CN104460079A - 柔性液晶面板制作方法及柔性液晶面板 - Google Patents
柔性液晶面板制作方法及柔性液晶面板 Download PDFInfo
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Abstract
本发明提供一种柔性液晶面板制作方法及柔性液晶面板。该柔性液晶面板制作方法先在第一柔性基板(1)上制作梳型像素电极(11)、栅极线、数据线、TFT、及彩色滤光层;采用卷对卷方式在柔性母板(30)上连续涂布封胶(51’)与液晶微胶囊(53)的混合液,同时进行UV照射,使封胶(51’)发生聚合反应固化成聚合物层(51),所述液晶微胶囊(53)分布于聚合物层(51)内,得到聚合物/液晶混合层(5);再对所述柔性母板(30)与聚合物/液晶混合层(5)的复合层进行裁切,得到第二柔性基板(3);然后将所述第一柔性基板(1)与第二柔性基板(3)进行贴合;最后贴合上偏光片(9)与下偏光片(7)。
Description
技术领域
本发明涉及显示技术领域,尤其涉及一种柔性液晶面板制作方法及柔性液晶面板。
背景技术
随着可穿戴应用设备如智能眼镜、智能手表等的逐渐兴起,显示行业对柔性显示器件的需求也不断增加。
有机发光二极管显示器件(Organic Light Emitting Display,OLED)具有自发光,不需背光源、厚度薄、视角广、反应速度快等特点,从而具有柔性显示的天然优势。但是,目前OLED产业仍然具有很高的技术门槛,制程难度大、良率低、成本高,这些难点都阻碍着OLED的广泛应用。
液晶显示器(Liquid Crystal Display,LCD)是目前市场上应用最为广泛的显示产品,其生产工艺技术十分成熟,产品良率高,成本相对较低,市场接受度高。
通常,液晶显示器包括壳体、设于壳体内的液晶面板及设于壳体内的背光模组。液晶面板由一彩色滤光片基板(Color Filter,CF)、一薄膜晶体管阵列基板(Thin Film Transistor Array Substrate,TFT Array Substrate)以及一填充于两基板间的液晶层(Liquid Crystal Layer)等组成。CF基板和TFT基板的相对内侧设有透明电极。液晶显示器通过电场对液晶层内的液晶分子取向进行控制,改变光的偏振状态,并藉由偏光板实现光路的穿透与阻挡,达到显示的目的。
图1所示为一现有液晶面板在平面状态下的结构示意图。由于液晶层300内的液晶材料为液体,具有流动性,TFT基板100与CF基板200由分布于两基板之间的柱状间隔物(Photo Spacer,PS)400支撑,以维持液晶层300的厚度(Cell Gap)及厚度均匀性。一般情况下,如图1所示的现有液晶面板在平面状态下能够满足显示均匀性的要求,所述液晶层300的厚度保持在设计值附近,厚度较均匀。但当原本处于平面状态的液晶面板弯曲之后,如图2所示,由于处于弯曲状态的液晶面板各处所受的压力不同,曲率较大的地方受力较大,导致位于TFT基板100与CF基板200之间不同位置处的柱状间隔物400的高度不同,同时液晶层300内的液态液晶材料受挤压而流动,最终造成各处液晶层300的厚度不均匀。
目前主流市场上常见的液晶面板分为三大类,分别是扭曲向列/超扭曲向列(TN/STN)型、平面转换(IPS)型及垂直配向(VA)型。尽管它们的调控液晶显示的原理有所不同,但是这三种类型的液晶显示面板的基本结构比较类似,其显示特性都与液晶层的厚度密切相关,液晶层厚度是否均匀对显示效果有直接影响,改变液晶层厚度会影响液晶面板的显示亮度、对比度、响应速度等。因此,必须对传统液晶面板进行改进,解决因弯曲而导致的液晶层厚度不均匀的问题,使得液晶面板能够应用于柔性显示。
发明内容
本发明的目的在于提供一种柔性液晶面板制作方法,能够消除现有液晶面板弯曲后液晶层厚度不均匀的问题,使得液晶面板适用于柔性显示,并提高制程效率。
本发明的目的还在于提供一种柔性液晶面板,能够使得液晶材料不会出现大范围流动,消除现有液晶面板弯曲后液晶层厚度不均匀的问题,适用于柔性显示。
为实现上述目的,本发明首先提供一种柔性液晶面板制作方法,先在第一柔性基板上制作梳型像素电极、栅极线、数据线、TFT、及彩色滤光层;采用卷对卷方式在柔性母板上连续涂布封胶与液晶微胶囊的混合液,同时进行UV照射,使封胶发生聚合反应固化成聚合物层,所述液晶微胶囊分布于聚合物层内,得到聚合物/液晶混合层;再对所述柔性母板与聚合物/液晶混合层的复合层进行裁切,得到第二柔性基板;然后将所述第一柔性基板与第二柔性基板进行贴合;最后贴合上偏光片与下偏光片。
所述柔性液晶面板制作方法,包括如下步骤:
步骤1、提供第一柔性基板,将所述第一柔性基板与玻璃贴合;
步骤2、通过微显影制程在所述第一柔性基板上制作梳型像素电极、栅极线、数据线、TFT、及彩色滤光层,然后去除玻璃;
步骤3、提供一柔性母板,将所述柔性母板放置于卷对卷设备的传送轮上,所述柔性母板的两端分别卷绕于卷对卷设备的两辊轴上,所述柔性母板的正上方垂直设置一狭缝型喷嘴,所述狭缝型喷嘴一侧设置一平行于所述柔性母板的UV灯管;
步骤4、驱动所述辊轴及传送轮转动,带动柔性母板沿狭缝型喷嘴向UV灯管的方向由一辊轴向另一辊轴运动,并通过所述狭缝型喷嘴向所述柔性母板上连续涂布封胶与液晶微胶囊的混合液,同时利用UV灯管进行UV照射,使封胶发生聚合反应固化成聚合物层,所述液晶微胶囊分布于聚合物层内,得到聚合物/液晶混合层;
所述封胶含有可聚合单体;所述液晶微胶囊包括一硬质外壳及包裹于所述硬质外壳内的多个液晶分子;
步骤5、对柔性母板与聚合物/液晶混合层的复合层进行裁切,得到第二柔性基板,该第二柔性基板的尺寸与所述第一柔性基板的尺寸相适应;
步骤6、将所述第一柔性基板与第二柔性基板进行贴合,使所述聚合物/液晶混合层封装于第一柔性基板与第二柔性基板之间;
步骤7、于所述第一柔性基板下表面贴合下偏光片,于所述第二柔性基板上表面贴合上偏光片;
所述上偏光片与下偏光片的轴向相互垂直,并分别相对于梳型像素电极倾斜。
所述第一柔性基板为塑料基板,所述柔性母板为塑料母板,所述第二柔性基板为塑料基板。
所述梳型像素电极在水平方向上交替间隔排列。
所述液晶微胶囊呈球状,其直径尺寸为20nm-200nm。所述上偏光片与下偏光片的轴向分别与梳型像素电极成45度及135度夹角。
所述可聚合单体为丙烯酸酯及其衍生物、甲基丙烯酸酯及其衍生物、苯乙烯及其衍生物、环氧树脂与脂肪胺类环氧固化剂的一种或组合。
本发明还提供一种柔性液晶面板,包括第一柔性基板、与所述第一柔性基板相对设置的第二柔性基板、设于所述第一柔性基板与第二柔性基板之间的聚合物/液晶混合层、设于第一柔性基板下表面的下偏光片、及设于第二柔性基板上表面的上偏光片;
所述第一柔性基板上设有梳型像素电极、栅极线、数据线、TFT、及彩色滤光层;
所述聚合物/液晶混合层包括聚合物层及分布于所述聚合物层内的液晶微胶囊;所述液晶微胶囊包括硬质外壳及包裹于所述硬质外壳内的液晶分子;
所述上偏光片与下偏光片的轴向相互垂直,并分别相对于梳型像素电极倾斜。
所述第一柔性基板为塑料基板,所述第二柔性基板为塑料基板。
所述液晶微胶囊呈球状,其直径尺寸为20nm-200nm。
所述梳型像素电极在水平方向上交替间隔排列;所述上偏光片与下偏光片的轴向分别与梳型像素电极成45度及135度夹角。
本发明的有益效果:本发明提供的一种柔性液晶面板制作方法,采用卷对卷方式连续涂布封胶与液晶微胶囊的混合液,同时进行UV照射,使封胶发生聚合反应固化成聚合物层,所述液晶微胶囊分布于聚合物层内,得到聚合物/液晶混合层,使液晶分子以液晶微胶囊的形式被聚合物层包围,不同液晶微胶囊之间相互独立,所以液晶材料不会出现大范围流动,能够消除现有液晶面板弯曲后液晶层厚度不均匀的问题,使得液晶面板适用于柔性显示,并提高制程效率。本发明提供的柔性液晶面板,具有聚合物/液晶混合层,液晶分子以液晶微胶囊的形式被聚合物层包围,不同液晶微胶囊之间相互独立,能够使得液晶材料不会出现大范围流动,消除现有液晶面板弯曲后液晶层厚度不均匀的问题,适用于柔性显示。
附图说明
下面结合附图,通过对本发明的具体实施方式详细描述,将使本发明的技术方案及其它有益效果显而易见。
附图中,
图1为现有液晶面板在平面状态下的结构示意图;
图2为现有液晶面板在弯曲状态下的结构示意图;
图3为本发明柔性液晶面板制作方法的流程图;
图4为本发明柔性液晶面板制作方法的步骤2的示意图;
图5为本发明柔性液晶面板制作方法的步骤3及步骤4的示意图;
图6为对应图5中A处的立体图;
图7为对应图5中A处的放大图;
图8为对应图7中的液晶微胶囊的示意图;
图9为本发明柔性液晶面板制作方法的步骤5的示意图;
图10为本发明柔性液晶面板制作方法的步骤6的示意图;
图11为本发明柔性液晶面板制作方法的步骤7的示意图;
图12为本发明柔性液晶面板未通电状态下的示意图;
图13为对应图12中液晶微胶囊内的液晶分子的排列情况示意图;
图14为本发明柔性液晶面板通电状态下的示意图;
图15为对应图14中液晶微胶囊内的液晶分子的排列情况示意图;
图16为本发明柔性液晶面板中上、下偏光片的轴向与梳型像素电极之间的角度关系的示意图。
具体实施方式
为更进一步阐述本发明所采取的技术手段极其效果,以下结合本发明的优选实施例极其附图进行详细描述。
请参阅图3,本发明首先提供一种柔性液晶面板制作方法,包括如下步骤:
步骤1、提供第一柔性基板1,将该第一柔性基板1与玻璃贴合。
所述第一柔性基板1透明且具有挠曲性,优选的,所述第一柔性基板1为塑料基板。将所述第一柔性基板1与玻璃贴合,能够保证后续步骤2微显影制程过程中,该第一柔性基板1始终处于平展状态,便于进行微显影制程。
步骤2、通过微显影制程在所述第一柔性基板1上制作梳型像素电极11、栅极线、数据线、TFT、及彩色滤光层等,即所述第一柔性基板1相当于一个设置了彩色滤光层的TFT基板。
如图4所示,所述梳型像素电极11在水平方向上交替间隔排列,用于产生水平电场,所述梳型像素电极11为透明的ITO电极。
当所述梳型像素电极11、栅极线、数据线、TFT、及彩色滤光层等制作完成后,去除玻璃。
步骤3、请参阅图5,提供一柔性母板30,将所述柔性母板30放置于卷对卷设备的传送轮21上,该柔性母板30的长度足够长,其两端分别卷绕于卷对卷(roll to roll)设备的两辊轴20上,两个辊轴20之间沿水平方向间隔一定距离,所述柔性母板30的正上方垂直设置一狭缝型喷嘴40,所述狭缝型喷嘴40的开口方向朝向柔性母板30并与柔性母板30间隔一定距离。所述狭缝型喷嘴40一侧设置一平行于所述柔性母板30的UV灯管60,所述UV灯管60也设置成与柔性母板30间隔一定距离。
所述柔性母板30透明且具有挠曲性,优选的,所述柔性母板30为塑料母板。
步骤4、请参阅图5至图8,驱动所述辊轴20及传送轮21转动,带动柔性母板30沿狭缝型喷嘴40向UV灯管60的方向由一辊轴20向另一辊轴20运动,采用卷对卷的方式通过狭缝型喷嘴40向所述柔性母板30上连续涂布封胶51’与液晶微胶囊53的混合液,同时通过UV灯管60进行UV照射,使封胶51’发生聚合反应固化成聚合物层51,所述液晶微胶囊53分布于聚合物层51内,得到聚合物/液晶混合层5。由于采用了卷对卷的方式来制作聚合物/液晶混合层5,制程效率大幅提高。
具体的,所述封胶51’含有可聚合单体。所述可聚合单体可以发生聚合反应,形成高分子量的固态、透明性好的物质,其可以但不限于为:丙烯酸酯及其衍生物、甲基丙烯酸酯及其衍生物、苯乙烯及其衍生物、环氧树脂与脂肪胺类环氧固化剂的一种或它们的组合物。
所述液晶微胶囊53包括一硬质外壳531及包裹于所述硬质外壳531内的多个液晶分子533。所述硬质外壳531由已固化好的聚合物构成。进一步的,所述液晶微胶囊53呈球状,其直径尺寸为20nm-200nm。
完成该步骤4后,所述多个液晶分子533随机排列,且以液晶微胶囊53的形式被聚合物层51包围,不同液晶微胶囊53之间相互独立,使得液晶材料不会出现大范围流动。
步骤5、如图9所示,对柔性母板30与聚合物/液晶混合层5的复合层进行裁切,得到多个独立的第二柔性基板3。
所述第二柔性基板3的尺寸与所述第一柔性基板1的尺寸相适应。
所述第二柔性基板3优选为塑料基板。
步骤6、如图10所示,将所述第一柔性基板1与第二柔性基板3进行贴合,并对两柔性基板之间的贴合胶进行固化,使所述聚合物/液晶混合层5封装于第一柔性基板1与第二柔性基板3之间。
步骤7、如图11所示,于所述第一柔性基板1下表面贴合下偏光片7,于所述第二柔性基板3上表面贴合上偏光片9。
如图16所示,所述上偏光片9与下偏光片7的轴向相互垂直,并分别相对于梳型像素电极11倾斜。优选的,所述上偏光片9与下偏光片7的轴向分别与梳型像素电极11成45度及135度夹角,能够使得在对所述梳型像素电极11施加电压产生水平电场驱动液晶分子533按统一方向排列后,液晶长轴与上偏光片9、下偏光片7的轴向的夹角分别为45度及135度,实现较高的光线穿透率。
至此,完成柔性液晶面板的制作。即使通过上述方法制作的柔性液晶面板被弯曲或挤压,液晶材料也不会出现大范围流动,能够消除现有液晶面板弯曲后液晶层厚度不均匀的问题,使得液晶面板适用于柔性显示。
请参阅图12至图16,在上述柔性液晶面板制作方法的基础上,本发明还提供一种柔性液晶面板。所述柔性液晶面板包括第一柔性基板1、与所述第一柔性基板1相对设置的第二柔性基板3、设于所述第一柔性基板1与第二柔性基板3之间的聚合物/液晶混合层5、设于第一柔性基板1下表面的下偏光片7、及设于第二柔性基板3上表面的上偏光片9。
所述第一柔性基板1与第二柔性基板3均透明且具有挠曲性,优选的,所述第一柔性基板1与第二柔性基板3均为塑料基板。所述第一柔性基板1上设有梳型像素电极11、栅极线、数据线、TFT、及彩色滤光层等,即所述第一柔性基板1相当于一个设置了彩色滤光层的TFT基板。
所述聚合物/液晶混合层5包括聚合物层51及分布于所述聚合物层51内的液晶微胶囊53。所述液晶微胶囊53呈球状,其直径尺寸为20nm-200nm,包括硬质外壳531及包裹于所述硬质外壳531内的液晶分子533。所述硬质外壳531由已固化好的聚合物构成。由于在所述聚合物/液晶混合层5内,液晶分子533以液晶微胶囊53的形式被聚合物层51包围,不同液晶微胶囊53之间相互独立,能够使得液晶材料不会出现大范围流动,消除现有液晶面板弯曲后液晶层厚度不均匀的问题,适用于柔性显示。
所述梳型像素电极11在水平方向上交替间隔排列。所述上偏光片9与下偏光片7的轴向相互垂直,并分别相对于梳型像素电极11倾斜,优选的,所述上偏光片9与下偏光片7的轴向分别与梳型像素电极11成45度及135度夹角。
请同时参阅图12与图13,未通电状态下,所述液晶微胶囊53内的液晶分子533呈无序随机排列状态,光线透过下偏光片7后进入聚合物/液晶混合层5,并不产生相位差,光线不能透过与下偏光片7的轴向垂直的上偏光片9,该柔性液晶面板呈现暗态。请同时参阅图14与图15,通电状态下,所述梳型像素电极11产生水平电场,液晶微胶囊53内的多个液晶分子533在水平电场的作用下发生偏转,按照统一方向重新排列,光线透过下偏光片7进入聚合物/液晶混合层5后产生宏观相位差,之后可透过上偏光片9,此时,该柔性液晶面板呈现亮态以进行显示。如图16所示,由于所述上偏光片9与下偏光片7的轴向分别与梳型像素电极22设置成45度及135度夹角,施加电压后,液晶微胶囊53内的液晶分子533的取向受电场方向决定,液晶长轴与上偏光片9、下偏光片7的轴向的夹角分别为45度及135度,使得光线的穿透率较高。
综上所述,本发明的柔性液晶面板制作方法,采用卷对卷方式连续涂布封胶与液晶微胶囊的混合液,同时进行UV照射,使封胶发生聚合反应固化成聚合物层,所述液晶微胶囊分布于聚合物层内,得到聚合物/液晶混合层,使液晶分子以液晶微胶囊的形式被聚合物层包围,不同液晶微胶囊之间相互独立,所以液晶材料不会出现大范围流动,能够消除现有液晶面板弯曲后液晶层厚度不均匀的问题,使得液晶面板适用于柔性显示,并提高制程效率。本发明的柔性液晶面板,具有聚合物/液晶混合层,液晶分子以液晶微胶囊的形式被聚合物层包围,不同液晶微胶囊之间相互独立,能够使得液晶材料不会出现大范围流动,消除现有液晶面板弯曲后液晶层厚度不均匀的问题,适用于柔性显示。
以上所述,对于本领域的普通技术人员来说,可以根据本发明的技术方案和技术构思作出其他各种相应的改变和变形,而所有这些改变和变形都应属于本发明权利要求的保护范围。
Claims (10)
1.一种柔性液晶面板制作方法,其特征在于,先在第一柔性基板(1)上制作梳型像素电极(11)、栅极线、数据线、TFT、及彩色滤光层;采用卷对卷方式在柔性母板(30)上连续涂布封胶(51’)与液晶微胶囊(53)的混合液,同时进行UV照射,使封胶(51’)发生聚合反应固化成聚合物层(51),所述液晶微胶囊(53)分布于聚合物层(51)内,得到聚合物/液晶混合层(5);再对所述柔性母板(30)与聚合物/液晶混合层(5)的复合层进行裁切,得到第二柔性基板(3);然后将所述第一柔性基板(1)与第二柔性基板(3)进行贴合,使所述聚合物/液晶混合层(5)封装于第一柔性基板(1)与第二柔性基板(3)之间;最后贴合上偏光片(9)与下偏光片(7)。
2.如权利要求1所述的柔性液晶面板制作方法,其特征在于,包括如下步骤:
步骤1、提供第一柔性基板(1),将所述第一柔性基板(1)与玻璃贴合;
步骤2、通过微显影制程在所述第一柔性基板(1)上制作梳型像素电极(11)、栅极线、数据线、TFT、及彩色滤光层,然后去除玻璃;
步骤3、提供一柔性母板(30),将所述柔性母板(30)放置于卷对卷设备的传送轮(21)上,所述柔性母板(30)的两端分别卷绕于卷对卷设备的两辊轴(20)上,所述柔性母板(30)的正上方垂直设置一狭缝型喷嘴(40),所述狭缝型喷嘴(40)一侧设置一平行于所述柔性母板(30)的UV灯管(60);
步骤4、驱动所述辊轴(20)及传送轮(21)转动,带动柔性母板(30)沿狭缝型喷嘴(40)向UV灯管(60)的方向由一辊轴(20)向另一辊轴(20)运动,并通过所述狭缝型喷嘴(40)向所述柔性母板(30)上连续涂布封胶(51’)与液晶微胶囊(53)的混合液,同时利用UV灯管(60)进行UV照射,使封胶(51’)发生聚合反应固化成聚合物层(51),所述液晶微胶囊(53)分布于聚合物层(51)内,得到聚合物/液晶混合层(5);
所述封胶(51’)含有可聚合单体;所述液晶微胶囊(53)包括一硬质外壳(531)及包裹于所述硬质外壳(531)内的多个液晶分子(533);
步骤5、对柔性母板(30)与聚合物/液晶混合层(5)的复合层进行裁切,得到第二柔性基板(3),该第二柔性基板(3)的尺寸与所述第一柔性基板(1)的尺寸相适应;
步骤6、将所述第一柔性基板(1)与第二柔性基板(3)进行贴合,使所述聚合物/液晶混合层(5)封装于第一柔性基板(1)与第二柔性基板(3)之间;
步骤7、于所述第一柔性基板(1)下表面贴合下偏光片(7),于所述第二柔性基板(3)上表面贴合上偏光片(9);
所述上偏光片(9)与下偏光片(7)的轴向相互垂直,并分别相对于梳型像素电极(11)倾斜。
3.如权利要求2所述的柔性液晶面板制作方法,其特征在于,所述第一柔性基板(1)为塑料基板,所述柔性母板(30)为塑料母板,所述第二柔性基板(3)为塑料基板。
4.如权利要求2所述的柔性液晶面板制作方法,其特征在于,所述梳型像素电极(11)在水平方向上交替间隔排列。
5.如权利要求2所述的柔性液晶面板制作方法,其特征在于,所述液晶微胶囊(53)呈球状,其直径尺寸为20nm-200nm。
6.如权利要求2所述的柔性液晶面板制作方法,其特征在于,所述上偏光片(9)与下偏光片(7)的轴向分别与梳型像素电极(11)成45度及135度夹角。
7.如权利要求2所述的柔性液晶面板制作方法,其特征在于,所述可聚合单体为丙烯酸酯及其衍生物、甲基丙烯酸酯及其衍生物、苯乙烯及其衍生物、环氧树脂与脂肪胺类环氧固化剂的一种或组合。
8.一种柔性液晶面板,其特征在于,包括第一柔性基板(1)、与所述第一柔性基板(1)相对设置的第二柔性基板(3)、设于所述第一柔性基板(1)与第二柔性基板(3)之间的聚合物/液晶混合层(5)、设于第一柔性基板(1)下表面的下偏光片(7)、及设于第二柔性基板(3)上表面的上偏光片(9);
所述第一柔性基板(1)上设有梳型像素电极(11)、栅极线、数据线、TFT、及彩色滤光层;
所述聚合物/液晶混合层(5)包括聚合物层(51)及分布于所述聚合物层(51)内的液晶微胶囊(53);所述液晶微胶囊(53)包括硬质外壳(531)及包裹于所述硬质外壳(531)内的液晶分子(533);
所述上偏光片(9)与下偏光片(7)的轴向相互垂直,并分别相对于梳型像素电极(11)倾斜。
9.如权利要求8所述的柔性液晶面板,其特征在于,所述第一柔性基板(1)为塑料基板,所述第二柔性基板(3)为塑料基板,所述液晶微胶囊(53)呈球状,其直径尺寸为20nm-200nm。
10.如权利要求8所述的柔性液晶面板,其特征在于,所述梳型像素电极(11)在水平方向上交替间隔排列;所述上偏光片(9)与下偏光片(7)的轴向分别与梳型像素电极(11)成45度及135度夹角。
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