Liquid crystal display and method for manufacturing the same

1. A liquid crystal display comprising:

an array substrate comprising a display region in which an image is displayed, and comprising a transparent substrate on which switching elements and pixel electrodes are arranged in array within the display region;

a counter substrate provided to face the array substrate with a liquid crystal layer interposed therebetween;

a sealant provided to surround an outside of the display region, and joining the array substrate to the counter substrate;

alignment films disposed on a surface of the array substrate and a surface of the counter substrate, the surfaces facing each other; and

the liquid crystal layer surrounded by the sealant, and held in a region in a gap between the array substrate and the counter substrate, the region corresponding at least to the display region, wherein

the alignment films are disposed at least in the display region, and each of the alignment films is positioned to comprise an overlap with a part of an inside of the sealant,

on each of the surfaces of the array substrate and the counter substrate in the overlaps, an uneven surface on which a projection pattern or a recess pattern is arranged,

all over an outer edge portion of the sealant, a portion is disposed in which the sealant is joined to the surfaces of the array substrate and the counter substrate without the alignment films interposed therebetween, and

in the outer edge portion of the sealant on the array substrate, in a direction from the display region to a region where the sealant is provided, the sealant directly contacts the transparent substrate inside a recess and outside that recess of the recess pattern or directly contacts the substrate at a base of at least one of the projections of the projection pattern at adjacent opposite sides of that projection, the transparent substrate being the same material exposed at the bottom and outside of the recess or at the opposite sides of the base of at least one projection.

2. The liquid crystal display according to claim 1 , comprising:

in the display region, a flattening film disposed on the array substrate and covering the switching element; and

in the display region, a plurality of columnar spacers disposed on the counter substrate, abutting the array substrate, and holding a gap between the array substrate and the counter substrate, wherein

the projection pattern or the recess pattern on the array substrate is made of the same material and has the same thickness as the flattening film, and

the projection pattern or the recess pattern on the counter substrate is made of the same material and has the same thickness as the columnar spacers.

3. The liquid crystal display according to claim 2 , wherein

the plurality of columnar spacers comprise a main spacer and a sub-spacer,

the main spacer has a relatively longer length than the sub-spacer in a direction perpendicular to the surface of the counter substrate,

the sub-spacer has a relatively shorter length than the main spacer in the direction perpendicular to the surface of the counter substrate,

the projection pattern or the recess pattern on the array substrate is made of the same material and has the same thickness as the flattening film, and

the projection pattern or the recess pattern on the counter substrate is made of the same material and has the same thickness as the sub-spacer.

4. The liquid crystal display according to claim 1 , wherein the sealant is in direct contact with an upper surface of a protrusion of the uneven surface.

5. The liquid crystal display according to claim 3 , wherein the sealant is in contact with an upper surface of a protrusion of the uneven surface with the alignment film, being thinner than the alignment film disposed on an upper surface of the sub-spacer, interposed therebetween.

6. The liquid crystal display according to claim 4 , wherein the projection pattern or the recess pattern is made of a porous material.

7. The liquid crystal display according to claim 1 , wherein a protrusion of the uneven surface disposed on the surface of the array substrate and a protrusion of the uneven surface disposed on the counter substrate are arranged in a staggered manner.

8. The liquid crystal display according to claim 1 , wherein

the uneven surface comprises a projection pattern arranged on the surface of each of the array substrate and the counter substrate,

the uneven surface further comprises a different projection pattern arranged on the surface of each of the array substrate and the counter substrate, in the portion, in which the sealant is joined to the surfaces of the array substrate and the counter substrate without the alignment films interposed therebetween, and

the different projection pattern is arranged in lower density than the projection pattern arranged in the overlap, or the different projection pattern has a smaller outer size than the projection pattern arranged in the overlap.

9. The liquid crystal display according to claim 8 , wherein the projection pattern disposed on the surface of the array substrate and the projection pattern on the surface of the counter substrate, in the outer edge portion of the sealant, comprise a protrusion on the surfaces of the array substrate and a protrusion on the counter substrate arranged in a staggered manner.

10. The liquid crystal display according to claim 1 , wherein the projection pattern or the recess pattern is formed of a rectangular pattern having a longer-side direction parallel to a direction in which the sealant extends.

11. The liquid crystal display according to claim 3 , wherein

the projection pattern or the recess pattern disposed on the array substrate is formed of the recess pattern disposed on the flattening film, and

the projection pattern or the recess pattern disposed on the counter substrate is formed of the projection pattern that is circular, is made of the same material, and has the same thickness as the sub-spacer.

12. A liquid crystal display comprising:

an array substrate comprising a display region in which an image is displayed, and comprising a switching element and a pixel electrode arranged in array within the display region;

a counter substrate provided to face the array substrate with a liquid crystal layer interposed therebetween;

a sealant provided to surround an outside of the display region, and joining the array substrate to the counter substrate;

alignment films disposed on a surface of the array substrate and a surface of the counter substrate, the surfaces facing each other; and

the liquid crystal layer surrounded by the sealant, and held in a region in a gap between the array substrate and the counter substrate, the region corresponding at least to the display region, wherein

the alignment films are disposed at least in the display region, and each of the alignment films is positioned to comprise an overlap with a part of an inside of the sealant,

on each of the surfaces of the array substrate and the counter substrate in the overlaps, an uneven surface on which a projection pattern or a recess pattern is arranged,

all over an outer edge portion of the sealant, a portion is disposed in which the sealant is joined to the surfaces of the array substrate and the counter substrate without the alignment films interposed therebetween,

the projection pattern or the recess pattern comprises a rectangular pattern having a longer-side direction parallel to a direction in which the sealant extends in a vicinity of the sealant on one pair of parallel sides of four sides of the counter substrate that has a rectangular shape, and

the projection pattern or the recess pattern comprises a rectangular pattern having a longer-side direction perpendicular to the direction, in which the sealant extends, in a vicinity of the sealant on the other pair of parallel sides of the four sides.

13. The liquid crystal display according to claim 12 , wherein the sealant is in direct contact with a bottom of a cavity of the uneven surface.

14. A method for manufacturing the liquid crystal display according to claim 12 , the method comprising:

forming, by the use of a rectangular pattern, the projection pattern or the recess pattern in all regions in which the sealant is formed, the rectangular pattern having a longer-side direction perpendicular to a particular direction, the all regions being located on the four sides of the counter substrate, which has a rectangular shape; and

moving, by the use of a flexography method, a transfer roller in the particular direction on the surface of the array substrate and on the surface of the counter substrate to apply, onto the surfaces, an alignment film material that forms the alignment films.

15. A method for manufacturing a liquid crystal display comprising an array substrate comprising a display region in which an image is displayed, and comprising a switching element and a pixel electrode arranged in array within the display region; a counter substrate provided to face the array substrate with a liquid crystal layer interposed therebetween; a sealant provided to surround an outside of the display region, and joining the array substrate to the counter substrate; alignment films disposed on a surface of the array substrate and a surface of the counter substrate, the surfaces facing each other; and the liquid crystal layer surrounded by the sealant, and held in a region in a gap between the array substrate and the counter substrate, the region corresponding at least to the display region, wherein the alignment films are disposed at least in the display region, and each of the alignment films is positioned to comprise an overlap with a part of an inside of the sealant, on each of the surfaces of the array substrate and the counter substrate in the overlaps, an uneven surface on which a projection pattern or a recess pattern is arranged, and all over an outer edge portion of the sealant, a portion is disposed in which the sealant is joined to the surfaces of the array substrate and the counter substrate without the alignment films interposed therebetween, the method comprising:

applying and forming a flattening film that covers the switching element onto the surface of the array substrate;

patterning the flattening film to simultaneously form, onto the array substrate, a contact hole disposed on the flattening film in the display region and the projection pattern or the recess pattern disposed in the overlap;

applying and forming a photosensitive resin film onto the surface of the counter substrate; and

patterning the photosensitive resin film to simultaneously form, onto the counter substrate, a plurality of columnar spacers disposed in the display region and the projection pattern or the recess pattern disposed in the overlap.

16. A method for manufacturing a liquid crystal display comprising an array substrate comprising a display region in which an image is displayed, and comprising a switching element and a pixel electrode arranged in array within the display region; a counter substrate provided to face the array substrate with a liquid crystal layer interposed therebetween; a sealant provided to surround an outside of the display region, and joining the array substrate to the counter substrate; alignment films disposed on a surface of the array substrate and a surface of the counter substrate, the surfaces facing each other; and the liquid crystal layer surrounded by the sealant, and held in a region in a gap between the array substrate and the counter substrate, the region corresponding at least to the display region, wherein the alignment films are disposed at least in the display region, and each of the alignment films is positioned to comprise an overlap with a part of an inside of the sealant, on each of the surfaces of the array substrate and the counter substrate in the overlaps, an uneven surface on which a projection pattern or a recess pattern is arranged, and all over an outer edge portion of the sealant, a portion is disposed in which the sealant is joined to the surfaces of the array substrate and the counter substrate without the alignment films interposed therebetween, the method comprising:

applying an alignment film material that forms the alignment films onto the surfaces of the array substrate and the counter substrate; and

rubbing a surface of the alignment film material with a mask that covers the display region to reduce a thickness of the alignment film material applied on an upper surface of a protrusion of the uneven surface.

17. The liquid crystal display according to claim 1 , wherein

in the outer edge portion of the sealant on the array substrate, in a direction from the display region to a region where the sealant is provided, the sealant directly contacts the transparent substrate without an intervening alignment film inside a recess and outside that recess of the recess pattern or directly contacts the substrate without an intervening alignment film at a base of at least one of the projections of the projection pattern at adjacent opposite sides of that projection, the transparent substrate being the same material exposed at the bottom and outside of the recess or at the opposite sides of the base of at least one projection.