UV curable liquid pre-polymer, and liquid crystal display device using the same and manufacturing method thereof

1. A liquid-crystal display comprising:

first substrate and second substrate disposed opposite the first substrate;

a plurality of pixel areas formed on the first substrate, each pixel area having red, green, blue, and white sub-pixel areas;

red, green and blue color filter layers disposed on the red, green and blue sub-pixel areas, respectively; and

an overcoat layer disposed over the red, green and blue color filter layers, wherein a portion of the overcoat layer forms a white color filter layer in the white sub-pixel area, and wherein the overcoat layer is formed from a UV-curable liquid pre-polymer material that includes monomers each having a mono-functional group, and at least one of a di-functional group or a tri-functional group.

2. The liquid-crystal display according to claim 1 , wherein the mono-functional group includes mono-functional initiators each have an active site of the mono-functional group as an initiator to induce an initial reaction on the monomers.

3. The liquid-crystal display according to claim 1 , wherein the tri-functional group is less than or equal to about 20% by volume of the UV-curable liquid pre-polymer material so as to maintain a viscosity below a predetermined value.

4. The liquid-crystal display according to claim 1 , wherein the UV-curable liquid pre-polymer includes a mono-functional monomer of about 30˜60% by volume, a di-functional monomer of about 20˜50% by volume, and a tri-functional monomer of about 10˜20% by volume, and a photo-initiator.

5. The liquid-crystal display according to claim 4 , wherein the mono-functional monomer is formed of CH 2 ═CHY or CH 2 ═CXY, wherein X and Y are formed of any one of halogen, alkyl, ester or phenyl.

6. The liquid-crystal display according to claim 1 , wherein the mono-functional monomer is a vinyl monomer formed in a carbon covalent bond structure.

7. The liquid-crystal display according to claim 1 , comprising

a plurality of column spacers formed on the overcoat layer, wherein the overcoat layer and the column spacers are integrally formed from the UV-curable liquid pre-polymer material.

8. A method of making a liquid display comprising:

providing a first substrate;

disposing a second substrate opposite the first substrate;

forming a plurality of pixel areas on the first substrate, each pixel area having red, green, blue, and white sub-pixel areas;

forming red, green and blue color filter layers on the red, green and blue sub-pixel areas, respectively; and

applying an overcoat layer over the red, green, and blue color filter layers, a portion of the overcoat layer forming a white color filter layer in the white sub-pixel area, wherein the UV-curable liquid pre-polymer material includes monomers each having a mono-functional group, and at least one of a di-functional group or a tri-functional group.

9. The method according to claim 8 , further comprising applying a mold to the overcoat layer, the mold having a plurality of cavities configured to form a plurality of corresponding column spacers on the overcoat layer, wherein the overcoat layer and the column spacers are integrally formed from the UV-curable liquid pre-polymer material.

10. The method according to claim 8 , further comprising curing UV-curable liquid pre-polymer material and forming an alignment layer over the cured UV-curable liquid pre-polymer material.

11. The method according to claim 9 , wherein the overcoat layer and the column spacers are formed of the cured UV-curable liquid pre-polymer material and function as a planerized pattern layer.

12. The method according to claim 8 , wherein the mono-functional group includes mono-functional initiators having an active site of the mono-functional group as an initiator to induce an initial reaction on the monomers.

13. The method according to claim 8 , wherein the tri-functional group is less than or equal to about 20% by volume of the UV-curable liquid pre-polymer material.

14. The method according to claim 8 , wherein the di-functional group or the tri-functional group in the UV-curable liquid pre-polymer material prevents shrinkage of the material during curing and/or baking.

15. The method according to claim 8 , wherein the monomer having the mono-functional group is activated by the mono-functional initiator, and each active site activated is combined repeatedly with another monomer on a horizontal plane to form a linear chain structure.

16. The method according to claim 15 , wherein multiple layers of the linear chain structure arrange vertically at substantially fixed distances to form a pattern layer.

17. The method according to claim 8 , wherein the UV-curable liquid pre-polymer includes a mono-functional monomer of about 30˜60% by volume, a di-functional monomer of about 20˜50% by volume, and a tri-functional monomer of about 10˜20% by volume, and a photo-initiator.

18. The method according to claim 17 , wherein the mono-functional monomer is formed of CH 2 ═CHY or CH 2 ═CXY, wherein X and Y are formed of any one of halogen, alkyl, ester or phenyl.

19. The method according to claim 8 , wherein the mono-functional monomer is a vinyl monomer formed in a carbon covalent bond structure.

20. A method of making a liquid display comprising:

forming red, green and blue color filter layers on the red, green and blue sub-pixel areas of a first substrate, respectively;

applying an overcoat layer over the red, green, and blue color filter layers, a portion of the overcoat layer forming a white color filter layer in the white sub-pixel area; and

forming a plurality of column spacers on the overcoat layer, wherein the overcoat layer and the column spacers are integrally formed from a UV-curable liquid pre-polymer material, wherein the UV-curable liquid pre-polymer material includes monomers each having a mono-functional group, and at least one of a di-functional group or a tri-functional group.