Liquid crystal display and method for manufacturing the same

Provided is a liquid crystal display including: a first substrate; a wire grid polarizer disposed on the first substrate and including a first region and a second region spaced apart from each other by a stitch line; and a first thin film layer disposed on the wire grid polarizer. The stitch line includes a shape of a curved line or a series of straight lines connected by bends.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of Korean Patent Application No. 10-2015-0051076 filed on Apr. 10, 2015, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Field

Exemplary embodiments relate to a liquid crystal display and a method of manufacturing the same.

Discussion of the Background

A liquid crystal display, which is one of the most common types of flat panel displays currently in use, generally include two sheets of display panels with field generating electrodes, such as a pixel electrode and a common electrode, disposed on the display panels, and a liquid crystal layer interposed between the display panels, generates an electric field in the liquid crystal layer by applying a voltage to the field generating electrodes, and controls the orientation of liquid crystal molecules in the liquid crystal layer by the generated electric field, thereby controlling the polarization of incident light so as to display images.

In general, the polarization of incident light is adjusted by attaching a polarizer to an outer surface of each of the two sheets of display panels with the field generating electrodes disposed thereon, and the polarizer is an absorptive polarizer that absorbs the remaining light other than intended polarized light rays. Therefore, with the polarizer, very few of the light sources supplying light to the liquid crystal display are used to display an image, so that optical efficiency of the light sources of the liquid crystal display deteriorates.

In order to improve the optical efficiency of the light sources of the liquid crystal display, a wire grid polarizer has been suggested. Particularly, a nano-imprint method with high manufacturing cost and accuracy has been proposed for forming the wire grid polarizer.

Meanwhile, the larger the liquid crystal display is, the larger the wire grid polarizer is, and when a large area wire grid polarizer is formed, a nano-imprint mold also needs to have a large area, so that it is difficult to manufacture the large nano-imprint mold and the manufacturing cost thereof is high. In addition, a method of manufacturing a large wire grid polarizer by repeating a step of forming a small wire grid polarizer using a small area mold several times has been introduced, but a stitch line is generated at a connection part between the small area wire grid polarizers, and light leakage occurs at the connection part, which might be recognized by a LCD display viewer. As a result, a display defect occurs.

SUMMARY

Exemplary embodiments provide a liquid crystal display including a large wire grid polarizer and a method of manufacturing the same.

An exemplary embodiment discloses a liquid crystal display including: a first substrate; a wire grid polarizer disposed on the first substrate and including a first region and a second region spaced apart from each other by a stitch line; and a first thin film layer disposed on the wire grid polarizer. The stitch line includes a shape of a curved line or a series of straight lines connected by bends.

An exemplary embodiment also discloses a method of manufacturing a liquid crystal display, including: forming a metal layer on a first substrate; dropping first resin drops onto a first part of the metal layer; forming first resin patterns by compressing the first resin drops using a mold; dropping second resin drops onto a second part of the metal layer not overlapping the first resin patterns; forming second resin patterns by compressing the second resin drops using the mold; and forming a wire grid polarizer including metal lines by etching the metal layer using the first resin patterns and the second resin patterns as a mask. The wire grid polarizer includes a first region and a second region spaced apart from each other by a stitch line, and the stitch line has a shape of a curved line or a series of straight lines connected by bends.

An exemplary embodiment further discloses a liquid crystal display including: a first substrate; a wire grid polarizer disposed on the first substrate and including a first metal line pattern and a second metal line pattern, the wire grid polarizer being disposed in a pixel; and a thin film layer disposed on the wire grid polarizer. The first metal line pattern is spaced apart from the second metal line pattern to form a gap between the first metal line pattern and the second metal line pattern, and the gap includes a portion corresponding to a bent line or a curved line.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Hereinafter, a liquid crystal display and a method of manufacturing the same according to an exemplary embodiment will be described with reference to the accompanying drawings.

First, a liquid crystal display according to an exemplary embodiment will be described with reference toFIG. 1andFIG. 2.FIG. 1is a layout view of a liquid crystal display according to an exemplary embodiment, andFIG. 2is a cross-sectional view taken along section line II-II ofFIG. 1according to an exemplary embodiment.

Referring toFIG. 1andFIG. 2, a liquid crystal display1000includes a first display panel100and a second display panel200facing each other, and a liquid crystal layer300interposed between the first and second display panels100and200.

First, the first display panel100will be described.

The first display panel100includes a first substrate110, a wire grid polarizer30including metal lines31, and a first thin film layer120.

The first substrate110may include or may be made of transparent glass, plastic, or the like.

The wire grid polarizer30is disposed on the first substrate110, and may include any one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chromium (Cr), iron (Fe), and the like. Further, the wire grid polarizer30may include an alloy of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chromium (Cr), iron (Fe), and the like. The line width of the metal line31of the wire grid polarizer30may be about 60 nm or less, the interval between two adjacent ones of the metal lines31of the wire grid polarizer30may be about 120 nm or less, and the entire area of the wire grid polarizer30may be 200 mm×200 mm or more.

The wire grid polarizer30includes a first region30A and a second region30B. In the first region30A and the second region30B, the metal lines31are disposed to have a predetermined width and a predetermined interval.

Further, the first region30A is spaced apart from the second region30B. A region between the first region30A and the second region30B is referred to as a stitch line S, and according to an exemplary embodiment, the stitch line S is formed in a curved line shape rather than a straight line. The stitch line S is formed in the curved line shape, so that lengths of the metal lines31disposed in the first region30A and the second region30B may vary. More specifically, the lengths of the metal lines31disposed in the first region30A and the second region30B become shorter as the locations thereof are closer to the stitch line S.

According to an exemplary embodiment, the wire grid polarizer30may include the first region30A and the second region30B, but is not limited thereto, and the wire grid polarizer30may further include regions in addition to the first region30A and the second region30B. In this case, the regions are spaced apart from each other, and another stitch line S is formed in a curved line shape.

The first thin film layer120is disposed on the wire grid polarizer30. The first thin film layer120may include thin film transistors, gate lines, data lines, and pixel electrodes. The thin film transistors may be disposed in a matrix form. A gate line is connected to a gate terminal of a thin film transistor, a data line is a connected to a source terminal of a thin film transistor, and a pixel electrode is connected to a drain terminal of a thin film transistor. The thin film transistors, the gate lines, the data lines, and the pixel electrodes constitute multiple pixels.

Next, the second display panel200will be described.

The second display panel200may include a second substrate210, a second thin film layer220, and a polarizer230.

The second substrate210may include or may be made of transparent glass, plastic, or the like.

The second thin film layer220is disposed between the liquid crystal layer300and the second substrate210, and may include a light blocking member, a color filter, and a common electrode. The light blocking member may divide a pixel area, the color filter may be disposed in a region partitioned by the light blocking member, and the common electrode may be disposed on the light blocking member and the color filter.

The polarizer230may be disposed on an outer surface of the second substrate210, but the location is not limited thereto.

In general, compared to a straight stitch line, a curved stitch line S is more blurredly recognized by a viewer, and in the case of the liquid crystal display1000according to an exemplary embodiment, the large wire grid polarizer30covering relatively a large area than the size of a wire grid mold includes the first region30A and the second region30B spaced apart from each other, and the stitch line S, which is a region between the first region30A and the second region30B spaced apart from each other, is formed in the curved line shape, which makes it difficult for the viewer of the display to recognize the stitch line S. Accordingly, it is possible to provide a liquid crystal display including the large wire grid polarizer without increasing manufacturing costs.

Hereinafter, a method of manufacturing the liquid crystal display according to an exemplary embodiment will be described with reference toFIG. 3throughFIG. 9, andFIG. 1andFIG. 2.FIG. 3throughFIG. 9are diagrams sequentially illustrating a method of manufacturing the liquid crystal display according to an exemplary embodiment.

Referring toFIG. 3andFIG. 4, a metal layer35is formed on the first substrate110, and then resin drops40are disposed on the metal layer35.

The metal layer35may include any one of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chromium (Cr), iron (Fe), and the like. Further, the metal layer35may include an alloy of aluminum (Al), gold (Au), silver (Ag), copper (Cu), chromium (Cr), iron (Fe), and the like.

The resin drops40may be dropped onto the metal layer35by using an Inkjet device400. Here, the resin drops40may be dropped onto a part of the metal layer35, not the entire surface thereof. Further, the resin drops40may be dropped at predetermined intervals in a row direction. In addition, the resin drops40may be dropped to have different lengths when progressing in a column direction. For example, the lengths in a row direction of the dropped resin drops40become shorter when progressing in the column direction.

Referring toFIG. 5andFIG. 6, a first resin pattern region50A may be formed by performing an imprint method using a mold500. The size of the mold500may be smaller than the entire size of the metal layer35in which a wire-grid pattern is to be formed.

When the dropped resin drops40are compressed by the mold500, the resin drops40form first resin patterns45A by grooves of the mold500. The first resin patterns45A formed by the mold500constitute the first resin pattern region50A. The lengths of the first resin patterns45A gradually increases or decreases when progressing in the column direction to form a curved line shape.

Referring toFIG. 7,FIG. 8, andFIG. 9, onto the metal layer35except for the portion where the first resin pattern region50A is formed, resin drops40may be dropped by using the inkjet device400, and then a second resin pattern region50B may be formed by performing the imprint method using the mold500.

At the time of dropping the resin drops40onto the metal layer35except for the portion where the first resin pattern region50A is formed, the resin drops40are dropped at a predetermined interval from the first resin pattern region50A.

As illustrated inFIG. 5andFIG. 8, when the dropped resin drops40are compressed by using the mold500or a mold has a shape corresponding to the second resin patterns45B, the resin drops40form second resin patterns45B by grooves of the mold500. The second resin pattern45B formed by the mold500constitutes the second resin pattern region50B. The first resin pattern region50A is spaced apart from the second resin pattern region50B with a predetermined interval, and the predetermined interval, that is, a stitch line S, is formed in a curved line shape. The lengths of the first resin patterns45A and the second resin patterns45B formed in the first resin pattern region50A and the second resin pattern region50B, respectively, become shorter as the locations of the first resin patterns45A and the second resin patterns45B are closer to the stitch line S.

Further, the first resin patterns45A may be used as a mask to form a first metal line pattern by an etching process. Portions of the metal layer35beneath the first resin patterns45A may not be etched during the etching process, and thus the first metal line pattern may have substantially the same pattern as the pattern shape of the first resin patterns45A. Similarly, the second resin patterns45B may be used as a mask to form a second metal line pattern by an etching process.

Portions of the metal layer35beneath the second resin patterns45B may not be etched during the etching process, and thus the second metal line pattern may have substantially the same pattern as the pattern shape of the second resin patterns45B. Thus, after the etching process, a wire grid polarizer including the first metal line pattern and the second metal line pattern may be formed. The wire grid polarizer may be disposed in one or more pixel areas, and a gap between the first metal line pattern and the second metal line pattern may correspond to the stitch line S described herein.

As shown in the drawings, e.g.,FIG. 8,FIG. 10,FIG. 11, andFIG. 12, the gap includes one or more portions corresponding to a bent line or a curved line. Further, the bent line or the curved line has a direction not parallel to edges of the pixels. Metal lines of the first metal line pattern and the second metal line pattern may have different lengths according to a proximity to the gap.

Referring toFIG. 1andFIG. 2, after the wire grid polarizer30including the metal lines31is formed by etching the metal layer35using the first resin patterns45A and the second resin patterns45B as a mask, a first thin film layer120is formed on the wire grid polarizer30, thereby manufacturing the first display panel100.

The wire grid polarizer30includes the first region30A and the second region30B. The first region30A and the second region30B are spaced apart from each other. The stitch line S, which is a region between the first region30A and the second region30B spaced apart from each other, is formed in the curved line shape.

After the second display panel200including the second substrate210, the second thin film layer220, and the polarizer230is formed, the liquid crystal layer300is formed by dropping liquid crystal onto the first display panel100or the second display panel200, and then the first and second display panels100and200are attached.

Further, after attaching the first and second display panels100and200, the liquid crystal layer300may also be formed by injecting liquid crystal between the first and second display panels100and200.

Hereinafter, a liquid crystal display according to an exemplary embodiment will be described with reference toFIG. 10,FIG. 11, andFIG. 12.

FIG. 10is a layout view schematically illustrating a liquid crystal display according to an exemplary embodiment.

Referring toFIG. 10, a liquid crystal display1000according to an exemplary embodiment includes a wire grid polarizer including metal lines31, a light blocking member BM, and multiple pixels PX divided by the light blocking member BM.

The wire grid polarizer may be divided into multiple regions by a stitch line S. In this case, the stitch line S has a shape in which a straight line extends in a diagonal direction to be bent in a zigzag shape, and overlaps the pixels PX and the light blocking member BM (e.g., the stitch line S may correspond to a triangle wave shape or a saw-tooth shape). As described above, the stitch line S overlaps the pixels PX, thereby reducing luminance deviation between the pixels.

FIG. 11is a layout view schematically illustrating a liquid crystal display according to an exemplary embodiment.

Referring toFIG. 11, a liquid crystal display1000according to an exemplary embodiment includes a wire grid polarizer including metal lines32, a light blocking member BM, and pixels PX divided by the light blocking member BM.

The wire grid polarizer may be divided into multiple regions by a stitch line S. In this case, the stitch line S has a curved wave line shape (e.g., the stitch line S may correspond to a sinusoidal wave shape) and overlaps the pixels PX and the light blocking member BM.

FIG. 12is a layout view schematically illustrating a liquid crystal display according to an exemplary embodiment.

Referring toFIG. 12, a liquid crystal display1000according to an exemplary embodiment includes a wire grid polarizer including metal lines33, a light blocking member BM, and multiple pixels PX divided by the light blocking member BM.

The wire grid polarizer may be divided into multiple regions by a stitch line S. In this case, the stitch line S has a shape in which a straight line is bent to include recess portions and convex portions (e.g., the stitch line S corresponds to a square wave shape), and overlaps the pixels PX and the light blocking member BM.

According to an exemplary embodiment, the wire grid polarizer includes the first region and the second region spaced apart from each other by the stitch line, and the stitch line is formed in the curved line shape, which may make it difficult for a viewer to recognize the stitch line. Accordingly, it is possible to provide the liquid crystal display including the large area wire grid polarizer without increasing manufacturing costs.

Moreover, the stitch line overlaps the pixels, thereby reducing a luminance deviation between the pixels.