Liquid crystal display device and method for producing same
09541797 ยท 2017-01-10
Assignee
Inventors
Cpc classification
C09K2323/023
CHEMISTRY; METALLURGY
International classification
Abstract
The present invention provides a liquid crystal display device that can prevent a decrease in the VHR and image sticking on the display screen because of residual DC voltage, and also can produce favorable alignment conditions; and a production method thereof. The liquid crystal display device of the present invention includes: a pair of substrates; a liquid crystal layer that contains liquid crystal molecules and is disposed between the pair of substrates; and an alignment film that is disposed on a liquid crystal layer side of at least one of the pair of substrates, the alignment film containing a polyamic acid or a polyimide with an imidization ratio of less than 100%, the liquid crystal display device including a monomolecular film on the alignment film.
Claims
1. A liquid crystal display device comprising: a pair of substrates; a liquid crystal layer that contains liquid crystal molecules and is disposed between the pair of substrates; an alignment film between the liquid crystal layer and at least one of the pair of substrates, the alignment film containing a polyamic acid or a polyimide with an imidization ratio of less than 100%, and a monomolecular film between the liquid crystal layer and the alignment film, wherein the polyamic acid or the polyimide of the alignment film includes a photo-reactive functional group, wherein the monomolecular film includes a structure that is derived from a silane-based surfactant that contains the following chemical formula (1) or (3):
Cl.sub.3Si(CR.sup.1.sub.2).sub.nCR.sup.2.sub.3(1),
or
Cl.sub.3Si(CR.sup.1.sub.2).sub.nNH.sub.2(3), wherein each R.sup.1 is the same as or different from each other, wherein each R.sup.1 represents a hydrogen atom or a halogen atom, wherein each R.sup.2 is the same as or different from each other, wherein each R.sup.2 represents a hydrogen atom or a halogen atom, and wherein n represents an integer of 3 to 17, wherein the monomolecular film is a single layer formed of a same material that covers and is in contact with the entire surface of the alignment film so that the silane-based surfactant included in the monomolecular film reacts with carboxyl groups in the alignment film, to form a covalent bond that is between a structure derived from a carboxyl group in the alignment film and silicon in a structure derived from the silane-based surfactant, and is represented by the following chemical formula (2): ##STR00011## thereby lowering the concentration of residual carboxyl groups contained in the alignment film without changing the imidization ratio, and wherein a pretilt angle of the liquid crystal molecules satisfies at least one of 0<8 and 81<90 due to the alignment film having undergone a photo-alignment treatment after forming the monomolecular film, which results in minimal changes in aligning ability of the alignment film.
2. The liquid crystal display device according to claim 1, wherein the silane-based surfactant contains a group represented by the following formula (3):
(CH.sub.2).sub.nNH.sub.2(3) wherein n represents an integer of 3 to 17.
3. The liquid crystal display device according to claim 1, wherein a pretilt angle of the liquid crystal molecules satisfies 0<8.
4. The liquid crystal display device according to claim 1, wherein the polyamic acid or the polyimide of the alignment film includes a first monomer unit and a second monomer unit, the first monomer unit having a side chain with the photo-reactive functional group, and the second monomer unit having a side chain without the photo-reactive functional group.
5. The liquid crystal display device according to claim 1, wherein the silane-based surfactant contains a linear alkyl group represented by the following formula (4):
(CH.sub.2).sub.nCH.sub.3(4), wherein n represents an integer of 3 to 11.
6. The liquid crystal display device according to claim 1, wherein at least one of R.sup.1 and R.sup.2 in formula (1) is a fluorine atom.
7. The liquid crystal display device according to claim 1, wherein the silane-based surfactant contains a linear alky group represented by the following formula (5):
(CH.sub.2).sub.nCF.sub.3(5) wherein n represents an integer of 3 to 17.
8. The liquid crystal display device according to claim 1, wherein the silane-based surfactant contains a linear alkyl group represented by the following formula (6):
(CH.sub.2).sub.n-1CF.sub.2CF.sub.3(6) wherein n represents an integer of 3 to 17.
9. The liquid crystal display device according to claim 1, wherein the imidization ratio is in the range of 20 to 80% to minimize DC image sticking effects by reducing a residual DC voltage, and the silane-based surfactant included in the monomolecular film is adsorbed on carboxyl groups in the alignment film to improve a voltage holding ratio (VHR) by lowering the concentration of residual carboxyl groups contained in the alignment film when compared to a liquid crystal display device without said monomolecular film.
10. A liquid crystal display device comprising: a pair of substrates; a liquid crystal layer between the pair of substrates, the liquid crystal layer containing liquid crystal molecules; an alignment film between the liquid crystal layer and at least one of the pair of substrates, the alignment film containing a polyamic acid or a polyimide with an imidization ratio in the range of 20 to 80%, which results in reduced residual DC voltage; and a monomolecular film between the liquid crystal layer and the alignment film, wherein the polyamic acid or the polyimide of the alignment film includes a photoreactive functional group, wherein the monomolecular film includes a structure that is derived from a silane-based surfactant that contains the following chemical formula (1) or (3):
Cl.sub.3Si(CR.sup.1.sub.2).sub.nCR.sup.2.sub.3(1),
or
Cl.sub.3Si(CR.sup.1.sub.2).sub.nNH.sub.2(3), wherein each R.sup.1 is the same as or different from each other, wherein each R.sup.1 represents a hydrogen atom or a halogen atom, wherein each R.sup.2 is the same as or different from each other, wherein each R.sup.2 represents a hydrogen atom or a halogen atom, and wherein n represents an integer of 3 to 17, wherein the monomolecular film is a single layer formed of a same material that covers and is in contact with the entire surface of the alignment film so that the silane-based surfactant included in the monomolecular film reacts with carboxyl groups in the alignment film to form a covalent bond that is between a structure derived from a carboxyl group in the alignment film and silicon in a structure derived from the silane-based surfactant, and is represented by the following chemical formula (2): ##STR00012## wherein a pretilt angle of the liquid crystal molecules satisfies at least one of 0<8 and 81<90 due to the alignment film having undergone a photo-alignment treatment after forming the monomolecular film, which results in minimal changes in aligning ability of the alignment film, wherein the silane-based surfactant included in the monomolecular film is configured to be adsorbed on carboxyl groups in the alignment film to thus lower the concentration of residual carboxyl groups contained in the alignment film, which results in improved voltage holding ratio (VHR), and wherein the residual DC voltage is less than or equal to 150 mV, and the VHR is more than or equal to 98.0%.
11. The liquid crystal display device according to claim 10, wherein the liquid crystal display device is capable of operating under one of TN mode and IPS mode, the imidization ratio of the alignment film is in the range of 50 to 80%, and a pretilt angle of the liquid crystal molecules satisfies 0<8 due to the alignment film having undergone a photo-alignment treatment after forming the monomolecular film, which results in minimal changes in aligning ability of the alignment film.
12. The liquid crystal display device according to claim 11, wherein the silane-based surfactant comprises a chlorosilane-based surfactant that contains the following chemical formula (7) or (8):
Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3(7)
Cl.sub.3Si(CH.sub.2).sub.nNH.sub.2(8) wherein n represents an integer of 3 to 11.
13. The liquid crystal display device according to claim 10, wherein the liquid crystal display device is capable of operating under one of VA mode, RTN mode and TBA mode, the imidization ratio of the alignment film is in the range of 20 to 50%, and a pretilt angle of the liquid crystal molecules satisfies 81<90 due to the alignment film having undergone a photo-alignment treatment after forming the monomolecular film, which results in minimal changes in aligning ability of the alignment film.
14. The liquid crystal display device according to claim 13, wherein the silane-based surfactant comprises a chlorosilane-based surfactant that contains the following chemical formula (7) or (9):
Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3(7)
Cl.sub.3Si(CH.sub.2).sub.nCF.sub.3(9) wherein n represents an integer of 3 to 11.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(16) Pretilt angles, voltage holding ratios (VHRs), and residual DC voltages of the liquid crystal display devices (liquid crystal display cells) of the embodiments of the present invention were measured as described below.
(17) (Pretilt Angle)
(18) The pretilt angle was measured by the crystal rotation method using OMS-AF2 produced by CHUO PRECISION INDUSTRIAL CO., LTD.
(19) (VHR)
(20) The VHR was measured using the 6254 model liquid crystal physical property measuring system produced by TOYO Corp. More specifically, charges are charged between the electrodes at 60 C. under a voltage of 1 V for 60 s, and then the potential between the electrodes during the open period (period for which no voltage is applied) of 16.61 ms was measured to determine the ratio of voltage to be retained.
(21) (Residual DC Voltage)
(22) The residual DC voltage was determined by the flicker elimination method (movement I) described in WO 2007/141935 (Patent Literature 1). More specifically, a direct current offset voltage of 5 V was applied to the liquid crystal cell for 20 hours. Then, the liquid crystal cell was driven under square wave voltage, and the direct current offset voltage applied was adjusted such that flickers would not be observed. The adjusted direct current offset voltage was taken as the residual DC voltage. The measurement was performed in a 50 C. oven, using an original device including a generator, a photo multiplier, an oscilloscope, and a computer for controlling these.
(23) The present invention will be described in more detail below with reference to the drawings based on embodiments which, however, are not intended to limit the scope of the present invention.
(24) First Embodiment
(25) In the present embodiment, description will be made with an example of a TN-mode liquid crystal display device having horizontal alignment films that horizontally align liquid crystals.
(26) In
(27) The TFT array substrate 110 has, on the liquid crystal layer 120-side main surface of a glass substrate (supporting substrate 111), multiple gate signal lines parallel to each other, multiple source signal lines perpendicular to the gate signal lines and extending in parallel to each other, and thin film transistors (TFTs) disposed at each crossing portion of a gate signal line and a source signal line, although these components are not illustrated.
(28) The gate signal lines and the source signal lines are covered with a gate insulating film, and drain electrodes are formed on the gate insulating film. The drain electrodes are covered with an interlayer insulating film, and pixel electrodes 115 are formed on the interlayer insulating film in such a manner so as to correspond to the respective pixels. The pixel electrodes 115 and the drain electrodes are connected to each other via contact holes formed in the interlayer insulating film. Each TFT has a gate electrode connected to a gate signal line, a source electrode connected to a source signal line, and a drain electrode.
(29) The liquid crystal layer 120 is formed from nematic liquid crystals showing positive dielectric constant anisotropy.
(30) The counter substrate 130 is, for example, a color filter substrate. Here, a color filter layer is provided on the main surface of the glass substrate (supporting substrate 131), and a counter electrode 135 is disposed on the color filter layer with an insulation layer therebetween. The counter electrode 135 is formed from ITO or the like.
(31) Horizontal alignment films 112 and 132 are formed on the respective liquid crystal layer 120-side surfaces of the TFT array substrate 110 and the counter substrate 130 which have the above structures.
(32) Furthermore, on the alignment films 112 and 132, the monomolecular films 113 and 133 are respectively formed.
(33) The liquid crystal display device 100 having the above structure was produced as described below. First, the substrates 110 and 130 before alignment film formation were produced by a conventionally known method. Then, the following steps were performed.
(34) (1-1. Alignment Film Formation Step)
(35) A liquid crystal alignment agent containing a polyimide produced by imidizing a polyamic acid represented by the following formula (6) was applied to the liquid crystal layer 120-side main surface of each of the TFT array substrate 110 and the counter substrate 130. The polyimide is dissolvable in the state of polyamic acid. The polyimide is imidized by a conventionally known method (e.g., a heating method, a chemical method using a catalyst), and the imidization ratio was adjusted to 50 to 80%. Thereafter, prebaking and postbaking were performed, and thereby horizontal alignment films 112 and 132 for TN mode were formed.
(36) ##STR00002##
(1-2. Monomolecular Film Formation Step)
(37) A chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3 was dissolved in a solvent containing at least one of water and ethanol, so that a solution was prepared. The solution was heated to 60 C., and the TFT array substrate 110 and the counter substrate 130 were immersed in the solution for 1 hour. Thereby, the monomolecular films 113 and 133 were formed on the alignment films 112 and 132. At this time, as illustrated in
(38) In the monomolecular film formation step, heating the solution makes it possible to promote the reaction between the residual carboxyl groups in the alignment films 112 and 132 and the chlorosilane-based surfactant.
(39) Instead of immersing the substrates 110 and 130 in the solution, the solution may be applied to the substrates 110 and 130.
(40) Thereafter, the substrates 110 and 130 were washed using a solvent containing at least one of water and ethanol. A chlorosilane-based surfactant containing a linear alkyl group represented by the above formula (2), including a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3, is easily dissolved in a solvent such as water and ethanol. Hence, components of the chlorosilane-based surfactant which have not reacted with the residual carboxyl groups in the monomolecular film formation step can be easily removed by washing with a solvent. Thereby, it is possible to prevent a decrease in the qualities of the liquid crystal display device because of unreacted components of the chlorosilane-based surfactant.
(41) Since it is possible to use a very low-toxic solvent such as water and ethanol can be used, the monomolecular film formation step can be performed in an open system. For this reason, the capital investment can be made low compared to the step in a sealed system using a large-sized box and the like.
(42) (1-3. Liquid Crystal Display Device Formation Step)
(43) Subsequently, rubbing treatment was performed on the substrates 110 and 130. A sealant (sealing agent) was applied to one of the substrates, beads were scattered on the other of the substrates, and the substrates were attached to each other in such a manner that the rubbing directions would form an angle of 90. The sealant is not particularly limited, and ultraviolet curable resin, thermosetting resin, and the like can be used. Liquid crystals having positive dielectric constant anisotropy were injected between the substrates, and a polarizer was disposed on the surface of each of the supporting substrates 111 and 131 on the opposite side of the liquid crystal layer 120, and thereby the TN-mode liquid crystal display device 100 including horizontal alignment films was produced. The liquid crystals may contain a chiral agent.
(44) In the following, the present embodiment will be described in detail based on examples and comparative examples.
EXAMPLES 1 to 5
(45) In the same manner as in the first embodiment, TN-mode liquid crystal display devices of Examples 1 to 5 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 1, monomolecular films were formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 2, n=7 in Example 3, n=9 in Example 4, and n=11 in Example 5.
(46) The pretilt angle, VHR, and residual DC voltage of each of the liquid crystal display devices were measured. The obtained results are shown in Table 1.
COMPARATIVE EXAMPLE 1
(47) No chlorosilane-based surfactant was used. That is, a TN-mode liquid crystal display device of Comparative Example 1 was produced in the same manner as in the first embodiment, except that monomolecular films were not formed and the residual carboxyl groups in the alignment films were not treated. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 1.
(48) TABLE-US-00001 TABLE 1 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 1 ple 2 ple 3 ple 4 ple 5 Example 1 Alkyl chain 4 6 8 10 12 N/A length (n) (3) (5) (7) (9) (11) Pretilt .sup.1.5 .sup.1.5 .sup.2.5 4 8 1.5 angle () VHR (%) 99.5 99.5 99.5 .sup.99.5 .sup.99.5 98.5 Residual DC 50 50 50 50 50 170 voltage (mV)
(49) As shown in Table 1, the VHRs in Examples 1 to 5 were as high as 99.5%. In contrast, the VHR in Comparative Example 1 was 98.5%, which was inferior to the results of Examples 1 to 5.
(50) The residual DC voltage in Comparative Example 1 was 170 mV, whereas the residual DC voltage in each of Examples 1 to 5 was 50 mV which was lower than the result of Comparative Example 1. As above, the residual DC voltage could be maintained low while a high VHR was maintained in Examples 1 to 5.
(51) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. This is probably because the carboxyl groups remaining in the polyimide-based alignment films were treated, and thereby the residual DC voltage was reduced while a high VHR was obtained.
(52) Also, a longer alkyl chain led to a larger pretilt angle, which was probably because the long alkyl chain changed the alignment of liquid crystals from the horizontal direction to the vertical direction.
(53) Second Embodiment
(54) Monomolecular films were formed using a chlorosilane-based surfactant represented by the chemical formula Cl.sub.3Si(CH.sub.2).sub.nNH.sub.2 instead of a chlorosilane-based surfactant represented by the chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3. Except for that, a TN-mode liquid crystal display device having horizontal alignment films was produced in the same manner as in the first embodiment.
(55) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 6 to 10
(56) In the same manner as in the second embodiment, TN-mode liquid crystal display devices of Examples 6 to 10 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 6, monomolecular films were formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 7, n=7 in Example 8, n=9 in Example 9, and n=11 in Example 10. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured in the same manner as in Examples 1 to 5.
(57) The obtained results are shown in Table 2 together with the results of Comparative Example 1.
(58) TABLE-US-00002 TABLE 2 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 6 ple 7 ple 8 ple 9 ple 10 Example 1 Alkyl chain 3 5 7 9 11 N/A length (n) (3) (5) (7) (9) (11) Pretilt .sup.1.5 .sup.1.5 .sup.1.5 .sup. 2 1.5 angle () VHR (%) 99.5 99.5 99.5 99.5 .sup.99.5 98.5 Residual DC 50 50 50 50 50 170 voltage (mV)
(59) Table 2 shows that, similarly to Examples 1 to 5, both the VHR and residual DC voltage values in Examples 6 to 10 were better than those in Comparative Example 1; that is, the residual DC voltage was made low while a high VHR was maintained.
(60) A longer linear alkyl chain led to a larger pretilt angle in Examples 1 to 5, whereas an increase in the linear chain structure did not change the pretilt angle much in Examples 6 to 10.
(61) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. Further introduction of an amino group (NH.sub.2) at an alkyl chain terminal to lengthen the alkyl chain changed the pretilt angle very slightly. This is probably because the compatibility between the terminal amino group and the liquid crystals is different from the compatibility between the methyl group and the liquid crystals.
(62) Third Embodiment
(63) The present embodiment is described based on an example of a VA-mode liquid crystal display device having vertical alignment films for vertically aligning liquid crystals.
(64) In
(65) The TFT array substrate 210 has TFTs and various wirings on the liquid crystal layer 220-side main surface of the glass substrate (supporting substrate 211) in the same manner as the TFT array substrate 110 in the first embodiment.
(66) Pixel electrodes 215 are formed to correspond to the respective pixels, and each of the pixel electrodes has multiple slits 214 for controlling the alignment of the liquid crystals. The slits 214 each have a V shape when the substrate surface is viewed from the normal direction, and are arranged at equal intervals. An alignment film 212 is formed on the liquid crystal layer 220-side surface of the TFT array substrate 210, and a monomolecular film 213 is formed on the alignment film 212.
(67) The liquid crystal layer 220 is not particularly limited as long as it is used in a VA-mode liquid crystal display device, and nematic liquid crystals having negative dielectric constant anisotropy, for example, can be used.
(68) The counter substrate 230 includes a glass substrate (supporting substrate 231) and a counter electrode 235 disposed to face the pixel electrodes 215, and has projections 234 forming ribs on the liquid crystal layer 220-side surface. The multiple projections 234 are for controlling the alignment conditions of the liquid crystals, and are belt-like objects that have a V shape in a view of the substrate surface from the normal direction and are arranged at equal intervals.
(69) The counter substrate 230 is, for example, a color filter substrate. Here, a color filter layer is provided on the main surface of the supporting substrate 231, and the counter electrode 235 is disposed on the color filter layer with an insulating layer therebetween. The counter electrode 235 is formed from ITO or the like. An alignment film 232 is formed on the liquid crystal layer 220-side surface of the counter substrate, and a monomolecular film 233 is formed on the alignment film 232.
(70) The slits 214 and the projections 234 are alternately arranged at equal intervals when the substrate surface is viewed from the normal direction. In such arrangement, liquid crystal molecules are aligned almost evenly in each pixel, and uniform display can be achieved in a wide viewing angle.
(71) The liquid crystal display device 200 having the above structure was produced as described below. First, the substrates 210 and 230 before alignment film formation were produced by a conventionally known method. Then, the following steps are performed.
(72) (2-1. Alignment Film Formation Step)
(73) To the liquid crystal layer 220-side main surface of each of the TFT array substrate 210 and the counter substrate 230, a liquid crystal alignment agent was applied which contained a polyimide produced by polymerizing (copolymerizing), by a conventionally known method, at least one of an acid anhydride represented by the following chemical formulas (7) to (13) and at least one of diamine monomers containing vertically aligning functional groups represented by the following chemical formulas (14) to (20). The polyimide is imidized by a conventionally known method (e.g., a heating method, a chemical method using a catalyst), and the imidization ratio was adjusted to 20 to 50%. Thereafter, prebaking and postbaking were performed, and thereby vertical alignment films 212 and 232 for VA mode were formed.
(74) ##STR00003## ##STR00004## ##STR00005##
(2-2. Monomolecular Film Formation Step)
(75) A chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3 was dissolved in a solvent containing at least one of water and ethanol, so that a solution was prepared. The solution was heated to 60 C., and the TFT array substrate 210 and the counter substrate 230 were immersed in the solution for 1 hour. Thereby, the monomolecular films 213 and 233 were formed on the alignment films 212 and 232. At this time, as illustrated in
(76) In the monomolecular film formation step, heating the solution makes it possible to promote the reaction between the residual carboxyl groups in the alignment films 212 and 232 and the chlorosilane-based surfactant.
(77) Instead of immersing the substrates 210 and 230 in the solution, the solution may be applied to the substrates 210 and 230.
(78) Thereafter, the substrates 210 and 230 were washed using a solvent containing at least one of water and ethanol. A chlorosilane-based surfactant containing a linear alkyl group represented by the above formula (2), including a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3, is easily dissolved in a solvent such as water and ethanol. Hence, components of the chlorosilane-based surfactant which have not reacted with the residual carboxyl groups in the monomolecular film formation step can be easily removed by washing with a solvent. Thereby, it is possible to prevent a decrease in the qualities of the liquid crystal display device because of unreacted components of the chlorosilane-based surfactant.
(79) (2-3. Liquid Crystal Display Device Formation Step)
(80) A sealant (sealing agent) was applied to one of the substrates, beads were scattered on the other one of the substrates, and the substrates were attached to each other. The sealant is not particularly limited, and ultraviolet curable resin, thermosetting resin, and the like can be used. Liquid crystals having negative dielectric constant anisotropy were injected between the substrates, and a polarizer was disposed on the surface of each of the supporting substrates 211 and 231 on the opposite side of the liquid crystal layer 220, and thereby the VA-mode liquid crystal display device 200 including vertical alignment films was produced.
(81) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 11 to 15
(82) In the same manner as in the third embodiment, VA-mode liquid crystal display devices of Examples 11 to 15 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 11, a monomolecular film was formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 12, n=7 in Example 13, n=9 in Example 14, and n=11 in Example 15.
(83) The pretilt angle, VHR, and residual DC voltage of each of the liquid crystal display devices were measured. The obtained results are shown in Table 3.
COMPARATIVE EXAMPLE 2
(84) No chlorosilane-based surfactant was used. That is, a VA-mode liquid crystal display device of Comparative Example 2 was produced in the same manner as in Example 11, except that monomolecular films were not formed and the residual carboxyl groups in the alignment films were not treated. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 3.
(85) TABLE-US-00003 TABLE 3 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 11 ple 12 ple 13 ple 14 ple 15 Example 2 Alkyl chain 4 6 8 10 12 N/A length (n) (3) (5) (7) (9) (11) Pretilt 90 90 90 90 90 90 angle () VHR (%) 99.5 99.5 99.5 .sup.99.5 .sup.99.5 98.5 Residual DC 70 70 70 70 70 220 voltage (mV)
(86) As shown in Table 3, the VHRs in the VA-mode liquid crystal display devices of Examples 11 to 15 in which the liquid crystal molecules were vertically aligned were as high as 99.5%. In contrast, the VHR in Comparative Example 2 was 98.5%, which was inferior to the results of Examples 11 to 15.
(87) The residual DC voltage in Comparative Example 2 was 220 mV, whereas the residual DC voltage in each of Examples 11 to 15 was as low as 70 mV. Similarly to the aforementioned other examples, the residual DC voltage could be maintained low while a high VHR was maintained in Examples 11 to 15.
(88) The pretilt angle in each of Examples 11 to 15 and Comparative Example 2 was 90. That is, the linear alkyl chain in the chlorosilane-based surfactant did not affect the alignment of the liquid crystal molecules in the present embodiment in which the liquid crystal molecules were vertically aligned.
(89) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. This is probably because the carboxyl groups remaining in the polyimide-based alignment film were treated, and thereby the residual DC voltage was reduced while a high VHR was obtained.
(90) In the case of the VA mode, the pretilt angle is 90 regardless of the alkyl chain length. This is probably because the polyimide as a vertical alignment film component sufficiently maintains the vertical alignment.
(91) Fourth Embodiment
(92) The present embodiment will be described based on an example of an RTN-mode liquid crystal display device provided with a photo-alignment film having vertically aligning ability.
(93) In
(94) The TFT array substrate 260 has, on the liquid crystal layer 270-side main surface of a glass substrate (supporting substrate 261), multiple gate signal lines parallel to each other, multiple source signal lines perpendicular to the gate signal lines and extending in parallel to each other, and thin film transistors (TFTs) disposed at each crossing portion of a gate signal line and a source signal line, although these components are not illustrated.
(95) The gate signal lines and the source signal lines are covered with a gate insulating film, and drain electrodes are formed on the gate insulating film. The drain electrodes are covered with an interlayer insulating film, and pixel electrodes 265 are formed on the interlayer insulating film in such a manner so as to correspond to the respective pixels. The pixel electrodes 265 and the drain electrodes are connected to each other via the contact holes formed in the interlayer insulating film. Each TFT has a gate electrode connected to a gate signal line, a source electrode connected to a source signal line, and a drain electrode.
(96) The liquid crystal layer 270 is formed from nematic liquid crystals showing negative dielectric constant anisotropy.
(97) The counter substrate 280 is, for example, a color filter substrate. Here, a color filter layer is provided on the main surface of the glass substrate (supporting substrate 281), and a counter electrode 285 is disposed on the color filter layer with an insulation layer therebetween. The counter electrode 285 is formed from ITO or the like.
(98) Horizontal alignment films 262 and 282 are formed on the respective liquid crystal layer 270-side surfaces of the TFT array substrate 260 and the counter substrate 280 which have the above structures.
(99) Further, on the alignment films 262 and 282, the monomolecular films 263 and 283 are respectively formed.
(100) As illustrated in
(101) The liquid crystal display device 250 having the above structure was produced as described below. First, the substrates 260 and 280 before alignment film formation were produced by a conventionally known method. Then, the following steps were performed.
(102) (3-1. Alignment Film Formation Step)
(103) To the liquid crystal layer 270-side main surface of each of the TFT array substrate 260 and the counter substrate 280, a liquid crystal alignment agent was applied which contained a polyimide produced by polymerizing (copolymerizing), by a conventionally known method, at least one of an acid anhydride represented by the above chemical formulas (7) to (13) and at least one of diamine monomers containing photo-reactive functional groups in their side chains represented by the following chemical formulas (21) to (44). The polyimide is imidized by a conventionally known method (e.g., a heating method, a chemical method using a catalyst), and the imidization ratio was adjusted to 20 to 50%. In addition to the diamine monomers containing photo-reactive functional groups in their side chains, a diamine monomer containing no photo-reactive functional groups in a side chain may be added to the monomer component. Thereafter, prebaking and postbaking were performed, and thereby vertical alignment films 262 and 282 for RTN mode were formed.
(104) ##STR00006## ##STR00007## ##STR00008## ##STR00009## ##STR00010##
(3-2. Monomolecular Film Formation Step)
(105) A chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3 was dissolved in a solvent containing at least one of water and ethanol, so that a solution was prepared. The solution was heated to 60 C., and the TFT array substrate 260 and the counter substrate 280 were immersed in the solution for 1 hour. Thereby, the monomolecular films 263 and 283 were formed on the alignment films 262 and 282. At this time, as illustrated in
(106) In the monomolecular film formation step, heating the solution makes it possible to promote the reaction between the residual carboxyl groups in the alignment films 262 and 282 and the chlorosilane-based surfactant.
(107) Instead of immersing the substrates 260 and 280 in the solution, the solution may be applied to the substrates 260 and 280.
(108) Thereafter, the substrates 260 and 280 were washed using a solvent containing at least one of water and ethanol. A chlorosilane-based surfactant containing a linear alkyl group represented by the above formula (2), including a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3, is easily dissolved in a solvent such as water and ethanol. Hence, components of the chlorosilane-based surfactant which have not reacted with the residual carboxyl groups in the monomolecular film formation step can be easily removed by washing with a solvent. Thereby, it is possible to prevent a decrease in the qualities of the liquid crystal display device because of the unreacted components of the chlorosilane-based surfactant.
(109) (3-3. Photo-alignment Treatment Step)
(110) The substrates 260 and 280 with monomolecular films 263 and 283, formed on the alignment films 262 and 282 through the above alignment film formation step and the monomolecular film formation step, were irradiated with ultraviolet light from an oblique direction for alignment treatment. Ultraviolet light is preferably linearly polarized light, elliptically polarized light, or circularly polarized light in the case that alignment is made through photo-dimerization reaction. Unpolarized light is preferred in the case that alignment is made through photo-isomerization reaction.
(111) The photo-alignment treatment step may be performed before the monomolecular film formation step. Still, since immersion into a solution or heating at the monomolecular film formation step may possibly change the aligning ability, the photo-alignment treatment is preferably performed after formation of the monomolecular film. Especially in the case of providing alignment through photo-isomerization reaction, the photo-alignment treatment is preferably performed after formation of the monomolecular film.
(112) (3-4. Liquid Crystal Display Device Formation Step)
(113) A sealant (sealing agent) was applied to one of the substrates, beads were scattered on the other one of the substrates, and the substrates were attached to each other in such a manner that the alignment directions would form an angle of 90. The sealant is not particularly limited, and ultraviolet curable resin, thermosetting resin, and the like can be used. Liquid crystals having negative dielectric constant anisotropy were injected between the substrates, and a polarizer was disposed on the surface of each of the supporting substrates 261 and 281 on the opposite side of the liquid crystal layer 270, and thereby the RTN-mode liquid crystal display device 250 including vertical alignment films was produced.
(114) As illustrated in
(115) As illustrated in
(116) In this way, each pixel (or each sub-pixel) is provided with a multi-domain alignment to halve each pixel (or each sub-pixel) in the substrates at equal pitches. Then, the top and bottom substrates 12 are arranged (attached) such that the alignment division directions (photo-alignment treatment directions) for the top and bottom substrates 12 are perpendicular to each other in a plan view of the substrates. Also, a liquid crystal material containing no chiral material is injected into the liquid crystal layer. Thereby, the four-domain alignment illustrated in
(117) On the boundaries between domains, the alignment direction of the liquid crystal molecules on one of the substrates is the same as the absorption axis direction of the polarizer, and the alignment direction of the liquid crystal molecules on the other of the substrates is almost perpendicular to the substrates. Therefore, the boundaries between the domains do not transmit light even under voltage application between the substrates in the case that the polarizers are arranged in crossed Nicols, and thus the boundaries appear to be dark lines.
(118) As described above, in the case that four domains in each of which alignment directions of liquid crystal molecules are different from (substantially perpendicular to) each other are formed, excellent viewing angle characteristics, i.e., a wide viewing angle, can be achieved.
(119) The layout of the domains in the liquid crystal display device of the present embodiment is not limited to the four-division pattern illustrated in
(120) In a method for forming such a pattern, the alignment in each pixel (or each sub-pixel) is divided in such a manner so as to halve each pixel (or each sub-pixel) in the substrates at equal pitches as illustrated in
(121) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 16 to 20
(122) In the same manner as in the fourth embodiment, RTN-mode liquid crystal display devices of Examples 16 to 20 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 16, a monomolecular film was formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 17, n=7 in Example 18, n=9 in Example 19, and n=11 in Example 20.
(123) The pretilt angle, VHR, and residual DC voltage of each of the liquid crystal display devices were measured. The obtained results are shown in Table 4.
COMPARATIVE EXAMPLE 3
(124) No chlorosilane-based surfactant was used. That is, an RTN-mode liquid crystal display device of Comparative Example 3 was produced in the same manner as in Example 16, except that monomolecular films were not formed and the residual carboxyl groups in the alignment film were not treated. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 4.
(125) TABLE-US-00004 TABLE 4 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 16 ple 17 ple 18 ple 19 ple 20 Example 3 Alkyl chain 4 6 8 10 12 N/A length (n) (3) (5) (7) (9) (11) Pretilt 87.5 87.5 88.0 .sup.88.0 .sup.89.5 87.5 angle () VHR (%) 99.5 99.5 99.5 .sup.99.5 .sup.99.5 99.5 Residual DC 100 100 100 100 100 350 voltage (mV)
(126) Table 4 shows that the VHR in each of Examples 16 to 20 and Comparative Example 3 was 99.5%, which means that no difference was seen between the examples and comparative examples.
(127) In contrast, the residual DC voltage in Comparative Example 3 was 350 mV, whereas the residual DC voltage in each of Examples 16 to 20 was as low as 100 mV. Similarly to the above other examples, the residual DC voltage could be made low while a high VHR was maintained in Examples 16 to 20.
(128) Also, a longer linear alkyl chain led to a pretilt angle closer to 90 in Examples 16 to 20 and Comparative Example 3.
(129) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. This is probably because the carboxyl groups remaining in the polyimide-based alignment film were treated, and thereby the residual DC voltage was reduced while a high VHR was obtained.
(130) Further, in the RTN mode using a photo-reactive alignment film, a longer alkyl chain leads to a pretilt angle closer to 90. The alkyl chain in the chlorosilane-based surfactant contributes to vertical alignment of the liquid crystals, and a longer chain length is considered to result in higher vertical-alignment ability. Hence, the pretilt angle can be adjusted by adjusting the alkyl chain length.
(131) Fifth Embodiment
(132) Monomolecular films were formed using a chlorosilane-based surfactant represented by the chemical formula Cl.sub.3Si(CH.sub.2).sub.nCF.sub.3 was used instead of a chlorosilane-based surfactant represented by the chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3 in the fourth embodiment. Except for that, an RTN-mode liquid crystal display device was produced in the same manner as in the fourth embodiment.
(133) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 21 to 25
(134) In the same manner as in the fifth embodiment, RTN-mode liquid crystal display devices were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 21, a monomolecular film was formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 22, n=7 in Example 23, n=9 in Example 24, and n=11 in Example 25. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured in the same manner as in Examples 16 to 20. The obtained results are shown in Table 5 together with the results of Comparative Example 3.
(135) TABLE-US-00005 TABLE 5 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 21 ple 22 ple 23 ple 24 ple 25 Example 3 Alkyl chain 4 6 8 10 12 N/A length (n) (3) (5) (7) (9) (11) Pretilt 88.0 89.0 89.5 .sup.89.7 .sup.89.7 87.5 angle () VHR (%) 99.5 99.5 99.5 .sup.99.5 .sup.99.5 99.5 Residual DC 100 80 50 50 50 350 voltage (mV)
(136) Table 5 shows that, similarly to Examples 16 to 20, the residual DC voltage in each of Examples 21 to 25 is lower than that in Comparative Example 3 in which no chlorosilane-based surfactant was used, and thus the residual DC voltage was made low while a high VHR was maintained.
(137) The pretilt angle in each of Examples 21 to 25 using a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCF.sub.3 was closer to 90 than the pretilt angles in Examples 16 to 20 using a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3.
(138) In this way, introduction of a fluorine atom in an alkyl chain in the chlorosilane-based surfactant enables to bring the pretilt angle closer to 90 degrees with a shorter alkyl chain length than in Examples 16 to 20 in which no fluorine atom was introduced. Further, fluorine atom introduction contributes to a larger effect of reducing the residual DC voltage.
(139) These results show that fluorine atom introduction into an alkyl chain in a silane-based surfactant makes it possible to effectively control the pretilt angle under low residual DC voltage.
(140) Also, the results of Examples 21 to 25 show that, in terms of further reducing the residual DC voltage, n is preferably an integer of 5 to 11, and more preferably an integer of 7 to 11, in the present embodiment.
(141) Sixth Embodiment
(142) The present embodiment will be described based on a liquid crystal display device that employs a lateral electric field system and is in an IPS mode using horizontal alignment films.
(143) In
(144) The TFT array substrate 310 has, on the liquid crystal layer 320-side main surface of a glass substrate (supporting substrate 311), multiple gate signal lines parallel to each other, multiple source signal lines perpendicular to the gate signal lines and extending in parallel to each other, and thin film transistors (TFTs) disposed at each crossing portion of a gate signal line and a source signal line, although these components are not illustrated.
(145) The TFT array substrate 310 has comb-like electrodes (pixel electrodes 340, common electrodes 350) for applying lateral electric field to the liquid crystal molecules, and the counter substrate 330 does not have an electrode thereon.
(146) The liquid crystal layer 320 is formed from nematic liquid crystals showing negative dielectric constant anisotropy.
(147) Horizontal alignment films 312 and 332 are formed on the respective liquid crystal layer 320-side surfaces of the TFT array substrate 310 and the counter substrate 330 which have the above structures.
(148) Furthermore, on the alignment films 312 and 332, the monomolecular films 313 and 333 are respectively formed thereon.
(149) The liquid crystal display device 300 having the above structure was produced as described below, for example. First, the substrates 310 and 330 before alignment film formation were produced by a conventionally known method. Then, the following steps are performed.
(150) (4-1. Alignment Film Formation Step)
(151) A liquid crystal alignment agent containing a polyimide produced by imidizing a polyamic acid represented by the above formula (6) was applied to the liquid crystal layer 320-side main surface of each of the TFT array substrate 310 and the counter substrate 330. The polyimide is dissolvable in the state of polyamic acid. The polyimide is imidized by a conventionally known method (e.g., a heating method, a chemical method using a catalyst), and the imidization ratio was adjusted to 50 to 80%. Thereafter, prebaking and postbaking were performed, and thereby horizontal alignment films 312 and 332 for IPS mode were formed.
(152) (4-2. Monomolecular Film Formation Step)
(153) A chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nNH.sub.2 was dissolved in a solvent containing at least one of water and ethanol, so that a solution was prepared. The solution was heated to 60 C., and the TFT array substrate 310 and the counter substrate 330 were immersed in the solution for 1 hour. Thereby, the monomolecular films 313 and 333 were formed on the alignment films 312 and 332. At this time, the residual carboxyl groups derived from polyamic acid in the alignment films 312 and 332 are bonded to the chlorosilane groups of the chlorosilane-based surfactant by a covalent bond through dehydrochlorination reaction. Thereby, the residual carboxylic acid concentration can be decreased. Therefore, eliminating the residual carboxyl groups while maintaining the imidization ratio at a certain level to avoid an increase in the residual DC voltage enables to achieve a high VHR.
(154) In the monomolecular film formation step, heating the solution makes it possible to promote the reaction between the residual carboxyl groups in the alignment films 312 and 332 and the chlorosilane-based surfactant.
(155) Instead of immersing the substrates 310 and 330 in the solution, the solution may be applied to the substrates 310 and 330.
(156) Thereafter, the substrates 310 and 330 were washed using a solvent containing at least one of water and ethanol. A chlorosilane-based surfactant including a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nNH.sub.2 is easily dissolved in a solvent such as water and ethanol. Hence, components of the chlorosilane-based surfactant which have not reacted with the residual carboxyl groups in the monomolecular film formation step can be easily removed by washing with a solvent. Thereby, it is possible to prevent a decrease in the qualities of the liquid crystal display device because of unreacted components of the chlorosilane-based surfactant remaining unreacted.
(157) (4-3. Liquid Crystal Display Device Formation Step)
(158) Subsequently, rubbing treatment was performed on the substrates 310 and 330. A sealant (sealing agent) was applied to one of the substrates, beads were scattered on the other one of the substrates, and the substrates were attached to each other in such a manner that the rubbing directions for the respective substrates would be substantially parallel to each other and point opposite directions (i.e., they are antiparallel) in a plan view of the substrates. The sealant is not particularly limited, and ultraviolet curable resin, heat-curable resin, and the like can be used. Liquid crystals having negative dielectric constant anisotropy were injected between the substrates, and a polarizer was disposed on the surface of each of the supporting substrates 311 and 331 on the opposite side of the liquid crystal layer 320, and thereby the IPS-mode liquid crystal display device 300 including horizontal alignment films was produced.
(159) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 26 to 30
(160) In the same manner as in the sixth embodiment, IPS-mode liquid crystal display devices of Examples 26 to 30 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 26, a monomolecular film was formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 27, n=7 in Example 28, n=9 in Example 29, and n=11 in Example 30. The pretilt angle, VHR, and residual DC voltage of each of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 6.
COMPARATIVE EXAMPLE 4
(161) No chlorosilane-based surfactant was used. That is, an IPS-mode liquid crystal display device of Comparative Example 4 was produced in the same manner as in Example 26, except that monomolecular films were not formed and the residual carboxyl groups in the alignment film were not treated. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 6.
(162) TABLE-US-00006 TABLE 6 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 26 ple 27 ple 28 ple 29 ple 30 Example 4 Alkyl chain 3 5 7 9 11 N/A length (n) (3) (5) (7) (9) (11) Pretilt .sup.0.5 .sup.0.5 .sup.1.0 .sup.1.0 1.0 0.5 angle () VHR (%) 98.0 98.5 98.5 98.5 .sup.98.5 98.0 Residual DC 150 100 100 70 50 200 voltage (mV)
(163) Table 6 shows that, similarly to the above other examples, both the VHR and residual DC voltage in each of Examples 26 to 30 were better than those in Comparative Example 4 using no chlorosilane-based surfactant, and the residual DC voltage was made low while a high VHR was maintained. Particularly, a longer linear chain structure was observed to lead to a lower value of the residual DC voltage.
(164) Here, a longer linear chain structure was observed to hardly affect the pretilt angle.
(165) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. This is probably because the carboxyl groups remaining in the polyimide-based alignment film were treated, and thereby the residual DC voltage was reduced while a high VHR was obtained.
(166) Also, the increase in the pretilt angle was small even with a longer alkyl chain. This is probably because an amino group was introduced to a terminal.
(167) Also, the results of Examples 26 to 30 show that, in terms of further lowering the residual DC voltage, n is preferably an integer of 5 to 11, and more preferably an integer of 9 to 11, in the present embodiment.
(168) Seventh Embodiment
(169) The present embodiment will be described based on an example of a TBA-mode liquid crystal display device that employs a lateral electric field system and have vertical alignment films.
(170) In
(171) The TFT array substrate 410 has, on the liquid crystal layer 420-side main surface of a glass substrate (supporting substrate 411), multiple gate signal lines parallel to each other, multiple source signal lines perpendicular to the gate signal lines and extending in parallel to each other, and thin film transistors (TFTs) disposed at each crossing portion of a gate signal line and a source signal line, although these components are not illustrated.
(172) The TFT array substrate 410 has comb-like electrodes (pixel electrodes 440, common electrodes 450) for applying lateral electric field to the liquid crystal molecules, and the counter substrate 430 does not have an electrode thereon.
(173) The liquid crystal layer 420 is formed from nematic liquid crystals showing positive dielectric constant anisotropy.
(174) Vertical alignment films 412 and 432 are formed on the respective liquid crystal layer 420-side surfaces of the TFT array substrate 410 and the counter substrate 430 which have the above structures.
(175) Furthermore, on the alignment films 412 and 432, the monomolecular films 413 and 433 are respectively formed thereon.
(176) The liquid crystal display device 400 having the above structure was produced as described below, for example. First, the substrates 410 and 430 before alignment film formation were produced by a conventionally known method. Then, the following steps are performed.
(177) (5-1. Alignment Film Formation Step)
(178) To the liquid crystal layer 420-side main surface of each of the TFT array substrate 410 and the counter substrate 430, a liquid crystal alignment agent was applied which contained a polyimide produced by polymerizing (copolymerizing), by a conventionally known method, at least one of an acid anhydride represented by the above chemical formulas (7) to (13) and at least one of diamine monomers containing vertically aligning functional groups represented by the above chemical formulas (14) to (20). The polyimide is imidized by a conventionally known method (e.g., a heating method, a chemical method using a catalyst), and the imidization ratio was adjusted to 20 to 50%. Thereafter, prebaking and postbaking were performed, and thereby vertical alignment films 412 and 432 were formed.
(179) (5-2. Monomolecular Film Formation Step)
(180) A chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3 was dissolved in a solvent containing at least one of water and ethanol, so that a solution was prepared. The solution was heated to 60 C., and the TFT array substrate 410 and the counter substrate 430 were immersed in the solution for 1 hour. Thereby, the monomolecular films 413 and 433 were formed on the alignment films 412 and 432. At this time, as illustrated in
(181) In the monomolecular film formation step, heating the solution makes it possible to promote the reaction between the residual carboxyl groups in the alignment films 412 and 432 and the chlorosilane-based surfactant.
(182) Instead of immersing the substrates 410 and 430 in the solution, the solution may be applied to the substrates 410 and 430.
(183) Thereafter, the substrates 410 and 430 were washed using a solvent containing at least one of water and ethanol. A chlorosilane-based surfactant containing a linear alkyl group represented by the above formula (2), including a chlorosilane-based surfactant represented by a chemical formula Cl.sub.3Si(CH.sub.2).sub.nCH.sub.3, is easily dissolved in a solvent such as water and ethanol. Hence, components of the chlorosilane-based surfactant which have not reacted with the residual carboxyl groups in the monomolecular film formation step can be easily removed by washing with a solvent. Thereby, it is possible to prevent a decrease in the qualities of the liquid crystal display device because of the unreacted components of the chlorosilane-based surfactant.
(184) (5-3. Liquid Crystal Display Device Formation Step)
(185) A sealant (sealing agent) was applied to one of the substrates, beads were scattered on the other of the substrates, and the substrates were attached to each other. The sealant is not particularly limited, and ultraviolet curable resin, thermosetting resin, and the like can be used. Liquid crystals having positive dielectric constant anisotropy were injected between the substrates, and a polarizer was disposed on the surface of each of the supporting substrates 411 and 431 on the opposite side of the liquid crystal layer 420, and thereby the TBA-mode liquid crystal display device 400 including vertical alignment films was produced.
(186) Hereinafter, the present embodiment will be described in more detail based on examples and comparative examples.
EXAMPLES 31 to 35
(187) In the same manner as in the seventh embodiment, TBA-mode liquid crystal display devices of Examples 31 to 35 were produced which included monomolecular films formed using chlorosilane-based surfactants having different linear alkyl chain lengths. Specifically, in Example 31, a monomolecular film was formed using a chlorosilane-based surfactant with n in the above chemical formula=3. Similarly, monomolecular films were formed using chlorosilane-based surfactants with n=5 in Example 32, n=7 in Example 33, n=9 in Example 34, and n=11 in Example 35. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 7.
COMPARATIVE EXAMPLE 5
(188) No chlorosilane-based surfactant was used. That is, a TBA-mode liquid crystal display device of Comparative Example 5 was produced in the same manner as in Example 31, except that monomolecular films were not formed and the residual carboxyl groups in the alignment film were not treated. The pretilt angle, VHR, and residual DC voltage of the obtained liquid crystal display devices were measured. The obtained results are shown in Table 7.
(189) TABLE-US-00007 TABLE 7 Compar- Exam- Exam- Exam- Exam- Exam- ative ple 31 ple 32 ple 33 ple 34 ple 35 Example 5 Alkyl chain 4 6 8 10 12 N/A length (n) (3) (5) (7) (9) (11) Pretilt 90 90 90 90 90 90 angle () VHR (%) 98.5 98.5 98.5 .sup.98.5 .sup.98.5 98.0 Residual DC 150 150 150 150 150 300 voltage (mV)
(190) Table 7 shows that, similarly to the above other examples, the VHR and residual DC voltage in each of Examples 31 to 35 were better than those in Comparative Example 5 using no chlorosilane-based surfactant, and the residual DC voltage was made low while a high VHR was maintained.
(191) The pretilt angle in each of Examples 31 to 35 and Comparative Example 5 was 90. That is, the linear alkyl chain in the chlorosilane-based surfactant did not affect the alignment of the liquid crystal molecules in the present embodiment in which the liquid crystal molecules were vertically aligned.
(192) In this way, introduction of the step of treating the alignment film surface with a chlorosilane-based surfactant enabled to achieve a high VHR and low residual DC voltage. This is probably because the carboxyl groups remaining in the polyimide-based alignment film were treated, and thereby the residual DC voltage was reduced while a high VHR was obtained.
(193) Also, since vertical alignment films were used, the linear alkyl chain did not affect the aligning ability.
(194) The present application claims priority to Patent Application No. 2010-066894 filed in Japan on Mar. 23, 2010 under the Paris Convention and provisions of national law in a designated State, the entire contents of which are hereby incorporated by reference.
EXPLANATION OF SYMBOLS
(195) 11: Liquid crystal molecule 10, 12: Substrate (top and bottom substrates) 13: Photomask 14: Light shielding portion 15: Absorption axis direction of polarizer arranged on bottom substrate side 16: Absorption axis direction of polarizer arranged on top substrate side 17: Average director direction under AC voltage application 100, 200, 250, 300, 400: Liquid crystal display device 110, 210, 260, 310, 410: TFT array substrate 111, 131, 211, 231, 261, 281, 311, 331, 411, 431: Supporting substrate 20, 112, 132, 212, 232, 262, 282, 312, 332, 412, 432: Alignment film 113, 133, 213, 233, 263, 283, 313, 333, 413, 433: Monomolecular film 115, 215, 265, 340, 440: Pixel electrode 120, 220, 270, 320, 420: Liquid crystal layer 130, 230, 280, 330, 430: Counter substrate 135, 235, 285, 350, 450: Counter electrode (common electrode) 214: Slit 234: Projection