LIQUID CRYSTAL DISPLAY AND MANUFACTURING METHOD THEREOF

Disclosed is a liquid crystal display, including: an insulation substrate; a microcavity formed on the insulating substrate and having an upper surface and sides; a liquid crystal layer injected into the microcavity; liquid crystal injection holes formed on one side of the microcavity to inject a liquid crystal into the microcavity; and a capping layer formed on the microcavity and having an upper surface patterned to form an arrangement of lenticular lenses.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2015-0052018 filed in the Korean Intellectual Property Office on Apr. 13, 2015, the entire contents of which are incorporated herein by reference.

BACKGROUND

Embodiments of the present disclosure relate to a liquid crystal display and a manufacturing method thereof, and more particularly, to a liquid crystal display and a manufacturing method thereof capable of implementing an autostereoscopic three-dimensional representation.

(b) Description of the Related Art

Generally, a stereoscopic image in 3D is implemented based on a principle of stereo vision by two eyes. That is, a three-dimensional effect can be realized due to a disparity, called binocular disparity, between the two eyes, which are spaced apart from each other by as much as about 65 mm. That is, left and right eyes each see different 2D images, and when the two images are transferred to the brain through the retinas, the brain fuses the two images with each other to reproduce original depth and reality of the 3D image. The ability is generally referred to as stereography.

A stereoscopic image display uses the binocular disparity and may be classified into a stereoscopic polarization type, a stereoscopic time division type, an autostereoscopic parallax-barrier type, a lenticular type, or a blinking light type depending on whether an observer wears separate glasses

The autostereoscopic stereoscopic image display uses an apparatus for separating a left-eye image and a right-eye image, like a lenticular lens layer on a liquid crystal display. The autostereoscopic stereoscopic image display has an advantage of providing the stereoscopic image without an observer additionally using glasses since the observer directly fixes his/her eyes on a screen. However, separately from a manufacturing process of a liquid crystal display, an additional process of separately providing the lenticular lens layer and attaching the lenticular lens layer on the liquid crystal display is required.

SUMMARY

The present disclosure has been made in an effort to provide a liquid crystal display and a manufacturing method thereof having advantages of omitting a process of additionally attaching a separate lenticular lens layer by providing a capping layer of the liquid crystal display in a form of the lenticular lens.

An exemplary embodiment of the present disclosure provides a liquid crystal display, including: an insulation substrate; a microcavity formed on the insulating substrate and having an upper surface and sides; a liquid crystal layer injected into the microcavity; liquid crystal injection holes formed on one side of the microcavity to inject a liquid crystal into the microcavity; and a capping layer formed on the microcavity and having an upper surface patterned to form an arrangement of lenticular lenses.

A lower surface of the capping layer may be patterned in an engaging shape corresponding to a shape of the liquid crystal injection hole, and the liquid crystal injection hole may be encapsulated with the capping layer.

The upper surface of the capping layer may include a plurality of lenticular lens parts extending in a vertical direction.

Any one of the plurality of lenticular lens parts may cover a plurality of pixel areas disposed in a horizontal direction.

Any one of the plurality of lenticular lens parts may cover a plurality of points of view.

The liquid crystal display may further include: a pixel electrode formed in the microcavity; and a common electrode positioned on the liquid crystal layer, in which the common electrode extends along the upper surface and the sides of the microcavity.

The common electrode may be formed in plural.

The liquid crystal display may further include: a roof layer covering the common electrode.

Another exemplary embodiment of the present disclosure provides a manufacturing method of a liquid crystal display, including: stacking a material for a sacrificial layer; forming the sacrificial layer by etching the material for the sacrificial layer; forming common electrodes which extend along an upper surface and sides of the sacrificial layer; forming a roof layer covering the sacrificial layer; forming a liquid crystal injection hole through which the sacrificial layer is exposed; forming a microcavity by removing the sacrificial layer through the liquid crystal injection hole; forming a liquid crystal layer in the microcavity through the liquid crystal injection hole; and covering the microcavity with a capping layer of which the upper surface is patterned to form an arrangement of lenticular lenses.

A lower surface of the capping layer may be patterned in an engaging shape corresponding to a shape of the liquid crystal injection hole, and the liquid crystal injection hole may be encapsulated with the capping layer.

The upper surface of the capping layer may include a plurality of lenticular lens parts extending in a vertical direction.

Any one of the plurality of lenticular lens parts may cover a plurality of pixel areas disposed in a horizontal direction.

Any one of the plurality of lenticular lens parts may cover a plurality of points of view.

The manufacturing method may further include: forming a pixel electrode of a transparent conductive material in a lower portion of the sacrificial layer.

The manufacturing method may further include: prior to forming the liquid crystal layer in the microcavity, forming an alignment layer in the microcavity through the liquid crystal injection hole.

The sacrificial layers formed in the forming of the sacrificial layers may be formed lengthwise along vertically adjacent pixels.

The roof layer may not be formed in a region in which the liquid crystal injection hole is formed.

The manufacturing method may further include: forming a lower insulating layer covering the common electrode prior to forming the roof layer; and forming an upper insulating layer covering the roof layer and the exposed lower insulating layer after forming the roof layer.

The forming of the liquid crystal injection hole may include etching the common electrode, the lower insulating layer, and the upper insulating layer.

According to an exemplary embodiment of the present disclosure, it is possible to omit the process of additionally attaching the separate lenticular lens layer for the autostereoscopic stereoscopic image display.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Further, in exemplary embodiments, since like reference numerals designate like elements having the same configuration, a first exemplary embodiment is representatively described, and in other exemplary embodiments in which only a configuration is different from the first exemplary embodiment, only the differences are described.

Hereinafter, a liquid crystal display according to an exemplary embodiment of the present disclosure is described in detail with reference toFIGS. 1 to 3.

FIG. 1is a layout view of a liquid crystal display according to an exemplary embodiment of the present disclosure.FIG. 2is a cross-sectional view taken along the line11-11ofFIG. 1.FIG. 3is a cross-sectional view taken along the line111-111ofFIG. 1.

Referring toFIGS. 1 to 3, a gate line121and a sustain voltage line131are formed on an insulating substrate110made of transparent glass, plastic, or the like. The gate line121includes a first gate electrode124a, a second gate electrode124b, and a third gate electrode124c. The sustain voltage line131includes storage electrodes135aand135band a protrusion134protruding in a direction of the gate line121. The sustain electrodes135aand135bhave a structure that encloses a first sub-pixel electrode192hand a second sub-pixel electrode1921of an adjacent pixel.

A horizontal part135bof the sustain electrode ofFIG. 1may be one wiring that is not separated from the horizontal part135bof the adjacent pixel.

A gate insulating layer140is formed on the gate line121and the sustain voltage line131. A semiconductor151disposed beneath a data line171, a semiconductor155disposed beneath source/drain electrodes, and a semiconductor154disposed at a channel portion of a thin film transistor are formed on the gate insulating layer140.

A plurality of ohmic contacts may be formed on each of the semiconductors151,154, and155and between the data line171and the source/drain electrodes, and is omitted in the drawings.

Data conductors171,173c,175a,175b,175cincluding a plurality of data lines171including a first source electrode173aand a second source electrode173b, a first drain electrode175a, a second drain electrode175b, a third source electrode173c, and a third drain electrode175care formed on each of the semiconductors151,154, and155and the gate insulating layer140.

The first gate electrode124a, the first source electrode173a, the first drain electrode175a, and the semiconductor154together form the first thin film transistor. A channel of the first thin film transistor is formed on the semiconductor154between the first source electrode173aand the first drain electrode175a. Similarly, the second gate electrode124b, the second source electrode173b, the second drain electrode175b, and the semiconductor154together form a second thin film transistor. The channel of the second thin film transistor is formed on the semiconductor154between the second source electrode173band the second drain electrode175b. The third gate electrode124c, the third source electrode173c, the third drain electrode175c, and the semiconductor154together form a third thin film transistor. The channel of the thin film transistor is formed on the semiconductor154between the third source electrode173cand the third drain electrode175c.

The data line171according to an exemplary embodiment of the present disclosure has a structure in which its width is narrower in a thin film transistor forming region in the vicinity of an extension175c′ of the third drain electrode175c. The data line171has the structure that maintains an interval from adjacent wirings and reduces signal interference, but is not necessarily formed so.

A first passivation layer180is formed on the data conductors171,173c,175a,175b, and175cand the exposed semiconductor154. The first passivation layer180may be made of inorganic insulating materials or organic insulating materials, such as silicon nitride (SiNx) and silicon oxide (SiOx).

A color filter230is formed on the first passivation layer180. The color filters230having the same color are formed at pixels adjacent in a vertical direction (data line direction). Further, the pixels adjacent in a horizontal direction (gate line direction) may be provided with the color filters230and230′ having different colors, and the two color filters230and230′ may overlap each other over the data line171. The color filters230and230′ may display one of the primary colors, such as three primary colors of red, green, and blue, and the like. However, the color filters230and230′ may also display one of cyan, magenta, yellow, white-based colors, without being limited to the three primary colors of red, green, and blue.

A black matrix220is formed on the color filters230and230′. The black matrix220is formed around a region (hereinafter, referred to as a ‘transistor forming region’) in which the gate line121, the sustain voltage line131, and the thin film transistor are formed and a region in which the data line171is formed. Furthermore, the black matrix is formed in a lattice structure having an opening corresponding to a region in which an image is displayed. The opening of the black matrix220is provided with the color filter230. Further, the black matrix220is made of a material through which light is not transmitted.

A second passivation layer185is formed on the color filter230and the black matrix220to cover the color filter230and the black matrix220. The second passivation layer185may be made of inorganic insulating materials or organic insulating materials, such as silicon nitride (SiNx) and silicon oxide (SiOx). According to another embodiment different from the one illustrated in the cross-sectional view ofFIGS. 2 and 3, when a step occurs due to a difference between a thickness of the color filter230and a thickness of the black matrix220, the second passivation layer185includes the organic insulating materials, thereby reducing or removing the step.

The color filter230, the black matrix200, and the passivation layers180and185are provided with a first contact hole186aand a second contact hole186bthat expose the first drain electrode175aand extension175b′ of the second drain electrode175b, respectively. In addition, the color filter230, the black matrix220, and the passivation layers180and185are provided with a third contact hole186cthat exposes the protrusion134of the sustain voltage line131and the extension175c′ of the third drain electrode175c.

According to an exemplary embodiment of the present disclosure, the black matrix220and the color filter230are provided with the contact holes186a,186b, and186c, but the etching of the contact holes of the black matrix220and the color filter230may be more difficult than that of the passivation layers180and185, depending on the material of the black matrix220and the color filter230. Therefore, at the time of etching the black matrix220or the color filter230, the black matrix220or the color filter230may be previously removed from positions at which the contact holes186a,186b, and186care formed.

According to an exemplary embodiment of the present disclosure, only the color filter230and the passivation layers180and185may be etched by changing a position of the black matrix220to form the contact holes186a,186b, and186c.

The pixel electrode192including the first sub-pixel electrode192hand the second sub-pixel electrode1921is formed on the second passivation layer185. The pixel electrode192may be made of transparent conductive materials, such as ITO (indium tin oxide) and IZO (indium zinc oxide).

The first sub-pixel electrode192hand the second sub-pixel electrode1921are adjacent to each other in a column direction, the overall shape thereof is a quadrangle, and the first sub-pixel electrode192hand the second sub-pixel electrode1921each include a cruciform stem part formed of a horizontal stem part and a vertical stem part intersecting the horizontal stem part. The sub-pixel electrode192hand the second sub-pixel electrode1921are divided into four sub-regions by the horizontal stem part and the vertical stem part, and each sub-region includes a plurality of fine branch parts.

The fine branch parts of the first sub-pixel electrode192hand the second sub-pixel electrode1921form an angle of about 40° to 45° with respect to the gate line121or the horizontal stem part. The fine branch parts of two adjacent sub-regions may be orthogonal to each other. A width of the fine branch part may be gradually increased, or an interval between the fine branch parts may be different. The first sub-pixel electrode192hand the second sub-pixel electrode1921are physically and electrically connected to the first drain electrode175aand the second drain electrode175b, respectively, through the contact holes186aand186band are supplied with data voltage from the first drain electrode175aand the second drain electrode175b.

Meanwhile, a connecting member194electrically connects the extension175c′ of the third drain electrode175cto the protrusion134of the sustain voltage line131through the third contact hole186c. As a result, some of the data voltage applied to the second drain electrode175bis divided by the third source electrode173c, such that a magnitude of the voltage applied to the second sub-pixel electrode1921may be smaller than that of the voltage applied to the first sub-pixel electrode192h.

Here, the area of the second sub-pixel electrode1921may have a size ranging from one to two times than that of the first sub-pixel electrode192h.

Meanwhile, the second passivation layer185may be provided with an opening that collects gas discharged from the color filter230and a cover part that is formed on the opening to cover the corresponding opening with the same material as the pixel electrode192. The opening and the cover part are structures for blocking the gas discharged from the color filter230from being transferred to another device, but are not necessarily included.

The opening and the cover part are formed on the second passivation layer185and the pixel electrode192and are provided with a microcavity305(seeFIGS. 13C, 13D, and 13E).

The microcavity305is provided with the liquid crystal layer3.

An upper surface of the microcavity305has a horizontal surface, and sides of the microcavity305may have approximately a vertical structure at an angle of 90±10°. The exemplary embodiment ofFIG. 2illustrates a tapered structure in which an angle θ of a side wall ranges from 80° to 90°.

The microcavity305is provided with the liquid crystal layer3. To arrange the liquid crystal molecules310injected into the microcavity305, the inside of the microcavity305may be provided with an alignment layer11(seeFIGS. 14 and 15). The alignment layer11may be a liquid crystal alignment layer that includes at least one of polyamic acid, polysiloxane, polyimide, or the like.

The inside of the microcavity305, or inside of the alignment layer, is provided with the liquid crystal layer3. The liquid crystal molecules310are initially aligned by the alignment layer11, and an alignment direction thereof is changed depending on the applied electric field. A height of the liquid crystal layer3corresponds to that of the microcavity305. The liquid crystal layer3positioned in the microcavity305is also called nano crystal.

The alignment layer11and the liquid crystal layer3, which are formed in the microcavity305, may be injected into the microcavity305using a capillary force.

A common electrode270is positioned on the second passivation layer185and the pixel electrode192and on the liquid crystal layer3that is injected into the microcavity305. The common electrode270extends along an upper surface and sides of the microcavity305or the liquid crystal layer3, and an extending direction thereof is the same as the extending direction of the gate line121. The common electrode270may keep a horizontal state even on the microcavity because the common electrode270is supported by a roof layer360, which is described below.

Further, the common electrode270may be formed as a plurality of common electrodes separated from each other around a liquid crystal injection hole307, and the plurality of common electrodes270may be formed at a predetermined distance from each other. The plurality of common electrodes270may be connected to each other at a portion from which the liquid crystal injection hole307is excluded.

The common electrode270is made of transparent conductive materials, such as ITO, IZO, and the like and generates an electric field along with the pixel electrode192to control the alignment direction of the liquid crystal molecules310.

A lower insulating layer350is positioned on the common electrode270and the second passivation layer185and on sides (or sides of the microcavity305) of the liquid crystal layer3. The lower insulating layer350may include inorganic insulating materials such as silicon nitride (SiNx).

The roof layer360is formed on the lower insulating layer350and may be made of organic materials. The roof layer360may serve as a support to form a space (microcavity) between the pixel electrode192and the common electrode270in which the nano liquid crystal is disposed.

The upper insulating layer370is formed on the roof layer360. The upper insulating layer370may include inorganic insulating materials such as silicon nitride (SiNx).

The lower insulating layer350, the roof layer360, and the upper insulating layer370may have the liquid crystal injection hole307positioned on one side thereof to inject a liquid crystal into the microcavity305. The liquid crystal injection hole307may be used even when a sacrificial layer for forming the microcavity305is removed.

The liquid crystal injection hole307has a trench shape in a horizontal direction (gate line direction).

According to an exemplary embodiment of the present disclosure, the lower insulating layer350and the upper insulating layer370may be omitted. The capping layer390is formed on the upper insulating layer370. That is, the capping layer390is formed on the microcavity305. The capping layer390may encapsulate the liquid crystal injection hole307. That is, the capping layer390seals the liquid crystal injection hole307and blocks the liquid crystal molecules310from leaking to the outside. As illustrated inFIGS. 2 and 3, the capping layer390may be formed to cover the whole upper surface of the insulating substrate110. The capping layer390may be made of an insulating material that does not react with the liquid crystal molecules310. According to an exemplary embodiment of the present disclosure, an inorganic layer (not illustrated) that encapsulates the liquid crystal injection hole307is formed on the upper insulating layer370, and the capping layer390may also be formed on the inorganic layer.

The capping layer390may be provided as a film of which the lower surface is patterned in an engaging shape corresponding to the trench shape of the liquid crystal injection hole307, and the upper surface is patterned to form an arrangement of lenticular lenses for displaying autostereoscopic images. The engaging shape of the lower surface of the capping layer390includes a horizontal part392(seeFIG. 16C) that contacts the upper insulating layer370, and a plurality of engaging parts393(seeFIG. 16C) that extends in a horizontal direction (with respect toFIG. 1). The arrangement shape of the lenticular lenses on the upper surface of the capping layer390includes a plurality of lenticular lens parts391(seeFIG. 16B) that extends in a vertical direction (with respect toFIG. 1). Each of the lenticular lens parts391covers a plurality of pixel areas in the horizontal direction. The pixel area refers to an area in which the pixel electrode192including the first sub-pixel electrode192hand the second sub-pixel electrode1921is formed.

The capping layer390is positioned on the upper insulating layer370so that the engaging part393of the capping layer390engages with the liquid crystal injection hole307, thereby forming the lenticular lens layer for displaying the stereoscopic image while encapsulating the liquid crystal injection hole307.

When the upper surface of the capping layer390forms a horizontal surface like the lower surface of the insulating substrate110, the lenticular lens layer may be additionally attached. However, according to the above-described exemplary embodiment of the present disclosure, the upper surface of the capping layer390is patterned in the arrangement shape of the lenticular lenses, and therefore, a separate process of additionally attaching the lenticular lens layer may be omitted.

A polarizer (not illustrated) may be positioned on the lower portion of the insulating substrate110and the upper portion of the capping layer390. The polarizer may include a polarization element generating polarization and a tri-acetyl-cellulose (TAC) layer for securing durability. According to some exemplary embodiments of the present disclosure, an upper polarizer and a lower polarizer have transmissive axes of which the direction may be vertical to or parallel with each other. Hereinafter, a manufacturing method of a liquid crystal display according to an exemplary embodiment of the present disclosure is described with reference toFIGS. 4 to 16.

FIGS. 4 to 16are diagrams sequentially describing a manufacturing method of the liquid crystal display according to the exemplary embodiment illustrated inFIGS. 1 to 3.

First,FIG. 4is a layout view in which the gate line121and the sustain voltage line131are formed on the insulating substrate110.

Referring toFIG. 4, the gate line121and the sustain voltage line131are formed on the insulating substrate110made of transparent glass, plastic, or the like. The gate line121and the sustain voltage line131may be made of the same material by the same mask during the same process step. Further, the gate line121includes the first gate electrode124a, the second gate electrode124b, and the third gate electrode124c, and the sustain voltage line131includes sustain electrodes135aand135band a protrusion134that protrudes in a direction towards the gate line121. The sustain electrodes135aand135bhave a structure that encloses a first sub-pixel electrode192hand a second sub-pixel electrode1921of a front pixel. The gate line121is applied with a gate voltage, and the sustain voltage line131is applied with a sustain voltage, and therefore, the gate line121and the sustain voltage line13are formed to be spaced apart from each other. The sustain voltage may have a constant voltage level or a swinging voltage level.

A gate insulating layer140is formed on the gate line121and the sustain voltage line131to cover the gate line121and the sustain voltage line131.

Next, as illustrated inFIGS. 5 and 6, the semiconductors151,154, and155, the data line171, and the source/drain electrodes173a,173b,173c,175a,175b, and175care formed on the gate insulating layer140.

FIG. 5illustrates a layout view in which the semiconductors151,154, and155are formed, andFIG. 6illustrates a layout view in which the data line and the source/drain electrodes173a,173b,173c,175a,175b, and175care formed. The semiconductors151,154, and155, the data line171, and the source/drain electrodes173a,173b,173c,175a,175b, and175cmay be formed together by the following process.

That is, the material forming the semiconductor and the material forming the data line/source/drain electrodes are sequentially stacked. Next, the two patterns are formed together by a one-time process that performs exposure, developing, and etching through a single mask (slit mask or halftone mask). In this case, to prevent the semiconductor154positioned at the channel portion of the thin film transistor from being etched, the corresponding portion is exposed through the slit or the halftone region of the mask.

In this case, a plurality of ohmic contacts may be formed on each of the semiconductors151,154, and155and between the data line171and the source/drain electrodes.

The first passivation layer180is formed over the whole area of the data conductors171,173c,175a,175b, and175cand the exposed semiconductor154. The first passivation layer180may be made of inorganic insulating materials or organic insulating materials, such as silicon nitride (SiNx) and silicon oxide (SiOx).

Next, as illustrated inFIGS. 7A and 7B, the color filter230and the black matrix220are formed on the first passivation layer180. Here,FIG. 7Ais a layout view corresponding toFIG. 1, andFIG. 7Bis a cross-sectional view corresponding toFIG. 2.FIG. 7Billustrates the color filter230ad the black matrix220, which are formed after the exposure and the etching.

In forming the color filter230and the black matrix220, the color filter230is first formed. The color filter230of one color is formed in a vertical direction (data line direction), and pixels adjacent in a horizontal direction (gate line direction) are provided with the color filters230and230′ of different colors. As the result, the exposing, developing, and etching processes are performed on each color filter230of each color. For example, a liquid crystal display including three primary colors goes through the exposing, developing, and etching processes three times to form the color filters230. In this case, the color filter230′ that is first formed on the data line171is positioned in the lower portion, and the color filter230that is formed later may overlap the color filter230′ while being positioned in the upper portion.

At the time of etching the color filter230, the color filter230may also be removed in advance at the positions where the contact holes186a,186b, and186care formed.

The black matrix220that is made of a material preventing light from being transmitted is formed on the color filter230. Referring to a shaded portion (representing the black matrix220) ofFIG. 7A, the black matrix220is formed in a lattice structure having the opening corresponding to the region in which the image is displayed. The color filter230is formed in the opening.

As illustrated inFIG. 7A, the black matrix220has a portion formed in the horizontal direction along the transistor forming region in which the gate line121, the sustain voltage line131, and the thin film transistor are formed and a portion formed in a vertical direction in the region in which the data line171is formed.

Referring toFIGS. 8A and 8B, the second passivation layer185is formed over the whole area of the color filter230and the black matrix220. The second passivation layer185may be made of inorganic insulating materials or organic insulating materials, such as silicon nitride (SiNx) and silicon oxide (SiOx). Here,FIG. 8Ais a layout view corresponding toFIG. 1, andFIG. 8Bis a diagram corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display that is formed up toFIG. 8A.

Next, the color filter230, the black matrix200, and the passivation layers180and185are provided with a first contact hole186aand a second contact hole186bthat expose the first drain electrode175aand extension175b′ of the second drain electrode175b, respectively. In addition, the color filter230, the black matrix220, and the passivation layers180and185are provided with a third contact hole186cthat exposes the protrusion134of the sustain voltage line131and the extension175c′ of the third drain electrode175c.

Next, the pixel electrode192including the first sub-pixel electrode192hand the second sub-pixel electrode1921is formed on the second passivation layer185. In this case, the pixel electrode192may be made of transparent conductive materials, such as ITO and IZO. Further, the first sub-pixel electrode192hand the second sub-pixel electrode1921each are physically and electrically connected to the first drain electrode175aand the second drain electrode175bthrough the contact holes186aand186b, respectively. Further, the connecting member194that electrically connects the extension175c′ of the third drain electrode175cto the protrusion134of the sustain voltage line131through the third contact hole186cis also formed. As the result, some of the data voltage applied to the second drain electrode175bis divided by the third source electrode173c, such that a magnitude of the voltage applied to the second sub-pixel electrode1921may be smaller than that of the voltage applied to the first sub-pixel electrode192h.

Next, as illustrated inFIGS. 9A to 9D, the sacrificial layer300is formed, and then the common electrode270is sequentially formed thereon. The sacrificial layer300and the common electrode270as illustrated inFIGS. 9A to 9Dare manufactured by the following method. Here,FIG. 9Ais a layout view corresponding toFIG. 1, andFIG. 9Bis a perspective view for describing the formation of the sacrificial layer300and the common electrode270.FIG. 9Cis a drawing corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 9A.FIG. 9Dis a diagram corresponding toFIG. 3and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 9A.

First, a process of forming the sacrificial layer300is described. As the material for the sacrificial layer, an organic layer, amorphous carbon, metal, or an inorganic layer is stacked on the whole surface of the liquid crystal panel on which the second passivation layer. Next, the structure of the sacrificial layer300is formed by etching the material for the stacked sacrificial layer. The material for the sacrificial layer may include an organic layer, amorphous carbon, metal, or an inorganic layer, and thus different etching methods or etchants depending on each material may be used. As illustrated inFIG. 9A, the sacrificial layer300is formed lengthwise along pixels that extend along the extending direction of the data line171and are adjacent vertically. The sacrificial layer300is not formed over the data line171

When the sacrificial layer300is not formed as an organic layer like a photoresist (PR), and the sacrificial layer300is formed of amorphous carbon, metal, or an inorganic layer, the sides of the sacrificial layer300have an angle of 90°±10° and thus may have approximately a vertical structure.

Next, transparent conductive materials such as ITO and IZO are stacked over the whole area of the structure of the sacrificial layer300to form the common electrode270. The common electrodes270are positioned on the upper surface and the sides of the sacrificial layer300and extend along the upper surface and the sides of the sacrificial layer300. The extending direction of the common electrode270may be an extending direction of the gate line121.

Next, as illustrated inFIGS. 10A to 10D, the lower insulating layer350that is positioned on the common electrode270and includes inorganic insulating materials, such as silicon nitride (SiNx), is formed over the whole surface of the liquid crystal panel. The lower insulating layer350covers the common electrode270. Here,FIG. 10Ais a layout view corresponding toFIG. 1, andFIG. 10Bis a perspective view for describing a form of the sacrificial layer300, the common electrode270, and the lower insulating layer350.FIG. 100is a diagram corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 10AFIG. 10Dis a diagram corresponding toFIG. 3and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 10A.

Next, the roof layer360is formed as illustrated inFIGS. 11A to 11D. The roof layer360may be formed and include an organic material. The roof layer360is not formed in the region (hereinafter, referred to as a ‘liquid crystal injection hole open region’) etched by the process of forming the liquid crystal injection hole307. Here,FIG. 11Ais a layout view corresponding toFIG. 1, andFIG. 11Bis a perspective view for describing the formation of the sacrificial layer300, the common electrode270, the lower insulating layer360, and the roof layer360.FIG. 11Cis a diagram corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 11A.FIG. 11Dis a diagram corresponding toFIG. 3and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 11A.

FIG. 11Aillustrates that the liquid crystal injection hole open region is formed corresponding to the thin film transistor forming region in which the liquid crystal injection hole open region has a structure extending along a direction in which the gate line is formed. Further, the roof layer360is not formed in the corresponding region and therefore the generally formed lower insulating layer350is exposed.

The roof layer360may be formed by stacking a material for the roof layer including the organic material in the whole panel region, exposing and developing the material using the mask, and then removing the material for the roof layer of the region in which the liquid crystal injection hole307is formed. The lower insulating layer350formed in the lower portion of the roof layer360is not etched and thus is exposed. Only the common electrode270and the lower insulating layer350are formed on the sacrificial layer300in the liquid crystal injection hole open region, and the sacrificial layer300, the common electrode270, the lower insulating layer350, and the roof layer360are stacked in other regions.

Next, as illustrated inFIGS. 12A to 12D, the upper insulating layer370is formed on the whole surface of the liquid crystal panel by stacking the material for the upper insulating layer including the inorganic insulating material such as silicon nitride (SiNx). Here,FIG. 12Ais a layout view corresponding toFIG. 1, andFIG. 12Bis a perspective view for describing a form of the sacrificial layer300, the common electrode270, the lower insulating layer350, the roof layer360, and the upper insulating layer370.FIG. 12Cis a diagram corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 12A.FIG. 12Dis a diagram corresponding toFIG. 3and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 12A.

Next, as illustrated inFIGS. 13A and 13E, the liquid crystal injection hole307is formed by etching the liquid crystal injection hole open region. Here,FIG. 13Ais a layout view corresponding toFIG. 1, andFIGS. 13B and 13Care perspective views for describing the process of forming the liquid crystal injection hole307.FIG. 13Dis a diagram corresponding toFIG. 2and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 13A.FIG. 13Eis a diagram corresponding toFIG. 3and illustrates a cross-sectional view of the liquid crystal display formed up toFIG. 13A.

Describing in detail, as illustrated inFIG. 13B, the lower insulating layer350and the upper insulating layer370formed in the liquid crystal injection hole open region among the upper insulating layer370and the lower insulating layer350stacked over the whole region of the liquid crystal panel are etched by the inorganic insulating material such as silicon nitride (SiNx). Next, the sacrificial layer300is exposed by etching the common electrode270formed in the liquid crystal injection hole open region. According to an exemplary embodiment of the present disclosure, the lower insulating layer350, the upper insulating layer370, and the common electrode270may also be etched by the same etching process.

To etch the liquid crystal injection hole open region, the photoresist (PR) is formed in the whole region, and the photoresist (PR) corresponding to the liquid crystal injection hole open region is removed to form the photoresist pattern, which is then is etched depending on the photoresist (PR) pattern to form the liquid crystal injection hole open region. In this case, the upper insulating layer370, the lower insulating layer350, the common electrode270, and the sacrificial layer300in the liquid crystal injection hole open region are etched, and the layer thereunder is not etched. According to some exemplary embodiments of the present disclosure, the sacrificial layer300may partially be etched or may not be etched. Here, the process of etching the liquid crystal injection hole open region may be performed by dry etching or wet etching.

Next, as illustrated inFIGS. 13C to 13E, the exposed sacrificial layer300is removed. According to an exemplary embodiment of the present disclosure, the sacrificial layer300is formed of an organic layer, that is, amorphous carbon, metal, or an inorganic layer, and therefore, the sacrificial layer300may be removed by wet etching or dry etching depending on each material.

Meanwhile, the photoresist pattern formed to etch the liquid crystal injection hole open region may be removed using a separate photoresist stripper.

Next, as illustrated inFIG. 14, the alignment layer11is formed inside the microcavity305. In detail, when an alignment solution including an alignment material is dropped by an inkjet method, the alignment solution is injected into the microcavity305through the liquid crystal injection hole307by capillary force. Next, a solution component of the alignment solution is evaporated during a hardening process, and the alignment material remains in an inner wall of the microcavity305to form the alignment layer11.

Next, as illustrated inFIG. 15, the liquid crystal layer3is injected into the microcavity305. In detail, when the liquid crystal material including the liquid crystal molecules310is dispersed by the inkjet method, the liquid crystal material is injected into the microcavity305through the liquid crystal injection hole307by capillary force to form the liquid crystal layer3.

Next, the microcavity305is covered with the capping layer390illustrated inFIGS. 16A to 16C, and the liquid crystal injection hole307is encapsulated to prevent the liquid crystal layer3injected into the microcavity305from leaking to the outside. The capping layer390may be made of a transparent insulating material that does not react with the liquid crystal molecules310.

Here,FIG. 16Ais a layout view illustrating the capping layer390, which covers the plurality of pixel areas (herein, a 6×3 pixel area illustrated) disposed in the horizontal direction (gate line direction) and the vertical direction (data line direction).FIG. 16Bis a cross-sectional view illustrating a cross section of the capping layer390taken along the line XVI-B ofFIG. 16A.FIG. 16Cis a cross-sectional view illustrating a cross section of the capping layer390taken along the line XVI-C ofFIG. 16A.

The capping layer390may be provided as a film of which the lower surface is patterned in an engaging shape corresponding to the trench shape of the liquid crystal injection hole307, and the upper surface is patterned to form an arrangement of lenticular lenses for displaying autostereoscopic images. The engaging shape of the lower surface of the capping layer390includes a horizontal part392that contacts the upper insulating layer370and a plurality of engaging parts393that extends in the horizontal direction to engage with the liquid crystal injection hole307. The arrangement shape of the lenticular lenses on the upper surface of the capping layer390includes a plurality of lenticular lens parts391that extend in a vertical direction. Each of the lenticular lens parts391covers a plurality of pixel areas in the horizontal direction.

The capping layer390is positioned on the upper insulating layer370so that the engaging part393of the capping layer390engages with the liquid crystal injection hole307, thereby forming the lenticular lens layer for displaying the stereoscopic image while encapsulating the liquid crystal injection hole307.

FIG. 16Aillustrates a case in which the capping layer390forms the single lenticular lens part391in the horizontal direction and corresponds to six pixel areas.FIG. 16Ais only an example and does not limit the present disclosure. The single lenticular lens part391may be formed to cover N points of view (N is a natural number). For example, the single lenticular lens part391may cover nine points of view. One point of view corresponds to one pixel, which includes a red sub-pixel, a green sub-pixel, and a blue sub-pixel. One sub-pixel may correspond to one pixel area.

According to the manufacturing method in accordance with the exemplary embodiment of the present disclosure as described above, the upper surface of the capping layer390is patterned in the arrangement shape of the lenticular lenses, and therefore, the separate process of additionally attaching the lenticular lens layer may be omitted.

The accompanying drawings and the detailed description of the present disclosure are only examples of the present system and method and do not limit the meaning or the scope of the present system and method described in the appended claims. Therefore, those of ordinary skill in the art would appreciate that various modifications and other equivalent embodiments are available.

While the present system and method have been described in connection with exemplary embodiments, the present system and method are not limited to the disclosed embodiments. On the contrary, the present system and method cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

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