Reflection type display device and method with pixel electrodes having predetermined dimensions and relationships to each other as to gap width therebetween on both short and long sides and pitch of cubic corner cubes

A reflection-type display device 200 includes: an active switch layer 201s including a plurality of switching elements 201t; a plurality of pixel electrodes 207 each connected to a corresponding one of the plurality of switching elements 201t; a reflective layer 205 formed between the active switch layer 201s and the plurality of pixel electrodes 207; and a modulation layer 213 provided at a side of the pixel electrodes 207 facing a viewer, the modulation layer 213 being capable of switching between a first state and a second state of respectively different optical characteristics. The reflective layer 205 is connected to neither the plurality of switching elements 201t nor the plurality of pixel electrodes 207.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a reflection-type display device and a method for producing the same.

2. Description of the Related Art

Liquid crystal display device (hereinafter “LCDs”) of a reflection type, which perform display by utilizing ambient light as a light source, have been known. Since reflection-type LCDs do not require a backlight as do transmission-type LCDs, reflection-type LCDs are suitably used for various devices which must have a light weight and a thin thickness. In particular, reflection-type LCDs of an active matrix driving type, in which a switching element is provided corresponding to each pixel, are capable of performing display with a high resolution and high quality.

In order to further improve the display performance of a reflection-type LCD, a retroreflection-type LCD which includes a retroreflection plate as a reflective layer for reflecting ambient light is proposed. As used herein, a “retroreflection plate” is an optical element which reflects an incoming ray of light with a plurality of reflection surfaces, regardless of the orientation of the ray, in the direction in which the ray entered the device. For example, a retroreflection plate is composed of a two-dimensional array of minute unit features.

Since retroreflection-type LCDs do not require any polarizing plates, there is no decrease in the efficiency of light utilization associated with the use of polarizing plates, and hence retroreflection-type LCDs can perform brighter display. Moreover, retroreflection-type LCDs are considered as promising because of their potential ability to realize an improved display contrast ratio.

Hereinafter, the structure of a retroreflection-type LCD of an active matrix driving type will be described with reference to the accompanying drawings.FIG. 1Ais a schematic cross-sectional view showing a retroreflection-type LCD.FIG. 1Bis a plan view showing reflection electrodes in the display device ofFIG. 1A. A structure as shown inFIGS. 1A and 1Bis disclosed in, for example, Japanese Laid-Open Patent Publication No. 2003-195788.

As shown inFIG. 1A, the retroreflection-type LCD comprises: a front substrate110on which color filters119, a transparent counter electrode111, and an alignment film112are provided; a rear substrate109provided so as to oppose the front substrate110; and a liquid crystal layer113interposed between the substrates110and109. The rear substrate109includes: a TFT substrate101having a plurality of switching elements (TFTs) formed thereon; an insulating layer102which is provided on the TFT substrate101and has a surface configuration that exhibits a retroreflection property; a plurality of reflection electrodes105; and an alignment layer118. The reflection electrodes105, which are formed on the insulating layer102, present an uneven surface corresponding to the surface configuration of the insulating layer102. As shown in FIG.1B, the reflection electrodes105are formed so as to be spaced apart from one another, corresponding to pixels (which define units of image displaying). Each reflection electrode105is connected to a drain electrode103of a corresponding switching element on the TFT substrate101, via a contact hole104which is formed in the insulating layer102. The alignment layer118, which is formed above the insulating layer102and the reflection electrodes105, has protrusions and depressions corresponding to the surface configuration of the insulating layer102. The liquid crystal layer113may be composed of, for example, a scattering type liquid crystal material which is capable of switching between a light transmitting state and a light scattering state (forward scattering) in accordance with a varying voltage which is applied between the counter electrode111and each reflection electrode105.

In a display device of this structure, the plurality of reflection electrodes105function as pixel electrodes and as a retroreflective layer. Hereinafter, the operation of this display device will be described.

While the liquid crystal layer113is controlled to be in a transmitting state, light from a light source which lies external to the display device or ambient light is transmitted through the front substrate110and the liquid crystal layer113, and thereafter reflected by the reflection electrodes105in the direction in which the light has entered. From the display device under this condition, an image of the eye(s) of the viewer himself or herself is perceived by the viewer, whereby a “black” displaying state is obtained.

On the other hand, while the liquid crystal layer113is controlled to be in a scattering state, the light from a light source or ambient light which has been transmitted through the front substrate110is scattered in the liquid crystal layer113. In the case where the liquid crystal layer113is a forward scattering-type liquid crystal layer, the scattered light is reflected by the reflective layer105, further travels through the liquid crystal layer113(which is in a scattering state), and goes out in the viewing direction. Since the retroreflection property of the reflective layer105is counteracted by the scattering in the liquid crystal layer113, the incident light does not go back in its incident direction. As a result, a “white” displaying state is obtained.

The retroreflection-type display device described above has the following problems.

Firstly, the reflection electrodes105of the shape as shown inFIG. 1Bare typically formed by patterning a concavo-convex metal film. However, it is difficult to perform a highly precise patterning for a concavo-convex metal film. In particular, when a metal film having a complicated surface configuration, e.g., a metal film having a corner cube array structure, it is difficult to form the reflection electrodes105in the designed manner, because the metal film is likely to be etched with dependence on the size and/or array pattern of the corner cubes. Therefore, it is difficult to reduce the interspaces between adjoining reflection electrodes105, and thus the aperture ratio is decreased. Furthermore, since any light entering the gaps between reflection electrodes105is not reflected, the efficiency of light utilization is lowered, too. In answer to this problem, the Applicant has proposed in Japanese Laid-Open Patent Publication No. 2003-195788, supra, to perform a patterning of the reflection electrodes105in a manner to match the array pattern of the corner cubes, thus to reduce the interspaces between adjoining reflection electrodes10; however, as the size of each corner cube becomes more minuscule, it becomes more difficult to apply this technique. In addition, design freedom of the reflection electrodes105is limited.

Secondly, the protrusions and depressions on the surface profile of the alignment film118of the rear substrate109make it difficult to realize a stable alignment in the liquid crystal layer113. In the case where there is a large difference in levels between the depressions and the protrusions on the surface of the alignment film118, the consequent variations in the thickness of the liquid crystal layer113may affect the displaying characteristics.

Although a retroreflection-type LCD is exemplified above, those reflection-type LCDs whose reflective layer is a reflection plate having diffuse reflection characteristics also have reflection electrodes which function both as a reflective layer and pixel electrodes, similarly to the structure shown inFIG. 1; therefore, such reflection-type LCDs also have problems similar to those described above.

Such a diffuse reflection-type LCD structure is disclosed in Japanese Patent No. 3166377, for example. In the structure disclosed in Japanese Patent No. 3166377, an insulative film having a large refractive index is formed between a liquid crystal layer and reflection electrodes whose surfaces have protrusions and depressions. As a result, the protrusions and depressions of the reflection electrodes are to some extent planarized by the insulative film, whereby the aforementioned second problem can be improved. However, a voltage drop is caused by the insulative film which is formed between the liquid crystal layer and the reflection electrodes, and therefore a high driving voltage is required.

As described above, in conventional reflection-type LCDS, a metal film whose surface has protrusions and depressions must be patterned in such a manner as to form reflection electrodes which are spaced apart from one another pixel corresponding to the pixels. However, it is difficult to perform a highly precise patterning for such a metal film. Moreover, there is a problem in the case of performing a patterning utilizing protrusions and depressions, in that the design freedom of the reflection electrodes is limited. Thus, it is difficult to enhance the aperture ratio and/or efficiency of light utilization by reducing the interspaces between reflection electrodes. Furthermore, there is also a problem in that, since a liquid crystal layer is formed on a surface having protrusions and depressions, it is difficult to stably control the alignment in the liquid crystal layer.

SUMMARY OF THE INVENTION

In order to overcome the problems described above, preferred embodiments of the present invention provide a reflection-type LCD which realizes an improved aperture ratio and an improved efficiency of light utilization while maintaining a stable alignment in the liquid crystal.

A reflection-type display device according to the present invention comprises: an active switch layer including a plurality of switching elements; a plurality of pixel electrodes each connected to a corresponding one of the plurality of switching elements; a reflective layer formed between the active switch layer and the plurality of pixel electrodes; and a modulation layer provided at a side of the pixel electrodes facing a viewer, the modulation layer being capable of switching between a first state and a second state of respectively different optical characteristics, wherein the reflective layer is connected to neither the plurality of switching elements nor the plurality of pixel electrodes.

Preferably, the reflective layer is present below gaps between adjoining pixel electrodes.

Preferably, the reflective layer is not divided into portions corresponding to pixels.

In a preferred embodiment, the reflective layer has a plurality of openings, and each of the plurality of pixel electrodes is connected to the corresponding switching element via a corresponding one of the plurality of openings in the reflective layer.

In a preferred embodiment, the reflection-type display device further comprises a plurality of contact portions for respectively connecting the plurality of pixel electrodes with the corresponding switching elements, each of the plurality of contact portions being provided via a corresponding one of the plurality of openings in the reflective layer, wherein each contact portion has a diameter which is smaller than a diameter of each opening.

In a preferred embodiment, the reflective layer has retroreflection characteristics.

The reflective layer may include a two-dimensional array of a plurality of unit features, and the gaps between adjoining pixel electrodes may not be aligned with the unit features of the reflective layer.

The unit features of the reflective layer may be cubic corner cubes.

Preferably, each pixel electrode has a substantially rectangular planar shape, and the relationship ((√{square root over ( )}3)/6×Ppix(L)×Pcc+Ppix(S)×Pcc/2)/(Ppix(L)×Ppix(S))>0.005 is satisfied, and more preferably the relationship ((√{square root over ( )}3)/6×Ppix(L)×Pcc+Ppix(S)×Pcc/2)/(Ppix(L)×Ppix(S))>0.01 is satisfied, where Ppix(S)is a pitch of the pixel electrodes along a direction of shorter sides thereof; Ppix(L)is a pitch of the pixel electrodes along a direction of longer sides thereof; and Pccis a pitch of the cubic corner cubes.

Preferably, the relationship ((√{square root over ( )}3)+3)/6×Pcc/Ppix>0.005 is satisfied, and more preferably the relationship ((√{square root over ( )}3)+3)/6×Pcc/Ppix>0.01 is satisfied, where Ppixis a pitch of the pixel electrodes; and Pccis a pitch of the corner cubes.

In a preferred embodiment, the modulation layer is capable of switching between a light scattering state and a light transmitting state.

A method for producing a reflection-type display device according to the present invention comprises the steps of: providing a substrate having an active switch layer formed thereon, the active switch layer including a plurality of switching elements; forming an insulating layer on the active switch layer; forming a reflective layer on the insulating layer, the reflective layer having a plurality of openings; forming a planarization resin layer on the reflective layer; forming a plurality of pixel electrodes on the planarization resin layer, each of the plurality of pixel electrodes being connected to a corresponding one of the plurality of switching elements; and providing a modulation layer on the plurality of pixel electrodes, the modulation layer being capable of switching between a first state and a second state of respectively different optical characteristics, wherein each of the plurality of pixel electrodes is connected to the corresponding switching element via a corresponding one of the plurality of openings in the reflective layer.

According to the present invention, a reflective layer is provided as a separate element from the pixel electrodes, and therefore it is unnecessary to split the reflective layer into portions which are spaced apart so as to correspond to the pixels. Therefore, the area of the reflective layer can be increased, whereby the efficiency of light utilization can be improved. Moreover, since the patterning of the pixel electrodes can be performed irrespectively of the configuration of the protrusions and depressions of the reflective layer, an improvement in the aperture ratio can be obtained by reducing the gaps between pixel electrodes. Therefore, bright and high-contrast ratio images can be displayed.

Furthermore, the protrusions and depressions of the reflective layer are planarized, so that the orientation of the liquid crystal molecules can be stably controlled. Since the layer for realizing planarization (planarization layer) is not formed between the liquid crystal layer and the pixel electrodes, there is no voltage drop associated with the provision of the planarization layer.

The present invention provides particular advantages when applied to a retroreflection-type LCD comprising a reflective layer having retroreflection characteristics.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A reflection-type LCD according to the present invention is characterized in that, between pixel electrodes and an active switch layer which includes switching elements, a reflective layer which is connected neither to the pixel electrodes nor the switching elements is provided. In other words, a reflective layer for making it possible to utilize ambient light or light from an external light source for the sake of displaying is provided independently from the pixel electrodes for applying voltages across the liquid crystal layer.

Hereinafter, with reference toFIGS. 2A to 2C, the structure of a reflection-type LCD according to the present invention will be described, by taking a retroreflection-type LCD as an example.FIG. 2Ais a plan view of the reflection-type display device200.FIGS. 2B and 2Care cross-sectional views taken along line2b-2b′ and2c-2c′ in the plan view ofFIG. 2A, respectively.

The reflection-type display device200comprises: a front substrate210on which color filters219, a transparent counter electrode211, and an alignment film212are provided; a rear substrate209provided so as to oppose the front substrate210; and a liquid crystal layer213interposed between the substrates210and209. The rear substrate209includes a substrate201, which has an active switch layer201sincluding a plurality of switching elements201t. Upon the substrate201, the following elements are disposed in this order: an insulating layer202which exhibits a retroreflection property, a reflective layer205formed on the insulating layer202, a planarization resin layer206, a plurality of transparent pixel electrodes207, and an alignment layer218. The surface of the alignment layer218is in contact with the liquid crystal layer213. The substrate201is, for example, a TFT substrate whose active switch layer201sincludes a plurality of thin film transistors201t. The reflective layer205has protrusions and depressions corresponding to the surface configuration of the insulating layer202. Since these protrusions and depressions are flattened out by the planarization resin layer206, the pixel electrodes207and the alignment layer218have a substantially planar surface. The insulating layer202and the planarization resin layer206have a plurality of contact holes204formed therein. Each pixel electrode207is connected to a drain electrode203of a corresponding switching element201tvia a contact hole204.

As shown inFIG. 2A, the reflective layer205is not divided into discrete portions corresponding to the pixels, unlike the reflection electrode105of the conventional reflection-type display device (FIG. 1). The reflective layer205is formed continuously over the displaying region of the TFT substrate201, and has openings220corresponding to the respective contact holes204. Since each opening220has a larger diameter than the diameter of each contact hole204, the reflective layer205is insulated from the switching elements and the pixel electrodes207.

The liquid crystal layer213may be any modulation layer which is capable of switching between a first state and a second state, the first and second states having respectively different optical characteristics. For example, the liquid crystal layer213may be a scattering type liquid crystal layer which is capable of switching between a light scattering state and a light transmitting state, or a liquid crystal layer of an electrically controlled birefringence mode (ECB mode) which can take two or more states associated with respectively different retardations. Alternatively, the liquid crystal layer213may be a TN type liquid crystal layer which utilizes the optical rotary power of the liquid crystal layer, for example.

Although not shown, the reflection-type display device200further comprises a gate drive circuit for selectively driving the thin film transistors201tin the TFT substrate201, a source driver circuit for supplying signals to the pixel electrodes207, among other elements. The gate drive circuit is connected to gate electrodes of the thin film transistors201tvia gate lines. The source drive circuit is connected to the pixel electrodes207via source lines and the thin film transistors201t.

The reflection-type LCD according to the present invention is not limited to a retroreflection-type LCD. As the reflective layer205, a diffuse reflection-type LCD including a reflective layer having scatter reflection (also called “diffuse reflection”) characteristics may alternatively be used.

The reflection-type display device200has the following advantages over the conventional reflection-type display device which has been described with reference toFIG. 1.

In the conventional reflection-type display device, the reflection electrodes105have the function of causing retroreflection or diffuse reflection of light, as well as the function of applying voltages across the liquid crystal layer (thus functioning as pixel electrodes). In order to cause retroreflection or diffuse reflection of light, the reflection electrodes105need to have protrusions and depressions on their surfaces. On the other hand, in order to function as pixel electrodes, the reflection electrodes105need to be spaced apart so as to correspond to the respective pixels. The reflection electrodes105as such are formed by patterning a reflective metal layer composed of Ag or the like. However, it is difficult to perform a highly precise patterning for a reflective metal layer having protrusions and depressions on its surface.

In particular, in the case of using a reflective metal layer having a complicated retroreflective configuration based on an array of unit features such as corner cubes, if a patterning of the reflective metal layer is performed along the border lines of the unit features, the interspaces between adjoining reflection electrodes105become relatively large, thus resulting in the problems of a lowered aperture ratio and a smaller effective reflecting region. In the present specification, an “aperture ratio” refers to a ratio of an area which contributes to displaying to the entire displaying region, i.e., a ratio of the total area of the pixel electrodes to the area of the displaying region. An “effective reflecting region” refers to a portion of the displaying region in which a reflection surface is formed. However, it is extremely difficult to pattern a reflective metal layer so as to make sufficiently small interspaces between adjoining reflection electrodes105, without being influenced by the surface configuration of the reflective metal layer. Even if such a patterning is realized, some of the surfaces composing each unit feature (e.g., a corner cube) will be removed in the peripheral portion of each reflection electrode105(near the pattern edge), and therefore, sufficient retroreflection characteristics cannot be obtained.

On the other hand, in accordance with the reflection-type display device200, it is unnecessary to pattern the reflective layer205, so that the aforementioned problems are avoided. Since the reflective layer205is formed continuously over the surface of the substrate201, an adequate reflection function is exhibited even at the pattern edges of the pixel electrodes207. Moreover, the pixel electrodes207can be formed by patterning a conductive film (e.g., an ITO film) which is formed on the planarization resin layer206. Patterning of such a conductive film can be performed freely, while escaping the constraints of the protrusions and depressions of the reflective layer205. Moreover, since the conductive film has a substantially planar surface configuration, it is relatively easy to perform a highly precise patterning for the conductive film. Thus, the interspaces between adjoining pixel electrodes207can be made sufficiently small. Furthermore, since the protrusions and depressions on the surface of the reflective layer205are flattened out, the liquid crystal in the liquid crystal layer213can be aligned well by the alignment layer218.

It is preferable that each interspace between adjoining pixel electrodes207is equal to or greater than 1 μm; under this condition, sufficient insulation can be secured between pixel electrodes207. Although the upper limit value of the interspaces between adjoining pixel electrodes207differs depending on a pitch Ppixof the pixel electrodes207, a sufficiently large aperture ratio can be obtained while the aperture ratio is equal to or less than 30 μm.

The diameter of each opening220simply needs to be greater than the diameter of each contact hole204. However, it is preferable that the diameter of each opening220is small enough to obtain a sufficient effective reflecting region (i.e., a sufficient area of the reflective layer205), e.g., 30 μm or less, although this value will depend on the resolution of the display device. On the other hand, it is preferable that the diameter of each contact hole204is large enough to ensure insulation from a contact portion (composed of a conductive material) which is provided inside the contact hole204, e.g., 1 μm or more.

The rear substrate209of the reflection-type display device200can be produced by the following method, for example.

First, as shown inFIG. 3A, on the surface of the TFT substrate201having a plurality of TFTs thereon, the insulating layer202having a retroreflective configuration is formed. Thereafter, a plurality of contact holes204a, which are deep enough to reach the drain electrodes203of the TFTs in the TFT substrate201, are formed in the insulating layer202. Instead of the TFT substrate201, a substrate having any other type of switching elements thereon may alternatively be used.

Thereafter, as shown inFIG. 3B, a metal205′ to become the reflective layer (e.g., Ag) is deposited on the inside of the contact holes204aand on the insulating layer202.

Next, as shown inFIG. 3C, portions of the metal205′ which are located inside the contact holes204and above the contact holes204are removed, thereby forming the openings220. The diameter of each opening220is prescribed so as to be greater than the diameter of each contact hole204. As a result, the reflective layer205is obtained.

Then, as shown inFIG. 3D, the planarization resin layer206is formed so as to flatten out the protrusions and depressions of the retroreflective configuration of the reflective layer205. Contact holes204bare also formed in the planarization resin layer206so as to be substantially aligned with the contact holes204ain the insulating layer202.

Thereafter, as shown inFIG. 3E, a transparent conductive film (e.g., an ITO film) is formed on the planarization resin layer206and on the inside of the contact holes204aands204b, and is patterned. As a result, the pixel electrodes207are formed. The pixel electrodes207are electrically connected to the drain electrodes203of the TFTs via the contact holes204aand204b. On the pixel electrodes207and the planarization resin layer206, the alignment layer218for realizing liquid crystal alignment is formed. Thus, the rear substrate209is obtained.

By using the rear substrate209which has been obtained in the aforementioned manner, the reflection-type display device200can be produced through processes similar to those used for producing a conventional reflection-type LCD. Specifically, the rear substrate209is attached to the front substrate210having the color filter layer219(in which RGB color patterns are delineated by black edges), the transparent conductive film211and the alignment layer212thereon, and the liquid crystal layer213is formed between the substrates209and210.

First Embodiment

Hereinafter, a first embodiment of the reflection-type LCD according to the present invention will be described.

FIG. 4Ais a plan view showing the structure of a rear substrate (TFT-side substrate)300in the reflection-type LCD of the present embodiment.FIG. 4Bis a cross-sectional view taken along line4b-4b′ in the plan view ofFIG. 4A.

The rear substrate300includes the following elements which are disposed in this order on a substrate301: an active switch layer301s; an insulating layer307; a reflective layer308; a planarization resin layer309; and pixel electrodes310. In the present embodiment, the active switch layer301sincludes a plurality of thin film transistors301t. Each thin film transistor301tincludes, for example, a gate electrode302, a gate insulative film303covering the gate electrode302, a semiconductor layer304formed on the gate insulative film303, a source line and source bus305, and a drain electrode306. Although the thin film transistors301tare illustrated as having a bottom gate structure, they may alternatively have a top gate structure. The surface of the insulating layer307has a retroreflective configuration based on an array of a plurality of corner cubes; therefore, the reflective layer308is a retroreflective layer. Each pixel electrode310is connected to the drain electrode306of the corresponding thin film transistor301tvia a contact portion311provided in the planarization resin layer309and the insulative film303. Since the reflective layer308has openings311′, each of which is sized so as not to be in contact with the contact portion311, the reflective layer308and the pixel electrodes310are not in electrical conduction with each other.

Each pixel electrode310is sized 60 μm×180 μm, for example. The gap width between adjoining pixel electrodes310is no less than 3 μm and no more than 8 μm, for example. The unit features (corner cubes) in the retroreflective layer308are arranged with a pitch of 3 μm to 20 μm, for example. The level difference between the depressions and the protrusions of the retroreflective layer308is 3 μm to 16 μm, for example.

The rear substrate300of the reflection-type LCD can be produced by a method similar to the method described with reference toFIG. 3. Hereinafter, the method for producing the rear substrate300will be described more specifically, with reference to the drawings.FIGS. 5A,5B, and5C are plan views illustrating steps of forming the rear substrate300.FIGS. 6A,6B, and6C are cross-sectional views taken along lines6a-6a′,6b-6b′, and6c-6c′ inFIGS. 5A to 5C, respectively.

First, a TFT substrate is formed as shown inFIGS. 5A and 6A. The TFT substrate can be formed in the following manner, for example. After the gate lines and gate buses302(e.g., tantalum (Ta)) are formed on the substrate301, the gate insulative film303(e.g., a tantalum oxide film) is formed thereupon. Thereafter, the semiconductor layers304(e.g., amorphous silicon) are formed. A source line and source bus305(e.g., titanium (Ti)) is formed so as to be in contact with one end of each semiconductor layer304, and a drain electrode306is formed so as to be in contact with the other end of each semiconductor layer304. In order to simplify the process, the source lines and source buses305are preferably formed in the same layer as that of the drain electrodes306. Thereafter, in order to improve the reliability of the TFTs, an insulative film (e.g., silicon nitride) may be formed.

Next, as shown inFIGS. 5B and 6B, the insulating layer307having contact holes311atherein and the reflective layer308, which is to be disposed on the insulating layer307and has openings311′ larger than the contact holes311a, are formed. Specifically, the insulating layer307and the reflective layer308can be formed in the following manner.

The insulating layer307(thickness: e.g. 5 μm) can be formed by, after forming a resin layer compose of a transfer resin material on the TFT substrate, transferring the configuration of a master (template) having protrusions and depressions thereon to the resin layer, by using an embossing technique or the like. Although there are no particular limitations as to the material of the insulating layer307, the material may be acrylic resin, for example. Thereafter, a resist mask is formed on the insulating layer307by a photolithography technique or the like. By etching the insulating layer307using this resist mask, the contact holes (diameter: e.g. 5 μm)311awhich reach the drain electrodes306of the TFTs are formed.

The reflective layer308is formed by depositing a layer of reflective metal (e.g., an Ag layer) over the surface of the insulating layer307and in the contact holes311aof the insulating layer307, and etching away the portions of the Ag layer which are located inside or above the contact holes311a. In order not to be in contact with a conductive layer which will be later formed in the contact holes311a, the reflective layer308needs to have openings311′ above the respective contact holes311a, such that each opening311′ has a greater diameter (e.g., 10 μm) than that of each contact hole311a. Such a reflective layer308can be formed by, for example, forming an etching mask which will leave exposed the portions of the Ag layer to become the openings311′, and performing a dry or wet etching using this mask. Alternatively, the reflective layer308can be formed by performing a wet etching for the Ag layer by using an etching mask having substantially the same shape as that of the resist mask which was used for forming the contact holes311ain the insulating layer307; in this manner, openings311which are larger than the contact holes311acan be formed in the Ag layer through overetching.

Thereafter, as shown inFIGS. 5C and 6C, the planarization resin layer309and the pixel electrodes310are formed, whereby the rear substrate300is completed.

The planarization resin layer309can be obtained by forming a resin layer covering the reflective layer308, and thereafter forming contact holes311bin the resin layer, such that each contact hole311bis aligned with a corresponding contact hole311a. Each contact hole311bhas substantially the same size as that of each contact hole311a. As the material of the planarization resin layer309, a material which facilitates the making of the contact holes311bis preferably used, e.g., a resin material which can be processed through photolithography. In order not to degrade the retroreflection characteristics of the reflective layer308, it is necessary to employ a material having a high transmittance. An example of a material which can be processed through photolithography and has a high transmittance is an acrylic resin which can be patterned through UV exposure. It is preferable that the planarization resin layer309is sufficiently thick (e.g., 5 μm or more) for flattening out the retroreflective configuration of the reflective layer308.

On the other hand, the pixel electrodes310can be produced by forming a transparent conductive film (e.g., indium tin oxide (ITO)) above the planarization resin layer309and inside the contact holes311aand311b(which will together be referred to as “contact holes311”), and patterning the transparent conductive film into pixel electrode shapes. In the case where the height of the contact holes311(i.e., the total height of the contact holes311aand311b) L is as small as several micrometers or less, or where each contact hole311has a tapered cross section, a usual vapor deposition technique such as sputtering can be used to form the transparent conductive film inside the contact holes311. However, in the case where the height L is relatively large, e.g., equal to or greater than twice as much as the diameter d of the contact holes311(i.e., L/d≧2), it will be difficult with a vapor deposition technique to form a transparent conductive film inside the contact holes311such that the transparent conductive film will reach the surfaces of the drain electrodes306. In the latter case, preferably, a solution-type conductive material is used as the material of the transparent conductive film, and the transparent conductive film is formed inside the contact holes311by using an ink jet technique.

Moreover, the transparent conductive film may be composed of two different materials, i.e., the contact portions to be formed inside the contact holes311may be composed of a different material from the material of the pixel electrode portions formed on the planarization resin layer309. For example, the contact portions may be formed of a material which can be formed into a thick film, and the pixel electrode portions may be formed by using a material which can be deposited through a vapor deposition technique or the like. Note that, regardless of the method of forming the transparent conductive film (pixel electrodes310), the material(s) of the transparent conductive film has a high transmittance in order not to degrade the retroreflection characteristics of the reflective layer308.

By using the rear substrate300which has been obtained as described above, a reflection-type LCD according to the present embodiment can be produced through processes similar to those used for producing a conventional reflection-type LCD. A specific method will be described below.

First, a polyimide film is formed on the rear substrate300, and the polyimide film is rubbed with a cloth to form an alignment layer for controlling the directions of liquid crystal molecules. On the other hand, a front substrate having a color filter layer, a transparent conductive film, and an alignment layer thereon is formed. The alignment layer of the front substrate can also be formed by a method similar to the method for forming the alignment layer of the rear substrate300. Next, the rear substrate300and the front substrate are attached together, and a liquid crystal layer is formed therebetween. The liquid crystal layer may be formed of a polymer dispersed liquid crystal (PDLC) material. Preferably, the liquid crystal layer is a so-called reverse-type PDLC, which appears transparent in the absence of an applied voltage. Thus, the reflection-type LCD of the present embodiment is completed.

The liquid crystal layer in the present embodiment is composed of a reverse-type PDLC having a liquid crystal backbone (mesogen groups) in its polymeric structure, and is capable of switching between a black displaying state and a white displaying state by varying the voltage applied across the liquid crystal layer, as described below. Hereinafter, the operation thereof will be described.

When the voltage applied across the liquid crystal layer is sufficiently low (i.e., in the absence of an applied voltage), the liquid crystal layer is in a transparent state. At this time, if the mesogen groups in the polymer are well aligned with the nematic liquid crystal, a good transparency can be obtained irrespective of the viewing angle; thus, the retroreflection property of the display device can be fully utilized, and good black displaying characteristics can be obtained. On the other hand, when a predetermined voltage is applied across the liquid crystal layer, the nematic liquid crystal molecules move in accordance with the electric field, but the mesogen groups in the polymeric structure are unlikely to move. As a result, a refractive index difference occurs between the nematic liquid crystal and the mesogen groups so as to cause the light entering the liquid crystal layer to be scattered, whereby white displaying characteristics are obtained.

As used herein, “absence of an applied voltage” refers to not only a state where the voltage applied across the liquid crystal layer is 0 V, but also a state where the voltage applied across the liquid crystal layer is lower than a voltage which causes an optical change in the liquid crystal layer such that scattering of the light entering the liquid crystal layer is observed.

The aforementioned reverse-type PDLC can be formed by preparing a prepolymer/liquid crystal mixture containing a low-molecular-weight liquid crystal composition and an unpolymerized prepolymer, and irradiating the prepolymer/liquid crystal mixture with UV (ultraviolet) to polymerize the unpolymerized prepolymer. In the example illustrated herein, a prepolymer/liquid crystal mixture containing a low-molecular-weight liquid crystal material and additionally 4% monoacrylate containing mesogen groups, 2% diacrylate containing mesogen groups, and 1% reaction initiator is prepared, and the prepolymer/liquid crystal mixture is irradiated with UV (e.g. 1 mW/cm2) for 20 minutes. However, the composition and curing condition of the liquid crystal material are not limited thereto.

Instead of reverse-type PDLC, a normal-type scattering liquid crystal material which does not include a liquid crystal backbone in its polymeric structure may alternatively be used. In this case, the liquid crystal layer will be in a scattering state in the absence of an applied voltage, and in a transparent state under an applied voltage. Similarly to reverse-type PDLC, normal-type PDLC also has a structure in which nematic liquid crystal is present within a polymeric structure. However, unlike reverse-type PDLC, normal-type PDLC does not contain mesogen groups in its polymeric structure. In this case, in the absence of an applied voltage, the liquid crystal molecules are randomly oriented so that the liquid crystal layer scatters light (scattering state), thus resulting in a white displaying state. On the other hand, under an applied voltage, the refractive index of the nematic liquid crystal molecules, which are oriented in accordance with the electric field, matches the refractive index of the polymer; therefore, the liquid crystal layer becomes transparent, thus resulting in a black displaying state. Note that it is difficult to ensure matching between the refractive index of the birefringent nematic liquid crystal and the refractive index of the non-birefringent polymer across the entire range of viewing angles, and therefore transparency as viewed from an oblique viewing angle is especially likely to be degraded. However, normal-type PDLC may also be a preferable choice depending on the purpose of use, because normal-type PDLC still provides a practical level of transparency and also provides high scattering characteristics in the absence of an applied voltage.

In the case where normal-type PDLC is adopted, it is common practice not to perform an alignment treatment. However, as necessary, an organic film such as polyimide may be applied on the surface of the substrate on which the liquid crystal layer is to be formed.

In the case where PDLC is employed as the material composing the liquid crystal layer, a lower planarity is required of the planarization layer than in the case where other materials (e.g. cholesteric liquid crystal (described later)) are used. Moreover, the thickness of the planarization layer only needs to be equal to or greater than a thickness which prevents electrical conduction between the reflective metal and the pixel electrodes, e.g., 3 μm.

As a scattering type liquid crystal material other than PDLC, a cholesteric liquid crystal material having a reflection band in the infrared region may also be used. A cholesteric liquid crystal material is formed by adding a chiral agent having a chiral center to a nematic liquid crystal material. The amount of chiral agent to be added is adjusted so as to obtain a helical pitch for reflecting light in a desired band. Since a liquid crystal layer composed of cholesteric liquid crystal will have different driving voltages and/or scattering characteristics depending on the thickness, it is preferable to reduce variations in the thickness of the liquid crystal layer.

Although the present embodiment illustrates an LCD of a scattering type display mode, a dynamic scatter mode or any other phase transition mode is also applicable as the display mode of the LCD according to the present invention.

The reflection-type LCD according to the present embodiment has an advantage in that the interspaces between electrodes can be reduced as compared to a reflection-type LCD having reflection electrodes which function as a reflective layer and as pixel electrodes (e.g., the display device shown inFIGS. 1A and 1B). This advantage will be described in detail below.

First,FIG. 7will be referred toFIG. 7is a plan view illustrating the shapes of pixel electrodes701of the conventional display device shown inFIG. 1. The pixel electrodes701of the conventional display device are formed by patterning a reflective metal layer having a retroreflective configuration (e.g., an Ag layer). The reflective metal layer has an array of unit features702. Each unit feature702may be e.g. a corner cube, and is preferably a cubic corner cube. The reflective metal layer has intensive protrusions and depressions, and, owing to its retroreflection property, tends to retroreflect the light which is used during photolithography. Therefore, when forming the pixel electrodes from a reflective metal layer having a retroreflective configuration in accordance with the design as shown by dotted lines703, it is quite difficult to form the pattern edges of the pixel electrodes as designed (i.e., so as to conform to the dotted lines703). The pattern edges of the pixel electrodes701to be actually formed through the patterning will deviate from the dotted lines703, depending on the shape of each unit feature702. As a result, each gap701gbetween adjoining pixel electrodes701will become much larger than the designed value so as to be aligned with the unit features702. Specifically, the width of each gap701gwill be equal to the pitch of the unit features, or n times that value (where n is an integer equal to or greater than two).

To be more specific, if the designed gap width is equal to or less than the unit feature pitch, the width of each gap701gof the actually-formed pixel electrodes701will be equal to the unit feature pitch, or n times that value (where n is an integer equal to or greater than two). If the designed gap width is greater than (m−1) times and is equal to or less than m times the unit feature pitch (where m is an integer greater than two), the actual gap width701gwill be equal to m times the unit feature pitch, or (m+k) times the unit feature pitch (where k is an integer equal to or greater than one). For example, if the designed gap width is 6 μm and the unit feature pitch is 10 μm, the gap width701gwill be 10 μm, or n times as much as 10 μm (i.e., 20 μm, 30 μm, etc.). If the designed gap width is 10 μm and the unit feature pitch is 6 μm, the gap width701gwill be 12 μm, or (2+k) times as much as 6 μm (i.e., 18 μm, 24 μm, etc.).

Next,FIG. 8will be referred to.FIG. 8is a plan view illustrating the shapes of pixel electrodes801according to the present embodiment. In the present embodiment, the pixel electrodes801are formed on a retroreflective layer having an array of unit features802, with a planarization resin layer interposed between the pixel electrodes801and the retroreflective layer. The pixel electrodes801are produced by forming a transparent conductive film on the planarization resin layer, and patterning the transparent conductive film. Since the transparent conductive film has a planarized surface, the photolithography which is conducted when patterning the transparent conductive film is not affected by the protrusions and depressions of the retroreflective layer, and is performed with a usual resolution. Therefore, if a pixel electrode pattern is designed as shown by the dotted lines703, the transparent conductive film will be patterned substantially as dictated by that design, so that the width of the gaps801gbetween adjoining pixel electrodes801can be kept small.

Thus, the width of the gaps801gbetween adjoining pixel electrodes801is determined independently of the unit feature pitch. For example, if the designed gap width is 6 μm and the unit feature pitch is 10 μm, the gap width801gof the actually-formed pixel electrode801will be 6 μm. If the designed gap width is 10 μm and the unit feature pitch is 6 μm, the gap width801gwill be 10 μm.

Thus, according to the present embodiment, the width of the gaps801gbetween adjoining pixel electrodes801can be reduced as compared to the conventional width, whereby the aperture ratio of the display device is improved.

Next, with reference to the drawings, the relationship between the design value and the actual value of the pixel electrode gap width will be described in more detail, in the case where the unit features702or802of the reflective metal layer or the retroreflective layer are cubic corner cubes having three substantially square faces which are perpendicular to one another. In the following description, any reference to a dimension should be construed as a dimension as measured in the plan view.

FIGS. 16A and 16Bare enlarged versions of the plan view ofFIG. 7showing the conventional display device, and explain a relationship between a design value and an actual value of the gap width between pixel electrodes which are provided along the x direction and the y direction in a conventional display device.FIGS. 17A and 17Bare enlarged versions of the plan view ofFIG. 8showing the display device of the present embodiment, and explain a relationship between a design value and an actual value of the gap width between pixel electrodes which are provided along the x direction and the y direction in the display device of the present embodiment.

In the following description, the distance between bottom points702bor802bof any two adjoining corner cubes702′ or802′ is defined as a pitch Pccof the corner cubes702′ or802′. A direction along which the bottom points702bor802bof adjoining corner cubes702′ or802′ are aligned is defined as the x direction, whereas a direction perpendicular to the x direction is defined as the y direction. One side of the square constituting each corner cube702′ or802′ has a length equal to (√{square root over ( )}3)/3×Pcc. Note that each pixel electrode is designed in a rectangular shape such that the substantially shorter or longer sides thereof are parallel to the x direction. Thus, there are two kinds of gaps between pixel electrodes: gaps extending along the x direction and gaps extending along the y direction.

First, with reference toFIG. 16A, the gaps extending along the x direction between pixel electrodes will be described.

In a conventional display device, the pixel electrodes are obtained by forming a resist pattern on a metal reflective layer which has an array of corner cubes702′ and then etching the metal reflective layer by using the resist pattern as a mask. The resist pattern itself can be formed by subjecting a resist film which is formed on the metal reflective layer to exposure and then development. The exposure of the resist film is performed by using a photomask. Herein, the photomask is designed so as to define the width of each gap extending along the x direction (hereinafter referred to as the “gap design value Ddx”) to be equal to or less than the length of one side of the corner cube702′ (i.e., Ddx≦(√{square root over ( )}3)/3×Pcc). Moreover, the photomask is placed in such a manner that each gap (as defined by the photomask) extending along the x direction is interposed between lines Ad1and Au1, each of which connects between saddle points of the corner cubes702in a row X.

When patterning a resist film on the metal reflective layer by using the above photomask, the light which is used during photolithography is retroreflected in the depression of each corner cube, so that, an area of the resist film which is greater than the area which is expected to be removed according to the photomask design will be removed. As a result, the gap width between pixel electrodes701as dictated by the actual resist pattern which is obtained after development (hereinafter referred to as the “resist pattern gap width” Drx) will be greater than the gap design value Ddxand equal to or less than the width (2√{square root over ( )}3)/3×Pccof each corner cube702′ along the y direction.

Typically, the resist pattern gap width Drxvaries in the range from (√{square root over ( )}3)/3×Pccto (2√{square root over ( )}3)/3×Pcc, along the y-direction width of the corner cubes702′ on the outer perimeter. In this case, the area of each gap as dictated by the actual resist pattern will be greater, by no less than a total area of triangles S1and S2of the respective corner cubes702′ in the row X, than the gap area as defined by the photomask. As shown inFIG. 16A, the triangles S1and S2are regions of each corner cube702′ excluding the region which is interposed between the lines Au1and Ad1. The total area ΔS(x) of each such pair of triangles S1and S2is equal to (√{square root over ( )}3)/6×Pcc2. Therefore, the area of the portions of the displaying region which are not contributive to displaying (i.e., the gaps) will be increased by (√{square root over ( )}3)/6×Pcc2or more per every corner cube in the row X, relative to the area of such portions as expected by design.

Next, with reference toFIG. 16B, the gaps extending along the y direction between pixel electrodes will be described. Herein, the photomask to be used during exposure of the resist film is designed so as to define the width of each gap extending along the y direction (hereinafter referred to as the “gap design value Ddy”) to be equal to or less than Pcc/2. Moreover, the photomask is placed in such a manner that each gap (as defined by the photomask) extending along the y direction is interposed between lines Al1and Ar1, each of which extends through the bottom points702b, vertices, and saddle points of the corner cubes702′ (the interval between the lines Al1and Ar1being Pcc/2).

When patterning the resist film by using the above photomask, as in the case ofFIG. 16A, the resist pattern gap width Drywill be greater than the gap design value Ddyand equal to or less than the width (i.e., pitch Pcc) of each corner cube702′ along the x direction.

Typically, the resist pattern gap width Drywill be equal to the pitch Pccof the corner cubes702′. In this case, the area of each gap as dictated by the actual resist pattern (each such gap will be present on some of the corner cubes) will be greater than the gap area as defined by the photomask, by no less than a total area of trapezoids S3and S4per every distance of (√{square root over ( )}3)×Pccalong the y direction. As shown inFIG. 16B, the trapezoids S3and S4are regions of each corner cube702′ excluding the region which is interposed between the lines Al1and Ar1. The total area ΔS(y) of each such pair of trapezoids S3and S4is equal to (√{square root over ( )}3)/2×Pcc2. Therefore, the area of the portions of the displaying region which are not contributive to displaying (i.e., the gaps) will be increased by (√{square root over ( )}3)/2×Pcc2or more per every distance of (√{square root over ( )}3)×Pccalong the y direction, relative to the area of such portions as expected by design.

On the other hand, according to the present embodiment, as has been described with reference toFIG. 8, the pixel electrodes are produced by forming a transparent conductive film on a retroreflective layer having an array of corner cubes802′, with a planarization resin layer interposed between the transparent conductive film and the retroreflective layer, and patterning the transparent conductive film. The patterning of the transparent conductive film is performed as follows. First, a resist film is formed on the transparent conductive film, and the resist film is subjected to exposure and development to achieve patterning of the resist film. At this time, irrespective of the shape or arrangement of the corner cubes802′ in the retroreflective layer, the resist film will be patterned in substantially the same pattern as defined by the photomask. Thereafter, the transparent conductive film is etched by using the resist pattern as a mask.

Therefore, as shown inFIGS. 17A and 17B, the resist pattern gap widths Drxand Dryassociated with the resist pattern which is used during the patterning of the transparent conductive film are substantially equal to the gap design values Ddxand Ddyas defined by the photomask. Accordingly, if the gap design value Ddxis equal to or less than (√{square root over ( )}3)/3×Pcc, the resist pattern gap width Drxwill also be equal to or less than (√{square root over ( )}3)/3×Pcc. If the gap design value Ddyis equal to or less than Pcc/2, the resist pattern gap width Drywill also be equal to or less than Pcc/2. Thus, according to the present embodiment, the area of the portions of the displaying region which are not contributive to displaying (i.e., the gaps) is reduced as compared to the conventional case, thus resulting in an improved aperture ratio.

Now, the relationship between the pitch Ppixof the pixel electrodes and the pitch Pccof the corner cubes for obtaining an effective improvement in the aperture ratio will be discussed.

In the conventional display device, the area of the gaps between actual pixel electrodes will increase from the area of the gaps between pixel electrodes as expected by design. To be more specific, the increase in area per pixel ΔS=ΔS(x)+ΔS(y) will vary depending on the pitch Ppixof the pixel electrodes and the pitch Pccof the corner cubes, according to eq. 1 below. Assuming that the pitch of the pixel electrodes along the x direction is Ppix(x)and the pitch of the pixel electrodes along the y direction is Ppix(y), it follows that:

According to the present embodiment, a most substantial improvement in the aperture ratio over the conventional aperture ratio can be obtained in the case where the ratio of the increase in area ΔS to the pixel area (Ppix(x)×Ppix(y)) is greater than 0.5%, and more preferably greater than 1%. Therefore, in order to obtain a substantial improvement in the aperture ratio, it is preferable that the pitch Ppixof the pixel electrodes (Ppix(x)or Ppix(y)) and the pitch Pccof the corner cubes satisfy eq. 2 below, and more preferably eq. 3 below. As a result, a displayed image which is brighter than a conventional displayed image can be realized.

In the case where the pitch Ppix(x)of the pixel electrodes along the x direction is equal to the pitch Ppix(y)of the pixel electrodes along the y direction (Ppix(x)×Ppix(y)=Ppix), eq. 2 and eq. 3 will read as follows.
((√{square root over ( )}3)+3)/6×Pcc/Ppix>0.005  eq. 4
((√{square root over ( )}3)+3)/6×Pcc/Ppix>0.01  eq. 5

For instance, if the display device has a resolution of about 200 ppi (ppi: pixels per inch), a substantial improvement in the aperture ratio over the conventional aperture ratio can be obtained in the case where the pitch Pccof the corner cubes is equal to or greater than 1 μm. If the pitch Pccof the corner cubes is about 2 μm, a substantial improvement in the aperture ratio over the conventional aperture ratio can be obtained in the case where the resolution of the display device is equal to or greater than about 85 ppi.

Although rectangular-shaped pixel electrodes having sides which are parallel to the x direction and the y direction are illustrated above, the present embodiment is also applicable to the case where the directions of the longer or shorter sides of the pixel electrodes do not correspond to the x and y directions of the corner cubes, and even in that case, relationships similar to those expressed by eq. 2 and eq. 3 will be true. In other words, assuming that the pitch of the pixel electrodes along the shorter sides thereof is Ppix(S)and the pitch of the pixel electrodes along the longer sides thereof is Ppix(L), a substantial improvement in the aperture ratio over the conventional aperture ratio can be obtained in the case where eq. 6 below, or more preferably eq. 7 below, is satisfied.
((√{square root over ( )}3)/6×Ppix(L)×Pcc+Ppix(S)×Pcc/2)/(Ppix(L)×Ppix(S))>0.005  eq. 6
((√{square root over ( )}3)/6×Ppix(L)×Pcc+Ppix(S)×Pcc/2)/(Ppix(L)×Ppix(S))>0.01  eq. 7

Furthermore, according to the present embodiment, better displaying characteristics than those of a conventional retroreflection-type display device can be realized, as described in detail below.

FIGS. 9A and 9Bare schematic cross-sectional views showing a black state and a white state, respectively, of a conventional retroreflection-type display device.FIGS. 10A and 10Bare schematic cross-sectional views showing a black state and a white state, respectively, of the retroreflection-type display device of the present embodiment. Note that both display devices are of an active matrix driving type, employing TFTs as switching elements.

The conventional retroreflection-type display device has a structure similar to that which was described above with reference toFIG. 1. In other words, the conventional retroreflection-type display device comprises a rear substrate509, a front substrate510, and a liquid crystal layer505interposed between the rear substrate509and the front substrate510. The rear substrate509includes: a TFT substrate501having a plurality of thin film transistors501tformed on its surface; and electrodes (reflection electrodes)503having retroreflection characteristics and being formed on the TFT substrate. The reflection electrodes503are spaced apart so as to correspond to the pixels. Between adjoining reflection electrodes503, a non-reflective layer504which does not have a reflection function is provided. On the surface of the front substrate510facing the liquid crystal layer505, color filters507and a black mask506are formed. The color filters507are disposed so as to correspond to the respective pixels. The black mask506is disposed so as to fill between adjoining color filters507and cover the non-reflective layer504. AlthoughFIGS. 9A and 9Billustrate an example where the thin film transistors501tare disposed below the non-reflective layer504, it may also be possible that only the wiring (source lines) of the TFT substrate501be disposed below the non-reflective layer504. The liquid crystal layer505, which is composed of e.g. PDLC, displays “black” while the liquid crystal layer505is in a transparent state, and displays “white” while the liquid crystal layer505is in a scattering state.

Now, the displaying principles of the conventional retroreflection-type LCD will be described. Firstly, the operation in a black displaying state will be described. Incident light from the light source500is generally reflected along a path indicated by arrow500ainFIG. 9A. In other words, the light from the light source500is transmitted through a color filter507, travels through the liquid crystal layer505(which is in a transparent state) so as to be reflected from the retroreflection plate503, and again travels through the liquid crystal layer505and the color filter507to go back to the light source500. In this case, the viewer will perceive an image of the eye(s) of the viewer himself or herself, whereby a black displaying state is obtained.

On the other hand, out of the light from the light source500, the light (shown by arrow500b) which obliquely enters at an edge of the color filter507(i.e., near the black mask506) travels through the color filter507and the liquid crystal layer505in a transparent state, and thereafter enters the non-reflective layer504. This light travels through the non-reflective layer504and reaches the surface of the thin film transistor501t, and is reflected back therefrom. Note that, in the case where the thin film transistor501tis not disposed below the non-reflective layer504but TFT substrate wiring is provided instead, the light which has been transmitted through the non-reflective layer504will be reflected at the surface of the wiring. The reflection from the surface of the thin film transistor501tor the wiring is usually metallic reflection. Although depending on the particular panel design, most of the light which is reflected from the surface of the thin film transistor501tor the like is absorbed by the black mask506. However, in the case where the black mask506is designed with a small width in order to improve display brightness, for example, a portion of the light (shown by arrow500b′) which has been reflected from the surface of the thin film transistor501tor the like may go out through a different color filter507from the color filter507which the light went through when entering the display device, thus deteriorating the black displaying characteristics.

Next, the operation in a white displaying state will be described. As shown by arrow500cinFIG. 9B, when light from the light source500enters, a portion of the incident light travels through a color filter507, and is thereafter scattered by the liquid crystal layer505, which is in a scattering state. In the case where the liquid crystal layer (PDLC)505has forward scattering characteristics, the light entering the liquid crystal layer505is scattered toward the retroreflection plate503(forward scattering), and reflected from the retroreflection plate503. The reflected light travels back through the liquid crystal layer505and the color filter507, thus reaching the eye(s) of the viewer. In the case where the liquid crystal layer505has backward scattering characteristics, a large portion of the incident light will be scattered by the liquid crystal layer505so as to travel back in the viewing direction, but a portion of the incident light will still be scattered forward so as to be reflected from the retroreflection plate503and reach the eye(s) of the viewer. In either case, the retroreflection tendency of the light reflected from the retroreflection plate503is canceled by the scattering characteristics of the liquid crystal layer505. Thus, most of the reflected light does not return toward the light source500, but rather contributes to the white displaying state.

On the other hand, out of the light from the light source500, the light (shown by arrow500d) which obliquely enters at an edge of the color filter507(i.e., near the black mask506) travels through the color filter507, and is scattered by the liquid crystal layer505. A portion of the scattered light travels through a portion of the non-reflective layer504which exists between adjoining reflection electrodes503to reach the surface of the thin film transistor501t, thus being reflected therefrom (metallic reflection). The black mask506is designed so as to absorb this reflected light. However, since the light which has been scattered by the liquid crystal layer505is reflected from the surface of the thin film transistor501tand further scattered by the liquid crystal layer505, a portion of the reflected light will not be absorbed by the black mask506, but rather will travel through a color filter507to go out toward the viewer. Any light which goes out through a different color filter507from the color filter507which the light went through when entering the display device will cause unwanted intermixing of colors. Note that, out of the reflected light, the amount of light which goes back through the same color filter507as that which the light went through when entering the display device and thus is available for displaying will be very small.

In contrast, the retroreflection-type display device of the present embodiment operates in the following manners. First, with reference toFIG. 10A, the operation in a black displaying state will be described. The retroreflection display device shown inFIG. 10Ais formed by using the rear substrate300which has been described with reference toFIGS. 4A and 4B. The liquid crystal layer and the front substrate have similar structures to those of the liquid crystal layer505and the front substrate510of the conventional display device as described above.

Incident light from the light source500is generally reflected along a path indicated by arrow600ainFIG. 10A. In other words, the light from the light source500is transmitted through a color filter507, travels through the liquid crystal layer505(which is in a transparent state), the transparent pixel electrode310, and the planarization resin layer309so as to be reflected from the retroreflection plate308, and again travels through the planarization resin layer309, the pixel electrode310, the liquid crystal layer505, and the color filter507to go back to the light source500.

On the other hand, out of the light from the light source500, the light (shown by arrow600b) which obliquely enters at an edge of the color filter507(i.e., near the black mask506) travels through the color filter507, the liquid crystal layer505in a transparent state, the transparent pixel electrode310, and the planarization resin layer309, and thereafter is reflected from the retroreflection plate308, so as to be absorbed by the black mask506. However, a portion of the light reflected from the retroreflection plate308does not enter the black mask506, but travels back through the color filter507to return toward the light source500. Thus, the light which has traveled through an edge of a color filter507is either absorbed by the black mask506, or returns toward the light source500via retroreflection, rather than going out in the viewing direction. As a result, good black displaying characteristics are obtained.

Next, the operation in a white displaying state will be described. As shown by arrow600cinFIG. 10B, incident light from the light source500light travels through a color filter507, and is thereafter scattered by the liquid crystal layer505. In the case where the liquid crystal layer505has forward scattering characteristics, the light entering the liquid crystal layer505is scattered toward the retroreflection plate308(forward scattering), travels through the transparent pixel electrode310and the planarization resin layer309, and thereafter is reflected from the retroreflection plate308. In the case where the liquid crystal layer505has backward scattering characteristics, a large portion of the incident light will be scattered by the liquid crystal layer505so as to travel back in the viewing direction and go out through the color filter507, although a portion of the incident light will still be scattered forward so as to be reflected from the retroreflection plate308. In either case, the retroreflection tendency of the light reflected from the retroreflection plate308is canceled by the scattering characteristics of the liquid crystal layer505. Thus, most of the light reflected from retroreflection plate308travels again through the color filter507to go out in the viewing direction. Although there is a portion of light which is scattered by the liquid crystal layer505toward the light source500and does not contribute to displaying, the amount thereof is very small.

On the other hand, out of the light from the light source500, the light (shown by arrow600d) which obliquely enters at an edge of the color filter507(i.e., near the black mask506) travels through the color filter507, and is scattered by the liquid crystal layer505. Irrespective of the scattering characteristics (forward scattering or backward scattering) of the liquid crystal layer505, a portion of the scattered light travels through the transparent pixel electrode310and the planarization resin layer309, so as to be reflected from the retroreflection plate308. Although a portion of the reflected light is absorbed by the black mask506, the rest of the light does not enter the black mask506, but rather travels through the same color filter507as that which the light went through when entering the display device, and goes out in the viewing direction. Thus, out of the light from the light source500, the light which travels from the pixel region and passes at an edge of the color filter507and heading toward the black mask region also returns in the viewing direction owing to the retroreflection characteristics of the retroreflection plate308. As a result, the efficiency of light utilization is improved so that a brighter displayed image can be obtained.

As described above, in accordance with the retroreflection-type LCD of the present embodiment, deterioration of the displaying characteristics due to light entering at an edge of the black mask506is suppressed. Therefore, in a black displaying state, good displaying characteristics are obtained. In a white displaying state, a brighter displayed image is obtained while suppressing unwanted intermixing of colors.

Furthermore, the present embodiment also provides the following advantages.

In the conventional reflection-type display device (FIG. 9), since the surface of the liquid crystal layer505facing the rear substrate has protrusions and depressions, the black displaying characteristics are deteriorated due to scattering in portions of the PDLC which are located in the depressions, even while the liquid crystal layer505is in a uniformly aligned state. This is because light is reflected by a plurality of faces composing each depression, thus resulting in light entering in different directions into each portion of the PDLC located in a depression, which is scattered due to the birefringence of the PDLC. Although such deterioration in the black displaying characteristics would be suppressed by providing a planarization layer between the liquid crystal layer505and the reflection electrodes503, the addition of such a planarization layer would cause a voltage loss. On the other hand, according to the present embodiment, the surface of the liquid crystal layer505facing the rear substrate is planarized, and therefore the aforementioned scattering by the PDLC does not occur. Therefore, the black displaying characteristics can be improved and high contrast displaying can be realized. Moreover, since the pixel electrodes308are in contact with (i.e., electrically conducted to) the drain electrodes306of the thin film transistors501t, there is no voltage loss associated with the planarization resin layer309.

The structure and the method of producing the retroreflection-type LCD of the present embodiment are not limited to those described above. For example, the rear substrate300in the present embodiment may be produced by utilizing a columnar resist pattern (resist columns) of a shape corresponding to the contact holes. Hereinafter, a production method using resist columns will be described with reference to the drawings.

First, as shown inFIG. 11A, a resist pattern (resist columns)1203having a size corresponding to the size of the contact holes to be formed (e.g., with a diameter of 5 μm) are formed on drain electrodes1202of a TFT substrate1200, by using a photolithography technique. The height of the resist columns1203is prescribed so as to be greater than the thickness of an insulating layer1204to be formed in a subsequent step, and is 8 μm, for example.

Next, as shown inFIG. 11B, a transfer resin1204′ such as an acrylic resin is applied to the TFT substrate1200.

Thereafter, as shown inFIG. 11C, the surface configuration of a master1220is transferred to the transfer resin1204′ by an embossing technique or the like. Specifically, a master1220having a corner cube array on a surface thereof is attached onto the transfer resin1204′, and the transfer resin1204′ is cured. The curing of the transfer resin may be enabled based on principles such as thermoplasticity, thermosetting, or photocuring. For example, in the case where an acrylic resin is used as the transfer resin1204′, the transfer resin1204′ may be cured by being irradiated with UV. A curing accelerator may optionally be added to the transfer resin1204.

There are no limitations as to the method and conditions for curing the transfer resin1204′. Note however that, if curing of the resist columns1203should progress during the step of curing the transfer resin1204, it will become difficult to peel the resist columns1203in a below-described step. For example, in the case where the resist columns1203are to be formed by using a positive type resist material, the transfer resin1204′ may be formed from a photocurable resin material, and cured by light irradiation. In this manner, although the resist columns1203will also be irradiated with light during the step of curing the transfer resin1204′, this will not promote the curing of the resist columns1203. Alternatively, the transfer resin1204′ may be formed from a thermosetting resin material, and cured at a temperature which is lower than the full-sintering temperature for the resist columns1203, since the resist columns1203will be relatively easily peeled unless fully sintered. Note that photocuring the transfer resin1204′ will provide an advantage in that the processing time is shorter than in the case of effecting the curing through thermosetting.

Next, the master1220is released from the TFT substrate1200, whereby the insulating layer1204having a corner cube array is obtained, as shown inFIG. 11D. On the surface of this insulating layer1204, as shown inFIG. 11E, a reflective metal layer (e.g. an Ag layer)1205is formed by a sputtering or vapor deposition technique, for example.

Next, as shown inFIG. 11F, a planarization resin layer1207is formed by applying a planarization material onto the reflective metal layer1205, and contact holes1207care formed on the planarization resin layer1207by a photolithography technique. The contact holes1207cmust be aligned with the resist columns1203. For example, the same mask as the mask used when forming the resist columns1203may be used.

Thereafter, as shown inFIG. 11G, openings (diameter: e.g. 8 μm)1205cwhich are greater than the contact holes1207care formed in the reflective metal layer1205. Specifically, by using the planarization resin layer1207as an etching mask, a portion of the reflective metal layer1205is removed by wet etching, for example. At this time, the etching time, etchant, and the like are selected so that each of the portions of the reflective metal layer1205to be removed will be broader than the portion exposed through the corresponding contact hole1207c(i.e., via overetching).

After the metal reflective layer1205is etched, as shown inFIG. 11H, the resist columns1203are detached by using a solution for dissolving the resist columns1203(peeling solution). As the peeling solution, an alkaline solution of an organic amine type, or a polar solvent such as acetone may be used. As a result, the contact holes1204care formed in the insulating layer1204. Each contact hole1204cis connected to the corresponding contact hole1207cformed in the planarization resin layer1207, thus resulting in a single contact hole1208which penetrates through the insulating layer1204and the planarization resin layer1207and reaches the corresponding drain electrode1202.

Alternatively, by using a solution which is prepared so as to be able to dissolve the resist columns1203and be used as an etchant for the reflective metal layer1205, the step of overetching the reflective metal layer1205(shown inFIG. 11G) and the step of removing the resist columns (shown inFIG. 11H) can be simultaneously performed.

Thereafter, as shown inFIG. 11I, an application-type ITO is applied to the planarization resin layer1207and the inside of the contact holes1208, thus forming an ITO film1209′. Next, as shown inFIG. 11J, the ITO film1209′ is patterned into pixel electrodes1209. Each pixel electrode1209is electrically connected to the drain electrode1202of the corresponding thin film transistor via a contact portion1210which is formed within the contact hole1208. Thus, the rear substrate1230is completed.

Although a retroreflective layer having a corner cube array is formed as the reflective metal layer1205in the above example, a similar method may be used to form a retroreflective layer of any other configuration, or form a diffuse reflection layer.

Instead of the resist columns1203, conductive columns may be formed from a conductive material. In this case, in the completed rear substrate, each conductive column will constitute a part of the contact portion connecting between the pixel electrode and the switching element. Hereinafter, a method for producing a rear substrate in the case of forming conductive columns (conductive portions) will be described.

First, as shown inFIG. 12A, columnar conductive portions1240are formed upon drain electrodes1202on a TFT substrate1200. The conductive portions1240may be formed by, for example, depositing and then patterning a conductive material. The size and thickness of the conductive portions1240may be the same as those of the above-described resist columns1203.

As the conductive material, a conductive material-dispersed resin obtained by dispersing a conductive material (e.g., carbon, aluminum) in an insulative resin (e.g., acrylic resin), or an organic conductive compound (e.g., polyacetylene) whose polymer component in itself has conductivity may be used. By using a conductive material-dispersed resin which contains a photocurable acrylic resin or the like as an insulative resin, it becomes possible to perform patterning by a photolithography technique, whereby the step of forming the conductive portions1240can be simplified.

Next, as has been described with reference to FIGS.11B to11G, an insulating layer1204is formed by an embossing technique, and thereafter a metal reflective layer1205having openings1205cand a planarization resin layer1207having contact holes1207care formed (FIGS. 12B to 12G).

Thereafter, as shown inFIG. 12H, an application-type ITO is applied to the planarization resin layer1207and the inside of the contact holes1207cso as to form an ITO film1211′. Next, as shown inFIG. 12I, the ITO film1211′ is patterned into pixel electrodes1211. Each pixel electrode1211is electrically connected to the drain electrode1202of the corresponding thin film transistor, via a contact portion which is composed of the ITO film which is formed inside the contact hole1207cand the conductive portion1240. Thus, the rear substrate1250is completed.

Second Embodiment

Hereinafter, a reflection-type display device according to a second embodiment of the present invention will be described.

FIG. 13Ais a plan view showing the structure of a rear substrate (TFT-side substrate)400in the reflection-type LCD of the present embodiment.FIG. 13Bis a cross-sectional view taken along line13b-13b′ in the plan view ofFIG. 13A.

The rear substrate400has a similar structure to that of the rear substrate300which has been described with reference toFIGS. 4A and 4B. However, the rear substrate400differs from the rear substrate300in that the insulating layer407has a diffuse reflection configuration rather than a retroreflective configuration, and the reflective layer408has scatter reflection characteristics rather than retroreflection characteristics.

The rear substrate400of the present embodiment can be formed by a method described below, for example.

First, a TFT substrate is formed by using a method similar to that which was described with reference toFIGS. 5A and 6A. Next, on the TFT substrate, a resin layer of a random pattern is formed by using an acryl type UV-curable resin, for example. The random pattern may be a pattern composed of a plurality of islet portions (each islet portion being sized, e.g., 10 μm×10 μm). Next, the resin layer is heated to 105° C., for example, to cause thermal deformation (thermal flow) of the resin layer, whereby an insulating layer407having protrusions and depressions on its surface is formed.

Then, by using a method similar to that which was described with reference toFIGS. 5B and 6B, contact holes311are formed in the insulating layer407, and thereafter a reflective metal layer (an Ag layer) is formed on the insulating layer407. In this reflective metal layer, openings311′ having a diameter than that of the contact holes311are formed. Thus, the reflective layer408having diffuse reflection characteristics is formed.

Thereafter, by using a method similar to that which was described with reference toFIGS. 5C and 6C, the planarization resin layer309and the pixel electrodes310are formed, whereby the rear substrate400is obtained.

By using the rear substrate400which has been obtained as described above, the reflection-type LCD of the present embodiment can be produced through processes similar to those used for producing a conventional reflection-type LCD. A specific method will be described below.

First, a polyimide film is formed on the rear substrate400, and the polyimide film is rubbed with a cloth to form an alignment layer for controlling the directions of liquid crystal molecules. On the other hand, a front substrate having a color filter layer, a transparent conductive film, and an alignment layer thereon is formed. The alignment layer of the front substrate can also be formed by a method similar to the method for forming the alignment layer of the rear substrate400. Next, the rear substrate400and the front substrate are attached together, and a liquid crystal layer (of e.g., a birefringence mode) is formed therebetween. Unlike in the retroreflection-type LCD of the first embodiment, a polarizing plate and a phase difference plate corresponding to the phase difference associated with the liquid crystal layer are attached to a surface of the front substrate. Thus, the reflection-type LCD of the present embodiment is completed.

The method for producing the rear substrate400and the display device of the present embodiment are not limited to the above-described method. For example, the rear substrate400may be produced by a method utilizing resist columns which has been described with reference toFIGS. 11A to 11J, and a method utilizing columnar conductive portions which has been described with reference toFIGS. 12A to 12I.

Hereinafter, with reference to the drawings, the advantages of the diffuse reflection-type LCD of the present embodiment over the conventional diffuse reflection-type display device will be described.FIGS. 14A and 14Bare schematic cross-sectional views showing a white state and a black state, respectively, of a conventional diffuse reflection-type LCD.FIGS. 15A and 15Bare schematic cross-sectional views showing a white state and a black state, respectively, of the diffuse reflection-type LCD of the present embodiment. Note that both display devices are of an active matrix driving type, employing TFTs as switching elements. As one exemplary display mode, a single-polarizing plate mode utilizing a polarizing plate, a phase difference plate, a liquid crystal layer, and a reflective layer is adopted. In the following example, a liquid crystal layer of an electrically controlled birefringence mode which is designed so as to take a “white” displaying state in the absence of an applied voltage is used. Alternatively, the liquid crystal layer may be designed so as to take a “black” displaying state in the absence of an applied voltage.

The conventional diffuse reflection-type LCD comprises a rear substrate909, a front substrate910, and a liquid crystal layer905interposed between the rear substrate909and the front substrate910. The rear substrate909includes: a TFT substrate901having a plurality of thin film transistors901tformed on its surface; and electrodes (reflection electrodes)903having diffuse reflection characteristics and being formed on the TFT substrate901. The reflection electrodes903are disposed so as to correspond to the pixels. Between adjoining reflection electrodes903, a non-reflective layer904is provided. On the surface of the front substrate910facing the liquid crystal layer905, color filters907and a black mask906are formed. The color filters907are disposed so as to correspond to the respective pixels. The black mask906is disposed so as to fill between adjoining color filters907and cover the non-reflective layer904. On the surface of the front substrate910facing toward the viewer, a phase difference plate921and a polarizing plate920are disposed in this order.

Now, the displaying principles of the conventional diffuse reflection-type LCD will be described. Firstly, the operation in a white displaying state will be described. Incident light from the light source900is generally reflected along a path indicated by arrow900ainFIG. 14A. The light from the light source900is led through the polarizing plate920so as to be converted into linearly-polarized light A1which is parallel to the direction of the transmission axis of the polarizing plate920, and thereafter is led through the phase difference plate921so as to be converted into clockwise circularly-polarized light B1. The circularly-polarized light B1travels through a color filter907, and then through the liquid crystal layer (retardation Δnd=λ/4)905so as to become linearly-polarized light A1, and is reflected from the diffuse reflection plate903. The reflected light again travels through the liquid crystal layer905to become circularly-polarized light B1, and after traveling through the color filter907, is converted by the phase difference plate921into linearly-polarized light A1, thus going out from the polarizing plate920in the viewing direction.

On the other hand, out of the light from the light source900, the light (shown by arrow900b) which obliquely enters at an edge of the color filter907(i.e., near the black mask906) travels through the liquid crystal layer905, and thereafter enters the non-reflective layer904between adjoining reflection electrodes903. This light travels through the non-reflective layer904and reaches the surface of the thin film transistor901t, and is reflected back therefrom. The reflection from the surface of the thin film transistor901tis usually metallic reflection. Although depending on the particular panel design, most of the light which is reflected from the surface of the thin film transistor901tis absorbed by the black mask906. However, since the distance between the color filter907and the surface (reflection surface) of the thin film transistor901tis longer than the distance between the color filter907and the diffuse reflection plate903, a portion of the light (shown by arrow900b′) which has been reflected from the surface of the thin film transistor901tmay go out through a different color filter907from the color filter907which the light went through when entering the display device. This light going out through a different color filter907from the color filter907which the light went through when entering the display device is converted by the phase difference plate921into linearly-polarized light A1, and travels through the polarizing plate920to return in the viewing direction, thus causing unwanted intermixing of colors.

Next, the operation in a black displaying state will be described. As shown by arrow900cinFIG. 14B, the light from the light source900is led through the polarizing plate920to be converted into linearly-polarized light A1which is parallel to the direction of the transmission axis of the polarizing plate920, and thereafter is led through the phase difference plate921to become clockwise circularly-polarized light B1, for example. The circularly-polarized light B1travels through a color filter907and then through the liquid crystal layer905. If a predetermined voltage (saturation voltage or higher) is being applied to the liquid crystal layer905, the retardation Δnd of the liquid crystal layer905is substantially zero. Therefore, the polarization state of the light traveling through the liquid crystal layer905is conserved. In this case, the circularly-polarized light B1which has been led through the liquid crystal layer905is reflected by the diffuse reflection plate903to become counterclockwise circularly-polarized light B2, and again travels through the liquid crystal layer905and the color filter907. The light (circularly-polarized light B2) which has traveled through the color filter907goes through the phase difference plate921, so as to become linearly-polarized light A2which is perpendicular to the linearly-polarized light A1. Since the linearly-polarized light A2is perpendicular to the direction of the transmission axis of the polarizing plate920and thus is absorbed by the polarizing plate920, a black state is obtained.

On the other hand, out of the light from the light source900, the light (shown by arrow900d) which obliquely enters at an edge of the color filter907(i.e., near the black mask906) travels through the liquid crystal layer905, and thereafter enters the non-reflective layer904. This light travels through the non-reflective layer904and reaches the surface of the thin film transistor901t, and is reflected back therefrom. The reflection from the surface of the thin film transistor901tis usually metallic reflection. Although depending on the particular panel design, most of the light which is reflected from the surface of the thin film transistor901tis absorbed by the black mask906. A portion of the light reflected from the surface of the thin film transistor901twhich is not absorbed by the black mask906but travels through a different color filter907from the color filter907which the light went through when entering the display device is absorbed by the polarizing plate920, so that the black displaying state is not degraded.

By varying the voltage applied across the liquid crystal layer905in a range from zero to the saturation voltage, gray scale displaying can be realized. If the applied voltage is zero, the retardation Δnd of the liquid crystal layer905is λ/4, so that the light which has been led through the liquid crystal layer905after being reflected from the diffuse reflection plate903is clockwise circularly-polarized light B1. If a voltage which is smaller than the saturation voltage is applied across the liquid crystal layer905, the light which has been led through the liquid crystal layer905after being reflected from the diffuse reflection plate903is elliptically-polarized light. Since a portion of the elliptically-polarized light does not go through the polarizing plate920, a gray scale tone is displayed. As a greater voltage is applied across the liquid crystal layer905, the retardation Δnd of the liquid crystal layer905becomes smaller, and the light going out from the polarizing plate920accounts for a greater proportion within the reflected light from the diffuse reflection plate903, thus approaching a black displaying state.

Next, with reference toFIGS. 15A and 15B, the operation of the diffuse reflection-type LCD of the present embodiment will be described. The diffuse reflection display device shown inFIGS. 15A and 15Bis formed by using the rear substrate400which has been described with reference toFIGS. 13A and 13B. The structures of the liquid crystal layer and the front substrate are similar to those of the liquid crystal layer905and the front substrate910of the above-described conventional display device.

Firstly, the operation in a white displaying state will be described. Incident light from the light source900is generally reflected along a path indicated by arrow1000ainFIG. 15A. The light from the light source900is led through the polarizing plate920so as to be converted into linearly-polarized light A1which is parallel to the direction of the transmission axis of the polarizing plate920, and thereafter is led through the phase difference plate921so as to be converted into clockwise circularly-polarized light B1, for example. The circularly-polarized light B1travels through a color filter907, and then through the liquid crystal layer (retardation Δnd=λ/4)905so as to become linearly-polarized light A1, goes through the planarization resin layer309, and is reflected from the diffuse reflection plate408. The reflected light travels through the planarization resin layer309and the liquid crystal layer905to become circularly-polarized light B1, and after traveling through the color filter907, is converted by the phase difference plate921into linearly-polarized light A1. Thus, the reflected light (linearly-polarized light A1) travels through the polarizing plate920to go out in the viewing direction.

On the other hand, out of the light from the light source900, the light which obliquely enters at an edge of the color filter907(i.e., near the black mask906) travels through the liquid crystal layer905and the planarization resin layer309, along a path similar to the path shown by arrow1000a, and thereafter is reflected by the diffuse reflection plate408. However, most of the reflected light is absorbed by the black mask906(arrow1000b). Note that the proportion of the reflected light which is not absorbed by the black mask906but travels through a different color filter907from the color filter907which the light went through when entering the display device is much smaller than in the conventional display device (FIG. 14A). This is because, in the present embodiment, the distance between the black mask906and the reflection surface (surface of the diffuse reflection plate408) is equal to the distance between the color filter907and the reflection surface, so that the expanse of the reflected light is reduced, thus reducing the proportion of the reflected light which travels through a different color filter907from the color filter907which the light went through when entering the display device. Therefore, unwanted intermixing of colors, which is a problem with the conventional display device, is suppressed.

Next, the operation in a black displaying state will be described. As shown by arrow1000cinFIG. 15B, the light from the light source900is led through the polarizing plate920to be converted into linearly-polarized light A1which is parallel to the direction of the transmission axis of the polarizing plate920, and thereafter is led through the phase difference plate921to become clockwise circularly-polarized light B1, for example. The circularly-polarized light B1travels through a color filter907and then through the liquid crystal layer905. If a predetermined voltage (saturation voltage or higher) is being applied to the liquid crystal layer905, the retardation Δnd of the liquid crystal layer905is substantially zero. Therefore, the polarization state of the light traveling through the liquid crystal layer905is conserved. In this case, the circularly-polarized light B1which has been led through the liquid crystal layer905travels through the planarization resin layer309, and is reflected by the diffuse reflection plate408to become counterclockwise circularly-polarized light B2, and again travels through the planarization resin layer309, the liquid crystal layer905, and the color filter907. The light (circularly-polarized light B2) which has traveled through the color filter907goes through the phase difference plate921, so as to become linearly-polarized light A2which is perpendicular to the linearly-polarized light A1. Since the linearly-polarized light A2is absorbed by the polarizing plate920, a black state is obtained.

On the other hand, out of the light from the light source900, the light which obliquely enters at an edge of the color filter907(i.e., near the black mask906) travels through the liquid crystal layer905and the planarization resin layer309, along a path similar to the path shown by arrow1000c, and thereafter is reflected by the diffuse reflection plate408. However, most of the reflected light is absorbed by the black mask906. A portion of the light reflected from the diffuse reflection plate408which is not absorbed by the black mask906but travels through a color filter907is absorbed by the polarizing plate920, so that the black displaying state is not degraded.

As described above, in accordance with the diffuse reflection-type LCD of the present embodiment, deterioration of the displaying characteristics due to light entering at an edge of the black mask906is suppressed. Therefore, in a black displaying state, good displaying characteristics are obtained. In a white displaying state, a brighter displayed image is obtained while suppressing unwanted intermixing of colors.

Furthermore, the present embodiment also provides the following advantages.

Generally speaking, in a diffuse reflection-type LCD, the liquid crystal molecules in the liquid crystal layer905are aligned in the direction of an electric field in a black state (i.e., under an applied voltage in this example). As a result, the anisotropy of refractive index of the liquid crystal layer905is reduced, and ideally the phase difference (retardation Δnd) would become zero. In practice, though, a layer (“anchoring layer”) which is present on the surface of the liquid crystal layer905, whose alignment state does not change in spite of changes in the applied voltage, prevents the retardation Δnd of the liquid crystal layer905from being reduced to zero. However, the retardation Δnd of the liquid crystal layer905can be minimized by reducing the thickness of the anchoring layer.

In the conventional display device shown inFIGS. 14A and 14B, an alignment film (not shown) is typically formed on the reflection electrodes903having protrusions and depressions, and the liquid crystal layer905is formed on the alignment film. The alignment film has a surface configuration which corresponds to the configuration of the reflection electrodes903. If the liquid crystal layer905is provided on a surface having protrusions and depressions, the orientation directions of the liquid crystal molecules are likely to become non-uniform in the neighborhood of the protrusions and depressions. This results in an increased apparent thickness of a layer of liquid crystal molecules which are not aligned in the direction of the electric field even under an applied voltage. Consequently, the retardation And (phase difference) of the liquid crystal layer905cannot be reduced sufficiently, making it different to obtain good black (dark) characteristics.

On the other hand, according to the present embodiment, an alignment film is formed on the planarization resin layer309, and the alignment surface which is in contact with the liquid crystal layer905is flat. Thus, the surface layer of the liquid crystal layer905can be made thinner than the surface layer of a conventional display device, whereby a substantial improvement in the black displaying characteristics can be obtained.

According to the present invention, there is provided a reflection-type LCD which realizes an improved aperture ratio and an improved efficiency of light utilization while maintaining a stable alignment in the liquid crystal. Since the reflection-type LCD of the present invention has high displaying characteristics, displayed images with a higher quality than conventionally can be realized.

The present invention is suitably used for a retroreflection-type LCD comprising a reflective layer having retroreflection characteristics.

This non-provisional application claims priority under 35 USC § 119 (a) on Patent Application No. 2004-171530 filed in Japan on Jun. 9, 2004, the entire contents of which are hereby incorporated by reference.