JP2000284113A - Production of color filter and color filter and display device as well as device having the display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process for producing color filters capable of producing the color filters at a high yield without lowering the working rate of the device. SOLUTION: This process for production is the process for producing the color filters for forming plural colored pixels on a light transparent substrate by discharging ink by an ink jet heat onto the substrate, and includes a detecting stage for detecting the defective pixels after the coloration of the color filters, a specifying stage for specifying a defective discharge nozzle from the defective pixel position detected by this detecting stage and the nozzle information of the ink jet head and a coloring stage for coloring the substrate without using the defective discharge nozzle specified in this specifying stage.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a color filter used for a color liquid crystal display of a color television, a personal computer, etc., and more particularly to a method of forming a colored portion by ink jetting using an ink jet recording technique. The present invention relates to a method for manufacturing a color filter, a color filter, a display device, and a device including the display device.

[0002]

2. Description of the Related Art With the rapid development of portable personal computers in recent years, the demand for liquid crystal displays, especially color liquid crystal displays, tends to increase. At the same time, the cost of the apparatus has been required to be reduced, and in particular, the demand for the cost reduction of a color filter having a relatively high cost ratio has been increased. Various methods have been proposed to satisfy the required characteristics of the color filter and the above-mentioned requirements, but they are still insufficient. Hereinafter, each method will be described.

The first method most frequently used is a pigment dispersion method. According to this method, first, a photosensitive resin layer in which a pigment is dispersed is formed on a substrate, and this is patterned to obtain a monochromatic pattern. This step is further repeated three times to obtain R, G, B color filter layers.

[0004] The second method is a dyeing method. In this method, a water-soluble polymer material, which is a material for dyeing, is formed on a glass substrate, patterned into a certain shape by a photolithography process, and the resulting pattern is immersed in a dye bath to form a colored pattern. obtain. By repeating this three times, R, G, and B color filters are formed.

A third method is an electrodeposition method. In this method, a transparent substrate is first patterned on a substrate. Then immersed in an electrodeposition coating solution containing pigment, resin, electrolyte, etc.
Electrodeposit the color. This process is repeated three times, and R, G, B
Is formed and finally baked.

As a fourth method, there is a printing method. In this method, a pigment is dispersed in a thermosetting resin, R, G, and B are separately applied by repeating printing three times, and then the resin is thermoset to form a colored layer. Also,
In either method, a protective layer is generally formed on the colored layer.

The common points of the above conventional methods are as follows.
The same process needs to be repeated three times in order to color the three colors of R, G, and B, which increases the cost. Also,
There is a problem that the yield decreases as the number of processes increases. Further, in the electrodeposition method, since the pattern shape that can be formed is limited, it is difficult to apply the current technology to a TFT. Further, the printing method is not suitable for forming a fine-pitch pattern due to poor resolution.

[0008]

In order to compensate for these drawbacks, Japanese Patent Application Laid-Open Nos. Sho 59-75205 and Sho 63-75205 disclose a method of manufacturing a color filter using an ink jet method.
JP-A-235901, JP-A-1-217320, JP-A-4
There is a proposal such as -123005. In these methods, unlike the above-described conventional method, ink of each color of R (red), G (green), and B (blue) is ejected from an inkjet head to a predetermined position on a light-transmitting substrate, and the ink is applied to the substrate. According to this method, R,
The formation of each color layer of G and B can be performed at one time, and further, since there is no waste in the amount of ink used, it is possible to obtain effects such as significant improvement in productivity and cost reduction.

However, an ink jet head having a large number of ink discharge nozzles often has a different ink discharge amount for each nozzle.
Since coloring is performed using a plurality of nozzles having different ejection amounts, color unevenness occurs in the nozzle arrangement direction as it is.

Various correction methods have been proposed for color unevenness that occurs in the arrangement direction of the nozzles, and a color filter free of color unevenness can be manufactured by an inkjet method.

However, the ink jet head is
When foreign matter enters the nozzles or ink adheres to the nozzle face surface, the discharge amount of a specific nozzle may decrease or non-discharge may occur, resulting in color unevenness. Will occur.

Further, once color unevenness occurs due to defective discharge of the nozzle, defective products are continuously manufactured until the discharge amount is re-corrected, and the yield is greatly reduced.

In general, when inspecting for color unevenness of a color filter, an apparatus for scanning and inspecting a line sensor using a CCD (charge coupled device) or an apparatus for performing image processing on an inspection surface collectively by an area sensor is used. Have been.

Most of these inspection apparatuses detect the presence or absence of color unevenness, and when color unevenness is detected, the color filter is generally treated as a defective product.

In response to such a problem, the present applicant has
A method for detecting a defective nozzle and performing coloring without using the detected defective nozzle has already been proposed in Japanese Patent Application No. 10-157974.

This proposal is based on a pre-coloring process.
The ejection state of each nozzle of the inkjet head (ejection amount,
Discharge the colored pattern for measurement)
An object of the present invention is to provide a method of detecting a defective nozzle in advance from a coloring result and performing coloring without using the nozzle.

If color unevenness due to a discharge failure is detected during the coloring step, the discharge state of each nozzle is measured again in the same manner as when measuring the initial discharge state. There has been proposed a method of detecting a defective nozzle and resuming coloring by not using the detected defective nozzle.

Discharging and measuring the discharge amount measurement pattern of each nozzle of the ink jet head every time color unevenness occurs as in this proposal leads to lowering the operation rate of the apparatus. It is desired to devise a method that can detect defective discharge nozzles without lowering the operation rate and perform coloring without using the detected defective discharge nozzles. Not obtained.

Further, in the case of a manufacturing method in which a color filter is colored using an ink-jet method, the occurrence of color unevenness is different from that in a manufacturing method using another coloring method, and there is a regularity in the arrangement direction of the nozzles of the ink-jet head. It has been known that streak-like color unevenness having a pattern tends to occur.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a color filter capable of manufacturing a color filter at a high yield without lowering the operation rate of the apparatus. Is to provide a way.

It is another object of the present invention to provide a color filter manufactured by the above manufacturing method, a display device using the same, and a device provided with the display device.

[0022]

Means for Solving the Problems The above-mentioned problems are solved,
In order to achieve the object, a method of manufacturing a color filter according to the present invention includes the steps of: discharging ink by an inkjet head onto a light-transmitting substrate; forming a plurality of colored pixels on the substrate; A manufacturing method, comprising: a detecting step of detecting a defective pixel after coloring of the color filter; and a specifying step of specifying a defective discharge nozzle from the defective pixel position detected in the detecting step and nozzle information of the inkjet head. And a coloring step of coloring the substrate without using the ejection failure nozzle specified in the specifying step.

In the method of manufacturing a color filter according to the present invention, in the specific step, NG nozzle number: defective ejection nozzle number, NG pixel: maximum number of defective pixel number, number of used nozzles: number of nozzles used for coloring , Scan number: number indicating the number of scanning when dividing and coloring the color filter, nozzle interval: number of nozzles ejected every other nozzle, leading nozzle number: leading nozzle number of used nozzle , NG nozzle number = (NG
The method is characterized in that a defective nozzle is specified by a calculation formula represented by pixel-number of used nozzles × (scan number−1) −1) × nozzle interval + head nozzle number.

Further, in the method of manufacturing a color filter according to the present invention, in the detecting step, a defective pixel is detected based on a density difference between colored pixels.

Further, in the method of manufacturing a color filter according to the present invention, the detection of the defective pixel in the detection step is limited to a partial area of the color filter.

The color filter according to the present invention comprises:
A color filter manufactured by ejecting ink on a light-transmitting substrate by an inkjet head to form a plurality of colored pixels on the substrate, and detecting a defective pixel after coloring the color filter. A step of specifying a defective nozzle from the defective pixel position detected in the detecting step and the nozzle information of the inkjet head; and the substrate without using the defective nozzle specified in the specifying step. And a coloring step of coloring the product.

A display device according to the present invention includes a color filter manufactured by discharging ink on a light-transmitting substrate by an inkjet head to form a plurality of colored pixels on the substrate. A detection step of detecting a defective pixel after coloring of the color filter,
A step of specifying a defective ejection nozzle from the defective pixel position detected in the detection step and the nozzle information of the inkjet head; and coloring the substrate without using the defective ejection nozzle specified in the specific step. The color filter manufactured through the coloring step and a light amount changing unit that can change the light amount are integrally provided.

Further, a device provided with a display device according to the present invention is a color filter manufactured by discharging ink from a light-transmitting substrate by an ink jet head to form a plurality of colored pixels on the substrate. A detecting step of detecting a defective pixel after coloring of the color filter, and detecting a defective pixel from the defective pixel position detected in the detecting step and nozzle information of the inkjet head. A specific step of specifying a nozzle, and a color filter manufactured through a coloring step of coloring the substrate without using the ejection failure nozzle specified in the specific step,
It is characterized by comprising a display device integrally provided with a light amount changing means capable of changing the light amount, and an image signal supply means for supplying an image signal to the display device.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

The color filter defined in the present invention is provided with a colored portion and an object to be colored, and is capable of obtaining output light having different characteristics from input light.

FIG. 1 is a schematic diagram showing the configuration of a color filter manufacturing apparatus by an ink-jet method, and shows a state during a coloring process.

In FIG. 1, reference numeral 51 denotes an apparatus mount; 52, an XYθ stage disposed on the mount 51; 53, a color filter substrate set on the XYθ stage 52;
Is a color filter formed on the color filter substrate 53; 55 is a head unit composed of red, green, and blue inkjet heads for coloring the color filter 54 and a head mount 55a that supports them;
Denotes a controller that controls the overall operation of the color filter manufacturing apparatus 90, 59 denotes a display unit of the controller, and 60 denotes a keyboard that is an operation unit of the controller.

The head unit 55 is detachably attached to the support portion 90a of the color filter manufacturing apparatus, and is mounted so that the rotation angle can be adjusted in a horizontal plane.

FIG. 2 is a configuration diagram of a control controller of the color filter manufacturing apparatus 90. 59 is a teaching pendant which is an input / output means of the controller 58;
Reference numeral denotes a display unit for displaying information such as the progress of manufacturing and whether or not the head is abnormal. Reference numeral 60 denotes an operation unit (keyboard) for instructing the operation of the color filter manufacturing apparatus 90 and the like.

Reference numeral 58 denotes a controller for controlling the overall operation of the color filter manufacturing apparatus 90; 65, an interface for transferring data to and from the teaching pendant 59; 66, a CPU for controlling the color filter manufacturing apparatus 90; ROM, which stores a control program for operating the color filter, 68, a RAM for storing abnormality information and the like, 70, a discharge control unit for controlling the discharge of ink into each pixel of the color filter, 71, a color filter manufacturing apparatus A stage control unit 90 for controlling the operation of the 90 XYθ stage 52 is connected to the controller 58, and shows a color filter manufacturing apparatus that operates according to the instruction.

FIG. 3 shows an ink jet head IJ.
FIG. 3 is a diagram showing a general structure of H. In the apparatus of FIG. 1, three ink jet heads are provided corresponding to the three colors of R, G, and B. However, since these three heads have the same structure, respectively, FIG. Is representatively shown for one of the three heads.

In FIG. 3, the ink jet head IJ
H generally includes a heater board 104 on which a plurality of heaters 102 for heating the ink are formed, and a top plate 106 overlaid on the heater board 104. The top plate 106 has a plurality of discharge ports 108.
A tunnel-like liquid passage 110 communicating with the discharge port 108 is formed behind the discharge port 108. Each liquid channel 110 is separated from an adjacent liquid channel by a partition 112. Each fluid channel 110 has one
The two ink liquid chambers 114 are connected in common, and ink is supplied to the ink liquid chambers 114 through ink supply ports 116, and the ink is supplied from the ink liquid chambers 114 to the respective liquid paths 110.

The heater board 104 and the top plate 106
Each heater 102 is positioned so as to come to a position corresponding to each liquid path 110, and assembled in a state as shown in FIG.
Although only two heaters 102 are shown in FIG. 3, one heater 102 is
Are arranged one by one. Then, when a predetermined drive pulse is supplied to the heater 102 in an assembled state as shown in FIG. 3, the ink on the heater 102 boils to form bubbles, and the ink expands from the ejection openings 108 by volume expansion of the bubbles. Extruded and discharged. Therefore, it is possible to control the driving pulse applied to the heater 102, for example, by controlling the magnitude of the electric power, to adjust the size of the bubble,
The volume of the ink ejected from the ejection port can be freely controlled.

FIG. 4 is a schematic diagram of an ink jet head having a plurality of nozzles for coloring pixels.

In FIG. 4, reference numeral 7 denotes an ink jet head having the structure shown in FIG. 3, and reference numerals 8a to 8d denote inks.

As shown in FIG. 4, the amount of ink discharged from each nozzle is often different, and if pixels are colored as they are, color unevenness occurs due to the difference in the amount of ink. Therefore, correction is performed to make the amount of ink applied to each colored pixel constant. In the present embodiment, the correction is performed by adjusting the number of ink dots (ink dot density) applied to each colored pixel.

In FIG. 4, nozzles having a large discharge amount, such as nozzles 8b and 8d, reduce the number of ink dots to be provided within a pixel, and nozzles having a small discharge amount, such as nozzles 8a and 8c, are provided within a pixel. Increase the number of ink dots to be printed.

As described above, the ink jet head is controlled so as to correct the number of ink dots to be applied to each pixel, and the pixels are colored.

FIG. 5 is a process chart showing a method for manufacturing a color filter. Then, a black matrix 2 as a light shielding portion is formed on a light transmitting substrate 1 as a color filter forming surface (step (a)).

As the substrate 1, glass is generally used. However, a resin such as plastic may be used as long as it does not impair the transparency of the color filter and has necessary characteristics such as mechanical strength according to the use of the color filter. It is possible.

The black matrix 2 is formed by forming a metal film such as chromium on a substrate by a film forming method such as sputtering or vacuum evaporation, and patterning an opening or the like by a photolithographic method. In addition, as the black matrix 2, a material formed by applying a photosensitive black resin and then patterning by a photolithographic method, or a material formed by a printing method can be used.

Next, the ink receiving layer 3 is formed on the substrate (step (b)).

The ink receiving layer 3 has no ink receiving property by itself, but shows a positive type which shows ink receiving property under a certain condition, or has an ink receiving property by itself.
A negative type that loses ink receptivity under certain conditions, a resin composition having any property, and having a property of curing under certain conditions is applied to the color filter forming surface, and prebaked as necessary. Form. Under certain conditions above,
For example, light irradiation, or light irradiation and heat irradiation are used. For the application of the resin composition, application methods such as spin coating, roll coating, bar coating, spray coating, and dip coating can be used.

In the present embodiment, it is desirable to use a negative photosensitive resin composition that is cured by light irradiation and that portion of the composition does not absorb ink.

The thickness of the ink receiving layer 3 is 0.3 to 0.3 when the color filter of this embodiment is used for a liquid crystal element.
It is about 3.0 μm.

The ink receptive layer 3 is subjected to pattern exposure using a photomask 4 and a part thereof is cured to form an ink repellent portion 5 having lost ink receptivity (step (c)).

In this case, the photomask 4 shown in FIG.
This is a case where the ink receiving layer 3 is formed using a negative photosensitive resin composition. When the ink receiving layer 3 is formed using a positive photosensitive resin composition, the ink receiving layer 3 is formed at an opening of the black matrix 2 opposite to the photomask 4 for exposing a portion corresponding to the black matrix 2 shown in FIG. The pattern exposure may be performed by using a photomask that exposes the corresponding portion and masking the ink-repellent portion.

As shown in the drawing, the ink-repellent portion 5 is formed at a position overlapping the black matrix 2. The width of the ink-repellent portion 5 is preferably formed to be smaller than the width of the black matrix.
It is about 0 to 30.0 μm. Thereby, coloring portions 9a to 9c described later are formed to extend to positions overlapping with the black matrix 2, and white spots are prevented.

The ink 8 of each color of R, G, and B is applied to a predetermined position of the unexposed portion 6 of the ink receiving layer 3 from the ink jet head 7 in which the correction data is set in advance in the step of correcting the ejection amount. (Step (d) and Step (e)).

Each unexposed portion is surrounded by the ink-repellent layer 5.

In the present invention, as an ink jet system, a bubble jet type using an electrothermal converter or a piezo jet type using a piezoelectric element can be used as an energy generating element, and the coloring area and the coloring pattern can be set arbitrarily. can do.

In the present embodiment, both dye-based and pigment-based inks can be used as coloring inks.
Further, the ink is not limited to a liquid at room temperature, but is an ink that solidifies at room temperature or lower, and softens at room temperature or is a liquid. In general, the temperature is adjusted within the range described above, and the temperature is controlled so that the viscosity of the ink is in the stable ejection range. Therefore, a liquid in which the ink is in a liquid state when the use recording signal is applied is preferably used.

Further, if necessary, the ink is dried.
Heat treatment is performed to completely cure the entire ink receiving layer 3 and fix the ink, thereby forming colored portions 9a to 9c of each color.
Thereby, the color filter 10 is formed. Thereafter, if necessary, a protective layer 11 is formed on the color filter 10 (step (f)).

As the protective layer 11, a resin film of a photo-curing type, a thermo-setting type, or a combination of light and heat, an inorganic film formed by vapor deposition, sputtering, or the like can be used. Can be used as long as it can withstand the subsequent ITO forming step, alignment film forming step, and the like.

FIGS. 6 to 8 are sectional views showing the basic structure of a color liquid crystal display device 30 incorporating the above-described color filter.

The color liquid crystal display device is generally formed by combining the color filter substrate 1 and the counter substrate 21 and enclosing the liquid crystal compound 18. A TFT (Thin Film Transistor) is provided inside one substrate 21 of the liquid crystal display device.
r) (not shown) and transparent pixel electrodes 20 are formed in a matrix. In addition, a color filter 54 is provided inside the other substrate 1 so that RGB color materials are arranged at positions facing the pixel electrodes, and a transparent counter electrode (common electrode) 16 is formed on the entire surface. Is done. The black matrix 2 is usually formed on the color filter substrate 1 side (see FIG. 6), but is formed on the opposite TFT substrate side in a BM (black matrix) on-array type liquid crystal panel (see FIG. 7). Further, an alignment film 19 is formed in the planes of both substrates, and rubbing the alignment film 19 allows liquid crystal molecules to be aligned in a certain direction. A polarizing plate 1 is provided outside each glass substrate.
The liquid crystal compound 18 is filled in the gap (about 2 to 5 μm) between these glass substrates.
In addition, a combination of a fluorescent lamp (not shown) and a scattering plate (not shown) is generally used as the backlight, and the display is performed by making the liquid crystal compound function as an optical shutter that changes the transmittance of the backlight light. I do.

As shown in FIG. 8, a colored portion may be formed on the pixel electrode 20 to function as a color filter. That is, the colored portion constituting the color filter is not limited to being formed on the glass substrate. In the form shown in FIG. 8, an ink receiving layer is formed on a pixel electrode and ink is applied to the receiving layer, and a resin ink containing a coloring material is directly irradiated on the pixel electrode. is there.

An example in which such a liquid crystal display device is applied to an information processing device will be described with reference to FIGS.

FIG. 9 is a block diagram showing a schematic configuration when the above-mentioned liquid crystal display device is applied to an information processing device having functions as a word processor, a personal computer, a facsimile device, and a copying device.

In the figure, reference numeral 1801 denotes a control unit for controlling the entire apparatus, which includes a CPU such as a microprocessor and various I / O ports, outputs control signals and data signals to each unit, and controls signals from each unit. And control by inputting data signals. Reference numeral 1802 denotes a display unit, on which various menus, document information, and the image reader 18 are displayed.
In step 07, the read image data and the like are displayed. 18
Reference numeral 03 denotes a transparent pressure-sensitive touch panel provided on the display unit 1802. By pressing the surface of the touch panel with a finger or the like, it is possible to input items, coordinate positions, and the like on the display unit 1802.

Reference numeral 1804 denotes an FM (Frequency Modulation) sound source unit, which stores music information created by a music editor or the like as digital data in the memory unit 1810 or the external storage device 1812, reads out the music information from the memory or the like, and reads out the FM information.
The modulation is performed. The electric signal from the FM sound source unit 1804 is converted into an audible sound by the speaker unit 1805.
The printer unit 1806 is used as an output terminal of a word processor, a personal computer, a facsimile machine, and a copying machine.

Reference numeral 1807 denotes an image reader unit for reading and inputting original data photoelectrically and is provided in the original transport path, and reads various originals such as facsimile originals and copy originals.

Reference numeral 1808 denotes facsimile transmission of original data read by the image reader unit 1807, and facsimile (F) for receiving and decoding the transmitted facsimile signal.
AX), and has an external interface function. Reference numeral 1809 denotes a telephone unit having various telephone functions such as a normal telephone function and an answering machine function.

Reference numeral 1810 denotes a ROM that stores a system program, a manager program, other application programs, character fonts, a dictionary, and the like; application programs and document information loaded from an external storage device 1812; and a memory that includes a video RAM and the like. Department.

Reference numeral 1811 denotes a keyboard for inputting document information and various commands.

Reference numeral 1812 denotes an external storage device using a floppy disk, a hard disk, or the like as a storage medium. The external storage device 1812 stores document information, music or audio information,
A user application program and the like are stored.

FIG. 10 is a schematic overview of the information processing apparatus shown in FIG.

In the figure, reference numeral 1901 denotes a flat panel display using the above-mentioned liquid crystal display device, which displays various menus, graphic information, document information and the like. By pressing the surface of the touch panel 1803 with a finger or the like on the display 1901, coordinate input and item designation input can be performed. A handset 1902 is used when the device functions as a telephone. Keyboard 190
3 is detachably connected to the main body via a cord,
Various document functions and various data inputs can be performed. The keyboard 1903 has various function keys 1904.
Etc. are provided. 1905 is an external storage device 1812
This is the slot for the floppy disk.

Reference numeral 1906 denotes a sheet placing portion on which a document to be read by the image reader portion 1807 is placed. The read document is discharged from the rear of the apparatus. In the case of facsimile reception or the like, printing is performed by the inkjet printer 1907.

When the information processing apparatus functions as a personal computer or a word processor, various information input from the keyboard unit 1811 is processed by the control unit 1801 according to a predetermined program, and
The image is output to an image 806.

When functioning as a receiver of a facsimile apparatus, facsimile information input from a facsimile transmission / reception unit 1808 via a communication line is received and processed by a control unit 1801 according to a predetermined program.
Is output as a received image.

When functioning as a copier, a document is read by an image reader 1807 and the read document data is transmitted to a printer 18 via a controller 1801.
06 is output as a copy image. When functioning as a facsimile receiver, the image reader unit 1
The original data read by 807 is transmitted to control unit 180.
After transmission processing according to a predetermined program by 1
The data is transmitted to the communication line via the facsimile transmission / reception unit 1808.

Note that the above-mentioned information processing apparatus may be of an integrated type in which an ink jet printer is built in the main body as shown in FIG. 11. In this case, the portability can be further improved. In the figure, parts having the same functions as those in FIG. 10 are denoted by the corresponding reference numerals.

Next, the step of coloring the pixels with the ink jet head will be described in detail.

The ink jet head used in this embodiment has 1360 nozzles, and the interval between adjacent nozzles is 70.5 μm (360 dpi).

Using a plurality of nozzles of this ink jet head, a screen size of 12.1 inches (600 pixels vertically,
A case will be described in which a color filter of an RGB stripe arrangement in which 800 pixels are formed horizontally is colored.

Usually, since the pixel pitch of the same color of the color filter is different from the nozzle pitch of the ink jet head, it is necessary to match the pixel pitch with the nozzle pitch.

In this case, a method of arranging the head at an angle is used.

FIG. 12 is a diagram schematically showing a part of the colored region of the color filter according to the present embodiment and the state of the ink jet head corresponding thereto.

As shown in FIG. 12, the ink jet heads 7a, 7b and 7c are arranged obliquely with respect to the coloring area of the color filter, and are set so as to discharge ink every five nozzles. Therefore, the number of nozzles that can be used for coloring is 272 nozzles = 1360 nozzles / 5 nozzles.

At this time, the ink jet heads 7a, 7
Reference numerals b and 7c denote inkjet heads for coloring R, G, and B, respectively, and are arranged at relative positions so that pixels of each color can be colored.

Also, the discharge amount of each nozzle of the ink jet head may fluctuate suddenly. When such a discharge fluctuation occurs in a certain nozzle, the pixel colored by that nozzle is replaced by another pixel. , A difference in density occurs, and color unevenness is observed.

Instead of coloring one pixel at a time to avoid the occurrence of color unevenness due to such fluctuations,
It is effective to use a method of coloring a plurality of times.

In the case where coloring is performed in a plurality of times, coloring using a plurality of nozzles has an effect of reducing the occurrence of color unevenness, as compared with the case where one pixel is colored with a single nozzle.

In this embodiment, when one pixel is colored by a plurality of scans using a single or a plurality of nozzles, this one scan is called a "pass".

However, when one pixel is colored by using a plurality of nozzles, the number of times of coloring is greatly related to the tact time at the time of coloring. Therefore, it is necessary to determine an optimum value in consideration of quality and productivity.

In this embodiment, the number of coloring passes (scanning) is set to five, and one pixel is colored by discharging from five different nozzles.

In other words, one pixel is colored while shifting the nozzle. In the present embodiment, this shift amount is referred to as the “number of nozzle shifts”.

Although the "number of nozzle shifts" can be always constant or can be changed for each scan, in the present embodiment, each scan is fixed for ease of control. Set the optimal value in consideration of the quality above.

FIG. 13 is a schematic diagram showing the coloring state of each pixel and the image of the nozzle used when coloring while shifting the nozzle.

In the case of FIG.
Discharge is performed every nozzle, and pixels are colored in five passes. The number of nozzle shifts is five.

In the present embodiment, the number of nozzle shifts is set to 20 (every 5 nozzles × 4) as an optimal value for obtaining good quality products.

FIG. 14 is a diagram schematically showing the relationship between the entire color filter and the ink jet head.

The ink jet head used in this embodiment has a screen size of 12.1 inches (600 pixels vertically and 80 pixels horizontally).
When coloring a color filter of an RGB stripe arrangement in which 0 pixels are formed), it is physically impossible to color the entire colored region at one time, and the region that can be colored at a time is about one third of the whole. It is.

For this reason, as shown in FIG. 14, the whole is divided into three parts, and coloring is performed for each third.

In the present embodiment, when the entire colored area is divided and colored, one of the divided areas is referred to as “scan”.

Further, in the present embodiment, the whole is divided into three parts and colored one third at a time. However, the number of nozzles of the ink jet head, the nozzle density (interval between adjacent nozzles),
If the number of nozzle shifts or the screen size for coloring is different from that of the present embodiment, it is needless to say that it is desirable to set the number of divisions of the coloring region to an optimum value according to these conditions.

The color filter thus formed is inspected for color unevenness and defects.

FIG. 15 is a diagram showing the configuration of this inspection apparatus.

In FIG. 15, 10 is a color filter,
21 is a light source, 22 is an optical fiber cable, 23 is a substrate stage, 24 is an objective lens, 25 is a CCD camera, 26
Denotes an image processing device, and 27 denotes a control personal computer.

Using the apparatus shown in FIG.
While scanning is performed, the image captured by the CCD camera 25 is processed to check for color unevenness.

FIG. 16 is a schematic diagram showing an inspection area in the color filter 10 for inspecting color unevenness.

As can be seen from FIG. 16, the measurement was performed for only one pixel in the drawing line direction of the color filter and for the number of pixels in the nozzle row direction.

It is known that when a color filter is colored by an ink jet method as in the present embodiment, color unevenness tends to occur in the direction in which the nozzles of the head are arranged.

Specifically, as in the present embodiment, the inside of the colored area is divided, and a plurality of passes (scans) are performed while shifting the nozzles.
When coloring is carried out by using, streaky color unevenness of several passes (for example, five in the case of coloring in five passes) often occurs in a scan.

When the color unevenness tends to occur as described above,
Even without measuring the entire area of the color filter, it is sufficiently possible to detect color unevenness by measuring only a part of the area,
Measurement time can be shortened.

As a result of inspecting the color filters as described above, the pixel numbers N1, N2, N3, N4, N5,.
.., N15 (N1 to N15 are arbitrary integers) are assumed to have periodic streaky color unevenness detected. FIG.
Is a diagram schematically showing the position of the defective pixel and the state of the ink jet head at this time, and the pixel numbers have a relationship as shown in the figure.

In the present embodiment, not only the case where the color unevenness is visually recognized but also the case where the density of each pixel has a certain density difference or more from the average density of the entire colored region is shown. . Since the ratio at this time differs depending on the chromaticity standard, the density standard, and the like, the correlation between the color unevenness and the density difference by visual observation is obtained, and based on this relationship, ±% or more of the average density of the entire colored region It is preferable to determine whether there is a density difference as color unevenness.

Next, based on the defective pixel number and the nozzle information of the ink jet head determined before coloring, the nozzle coloring the pixel is specified.

FIG. 18 is a diagram showing a flow of processing when a defective nozzle is specified.

When coloring is performed in a plurality of passes while shifting the nozzle as in this embodiment, streaky color unevenness often appears for a number of passes within a fixed interval (one scan).

Therefore, first, in the case where the screen is divided into three and colored, it is determined which of the three scans occurs by the following conditional expressions (1-1) and (1-2).

When coloring is performed by three scans as in this embodiment, the first pixel <defective pixel number <number of nozzles used-((number of nozzle shifts / nozzle interval) × (number of passes−1)) If (1-1) holds, it exists within the first scan.

Number of used nozzles − ((number of nozzles shifted / nozzle interval) × (number of passes−1)) <defective pixel number <number of used nozzles × 2 − ((number of nozzles shifted / nozzle interval) × (number of passes−1) )) If the equation (1-2) is established, it exists within the second scan.

If not, it exists within the third scan.

When unevenness exists in a plurality of scans, pixel information of the second scan is used as a representative.

Next, the number of defective nozzles in one scan is determined by equation (2).

The number of defective nozzles = the number of defective pixels in one scan / the number of passes Equation (2) In this embodiment, N6 to N are set within the second scan.
There were 10 defective pixels.

At this time, N10−N9 = N9−N8 = N8
The relationship of -N7 = N7-N6 = number of nozzle shifts / number of passes is established.

Based on the information of the defective pixels detected in this way, the discharge defective nozzle can be obtained by the following formula (3).

NG nozzle number = (NG pixel−number of used nozzles × (scan number−1) −1) × nozzle interval + head nozzle number Formula (3) Each parameter will be described below.

NG nozzle number: ejection failure nozzle number NG pixel: maximum value of defective pixel number Number of nozzles used: number of nozzles used for coloring Scan number: when coloring by dividing a color filter
Number indicating the number of the scan Nozzle interval: How many nozzles are ejected nozzles First nozzle number: First nozzle number of used nozzles If there are two or more ejection failure nozzles, the NG pixel follows the above formula in the above formula And the nozzle detection is repeated.

Next, the processing of the defective nozzle specified by the equation (3) is performed.

The detected defective nozzle is treated as non-ejection,
Coloring will be performed without using this nozzle.

Four nozzles other than the nozzle which colored the pixel number at which a defect was detected based on the ejection amount of each nozzle measured in the initial stage (in this embodiment, five different nozzles per pixel) The number of ink dots is readjusted in accordance with the ejection amount of each nozzle so that the pixels are colored with (colored by the nozzle).

Using the ink jet head thus adjusted again, coloring was performed to produce a color filter.

When the color filter thus manufactured was measured by the inspection apparatus shown in FIG. 15, a color filter having no problematic color unevenness could be manufactured.

In the present embodiment, as a method of correcting the ejection amount, a method of changing the number of ink dots to be provided in the pixel according to the ejection amount of each nozzle is used. A method of changing the amount of ink ejected from the nozzle itself by changing the drive pulse for each nozzle can be used.

Further, in the inspection of the color filter, an apparatus using an area sensor is used. However, there is no problem if an apparatus having the same performance as the ability to detect color unevenness is used.

Hereinafter, specific examples will be described.

(First Embodiment) First, the process of measuring the discharge amount of each nozzle of the ink jet head will be described.

A line pattern is formed on a light transmitting substrate using all the nozzles used for coloring.

The transmittance of this line pattern is measured using the apparatus shown in FIG.

In FIG. 19, reference numeral 31 denotes an image processing device,
Reference numeral 2 denotes a personal computer for controlling and converting the transmittance into a discharge amount, reference numeral 33 denotes a line sensor camera, reference numeral 34 denotes a substrate stage, and reference numeral 35 denotes a light transmitting substrate on which a line pattern is formed.

The substrate stage 34 is scanned to capture an image into the line sensor camera 33, and the personal computer 32 calculates the discharge amount from the transmittance.

Based on the ejection amount of each nozzle, the number of ink dots is adjusted so that the amount of ink applied to each pixel at the time of coloring becomes uniform.

At this time, the nozzle information of the ink jet head is determined as follows.

The ink jet head used in this embodiment has 1360 nozzles, and the interval between adjacent nozzles is 70.5 μm (360 dpi).

The head is tilted in order to make the pixel pitch of the same color coincide with the nozzle pitch, and the head is set to use every five nozzles as shown in FIG. That is,
The number of nozzles used for coloring is 272 nozzles = 1360
Nozzle / 5 nozzles, the leading nozzle is 1.

When coloring a 12.1-inch size color filter (RGB stripe array having 600 pixels vertically and 800 pixels horizontally) with this ink jet head, it is impossible to color the entire colored region at once. As shown in FIG. 14, the whole is divided into three parts, and coloring is performed one third at a time (coloring in three scans).

Further, in the present embodiment, based on the result of experimentally calculating conditions for achieving a state without color unevenness,
The area for one scan was colored in five passes (scans), and each pixel was colored by ejection from five different nozzles.

The number of nozzle shifts was similarly set to 20 (every 5 nozzles × 4) from the results of experiments.

Next, a color filter is actually formed with the ink jet head for which correction and nozzle information have been determined as described above.

First, chromium (C) having a predetermined opening
r), 10 parts by weight of a terpolymer of N-methylolacrylamide, methyl methacrylate, and hydroxyethyl methacrylate and 0.1% of triphenylsulfonium triflate were formed on a glass substrate on which a 12.1-inch-size SVGA type black matrix composed of the above (1) was formed. A water-based ink absorbing agent consisting of 4 parts by weight, a light-irradiating or light-irradiating and heat-treating ink-absorbing portion of the light-irradiated portion is reduced, and a water-repellent ink-forming composition material is formed by spin coating. It was applied to a thickness of 1.0 μm and prebaked at 60 ° C. for 10 minutes to form a resin composition layer.

Next, exposure was performed with a high-pressure mercury lamp through a photomask having a pattern shape smaller than the black matrix. After the exposure was completed, the ink was heated on a hot plate at 110 ° C. for 90 seconds to form an ink water-repellent portion serving as a colored region and a color mixing prevention region.

Next, R, R were applied to the pixel portion, which is the above-mentioned colored region, by an ink jet head whose ejection amount was corrected in advance.
G and B inks were applied to form colored portions.

The substrate colored by the above-mentioned method was
The ink was dried at 10 ° C. for 10 minutes, and the resin composition layer was completely cured by a heat treatment at 230 ° C. for 30 minutes to prepare a color filter.

The color filter thus formed was inspected for color unevenness in the region shown in FIG. 16 using the inspection apparatus shown in FIG.

As a result of the inspection, pixel numbers 20, 24, 28,
32, 36, 292, 296, 300, 304, 30
Streak-like color unevenness was detected in 15, 564, 568, 572, 576, and 580 pixels.

In this embodiment, the nozzle number of the head,
The numbers of the pixels and the numbers of the pixels are those defined in FIG.
Next, the ejection failure nozzle is specified.

First, which of the three scans the defective pixel is included in is determined by the above-mentioned conditional expressions (1-1) and (1).
-2).

As a result of the judgment, pixel numbers 20, 24, 28,
32, 36 are the first scan, pixel numbers 292, 296,
300, 304, 308 are the second scan, pixel number 56
4, 568, 572, 576, and 580 were confirmed to be present in the third scan.

Next, the number of defective nozzles is obtained by the above equation (2).

Number of defective nozzles = 1 Number of defective pixels in one scan / Number of passes = 5/5 = 1 Next, discharge defective nozzles are specified by the above-described formula (3).

NG nozzle number = (NG pixel−number of used nozzles × (scan number−1) −1) × nozzle interval + head nozzle number = (308−272 × (2-1) −1) × 5 + 1 = 176 Therefore, it could be detected that the 176th nozzle was defective in ejection.

The 176th nozzle was treated as a non-ejection nozzle.

Therefore, the number of ink dots ejected from the other four nozzles is increased by increasing the number of ink dots ejected from the other four nozzles by not using the nozzle 176, thereby reducing the amount of ink applied to the pixel. adjust.

At this time, the number of ink dots is adjusted based on the ejection amounts of these four nozzles measured at the beginning.

Coloring was performed using the ink jet head that had been corrected again in this way, and color unevenness was inspected with the inspection apparatus shown in FIG. 15. As a result, a color filter having no problematic color unevenness was produced. did it.

The present invention can be applied to a modification or a modification of the above embodiment without departing from the gist of the invention.

For example, in recent years, there has been a panel provided with a color filter on the TFT array side, but the color filter defined in this specification is an object to be colored colored with a coloring material, and is located on the TFT array side. Both are included, regardless of whether or not.

The present invention is particularly provided with a means (for example, an electrothermal converter or a laser beam) for generating thermal energy as energy used for performing ink ejection even in an ink jet recording system. The printing apparatus of the type that causes a change in the state of the ink has been described.
High definition can be achieved.

The typical configuration and principle are described, for example, in US Pat. Nos. 4,723,129 and 4,740.
It is preferable to use the basic principle disclosed in the specification of Japanese Patent No. 796. This method is applicable to both on-demand type and continuous type. In particular, in the case of the on-demand type, liquid (ink)
By applying at least one drive signal corresponding to the recorded information and providing a rapid temperature rise exceeding the film boiling to an electrothermal transducer arranged corresponding to the sheet or the liquid path in which Since thermal energy is generated in the electrothermal transducer and film boiling occurs on the heat-acting surface of the recording head, bubbles in the liquid (ink) corresponding to this drive signal on a one-to-one basis can be formed. It is valid. By discharging the liquid (ink) through the discharge opening by the growth and contraction of the bubble, at least one droplet is formed. When the drive signal is formed into a pulse shape, the growth and shrinkage of the bubbles are performed immediately and appropriately, so that the ejection of liquid (ink) having particularly excellent responsiveness can be achieved, which is more preferable.

As the pulse-shaped drive signal, those described in US Pat. Nos. 4,463,359 and 4,345,262 are suitable. Further, if the conditions described in US Pat. No. 4,313,124 relating to the temperature rise rate of the heat acting surface are adopted, more excellent recording can be performed.

As the configuration of the recording head, in addition to the combination of the discharge port, the liquid path, and the electrothermal converter (linear liquid flow path or right-angle liquid flow path) as disclosed in the above-mentioned respective specifications, A configuration using U.S. Pat. No. 4,558,333 or U.S. Pat. No. 4,459,600, which discloses a configuration in which a heat acting surface is arranged in a bent region, is also included in the present invention. In addition, for multiple electrothermal transducers,
JP-A-59-123670 which discloses a configuration in which a common slot is used as a discharge part of an electrothermal transducer, and JP-A-59-123670 which discloses a configuration in which an opening for absorbing a pressure wave of thermal energy corresponds to a discharge part. A configuration based on 138461 may be adopted.

Further, as a full-line type recording head having a length corresponding to the width of the maximum recording medium that can be recorded by the recording apparatus, the length is determined by a combination of a plurality of recording heads as disclosed in the above specification. This may be either a configuration satisfying the above requirements or a configuration as a single recording head formed integrally.

In addition, the print head is replaceable with a print head of a replaceable chip type, which can be electrically connected to the main body of the apparatus or supplied with ink from the main body of the apparatus, or is integrated with the print head itself. Alternatively, a cartridge type recording head provided with an ink tank may be used.

It is preferable to add recovery means for the printhead, preliminary auxiliary means, and the like provided as components of the printing apparatus of the present invention since the effects of the present invention can be further stabilized. . If these are specifically mentioned, capping means for the recording head, cleaning means, pressurizing or suction means, preheating means using an electrothermal transducer or another heating element or a combination thereof, and printing Performing a preliminary ejection mode for performing another ejection is also effective for performing stable printing.

In the embodiments of the present invention described above, the ink is described as a liquid. However, an ink that solidifies at room temperature or lower, or an ink that softens or liquefies at room temperature may be used. It is only necessary that the ink be in a liquid state when the recording signal is applied.

In addition, in order to positively prevent the temperature rise due to thermal energy as energy for changing the state of the ink from the solid state to the liquid state,
Alternatively, in order to prevent evaporation of the ink, an ink which solidifies in a standing state and liquefies by heating may be used. In any case, the application of heat energy causes the ink to be liquefied by application of the heat energy according to the recording signal and the liquid ink to be ejected, or to start to solidify when reaching the recording medium. The present invention is also applicable to a case where an ink having a property of liquefying for the first time is used. In such a case, as described in JP-A-54-56847 or JP-A-60-71260, the ink is held in a liquid state or a solid state in the concave portion or through hole of the porous sheet. It is good also as a form which opposes an electrothermal transducer. In the present invention, the most effective one for each of the above-mentioned inks is to execute the above-mentioned film boiling method.

[0176]

As described above, according to the present invention,
The defective nozzle of the ink jet head can be specified from the defective color pixel number, and the color filter without color unevenness can be reduced by performing re-correction without using the defective nozzle, thereby lowering the operation rate of the apparatus. It is possible to manufacture at a high yield without any problems.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing a configuration of an embodiment of a color filter manufacturing apparatus.

FIG. 2 is a diagram illustrating a configuration of a control unit that controls the operation of the color filter manufacturing apparatus.

FIG. 3 is a diagram illustrating a structure of an ink jet head used in a color filter manufacturing apparatus.

FIG. 4 is a schematic diagram of an ink jet head used for coloring a color filter.

FIG. 5 is a diagram illustrating an example of a manufacturing process of a color filter.

FIG. 6 is a cross-sectional view illustrating an example of a basic configuration of a color liquid crystal display device incorporating a color filter according to an embodiment.

FIG. 7 is a cross-sectional view showing another example of the basic configuration of the color liquid crystal display device incorporating the color filter of one embodiment.

FIG. 8 is a cross-sectional view showing still another example of the basic configuration of the color liquid crystal display device incorporating the color filter of one embodiment.

FIG. 9 is a diagram illustrating an information processing apparatus in which a liquid crystal display device is used.

FIG. 10 is a diagram illustrating an information processing device in which a liquid crystal display device is used.

FIG. 11 is a diagram illustrating an information processing apparatus in which a liquid crystal display device is used.

FIG. 12 is a schematic diagram illustrating a relationship between colored pixels of a color filter and nozzles of an inkjet head.

FIG. 13 is a diagram schematically showing a state of coloring by nozzle shifting.

FIG. 14 is a schematic diagram showing a coloring region when coloring a color filter.

FIG. 15 is a schematic diagram of an inspection device for inspecting color unevenness of a color filter.

FIG. 16 is a view schematically showing an inspection area when inspecting using the inspection apparatus shown in FIG.

FIG. 17 is a schematic diagram illustrating an example of a relationship between a pixel number of a color filter and a nozzle number of an inkjet head.

FIG. 18 is a diagram showing a flow of processing until a defective nozzle is specified and colored again.

FIG. 19 is a schematic diagram of a measuring device for measuring the discharge amount of the ink jet head.

FIG. 20 is a schematic diagram illustrating a relationship between a pixel number of a color filter and a nozzle number of an inkjet head.

[Explanation of symbols]

 Reference Signs List 1 substrate 2 black matrix 3 ink receiving layer 4 photomask 5 ink repellent part 6 unexposed part 7 inkjet head 7a R colored inkjet head 7b G colored inkjet head 7c B colored inkjet head 8,8a-8d ink 9a-9d ink colored part DESCRIPTION OF SYMBOLS 10 Color filter 11 Protective layer 21 Light source 22 Optical fiber cable 23 Substrate stage 24 Objective lens 25 CCD camera 26 Image processing device 27 Control personal computer 30 Inspection area 31 Image processing device 32 Control and discharge amount calculation personal computer 33 Line sensor camera 34 Substrate stage 35 Line pattern drawn substrate

 ──────────────────────────────────────────────────続 き Continued on front page F term (reference) 2C056 EB27 EB29 EB40 EB42 FB01 FB08 2H048 BA02 BA11 BA45 BA55 BA64 BB02 BB22 2H091 FA02Y FA08X FA08Z FA41Z FC02 FC12 FC30 LA15 LA30

Claims (7)

[Claims] 1. A method of manufacturing a color filter for forming a plurality of colored pixels on a light-transmitting substrate by ejecting ink from an inkjet head on the substrate, the method comprising: A detecting step of detecting a defective pixel; a specifying step of specifying a defective discharge nozzle based on the defective pixel position detected in the detecting step and nozzle information of the inkjet head; and a discharging defective nozzle specified in the specifying step. And a coloring step of coloring the substrate without using the same. 2. In the specific step, NG nozzle number: ejection failure nozzle number, NG pixel: maximum number of defective pixel numbers, number of used nozzles: number of nozzles used for coloring, scan number: color filter divided and colored NG nozzle number = (NG pixel-used nozzle) The method for manufacturing a color filter according to claim 1, wherein the defective nozzle is specified by a calculation formula represented by (number × (scan number−1) −1) × nozzle interval + first nozzle number. 3. The method according to claim 1, wherein in the detecting step, a defective pixel is detected based on a density difference between colored pixels.
3. The method for producing a color filter according to item 1. 4. The method for manufacturing a color filter according to claim 1, wherein in the detection step, the detection of the defective pixel is performed only in a partial area of the color filter. 5. A color filter manufactured by discharging ink from an inkjet head onto a light-transmitting substrate to form a plurality of colored pixels on the substrate, wherein the color filter has a defect after coloring. A detecting step of detecting a pixel, a specifying step of specifying a defective discharge nozzle from the defective pixel position detected in the detecting step and nozzle information of the inkjet head, and using the defective discharge nozzle specified in the specifying step A color filter manufactured through a coloring step of coloring the substrate without performing the same. 6. A display device comprising a color filter manufactured by forming a plurality of colored pixels on the substrate by discharging ink from an inkjet head onto a light-transmitting substrate, wherein the color filter is A detecting step of detecting a defective pixel after coloring; a specifying step of specifying a defective discharge nozzle from the defective pixel position detected in the detecting step and nozzle information of the inkjet head; and a discharging step specified in the specifying step. A display device, comprising: a color filter manufactured through a coloring step of coloring the substrate without using a defective nozzle; and a light amount changing unit capable of changing a light amount. 7. An apparatus provided with a display device having a color filter manufactured by discharging ink on a light-transmitting substrate by an inkjet head and forming a plurality of colored pixels on the substrate, A detecting step of detecting a defective pixel after coloring of the color filter, a specifying step of specifying an ejection defective nozzle from the defective pixel position detected in the detecting step and nozzle information of the inkjet head, A display device integrally including a color filter manufactured through a coloring step of coloring the substrate without using the specified ejection failure nozzle, and a light amount changing unit configured to change a light amount; An apparatus comprising a display device, comprising: an image signal supply unit that supplies an image signal.