Method and apparatus for integrating microlens array into a liquid crystal display device using a sacrificial substrate

摘要

A method and apparatus is presented for transmissive liquid crystal display devices with increased apparent aperture ratios. The aperture ratio is increased by focusing light into the transparent area using a microlens array on a per pixel basis. The method includes the steps of forming a top substrate having a sacrificial substrate adhered to a first transmissive substrate, a transmissive electrode layer adhered to the first transmissive substrate in which a plurality of color filters are disposed, the top substrate further having a rubbing layer formed proximate to the transmissive electrode layer. Forming a bottom substrate comprising a second transmissive substrate and a thin film transistor array disposed within the second transmissive substrate. Disposing a sealing material on one of the top or bottom substrates so as to form an outline of display. Aligning and assembling the top and bottom substrates together such that the sealing material is sandwiched between the top and bottom substrates which are maintained at a constant separation of a few microns uniformly across the display with the help of spacer balls or posts and the rubbing layer is proximate to the thin film transistor array. Releasing the sacrificial substrate from the first transmissive substrate and adhering a microlens array to the first transmissive substrate. Lastly, filling the outline of sealing material with liquid crystal material and sealing the liquid crystal material. Also provided is an apparatus for carrying out the method of the present invention.