Image display device and manufacturing method of the same

Abstract

Disorder of the initial orientation (pretilt angle) of liquid crystal molecules and disorder of the active orientation of the liquid crystal molecules associated with higher resolution can be reduced to achieve high image quality display. A layer in which a drive element is configured is bonded into an adhesive layer above color filters for a plurality of colors provided on the inner surface of a rear panel. The layer in which the drive element is configured, a drive electrode (pixel electrode), a counter electrode, and the like are buried in the adhesive layer, so that the surface on the liquid crystal layer side is a smooth surface. An orientation film is formed on the smooth surface, so that a liquid crystal orientation control capability (orientation capability) is imparted thereto. A front panel includes a transparent substrate formed of a glass plate or a resin sheet, the surface of which on the liquid crystal layer side is a smooth surface. An orientation film is formed on the smooth surface, so that a liquid crystal orientation control capability (orientation capability) is imparted thereto.

1 . An image display device in which a rear panel and a front panel sandwich a liquid crystal layer, the rear panel comprising:
 a transparent substrate;   a color filter layer for a plurality of colors formed on the liquid crystal layer side of the transparent substrate;   an adhesive layer that buries a layer in which a drive element is configured, the drive element formed above the color filter layer for a plurality of colors, a drive electrode driven by the drive element, and a counter electrode for forming an electric field that controls the orientation of the liquid crystal molecules in the liquid crystal layer in cooperation with the drive electrode; and   an orientation film formed on the interface between the rear panel and the liquid crystal layer,   wherein the interface between the rear panel and the liquid crystal layer is a uniform flat surface across a plurality of pixels formed in correspondence to the color filters for a plurality of colors.   
     
     
         2 . The image display device according to  claim 1 ,
 wherein a stopper layer is provided under the orientation film of the rear panel, the stopper layer having a capability of preventing impurities from the layer in which the drive element is configured, the adhesive layer, or the color filters from diffusing into the liquid crystal layer.   
     
     
         3 . The image display device according to  claim 1 ,
 wherein the drive element is disposed in the adjacent boundary region of the color filters for a plurality of colors, and a light blocking layer is provided in the adjacent boundary region to block light incident from the transparent substrate side on the drive element.   
     
     
         4 . The image display device according to  claim 3 ,
 wherein the light blocking layer is provided between the drive element and the adjacent boundary region of the color filters for a plurality of colors.   
     
     
         5 . The image display device according to  claim 3 ,
 wherein the light blocking layer is provided between the adjacent boundary region of the color filters for a plurality of colors and the transparent substrate.   
     
     
         6 . The image display device according to  claim 1 ,
 wherein a polarizer plate is provided on each of the outer sides of the rear panel and the front panel.   
     
     
         7 . The image display device according to  claim 1 ,
 wherein the transparent substrate is a plastic substrate.   
     
     
         8 . A method for manufacturing an image display device in which a rear panel and a front panel sandwich a liquid crystal layer, the step of forming the rear panel at least comprising the steps of:
 the drive element formation substrate fabrication step of forming a drive element, a drive electrode, and a counter electrode on a stopper layer, the stopper layer provided on an element formation substrate;   the adhesion step of forming an integrated drive element formation substrate/transparent substrate by interposing an adhesive layer in the gap between the surface of the drive element formation substrate, fabricated in the drive element formation substrate fabrication step, on which the drive element, the drive electrode, and the counter electrode are formed and the color filter side of a transparent substrate on which color filters for a plurality of colors are formed in advance, burying the drive element, the drive electrode, and the counter electrode in the adhesive layer, and bonding the drive element formation substrate;   the element formation substrate removal step of removing the element formation substrate from the integrated drive element formation substrate/transparent substrate; and   the orientation film formation step of forming an orientation film on the stopper layer exposed by removing the element formation substrate so as to impart a liquid crystal orientation control capability.   
     
     
         9 . A method for manufacturing an image display device in which a rear panel and a front panel sandwich a liquid crystal layer, the step of forming the rear panel at least comprising the steps of:
 the drive element formation substrate fabrication step of forming a drive element, a drive electrode, and a counter electrode on a stopper layer, the stopper layer provided on an element formation substrate;   the adhesion step of forming an integrated drive element formation substrate/transparent substrate by interposing an adhesive layer in the gap between the surface of the drive element formation substrate, fabricated in the drive element formation substrate fabrication step, on which the drive element, the drive electrode, and the counter electrode are formed and the color filter side of a transparent substrate on which color filters for a plurality of colors are formed in advance, burying the drive element, the drive electrode, and the counter electrode in the adhesive layer, and bonding the drive element formation substrate;   the element formation substrate/stopper layer removal step of removing the element formation substrate and the stopper layer from the integrated drive element formation substrate/transparent substrate; and   the orientation film formation step of forming an orientation film on the surface obtained by removing the element formation substrate and the stopper layer so as to impart a liquid crystal orientation control capability.   
     
     
         10 . The method for manufacturing an image display device according to  claim 8 ,
 wherein the drive element formation substrate fabrication step includes the step of forming a light blocking layer for blocking light incident from the transparent substrate side on the drive element, the light blocking layer disposed between the drive element and the adjacent boundary region of the color filters for a plurality of colors.   
     
     
         11 . The method for manufacturing an image display device according to  claim 8 ,
 wherein the transparent substrate on which the color filters for a plurality of colors are formed in advance is a transparent substrate having a light blocking layer disposed on the transparent substrate side of the adjacent boundary region of the color filters for a plurality of colors for blocking light incident from the transparent substrate side on the drive element.   
     
     
         12 . The method for manufacturing an image display device according to  claim 8 ,
 wherein the transparent substrate is a plastic substrate.