JP2006085068A - Manufacturing method of liquid crystal optical modulator, liquid crystal optical modulator, and liquid crystal display - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a liquid crystal optical modulator by which a boundary between a resin structure and a liquid crystal can be made clear as a forming technique of the resin structure of a liquid crystal optical modulator, increase of driving voltage, and decrease of contrast can be prevented, simplification of a manufacturing process and reduction of manufacturing costs can be attained and reduction of optical modulation characteristics of a liquid crystal can be prevented, and to provide the liquid crystal optical modulator and provide a liquid crystal display. <P>SOLUTION: An alignment layer 1 is provided on a transparent substrate 5 on which a transparent electrode 4 is formed, an optical mask 6 wherein a light transmission part and a light shielding part with respect to UV are disposed in a prescribed pattern is covered on the alignment layer and the alignment layer is irradiated with UV 7 to remove the alignment layer 1 positioned in a region corresponding to the UV light transmission part ((a) of Fig.). Two members each thus formed are oppositely disposed and mixed liquid of the liquid crystal 2 and a resin 3 is packed between the alignment layers 1 in a heated state ((b) of Fig.). The mixed liquid is cooled to induce phase separation of the liquid crystal 2 and the resin 3 to form the resin structure 8 at an alignment layer non-functioning part 1b ((c) of Fig.). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method of manufacturing a liquid crystal light modulator that modulates light using liquid crystal, a liquid crystal light modulator, and a liquid crystal display device, and more particularly to a flat panel display that requires low power consumption and high-speed gradation image display. The present invention relates to a method of manufacturing a liquid crystal light modulator suitable for a flexible display, a liquid crystal light modulator, and a liquid crystal display device.

An optical modulator can be realized by applying an electro-optic effect of changing the alignment state of liquid crystal molecules by applying an electric field to the liquid crystal material. Liquid crystal light modulators have been attracting attention as electro-optical elements for display devices in recent years because they operate at a lower voltage than optical crystals exhibiting other electro-optical effects.
As such a liquid crystal light modulator, a structure in which a fine structure of a synthetic resin is formed in a liquid crystal and the liquid crystal alignment is three-dimensionally controlled by the alignment regulating force is known.
In such a composite formed by mixing a synthetic resin in a liquid crystal, since the alignment regulating force of the liquid crystal on the resin surface works, a high-speed response can be obtained as compared with a case where the synthetic resin is not dispersed in the liquid crystal. As a result, application to flat panel displays, projection displays, and the like is expected.

  By the way, the formation of the complex generally uses a self-organization phenomenon (phase separation) of a synthetic resin in a liquid crystal. In phase separation, a raw material of a synthetic resin (monomer, oligomer, etc.) is dissolved in a liquid crystal, and the resin raw material is subjected to a photopolymerization reaction process (see Non-Patent Document 1) or a thermal polymerization reaction process (Non-Patent Document). 2).

In recent years, it has also been confirmed that when the mixed liquid of the liquid crystal and the resin raw material is molecularly oriented, the dispersion structure of the synthetic resin becomes anisotropic and stabilizes the initial orientation of the liquid crystal. And is expected as a new light modulation element using a composite.
The synthetic resin dispersion technology in these liquid crystals not only expands the degree of freedom of liquid crystal alignment design, but also makes use of the mechanical stability of the synthetic resin to keep the thickness of the liquid crystal layer constant against external stress. Therefore, the possibility of application to a flexible element using a plastic film substrate is also opened.

On the other hand, as a technique for keeping the thickness of the liquid crystal layer constant without using phase separation, a spacer in which a thermoplastic resin is chemically bonded around the substrate is sprayed on the substrate, and the spacer is bonded to the substrate by heat treatment (patent) Reference 1) and a method of regularly forming a photoresist material on a substrate by a photolithography method are known.
However, in the former, there is a problem that the adhesive force is weak and the spacer is easily peeled off from the substrate when an external force is applied, and in the latter, since the structure is not bonded to both substrates, the thickness is increased when the substrate is bent. There is a problem that is easy to change.

On the other hand, if phase separation is used, since the resin is fixed between the two substrates, the thickness hardly changes, and the strength can be increased by increasing the content of the synthetic resin in the composite.
On the other hand, however, an increase in the content of the synthetic resin in the composite also increases the effect of regulating the alignment of the liquid crystal, leading to an increase in driving voltage and a decrease in contrast.

  Therefore, a technique has been proposed in which synthetic resin is concentrated in a specific region to form a three-dimensional resin structure between substrates. Thereby, the mechanical stability of the synthetic resin can be obtained without causing an increase in drive voltage or a decrease in contrast.

As the resin structure forming technology, the following three methods have been proposed so far.
First of all, the first method is to irradiate the liquid crystal / resin raw material mixture filled between both substrates with ultraviolet rays through an optical mask to promote the precipitation of the resin at the ultraviolet light transmitting portion, and at that position the resin A structure is formed (see Non-Patent Document 3).

  Next, the second method is to pattern an electrode film, fill a heated liquid crystal / resin raw material mixture between the electrode film pairs, and then apply a voltage between the electrode film pairs. This is a technique for performing a cooling phase separation process. Thereby, liquid crystal molecules are deposited in the voltage application region, and the resin raw material remains in the other region. In this second method, after the phase separation process is completed, the resin raw material is cured at that position by ultraviolet irradiation to form a resin structure (see Non-Patent Document 4).

  Furthermore, the third method is to apply an alignment film on a substrate provided with a concavo-convex portion with a depth of about several hundreds of nanometers, and fill a heated liquid crystal / resin raw material mixture between such a pair of substrates, This is a method for cooling phase separation of liquid crystal and resin raw materials. That is, in this method, the liquid crystal and the resin raw material are deposited on each concavo-convex portion, and the arrangement thereof varies depending on the surface treatment (wetting property) of the alignment film attached to the surface of the concavo-convex portion. After the phase separation treatment, as in the second method, the resin raw material is cured by ultraviolet irradiation to form a resin structure (see Non-Patent Document 5).

Japanese Patent Laid-Open No. 9-235527 N. A. Vaz, G. W. Smith and G. P. Montgomery. Jr .: “A lightcontrol film composed of liquid crystal droplets dispersed in a UV-curable polymer”, Mol. Cryst. Liq. Cryst., Vol. 146, pp. 1-15 (1987) N. A. Vaz, G.W. Smith and G. P. Montgomery. Jr .: “A light control film composed of liquidcrystal droplets dispersed in an epoxy matrix”, Mol. Cryst. Liq. Cryst., Vol. 146, pp. 17-34 (1987) T. Shinomiya, K. Fujimori, S. Yamagishi, K. Nishiguchi, S. Kohzaki, Y. Ishii, F. Funada and K. Awane: “A polymer matrix (PM) STN-LCD with excellent pressure resistance”, ASIA Display '95 Digest, p.255-258 (1995) Y. Kim, J. Francl, B. Taheri and JL West: "Amethod for the formation of polymer walls in liquid crystal / polymermixtures", Appl. Phys. Lett., Vol.72, no.18, pp.2253-2255 (1998) E. Y. Park, B. Taheri, J. L. West and P. Palffy-Muhoray: “Surface induced polymer walls and islands using a polymer / liquid crystalmixture”, SID '00 Digest, p. 782-785 (2000)

However, the three resin structure forming techniques described above have the following problems.
That is, in the first method, since the liquid crystal / resin raw material mixture is irradiated with ultraviolet rays through the optical mask, the resin structure is also applied to regions other than the desired region due to the light diffraction phenomenon at the edge of the mask opening. Is formed. In addition, since the uncured resin diffuses in the composite liquid mixture due to thermal motion, the resin is dispersed in the liquid crystal near the structure, increasing the drive voltage of the device and lowering the contrast.

  On the other hand, in the second method, since the local photopolymerization reaction treatment is not used, the resin is hardly precipitated in the vicinity of the structure by light diffraction or thermal diffusion, and the boundary between the resin structure and the liquid crystal. Thus, an increase in drive voltage and a decrease in contrast can be drastically improved. However, it induces phase separation while applying a high voltage of several tens of volts, and further requires a two-step production process of phase separation and ultraviolet irradiation, which makes the production process complicated and the production cost expensive. Become.

  Furthermore, in the third method, it is not necessary to apply a high voltage. However, since the alignment film is applied on a substrate provided with a concavo-convex part having a depth of about several hundreds of nanometers, uneven coating of the alignment film may occur. This is likely to occur and the light modulation characteristics of the liquid crystal deteriorate. Furthermore, as in the second method, a two-stage manufacturing process is required.

  The present invention has been made to solve such a problem, and a resin structure is obtained by intensively depositing a resin in a specific region from a liquid crystal / resin mixture filled between substrates. As a resin structure forming technology to be formed, the boundary between the resin structure and the liquid crystal can be clarified, the increase in driving voltage and the decrease in contrast can be prevented, and the manufacturing process is simplified and the manufacturing cost is reduced. It is an object of the present invention to provide a method of manufacturing a liquid crystal light modulator, a liquid crystal light modulator, and a liquid crystal display device that can prevent the deterioration of the light modulation characteristics of the liquid crystal.

A method for manufacturing a liquid crystal light modulator according to the present invention includes:
A pair of substrates provided with electrode films are arranged so that the electrode films face each other,
An alignment film is provided on each of the opposing surfaces of the electrode film, and at least one of the alignment films is formed in a patterning state in which alignment film non-functional parts are interspersed between alignment film functional parts,
Filled with a mixture of liquid crystal and resin between the pair of substrates,
Thereafter, liquid crystal is deposited in a region facing the alignment film functional part, and a phase separation process is performed so as to form a resin structure in the region facing the alignment film non-functional part. It is.

  In the present specification, for convenience, the region where the alignment film has been removed by drilling processing or the like (or the function of the alignment film is suppressed) is referred to as an alignment film non-functional part, and the alignment film is removed. The region that is not present (or the function of the alignment film is not suppressed) is referred to as an alignment film function part.

  Further, as the mixture is cooled, the phase separation treatment causes liquid crystal to be deposited in a region facing the alignment film functional part, and the resin is applied to the other region facing the alignment film non-functional part. It is preferable to concentrate and form the resin structure.

  Further, the phase separation treatment is performed before the filling operation, where the resin is heated to a temperature at which the resin can be dissolved in the liquid crystal, and after the filling operation, the resin and the liquid crystal are re-separated. It is preferable that it is gradually cooled to a temperature equal to or lower than

  The liquid crystal light modulator according to the present invention is manufactured by any one of the above-described liquid crystal light modulator manufacturing methods.

  A liquid crystal display device according to the present invention includes the above-described liquid crystal light modulator.

According to the method for manufacturing a liquid crystal optical modulator according to the present invention, a mixture of liquid crystal and resin is phase-separated, preferably cooled phase-separated, between substrates on which a two-dimensionally patterned alignment film is applied and arranged. It is produced by. As a result, a structure is obtained in which the liquid crystal is arranged in the region facing the alignment film functional part, and the resin structure is formed in the region facing the other alignment film non-functional part. This is because liquid crystal is selectively deposited on the surface of the alignment film (alignment film function part) because a strong intermolecular force (alignment regulation force) is generated between the liquid crystal molecules and the alignment film (alignment film function part). .
In particular, by using cooling phase separation, the boundary between the resin structure and the liquid crystal becomes clear, so that a reduction in contrast can be prevented and an increase in driving voltage can be suppressed.

Further, by using the resin itself instead of the resin raw material, the resin structure can be obtained by one process. This simplifies the manufacturing process and reduces the manufacturing cost. Further, since it is not necessary to apply a voltage or provide an uneven structure, the manufacturing cost can be suppressed without degrading the light modulation characteristics of the liquid crystal.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a schematic diagram (cross-sectional view) for explaining a method of manufacturing a liquid crystal light modulator according to an embodiment of the present invention.

  The liquid crystal light modulator manufactured by the method of the present embodiment is a transmissive liquid crystal light modulator 10 as shown in FIG. 1 (c), and a pair of transparent substrates 5 are arranged to face each other, and each transparent light modulator 10 is transparent. The transparent electrode 4 and the alignment film 1 are laminated inside the substrate 5, and a resin structure 8 that functions as a spacer is provided at a desired position between the opposing transparent electrodes 4. Are filled with a liquid crystal 2 of nematic type or the like.

In the liquid crystal light modulator of the present embodiment, two polarizing plates 9 whose polarization transmission axes are orthogonal or parallel to each other are disposed outside the transparent substrate 5.
That is, since the orientation of the liquid crystal 2 changes according to the intensity of the voltage applied between the transparent electrodes 4, the polarization direction of the polarized light from one polarizing plate 9 is changed by the liquid crystal 2, and the other polarization The light is emitted as intensity-modulated light by the light absorption of the plate 9.

Hereinafter, a method for manufacturing the liquid crystal light modulator 10 will be described.
First, as shown in FIG. 1 (a), an alignment film 1 is provided on a transparent electrode 4 of a transparent substrate 5 on which a transparent electrode 4 is formed. An optical mask 6 arranged in a pattern is covered and is closely attached to the alignment film 1.
Next, ultraviolet rays 7 are irradiated from the outside of the optical mask 6 to remove the alignment film 1 located in a region corresponding to the ultraviolet light transmitting part.

  Thereafter, as shown in FIG. 1B, two members prepared by the above-described method are held so that the alignment film 1 faces each other, and the liquid crystal 2 and the resin are interposed between the two alignment films 1. An assembly is produced by filling the mixture 3 in a heated state.

Further, by cooling the assembly, the liquid mixture is cooled to induce phase separation between the liquid crystal 2 and the resin 3. At that time, a strong intermolecular force (alignment regulating force) is generated between the molecules of the liquid crystal 2 and the alignment film 1, and the liquid crystal 2 is deposited in a region facing the alignment film 1 (alignment film function part 1 a). Resin structure 8 is formed in a region other than (alignment film non-functional portion 1b) (cooling layer separation process). FIG. 1C shows a state in which the resin structure 8 is thus formed on the alignment film non-functional portion 1b.
In addition, since the resin 3 itself is mixed with the mixed liquid, not the raw material, the resin structure 8 can be formed without performing a separate process in the alignment film non-functional part 1b.
Thereafter, two polarizing plates 9 are disposed outside the assembly.

  The liquid crystal light modulator 10 thus obtained can control the liquid crystal alignment by applying a predetermined voltage between the transparent electrodes 4 and can perform desired light modulation. At that time, liquid crystal alignment can be realized by selecting an alignment film in various alignment states such as parallel alignment, vertical alignment, and twist alignment.

  As the material of the alignment film 1 described above, polyimide resin, polyvinyl alcohol resin, polyvinyl cinnamate resin, azo compound, or the like can be used. As the alignment treatment method, rubbing alignment treatment in which the alignment film surface is rubbed with rayon or nylon cloth, exposure treatment by irradiation with polarized ultraviolet rays, or the like can be used. As a coating method of the alignment film 1, roll coating, dipping, spin coating, casting, spraying, doctor blade coating, wire bar coating, and the like can be used, but other coating techniques can also be used.

  In addition, the patterning process of the alignment film 1 should just be what can provide the alignment film functional part 1a and the alignment film non-functional part 1b by predetermined arrangement | positioning, and is not restricted to the method using the ultraviolet-ray mentioned above. Absent.

  In addition, this patterning process may be performed only on the alignment film 1 provided on one substrate 5, and a certain degree of effect can be obtained by only one patterning process.

  Further, the material of the resin 3 is preferably a material having high compatibility with the liquid crystal 2, such as polyethylene resin, polypropylene resin, polyolefin resin, acrylic resin, methacrylic resin, epoxy resin, urethane resin, polystyrene resin, polyvinyl alcohol. It is preferable to use a resin, a fluorine-based resin (for example, polytetrafluoroethylene), a copolymer thereof (for example, an acrylic urethane resin), a polymer liquid crystal, or the like, but other resins can also be used. In this case, the molecular weight of the resin 3 is preferably high in order to obtain mechanical stability, but an increase in the molecular weight decreases compatibility with the liquid crystal 2, so that it is about several thousand to several hundred thousand. It is preferable.

  The mixing ratio of the liquid crystal 2 and the resin 3 in the mixed liquid is generally determined by the area ratio (volume ratio) of the resin structure 8 and the liquid crystal 2 in the liquid crystal light modulator 10 to be formed. The mixing ratio is not excluded.

  In addition, the cooling rate of the mixed solution is preferably adjusted as appropriate depending on the material used and the blending ratio.

  The shape of the resin structure 8 is a wall structure, and the wall thickness is preferably 1 μm or more and 200 μm or less. At this time, when the walls are arranged in a lattice shape or a stripe shape, it is preferable to match the wall interval to the pixel pitch, but other intervals can be set according to the strength of the element. The wall structure is not limited to a straight line, and may be a curved line. Further, the wall thickness and length may not be all constant.

  In addition to the wall structure described above, the resin structure 8 may be a columnar shape having a cross section that fits within a circle having a diameter of 1 μm or more and 200 μm or less, and may be arranged in an island shape. In that case, it is desirable to ensure that the distance between the adjacent resin structures 8 is larger than the diameter of the cross section of the column in order to ensure the brightness of the modulated light. Not as long.

Further, when the resin structure 8 has a columnar shape, the column shape is preferably a cylindrical column having good symmetry, but is not limited to this, and the width of the column may not be constant.
The resin structure 8 can also be configured by combining the wall structure and the columnar structure.

Further, as the liquid crystal 2, various types of liquid crystal such as nematic liquid crystal, cholesteric liquid crystal, or smectic liquid crystal can be used.
However in order to obtain a fast response is a liquid crystal material having a low viscosity and high elasticity is suitable, as the chemical structure, the refractive index of the liquid crystal 2 anisotropy [Delta] n ([Delta] n = extraordinary refractive index n _e - ordinary refractive index n _o A nematic liquid crystal such as cyano, biphenyl, terphenyl, pyrimidine, tolan or fluorine is suitable.

  When using a smectic liquid crystal, a ferroelectric liquid crystal having spontaneous polarization and showing a high-speed response is useful. For example, a Schiff base ferroelectric liquid crystal, an azo ferroelectric liquid crystal, an azoxy ferroelectric liquid crystal, a biphenyl ferroelectric liquid crystal, an ester ferroelectric liquid crystal, or a phenylpyrimidine ferroelectric liquid crystal may be used. preferable.

  Further, as the transparent substrate 5, it is useful to use a thin glass plate having a thickness of 0.7 mm or less.

  Further, a flexible plastic film such as an amorphous transparent resin such as polycarbonate, polyethylene terephthalate, polyethersulfone, polyarylate, or amorphous polyolefin having a thickness of 0.4 mm or less can be used. When such a flexible plastic film substrate is used, a liquid crystal light modulator that can be bent lightly can be realized.

  Moreover, as the transparent electrode 4, it is good to use metal oxides, such as indium oxide and indium oxide which doped tin indium oxide (ITO), as a material. These transparent electrodes 4 are formed on the transparent substrate 5 by a well-known film forming technique such as vacuum deposition, ion plating, or sputtering.

  The transparent electrode 4 may be formed by forming a transparent organic conductive material such as a polythiophene resin on the transparent substrate 5 by using a spin coating method, a printing method, or the like.

  A spherical spacer for controlling the thickness of the mixed liquid layer composed of the liquid crystal 2 and the resin 3 may be dispersed in the mixed liquid or at least on the surface of the alignment film 1.

  In addition, a high contrast liquid crystal display device can be configured by providing a backlight in the liquid crystal light modulator 10 of the above embodiment.

  Further, by providing the liquid crystal light modulator 10 with a light reflecting plate or a light diffusing plate, it is possible to constitute a low power consumption reflective liquid crystal display device which does not require a backlight.

  In the case of configuring such a reflective liquid crystal display device, in the above-described embodiment, one transparent substrate 5 is made opaque, or one transparent electrode 4 is replaced with an opaque metal electrode. Is also possible.

  Hereinafter, the effect of the liquid crystal light modulator of the present invention, that is, the effect of the alignment regulating force will be described more specifically with reference to examples.

First, a polyimide film functioning as the alignment film 1 was applied onto the transparent electrode 4 of the transparent substrate 5 provided with the transparent electrode 4 using a spin coating method (4500 rpm, 90 s), and then baked at 180 ° C. for 2 hours.
Note that AL-1254 manufactured by Nippon Synthetic Rubber Co. was used as the polyimide film.

The orientation treatment was performed by rubbing the polyimide film surface with a nylon cloth (the amount of pushing the hair tip 0.4 mm). In order to pattern the polyimide film, an optical mask provided with a light-shielding part that does not transmit ultraviolet light and a light-transmitting part that transmits ultraviolet light (the width of the light-transmitting part is 20 μm and the interval between the light-shielding parts is 250 μm) is adhered to the polyimide film. (Wavelength: 185 nm and 253 nm) was irradiated for 60 minutes.
In this example, a patterning was used for only one of the opposing polyimide films.

Next, a pair of the obtained polyimide film-coated substrates 5 is made to face each other, and a 2 μm spacer is dispersed between them, and a liquid mixture of liquid crystal 2 and resin 3 (weight ratio: 9 (liquid crystal) / 1 (resin) , 100 ° C.).
As the liquid crystal 2, nematic liquid crystal (BL-008, manufactured by Merck) was used, and as the resin 3, polystyrene (made by Chemco, molecular weight: 2000) was used.

  Next, in a state where the thickness of the mixed liquid layer was kept constant, the mixed liquid was cooled to room temperature at a rate of 2 ° C. per minute to form a resin structure 8 between the substrates 5.

  Moreover, the comparative example with respect to the said Example was produced by the method similar to a present Example except the point which does not perform an orientation process to the said polyimide film.

  The resin structure 8 of the present example and the resin structure of the comparative example thus obtained were compared and observed with a polarizing microscope. As a result, it was confirmed that the resin structure 8 was formed along the patterning in the example of the present example that was subjected to the rubbing process (see FIG. 2A), but the rubbing process was not performed. In the comparative example, it was confirmed that the resin structure was close to a random state (see FIG. 2B).

Schematic diagram showing a method of manufacturing a liquid crystal light modulator according to an embodiment of the present invention. The figure which shows the result of having comparatively observed the resin structure which concerns on the Example and comparative example of this invention with a polarizing microscope.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Alignment film 1a Alignment film functional part 1b Alignment film non-functional part 2 Liquid crystal 3 Resin 4 Transparent electrode 5 Substrate 6 Optical mask 7 Ultraviolet ray 8 Resin structure 9 Polarizing plate 10 Liquid crystal light modulation

Claims (5)

A pair of substrates provided with electrode films are arranged so that the electrode films face each other,
An alignment film is provided on each of the opposing surfaces of the electrode film, and at least one of the alignment films is formed in a patterning state in which alignment film non-functional parts are interspersed between alignment film functional parts,
Filled with a mixture of liquid crystal and resin between the pair of substrates,
Thereafter, a liquid crystal is deposited in a region facing the alignment film functional part, and a phase separation process is performed so as to form a resin structure in a region facing the alignment film non-functional part. Manufacturing method of optical modulator.   In the phase separation treatment, as the mixture is cooled, liquid crystal is deposited in a region facing the alignment film functional part, and the resin is concentrated in the other region facing the alignment film non-functional part. 2. The method of manufacturing a liquid crystal light modulator according to claim 1, wherein the resin structure is formed.   In the phase separation treatment, the resin is heated to a temperature at which the resin can be dissolved in the liquid crystal before the filling operation, and the resin and the liquid crystal are re-separated after the filling operation. The method for producing a liquid crystal light modulator according to claim 1, wherein the liquid crystal light modulator is gradually cooled to a temperature or lower.   A liquid crystal light modulator manufactured by the method for manufacturing a liquid crystal light modulator according to claim 1.   A liquid crystal display device comprising the liquid crystal light modulator according to claim 4.

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