATE AND METHOD OF MANUFACTURING THE SAME, DISPLAY PANEL AND DISPLAY DEVICE

An array substrate and a manufacturing method thereof, a display panel and a display device are provided. The array substrate includes a plurality of pixel units, at least some of which respectively having a reflective region provided with a reflective layer in a concave-convex shape, wherein a first insulating layer is disposed on a light reflecting side of the reflective layer, and a surface of the first insulating layer adjacent to the reflective layer is in a concave-convex shape conforming to the concave-convex shape of the reflective layer, and a surface of the first insulating layer away from the reflective layer is a planar surface; the at least some of the pixel units further respectively comprise a first electrode and a second electrode which are oppositely disposed in different layers and are spaced apart from each other, and the first electrode is disposed on a side of the first insulating layer away from the reflective layer.

TECHNICAL FIELD

Embodiments of the present disclosure relate to a technical field of display technologies, and in particular, to an array substrate and a method of manufacturing the same, a display panel and a display device.

BACKGROUND

A liquid crystal display panel of a reflective type or a transflective type has a reflective region in a pixel structure thereof, and a portion of the array substrate corresponding to the reflective region has a reflective layer to reflect external light. In a liquid crystal display panel of the reflective type or the transflective type in the related art, in order to improve reflection efficiency of the reflective region, the reflective layer in the array substrate is configured to be in a concave-convex structure. However, such a structure causes electrodes above the reflective layer to be disposed on a concave-convex surface, so that an electric field formed in the liquid crystal display panel is distorted, thereby causing the liquid crystal molecules to be deflected abnormally, reducing the transmittance of the light emitted out of the reflective region, and resulting in that the reflective region fail to achieve a desired brightness, which adversely affects the display effect of the liquid crystal display panel.

SUMMARY

One of the purposes of the present disclosure is to provide an array substrate and a method of manufacturing the same, a display panel and a display device.

According to an aspect of the present disclosure, there is provided an array substrate comprising a plurality of pixel units, at least some of which respectively having a reflective region provided with a reflective layer in a concave-convex shape, wherein a first insulating layer is disposed on a light reflecting side of the reflective layer, and a surface of the first insulating layer adjacent to the reflective layer is in a concave-convex shape conforming to the concave-convex shape of the reflective layer, and a surface of the first insulating layer away from the reflective layer is a planar surface; the at least some of the pixel units further respectively comprise a first electrode and a second electrode which are oppositely disposed in different layers and are spaced apart from each other, and the first electrode is disposed on a side of the first insulating layer away from the reflective layer.

According to an embodiment of the present disclosure, the first electrode is a comb electrode and the second electrode is a plate electrode.

According to an embodiment of the present disclosure, the array substrate further comprises a second insulating layer disposed on a side of the reflective layer away from the first insulating layer, the surface of the second insulating layer adjacent to the reflective layer is in a concave-convex shape conforming to the concave-convex shape of the reflective layer.

According to an embodiment of the present disclosure, the second electrode is disposed on a side of the reflective layer away from the first insulating layer.

According to an embodiment of the present disclosure, the second electrode is disposed between the reflective layer and the second insulating layer, and the second electrode is in a concave-convex shape conforming to the concave-convex shape of the reflective layer.

According to an embodiment of the present disclosure, the second electrode is disposed on a side of the second insulating layer away from the reflective layer.

According to an embodiment of the present disclosure, the second electrode is disposed on a side of the reflective layer away from the second insulating layer and is a transparent electrode.

According to an embodiment of the present disclosure, the second electrode is disposed between the reflective layer and the first insulating layer, and the second electrode is in a concave-convex shape conforming to the concave-convex shape of the reflective layer.

According to an embodiment of the present disclosure, the second electrode is disposed between the first electrode and the first insulating layer, a third insulating layer is disposed between the second electrode and the first electrode, and the second electrode extends in a plane parallel to a planar surface of the first insulating layer.

According to an embodiment of the present disclosure, the second electrode is formed integrally with the reflective layer.

According to an embodiment of the present disclosure, one of the first electrode and the second electrode is a pixel electrode, and the other of the first electrode and the second electrode is a common electrode.

According to an embodiment of the present disclosure, the at least some of the pixel units further respectively comprise a transmissive region, the transmissive region not including the reflective layer.

According to an embodiment of the present disclosure, each of the pixel units comprises a reflective region.

According to another aspect of the present disclosure, there is provided a method of manufacturing an array substrate, the array substrate comprising a plurality of pixel units, at least some of which respectively having a reflective region, the method comprising at least: forming a reflective layer in a concave-convex shape in the reflective region; forming a first insulating layer on a light reflecting side of the reflective layer; performing a planarization process a surface of the first insulating layer away from the reflective layer to form a planar surface; and forming a first electrode on a side of the first insulating layer away from the reflective layer, the first electrode extending on the planar surface of the first insulating layer.

According to an embodiment of the present disclosure, the method further comprises forming a second insulating layer before forming the reflective layer; patterning the second insulating layer such that a surface of the second insulating layer adjacent to a subsequently formed reflective layer is in a concave-convex shape; forming the reflective layer on a side of the second insulating layer in a concave-convex shape such that the reflective layer is also in a concave-convex shape.

According to an embodiment of the present disclosure, the planarization process is chemical mechanical polishing.

According to an embodiment of the present disclosure, disposing the second electrode on a side of the reflective layer away from the first insulating layer, or configuring the second electrode as a transparent electrode and disposing the second electrode on a side of the reflective layer away from the second insulating layer.

According to another aspect of the present disclosure, there is provided a display panel comprising: the array substrate mentioned above.

According to another aspect of the present disclosure, there is provided a display device comprising the display panel mentioned above.

According to an embodiment of the present disclosure, a depth of the planarization process to the surface of the first insulating layer away from the reflective layer is less than a thickness of the first insulating layer.

DETAILED DESCRIPTION OF EMBODIMENTS

The embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. It is to be understood that the following description of the embodiments is intended to be illustrative. In the specification and the drawings, the same or similar reference numerals are used to refer to the same or similar components or members. For the sake of clarity, the drawings are not necessarily drawn to scale, and some of the known components and structures may be omitted in the drawings.

Unless otherwise defined, technical or scientific terms used in the present disclosure shall be of ordinary meaning as understood by those skilled in the art. The words “first” “second” and similar terms used in the present disclosure do not denote any order, quantity, or importance, but are used to distinguish different components. The words “a” or “an” don't exclude a plurality. The words “including” or “comprising” and the like, are intended to mean that the elements or items that appear before such words cover the elements or items and the like which are listed after such words and don't exclude other elements or items. The words “connected” or “coupled” and the like are not limited to physical or mechanical connections, but may include electrical connections, regardless directly or indirectly. “Upper”, “lower”, “left”, “right”, “top” or “bottom” and the like are only used to indicate relative positional relationship. When absolute position of the object to be described is changed, the relative positional relationship may also be changed correspondingly. When an element such as a layer, a film, a region or a substrate is referred to as being “on”, “above” or “below” or “under” another element, the element can be “directly” on or under the other element, or there may be intermediate elements.

In the present disclosure, when referring to formation a “normal” electric field between two electrodes, it means that the electric field is formed in a situation that the two electrodes are in two parallel planes and the layers between the two electrodes are planar layer. Under the action of the “normal” electric field, long axes of the liquid crystal molecules are in a plane parallel to the two electrodes, and such a deflection of the liquid crystal molecules is called “normal” deflection of the liquid crystal molecules, so that the display panel displays pictures “normally”. In contrast, if a “normal” electric field is not formed between the two electrodes, the electric field formed between the two electrodes is referred to as “distorted”, at which time long axes of at least some of the liquid crystal molecules are not parallel to the plane in which the electrodes are located.

In the present disclosure, a “concave-convex shape” refers to a non-planar shape, surface of which has undulations. A surface in a concave-convex shape is referred to as a “concave-convex surface”. In the case where an upper surface and a lower surface of one layer are both concave-convex surfaces, the degree and manner of undulation in the two concave-convex surfaces may be the same, at which time such a layer has a substantially constant thickness. The degree and manner of undulation in a concave-convex surface can vary. The degree of undulation refers to difference in height between a peak and a valley on the concave-convex surface, which may be, for example, 10% to 200% of the thickness of the layer having a concave-convex surface. The concave-convex surface may be concave and convex in one dimension in the surface and be planar in another dimension perpendicular the one dimension, or may be concave and convex in both dimensions. A cutting line of the concave-convex surface which is substantially perpendicular to the surface may be in a zigzag shape or a wavy shape, especially in a triangular function curve shape, or may be, for example, in a periodic conical curve shape, or in a shape or other shape similar to these shapes. In the case where one layer has a concave-convex surface and is in close contact with a surface of another layer by the concave-convex surface, the surface of the another layer generally also has a concave-convex surface conforming to the concave-convex surface of said one layer, or the another layer is in a concavo-convex shape that conforms to the concavo-convex shape of the one layer.

In the present disclosure, a “planar surface” as with respect to a “concave-convex surface” refers to a planar or substantially planar surface. There may be slight undulations in the planar surface, or there may be coarse structures, in which case the height difference between the peaks and valleys of the planar surface is typically less than, for example, 10%, especially less than 5%, of the thickness of the layer having the planar surface.

FIG. 1shows a structural schematic view of an array substrate100of a liquid crystal display panel of the reflective type according to an exemplary embodiment of the present disclosure. As shown inFIG. 1, the array substrate100includes, in an order from bottom to top inFIG. 1, a base substrate101, a second insulating layer102, a second electrode103, a reflective layer104, a first insulating layer105and a first electrode106. One of the first electrode106and the second electrode103is a pixel electrode, and the other of the first electrode106and the second electrode103is a common electrode.

The base substrate101may be, for example, a planar glass substrate on which a TFT element film layer may be formed for supplying a driving voltage to the first electrode106or the second electrode103. The second insulating layer102is disposed on the base substrate101, and an upper surface102aof the second insulating layer102is in a concavo-convex shape. The second electrode103above the second insulating layer102is a plate-shaped electrode and has a uniform thickness, and a lower surface of the second electrode103is in a concavo-convex shape conforming to the concavo-convex shape of the upper surface of the second insulating layer102. The reflective layer104above the second electrode103has a uniform thickness, and the reflective layer104is also in a concavo-convex shape that conforms to the concavo-convex shape of the upper surface of the second insulating layer102. Here, the concavo-convex shape of the reflective layer104may be any structure capable of enhancing the reflectance of the reflective layer to light, such as a zigzag shape, a wavy shape, or the like. The first insulating layer105is disposed above the reflective layer104. A lower surface105bof the first insulating layer105is in a concavo-convex shape that conforms to the concavo-convex shape of the reflective layer104. An upper surface105aof the first insulating layer105is formed as a planar surface. The first electrode106is a comb electrode and is formed on the planar surface, i.e., the upper surface105aof the first insulating layer105, and the first electrode106extends on the planar surface of the first insulating layer105.

According to this embodiment, the second electrode103is disposed on a side of the second insulating layer102adjacent to the reflective layer104, the second electrode103is disposed below the reflective layer104, and the second electrode103is disposed to abut against the reflective layer104. Therefore, the second electrode103does not adversely affect the reflectance of the reflective layer104, and the thickness of the array substrate is relatively small.

FIGS. 2A-2Cshow schematic views of a manufacturing process of the array substrate shown inFIG. 1. As shown inFIG. 2A, firstly, a base substrate101is provided, which may include a TFT film layer; an insulating layer (second insulating layer)102, e.g. a photoresist layer, is laid on the base substrate101. The upper surface102aof the second insulating layer102is formed into a concavo-convex shape by, for example, a molding process. Next, a second electrode layer is deposited on the second insulating layer102, whose upper surface is in a concavo-convex shape, by for example a sputtering process, and then is patterned to form the second electrode103. The material of the second electrode may be a metal or an alloy. Next, the reflective layer104is deposited on the second electrode103by, for example, a sputtering process. The material of the reflective layer104may be a metal such as silver that has a function to reflect lights. Next, a transparent insulating layer (i.e. the first insulating layer)105is deposited on the reflective layer104, for example, by a chemical vapor phase process. The first insulating layer is made of a transparent material. The second electrode103, the reflective layer104, and the first insulating layer105are deposited respectively, each of which has a uniform thickness, such that the upper and lower surfaces of the second electrode103, the reflective layer104, and the first insulating layer105are also in a concave-convex shape conforming to the shape of the upper surface of the second insulating layer102. A height h of the concavo-convex shape of the upper surface of the first insulating layer105(a vertical height between the highest point and the lowest point of the concave-convex surface) should be smaller than the thickness H of the first insulating layer105.

Thereafter, as shown inFIG. 2B, the upper surface105aof the first insulating layer105is ground to become a planar surface, for example, by a chemical mechanical grinding process. In order to ensure that the concave-convex structure on the upper surface105aof the first insulating layer105is entirely removed, the grinding should be performed to the first insulating layer105by a depth greater than h and less than H. In addition, the remaining portion of the first insulating layer after being ground is configured to ensure that the first insulating layer105covers the entire reflective layer104in the concavo-convex shape. Note that the process of planarizing the upper surface of the first insulating layer105is not limited to the chemical mechanical grinding process. It is possible to employ other planarization processes, which are not limited herein.

Next, as shown inFIG. 2C, a transparent electrode layer of uniform thickness, e.g. an ITO layer, is deposited on the first insulating layer105having a upper surface105ain a planar shape, and then the first electrode106in a comb-shape is formed with a patterning process. Since the first electrode106is formed on the planar upper surface105aof the first insulating layer105, the first electrode106extends on the planar upper surface of the first insulating layer105. Therefore, the first electrode106as well as the second electrode below103it cooperate to form a substantially normal electric field, which prevents electric field distortion.

FIG. 3shows a structural schematic view of the liquid crystal display panel of the reflective type1including the array substrate100shown inFIG. 1. As shown inFIG. 3, the liquid crystal display panel of the reflective type1includes the array substrate100as shown inFIG. 1and a color filter substrate150disposed opposite to the array substrate100, and a liquid crystal layer between the array substrate100and the color filter substrate150. The liquid crystal layer160contains a plurality of liquid crystal molecules160atherein. A distribution of electric power lines L in the electric field formed between the first electrode106and the second electrode103is shown inFIG. 3. As shown inFIG. 3, a substantially normal electric field is formed between the first electrode106and the second electrode103, and the liquid crystal molecules160aabove the array substrate100are normally deflected in a horizontal electric field, and the long axes of the liquid crystal molecules are arranged in a direction parallel to the array substrate100and the color filter substrate150, so that the display panel1may normally display pictures. Moreover, since the reflective layer104is in a concavo-convex shape, light reflectance may be increased, thereby increasing the display brightness of the display panel.

In comparison,FIG. 7shows a structural schematic view of a liquid crystal display panel of the reflective type10as an alternative example. The liquid crystal display panel10shown inFIG. 7has a structure similar to that of the liquid crystal display panel shown inFIG. 3, except that the upper surface of the first insulating layer105′ is in a concavo-convex shape conforming to the concavo-convex shape of the reflective layer104. In this case, the comb-shaped first electrode106′ is distributed on the upper surface105a′ of the first insulating layer105′ in the concavo-convex shape, and parts of the first electrode106′ at different locations thereof forms different inclined angles with respect to the base substrate101, thereby the electric fields generated by the first electrodes106and the second electrode103are mutually interfered, so that the liquid crystal molecules160amay not be deflected normally, thereby reducing the transmittance of the light, resulting in uneven distribution of brightness of the display panel. In other words, although the concave-convex surface of the reflective layer104may increase the reflectance of the light, it reduces the light transmittance and thus may not increase the brightness of the display panel.

FIG. 4shows a structural schematic view of an array substrate of a liquid crystal display panel of the reflective type200according to another exemplary embodiment of the present disclosure. As shown inFIG. 4, the array substrate200includes, in an order from bottom to top inFIG. 4, a base substrate201, a second electrode203, a second insulating layer202, a reflective layer204, a first insulating layer205, and the first electrodes206.

In the embodiment shown inFIG. 4, a second insulating layer202is disposed between the second electrode203and the reflective layer204. The second electrode203is disposed on a side of the second insulating layer202away from the reflective layer203. The second electrode203deposited on the planar base substrate201is a plate electrode and has a uniform thickness. Further, the second electrode203extends in a plane parallel to the base substrate201of the array substrate200, and is in a planar shape. The second insulating layer202is formed on the second electrode203in a flat shape, a lower surface202bof which is a planar surface, and an upper surface202aof which is in a concavo-convex shape. The reflective layer204is formed on the second insulating layer202having an upper surface of a concavo-convex shape and has a uniform thickness. Therefore, the reflective layer204is also in a concavo-convex shape conforming to the concavo-convex shape of the upper surface202aof the second insulating layer202. The first insulating layer205is disposed above the reflective layer204. A lower surface205bof the first insulating layer205is in a concavo-convex shape that conforms to the concavo-convex shape of the reflective layer204. An upper surface205aof the first insulating layer205is formed as a planar surface. The first electrode206is a comb electrode and is formed on the planar upper surface205aof the first insulating layer205, so that the first electrode206extends on the planar upper surface of the first insulating layer205, that is, extends in a plane parallel to the base substrate201of the array substrate200.

The method of manufacturing the array substrate200of this embodiment is similar to the embodiment shown inFIG. 1, except that the second electrode203extends on the planar surface of the first insulating layer205of the array substrate200and is parallel to the first electrode206. A second insulating layer202is formed between the second electrode203and the reflective layer204. The lower surface of the second insulating layer202is a planar surface, and the upper surface thereof is in a concavo-convex shape. The reflective layer204is formed on the upper surface of the second insulating layer202in the concavo-convex shape to have a concave-convex shape. Other aspects of this embodiment are the same as those of the embodiment shown inFIG. 1, and details are not described herein again.

According to this embodiment, both the first electrode206and the second electrode203extend in a plane parallel to the planar upper surface of the first insulating layer205, and the first electrode206and the second electrode203are parallel to each other, thereby prevent the electric field between the first electrode206and the second electrode203from being distorted. A normal electric field can be formed between the first electrode206and the second electrode203. Therefore, the liquid crystal molecules contained in the liquid crystal display panel having the array substrate200can be normally deflected, and the quality of the picture displayed by the display panel is improved.

FIG. 5shows a structural schematic view of an array substrate300of a liquid crystal display panel of the reflective type according to another exemplary embodiment of the present disclosure. As shown inFIG. 5, the array substrate300includes, in an order from bottom to top inFIG. 5, a base substrate301, a second insulating layer302, a reflective layer304, a second electrode303, a first insulating layer305, and the first electrode306. This embodiment differs from the embodiment shown inFIG. 1in that, in the embodiment shown inFIG. 1, the reflective layer104is located above the second electrode103; and in the embodiment shown inFIG. 5, the reflection layer304is located below the second electrode303, and the second electrode303is disposed between the reflective layer304and the first insulating layer305. In this case, the second electrode303should be a transparent electrode, for example, made of a transparent conductive material such as ITO.

Specifically, in the array substrate300shown inFIG. 5, the base substrate301may be, for example, a flat glass substrate on which a TFT element film layer may be formed for supplying a driving voltage to the first electrode306or the second electrode303. The second insulating layer302is disposed on the base substrate301, and an upper surface302aof the second insulating layer302is in a concavo-convex shape. The reflective layer304above the second insulating layer302has a uniform thickness, and therefore, the reflective layer304is in a concavo-convex shape that conforms to the concavo-convex shape of the upper surface302aof the second insulating layer302. The second electrode303is formed on the reflective layer304having a concavo-convex shape and has a uniform thickness. Therefore, the second electrode303is also in a concavo-convex shape conforming to the concavo-convex shape of the upper surface of the second insulating layer302. The first insulating layer305is disposed above the second electrode303. A lower surface305bof the first insulating layer305is in a concavo-convex shape that conforms to the concavo-convex shape of the second electrode303. An upper surface305aof the first insulating layer305is formed as a planar surface. The first electrode306is a comb electrode and is formed on the planar upper surface305aof the first insulating layer305such that the first electrode306extends in a plane substantially parallel to the base substrate301of the array substrate300.

The method of manufacturing the array substrate of this embodiment is substantially the same as the method of manufacturing the array substrate of the embodiment shown inFIG. 1, except that the order of forming the reflective layer and the second electrode is reversed, and the second electrode is disposed on a side of the reflective layer away from the second insulating layer. and is a transparent electrode. Specifically, the second electrode is disposed between the reflective layer and the first insulating layer. Other aspects of this embodiment are the same as those of the embodiment shown inFIG. 1, and details are not described herein again.

According to this embodiment, the comb-shaped first electrode306is formed on the planar upper surface of the first insulating layer305, and extends on the planar upper surface of the first insulating layer305. Therefore, a substantially normal electric field is formed between the first electrode306and the second electrode303. When being used in a liquid crystal display panel, liquid crystal molecules above the array substrate300are normally deflected in a horizontal electric field, and the display panel may normally display a picture.

The embodiments ofFIGS. 1 and 5show that, in the array substrate, the reflective layer and the second electrode are formed separately and are located in different layers. However, as a variation of the embodiments shown inFIGS. 1 and 5, the reflective layer and the second electrode inFIGS. 1 and 5may also be formed in a unitary structure, that is, the second electrode itself functions as a reflective layer. In this way, the fabrication process of the array substrate can be simplified and the processes may be saved.

FIG. 6shows a structural schematic view of an array substrate of a liquid crystal display panel of the reflective type400according to another exemplary embodiment of the present disclosure. As shown inFIG. 6, the array substrate400includes, in an order from bottom to top inFIG. 6, a base substrate401, a second insulating layer402, a reflective layer404, a first insulating layer405, and a second electrode403, a third insulating layer436and a first electrode406.

In the embodiment shown inFIG. 6, the second insulating layer402is disposed on the planar base substrate401, and an upper surface402athereof is formed in a concavo-convex shape. The reflective layer404on the second insulating layer402has a uniform thickness. Therefore, the reflective layer404is also in a concavo-convex shape that conforms to the concavo-convex shape of an upper surface402aof the second insulating layer402. The first insulating layer405is disposed above the reflective layer404. A lower surface405bof the first insulating layer405is in a concavo-convex shape that conforms to the concavo-convex shape of the reflective layer404. An upper surface405aof the first insulating layer405is formed as a planar surface. The second electrode403is deposited on the planar upper surface405aof the first insulating layer405and has a uniform thickness. Therefore, the second electrode403extends in a plane parallel to the planar upper surface of the first insulating layer405. The third insulating layer436is formed on the second electrode403and has a uniform thickness, and the upper and lower surfaces thereof are both planar surfaces. The first electrode406is a comb electrode and is formed on the planar upper surface436aof the third insulating layer436. Further, the first electrode406also extends on the upper surface of the first insulating layer405in a planar shape and is parallel to the second electrode403. Other aspects of the array substrate of this embodiment are the same as those of the embodiment shown inFIG. 5, and details are not described herein again.

The method of manufacturing the array substrate of the embodiment is similar to the embodiment shown inFIG. 5, except that the second electrode403is disposed on the planar upper surface405aof the first insulating layer405, and is spaced apart from the reflective layer404. Specifically, the second electrode403is disposed between the first electrode406and the first insulating layer405, and the third insulating layer436is disposed between the second electrode403and the first electrode406, and the second electrode403extends in a plane parallel to the planar surface of the first insulating layer405. The upper and lower surfaces of the third insulating layer436are both planar surfaces, and the first electrode406is disposed on the upper surface of the third insulating layer436. Other aspects of this embodiment are the same as those of the embodiment shown inFIG. 5, and details are not described herein again.

According to this embodiment, the first electrode406and the second electrode403are both disposed above the first insulating layer405, and the first insulating layer405is disposed above the reflective layer404and serves to flatten the concave-convex shape of the reflective layer. Both the first electrode406and the second electrode403extend in a plane parallel to the planar upper surface405aof the first insulating layer405, and the first electrode406and the second electrode403are parallel to each other. Thus, the electric field between the first electrode406and the second electrode403is further prevented from being distorted. Therefore, the liquid crystal molecules in the liquid crystal display panel including the array substrate400are normally deflected, and the display panel may display the screen normally.

The above embodiments are all described by taking an array substrate of a liquid crystal display panel of the reflective type as an example. It should be understood that the concepts of the present disclosure may be applied to any liquid crystal display panel having a reflective region.FIG. 8shows a schematic structural view of an array substrate of a liquid crystal display panel of the transflective type according to an exemplary embodiment of the present disclosure.FIG. 8shows the structure of one pixel unit of the array substrate. As shown inFIG. 8, each pixel unit of an array substrate500includes a transmissive region511and a reflective region512. In the transmissive region511, the array substrate500includes, in an order from bottom to top inFIG. 8, a base substrate501, a second insulating layer502, a second electrode503, a first insulating layer505, and a first electrode506. In the reflective region512, the array substrate500includes, in an order from bottom to top inFIG. 8, a base substrate501, a second insulating layer502, a second electrode503, a reflective layer504, a first insulating layer505, and a first electrode506. There is no reflective layer in the transmissive region511so as to achieve the image display with light transmitted upward from a bottom side of the array substrate500. A reflective layer504is provided in the reflective region512to reflect light emitted from a top side of the array substrate500to achieve the image display.

The base substrate501may be, for example, a flat glass substrate on which a TFT element film layer may be formed for supplying a driving voltage to the first electrode506or the second electrode503. The second insulating layer502is disposed on the base substrate501. In the transmissive region511, an upper surface502aof the second insulating layer502is in a flat shape. In the reflective region512, the upper surface502aof the second insulating layer502is in a concavo-convex shape. The second electrode503deposited on the upper surface502aof the second insulating layer502is a plate electrode and has a uniform thickness, and therefore, the second electrode503is in a flat shape in the transmissive region511and is in a concavo-convex shape in the reflective region512. The reflective layer504is formed on the second electrode503in the reflective region512and has a uniform thickness, and therefore, the reflective layer504is in a concavo-convex shape. The first insulating layer505is formed on the second electrode503in the transmissive region511and formed on the reflective layer504in the reflective region512. In the transmissive region511, upper and lower surfaces of the first insulating layer505are both in a flat shape. In the reflective region512, the lower surface505bof the first insulating layer505is in a concavo-convex shape, and the upper surface505ais in a flat shape. The first electrode506is a comb electrode and is formed on the planar upper surface505aof the first insulating layer505, so that the first electrode506extends on the plane of the base substrate501of the array substrate500.

FIGS. 9A-9Cshow schematic views of a manufacturing process of the array substrate500shown inFIG. 8. As shown inFIG. 9A, firstly, a base substrate501is provided, which may include a TFT film layer; an insulating layer (i.e. the second insulating layer)502, e.g. a photoresist layer, is laid on the base substrate501, and the upper surface502aof the second insulating layer502in the reflective region512is formed into a concavo-convex shape by, for example, a molding process. Next, a second electrode layer is deposited on the second insulating layer502by, for example, a sputtering process, and patterned to form the second electrode503. The material of the second electrode may be a metal or an alloy. Next, in the reflective region512, a reflective layer504is deposited on the second electrode503by, for example, a sputtering process. The material of the reflective layer504may be a metal such as silver that has a function to reflect light. Next, a transparent insulating layer (i.e. the first insulating layer)505is deposited on the reflective layer504, for example, by a chemical vapor phase process. The first insulating layer is made of a transparent material. The second electrode503, the reflective layer504, and the first insulating layer505are deposited respectively, each having a uniform thickness, so as to have a shape conforming to the shape of the upper surface of the underlying second insulating layer502. That is, in the transmissive region511, the second electrode503and the first insulating layer505are in a flat shape; in the reflective region512, the second electrode503, the reflective layer504, and the first insulating layer505are in a concavo-convex shape. The height h of the concavo-convex shape of the upper surface of the first insulating layer505(the vertical height between the highest point and the lowest point of the concave-convex surface) should be smaller than the thickness H of the first insulating layer505.

Thereafter, as shown inFIG. 9B, the upper surface505aof the first insulating layer505is ground to a planar surface, for example, by a chemical mechanical grinding process. In order to ensure that the concavo-convex structure on the upper surface505aof the first insulating layer505is entirely removed, the first insulating layer505is ground by a height greater than h and less than H. In addition, the remaining portion of the first insulating layer after being ground is configured to ensure that the first insulating layer505covers the entire reflective layer504in the concavo-convex shape.

Next, as shown inFIG. 9C, a transparent electrode layer of a uniform thickness, e.g. an ITO layer, is deposited on the first insulating layer505having the planar upper surface505a, and a comb-shaped first electrode506is formed with a patterning process. Since the first electrode506is formed on the planar upper surface505aof the first insulating layer505, that is, the first electrode506extends on the planar upper surface of the first insulating layer505, that is, extends in a plane parallel to the base substrate501. Therefore, in the transmissive region511and the reflective region512, the first electrode506and the second electrode503therebelow may form a substantially normal electric field, preventing electric field distortion.

FIG. 10shows a schematic structural view of a liquid crystal display panel5of the transflective type including the array substrate500shown inFIG. 8. As shown inFIG. 10, the transflective liquid crystal display panel5includes an array substrate500as shown inFIG. 8and a color filter substrate550disposed opposite to the array substrate500, and a liquid crystal layer560between the array substrate500and the color filter substrate550. The liquid crystal layer560contains a plurality of liquid crystal molecules560a. The distribution of the electric power lines L in the electric field formed between the first electrode506and the second electrode503is shown inFIG. 10. As shown inFIG. 10, a substantially normal electric field is formed between the first electrode506and the second electrode503, and the liquid crystal molecules560aabove the array substrate500are normally deflected in the electric field, and the long axes of the liquid crystal molecules are arranged in a direction parallel to the array substrate500and the color filter substrate550, so that the display panel5may display pictures normally. Moreover, since the reflective layer504is in a concavo-convex shape, the light reflectance can be increased, thereby increasing the display brightness of the display.

As a variation of the embodiment of the array substrate for the transflective liquid crystal display panel shown inFIG. 8, in the array substrate shown inFIG. 8, the positions of the second electrode503and the reflective layer504may be interchanged. When the second electrode is formed on the reflective layer, the second electrode is a transparent electrode. In this case, similar to the case shown inFIG. 6, an additional insulating layer may be disposed as a planarized layer between the second electrode and the reflective layer, such that the second electrode also has a flat shape which is parallel to the base substrate of the array substrate. In this case, the first electrode and the second electrode are both parallel to the base substrate with a normal electric field being formed therebetween, and the display panel can normally display the picture.

Although the various embodiments of the present disclosure have been described above with reference to the drawings, it is obvious that the described embodiments are some of the embodiments of the present disclosure, and not all of the embodiments. The general inventive idea of the present disclosure relates to an array substrate, comprising a plurality of pixel units, at least some of which respectively having a reflective region provided with a reflective layer in a concave-convex shape, wherein a first insulating layer is disposed on a light reflecting side of the reflective layer, and a surface of the first insulating layer adjacent to the reflective layer is in a concave-convex shape conforming to the concave-convex shape of the reflective layer, and a surface of the first insulating layer away from the reflective layer is a planar surface; the at least some of the pixel units further respectively comprise a first electrode and a second electrode which are oppositely disposed in different layers and are spaced apart from each other, and the first electrode is disposed on a side of the first insulating layer away from the reflective layer.

Accordingly, an embodiment of another aspect of the present disclosure relates to a method of manufacturing an array substrate, the array substrate comprising a plurality of pixel units, at least some of which respectively having a reflective region, the method comprising at least: forming a reflective layer in a concave-convex shape in the reflective region; forming a first insulating layer on a light reflecting side of the reflective layer; performing a planarization process a surface of the first insulating layer away from the reflective layer to form a planar surface; and forming a first electrode on a side of the first insulating layer away from the reflective layer, the first electrode extending on the planar surface of the first insulating layer.

Embodiments of another aspect of the present disclosure also relates to a display device including the array substrate of each of the above embodiments. Examples of the display device may include a device having a display function, such as a mobile phone, a tablet, a notebook computer, a digital photo frame, a personal digital assistant, a navigator, a television, which is not limited in the present disclosure. In the case where the display panel is a liquid crystal display panel of the transflective type, the display device may further include a backlight device disposed on a side of the array substrate opposite to the color filter substrate to provide a backlight source in the transmissive display.

According to an array substrate and a method of manufacturing the same, a liquid crystal display panel, and a display device according to an embodiment of the present disclosure, a first insulating layer is provided on the reflective layer in the concave-convex shape in the array substrate. The first insulating layer has a planar upper surface. The first electrode formed above the planar upper surface of the first insulating layer extends in a plane parallel to the planar surface of the first insulating layer, thereby forming a substantially normal electric field between the first electrode and the second electrode, preventing distortion of the electric field between the first electrode and the second electrode which would have caused a poor display effect of the display device. According to the display device of the present disclosure, it is possible to eliminate the adverse effect of the electric field distortion on the displayed picture and improve the quality of the display screen.

Although various embodiments of the present disclosure have been described above with reference to the drawings, those skilled in the art will understand that different embodiments may be combined or partially substituted without causing a conflict. Various modifications and variation may be made to the embodiments of the present disclosure without departing from the scope of the invention. All such modifications and variations are intended to fall within the scope of the present disclosure. Therefore, the protection scope of the present disclosure should be determined by those defined by the claims.