JP2000075126A - Production of color filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a processing for producing large-sized color filters having a high-accuracy pixel shape and high-accuracy pixel sections in spite of the large-sized color filters. SOLUTION: This process includes stages for manufacturing a transfer sheet 5 provided with a UV curing type tacky adhesive layer 1 on a base material 2 and a photosensitive colored transfer layer 4 on a transfer sheet base material 3, bringing the tacky adhesive layer surface and the colored transfer layer surface into pressurize contact with each other, irradiating the transfer sheet with UV rays 7 via a mask, curing the pixel parts of the colored transfer layer to decrease the adhesive power thereof and to increase the adhesive power of the pixel parts of he tacky adhesive layer, peeling the transfer sheet to transfer the pixel parts of the colored transfer layer onto the tacky adhesive layer and to allow the portions exclusive of the pixel parts to remain on the transfer sheet base material, baking the base material to remove the tacky adhesive layer and the components exclusive of the pigments of the pixel parts, forming a transparent over-coating layer 9 and baking the same.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a color filter used for a plasma display or the like, and more particularly, to a method for manufacturing a large and high-precision color filter.

[0002]

2. Description of the Related Art As a method for producing a color filter, conventionally, a dyeing method, a pigment dispersion method, a printing method, an electrodeposition method and the like are known. The dyeing method is to provide an easily dyeable transparent layer and a photosensitive resin layer on a transparent substrate, form a desired pattern using photolithography technology, etc., and dye one color at a time. Is to manufacture. The pigment dispersion method is a method in which a photosensitive resin in which a pigment such as a pigment is dispersed is applied on a transparent substrate, and a desired pattern is formed using a photolithography technique or the like to manufacture a color filter.

In the printing method, a color filter is manufactured on a substrate by using offset printing, screen printing, or the like. In the electrodeposition method, a transparent conductor layer is provided on a transparent substrate, a desired pattern is formed by using a photolithography technique or the like. The colored pattern is formed by electrodeposition in a dispersed solvent.

However, none of the above methods is necessarily satisfactory as a method for manufacturing a color filter. For example, in the dyeing method and the pigment dispersion method, since a photolithography technique is used, it is possible to stably produce a high-resolution and high-precision pattern. Coating, pre-baking, pattern exposure, development,
Dyeing (in the case of the dyeing method), washing, drying, post-baking and other steps are required, and in order to produce a color filter of a plurality of colors, that is, red, green, and blue (and even black), these filters are required. It is necessary to repeat the process a plurality of times, which is difficult in terms of yield. In addition, application of a photosensitive resin or the like, pre-baking and post-baking require a relatively long time, so that it is difficult to reduce the manufacturing time.

[0005] The application of a photosensitive resin in the pigment dispersion method is conventionally performed by a spinner, but only a few percent of the dropped resin is used as a colored layer. The conductive resin will be discarded. In addition, since these manufacturing methods include a wet development process, processing equipment for waste liquid or the like is required, and it is generally difficult to improve productivity and reduce costs. Further, in a color filter used for a plasma display or the like, it is difficult to uniformly apply a photosensitive resin because the substrate itself becomes large.

The printing method does not use photolithography techniques such as coating, exposing, and developing a photosensitive resin, and therefore has major advantages such as a short manufacturing process, low manufacturing cost, and excellent mass productivity. Display quality such as bleeding, difficulty in maintaining the shape and position of the colored pattern with high accuracy, and unevenness in the cross-sectional shape of the formed colored pattern, resulting in uneven thickness and uneven color Is difficult to improve.

In the electrodeposition method, a transparent conductive layer is formed on a transparent substrate, finely processed in accordance with a color pattern, and then a current is supplied to the transparent conductive layer for each color to electrodeposit a coloring material. Therefore, the film thickness can be controlled, and a thermosetting resin can be used as a binder for the dye, so that heat resistance, light resistance, and chemical resistance can be improved. Therefore, there is an advantage that the size of the substrate can be increased. However, the transparent conductor layer is electrically connected at the terminal portion between the same colors, so that the pixels are connected to each other, and between the different colors, the pixels must not be electrically connected. Very advanced microfabrication technology is required for patterning the conductor layer. Therefore, it is difficult to improve the yield or reduce the cost.

Under such technical background, in recent years, a transfer method has been developed in which a transfer layer having a pixel pattern shape is previously formed on a transfer base, and the transfer layer is transferred to a color filter substrate to manufacture a color filter. I have. This transfer method is excellent in terms of cost and simplicity at the time of manufacturing, and is attracting attention as a technique that can sufficiently cope with future enlargement. However, in this method, positioning of the color filter substrate and the transfer sheet is required with high accuracy in order to transfer a transfer layer having a pixel pattern shape to a predetermined portion (ie, a pixel portion) of the color filter substrate. As the shape becomes finer, it becomes very difficult to perform the above-described positioning accurately, and there is a problem that the simplicity in manufacturing, which is a feature of the transfer method, is impaired.

[0009]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a large color filter used in a large plasma display or the like, in which a colored layer forming pixels is uniform even in a large color filter. It is an object of the present invention to provide a method for manufacturing a large-sized color filter having a high-precision pixel shape and a high-precision pixel portion.

[0010]

SUMMARY OF THE INVENTION The present invention relates to a method for manufacturing a color filter having a color layer provided on a color filter substrate, comprising: (1) an ultraviolet curing type wherein the adhesive strength is increased by ultraviolet rays on the color filter substrate; Providing a pressure-sensitive adhesive layer, (2) providing a photosensitive colored transfer layer whose adhesive strength is reduced by ultraviolet rays on the transfer sheet substrate to form a transfer sheet, and (3) providing the color filter substrate A step of pressing the upper ultraviolet curable adhesive layer surface and the photosensitive colored transfer layer surface of the transfer sheet, and (4) having a first color pixel pattern from the transfer sheet substrate side of the pressed transfer sheet. Irradiating ultraviolet rays through a mask, curing the pixel parts of the photosensitive colored transfer layer that have been irradiated with ultraviolet rays, and reducing the adhesive strength between the pixel parts that have been irradiated with the ultraviolet rays and the transfer sheet base material,
At the same time, the step of increasing the adhesive strength between the pixel portion of the ultraviolet-curable adhesive layer irradiated with ultraviolet rays and the color filter substrate, and (5) peeling off the pressed transfer sheet to form the photosensitive color (6) a step of transferring the ultraviolet-ray-irradiated pixel portion of the transfer layer onto the ultraviolet-curable adhesive layer and, at the same time, leaving a portion other than the ultraviolet-irradiated pixel portion on the transfer sheet substrate; (2) repeating the above steps (2) to (5) a desired number of times; and (7) firing the color filter substrate obtained by repeating the desired number of times a number of times, and setting an ultraviolet curable adhesive on the color filter substrate. And (8) forming a transparent overcoat layer on the fired color filter substrate and firing it. Characteristic color filter manufacturing method A.

The present invention also relates to a method of manufacturing a color filter according to the above-mentioned invention, wherein black color for inter-pixel light shielding is added to the desired number of colors.

[0012] The present invention also provides a method of manufacturing a color filter according to the above invention, wherein the material of the overcoat layer is a transparent low-melting glass or a transparent inorganic oxide. is there. Further, the present invention is the method for producing a color filter according to the above invention, wherein the dye of the photosensitive colored transfer layer is an inorganic pigment.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a color filter according to the present invention will be described in detail based on one embodiment.

FIG. 1 is an explanatory view showing the concept of pixel formation of a color filter according to the present invention. The UV curable adhesive layer 1 of the color filter substrate 2 provided with the UV curable adhesive layer 1 whose adhesive strength is increased by ultraviolet rays, and the photosensitive material whose adhesive strength is decreased by the ultraviolet rays of the transfer sheet 5 The surface of the transferable colored transfer layer 4 is pressed, a mask 6 is placed on the transfer sheet 5 side of the transfer sheet 5, and ultraviolet rays 7 are irradiated on the mask 6.
By the irradiation of the ultraviolet rays, the pixel portions 4 ′ of the photosensitive colored transfer layer 4 irradiated with the ultraviolet rays are cured, and the adhesive strength of the pixel portions 4 ′ irradiated with the ultraviolet rays to the transfer sheet base material is reduced. The adhesive strength between the pixel portion 1 ′ and the color filter substrate of the ultraviolet curable adhesive layer 1 irradiated with ultraviolet rays is increased. Then, the transfer sheet 5 is peeled off, and the pixel section 4 ′ of the photosensitive colored transfer layer irradiated with the ultraviolet rays is transferred onto the pixel section 1 ′ of the ultraviolet-curable adhesive layer 1 irradiated with the ultraviolet rays. A pixel is formed.

2 (A) to 2 (D) and FIG. 3 (A) to
(D) is an explanatory view showing a step of a method of manufacturing a color filter according to the present invention in a cross section. FIG. 2 (A) to (D)
Shows a process of forming a pixel of the first color. FIG. 2A shows a color filter substrate 2 provided with an ultraviolet-curable adhesive layer 1 whose adhesive strength is increased by ultraviolet rays.
2 shows a state in which a transfer sheet 5 provided with a photosensitive colored transfer layer 4 whose adhesive strength to the transfer sheet base material 3 is reduced by ultraviolet rays and a mask 6 are superposed.

As shown in FIG. 2B, one surface of the ultraviolet curable adhesive layer 1 of the color filter substrate 2 and the transfer sheet 5
The surface of the photosensitive colored transfer layer 4 is pressure-bonded, and a mask 6 is provided.
Irradiate with ultraviolet light. Next, as shown in FIG. 2 (C), the transfer sheet 5 is separated from the color filter substrate 2 and the photosensitive colored transfer layer (pixel portion) 4 ′ at the irradiated portion is irradiated with the ultraviolet curable adhesive agent at the irradiated portion. It is transferred onto the layer (pixel portion) 1 '. Thus, pixels of the first color are formed. (Figure 2
(D)).

FIGS. 3A to 3D are explanatory views showing the steps for the second and subsequent colors. By repeating the steps shown in FIGS. 2B to 2D a desired number of times, for example,
As shown in FIG. 3B, red (4′R) and green (4′R)
G), blue (4′B) pixels are obtained. Since the UV-curable adhesive layer 1 serves as a cushion for the second and subsequent colors, the first color red (4′R) exists on the UV-curable adhesive layer 1 and is flat. Even if it is not a surface, the adhesion of the photosensitive colored transfer layer is maintained.

After all the pixels are formed, a light-shielding layer may be formed between the pixels using a transfer sheet having a black photosensitive colored transfer layer. Then, after forming all the pixels and the light-shielding layer, as shown in FIG. 3C, the color filter base material is baked, and components other than the pigment such as the resin and the solvent in the pixels 4 ′ and the UV-curable adhesive are used. Remove the adhesive layer.
Subsequently, as shown in FIG. 3D, for example, a transparent low-melting glass is applied as the overcoat layer 9 and baked at a high temperature to form a transparent overcoat layer. Thereafter, an electrode may be formed on the overcoat layer 9. (Not shown).

FIGS. 4 and 5 show the obtained color filters (10, 20). The color filter (20) shown in FIG. 5 has a light shielding layer 8 formed between its pixels.

Hereinafter, the photosensitive colored transfer layer of the present invention will be described. First, this photosensitive colored transfer layer is composed of a composition mainly composed of an epoxy acrylate resin, an epoxy resin, a photopolymerizable monomer, a photopolymerization initiator, and a pigment.

Examples of the epoxy acrylate resin include those obtained by adding an acid anhydride to a bisphenol fluorene type epoxy acrylate resin. Specific examples of epoxy acrylate compounds include 9,9-bis (4-hydroxyphenyl) fluorene, 9,9-bis (4-hydroxy-3-methylphenyl) fluorene, and 9,9-bis (4-hydroxy- 3-
Chlorophenyl) fluorene, 9,9-bis (4-hydroxy-3-bromophenyl) fluorene, 9,9-
(4-hydroxy-fluorophenyl) fluorene,
9,9- (4-hydroxy-methoxyphenyl) fluorene, 9,9- (4-hydroxy-dimethylphenyl)
Fluorene, 9,9- (4-hydroxy-dichlorophenyl) fluorene, 9,9- (4-hydroxy-dibromophenyl) fluorene, and the like.

The acid anhydrides include maleic anhydride, succinic anhydride, itaconic anhydride, phthalic anhydride,
Tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, methylendomethylenetetrahydrophthalic anhydride, chlorendic anhydride, trimetridic anhydride, pyromellitic anhydride, benzophenone tetracarboxylic dianhydride, biphenyl ether tetracarboxylic acid And dianhydrides. Further, epoxy acrylate resins containing methane, propane, ether, ketone, sulfone, hexafluoropropane, dimethylsilane, etc. may be used in place of fluorene in the bisphenol fluorene type epoxy acrylate resin. Using one or more of these monomers,
A resin synthesized with a molecular weight of about 5 × 10 ³ to about 100 × 10 ³ is used.

The epoxy resin includes a phenol novolak type epoxy resin, a cresol novolak type epoxy resin, a bisphenol A type epoxy resin,
Bisphenol F type epoxy resin, bisphenol S type epoxy resin, bisfinyl type epoxy resin, alicyclic epoxy resin, phenyl glycidyl ether, P-butylphenol glycidyl ether, diglycidyl isocyanurate, triglycidyl isocyanate, allyl glycidyl ether, glycidyl methacrylate And the like.

The above-mentioned polymerizable monomers include bifunctional, trifunctional and polyfunctional monomers. Examples of the bifunctional monomers include 1,6-hexadiol diacrylate, ethylene glycol diacrylate, and neopentyl glycol diacrylate. Acrylate, triethylene glycol diacrylate, etc., and trifunctional monomers include trimethylolpropatone triacrylate, pentaerythritol triacrylate, tris (2-hydroxyethyl) isocyanate, etc., and polyfunctional monomers include ditrimethylolpropane. There are tetraacrylate, dipentaerythritol penta and hexaacrylate, etc.
Examples of these monomers include commercially available products such as Showa High Polymer Co., Ltd., Toa Gosei Co., Ltd., Nippon Kayaku Co., Ltd. The amount of the photopolymerizable monomer is not particularly limited, but may be 100% by weight of an epoxy acrylate resin.
To 50 to 50% by weight.

Examples of the photopolymerization initiator include tridian compounds and imidazole compounds. Examples of the tridian compounds include 2,4,6-tris (trichloromethyl) -s-tridian and 2- ( p-methoxystyryl) -4,6-bis (trichloromethyl)
-S-tridian, 2-phenyl-4,6-bis (trichloromethyl) -s-tridian, 2- (p-methoxyphenyl) -4,6-bis (trichloromethyl) -s-
Tridian, 2- (p-chlorophenyl) -4,6-bis (trichloromethyl) -s-tridian, 2- (4 ′
-Methoxy-1'-naphthyl) -4,6-bis (trichloromethyl) -s-tridian and the like.

Examples of the imidazole compound include 2- (2,3-dichlorophenyl) -4,5-diphenyl-imidazole dimer and 2- (2,3-dichlorophenyl) -4,5-bis ( 3-methoxyphenyl)
-Imidazole dimer, 2- (2,3-dichlorophenyl) -4,5-bis (4-methoxyphenyl) -imidazole dimer, 2- (2,3-dichlorophenyl)-
4,5-bis (4-chlorophenyl) -imidazole dimer, 2- (2,3-dichlorophenyl) -4,5-di (2-furyl) -imidazole, 2,2′-bis (2-
Chlorophenyl) -4,5,4 ', 5'-tetraferyl-1-2'-biimidazole, HB22 (manufactured by Hodogaya Chemical) and the like.

Other photopolymerization initiators include Irgacure 907,651 (benzyldimethyl ketal),
184 (manufactured by Ciba Gaiki Co., Ltd .: trade name), diethylthioxanthone (manufactured by Nippon Kayaku Co., Ltd.), benzophenone, and the like can be used, and a mixture of a plurality of these can also be used. The amount of the photopolymerization initiator to be added is not particularly limited, but 1 to 50% by weight, preferably 5 to 30% by weight, based on 100% by weight of the total resin, is used by adding one or two kinds. Can be

Further, a photopolymerization initiation aid may be blended to promote the photoreaction. Generally, amines are used as the photopolymerization initiation aid, and examples thereof include tertiary amines such as triethanolamine, 4,4-dimethylaminobenzophenone, and ethyl 4-dimethylaminobenzoate.

In addition, in order to improve the heat resistance of the resin, it is effective to add a small amount of an antioxidant or a heat stabilizer. For example, 2,6-di-tbutyl-p-cresol, n-octadecyl-3- (4′-hydroxy-
3 ', 5'-di-tert-brylphenol) propionate, tetrakis [methylene-3- (3,5-di-
tert-butyl-4-hydroxyphenyl) propionate] methane, thiobis (β-naphthol), tetramethylthiuram disulfide, distearylthiodipropionate, triphenyl phosphite, tri (nonylphenyl) phosphite, trilauryl trithiophos Fight and the like.

In the present invention, the above pigment is preferably an inorganic pigment.
₂ O ₃ , TiO ₂ —CoO—NiO—
ZnO and CoO-Al ₂ O ₃ can be used as the blue pigment. The inorganic pigment used for the light shielding layer is FeCr.
Fe, Cr, Mn including ₂ O ₄ , CuMnO ₄
Can be used, and other metal materials and inorganic pigments can be mixed and used.

As a transparent material used for the overcoat layer, a low-melting glass such as lead borosilicate glass can be used, but the material is not limited thereto. For example, the transparent inorganic oxides SiO ₂ and TiO
_2, a composite oxide or the like can be used.

Further, a dispersant may be added as required. As the dispersant, a wide range of dispersants such as surfactants and pigment intermediates can be used. The proportion of the composition at the time of dispersion is not particularly limited, but the addition amount of the pigment is 50 to 400% by weight based on 100% by weight of the resin, and the dispersant is about 1 to 10% by weight based on 100% by weight of the pigment. It is. Further, a plurality of arbitrary pigments may be mixed and adjusted for spectral adjustment of the color filter.

Further, a solvent may be blended if necessary. As the solvent, toluene, xylene, ethyl cellosolve, ethyl cellosolve, diclime, cyclohexanone, ethyl carbitol, etc. are used, but they vary depending on the monomer composition of the resin, the photopolymerizable monomer, the photopolymerization initiator, etc. A solvent having a single or a plurality of solvent compositions is appropriately selected.

The composition of the photosensitive colored transfer layer is, for example, 5 to 50 parts by weight of epoxy resin based on 100 parts by weight of epoxy acrylate resin (alkali-soluble photosensitive resin) to which an acid anhydride has been added. Parts, 50 parts by weight or less of a photopolymerizable monomer, 0.1 to 30 parts by weight of a photopolymerization initiator, 10 to 200 parts by weight of a pigment, and a small amount of other components. Further, the above composition may be appropriately added to and dispersed in a solvent and used together with the coating method. The epoxy acrylate resin (alkali-soluble photosensitive resin) is desirably contained in an amount of 20% by weight or more, and the amount of the acid anhydride used is preferably in the range of 50 to 100 mol% based on the OH of the epoxy acrylate compound. Good.

The application of the coating solution for the photosensitive colored transfer layer to the transfer sheet substrate is performed by, for example, a gravure coater, a gravure offset coater, a gravure reverse coater, a bar coater, a lip coater, a knife coater, and a silk screen. Alternatively, it can be performed by a roll coater. By using such a coating method, a colored layer serving as a pixel can be uniformly formed even with a large color filter base material. Also, the amount of non-volatile components contained in the solution at the time of application,
It may be appropriately selected depending on the desired film thickness and the type of the coater, and the film thickness after drying is preferably 1 to 10 μm, particularly preferably 3 to 5 μm.

The transfer sheet substrate may be heat,
A material that is stable to chemicals, light, etc., and at the same time, transmits actinic rays is preferable. For example, films or sheets of polyethylene terephthalate, polypropylene, triacetate, cellulose acetate, polystyrene, polyvinyl chloride, polycarbonate, polyimide and the like can be mentioned. In particular, polyester film and polypropylene film (biaxially stretched) have transparency, heat stability,
It is preferable because it has excellent strength and dimensional stability and has an appropriate adhesive force with the photosensitive colored transfer layer. These sheets may be used as they are, or may be subjected to an appropriate primer treatment, corona discharge treatment, or peeling treatment to control the adhesive force. The thickness of the transfer sheet substrate is preferably about 5 to 100 μm.

Next, the color filter substrate will be described. The color filter base material is not particularly limited as long as it is transparent and has good dimensional stability and can withstand heat when forming a colored layer or a light-shielding layer, and polyethylene terephthalate, polyethylene naphthalate, polyamide, polyimide, polycarbonate, A heat-resistant plastic film such as polysulfone, polyvinyl alcohol cellophane, or polystyrene, a glass substrate, or the like is used.

Next, the UV-curable adhesive layer provided on the color filter substrate will be described. The ultraviolet-curable adhesive layer has a property of exhibiting tackiness when not irradiated with ultraviolet rays, and exhibiting a property of being cured when exposed to ultraviolet rays and having an increased adhesive strength. Examples of such materials include one carbon-carbon double bond in the side or backbone of the polymer, or
A composition formed by bonding an ultraviolet-polymerizable group having an epoxy group can be exemplified.

As the polymer that forms the main chain, conventionally known polymers are widely used, and specifically, acrylic polymers selected from homopolymers and copolymers containing an acrylate ester as a main constituent monomer (Acrylic polymer), copolymers with other functional monomers, and mixtures of these polymers are used. For example, an acrylate, a methacrylate, a vinyl acetate, an acrylonitrile, a vinyl ethyl ether, etc. of a C1-C10 alkyl alcohol are mentioned. The acrylic polymers may be used alone or in combination of two or more.

Specific examples of the compound which is introduced into the side chain or main chain of the acrylic polymer (acrylic polymer) and induces a UV-polymerizable group having one carbon-carbon double bond or an epoxy group include: Include pentaerythritol monoacrylate, pentaerythritol monomethacrylate, dipentaerythritol monoacrylate,
Examples thereof include compounds having a carbon-carbon double bond such as dipentaerythritol monomethacrylate, trimethylolpropane monoacrylate, and trimethylolpropane monomethacrylate, and compounds having an epoxy group such as glycidyl acrylate and glycidyl methacrylate. The above compounds can be used alone or in combination of two or more.

In order to produce an ultraviolet-curable adhesive layer using a compound having an epoxy group, an active site (for example, -COOH, -N
CO, epoxy groups, -OH, after introducing the -NH _2),
It is obtained by reacting this active site with the compound that induces the ultraviolet-polymerizable group.

The introduction of the above-mentioned active site into the polymer is different from the "cleavage of double bond" such as a carboxyl group, an isocyanate, a hydroxyl group, an amino group and an epoxy group when producing an acrylic polymer. A monomer or oligomer having both a functional group capable of reacting by a mechanism and a carbon-carbon double bond may coexist in the reaction system. Specifically, the following compounds are used.

In order to introduce a -COOH group, acrylic acid, methacrylic acid or the like is used. To introduce an -NCO group, methacryloyloxy isocyanate, acryloyloxy isocyanate or the like is used. To introduce an epoxy group, glycidyl acrylate, glycidyl methacrylate, or the like is used. To introduce an -OH group, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 1,6-hexanediol monoacrylate, 1,6-hexanediol dimethacrylate, or the like is used. To introduce a -NH ₂ group, N-
Methylacrylamide, N-methylmethacrylamide and the like are used.

The molecular weight of the UV-curable pressure-sensitive adhesive layer polymer is about 1 × 10 ⁴ to 1 × 10 ⁶ , preferably about 1 × 10 ⁵ to 8 × 10 ⁵ . Further, a trace amount of active sites remaining in the ultraviolet curable adhesive layer is -COO.
In the case of an H group, a —OH group, and a —NH ₂ group, the initial adhesive can be set to an arbitrary value by mixing an isocyanate-based curing agent into the ultraviolet-curable adhesive. As such a curing agent, specifically, a polyvalent isocyanate compound, for example, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 1,3-
Xylylene diisocyanate, 1,4-xylene diisocyanate, diphenylmethane-4,4'-diisocyanate, diphenylmethane-2,4'-diisocyanate, 3-methyldiphenylmethane diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'- Diisoanate, dicyclohexylmethane-2,4'-diisocyanate, lysine isocyanate and the like are applied.

When the active site is a —NCO group, diols such as glycol, cresol, hexamethylenediol, and trimethylolpropane are used as a curing agent. On the other hand, when the active site is an epoxy group, amines such as hexamethylenediamine and ethylenetetraamine are applied as a curing agent.

By mixing an ultraviolet-ray initiator into this ultraviolet-curable adhesive layer, it is possible to reduce the polymerization curing time by ultraviolet irradiation and the amount of ultraviolet irradiation. Specific examples of such an ultraviolet initiator include benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzyl diphenyl sulfide, tetramethyl thiuram monosulfide, azobisisobutyronitrile, dibenzyl, diacetyl, β- Chloranthraquinone and the like. It is also possible to apply a known epoxy initiator.

Further, a thermal polymerization inhibitor can be added to the ultraviolet curing agent-adhesive layer. For example, P-methoxyphenol, hydroquinone, alkyl or aryl substituted hydroquinone, tert-butyl catechol, pyrogallol, naphthylamine, β-naphthol,
Examples include, but are not limited to, phenothiazine, pyridine, nitrobenzene, φ-tolutinone, aryl phosphite, and the like.

Other components that can be added to the ultraviolet-curable adhesive layer include plasticizers, residual solvents, surfactants, and inert fillers. Examples of the plasticizer include diphenyl phthalate, dihexyl phthalate, dicyclohexyl phthalate, dihydroabiethyl phthalate, dimethyl isophthalate, sucrose benzoate, ethylene glycol dibenzoate, trimethylethane tribenzoate, glyceride tribenzoate, and tetrabenzoate. Acid pentaerythritol, sucrose octaacetate, tricyclohexyl citrate, N-cyclohexyl-p-toluenesulfonamide and the like.

The UV-curable adhesive layer containing the above-mentioned components is applied to the UV-curable adhesive layer according to the same coating method as that for forming the photosensitive colored transfer layer on the transfer sheet substrate. It can be formed by applying a coating liquid for forming a layer on the color filter substrate and drying. The thickness of the ultraviolet-curable adhesive layer is about 0.1 μm to 100 μm, preferably about 1 μm to 50 μm.
m. The ultraviolet-curable adhesive layer has a property of being cured when exposed to ultraviolet rays, changing from tackiness to adhesiveness, and having an extremely high adhesive strength as described above. .

[0050]

Embodiments of the present invention will be described below. <Example 1> First, 67 parts by weight of 2-ethylhexyl acrylate, 10 parts by weight of vinyl acetate, and 3 parts by weight of hydroxyethyl methacrylate were used as an ultraviolet curable adhesive layer formed on a color filter substrate. 20 parts by weight of glycidyl acrylate was reacted at 60 ° C. for 10 hours in ethyl acetate. To 100 parts by weight of the polymer obtained by this reaction, 0.5 parts by weight of a crosslinking agent (Coronate L, manufactured by Nippon Polyurethane Co., Ltd.) was added to prepare an ultraviolet-curable adhesive. Then, using a transparent glass substrate as a color filter substrate, the above-mentioned ultraviolet curable adhesive is applied on the transparent glass substrate by screen printing as an application method applicable to a large substrate, and dried at 40 ° C. To form an ultraviolet-curable adhesive layer. The thickness of the ultraviolet-curable adhesive layer was 20 μm.

The composition of the photosensitive pigment-dispersed resist for forming the photosensitive colored transfer layer was as follows. <For blue color> Epoxy resin 11.32 parts by weight Photopolymerizable monomer 6.79 parts by weight Photopolymerization initiator 1.36 parts by weight Diluent solvent 56.49 parts by weight Color pigment "Cobalt Blue" manufactured by Toyo Pigment Co., Ltd. 24.05 Parts by weight <for green> Epoxy resin 10.05 parts by weight Photopolymerizable monomer 6.03 parts by weight Photopolymerization initiator. 1.21 parts by weight Diluent 57.60 parts by weight Dispersant 1.20 parts by weight Color pigment "ND-801" manufactured by Nippon Denko KK 25.25 parts by weight <red> Epoxy resin 20.39 parts by weight Photopolymerizable Monomer 12.24 parts by weight Photopolymerization initiator 2.45 parts by weight Diluent 52.08 parts by weight Dispersant 0.61 parts by weight Color pigment 52.08 parts by weight "BASCO Trans Red L-2817"

Next, a transfer sheet substrate having a thickness of 30 μm was prepared.
m, a red-colored photosensitive pigment-dispersed resist is applied as a photosensitive colored transfer layer on a polyester film using a wire bar coater, dried at 70 ° C., and dried to a thickness of 3.0 μm to form a red-colored transfer layer. A transfer sheet was prepared. Similarly, a transfer sheet for green and a transfer sheet for blue were prepared using the photosensitive pigment-dispersed resist for green and the photosensitive pigment-dispersed resist for blue, respectively.

Then, the surface of the photosensitive color transfer layer of the red transfer sheet is brought into close contact with the color filter substrate on which the ultraviolet-curable adhesive layer is formed, and the color filter is pressed by a pressure roll. It was adhered to the substrate. Then, a chrome mask having a red pixel pattern is overlapped from the transfer sheet substrate side of the transfer sheet, and 400 mJ / cm ² is exposed from the transfer sheet substrate side by an ultraviolet exposure device to correspond to the mask opening (exposed portion). Cures the photosensitive colored transfer layer at the exposed portion (pixel), weakens the adhesion between the photosensitive colored transfer layer and the transfer sheet substrate, and also corresponds to the mask opening (exposed portion) (pixel). Of the ultraviolet-curable pressure-sensitive adhesive layer was increased.

Subsequently, the transfer sheet substrate of the transfer sheet was peeled off from the UV-curable adhesive layer, and a red pixel was transferred onto the UV-curable adhesive layer. The same process was repeated for a red pixel, that is, a color filter substrate on which a red filter was formed, to form a green pixel (green filter) and a blue pixel (blue filter).

As described above, the color filter substrate on which the red pixel (red filter), the green pixel (green filter), and the blue pixel (blue filter) were formed was heated at 580 ° C. for 1 hour.
It was baked for 0 minutes to remove the UV curable adhesive layer on the color filter substrate and the pigment other than the pigment in the photosensitive colored transfer layer.

Further, a low-melting glass was applied as a transparent overcoat material using a 300-mesh screen printing plate on the color filter substrate (glass substrate) in which only the pigment was left. The overcoat material used here was a low melting glass paste (Okuno Pharmaceutical Co., Ltd.)
"ELD-350").

The color filter substrate (glass substrate) was baked in air at 580 ° C. for 10 minutes to form an overcoat layer of low melting point glass on the glass substrate. This removes the solvent contained in the overcoat material and removes the pigment from the color filter substrate (glass substrate).
It was fixed to.

In the obtained color filter, the photosensitive colored transfer layer serving as the pixel was applied by the wire bar coater without using a spinner, so that the photosensitive colored transfer layer became uniform. The UV-curable adhesive was applied by the screen printing without using a spinner, so that the UV-curable adhesive layer was uniform. Since a mask was used to form the pixel, a color filter having a highly accurate pixel shape and a highly accurate pixel portion was obtained.

[0059]

【The invention's effect】

The present invention relates to a method for manufacturing a color filter having a color layer provided on a color filter substrate, comprising the steps of: (1) providing, on the color filter substrate, an ultraviolet-curable adhesive layer whose adhesive force is increased by ultraviolet rays; (2) a step of providing a photosensitive colored transfer layer whose adhesive strength is reduced by ultraviolet rays on the transfer sheet base material to prepare a transfer sheet; and (3) an ultraviolet-curable adhesive on the color filter base material. (4) irradiating ultraviolet rays through a mask having a pixel pattern of a first color from a side of the transfer sheet substrate of the pressed transfer sheet, The UV-irradiated pixel portion of the photosensitive colored transfer layer is cured, and the adhesive force between the UV-irradiated pixel portion and the transfer sheet substrate is reduced. Irradiation (5) peeling off the pressed transfer sheet, and applying the ultraviolet ray of the photosensitive colored transfer layer to the pixel section by ultraviolet curing. A step of transferring onto the adhesive layer and, at the same time, leaving a portion other than the pixel portion irradiated with ultraviolet rays on the transfer sheet base material; and (6) performing the above steps (2) to (5) in a desired color. (7) baking the color filter substrate repeated the desired number of times, and curing the UV curable adhesive layer on the color filter substrate, and the components other than the transferred pixel portion pigment. And (8) a step of forming a transparent overcoat layer on the fired color filter base material and firing the same, and a method of manufacturing the color filter. Method and before Since a desired color filter manufacturing method of applying light-shielding black among the pixels to the number of colors, when manufacturing a large-sized color filters for use in large-sized plasma display,
Even in the case of a large-sized color filter, a colored layer forming pixels is formed uniformly, and a method for manufacturing a large-sized color filter having a highly accurate pixel shape and a highly accurate pixel portion is provided.

Further, according to the present invention, in the above method for producing a color filter, the material of the overcoat layer is a transparent low-melting glass or a transparent inorganic oxide, and the dye of the photosensitive colored transfer layer is Because it is an inorganic pigment, when manufacturing large color filters used in large plasma displays, etc., even if the color filters are large, the colored layers that form the pixels are formed uniformly, and the pixel shape with high precision And a method for manufacturing a large-sized color filter having a highly accurate pixel portion.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing a concept of pixel formation of a color filter according to the present invention.

FIGS. 2A to 2D are process diagrams for forming a first color pixel;

FIGS. 3A to 3D are process diagrams showing processes of a second color and thereafter.

FIG. 4 is a color filter according to the present invention.

FIG. 5 is a color filter according to the present invention.

[Description of Signs] 1 ... Ultraviolet curing type adhesive layer 1 '... Pixel part of ultraviolet curing type adhesive layer irradiated with ultraviolet rays 2 ... Color filter substrate 3 ... Transfer sheet substrate 4 ... Photosensitive coloring Transfer layer 4 '... Pixel portion of photosensitive colored transfer layer irradiated with ultraviolet rays 4'R ... Red pixel 4'G ... Green pixel 4'B ... Blue pixel 5 ... Transfer sheet 6 ... Mask 7 ... Ultraviolet 8 ... Light shielding layer 9 ... overcoat layer 10 ... color filter layer 20 ... color filter layer

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2H048 BA64 BB02 BB37 BB41 2H091 FA02Y FA34Y FB04 FB06 FB07 FB13 FC01 FC23 FD16 GA16 GA17 LA02 LA12 LA30

Claims (4)

[Claims] 1. A method of manufacturing a color filter comprising a color filter substrate provided with a colored layer, wherein (1) providing an ultraviolet-curable adhesive layer whose adhesive force is increased by ultraviolet rays on the color filter substrate. And (2) providing a photosensitive colored transfer layer whose adhesive strength is reduced by ultraviolet rays on the transfer sheet base material to form a transfer sheet; and (3) UV-curable adhesive on the color filter base material. (4) irradiating ultraviolet rays through a mask having a pixel pattern of a first color from the transfer sheet substrate side of the press-bonded transfer sheet, Curing the pixel portion of the photosensitive colored transfer layer irradiated with ultraviolet rays, and reducing the adhesive strength of the pixel portion irradiated with ultraviolet rays with the transfer sheet base material, and at the same time, the ultraviolet rays of the ultraviolet curable adhesive layer Irradiate (5) peeling off the pressed transfer sheet and irradiating the pixel portion of the photosensitive colored transfer layer irradiated with ultraviolet light with the ultraviolet curable type. A step of transferring onto the adhesive layer and, at the same time, leaving a portion other than the pixel portion irradiated with ultraviolet rays on the transfer sheet base material;
Repeating the step (5) a desired number of times, and (7)
Baking the color filter base material which has been repeated the desired number of times, to remove components other than the ultraviolet curable adhesive layer on the color filter base material and the pigment of the transferred pixel portion; (8) Forming a transparent overcoat layer on the fired color filter substrate and firing the color filter substrate. 2. The method for manufacturing a color filter according to claim 1, wherein a black color for shielding between pixels is added to the desired number of colors. 3. The method according to claim 1, wherein the material of the overcoat layer is a transparent low-melting glass or a transparent inorganic oxide. 4. The method for producing a color filter according to claim 1, wherein the dye in the photosensitive colored transfer layer is an inorganic pigment.