1. Field of the Invention
The present invention relates to a transflective liquid crystal display panel capable of displaying an image using reflected light of external light and illumination light from an illuminating device, a transflective liquid crystal display device using the same, and a manufacturing method of the transflective liquid crystal display panel.
2. Description of the Related Art
In portable electronic apparatuses, such as mobile phones and portable game machines, a transflective liquid crystal display device having low power consumption is used as a display unit since the battery drive time greatly influences the ease of use. Such a transflective liquid crystal display device is equipped with a transflective film for entirely reflecting external light (natural light) coming from the front surface of the display device, and for transmitting light emitted from a backlight through apertures formed therein. Therefore, it is possible to brightly illuminate the liquid crystal display panel using reflected light of external light or the illuminated light from an illuminating device.
In such a transflective liquid crystal display device, when an optical path length of external light is different from an optical path length of the illumination light from the illuminating device, the liquid crystal display panel does not have the same color and brightness in one mode in which external light is used as a light source for illuminating the liquid crystal display panel and in another mode in which light emitted from the backlight is used as the light source. Thus, in order to obtain the same color and brightness from the liquid crystal display device regardless of the kind of the light source for illuminating the liquid crystal display panel, conventionally, a so-called multi-gap type liquid crystal display device has been suggested (for example, see Japanese Patent Application Publication No. 2002-62525)
However, in order to make the optical path length of external light equal to the optical path length of illumination light, the above-mentioned conventional transflective liquid crystal display device is manufactured through many processes, such as a process for forming a thick reflective film on a substrate and then a process for forming a filter layer so as to cover the reflective film, resulting in an increase in manufacturing cost and the difficulty of manufacture.
Accordingly, the present invention has been made to solve the above problems, and it is an object of the present invention to provide a transflective liquid crystal display panel and a transflective liquid crystal display device that can display a high-definition image though using any one of external light and illumination light, and can be easily manufactured at low cost.
In order to attain the above object, the present invention provides a transflective liquid crystal display panel comprising: an insulating layer having a flat upper surface; a resin layer formed on the upper surface of the insulating layer; light-transmitting portions each having a groove which is formed in a portion of the resin layer and through a bottom surface of which the upper surface of the insulating layer is exposed; light transmissive electrodes each covering the bottom surface of the groove; light-reflecting portions in which portions of the resin layer other than portions corresponding to the light-transmitting portions are covered with a reflective film; and a filter layer which is formed over the resin layer with a liquid crystal layer interposed therebetween, and in which portions of the filter layer corresponding to the light-transmitting portions are thicker than other portions.
According to the transflective liquid crystal display panel, even if any one of reflected light and transmitted light is used as light for illuminating the liquid crystal display panel, it is possible to make an optical path length of reflected light equal to an optical path length of transmitted light when they pass through the liquid crystal display panel.
By making the optical path length of reflected light equal to the optical path length of transmitted light, even if any one of reflected light of external light and transmitted light 6f illumination light from the illuminating device is used for illuminating the liquid crystal display panel, it is possible for the liquid crystal display panel to exhibit the same color and brightness. More specifically, even when any one of a frontlight and a backlight is used, it is possible for the liquid crystal display panel to display a high-definition image and have a good visibility constantly.
When the depth of the groove in the light-transmitting portion is ‘D’, the difference in thickness between the liquid crystal layer in the light-transmitting portion and the liquid crystal layer in the light-reflecting portion is ‘L’, and the difference in thickness between the filter layer in the light-transmitting portion and the filter layer in the light-reflecting portion is ‘F’, the respective values are set to satisfy the formula D=L+F. In this way, the optical path length of reflected light becomes equal to the optical path length of transmitted light, and thus the liquid crystal display panel can exhibit the same color and brightness even if any one of reflected light and transmitted light is used.
According to the present invention, preferably, the thickness FR of the filter layer in the light-reflecting portion is set in the range of 0.4 to 2.0 μm, the thickness FT of the filter layer in the light-transmitting portion is set in the range of FR to FR+1.0 μm, the thickness LR of the liquid crystal layer in the light-reflecting portion is set in the range of 1.8 to 3.3 μm, and the thickness LT of the liquid crystal layer in the light-transmitting portion is set in the range of 3.5 to 5.3 μm.
According to the present invention, the liquid crystal display panel may further comprises switching elements covered with the insulating layer and contact holes for electrically connecting the switching elements formed in the insulating layer to the light transmissive electrodes. In addition, the present invention provides a transflective liquid crystal display device comprising the transflective liquid crystal display panel according to any one of the above-mentioned aspects and an illuminating device for illuminating the transflective liquid crystal display panel.
Further, the present invention provides a method for manufacturing a transflective liquid crystal display device comprising an insulating layer having a flat upper surface, a resin layer formed on the upper surface of the insulating layer, light-transmitting portions each having groove which is formed in the insulating layer and through a bottom surface of which the upper surface of the insulating layer is exposed; light transmissive electrodes each covering the bottom surface of the groove; and light-reflecting portions in which potions of the resin layer other than portions corresponding to the light-transmitting portions are covered with a reflective film, the method comprising the steps of: depositing a filter material on a substrate; forming a light transmissive resist layer on portions of the filter material corresponding to the light-transmitting portions; and forming a filter layer having a different thickness in portions corresponding to the light-reflecting portion and the light-transmitting portion, by etching the filter material and the resist layer to thin the portions of the filter layer corresponding to the light-reflecting portions.
As an embodiment of a transflective liquid crystal display panel of the present invention, an active matrix type transflective liquid crystal display device will now be described. In the drawings, a rate of a film thickness or other dimensions of each component is differently illustrated from an actual value thereof for promoting understanding.
As shown in
As shown in
Returning to
As the substrate main body 111, a transmissive insulating substrate made of a natural resin or a synthetic resin, such as polyvinyl chloride, polyester, or polyethyleneterephthalate, other than glass may be used, which transmits light emitted from the backlight 200.
The gate electrode 112 is preferably made of a metallic material, such as aluminum (Al), molybdenum (Mo), tungsten (W), tantalum (Ta), titanium (Ti), copper (Cu), or chromium (Cr), or an alloy of two or more of these metallic materials, such as Mo—W. As shown in
The gate insulating layer 113 is made of a silicon-based insulating film of, for example, silicon oxide (SiOx) or silicon nitride (SiNy), and is formed on an entire surface of the substrate main body 111 so as to cover the scanning lines 126 and the gate electrodes 112 shown in
The semiconductor layer 114 is an i-type semiconductor layer made of amorphous silicon (a-Si) in which no impurities are doped. A portion of the semiconductor layer 114 which is opposite to the gate electrode 112 with the gate insulating layer 113 interposed therebetween becomes a channel region. The source electrode 116 and the drain electrode 117 are preferably made of a metallic material, such as Al, Mo, W, Ta, Ti, Cu, or Cr, or an alloy of two or more of these metallic materials, and are formed on the i-type semiconductor layer 114 so as to be opposite to each other with the channel region interposed therebetween. Further, the source electrode 116 is formed by extending the signal line 125 arranged in the vertical direction.
Moreover, an n-type semiconductor layer 115 in which a V-group element, such as phosphorous (P), is highly doped is provided between the i-type semiconductor layer 114 and the source and drain electrodes 116 and 117 in order to obtain a good ohmic contact between the i-type semiconductor layer 114 and the source and drain electrodes 116 and 117.
An insulating layer 119 having a flat upper surface is formed on the substrate main body 111 so as to cover the TFTs 130. The insulating layer 119 is preferably made of an inorganic insulating material including a silicon-based insulating film, such as a silicon nitride (SiN) film, or an organic insulating material, such as acryl-based resin, polyimide resin, or benzocyclobutene polymer.
The insulating layer 119 is formed on the TFT 130 as a comparatively thick film to reliably insulate the reflective film 120 from the TFTs 130 and the lines 126 and 125. Therefore, it is prevented that a large parasitic capacitance is generated between the TFTs 130 and the reflective film 120. Further, with the insulating layer 119, the step difference formed by the TFTs 130 and the lines 126 and 125 on the substrate main body 111 is smoothed.
A resin layer 160 is formed on the insulating layer 119. The resin layer 160 is preferably made of, for example, a photosensitive resin (photoresist). The resin layer 160 is preferably formed in a predetermined pattern by means of a photolithography method.
Grooves 155 for transmitting light emitted from the backlight 200 are formed in the resin layer 160. Each of the grooves 155 is formed in a rectangular shape having a size of, for example, 30 μm by 30 μm to 60 μm by 140 μm, and is filled with the liquid crystal layer 150. In addition, a light transmissive electrode 151 is formed to cover the bottom surface 155a of the groove 155. The light transmissive electrode 151 is made of a transparent conductive material, such as ITO, to have a thickness of about 0.05 to 0.3 μm. A light-transmitting portion T for transmitting illumination light emitted from the backlight 200 is formed by the groove 151 and the light transmissive electrode 151.
Contact holes 121 for electrically connecting the drain electrodes 117 to the light transmissive electrodes 151 are formed in the insulating layer 119. The reflective film 120 constituting the pixel electrode is electrically connected to the light transmissive electrode 151 and the drain electrode 117 arranged below the insulating layer 119 via a conductor 122 filled in the contact hole 121. Any number of contact holes 121 may be formed with respect to one pixel.
The reflective film 120 is formed on the resin layer 160 excepting portions in which the grooves 155 are formed. The reflective film 120 is made of a metallic material having high reflectance, such as Al or Ag, to reflect light (external light) coming from the substrate 140. The reflective film 120 is formed at a plurality of places in a matrix type on the resin layer 160 so as to respectively correspond to regions divided by the scanning lines 126 and the signal lines 125. The edges of the reflective film 120 are arranged along the scanning line 126 and the signal line 125, such that almost the entire surface of the substrate main body 111 other than the TFTs 130, the scanning lines 126, and the signal lines 125 becomes the pixel regions.
As shown in
As shown in
Furthermore, for the purpose of the ease of assembly, the concave portion 120a has a diameter of 5 μm to 100 μm and a depth of 0.1 μm to 3 μm. The reason is that, when the depth of the concave portion 120a is less than 0.1 μm, the diffusion effect of reflected light is insufficient, and when the depth of the concave portion 120a is more than 3 μm, the pitch between the concave portions 120a must be widened in order to satisfy the conditions for the inclined angle of the inner surface, which may cause moire.
Returning to
A filter layer 170 is formed underneath the substrate 140. The filter layer 170 is preferably composed of color filters for allowing each pixel in the liquid crystal panel 100 to display three primary colors R, G, and B. The filter layer 170 is preferably twice thicker in the portion corresponding to the light-transmitting portion T than in the portion corresponding to the light-reflecting portion R. The filter layer 170 comprises a thin portion 170a corresponding to the light-reflecting portion R and a thick portion 170b corresponding to the light-transmitting portion T.
Since the thick portion 170b of the filter layer 170 in the light-transmitting portion T is twice thicker than the thin portion 170a in the light-reflecting portion R, external light (reflected light) N reciprocatively passes through the filter layer 170, that is, the thin portion 170a just one time, and the illumination light (transmitted light) B passes through the filter layer 170, that is, the thick portion 170b only once. Therefore, the optical path lengths of external light N and the illumination light B can be equal to each other when they pass through the filter layer 170. Accordingly, it is possible to obtain the same degree of color and brightness even if any one of external light and illumination light emitted from the backlight is used as light for illuminating the liquid crystal panel 100.
The optimum thicknesses of the respective layers constituting the liquid crystal display device 1 constructed as above will be described. First, we define that the thickness of the filter layer 170 in the light-reflecting portion R (the thickness of the thin portion 170a) is ‘FR’, the thickness of the filter layer 170 in the light-transmitting portion T (the thickness of the thick portion 170b) is ‘FT’, the thickness of the light-reflecting portion R in the liquid crystal layer 150 is ‘LR’, the thickness of the liquid crystal layer 150 in the light-transmitting portion T is ‘LT’, and the depth of the groove 115 is ‘D’.
In the liquid crystal display device 1 of the present embodiment, the depth D of the groove 115 formed in the resin layer 160 is formed to satisfy the following formula:
D=(LT−LR)+(FT−FR)
Here, with defining LT−LR as ‘L’ and FT−FR as ‘F’, the above formula becomes D=L+F. If the depth D of the groove satisfies the formula, it is possible to make the optical path length of external light N equal to the optical path length of the illumination light B from the backlight 200 when they pass through the liquid crystal panel 100.
In this way, by making the optical path length of external light N equal to the optical path length of the illumination light B, even if any one of external light N under situations such as out of doors and illumination light B from the backlight 200 is used, it is possible to obtain the same color and brightness from the liquid crystal panel 100. More specifically, even when any one of a frontlight and a backlight is used as a light source, it is possible to display a high-definition image and have a good visibility constantly.
For the thicknesses of each of the above layers, preferably, the thickness FR of the thin portion 170a in the filter layer 170 is set in the range of 0.4 to 2.0 μm, and the thickness FT of the thick portion 170b in the filter layer 170 is set in the range of FR to FR+1.0 μm. In addition, the thickness LR of liquid crystal layer 150 in the light-reflecting portion R is set in the range of 1.8 to 3.3 μm, and the thickness LT of the liquid crystal layer 150 in the light-transmitting portion T is set in the range of 3.5 to 5.3 μm. With the above thickness ranges, even when any one of a frontlight and a backlight is used as a light source, it is possible to display a high-definition image and have a good visibility constantly.
A manufacturing method of the transflective liquid crystal display panel according to the present invention will be described with reference to
Subsequently, as shown in
As shown in
In this way, the filter layer 170 comprising the thin portion 170a corresponding to the light-reflecting portion R and the thick portion 170b corresponding the light-transmitting portion T is formed. Subsequently, the layers shown in
As shown in
In the above-mentioned embodiment, an active matrix transflective liquid crystal display device is adopted as an example of the transflective liquid crystal display device. However, the present invention is not limited thereto, and can also be similarly applied to a passive liquid crystal display device.
As described above in detail, according to the transflective liquid crystal display panel of the present invention, even if any one of reflected light and transmitted light is used as light for illuminating the liquid crystal display panel, it is possible to make the optical path length of reflected light equal to the optical path length of transmitted light when they pass through the liquid crystal display panel.
By making the optical path length of reflected light equal to the optical path length of transmitted light, even if any one of reflected light of external light and transmitted light of illumination light emitted from an illumination device is used for illuminating the liquid crystal panel, the liquid crystal panel can have the same color and brightness. More specifically, even when any one of the frontlight and the backlight is used, it is possible to display a high-definition image and have a good visibility constantly.
Furthermore, according to the present invention, when the depth of the groove in the light-transmitting portion is ‘D’, the difference in thickness between the liquid crystal layer in the light-transmitting portion and the liquid crystal layer in the light-reflecting portion is ‘L’, and the difference in thickness between the filter layer in the light-transmitting portion and the filter layer in the light-reflecting portion is ‘F’, the respective values are determined to satisfy the expression D=L+F. As a result, the optical path length of reflected light becomes equal to the optical path length of transmitted light, and thus even if reflected light and transmitted light is selectively used, the liquid crystal display panel can exhibit the same color and brightness.
Moreover, preferably, the thickness FR of the filter layer in the light-reflecting portion is set in the range of 0.4 to 2.0 μm, the thickness FT of the filter layer in the light-transmitting portion is set in the range of FR to FR+1.0 μm, the thickness LR of the liquid crystal layer in the light-reflecting portion is set in the range of 1.8 to 3.3 μm, and the thickness LT of the liquid crystal layer in the light-transmitting portion is set in the range of 3.5 to 5.3 μm.
Further, the liquid crystal display panel according to the present invention may further comprise switching elements covered with the insulating layer and contact holes for electrically connecting the switching elements formed in the insulating layer to the light transmissive electrodes. In addition, the present invention provides a transflective liquid crystal display device comprising the liquid crystal display panel according to any one of the above-mentioned aspects and an illuminating device for illuminating the liquid crystal display panel.
Number | Date | Country | Kind |
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2003-198681 | Jul 2003 | JP | national |