Liquid crystal displays and manufacturing methods thereof

Abstract

Liquid crystal displays are manufactured by securing overlying first and second substrates with an intermediate sealant together such that they form a cell cavity with an injection opening. In one embodiment, a plurality of over-sized spacers are disposed intermediate the first and second substrates in the cell cavity. The first and second substrates are structurally secured by heat compressing the layers together with a pressure in the range of about 0.4-0.55 kg/cm.sup.2. A quantity of liquid crystal material is injected into the cell cavity through the injection opening to expand the substrate layers to a non-planar configuration. A second sealant is applied proximate to the injection opening and a second compressing step is used to facilitate the proper positioning of the second sealant into injection opening. The second compressing step employs a pressure about 0.1-1.0 kg/cm.sup.2 greater than the pressure in the first compressing step. In one embodiment, the second compressing step is delayed by about 3-20 hours after the injecting step. In another embodiment, the over-sized spacers arc sized such that they are 10-30% larger than the cell cavity gap. The liquid crystal display includes first and second substrate layers and a first sealant which define a cell cavity and spacers in the cell cavity which are compressed by about 10-30% relative to their uncompressed configurations.