JP2000310784A - Liquid crystal panel, color filter and their production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a panel of a liquid crystal display device or the like by properly controlling the gap between substrates and rigidity in the pixel part, black matrix part, sealing part or the like, to improve pressure resistance of the display part as a product, and to obtain good display quality, performance and productivity. SOLUTION: Protruding spacers 6 or spherical spacers 7 comprising an elastic material are formed in the display region and in the region where a seal is to be formed so as to maintain the gap between substrates 101, 102 constant. In this method, the modulus of elasticity or spraying density of these spacers is controlled to the optimum. Or, formation or distribution density of the spacers is varied depending on the objective place. Moreover, the spacers in the display region and the sealing part 5 are produced in one process, and the spacers can be formed in a single process.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a color filter of a plasma panel used for image display and a panel used for a liquid crystal display device, an optical shutter, and the like, and more particularly to a method for maintaining a distance between substrates of the panel.

[0002]

2. Description of the Related Art In recent years, liquid crystal panels (parts directly related to the display of a display device using liquid crystal; CPU, keyboard,
Excluding power supply. ) Is widely used in watches, electronic desk calculators, personal computers, personal word processors, etc. because of its advantages such as thinness, weight reduction, and low voltage drive.

In order to keep a constant distance between the front and back substrates on which liquid crystal and pixel circuits are formed, a spacer is provided in the display area of the conventional liquid crystal panel before the two substrates are bonded to each other. Are sprayed using N ₂ gas, air, ethanol or the like.

Further, in order to seal the liquid crystal between the pair of substrates, a seal portion made of a resin solidified for sealing is formed outside the display region, and the resin of the seal portion is also solidified before the solidification. In order to keep the distance between the substrates constant, a spacer is mixed in advance.

[0005] As these spacers, spherical resins, SiO ₂ or columnar glass (glass) fibers having no alkali have been used.

If the spacers in the display area are too hard, an array element such as a transistor for driving a pixel on a substrate or a wiring may be broken when a user applies an external force for some reason. Also, depending on the room temperature, the temperature of the panel changes greatly with the user's use, and in extreme cases, the spacer cannot properly follow the shrinkage and expansion of the liquid crystal due to the temperature change. Bubbles may be generated in the air. For this reason,
Generally, a spherical resin-based spacer having physical properties, particularly elasticity, coefficient of thermal expansion, specific gravity, etc., closer to that of liquid crystal has been used as compared with SiO ₂ or glass fiber. In this case, the density of the resin spacer is about 70 to 100 pieces / mm ² .

On the other hand, as a spacer in the seal portion,
There is no need to form it on an array element such as a transistor that drives a liquid crystal, and because it is not only in contact with the liquid crystal but also in the solidified sealing resin, the generation of bubbles due to thermal expansion and contraction is a problem. Not to be used, it is inexpensive, it is difficult for the spacer to move before the sealing resin is hardened, and because of its rigidity, the fluctuation of the pressing force to keep the substrate interval constant especially when hardening the sealing resin 2 to 12 μm in diameter because of its relatively good compatibility (adhesion) with sealing resins that often have a polarity (OH group or the like) such as epoxy resin or phenol resin.
Glass fibers having a length of about 20 m and a length of about 20 to 120 μm have been used. The density of the glass fibers at this time is about 50 to 60 fibers / mm ² .

[0008]

Conventionally, transistors (elements) for driving pixels of an active matrix panel of a type in which individual pixels of a liquid crystal display device are driven.
Amorphous silicon is used as a semiconductor of the material for the pixel, and a circuit for driving the pixel is TAB (Tape).
(Automated Bonding) method. In this method, a driving IC is mounted on a film, and the film is attached to a liquid crystal panel and a printed circuit board.

In recent years, a method of using polysilicon, which has a high electron transfer speed and a high response, as a semiconductor (material) for a transistor (element) has recently been put into practical use.

When this polysilicon is used, a circuit for driving a pixel can be formed as a peripheral drive circuit integrated with a transistor for a pixel around a substrate on which the pixel is formed. At this time, if the peripheral driving circuit is arranged under a liquid crystal seal portion present around the display area of the two glass substrates on which the liquid crystal and the circuit for the liquid crystal are formed, the substrate size can be further reduced. it can.

FIG. 1 shows an example of such a liquid crystal display device.

In FIG. 1, reference numeral 1 denotes a substrate. 20
Is a display area portion having a large number of pixels arranged in a grid pattern. Reference numeral 21 denotes a driving circuit for driving peripheral gates. Reference numeral 22 denotes a source driving circuit.
Reference numeral 5 denotes a resin portion obtained by curing a sealing resin. 9
Is a conductive paste. Reference numeral 50 denotes a sealing portion formed by curing the sealing resin.

The width of the seal is about 1 mm.
It is about. Also, at the time of solidification of the sealing resin at the time of manufacture, even if the volume changes, bubbles occur, or other unexpected situations occur, the upper and lower (front and back) substrate spacing is kept constant, In addition, in order to perform good adhesion between the substrate and the resin, a pressing force of about 1 kg / cm ² is applied based on the density of the glass fiber described above.

However, when glass fibers or SiO ₂ spheres are used as spacers in the seal portion as in the prior art, especially when the front and back substrates are bonded for manufacturing a panel, the distance between the substrates is kept at a predetermined value. Therefore, when both substrates are pressed, if the pressing force is large due to an error of the operator at the initial setting of the pressing machine, an earthquake or vibration accompanying the start of a large machine nearby, for any reason, Even if it lasts only a fraction of the time, hard glass fibers can destroy the peripheral drive circuits. In particular, this danger is important because the device itself is becoming smaller and lighter and more precise, as well as transistors and other elements and connections.

[0015] In addition, in the case of mass production under the recent miniaturization of the apparatus, it is important to control the pressing force throughout the time required for the sealing resin to be completely solidified. Similarly, this is particularly important when a plurality of display devices are stacked and pressed in the vertical direction.

Further, as can be easily understood from FIG.
In the periphery of the substrate, there are parts where the conductive paste exists, the drive circuit part does not exist, and there are also bent parts, so from this surface also appropriate pressing over the entire peripheral drive circuit part Becomes difficult.

Furthermore, there is a manufacturing error in the thickness of the glass substrate and the diameter of the glass fiber. In addition, even with an error of the same thickness such as 1 μm, as the thickness of the substrate becomes thinner, the second moment of area is inversely proportional to the cube of the thickness. The variation in power increases. For this reason, it is difficult to appropriately control the pressing force from this aspect as well.

However, it is also difficult to prevent glass fiber or the like from coming into a portion where an element or the like which is easily damaged by the pressing force is present.

Next, in the case of performing color display in recent years, a display system that uses no cyan, magenta, and yellow guest / host cells as shown in FIG. A system using a plurality of (in principle, three) liquid crystal layers is being developed.

It should be noted that in FIG.
Reference numerals 12, 213 and 214 denote substrates and electrodes.
Reference numerals 02 and 303 denote liquid crystals and pigments for each color. Also, 4
0 is light.

By the way, in this case, as shown in FIG. 2B, the distance between the display area and the peripheral drive circuit portion is different, or the distance between the lowermost substrate and each color substrate is different. Differences can occur.

In FIG. 2B, 221, 222,
Reference numeral 223 denotes a peripheral drive circuit section of each color pixel substrate / electrode, and 224 denotes an adjustment drive section. Reference numeral 91 denotes an upper substrate / electrode 212, 213, 214 and an adjustment driving unit 2.
24 are connection lines.

In this case, if a glass fiber spacer 19 is used for the sealing portion as in the prior art, the required glass fiber diameter may differ depending on the substrate, and the number and density distribution of the required glass fiber, the support by the spacer, etc. It is not preferable from the viewpoint of maintaining an appropriate distance between the supporting points of the formed glass substrate.

Also, in this case, if a spherical resin spacer is used in the display section in order to maintain the distance between the substrates, the density of the spacer is three times that of a single liquid crystal layer system, ie, Approximately (70-100) ×
This is about 3 / mm ² , which is not preferable in terms of the orientation of liquid crystal, transmission and scattering of light, and the like, and further from the viewpoint of display quality. Furthermore, in the color display method using a single liquid crystal layer, the size of pixels is being reduced along with the demand for high image quality in recent years, and in this case, a spherical spacer is also used. It is not very desirable to be in the display area.

The same applies to a double (two-layer) matrix type display device or a multi-matrix type display device which is currently being developed for higher pixel density.

When the spacers are formed by the spraying method, the scattering density in the display area may vary, and therefore, the cell thickness of the liquid crystal panel varies in the screen, and display unevenness may occur.

Conventionally, the liquid crystal is injected between the substrates by a vacuum injection method (an empty panel sealed except for the injection port is placed in a tank filled with liquid crystal at the bottom, and after the inside of the panel is evacuated, the injection port is closed. The liquid crystal is injected into the panel by putting it in the liquid crystal layer and then returning the pressure in the tank to normal pressure in this state), but in this case, the area where the liquid crystal flows into the panel is large, and the injection time is large. And the liquid crystal suddenly enters the empty panel at the start of the injection, so that the liquid crystal is easily affected by the spacer, and the alignment unevenness at the time of the injection is likely to occur.
In addition, the distribution of the spacers may be affected.

In addition to the above, the required rigidity is different between the portion for sealing the liquid crystal layer at the edge of the substrate and the display portion at the center of the panel. However, simply spraying the spherical glass spacer can cope with this. Have difficulty. In addition, it is troublesome to spray glass fibers and glass spheres separately on the seal portion and the display portion, but rather, it causes various difficulties.

Further, the rigidity required for the panel, particularly the sealing portion, the substrate spacing, and the like differ depending on the use, shape, dimensions, and the like of the liquid crystal display device. However, glass fibers are mixed in advance with the sealing resin. Then, it becomes necessary to manufacture a sealing resin mixture adapted to each of them.

In order to solve these problems, a method of forming a columnar spacer (JP-A-9-73093 and JP-A-10-68955) has been proposed. However, in these methods, a columnar spacer is formed in the display area, and the columnar spacer is not formed in the seal portion.

Japanese Patent Application Laid-Open No. 9-49916 has also devised a method of forming a spacer by laminating colored layers of three primary colors in a region corresponding to a matrix and a seal portion in a display region. However, in this method, it is necessary to change the height (size) of the colored layer in order to change the cell thickness, and thus the color purity also changes. Further, since the spacers are formed by lamination, the lamination accuracy of the lamination is required, and therefore, a large spacer needs to be formed.

Japanese Patent Application Laid-Open No. H07-281195 proposes that a spacer is formed by a black matrix formed on an array substrate and a projection formed by a method of laminating a colored layer on a color filter substrate. However, this method has the same problem as JP-A-9-49916. That is, since the spacer is formed by superimposing the array substrate and the color filter substrate, the accuracy of the superposition becomes a problem, so that the spacer needs to be made considerably large.

For this reason, in a liquid crystal panel using a polysilicon and a peripheral driving circuit formed under the liquid crystal sealing portion of the display area on the substrate, the peripheral driving circuit is formed while keeping the substrate interval constant. There was a need for the development of a seal technology that would not cause any danger or damage.

In addition, when a liquid crystal layer is filled between the substrates, it has been desired to develop a technique for maintaining the distance between the substrates without causing any inconvenience.

It has been desired to develop a sealing technique for providing appropriate rigidity according to the use, shape, and size of the panel.

In a color display type panel having a structure having a plurality of liquid crystal layers instead of using a color filter, an appropriate substrate interval can be maintained while completely sealing the peripheral portion. Technology development was desired.

Further, in a small and high-performance liquid crystal panel, particularly a panel having a plurality of liquid crystal layers, it has been desired to develop a spacer having a structure that does not cause liquid crystal alignment or light scattering in the display area.

In a display device using a polymer-dispersed liquid crystal or a method for simultaneously forming a liquid crystal layer and a transparent resin film thereon, the dispersed liquid crystal and its matrix,
It has been desired to develop a technique for securing and protecting appropriate thicknesses of the liquid crystal layer and the transparent resin film formed at the same time.

In addition, there have been demands for liquid crystal panels to solve various problems, such as increasing the viewing angle, preventing and uniformizing disclination (lines), and obtaining high-speed response.

The above is the conventional technology for liquid crystal display devices and its problems. However, there are similar problems with optical shutters using liquid crystal, projection displays, and other color filters of plasma displays. Was desired.

That is, for example, in the case of a plasma display, it is attempted to provide a color filter at a predetermined distance in front of the original display in order to maintain a specific gas in each pixel portion of the light emitting surface and to improve the color display characteristics. However, in order to accurately maintain a constant dimension between two planes, a similar problem occurs.

The structure of the plasma display using the liquid crystal is shown at the end of the embodiment of the present invention.

[0043]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and for that purpose, a resin spacer having a specific property is employed in a sealing resin.

Further, a projection is formed on the substrate of the seal portion to keep the substrate at a constant interval.

In addition, the invention is devoted to the distribution density of the resin spacers and the formation position and density of the protrusions.

In addition to the formation of the projection for keeping the substrate interval constant in the display area as in the case of the seal portion,
Each time the shape is formed, the shape, size, and the like are devised.

Further, in addition to maintaining the distance between the substrates, the projections have predetermined roles such as maintaining rigidity and arranging liquid crystal molecules.

Further, injection of liquid crystal into the liquid crystal panel,
Efforts are made to fill and form the liquid crystal layer. At this time, air is prevented from entering the liquid crystal.

In addition, simplification of the manufacturing process, convenience of material arrangement, and the like are also taken into consideration.

More specifically, the configuration is as follows.

According to the first aspect of the present invention, the periphery of a display area on a substrate of a liquid crystal panel employing a small-sized high-performance transistor (element) manufactured using a small-sized high-performance semiconductor (material) such as polysilicon (for example, In the case where the drive circuit portion is formed on the entire periphery (as in one-side mounting), and the seal of the liquid crystal in the display area is formed on the drive circuit (including other portions) A) The liquid crystal panel is characterized in that an elastic spacer is provided in (the cured part of) the liquid crystal sealing resin.

The following operation is performed by the above configuration.

In a liquid crystal panel in which a drive circuit portion is formed immediately above and directly to the left of the display area on the substrate, or around the entire periphery, and a seal for liquid crystal in the display area is formed on the drive circuit, Since an elastic spacer made of a non-hard substance (organic material) such as glass wool or SiO ₂ is mixed in the resin for the sealing portion of the liquid crystal before solidification or sprayed before coating, the resin solidifies. Later, there is an elastic spacer as a spacer for maintaining the distance between the substrates in the seal portion.

In addition to the above, it is needless to say that a polarizing plate, a reflecting plate, a power source, and other structural parts which are indispensable to a panel of a liquid crystal display device are provided as required.

According to the second aspect of the present invention, the spacer made of an elastic material is solid at room temperature, and softens or melts at a temperature to which the liquid crystal panel is exposed at the time of manufacturing, for example, 220 ° C. or a temperature range slightly over this. Polymerizable organic materials, such as petroleum-based resins, and other resins such as Teflon-based resins and nylon-based resins, which are preferably produced using metallocene catalysts, particularly geometrically constrained catalysts, to have specific mechanical and physical properties. It is.

The following operation is performed by the above configuration.

As the elastic spacer, a material which is easy to manufacture and has an appropriate elasticity value or the like is selected.

According to the third aspect of the present invention, the elastic spacer is a spherical spacer made of a material having the same or substantially the same elastic modulus as the resin spacer in the display area.

The following operation is performed by the above configuration.

The elastic spacers have the same or substantially the same elastic modulus (difference within ± 10%), regardless of whether they are the same size or the same material as the resin spacer in the display area.
Is a spherical spacer made of the following material.

Even when the sealing resin is uncured due to the unevenness due to the presence of the element and the wiring, the sealing resin is deformed according to the unevenness formed on the substrate surface and fits as it is.
Movement on the substrate surface can be prevented as much as possible.

In the invention according to claim 4, the diameter is 6 μm.
100 spherical spacers of about m (4-10 μm) /
It has a density of not less than 200 mm ² , preferably 200 pieces · mm ² (dispersed).

The following operation is performed by the above configuration.

Since the number of spherical spacers is large, the pressing force applied to each spacer is dispersed, and furthermore, the error of the diameter of each spacer caused by the manufacturing technique or the like is well compensated in combination with appropriate elastic deformation. .

Further, it is easy to ensure uniformity such as pressing when the resin is cured. Further, it is easy to manufacture substrates at regular intervals.

In addition, if the resin diameter is large, the number (density) thereof will generally decrease in inverse proportion thereto or inversely proportional to its square.

In the fifth aspect of the present invention, when the spacer made of an elastic material has a diameter of 6 μm,
It is characterized in that it is an appropriate elastic spacer made of a substance that requires a load of 1 g or less for% compression.

The following operation is performed by the above configuration.

The spacer made of an elastic body prevents the transistor from being damaged by excessive pressing when the sealing resin is cured.
When the diameter of the sphere determined by the distance between the substrates to be held is 6 μm, the appropriate elastic spacer is made of a substance in which the load required for 10% compression is 1 g or less.

Therefore, for other diameters, whether or not the elasticity value is equal to the material of the present invention is converted by the theory of elastic contact between a Hertzian curved surface and a sphere. However, this is for maintaining the substrate interval of the liquid crystal display device.
Since the diameter is unlikely to be several times or several times smaller than m, other diameters are at most about 10 to 2 μm, so that the elasticity does not change so much. It is.

Further, even if the material has another shape such as a columnar shape, a material having the same elastic modulus is selected.

Further, under this condition, the pressing force (kg / cm
^Two) And resin distribution density (pcs / mm ^TwoShrinkage determined from)
The spacer with the appropriate diameter is selected in consideration of
Become.

According to the sixth aspect of the present invention, when the appropriate elastic spacer is a sphere having a diameter of 6 μm, the glass substrate and the semiconductor itself are sufficiently hard as compared with the resin. For example, it is a most suitable elastic spacer that requires a load of 0.5 g or less to compress 10% in a state sandwiched between a pressing portion and a receiving portion of a steel pressing tester.

The following operation is performed by the above configuration.

A suitable elastic spacer has a diameter of 6 μm.
, The load required for 10% compression is 0.5
Since the most suitable elastic spacer is less than g, the transistor is less likely to be broken.

In addition, since the pixel portion is appropriately deformed by the unevenness of the array of semiconductors, wirings and the like in the pixel portion, the movement can be prevented even when the sealing resin is not cured.

In addition, any unevenness in the diameters of the individual spacers does not pose any problem because they are distributed at a density of 100 spacers / mm ² or more.

According to the seventh aspect of the present invention, when the spacer made of an elastic body is a sphere having a diameter of 6 μm,
Deformation amount when applying 1g load to the spacer is 0.5μm
As described above, this is an appropriate proportional elastic spacer made of a substance whose deformation amount increases in proportion to an increase in the load or within 10% less than the proportion when the change in load is within 0.25 g. It is characterized by:

The following operation is performed by the above configuration.

The spacer made of an elastic body is an appropriate proportional elastic spacer. Therefore, when the spacer is a sphere having a diameter of 6 μm, the amount of deformation when a 1 g load is applied to the spacer is 0.5 μm or more, and When the change is within the range of 0.25 g, the deformation increases in proportion to the increase of the load, or increases within a range of less than 10% smaller than the proportion (protruding downward. For this reason, excessive force causes excessive It is made of an elastic material (deformable).

According to the eighth aspect of the present invention, when the appropriate proportional elastic spacer is a sphere having a diameter of 6 μm, the amount of deformation when a load of 1 g is applied to the spacer is 1.0.
The most appropriate proportional elastic spacer made of a substance whose deformation amount increases in proportion to an increase in load or within 10% less than that in the case where the change in load is within 0.25 g and the change in load is within 0.25 g. It is characterized by being.

The following operation is performed by the above configuration.

The appropriate proportional elastic spacer is the most appropriate proportional elastic spacer. For this reason, when the sphere has a diameter of 6 μm, the amount of deformation when a 1 g load is applied to the spacer is 1.0 μm or more, and When the change is within the range of 0.25 g, the deformation amount increases in proportion to the increase of the load, or increases within a range of less than 10% less than the proportional change.

According to the ninth aspect of the present invention, since the spacer made of an elastic material is advantageous for at least one of the substrates and in terms of alignment and process, in principle, the array side substrate (surface)
In addition, it is characterized in that it is a formed columnar or semi-conical projection spacer.

The following operation is performed by the above configuration.

The elastic spacer is a protrusion spacer formed (fixed) on at least one substrate and having a flat top. As a result, at the time of vacuum filling of the liquid crystal into the liquid crystal panel and heating for curing the resin of the seal portion,
In particular, it is fixed to the substrate by van der Waalska even without applying an adhesive or the like.

According to a tenth aspect of the present invention, the spacer made of an elastic material is a columnar spacer made of a polar substance in which a substance having a polar group such as OH or NH ₃ is formed into a column shape due to acidity or the like.

The following operation is performed by the above configuration.

For the spacer made of an elastic material, a sealing resin having a polar group is often used as a sealing material under various demands such as a small volume change during curing.
This is a columnar spacer made of a polar substance in which a substance having a polarity in view of compatibility with the resin is formed in a columnar shape.

In this case, the position is hard to move even before the sealing resin is cured due to the columnar shape and the unevenness of the substrate.

According to the eleventh aspect of the present invention, the projecting spacers are formed when a large load is applied to the array-side substrate on which the drive circuit portion is formed due to some inconvenience during manufacturing of the transistor element forming portion and the like. Are characterized by being array-side protrusion spacers formed so as to avoid portions that are easily damaged.

The following operation is performed by the above configuration.

The projecting spacer is an array-side projecting spacer which is fixedly formed in consideration of the position on the array-side substrate on which the drive circuit section around the display area of the liquid crystal panel is formed. For this reason, it becomes easy to install the upper substrate after applying the seal.

In addition, since the array substrate usually has many other complicated processes, the formation of the protrusion spacers is also adjusted while adjusting these processes, so that the complexity of the operation does not particularly increase.

In the twelfth aspect of the present invention, the array-side projection spacer is a layout-consideration array-side projection spacer formed so as to avoid a small transistor element of a drive circuit around the display area.

The following operation is performed by the above configuration.

The array-side protrusion spacer is a layout-side array-side protrusion spacer, and although there are some unavoidable exceptions such as 3 to 4% of the whole, in principle, the drive circuit around the display area is small. It is formed avoiding a transistor element which is liable to cause a problem due to unexpected pressing or the like.

According to the thirteenth aspect of the present invention, the projection spacer is a light-using projection spacer formed by patterning a photosensitive resin.

The following operation is performed by the above configuration.

The projecting spacer is a light-using projecting spacer, and is formed by patterning a photosensitive resin regardless of the photo-curing type or the photo-softening type in consideration of the position of the transistor. Have been. As a result, the position accuracy and the mass productivity are excellent.

According to a fourteenth aspect of the present invention, a projection spacer made of an elastic material is formed in a non-pixel portion of a display area so as to maintain a constant substrate interval.

The following operation is performed by the above configuration.

In the vicinity of the pixel element in the display area and other non-pixel portions such as the black matrix portion which are not the original display portion (light transmitting portion), the resin expands when the sealing resin is cured, and changes in gravity and temperature during use. By preventing the substrate interval from fluctuating, a projection spacer made of an elastic body is formed to keep the substrate interval constant.

In the invention according to the fifteenth aspect, at least one of the liquid crystal panels on which at least one liquid crystal panel (including, for example, an addition or mixture of a dye or the like) for color display such as a GH cell is overlapped has a non-display area. The pixel portion is characterized by having a projection spacer made of an elastic body and formed so as to maintain a constant distance between substrates opposed to each other with a liquid crystal layer interposed therebetween.

The following operation is performed by the above configuration.

[0106] At least one (in principle, all) substrates of a liquid crystal panel in which a plurality of liquid crystal layers are overlapped, and a non-pixel portion such as between pixels in a display region is opposed to each other with the liquid crystal layer interposed therebetween. It has a projection spacer made of an elastic body formed to keep the interval constant.

In the invention according to claim 16, the projection spacer is a low-density distribution projection spacer formed on the substrate at a density of 20 / mm ² or less.

With the above configuration, the following operation is performed.

The projection spacer is a low-density distribution projection spacer. For this reason, at the time of manufacturing, the liquid crystal smoothly enters between the two substrates, and is provided on the substrate so as to have elasticity and easily follow a temperature change. 20 pieces / mm ^2, preferably 1
It is formed with a density of 0 / mm ² or less.

According to the seventeenth aspect of the present invention, the elasticity is formed at a predetermined position such as the center in the pixel of the display area so as to keep the distance between the substrates constant and to arrange the liquid crystal molecules around the same constant. It is characterized by having a molecular alignment adjusting / combination projection spacer made of a body.

With the above configuration, the following operation is performed.

The molecular alignment adjusting / projecting spacer is an elastic spacer formed at a predetermined position such as the center of a pixel in the display area so as to keep the distance between the substrates constant and to align the liquid crystal molecules around the substrate at a constant alignment. Consists of a body. For this reason, the viewing angle of liquid crystal and display devices is expanded, disclination (line)
Uniformity of the image by MVA mode or O
The rising (starting, response) characteristics of the CB mode liquid crystal are improved.

For the above reason, the top is fixed to the upper (lower) substrate in the process of manufacturing the liquid crystal panel, and the pixel portion of the substrate is prevented from being swollen.

According to the eighteenth aspect of the present invention, at a predetermined position in a pixel of a display area on each substrate of a liquid crystal panel in which a plurality of liquid crystal layers are overlapped, a distance between substrates facing each other with the liquid crystal layer interposed therebetween is kept constant. In addition, each layer is made of an elastic body formed so as to arrange liquid crystal molecules around it in a fixed arrangement, and each layer has a molecular arrangement adjusting / projecting spacer arranged in a line along the light traveling direction. It is characterized by.

With the above configuration, the following operation is performed.

The projection alignment spacers for both molecular alignment adjustment and opposing are arranged at predetermined positions in the pixels of the display area on each substrate of a liquid crystal panel in which a plurality of liquid crystal layers such as a double-stacked matrix and a GH cell are overlapped, with the liquid crystal layers interposed therebetween. The substrate is made of an elastic body formed so as to keep the distance between the substrates constant and to arrange liquid crystal molecules around the substrate at a constant arrangement, and is arranged in a line along the traveling direction of light.

Therefore, the same operation as that of the sixteenth aspect is performed, and the projection surface occupied by the protrusion spacers of each layer in the light traveling direction is common, so that the light transmittance is improved.

At this time, the pixel portion for each color and the drive circuit portion thereof have the same arrangement of TFTs and the like (except for the connection portion of each stage, etc.), so that the photolithography used for forming the protrusion spacers is performed. And the like can use a common mask.

In the invention of claim 19, at least one of the projecting spacer and the array / projecting spacer is a light utilizing projecting spacer formed by patterning a photosensitive resin in consideration of the position of the element. It is characterized by:

The following operation is performed by the above configuration.

The projection spacer is a light-using projection spacer formed by patterning a photosensitive resin in consideration of the position of a transistor or the like.
It is easy to form.

According to the twentieth aspect of the present invention, in the substrate used for the image display panel, regardless of the material such as glass and one of transparent resin, the elastic material is used to keep the distance between the substrates constant. The protrusion spacers are formed in the display area and in the area where the seal is formed, such as for sealing the liquid crystal in the outer peripheral area, regardless of whether the same process or the same material is used. Is formed on the surface of an insulating film, a color filter film, an alignment film, or the like on the inner surface side of the substrate).

With the above configuration, a uniform cell thickness can be obtained from the central portion of the display section to the display area around the seal. Further, since the display region and the spacer of the seal portion can be manufactured in the same process, it is advantageous in terms of processes and materials.

Further, since it is an elastic body, there is no danger of damaging elements such as minute liquid crystal display devices even if there is any pressing error during manufacturing.

[0125] In addition to the above, needless to say, steps such as attachment of a polarizing plate, rubbing of an alignment film, formation of an antireflection film on a substrate, painting, assembly, and inspection are performed as required. is there.

According to the twenty-first aspect of the present invention, the projection spacer is formed on at least one of the array substrate and the counter substrate.

By forming the spacers on the array side substrate, it is possible to form the protrusion spacers simultaneously with the array fabrication process. For this reason, it is easy to form the pixel at the pixel center and the pixel driving semiconductor formation portion, avoid the pixel matrix as much as possible, form the black matrix portion as much as possible, or conversely increase the viewing angle to form the pixel at the pixel center. . On the other hand, by forming on the counter substrate side, it is difficult to change the arrangement of elements of the array substrate because a large number of masks to be used are changed, or because the various elements are arranged, the formation on the array substrate itself Can be formed even when the formation is difficult.

Also, by forming on both substrates,
It is also possible to obtain optimum panel rigidity and display characteristics by forming the display portion, the seal portion, and the like with a different material for each formation region.

Further, since the liquid crystal panel and the color filter are arranged without difficulty on both substrates, the substrates are also durable.

In the invention according to claim 22, the protrusion spacers of the seal portion and the display portion have the same vertical position in the direction (vertical direction or front and back direction) perpendicular to the substrate surface, and hence the spacers. It is characterized by equal lengths.

With the above configuration, the formation of the protrusion spacers is completed in a single step.

The invention according to claim 23 is characterized in that a film for adjusting the height is formed at a lower part or an upper part of the protrusion spacer at at least a part or at least a part of the position.

With the above configuration, the following operation is performed.

This is especially true when a film for height adjustment is formed at the same time as the formation of the semiconductor insulating layer and the alignment film.
Due to the presence of this height adjustment film, the height of the projection spacer formation position is equal, and thus the formation of the projection spacer only needs to be performed in one process. Since the film is formed, a uniform cell thickness can be secured.

In the twenty-fourth aspect of the present invention, the film for adjusting the height is a pixel portion (including a black matrix portion).
Conductive film, reflector, alignment film and color filter (including
Black filter for forming a black matrix).

With the above configuration, the following operation is performed.

The substrate on the array side and the like are formed on the same plane by a transparent and thin resin film by spin coating or the like. Under this, a projection spacer for maintaining a substrate interval is formed, and furthermore, orientation information is given to the orientation film by irradiation of ultraviolet rays or the like. Alternatively, the membrane may be a color filter.

[0138] The invention according to claim 25 is characterized in that the protrusion spacer is formed of a photosensitive resin.

According to the above-described structure, minute and many protrusion spacers can be formed in a predetermined arrangement by a simple photolithography process.

According to the twenty-sixth aspect of the present invention, (density × cross-sectional area of the lower surface) of the projecting spacer formed in the display area is larger than that of the projecting spacer formed in the area where the seal is formed. Is small.

According to the above configuration, the seal portion is firmly fixed and the distortion of the panel is reduced, while the display is improved.

According to the twenty-seventh aspect, the density of the protrusion spacers is not less than 5 / mm ^{2 and not} more than 50 / mm ² , preferably not less than 7 / mm ^{2 and} 15 in the display area.
Pieces / mm ² or less, and 1 in a region where a seal is formed.
0 pieces / mm ² or more and 80 pieces / mm ² or less, preferably 30
The number is not less than 50 pieces / mm ^{2 and not} more than 50 pieces / mm ² .

According to the above configuration, the panel can be firmly fixed by the projection at the seal portion, and the distortion of the panel can be suppressed to a small extent. In the display area, the number of spacers is small, so that it is appropriate for temperature change. Following is possible.

This is especially true when the size of the display area is 48
(× 2 to １ ／) cm square, pixel dimensions are 0.3 (× 2 to
This is the case in the case of [1/2] μm square. (Of course, other dimensions are also applicable.) In the invention according to claim 28, the protrusion spacers formed in the display area are arranged in the horizontal direction (up and down) more than those formed in the area where the seal is formed. , In a direction perpendicular to the front and back directions).

According to the above configuration, the seal portion is firmly fixed, the distortion of the panel is small, and the display is also good.

According to the twenty-ninth aspect of the present invention, the protrusion spacers formed in the display area have a ratio of 0.05% or more to the total display area of the entire lower surface.
% Or less, preferably 0.07% or more and 0.3% or less, and the ratio of the lower surface to the total seal area, although formed in the area where the seal is formed, is 0.1% or more and 1.0% or less.
Or less, preferably 0.3% or more and 0.8% or less.

With the above structure, the seal portion is firmly fixed, distortion of the panel is suppressed, and the number of spacers in the display area is small, so that a liquid crystal panel or the like that can appropriately follow a temperature change can be obtained.

This is especially true when the size of the display area is 48
(× 2 to １ ／) cm square, pixel dimensions are 0.3 (× 2 to
This is the case in the case of [1/2] μm square. (Of course, other dimensions are also applicable.) In the invention according to claim 30, the ratio of the area of the upper surface of the protrusion spacer (formed on the array substrate) / the area of the lower surface is 0.2 to 0.9. Features.

According to the above configuration, the disturbance of the alignment due to the projections can be reduced, and the stable projections can be formed, so that the display becomes good. This is especially true when the size of the display area is 48 (× 2 to 1). /
2) cm square, pixel size is 0.3 (× 2 to 1/2) μm
This is the case for corners. (Of course, other dimensions are also applicable.) In the case where the projecting spacer is also formed on the opposing substrate, it is preferable that the columnar shape be as uniform as possible.

The invention according to claim 31 is characterized in that the height of the projecting spacer is different between the display area and the sealing portion in accordance with the formation of the element and the like. I have.

According to a thirty-second aspect of the present invention, in the method for manufacturing a liquid crystal panel having a liquid crystal sandwiched between substrates,
In order to maintain a constant substrate spacing on at least one substrate,
In many cases, a projection spacer forming step of forming a projection spacer made of an elastic material in a display region and a region around which a seal is formed, and at least an outer peripheral portion of the display region of one of the substrates (and, in principle, the projection spacer An empty panel forming step of applying a seal resin to an outer peripheral portion and a portion including the outer panel), aligning and bonding the two substrates, and further curing the seal resin by heating or the like to form an empty panel; It is characterized by having a liquid crystal injection step of injecting a liquid crystal therein by, for example, a vacuum injection method.

According to the above configuration, when the liquid crystal is injected by vacuum injection or the like, the projection spacer formed on the substrate does not move at all, unlike the spacer made of a glass sphere, so that the display characteristics of the liquid crystal are improved.

According to the thirty-third aspect of the present invention, there is provided a projection spacer forming step of forming a projection spacer for maintaining a constant substrate interval in a display region and a region around which a seal is formed. A sealing resin application step of applying a sealing resin to an outer peripheral portion of the display area of the substrate (and, in principle, an outer peripheral portion of the projection spacer and a portion including the same), and a predetermined amount of liquid crystal is applied to several places on the substrate to which the sealing resin is applied. A step of dropping the liquid crystal to be dropped, a step of covering the upper surface of the substrate on which the liquid crystal is dropped with the other substrate in a state where gas such as air does not enter the panel, and curing the applied sealing resin by means that does not adversely affect the liquid crystal. And a resin-cured tape for pasting the two substrates together.

According to the above configuration, there is less danger that impurities on the surface of the protrusion spacer will be dissolved in the liquid crystal.

Further, unlike the vacuum injection, the hardening treatment of the resin in the liquid crystal injection portion is not required.

It is preferable that the covering step be performed in a vacuum and at a certain elevated temperature in view of securing the fluidity of the liquid crystal and expelling gas in the liquid crystal.

According to a thirty-fourth aspect of the present invention, in the method for manufacturing a liquid crystal panel according to the thirty-second or thirty-third aspect, prior to the step of forming the protrusion spacer, the display area and the surrounding area where the seal is formed are formed. Therefore, many fine irregularities occur due to the existence of the semiconductor element and the pixel electrode and the processing required for their formation, and therefore, a film is formed to adjust the difference in the height required for the protrusion spacer depending on the formation position. And a height adjusting film forming step.

According to the above configuration, the formation of the protrusion spacers can be completed in at least one step for one substrate.

In the invention according to claim 35, the step of forming the height adjusting film is also a step of forming a conductive film, in particular, an organic conductive film, a reflector or a color filter. It is a height adjusting film forming step.

With the above-described structure, even if a color filter or the like is formed on any of the substrates, the uppermost layer of the substrate or a layer close to the uppermost layer is formed. Become. In addition, it is also possible to share the steps.

The invention according to claim 36 is characterized in that the height adjusting film forming step is an alignment film forming / adjusting film forming step also serving as an alignment film.

With the above structure, an alignment film exists as a height adjustment film regardless of whether or not there is a color filter also serving as a height adjustment film on the substrate side. Is formed on the liquid crystal side surface anyway.

In the invention according to the thirty-seventh aspect, after the step of forming a height adjusting film that also serves as an alignment film, and the subsequent step of forming a projection spacer, a non-contact type alignment treatment in which the alignment film is subjected to an alignment treatment by ultraviolet irradiation or the like. It is characterized by having steps.

With the above configuration, the alignment treatment can be performed without giving any adverse effect to the columnar projection spacer formed on the alignment film surface. Needless to say, contact-type processing such as rubbing may be performed supplementarily or locally.

In the thirty-eighth aspect of the present invention, the step of forming a height adjustment film is a step of forming a height adjustment film using spin coating, which forms a height adjustment film by spin coating of a resin having fluidity during application. It is characterized by.

According to the above configuration, the unevenness on the substrate is naturally eliminated, so that there is no possibility that impurities and air remaining in the uneven portion in the liquid crystal are mixed.

According to the thirty-ninth aspect of the present invention, in the step of forming the protrusion spacer, regardless of whether or not the height adjusting film is formed before that, a seal is formed on the outer peripheral portion of the display area. The present invention is characterized in that it has a small step of forming a projecting spacer which also serves as a peripheral wall, which continuously forms a projecting spacer in a region to form a wall.

According to the above configuration, it is easy to fill a liquid crystal in the peripheral wall / projection spacer before bonding the upper and lower substrates, and to manufacture a liquid crystal display device using a special type of liquid crystal.

At this time, the sealing resin may be applied only to the outer peripheral portion of the peripheral wall / projection spacer. As a result, the liquid crystal does not come into contact with the uncured sealing resin (however, the effect of this feature is exhibited depending on the type of the liquid crystal or the like).

Further, in this case, the top of the peripheral wall / projection spacer is bonded to the upper substrate by van der Waals force at a certain temperature for fluidizing the liquid crystal and driving out gas. If reliable bonding is desired,
A thin sealing resin may be applied only to the outer half of the top.

According to the forty-ninth aspect, on the substrate on which the semiconductor element and at least one of the electrodes are formed, the projection spacer is formed in the display area, and the wall-shaped projection is formed in the periphery of the display area. Is formed, and the portion surrounded by the wall-shaped projections is filled with a mixed liquid of the polymer-dispersed liquid crystal or a precursor thereof and a resin serving as a resin matrix or a precursor thereof.
Under this, a resin matrix and polymer-dispersed liquid crystal droplets inside the resin matrix are formed by ultraviolet irradiation or the like.

With the above configuration, the thickness of the liquid crystal layer is naturally kept constant, and the liquid crystal layer is further protected against pressing from the display surface, external distortion and the like.

[0173] In addition to the above, the upper panel may be attached as necessary.

In the invention according to claim 41, the invention according to claim 39 is a liquid crystal panel using a polymer-dispersed liquid crystal, but a liquid mixture of the liquid crystal and a resin to be a transparent panel on the liquid crystal is used. The liquid crystal panel used.

With the above structure, the lower substrate, the liquid crystal layer thereon, and the transparent or colored transparent translucent panel on the upper surface thereof,
The case and the upper substrate are simultaneously formed by the case.

[0176]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described based on its embodiments.

(First Embodiment) FIGS. 3A and 3B are cross-sectional views of main parts of a liquid crystal panel according to a first embodiment of the present invention. FIG. 1 shows the configuration of the drive circuit section.

In the following, the present embodiment will be described with reference to this drawing. However, just in case, a method of forming a pixel electrode and a semiconductor layer as (a material component of) a switching element for driving the pixel electrode is described beforehand. explain.

The pixel transistors in the display area shown in FIG. 3A have a video signal line (source) 10 and a scanning signal line (gate) 12 as metal wiring on a glass substrate 101.
Are formed in a matrix (lattice) shape, and a semiconductor layer (TFT: Thi) is formed as an active element (switching element) at the intersection.
n Film Transistor 14 is formed. The pixel electrode 201 is formed of a transparent conductive film (ITO: indium oxide tin oxide) and is connected to the semiconductor layer 14 through the drain 11. These have a structure in which a current flows between the source and the drain when a voltage is applied to the gate. Further, the semiconductor layer and the gate are covered with an insulating film 13 such as SiO ₂ for protection, and the source and the drain are covered with an insulating film 15 such as SiNx for protection.

Next, a transparent conductive film (ITO film) is formed on the opposing glass substrate 102 in accordance with the conductive film 201 of the array substrate.
After forming 202, the alignment film 4 (AL5417: manufactured by JSR) is printed on both substrates 101 and 102, and rubbing is performed.

Next, the peripheral drive circuit shown in FIG. 3B includes a circuit for driving the gate and a circuit for driving the source. These are composed of a shift register, a buffer, an analog switch and the like. Although the sizes and the like are different, they are basically formed of arrays 11 to 14 including the same transistors (elements) and wiring as the pixel portion.

However, the printing and rubbing of the alignment film may be performed by other methods for the sake of convenience of manufacture and the like. Further, it goes without saying that these may be only the display area.

Next, as shown in FIG. 1, a 1 mm-wide sealing resin 5 (structural bond:
(Made by Mitsui Toatsu). At this time, in the sealing resin, in order to keep the substrate interval of the sealing portion constant,
A resin spacer 7 having a diameter of 6 μm is mixed in advance. The mixing ratio at this time is as follows.
It is preferable from the viewpoint of ensuring proper pressing and sealing properties to such a m ² per 200 to 240 amino spacer density. Further, in this case, since the spacer is spherical, unlike a glass fiber, there is no possibility that the spacers overlap. In addition, mixing into the sealing resin becomes easy.

Thereafter, in order to keep the distance between the substrates in the display area constant, as shown in FIG. 3A, resin balls having a diameter of 6.5 μm (eposter GP-HC: Nippon Shokubai) (Manufactured by Co., Ltd.). In addition,
The diameter of the spacer is 0.5 μm larger than that of the seal portion. The difference of 0.5 μm corresponds to the difference in the thickness of the array and the shrinkage of the spacer in the seal portion when pressed.
Although the spacer of the seal portion is not strictly spherical due to the pressing force, it is ignored in the drawing because the deformation is very small as a practical problem. This is the same in the drawings of the other embodiments.

Further, in order to establish electrical continuity between the lower array substrate on which the elements are formed and the upper counter substrate, conductive paste 9 is applied to four places on the lower substrate edge as shown in FIG.

Thereafter, the substrate 101 and the counter substrate 102 shown in FIG. 3 are bonded (orientated) so that the electrode surfaces face each other, and pressed and held at 150 ° C. for 2 hours to cure the sealing resin 5.

The liquid crystal 3 (E-7: manufactured by BDH) was injected into the empty panel prepared as described above by a vacuum injection method (the empty panel was placed in a liquid crystal tank, and the inside of the tank was evacuated. The liquid crystal is injected into the panel by bringing it into contact with the liquid crystal and returning the pressure in the tank to normal pressure in that state. In this case, the spherical resin in the pixel portion has a shape in which the upper and lower ends are slightly crushed by the pressing force, and is the same organic material as the alignment film on the inner surface of the glass substrate, so that the contact property is improved, and Due to the vacuum, this contact property was increased, and the movement of the liquid crystal was small despite the flow of the liquid crystal entering the panel.

Thereafter, the sealing resin 3 is inserted into the injection port of the liquid crystal panel.
As 1, a photocurable resin (Loctite 352A: manufactured by Nippon Loctite) is applied to the entire injection port, and the resin is irradiated with light at 10 mW / cm ² for 5 minutes, cured, and sealed.

In addition, the upper and lower sides of the panel (outside the glass substrate)
(Not shown).

In the present embodiment, six kinds of spacers shown in the following table are used for comparison at this time.

[Description of Table Format] Number Product Name Manufacturer Material A Glass fiber Nippon Electric Glass B Shinshin sphere Catalyst modified SiO ₂ CB Improved product Same as above D Micropearl Sekisui Fine Chemical Resin ED Improved product Same as above F E poster Nippon Shokubai Resin In addition, when the sealing resin is cured,
Both substrates are pressed for the purpose of preventing the fluctuation of the substrate interval due to the generation of air bubbles, etc., and at the same time, for good adhesion between the resin and the substrate. It was doubled to 2 kg / cm ² .

When the sealing portion of the liquid crystal panel manufactured using these spacers was observed using a microscope, it was found that spacer A was used as the spacer mixed into the sealing resin.
(Glass fiber) and the liquid crystal panel mixed with the spacer B (SiO ₂ ) have some scratches on the drive circuit under the seal because the glass fiber is hard.
When a liquid crystal panel was displayed, some point defects and line defects occurred.

The liquid crystal panel using the spacer C (improved product of B) was slightly damaged, though not so much as A and B. On the other hand, when the spacers D, E, and F (resin spacers) were used as the spacers to be mixed into the seal resin, the drive circuit portion below the seal portion had no damage, and a good display was observed. .

FIG. 4 shows the amount of deformation when a load is applied to these spacers.

That is, since the glass substrate can be regarded as a rigid body compared to the resin, the spacer in the seal is compressed by 10% while being sandwiched between the metal parts (rigid bodies) for the trial press of the compression deformation tester ( Here, the spacer diameter is 6
It is sufficient to use spacers C, D, E, and F, which have a compression load of 1 g or less for a deformation amount of 0.6 μm. (If the diameter of the spacer is different from 6 μm, the necessary conversion may be made based on the theory of elastic contact under pressure on a Hertzian curved surface. This theory itself is, for example, the Japan Society of Mechanical Engineers. Edited, "Mechanical Engineering Handbook A4 (Material Mechanics), page 109 (2nd print)" is a well-known theory (rule) described in, for example, published in 1985, so the description is omitted.) More preferably, the same conditions as above A spacer D whose compression load required to compress the spacer in the seal by 10% (the deformation amount is 0.6 μm in this case) is 0.5 g or less;
E and F may be used. In other words, the more flexible the material of the spacer, the more the pressing force applied to the transistor is absorbed by the deformation of the spacer,
Irregularity of each spacer, irregularity of thickness of glass substrate,
This is because a change in the pressing force due to the presence or absence of the driving circuit portion is more easily absorbed. (However, these irregularities and the like may cause a problem when an unexpectedly large pressing force is applied, and it is a matter of course that the irregularities are within a certain range by a product inspection for each material in advance. At this time, as clearly understood from FIG. 4, the shrinkage due to the deformation of the spacer and the load, that is, the pressing force, was 0.5 g / g.
Within the range of individual loads, preferably within the range of 0.25 g / load, an approximately proportional relationship is established, with a difference of 5%, at most 10%. Therefore, if the pressure is measured while measuring the distance between the glass substrates with a laser beam or the like with reference to this drawing, an appropriate pressing force is naturally maintained.

Further, the spacer mixed in the seal and the spacer dispersed in the display area are made of the same material, at least the same elastic modulus, thermal expansion coefficient and a resin spacer having a difference of at most 10% or less. HC: Nippon Shokubai Co., Ltd., physically, polybenzoguanamine resin,
Poly-di-vinylbenzene and similar substances. ) Is more preferable because it is matched with the linearity (proportionality) of the deformation due to the pressing force, the pressing control becomes easy, and the expansion and contraction due to heat become the same in the seal portion and the display portion.

Next, the required mechanical and physical properties, such as rigidity and translucency, are different between the seal portion and the pixel portion, so that the required density of the spherical spacers is also different. For this reason, first, a spherical elastic spacer is scattered before the entire substrate, and a sealing resin is further applied to the sealing portion. At this time, the sealing resin is mixed at a density in consideration of the scattered spherical elastic spacer. You may do so.

(Second Embodiment) In the present embodiment, a columnar projection for maintaining a substrate interval is formed in a drive circuit portion around a display area.

That is, in the above embodiment, a spacer is mixed in the sealing resin for this purpose, but in this embodiment, a protrusion is formed instead. This is shown in FIG.

This figure is a sectional view of a main part of the liquid crystal panel of the present embodiment. (A) of this figure is for the drive circuit section, and (b) is for the configuration of the display area section.

Hereinafter, this will be described.

As in the first embodiment, the substrate 10
An array of driving transistors and the like is formed around the upper display area (for simplicity, the reference numerals of the respective transistor element portions are omitted in this figure and thereafter).

Thereafter, a semi-conical projection 6 having a narrow upper portion as shown in FIG. 2 made of an elastic material is formed as a spacer for maintaining a space between the substrates on a portion of the insulating film 15 where the sealing resin is to be formed.

As a forming method, a photoresist is applied by spin coating and a photolithography method is used.

That is, a photosensitive resist (HRC-12)
6: JSR) is applied on the array substrate by spin coating, and dried on a hot plate at 90 ° C. for 2 minutes.

Thereafter, exposure is performed at 5 mW / cm ² using a mask, and development is performed by developing with a developing solution for 2 minutes. In this case, it is needless to say that the projection is formed while avoiding the portion where the element exists as much as possible.

Thereafter, the substrate was washed with ultrapure water for 1 minute.

As described above, a protrusion having a height of 6 μm was formed on the array substrate.

Next, after a transparent conductive film (ITO film) 202 is formed on the glass substrate 102 which faces separately, both substrates 1
The alignment film 4 (AL5417: J
SR) was printed and rubbed.

The sealing resin 5 is applied to the edge of the glass substrate 102.
(Structure bond: manufactured by Mitsui Toatsu) was applied by a dispenser (drawing machine). At this time, of course, no spacer is mixed in the sealing resin. Also, the sealing resin adheres to the tops of the projections, which contributes to the adhesion between the two substrates via the projections.

Thereafter, as in the previous embodiment, in order to maintain the distance between the substrates in the display area, a resin ball 71 having a diameter of 6.5 μm is formed in the area as a spacer as shown in FIG. 5B. (Eposter GP-HC: Nippon Shokubai Co., Ltd.
Was sprayed, and the process from the application of the conductive paste to the mounting of the polarizing plate on the panel was performed to produce a liquid crystal display panel. The pressing force and the control thereof are the same as in the first embodiment.

Further, as a comparative example, a panel using a sealing resin in which glass fiber was previously mixed as a spacer instead of forming a projection was also manufactured.

When these liquid crystal panels were observed with a microscope, the liquid crystal panel in which the glass fiber was mixed as a spacer in the sealing resin had some scratches on the portion of the drive circuit below the sealing portion because the glass fiber was hard. Had occurred. Therefore, when a liquid crystal panel was displayed, some point defects and line defects occurred.

On the other hand, in the case where the projection is formed in the sealing resin, the projection itself is not only flexible but also formed by avoiding the TFT portion of the driving circuit in the first place. Despite the application of excessive pressing force, there was no flaw or the like in the drive circuit portion below the seal portion. Therefore, the display of the image was also good.

(Third Embodiment) In the present embodiment, a projection is formed not only in the seal portion but also in the display area.

FIG. 6 is a cross-sectional view of a main part of the liquid crystal panel of the present embodiment. FIG.
(B) is for the display area.

In this embodiment, as in the first embodiment, transistors arranged on the substrate 101 along the pixels and the driver circuit, that is, an array are manufactured.

After that, elastic projections 6 and 60 are formed as spacers, avoiding the transistor portion as much as possible, in the portion where the seal resin is formed and the display region on the substrate on which the array is formed.

That is, in the first embodiment, the spacer is mixed in the seal and the spacer is scattered in the display area. In the present embodiment, a protrusion is formed instead of mixing the spacer in the seal. In addition, in the vicinity of the pixel driving element in the display area, and other troubles, scatter of the spacer is also applied to a non-pixel portion (a portion that does not affect vision), such as a black matrix portion and a boundary between pixels, which are not shown. Instead, a projection is formed. (However, there is a limit to the size of the projections and the black matrix, etc., and there is a limit in the manufacturing accuracy, and there may be a portion that slightly protrudes from the black matrix, but even this case does not affect the visual sense.) The method of forming the projection is the same as that of the second embodiment.

Thereafter, a liquid crystal display panel was manufactured in the same manner as in the first embodiment.

For comparison, a spacer mixed with glass fiber was also manufactured as a spacer mixed into the sealing resin (not shown).

When these liquid crystal panels were observed using a microscope, it was found that the liquid crystal panel in which glass fiber was mixed as a spacer mixed in the sealing resin had a small size in the drive circuit under the seal because the glass fiber was hard. Scratches were generated, which caused some point defects and line defects when displaying the liquid crystal panel.

On the other hand, in the case where the protrusions were formed in the sealing resin, the protrusions were formed avoiding the TFT portion of the drive circuit. An indication was observed. From the above, it was found that the formation of the projections in the display area had no adverse effect on the seal portion.

In the present embodiment, since no spacers are scattered in the display area of the panel and projections are formed in areas other than the pixel electrodes, the spacers are not photosensitive. Even if the orientation of the liquid crystal molecules in the vicinity is disturbed, there is no adverse effect on the display of the panel, and on the other hand, since there is no spacer in the pixel, there is no disturbance in the orientation or opacity of light due to this. A better display than before can be observed.

In this embodiment, since the projections are formed on the non-pixel portion in the display area at the same time as the projections are formed on the seal portion, the spherical resin spacers are dispersed in the display area. Can be omitted, leading to a reduction in manufacturing cost.

The distribution density of the columnar protrusions in the display area is about 6 to 7 μm and the diameter of the protrusions is about 5 to 20 μm. Since the panel loses its elasticity and cannot follow a temperature change, and may become a resistance when liquid crystal molecules are injected by a vacuum method, the number is set to 20 / mm ² or less, preferably 10 / mm ² or less. Is good.

However, since this is related to the use of the display device, the thickness of the glass substrate, and the properties and molecular weight of the liquid crystal molecules to be employed, it is of course not absolute.

(Fourth Embodiment) In the present embodiment, a projection is formed at the center of each pixel portion in the display area.

FIG. 7 shows a main part of the liquid crystal panel of the present embodiment.

As shown in (a) of this figure, in this liquid crystal display panel, a semi-conical bar-shaped projection 601 having an upper part of 5 μm and a lower part of 10 μm is formed in the center of each pixel part of 100 μm × 100 μm. .

For this reason, as shown in (b) of this figure, substantially elliptical liquid crystal molecules are regularly arranged around the rod-shaped projection. As a result, the viewing angle characteristics of the liquid crystal panel are improved.

Further, in the OCB type liquid crystal, the starting characteristics at low voltage can be improved under the anisotropy of the arrangement of molecules in advance. Further, in order to further exert this effect, a projection for liquid crystal molecule alignment having a height halfway may be provided in the center of the pixel, in addition to the rod-shaped projection for maintaining the substrate interval. Further, in this case, if the protrusion spacer is formed at a portion higher than the pixel on the substrate, the electrode or the alignment film thereon (a portion close to the opposing substrate), the protrusion at the top is different but the protrusion is They have the same vertical length, and can be formed in one step.

As shown in (c) of this drawing, this projection 602 has a specific shape such as a right-angled trapezoidal cross section.
By arranging the pixel at a specific end of the pixel, the viewing angle characteristics in a specific direction can be improved. Consequently, the viewing direction of the display panel in the train is suitable for a specific display panel.

(Fifth Embodiment) This embodiment relates to a liquid crystal panel for color display without using a color filter and a projection type display using liquid crystal.

In recent years, as shown in FIG. 2, cyan, magenta, yellow or G,
Liquid crystal panels have also been developed in which dyes for R and Y are mixed in liquid crystal, or color display is performed using a filter or the like. In this case, there will be three liquid crystal layers separated by transparent glass on the bottom substrate.

In this case, the seal portion is formed, for example, as shown in FIGS.

In this figure, the liquid crystal layer of each of the types (a) and (b) is, for example, a liquid crystal layer 30 in which yellow, magenta, and cyan dyes or R, B, and G dyes are mixed in order from the bottom.
1, 302 and 303 are formed, and therefore, a total of four substrates 211, 212, 213 and 214 are provided.

Further, in the case shown in (a), drive circuits 221, 222, and 223 around the display area of each liquid crystal layer are formed on substrates 211, 212, and 213 below each layer, and the lowermost stage A drive circuit 224 for overall adjustment is provided on the outer peripheral portion of the seal portion of the substrate 211.

[0239] In the case shown in (b), the peripheral drive circuits are provided only on the lowermost substrate 211 in order from the left, for total adjustment 224, uppermost liquid crystal layer 223, and middle liquid crystal layer 22.
2. The lowermost liquid crystal layer 221 is formed.

In the seal portion shown in (a), first, the lowermost liquid crystal seal portion 51 is formed, then the intermediate liquid crystal seal portion 52 is formed, and finally, the uppermost liquid crystal seal portion is formed. A portion 53 is formed. For this reason,
In the case shown in (a), the seal portion 51 on the upper surface of the peripheral drive circuit portion for each liquid crystal layer provided on the lower substrate for each liquid crystal layer,
Projections 61, 62, 6 for maintaining the substrate interval are provided in 52, 53.
3 are formed while adjusting their positions.

Next, as shown in (b), in this case, the height of the upper glass substrate for each liquid crystal layer and the height of the lowermost glass substrate 211 of the entire liquid crystal panel are equal to the height of each layer ( This will be different for each substrate in (stage). In this case, it is not preferable to keep the distance between the substrates constant by using a spherical spacer or a fibrous spacer having a different diameter for each glass substrate because the types of spacers and the like increase.

Therefore, the seal portions 51, 5 on the upper counter substrate of the liquid crystal layer corresponding to the respective drive circuit portions for each liquid crystal layer.
4, 55, 56, corresponding height 64,
65, 66 and 67 are formed.

In this case, the wiring between the peripheral drive circuit section for each liquid crystal layer and the pixel section of the liquid crystal layer, the peripheral drive circuit for each liquid crystal layer, and the comprehensive adjustment drive circuit section are performed while forming and adjusting the projections. Of course, the formation of the wirings 92, 93, 93 and the contact holes (not shown) as necessary for the formation are performed by applying and curing the sealing resin and forming and adjusting the semiconductor element prior thereto. is there.

In this case, in any of the types (a) and (b), the projections are formed by patterning.
The formation position can be appropriately adjusted in the entire layer. Consequently, the rigidity and the like of the seal portion are sufficiently high and excellent.

Further, it is possible to flexibly cope with a difference in height of each liquid crystal layer.

(Sixth Embodiment) The present embodiment relates to a color display panel having three liquid crystal layers similarly to the above fifth embodiment. The difference is that a projection is also formed.

That is, in the system using a plurality of liquid crystal layers for color display, when a spherical spacer is scattered to keep the interval between two substrates, display is performed as compared with the ordinary color filter system. This means that the spacers are spread by the number of layers per area.

By the way, no matter what kind of material is selected for the spacer, the orientation of the liquid crystal near the spacer is irregularly disturbed to some extent at the present time, causing disclination and scattering of light. . For this reason, increasing the spacer density is not very desirable from the viewpoint of maintaining good display quality.

In addition, the distribution of the spacer density may be irregular in each layer, and unexpected distortion may be caused based on the unevenness, which may result in a difference between the design value of the substrate interval of each layer. This is not preferable in terms of good color display.

In this embodiment, in order to maintain the distance between the substrates in each layer, a projection is formed on each substrate. In this case, as shown in FIG. 9, the formation position on each substrate is the same. In addition, it is formed in a non-pixel portion such as a boundary between pixels as much as possible. In this figure, (a) shows that a projection is formed in the non-pixel portion near the pixel driving element 17 (corresponding to 11 to 14 or the like in FIG. 3) on the substrate below each liquid crystal layer. (B) shows the relationship between the direction of the light 40 passing through the liquid crystal layer and the projection 60 of each layer.

In this way, the projections of each stage are arranged in a line with respect to the light ray 40, and are present in the non-transmissive portion. Therefore, a panel having not only a fixed substrate interval but also excellent display quality was obtained.

In FIG. 9A, rod-shaped protrusions are formed corresponding to each pixel. However, it is needless to say that one bar may be provided for every four pixels composed of 2 × 2 pixels. It is.

(Seventh Embodiment) Although the seal portion is not formed at the end of the substrate in FIG. 1, the driving circuit is formed on one of the upper and lower sides, left and right May be formed on only one of them, and the seal may be formed on the end. The present embodiment shows an application of the present invention in the case of this one-side mounting.

As shown in FIG. 10A, 70 mm ×
Peripheral drive circuits 21 and 22 are formed in a portion within 2 mm of the left end of the 90 mm substrate and in a range of 4 to 7 mm below the upper end, and the display area 20 is 88 mm × 6 near the lower right.
It is formed in a range of 3 mm. The seal portion 5 includes a central portion of the peripheral drive circuit portions 21 and 22 and a right end portion of the substrate,
It is formed at the lower end.

In this case, if the elastic resin spacer is used, the sealing portion can be somewhat shrunk when pressed such as solidification or fixing, so that the resin slightly protrudes from the end portion of the panel as shown in FIG. There is fear. In the figure, reference numeral 58 denotes a resin that has protruded and solidified.

If it is inconvenient to leave the protruding and solidified resin as it is, it is necessary to perform an operation such as separate cutting, but it is troublesome just because it is cured.

Therefore, as shown in (c) of the figure, a so-called wall-shaped projection 603 is formed at the end of the substrate. This prevents the resin 58 from protruding.

It is needless to say that the other parts are merely protrusion spacers 6.

In addition to the above, it is needless to say that it may be provided at a position several μm inward from the edge of the substrate, or may be provided in a so-called dotted line within a range where the resin does not flow out.

(Eighth Embodiment) This embodiment relates to an electrical connection at an end of a panel having a structure in which a plurality of liquid crystal layers shown in FIGS. 2 and 8 are stacked.

By the way, in the case of the multilayer structure, reference numeral 91 in FIG.
As shown at 91 to 94, a connection line portion for electrically connecting the lowermost substrate and each substrate is required. By the way, when this connection line portion is formed on the end face of each substrate, there is a problem with the resin that has protruded from between the substrates during the solidification and has been solidified.

That is, even if there is no deformation due to pressing (a reduction in the width between the substrates) due to the use of the glass spacers, the resin is somewhat out of the substrate due to flow, generation of bubbles, volume expansion due to a chemical reaction, and the like. Protrude. For this reason, as it is, there is a problem in attaching a seal or the like having a connection line portion formed on the outer surface or the inner surface thereof or attaching a thin plate.

Therefore, in the present embodiment, like the seventh embodiment, the rod-like projections also serve as walls for preventing the resin from protruding, and are slightly inward, such as at the end face of each substrate or 2-3 μm, so-called wall-like or dotted lines. It is formed in a shape. Thus, the attachment of the seal as the connection line portion is facilitated.

FIG. 11A shows a case where the present invention is applied to a panel having three liquid crystal layers shown in FIG. FIG.
(B) is a modified example of this.

As shown on the right side of this figure (b), the connection lines 91 to 93 of the substrate of each layer are attached to the end face in order from the lower layer. It is needless to say that the connection line portion has the electric wire 95 formed in the contact hole as shown on the left side of FIG. In addition to the above, it is a matter of course that the contact hole may be formed in the wall-shaped rod-shaped projection.

(Ninth Embodiment) In the ninth embodiment, a thin film having a thickness of about 1 to 3 μm is formed in a drive circuit portion by using only an alignment film, a film also serving as a color filter, or a sealing resin alone. Thereafter, a sealing resin mixed with glass fibers cut short in a columnar shape is printed and applied, and cured by heating.

This is shown in FIG.

In this case, the glass fiber 19 does not come into direct contact with the transistor 15 or the like in the presence of the cured resin film layer also serving as an alignment film or the sealing resin layer 18, which is different from the current state. Even if a pressing force twice as large as that described above, no damage to the transistor or the like occurs, and the portion of only the lower sealing resin layer is 1 μm in comparison with the sealing width of 1 mm.
Because it is very thin, no bubbles etc. are generated, there is no volume change,
Moreover, the seal part had sufficient rigidity as a whole and, consequently, accuracy of height.

In this case, no pressing is performed when the sealing resin of the first layer is cured, but since the resin layer is thin and the volume change due to curing is small in the first place, the distance between the substrates is maintained by using the glass fiber. Needless to say, it can be adjusted sufficiently when the sealing resin portion 57 is cured.

Further, the resin film can be formed in accordance with the formation of the alignment film on the pixels in the process, so that the manufacturing is facilitated.

(Tenth Embodiment) This embodiment is directed to
Instead of glass fibers, use nylon fibers which have been cut very short, about 1 to 3 times the diameter, preferably about 1.5 times (+ -0.5 times), and therefore about 10 μm if the diameter is 6 μm. .

In this case, since the nylon molecule has a polar group, the nylon molecule has a polar group, so that the compatibility with the sealing resin is good.

Further, since they are short columns, they are not easily overlapped, and do not move in the horizontal direction which occurs at the time of pressing. In addition, since the seal portion is slightly separated from the display area, the alignment of the liquid crystal in the pixel portion is not disturbed by the nylon fiber. As a result, the display quality did not change, and an excellent seal portion was formed.

In the case of the present embodiment, since there is no sealing resin layer 18 in FIG. 12 and only the granular glass fiber 19 is a columnar nylon fiber, the illustration is omitted.

(Eleventh Embodiment) This embodiment is a modification of the eleventh embodiment.
The present invention relates to the formation of protrusions on the display unit and the seal unit.

FIG. 14 is a plan view of the liquid crystal panel of this embodiment as viewed from above.

FIG. 15 is a diagram showing a main part of the liquid crystal panel of the present embodiment, and a) is a drawing showing a configuration of a pixel. Also, b) is a diagram of the AA cross section of a). Also, c) is a cross-sectional view of the seal portion.

Hereinafter, the liquid crystal panel will be described with reference to FIGS.

A video signal line (source) 110 and a scanning signal line (gate) 111 are formed in the form of a matrix on a glass substrate 101 on the array side as metal wiring, and a semiconductor layer (TFT) is formed as an active element (switching element) at the intersection. : Th
in Film Transistor).

Hereinafter, there is no direct relation to the purpose of the present invention.
Although it is a well-known technique, since it is a technique premised on the present invention, formation of a semiconductor layer, a color filter, and an alignment film will be briefly described.

A gate electrode is selectively formed on a glass substrate 101 having a display portion of a diagonal of 48 cm and a thickness of about 0.7 mm by using a metal such as Al. Next, SiNx to be a first gate insulating film was formed to a thickness of 3000 ° by a plasma CVD method.

Next, a semiconductor layer (amorphous silicon layer) serving as a channel portion of the transistor is formed to a thickness of 500.degree.
で were sequentially formed.

At this time, as a method for forming a channel portion of the transistor, an insulating film SiNx on the gate electrode is formed smaller than the gate electrode to serve as an etching stopper, and an n + amorphous silicon containing phosphorus is formed thereon by a plasma CVD method. A silicon layer was formed with a thickness of 500 ° to obtain an ohmic junction (n +: high concentration doping, and a large proportion of n-type impurity addition).

Next, a contact hole was formed in a peripheral portion where an electrode and the like were to be formed so that a contact with a wiring portion could be obtained.

Next, a transparent conductive film (ITO: indium oxide tin oxide) is formed.

Next, a signal wiring (source line) and a drain line were formed with a thickness of 4000 ° using a metal such as Al / Ti.

Thereafter, in order to protect the wiring, SiNx is applied as a second insulating film (passivation film) to the plasma C.
It is formed with a thickness of 3500 ° by using the VD method.

At this time, after washing the substrate in advance, a resist was applied by a spinner and mask exposure was performed so that a part of the insulating film was not formed on the pixel electrode.

A color filter layer was formed on the opposite glass substrate 102.

The color filter layer is formed by applying a colored resist obtained by dispersing a pigment in an acrylic photosensitive resin onto a substrate,
Exposure is performed by masking necessary portions or using light that has been patterned in advance, and then developing (photolithography) to remove unnecessary portions is performed for each color (red, green). , Blue and black) for a total of 4 repetitions. Here, the presence of black is due to the black matrix.

Although the substrate in this state is described in b) and c) in this drawing (however, b) and c) are described, the protrusion spacers and the seals at the ends are still formed at this point. It has not been). The size of the pixel is 0.3 mm.

In b) and c), 102 and 101
Are upper and lower glass substrates. Reference numeral 155 denotes any one of R, G, and B color filters, and 156 denotes a black color filter. 202 and 201 are upper and lower pixel electrodes, and 4 is an upper and lower alignment film. 5 is a sealing resin, and 6 and 60 are protrusion spacers. Further, 17 at the lower left of b) is a semiconductor element formed by the above-described procedure. Actually, a transparent insulating ceramic film for preventing diffusion of impurities from glass, a protective insulating film for covering the semiconductor element 17, and the like may be formed. However, these are the same as the formation of the semiconductor element itself. The purpose of the present invention is not directly related and is not shown because it is complicated. This is the same in other drawings.

Next, a transparent conductive film (ITO: indium tin oxide monoxide) was formed.

Next, a projection as a spacer is formed. This forming method was performed as follows using a photosensitive acrylic resin (PC335: manufactured by JSR).

Photosensitive acrylic resin (PC335: JSR
Is applied on the substrate by spin coating,
For 1 minute. Thereafter, exposure was performed at 300 mj / cm ² using a predetermined mask. Thereafter, development was performed with a developing solution CD702AD at 25 ° C. for 1 minute, washed with running water, and post-baked at 220 ° C. for 1 hour (the temperature was raised from room temperature) to form a projection having a thickness of 5.0 μm.

In this case, the projection is formed so as to be located in the display portion but not at the position of the pixel electrode when bonded to the array substrate, for example, at the position 61 shown in FIG. 15A. ing. In addition, for this reason, the color filter was formed on the substrate 102 on the side of the color filter. In FIG. 15 (b), the protrusion spacer formed at this location 61 is visible on the opposite side of the AA cross section. Further, the resin was formed on the color filter substrate side where the resin 5 to be sealed was formed.

The area of the projection is 100 μm in a square having a side of 10 μm in both the display area and the seal area.
^2. The area of the upper surface was set to 64 μm ^{2 as} a square having a side of 8 μm, and the area of the upper surface / the area of the lower surface was set to 0.64.

Here, the density of the projections is 10 / mm ² in the display area and 40 / mm ² in the seal area. .

Next, the alignment film 4 (AL5417: manufactured by JSR) is printed on the substrate on which the array is formed and the counter substrate, and after hardening, rubbing (processing) is performed. In this rubbing, since a projection was formed, a soft nylon cloth using a thin thread was used. In addition, rubbing near the place where the protrusions are formed may have an incomplete portion, but since it is a black matrix portion, there is no adverse effect on display performance. Also, in order to obtain a perfect orientation near the place where the protrusions are formed,
Instead of rubbing, other orientation treatments such as ultraviolet irradiation may be used. Of course, you may use together.

Next, a seal resin (Stract Bond: manufactured by Mitsui Toatsu) 5 is printed on the edge portion of the counter substrate 102 with a width of 2 mm.

Thereafter, the two substrates were bonded together and heated at 150 ° C. for 2 hours to cure the sealing resin.

A liquid crystal (MT5087: manufactured by Chisso Corporation) was injected into the empty panel manufactured as described above by a vacuum injection method.

Thereafter, a photocurable resin (Loctite 352A: manufactured by Nippon Loctite) was applied to the entire injection port of the liquid crystal panel as a sealing resin, and cured by irradiating light at 10 mW / cm ² for 5 minutes.

Thereafter, polarizing plates (NPF-HEG1425DU: manufactured by Nitto Denko; not shown for the above-mentioned reasons) were attached to the upper and lower sides of the panel composed of both substrates.

For the sake of comparison, a resin ball 71 (Eposter-GP-H5) having a diameter of 5.0 μm was used as a spacer in the display area instead of forming a projection to keep the cell thickness constant.
0: Nippon Shokubai Co., Ltd.), and a glass fiber 19 (PF-50) having a short axis diameter of 5.0 μm as a seal portion.
S: manufactured by Nippon Electric Glass Co., Ltd.) was manufactured using a liquid crystal panel mixed with a sealing resin. This is shown in FIG. In this figure, the glass fiber has a circular cross section. The other conditions are the same.

When these two liquid crystal panels were compared with each other, good alignment was observed in the liquid crystal panel on which the projections were formed, but the liquid crystal panel using the dispersion spacer of the comparative example had a certain cell thickness due to the reasons described above. Is unavoidable, and the display becomes slightly non-uniform when reference is made to severe or high display levels in the future.
In addition, in the comparative example, the degree of mixing of the glass fiber in the seal portion is inevitably varied depending on the location, so that the seal is somewhat non-uniform, and the rigidity and hardness vary somewhat depending on the location. These are not very favorable in recent years, as users and consumers demand for display quality and the like become more sophisticated.

Next, the shape of the projection, particularly the ratio of the area of the upper surface (display side surface) to the area of the lower surface, is 0.2 <area of the upper surface / area of the lower surface <0.9. desirable. That is, if the area of the upper surface is too small (smaller than 0.2), rigidity is inevitably reduced, so that it is difficult to form an accurate cell thickness, and if the area of the upper surface is too large (greater than 0.9). This is because alignment defects such as disclination tend to occur. Incidentally, such an area ratio of the upper and lower surfaces can be achieved by rapidly performing post-baking to generate heat dripping, but other means such as irradiating ultraviolet rays obliquely from a plurality of directions. It is possible.

However, this area ratio is appropriately selected in accordance with the type of liquid crystal to be used, the dimensions of the pixels, the use of the panel, the formation position on the panel, and the like, and may have a value outside this range. Obviously you get it. Further, in the case where the spacer is formed not on the array side substrate but on the opposite substrate, the projection spacer is of course not applicable.

Depending on the conditions such as the difference in the required vertical dimension of the protrusions and the like, instead of forming the alignment film, the spacer may be formed by using an alignment film forming material layer film before forming the columnar protrusion spacer. It is a matter of course that a lower layer may be formed, and irradiation of ultraviolet rays or oblique deposition or application of a chemical substance may be performed under the lower layer so as to act as an alignment film while compensating for the difference.

(Twelfth Embodiment) This embodiment is different from the twelfth embodiment in that
It is the same as the previous embodiment except that a film for adjusting the height is formed below the protrusions in order to make the cell thickness uniform.

The array side substrate is particularly so, but the height differs in the seal portion, the pixel portion and the like. Therefore, as shown in FIG. 17, a film 154 for height adjustment is formed in advance below the protrusion spacer in the region where the seal 5 is formed. This film may be a metal such as Al or Cu or a resin.

By forming the film for adjusting the height in this way, the substrate has irregularities depending on the location. However, the height of the protrusion spacers is the same, so that not only a uniform cell thickness can be ensured, but also each protrusion can be secured. Since the rigidity of the object spacers is the same, it is easy to sufficiently form the panel by sufficiently satisfying the rigidity required for the panel depending on the location such as the seal portion and the display portion. It is to be noted that, although this film is different from the film shape shown in the figure, it is needless to say that the film may be formed only directly below the protrusion spacer.

(Thirteenth Embodiment) This embodiment is a modification of the thirteenth embodiment.
This is the same as the eleventh embodiment except that the density of the protrusions is changed.

Table 1 shows the results of the display quality when the density of the projections in the display area and the density of the projections in the sealing area were changed.

[0315]

[Table 1]

As shown in this table, if there are too many projections in the display area, the liquid crystal panel itself becomes too hard, and when a temperature change occurs, expansion and contraction of the projections are caused by expansion and contraction of the liquid crystal. Since it does not follow, there is a possibility that bubbles may be generated.

If the number of protrusions in the display area and the seal area is too small, they will not serve as a spacer.

Since the projections in the sealing region are in the sealing resin, they are not in contact with the liquid crystal, so that the influence of expansion and contraction of the liquid crystal is small. On the other hand, a difference in expansion coefficient from the sealing resin becomes a problem, but the difference can be reduced by forming the protrusions with the resin. Therefore, the density of the protrusions in the seal region can be higher than that in the display region. Also, higher than the density,
Increasing the rigidity of the seal reduces the distortion of the panel,
A liquid crystal panel with a uniform display can be obtained.

As described above, the density of the protrusions in the display area is 5
Pieces / mm ² 50 or more / mm ² or less, the density of the protrusions of the seal region has been found that it is possible to 80 10 / mm ² or more pieces / mm ² or less. More preferably, the density of the projections in the display area is 10 / mm ² or more and 15 / m ²
m ² , the density of protrusions in the seal area is 30 / mm
^It is good to be ² or more and 50 pieces / mm ² or less.

(Fourteenth Embodiment) This embodiment also
This is the same as the eleventh embodiment except that the size and density of the protrusion are changed.

Now, regarding the size and density of the projections in the display area, the lower surface is a square with a side of 10 μm and 100 μm.
^{2. The} upper surface was a square of 8 μm on a side and 64 μm ^2, and the area of the upper surface / the area of the lower surface = 0.64.

The protrusions in the seal area have a lower surface of a square having a side of 20 μm of 400 μm ² and an upper surface of a protrusion of 15 μm.
In square and 225 .mu.m ^2, and the upper surface area / lower surface area = 0.5625.

Further, the density of the projections was set to 20 / mm ² in both the display area and the seal area.

By forming the projections in the sealing area larger than the projections in the display area, the sealing portion can be made strong, so that the panel is less distorted and uniform. A display liquid crystal panel was obtained.

(Fifteenth Embodiment) The present embodiment also
This is the same as the eleventh embodiment except that the ratio of the area of the lower surface of the projection is changed.

Table 2 shows the results of the display quality when the area ratio of the projections formed in the display area to the display area and the area ratio of the projections in the seal area to the seal area were changed.
Shown in

[0327]

[Table 2]

As is clear from this table, if the area occupied by the protrusions in the display area is too large, the liquid crystal panel itself becomes too hard, and when the temperature changes, the expansion and contraction of the liquid crystal causes the expansion of the protrusions. Since shrinkage does not follow, air bubbles may be generated. On the other hand, if the area occupied by the protrusions in the display area is too small, it becomes difficult to function as a spacer.

Also, in the sealing region, if the area occupied by the projections is too small, it will not serve as a spacer. However, as in the thirteenth embodiment and the like, the protrusions in the sealing area are not in contact with the liquid crystal, so that the expansion and shrinkage of the liquid crystal have little effect. Since the size can be reduced by forming, the area occupied by the protrusion can be made larger than that in the display region. As a result, even if the seal portion is firmly fixed, no problem is caused in the display or the like. On the other hand, a liquid crystal panel with less distortion of the panel and a uniform display can be obtained.

As described above, the ratio of the protrusions formed in the display area to the display area is 0.05% or more and 0.5% or more.
Hereinafter, it is preferable that the ratio of the protrusions formed in the region where the seal is formed to the seal region be 0.1% or more and 1.0% or less.

(Sixteenth Embodiment) The present embodiment is a
The liquid crystal injection was devised. Except for the method of injecting the liquid crystal, it is the same as the eleventh embodiment.

In the eleventh embodiment, the liquid crystal is injected by using the vacuum injection method. In this embodiment, the liquid crystal is injected by the following method.

First, the process is the same as that of the eleventh embodiment up to the point where an alignment film (AL5417: manufactured by JSR) is printed on the substrate on which the array is formed and the opposite substrate and rubbing is performed.

Thereafter, a UV (ultraviolet) curable resin (World Lock 886M:
(Kyoritsu Chemical). Then, a predetermined amount of liquid crystal is dropped at a certain position on the display area of the counter substrate filled with the liquid crystal by using a dispenser (a liquid application / injection device used in the liquid crystal field).

Next, the two substrates were bonded together in a low vacuum of 0.1 Torr, the display area was covered with a light-shielding mask, and only the seal portion was irradiated with 1500 mj of UV light to cure the seal.

Next, the liquid crystal panel was placed in a high-temperature bath at 110 ° C. for 1 hour so that the dropped liquid crystal spread all over the display area.

FIG. 18 schematically shows how this liquid crystal is injected.

In the conventional vacuum injection, as shown in (a) of the figure, the liquid crystal enters from one injection port 30 in the panel and spreads over the entire panel. Is large and takes time. In particular, when the injection is started (when the liquid crystal is injected into the panel by returning the inside of the tank to normal pressure), the liquid crystal suddenly flows into the empty panel. In this case, the liquid crystal is affected by the protrusions in the display area, and there is a risk that impurities in the protrusions may be dissolved in the liquid crystal, which may cause uneven alignment and display failure.

On the other hand, as shown in (b) of the figure, when the liquid crystal is dropped on a large number of places on the substrate, and then the two substrates are bonded to fill the panel with the liquid crystal. Since the flow of the liquid crystal from the dropping point 80 is weak, the flow area is small, and the time is short, the liquid crystal is not easily affected by the spacer at the time of injection, and there is no display unevenness, and a liquid crystal panel with good display quality can be obtained. did it. In addition, a) of this figure,
The arrow shown in b) is the flow of the liquid crystal, and its thickness,
The length indicates the strength of the flow.

Further, since only the sealing resin is irradiated with ultraviolet rays, the liquid crystal is not deteriorated by heat or ultraviolet rays.

(Seventeenth Embodiment) This embodiment is different from the eleventh embodiment in that a projection is formed on the array substrate side.

FIG. 19 shows the structure of the liquid crystal panel of the present embodiment.

Hereinafter, the liquid crystal panel shown in this figure will be described.

First, in the manufacture, Al is placed on a glass substrate.
Then, a gate electrode is selectively formed using a metal such as, for example, and then SiNx serving as a first gate insulating film is formed to a thickness of 3000 ° using a plasma CVD method.

After the substrate is washed, a resist is applied by a spinner, and mask exposure is performed so that a part of the insulating film 2 is not formed on the pixel electrode (therefore, up to this point, This is the same as the eleventh embodiment).

Next, a projection is formed. As the formation method, a photosensitive acrylic resin (PC335: manufactured by JSR)
Was carried out as follows.

A photosensitive acrylic resin (PC335: JSR
Is applied on the substrate by spin coating,
For 1 minute. Thereafter, exposure was performed at 300 mj / cm ² using a predetermined mask. Thereafter, development was performed with a developing solution CD702AD at 25 ° C. for 1 minute, washed with running water, and post-baked at 220 ° C. for 1 hour (the temperature was raised from room temperature) to form a projection having a thickness of 5.0 μm.

The projections are formed on the side of the array substrate which does not interfere with the pixel electrodes.

Note that, of course, a projection 60 is also formed on the array substrate 1 side where the sealing resin 5 is formed. Here, the density of the protrusions is 10 / mm ² in the display area,
In the sealed area, 40 pieces / mm ^{2 were} formed. The area of the projections in both the display area and the seal area is 100 μm ^{2 for} a 10 μm-square lower surface and 64 μm ^{2 for an} 8 μm-square upper surface, and the area of the upper surface / the area of the lower surface = 0. 64.

[0350] A color filter layer is formed on the opposite glass substrate 102. This color filter layer 155
A colored resist in which a pigment is dispersed in an acrylic photosensitive resin is applied onto a substrate, exposed, and then developed (photolithography) four times in total for each color (red, green, blue and black). Obtained by repeating.

Next, a transparent conductive film (ITO: indium oxide tin oxide) was formed.

Next, an alignment film 4 (AL5417, manufactured by JSR) is formed on the substrate 101 on which the array is formed and the counter substrate 102.
Was printed and cured, and then subjected to a rubbing treatment.

Next, a seal resin (Struct Bond: manufactured by Mitsui Toatsu) is printed on the edge of the counter substrate. Thereafter, the two substrates were bonded together and heated at 150 ° C. for 2 hours to cure the sealing resin.

Liquid crystal (MT5087: manufactured by Chisso Corporation) was injected into the empty panel manufactured as described above by a vacuum injection method.

Thereafter, a photocurable resin (Loctite 352A: manufactured by Nippon Loctite) was applied to the entire injection port of the liquid crystal panel as a sealing resin, and light was applied at 10 mW / cm.
Irradiation was performed for 5 minutes at ² to cure the sealing resin.

Thereafter, a polarizing plate (NPF-HEG1425DU: manufactured by Nitto Denko) was attached to the top and bottom of the panel (outside of the glass substrate). This state is shown in FIGS. 19B and 19C. These correspond to FIGS. 15B and 15C. In this drawing, a columnar protrusion spacer 6,
Since 60 is formed on the array-side substrate 101, it can be clearly seen that the substrate side is thin.

Also in the liquid crystal panel of the present embodiment, uniform display was observed at the center of the display area and near the seal. Further, in the present embodiment, by forming the projections, the step of mixing the glass fiber into the sealing material, the step of dispersing the spacer, and the preliminary dispersing step and the cleaning step of the dispersing device associated therewith are unnecessary. .

[0358] In this embodiment, the projection is formed of a photosensitive resin, but may be formed of an insulating film such as SiNx instead of the photosensitive resin. By forming with an insulating film such as SiNx or SiO _2, it can be formed by a conventional array process, so that material arrangement and factory equipment can be reduced.

Further, as shown in FIG.
A flattening layer 153 is formed on a switching element such as a resin or an insulating film such as SiNx capable of easily flattening the surface by spin coating or the like.
1 and the protrusion 60 may be formed. With such a structure, the area of the pixel electrode can be increased.

Further, as shown in FIG. 20C), a resin film 154 for height adjustment may be formed including the seal portion, and the projection spacer 69 may be formed thereon.

As a result, the height of the protrusion spacers becomes the same regardless of the height of each part of the array-side substrate, and the formation of the protrusion spacers is completed in one step.

The flattening film 153 and the height adjusting film 154 may be formed of the same material and in the same process, and the flattening film may serve as an alignment film. In this case, the display portion of the pixel, which is at the highest position due to the formation of the pixel electrode, the insulating film, and the like, has the thinnest flattening film, and thus has less light absorption. Functions can be exhibited.

It is needless to say that a color filter such as a reflection type liquid crystal display device may also be used.

In this case, it goes without saying that the pixel electrode may overlap the source electrode and the gate electrode. It should be noted that b) and c) in FIG. 20 correspond to b) and c) in FIGS.

(Eighteenth Embodiment) This embodiment is a modification of the eighteenth embodiment.
Except for the method of injecting liquid crystal, it is the same as the seventeenth embodiment.

In the present embodiment, the liquid crystal is injected according to the first method.
The liquid crystal is dropped on the substrate similarly to the sixth embodiment.

[0367] After the liquid crystal is dropped on the substrate, the two substrates are bonded to each other. When the liquid crystal is injected, the flow of the liquid crystal is weak, the flowing area is small, and the time is short. A liquid crystal panel having good display quality without display unevenness was obtained.

(Nineteenth Embodiment) This embodiment is a modification of the nineteenth embodiment.
A color filter is formed on the array side together with the protrusion spacer.

FIG. 21 shows the structure of the liquid crystal panel of the present embodiment.

Hereinafter, the liquid crystal panel shown in this figure will be described.

FIGS. 21 (b) and 21 (c) correspond to FIGS.
20) correspond to b) and c).

In this drawing, reference numerals 6 and 60 are columnar projection spacers. 155 is an R, B, or G color filter, and 156 is a black color filter, all of which are formed on the array substrate side.
Reference numeral 201 denotes an electrode on the lower substrate 101 side, and reference numeral 202 denotes an electrode on the upper substrate 102 side. Reference numeral 4 denotes an alignment film. Fifteen
Reference numeral 4 denotes a height adjusting film.

Hereinafter, a method for manufacturing this liquid crystal display device will be described.

As in the eleventh embodiment, a gate electrode was selectively formed on a glass substrate using a metal such as Al.

The following is the same as the eleventh embodiment up to the point that SiNx is formed to a thickness of 3500 ° by the plasma CVD method as the second insulating film.

Next, the color filter layer 155 is
Unlike the first embodiment, it is formed on the array substrate 101 side.

The color filter layer 155 is formed by applying a colored resist in which a pigment is dispersed in an acrylic photosensitive resin onto a substrate, exposing the substrate to light, and then developing the substrate (photolithography method). (Blue and black) once, a total of four times.

A transparent conductive film (IT) is formed on the color filter layer.
O: indium oxide tin oxide).

Next, a projection 60 was formed. The formation was performed by the following method using a photosensitive acrylic resin (PC335: manufactured by JSR).

A photosensitive acrylic resin (PC335: JSR
Is applied on the substrate by spin coating,
For 1 minute. Thereafter, exposure was performed at 300 mj / cm ² using a predetermined mask. Thereafter, development was performed at 25 ° C. for 1 minute with a developing solution CD702AD, washed with running water, and post-baked at 220 ° C. for 1 hour (the temperature was raised from room temperature) to form a projection having a thickness of 3.0 μm.

[0381] The projections were formed at portions where the pixel electrodes were not hindered.

Also, as shown in FIG. 21C, a projection is also formed on the side of the array substrate 101 where the sealing resin is formed. A film 6 for height adjustment is provided under the protrusion 6.
2 is formed in advance. This film may be a metal such as Al or Cu, or a resin or the like. At this time, the formation density of the protrusions was 10 / mm ² in the display area and 40 in the seal area.
Pieces / mm ² . Also, the area of the protrusion is within the display area,
In the sealing region, the area of the lower surface is 100 μm ^{2 for} a square having a side of 10 μm, and the area of the upper surface is 6 for a square having a side of 8 μm.
4 μm ² and the area of the upper surface / the area of the lower surface = 0.64.

[0383] A transparent conductive film (ITO: indium oxide tin oxide) was formed on the opposite glass substrate.

Next, an alignment film 4 (AL5417, manufactured by JSR) is formed on the substrate 101 on which the array is formed and the counter substrate 102.
Was formed by printing and curing, followed by rubbing.

Next, a seal resin (Struct Bond: manufactured by Mitsui Toatsu) was printed on the edge of the opposing substrate.

Thereafter, the two substrates were bonded together and heated at 150 ° C. for 2 hours to cure the sealing resin.

A liquid crystal (MT5087: manufactured by Chisso Corporation) was injected into the empty panel manufactured as described above by a vacuum injection method.

Thereafter, a photocurable resin (Loctite 352A: manufactured by Nippon Loctite) was applied as a sealing resin to the entire injection port of the liquid crystal panel, and light was irradiated at 10 mW / cm ² for 5 minutes to cure the sealing resin. Was.

Next, a polarizing plate (NPF-H) was placed above and below the panel.
EG1425DU: manufactured by Nitto Denko).

In the liquid crystal panel of the present embodiment, uniform display was observed even in the center of the display area and its periphery, that is, near the seal.

By forming the color filters on the array side as in this embodiment, it is possible to widen the margin of the alignment accuracy between the array substrate and the counter substrate.

In this embodiment, the protrusions are formed of a photosensitive resin, but may be formed of a material of a color filter such as a black matrix. As a result, since it can be formed in the conventional manufacturing process, material costs, process equipment, and the like can be reduced.

(Twentieth Embodiment) This embodiment is different from the twentieth embodiment in that
This is the same as the nineteenth embodiment except that the liquid crystal injection method is changed.

For the injection of the liquid crystal, the liquid crystal was dropped on the substrate in the same manner as in the sixteenth embodiment.

As a result, as in the case of the sixteenth embodiment, good display was obtained.

(Twenty-First Embodiment) The present embodiment is a
Projections are formed on the array side and the counter substrate side.

FIG. 22 and FIG. 23 show a liquid crystal panel of the present embodiment. 22) b) and c) correspond to b) and c) of FIG. 15 and the like.

In the present embodiment, as shown in FIG. 22B and FIG. 23, the columnar protrusion spacers 60 are formed on the alignment film 4 on the counter substrate 102 side in the pixel portion. Is formed at the substrate end on the array substrate 101 side. In addition, due to the convenience of forming other films, the length on the array substrate side is longer.

Hereinafter, a method of manufacturing this liquid crystal panel will be described.

As in the eleventh embodiment, a gate electrode is selectively formed on a glass substrate by using a metal such as Al.

Thereafter, after the substrate is washed, a resist is applied by a spinner, and mask exposure is performed, so that a part of the insulating film is not formed on the pixel electrodes 13 until the resist is applied. This is the same as the embodiment.

Next, a projection is formed. The method of forming the projection is a photosensitive acrylic resin (PC335: JSR
Was performed as follows.

A photosensitive acrylic resin (PC335: JSR
Is applied on the substrate by spin coating,
For 1 minute. Thereafter, exposure was performed at 300 mj / cm ² using a predetermined mask. Thereafter, development was performed with a developing solution CD702AD at 25 ° C. for 1 minute, washed with running water, and post-baked at 220 ° C. for 1 hour (the temperature was raised from room temperature) to form a projection having a thickness of 5.0 μm.

[0404] The projections are formed at positions not interfering with the pixel electrodes, for example, at the position indicated by reference numeral 61 in Fig. 15A.

Also, a projection is formed on the array substrate side where the sealing resin is to be formed.

[0406] During these, the formation density of the projections is within the display area 5 / mm ^2, the sealing area was 20 / mm ^2.

[0407] The area of the protrusion is a square having a side of 10 µm on one side in both the display area and the seal area.
00 μm ² , the area of the upper surface is 64 μm in a square of 8 μm on a side
m ² and the area of the upper surface / the area of the lower surface = 0.64.

Next, a color filter layer was formed on the opposite glass substrate. This color filter layer is formed by applying a colored resist in which a pigment is dispersed in an acrylic photosensitive resin onto a substrate, exposing the substrate, and then developing (photolithography method) each color (red, green, blue and black). Obtained by repeating a total of four times each time.

Next, a transparent conductive film (ITO: indium tin oxide monoxide) was formed. Next, a projection is formed. The method for forming the protrusions 60 was the same as the method for forming the protrusions formed on the array side, but the coating conditions were changed so that the film thickness (height) was 6 μm.

Next, after an alignment film 4 (AL5417: manufactured by JSR) was formed on the substrate on which the array was formed and the counter substrate by printing and curing, rubbing was performed.

Next, a seal resin wall (Stract Bond: manufactured by Mitsui Toatsu) was formed on the edge of the counter substrate by printing.

Thereafter, the two substrates were bonded together and heated at 150 ° C. for 2 hours to cure the sealing resin.

A liquid crystal (MT5087: manufactured by Chisso Corporation) was filled into the empty panel manufactured as described above by a vacuum injection method.

Thereafter, a photocurable resin (Loctite 352A: manufactured by Nippon Loctite) was applied to the injection port of the liquid crystal panel, and was irradiated with light at 10 mW / cm ² for 5 minutes to be cured.

Finally, a polarizing plate (NPF-
HEG1425DU: manufactured by Nitto Denko).

In the liquid crystal panel of this embodiment, uniform display was also observed in the vicinity of the center of the display area and the periphery of the seal.

[0417] In the present embodiment, by forming projections on both sides of the array substrate and the opposing substrate, the liquid crystal panel is held down from both substrates, so that a robust liquid crystal panel can be obtained.

In this embodiment, the projections are formed on the display portion and the seal portion of the substrate on both the array side and the opposite side. However, the display portion and the seal portion may be formed separately. For example, a protrusion is formed only on the display portion on the array substrate side, and a protrusion is formed only on the seal portion on the counter substrate side. Alternatively, the reverse is performed.

In this embodiment, the projections on both substrates are formed by the same method, but they may be formed by different methods.

(Twenty-second Embodiment) The present embodiment is directed to
This is the same as the twenty-first embodiment except that the liquid crystal injection method is changed.

In this embodiment mode, the liquid crystal is injected by the dropping method as in the sixteenth embodiment mode.

Therefore, as in the previous embodiment, a liquid crystal panel having no display unevenness and good display quality could be obtained.

(Twenty-third Embodiment) This embodiment is directed to
The protrusion 60 surrounds the entire area where the seal is formed.
4 is formed continuously, and the other is the 18th
This is the same as the embodiment.

FIG. 24 shows this state. As shown in this drawing, by continuously forming the projections 604, it is possible to manufacture a highly reliable liquid crystal panel which is hardly affected by moisture or the like from the outside.

In this case, the projection spacer is
It may be formed on a color filter (not shown) on the substrate surface. Further, as shown in FIG. 25, the projection spacer 605 may be formed so as to form the injection port 30 so as to facilitate the production of the liquid crystal panel by vacuum injection.

(Twenty-fourth Embodiment) This embodiment is different from the twenty-fourth embodiment.
The present invention relates to a reflective liquid crystal panel.

FIGS. 26A and 26B are views showing the structure of the main part of the liquid crystal panel of the present embodiment, wherein a) is a display area and b) is a cross section of an end. In this drawing, reference numeral 203 denotes a reflector and a lower electrode formed on a lower substrate. Reference numeral 202 denotes a conductive film on the upper substrate side. 155r, 155g and 155b are red, green and blue color filters, respectively. Furthermore, these color filters also serve as a black matrix by being left over in a non-display area of a pixel. In addition,
Needless to say, unnecessary color filters are removed from the display area of the pixels.

Reference numeral 4 denotes an alignment film. Reference numeral 170 denotes various film layers on the upper surface of the lower substrate.

Now, in a), reference numeral 60 indicates 61 in FIG.
And the like are protrusion spacers formed on the black matrix portion. (Therefore, in this portion, the above-mentioned three color filters are all present.) Reference numeral 6 denotes an elastic projection spacer formed at the end of the panel.

In the present embodiment, the alignment films 4 on the upper and lower substrates are formed by spin coating, and at this time, they also serve as flattening films for erasing projections and depressions on the upper and lower substrates. For this reason, the elastic protrusion spacers have the same height in both the display region portion 60 and the non-display region.
Consequently, they can be formed in the same process.

Furthermore, since the space between the upper and lower substrates is flat, there is no danger that when filling the empty panel with liquid crystal, even if the vacuum injection method is not used, the slight gas present in the convex and concave portions will remain as bubbles. Absent.

Further, since there is a small amount of an elastic body composed of a color filter and an alignment film between the upper and lower hard glass substrates, expansion and contraction of the liquid crystal due to a change in humidity can be absorbed without difficulty. In addition, the resistance to the impact applied to the glass substrate due to any error of the user is improved to some extent.

(Twenty-fifth Embodiment) This embodiment is different from the twenty-fifth embodiment in that
The present invention relates to a liquid crystal of a polymer dispersion type or a liquid / fat filter mixed type.
FIG. 27 illustrates a method for manufacturing a liquid crystal panel of the present embodiment.

In this figure, a) shows the lower substrate 101
5 shows a state in which the elastic projection spacer 60 is formed in the black matrix portion in the display area and the wall-shaped projection spacer 603 is formed outside the display area. b) is a sectional view taken along the line AA. c) is a wall-shaped protrusion spacer 60 on the outer peripheral portion of the substrate.
A state in which a predetermined liquid crystal and resin mixture 32 is filled in a region surrounded by 3 and ultraviolet light or heat indicated by an arrow is applied. d) is a state where the liquid crystal and the resin are separated by this. The left side of the present d) is formed in the resin 34 layer in which the droplets 33 of the polymer dispersed liquid crystal are solidified. On the right is the liquid crystal layer 35
Are separated at the bottom, and the resin film 36 is separated at the top. And
In any of these cases, the projection spacer forms a liquid crystal or resin layer having a certain thickness on the substrate, and after the formation, protects the layer.

Based on the above, an organic conductive film is formed on the upper portion and the substrate is bonded as needed, and the substrate is bonded to a substrate having a liquid crystal layer of another color as shown in FIG. You. In the latter case, if necessary, the liquid crystal has a fine capsule containing predetermined pigment particles 2, and the capsule after the liquid crystal layer or the liquid crystal particle droplets have been formed is subjected to heat, ultraviolet light, liquid crystal or the like in advance. Particles such as cyan, magenta, and yellow in the capsules are destroyed by the mixed chemicals and the like, and are dispersed in the liquid crystal.

Although the present invention has been described with reference to some embodiments particularly taking a liquid crystal display device as an example,
Of course, the present invention is not limited to these. That is, for example, the following may be performed.

[0437] 1) A display device having a plurality of liquid crystal layers
Instead of an H cell, a double matrix type, a three-division double matrix type, or a projection type liquid crystal display as shown in FIG. Further, the liquid crystal is a color filter for a plasma panel or the like. 2) As a liquid crystal, not only E-7 (manufactured by BDH) having a positive dielectric anisotropy but also E-8 (BDH) or ZLI4792 (manufactured by Merck) or the like. TL202 (manufactured by Merck) or the like is used. Alternatively, ZLI4788 (manufactured by Merck) having a negative dielectric anisotropy is used. In this case, it is desirable to use a vertical alignment film as the alignment film.

3) Further, other types of liquid crystal such as a ferroelectric liquid crystal and an antiferroelectric liquid crystal are used instead of the nematic liquid crystal.

As the material of the alignment film, another material is used.

4) Three-terminal TFT as an active element
Instead of a two-terminal element MIM (Metal-Insul
ator-Metal), a ZnO varistor, a SiNx diode, an a-Si diode and the like. Alternatively, the present invention is applied to a passive type panel such as TN or STN where no active element is formed.

5) A flattening film such as polyimide is formed on SiNx.

6) In the liquid crystal mode, a vertical alignment method or a method using an in-plane switch (in-plane switch) is used.
g) and so on.

7) The pixels are formed of a metal such as Al instead of ITO and used as a reflection panel.

8) One or both of the substrates are made of film, plastic, or the like.

9) The opposite substrate is not a glass substrate with ITO but a substrate with a color filter or a substrate with a color filter formed on the array substrate side. Further, in this case, the protrusion spacers are formed on the array substrate, the opposing substrate, or both.

10) As the spherical or fibrous resin for the spacer in the seal portion, an acid-modified polyethylene or polypropylene pet or the like is used.

Also, a nylon resin or a fluorine resin is employed as the sealing resin.

11) With the development of future technologies, semiconductors other than polysilicon are used as semiconductors for pixels and elements for driving the pixels.

12) Since the projections are formed along or instead of the black matrix of the color filter, the projections are generally lattice-shaped as a whole even if there are notches or the like at various places for convenience of liquid crystal injection.

When a multi-layer liquid crystal layer is provided, it is formed substantially in a lattice at the boundary between pixels.

13) The protrusion is not HRC-126, but P
C403, PC335, PC339H, JNPC-43
(All manufactured by JSR Corporation).

14) About 90% of the rod-shaped projections shown in FIG. 7 are partially cut off, thereby exerting other functions such as alignment of liquid crystal molecules while eliminating excessive rigidity of the panel. .

15) The shape of the projection may be smaller than the height depending on the size, other conditions and applications.

16) The color filter is formed not by photolithography or pigment dispersion but by printing, ink-jet, electrodeposition, or dyeing.

17) The projections are also formed by a printing method or an ink-jet method.

18) FIGS. 28 and 29 show the case where the present invention is applied to a plasma addressed liquid crystal display (PALC). This is a combination of plasma and liquid crystal, and uses plasma as a switching element to drive the liquid crystal.

In FIG. 28, reference numeral 501 denotes a plasma glass substrate. Reference numeral 502 denotes a Ni electrode. 503 is a rib. 504 is a thin plate glass. 505 is
It is a frit. 506 is a protrusion spacer. 5
Reference numeral 07 denotes a liquid crystal sealant. 508 is a liquid crystal layer. 509 is a front plate.

In FIG. 29, reference numeral 701 denotes a backlight. 702 is a cathode. 703 is an anode. 704 is a polarizing plate. 705 is a back plate. 706 is a partition. 707 is an insulating plate. 708 is a liquid crystal layer. 709 is a front plate. 710 is a polarizing plate. 711
Is a striped color filter. 712
Is a transparent electrode made of ITO. It goes without saying that there are various modifications in details such as a color filter on the front plate.

The PALC is basically a TFT-L
In this example, the TFT array portion of the CD is replaced with a plasma channel. However, the detailed principle and detailed operation of each part are described in, for example, “Monthly LCD Intell.
gene, No. 1997, No. 2 ". Therefore, the description is omitted.

In any case, a projecting spacer (a material may be metal in some places) can be adopted for a spacer of each part and a seal part of gas or liquid crystal.

[0461]

As can be seen from the above description, according to the present invention, compared with glass wool or the like, the liquid crystal seal portion provided in the drive circuit portion around the display area of the liquid crystal panel maintains the distance between the substrates. The spacers can damage the peripheral drive circuit even if an excessive pressing force is applied when bonding the substrates, especially when the sealing resin is cured, because of the use of a soft resin spacer. Disappears.

Also, since a resinous spherical spacer is employed in the seal portion formed on the drive circuit portion in order to keep the distance between the substrates constant, it can be used at the time of bonding the substrates, particularly at the time of curing the sealing resin. Even if excessive pressing force is applied,
This spacer does not destroy the peripheral driving circuit. Further, in this case, since it is spherical, unlike a fiber, the spacer does not overlap, and no inconvenience occurs even if it is mixed in the sealing resin in advance.

Also, since a protrusion made of an elastic material for keeping the distance between the substrates constant is formed on a seal portion formed on the drive circuit portion so as to avoid a portion which is easily damaged such as an element of a peripheral drive circuit. Even if excessive pressing force is applied at the time of laminating the substrates, especially when the sealing resin is cured, not only will the spacer not destroy the peripheral drive circuit, but also the excessive The resistance to damage is also improved with respect to pressing or the like.

Also, in the display area of the liquid crystal panel,
Since the projections for keeping the distance between the substrates constant are formed avoiding the pixel portion, the alignment of the liquid crystal molecules is not disturbed or the light is not transmitted, so that the display is more excellent than before. Further, in this case, since the pixels in the display region do not have spacers, the spacers do not disturb the alignment or scatter the light, so that a better display can be obtained.

In particular, in a panel of a system having a plurality of liquid crystal layers for the purpose of color display or the like, this effect is enhanced. Further, in this case, it is possible to flexibly cope with the difference in the thickness of each resin layer.

Further, a step of dispersing a spherical spacer or the like becomes unnecessary.

Furthermore, in this case, it can be used for electrical connection between the substrates of each layer.

Furthermore, by forming the display area and the projection of the seal portion in the same step, etc., the steps can be omitted,
It also leads to material savings.

Further, by providing a rod-like projection in the pixel to control the arrangement of liquid crystal molecules, the viewing angle characteristics and the response can be improved.

Further, since the formation density can be easily changed between the seal portion and the display portion, a liquid crystal panel having excellent rigidity as a panel and display characteristics as a display device can be obtained.

In the manufacture of a liquid crystal display device of a polymer dispersion type or a simultaneous formation of a liquid crystal and a resin for a panel, the thickness accuracy of the liquid crystal layer can be secured and the liquid crystal layer can be protected after the manufacture. Liquid crystal display device is inexpensive and has high performance.

As a result, a small size using polysilicon,
A high-performance and highly reliable liquid crystal display device can be provided.

Further, a liquid crystal panel with better display quality without defects can be obtained even if it does not employ polysilicon.

Also, the present invention can be applied to a display using a liquid crystal, for example, an image projection display, a color filter of a plasma display, and a windshield which also serves as a color filter. The effect is obtained.

[Brief description of the drawings]

FIG. 1 is a diagram showing a small-sized device in which a driving circuit is provided around a display area on a substrate in addition to the use of polysilicon which is being developed and put into practical use in recent years, and a liquid crystal sealing portion is provided on the driving circuit. FIG. 2 is a plan view of the liquid crystal panel of FIG.

FIG. 2 is a diagram showing an outline principle of a liquid crystal display device without a color filter and an example of a structure of a seal portion.

FIG. 3 is a sectional structural view of a main part of the liquid crystal panel according to the first embodiment of the present invention.

FIG. 4 is a diagram showing a relationship between an applied load (pressing force) and an amount of (shrinkage) deformation of the spherical resin spacer employed in the first embodiment.

FIG. 5 is a sectional structural view of a main part of a liquid crystal panel according to a second embodiment of the present invention.

FIG. 6 is a sectional structural view of a liquid crystal panel according to a third embodiment.

FIG. 7 is a sectional structural view of a liquid crystal panel according to a fourth embodiment.

FIG. 8 is a sectional view and a plane structural view of a main part of a liquid crystal panel according to a fifth embodiment.

FIG. 9 is a sectional structural view of a main part of the liquid crystal panel of the sixth embodiment.

FIG. 10 is also a diagram centering on a cross-sectional structure of an end portion of a liquid crystal panel according to a seventh embodiment.

FIG. 11 is a view centering on a sectional structure of an end portion of a liquid crystal panel according to an eighth embodiment.

FIG. 12 is a view centering on the sectional structure of the end portion of the liquid crystal panel according to the ninth and tenth embodiments.

FIG. 13 is a configuration diagram of various double matrix type panels having a plurality of liquid crystal layers.

FIG. 14 is a plan view of a liquid crystal panel according to an eleventh embodiment of the present invention.

FIG. 15 is a diagram showing a structure of a main part of the liquid crystal panel of the above embodiment.

FIG. 16 is a diagram showing a structure of a liquid crystal panel using a spherical liquid crystal spacer manufactured for comparison with the above embodiment.

FIG. 17 is a diagram showing a structure of a main part of a twelfth embodiment of the liquid crystal panel according to the present invention.

FIG. 18 is a diagram schematically showing liquid crystal injection into a panel and a state of injection according to a conventional technique in a fifteenth embodiment of the liquid crystal panel according to the present invention.

FIG. 19 is a diagram showing a structure of a main part of a liquid crystal panel according to a seventeenth embodiment of the present invention.

FIG. 20 is a diagram showing a structure of a main part of a liquid crystal panel according to a seventeenth embodiment of the present invention.

FIG. 21 is a diagram showing a structure of a main part of a nineteenth embodiment of the liquid crystal panel according to the present invention.

FIG. 22 is a diagram showing a structure of a main part of a liquid crystal panel according to a twenty-first embodiment of the present invention.

FIG. 23 is a diagram illustrating a structure of a seal portion of the liquid crystal panel of the above embodiment.

FIG. 24 is a diagram showing a structure of a main part of a liquid crystal panel according to a twenty-third embodiment of the present invention.

FIG. 25 is a diagram of a modification of the liquid crystal panel of the above embodiment.

FIG. 26 is a diagram showing a structure of a main part of a liquid crystal panel according to a twenty-fourth embodiment of the present invention.

FIG. 27 is a diagram illustrating a manufacturing method as a twenty-fifth embodiment of the liquid crystal panel according to the present invention.

FIG. 28 is a diagram showing a method of manufacturing PALC employing the present invention.

FIG. 29 is a view showing a structure of a main part of the PALC.

[Explanation of symbols]

101, 102 Glass substrate 201, 202 Electrode 211, 212 Substrate / electrode 213, 214 Same as above 221 to 224 Peripheral drive circuit section for each color pixel 3 Liquid crystal 303 to 304 Liquid crystal layer liquid crystal filter for each color 31 Arrayed liquid crystal molecules 32 Liquid crystal (precursor) Body (object)) and resin (precursor) 33 Liquid crystal droplets 34 Matrix resin 35 Liquid crystal layer 36 Resin film 4 Alignment film 5, 50, 51 to 58 Sealing resin (seal part) 6, 61 to 67 In sealing resin 60 resin protrusion in display area 601 resin protrusion combined with molecular arrangement in display area 603 wall-shaped resin protrusion 604 wall-shaped resin protrusion spacer 605 wall-shaped resin protrusion Object spacer 7 Resin spherical spacer in seal part 71 Resin spherical spacer in display area 8 Projection 9 Conductive page Strike 10 source 110 video (source) signal line 11 drain 111 scanning (gate) signal line 12 gate 13 insulating film (SiO ₂ ) 14 semiconductor layer 15 insulating film (SiNx) 153 flattening layer 154 height adjusting films 155, 156 Color filter, black matrix 16 Polarizer 17 Pixel element 18 Pure resin layer for sealing 19 Glass fiber piece 20 Display area 21 Peripheral drive circuit section (gate) 22 Peripheral drive circuit section (source) 30 Sealing (injection) section 40 Light 80 Dropped liquid crystal 91-94 Connection line part 95 Electric wire 501 Plasma glass substrate 502 Ni electrode 503 Rib 504 Thin plate glass 505 Frit 506 Projection spacer 507 Liquid crystal sealant 508 Liquid crystal 509 Front plate 701 Backlight 702 Cathode 703 Anode 704, 10 polarizing plate 705 back plate 706 bulkhead 707 insulating plate 708 LCD 709 front plate 711 color filter

 ──────────────────────────────────────────────────の Continuing on the front page (72) Inventor Sadayoshi Hotta 1006 Kazuma Kadoma, Osaka Pref. Matsushita Electric Industrial Co., Ltd. (72) Inventor Akinori Shioda 1006 Kazuma Kadoma, Osaka Pref. 1006 Matsushita Electric Industrial Co., Ltd. (72) Inventor Shinetsu Takehashi 1006 Kazuma Kadoma, Osaka Prefecture Matsushita Electric Industrial Co., Ltd. (72) Inventor Seiji Nishiyama 1006 Odaka Kazuma Kadoma City, Osaka Matsushita Electric Industrial Co., Ltd. (72) Inventor Hirofumi Yamakita Matsushita Electric Industrial Co., Ltd.

Claims (41)

[Claims] 1. A liquid crystal panel in which a driving circuit portion is formed around a display area on a substrate and a liquid crystal seal of the display area is formed on the driving circuit, wherein an elastic spacer is provided in a sealing resin. A liquid crystal panel characterized by: 2. The liquid crystal panel according to claim 1, wherein the elastic spacer is a resin spacer. 3. The liquid crystal panel according to claim 1, wherein the elastic spacer is a spherical spacer made of a material having the same or substantially the same elastic modulus as the resin spacer in the display area. . 4. The liquid crystal panel according to claim 3, wherein the spherical spacers have a density of 100 pieces / mm ² or more. 5. The elastic spacer is a suitable elastic spacer made of a substance having a load of 1 g or less required for 10% compression in the case of a sphere having a diameter of 6 μm. Claim 1, Claim 2,
The liquid crystal panel according to claim 3. 6. The suitable elastic spacer is a most suitable elastic spacer made of a substance having a load required for compressing 10% to be 0.5 g or less when the sphere is 6 μm in diameter. The liquid crystal panel according to claim 5, wherein 7. When the spacer made of an elastic body is a sphere having a diameter of 6 μm, 1 g of the spacer is used.
In the range where the amount of deformation when applying a load is 0.5 μm or more and the change in load is within 0.25 g, the amount of deformation increases in proportion to the increase in load or within 10% less than the proportion 5. The liquid crystal panel according to claim 1, wherein the liquid crystal panel is an appropriate proportional elastic spacer made of a material that increases in the range. 8. When the appropriate proportional elastic spacer is a sphere having a diameter of 6 μm, the spacer has a weight of 1 g.
In the range where the amount of deformation when a load is applied is 1.0 μm or more and the change in load is within 0.25 g, the amount of deformation increases in proportion to the increase in load or within 10% less than the proportion 7. The liquid crystal panel according to claim 6, wherein the liquid crystal panel is a most appropriate proportional elastic spacer made of a substance which increases in the range. 9. The spacer according to claim 1, wherein the elastic spacer is a protrusion spacer formed on at least one of the substrates. Alternatively, the liquid crystal panel according to claim 8. 10. The liquid crystal panel according to claim 9, wherein said projection spacer is a projection spacer made of a polar substance made of a substance having a polar group. 11. The liquid crystal panel according to claim 9, wherein the protrusion spacer is an array-side protrusion spacer formed on the array-side substrate on which the drive circuit section is formed. . 12. The liquid crystal panel according to claim 11, wherein the array-side protrusion spacer is a layout-consideration array-side protrusion spacer formed avoiding a transistor element of a drive circuit. 13. The projection spacer according to claim 9, wherein the projection spacer is a light utilization projection spacer formed by patterning a photosensitive resin.
13. The liquid crystal panel according to claim 11. 14. A liquid crystal panel comprising a projection spacer made of an elastic material and formed in a non-pixel portion of a display area to keep a constant substrate interval. 15. An elastic body formed in a non-pixel portion of at least one display area on a substrate of a liquid crystal panel in which a plurality of liquid crystal layers are overlapped so as to maintain a constant distance between substrates opposed to each other with the liquid crystal layer interposed therebetween. A liquid crystal panel having a plurality of liquid crystal layers, characterized in that the liquid crystal panel has a projection spacer made of the same. 16. The liquid crystal according to claim 14, wherein the projection spacer is a low-density distribution projection spacer formed on a substrate at a density of 20 / mm ² or less. panel. 17. A spacer for molecular alignment adjustment / combination made of an elastic body formed at a predetermined position in a pixel of a display area to maintain a constant substrate spacing and to arrange liquid crystal molecules around the substrate at a constant alignment. A liquid crystal panel comprising: 18. A liquid crystal panel in which a plurality of liquid crystal layers are overlapped, a predetermined distance in a pixel in a display area on each substrate in a liquid crystal panel, a constant distance between substrates opposed to each other with the liquid crystal layer interposed therebetween, and liquid crystal molecules around the liquid crystal layer. A plurality of liquid crystals comprising an elastic body formed so as to form a fixed array, and having, in each layer, a molecular alignment adjusting / projecting spacer arranged in a line along the light traveling direction. Liquid crystal panel having layers. 19. The projection spacer according to claim 14, wherein the projection spacer or the array / projection spacer is a light utilization projection spacer formed by patterning a photosensitive resin.
The liquid crystal panel according to claim 5, claim 16, claim 17, or claim 18. 20. A liquid crystal panel or a color filter comprising a projection spacer formed in a display area and an area where a seal is formed to maintain a constant substrate interval. 21. The liquid crystal panel or color filter according to claim 20, wherein the protrusion spacer is formed on at least one of the array substrate side and the counter substrate side. 22. The projection spacer according to claim 20, wherein the projection spacer is an isometric projection spacer having a height equal to a vertical length between a display region and a region where a seal is formed. Item 24. A liquid crystal panel or a color filter according to item 21. 23. A height of at least one of a lower portion and an upper portion of the protrusion spacer is adjusted in order to adjust a height based on a difference in a position where the seal is formed in the display region or the like. 23. The liquid crystal panel or color filter according to claim 20, further comprising an adjustment film portion. 24. The height adjusting film, wherein the height adjusting film is a film that also serves as at least one of a conductive film, a reflector, an alignment film, and a color filter of a pixel portion. The liquid crystal panel or the color filter according to claim 23, wherein 25. The liquid crystal panel or color filter according to claim 20, wherein the spacer is a photosensitive resin protrusion spacer. 26. The protrusion spacer (forming density × cross-sectional area of the lower surface) of the protrusion formed in the display area is formed by (forming density × lower surface of the lower surface) formed in a region where a seal is formed. 26. The liquid crystal according to claim 20, wherein the projection area spacer is a formation area-considered projection spacer that is smaller than the cross-sectional area). Panel or color filter. 27. The protrusion spacers have a density formed in the display area of 5 pieces / mm ² or more and 50 pieces / mm ² or less, and a density formed in the area where the seal is formed is 10 pieces / mm ^2. 20/21, Claim 22, Claim 23, Claim 24, Claim 25 or Claim 25, wherein the number-of-forms-considering projection spacer is not less than / mm ^{2 and not} more than 80 pieces / mm ^2. A liquid crystal panel or a color filter according to claim 26. 28. The spacer according to claim 20, wherein the projection spacer is a rigid transmission light-considered spacer having a smaller horizontal cross-sectional area than that of a region where a seal is formed in a display region. Claim 21, Claim 2
2, Claim 23, Claim 24, Claim 25, Claim 26
28. A liquid crystal panel or a color filter according to claim 27. 29. The projection spacer formed in the display area has a ratio of 0.05% or more to 0.5% or less with respect to the total display area of the entire lower surface, and a seal is formed. 21. The projection spacer formed in the region is a specific range area ratio projection spacer in which the ratio of the entire lower surface to the total sealing region is 0.1% or more and 1.0% or less. Claim 21, Claim 22, Claim 23, Claim 24, Claim 25, Claim 2
6. The liquid crystal panel or color filter according to claim 27 or claim 28. 30. The protrusion spacer has a ratio of (area of the upper surface / area of the lower surface) of 0.2 to 0.9.
Claims 20 and 21, characterized in that:
Claim 22, Claim 23, Claim 24, Claim 25, Claim 26, Claim 27, Claim 28 or Claim 29
A liquid crystal panel or a color filter as described. 31. The projection spacer according to claim 20, wherein the height of the projection spacer is different between the inside of the display area and the height of the seal portion.
2, claim 23, claim 24, claim 25, claim 2
6. The liquid crystal panel or the color filter according to claim 27, claim 28, claim 29, or claim 30. 32. A method of manufacturing a liquid crystal panel comprising a liquid crystal sandwiched between substrates, wherein at least one of the substrates is provided with a projection spacer for keeping the distance between the substrates constant, a display region and a seal around the display region. A step of forming a projection spacer in a region to be formed in a region to be formed; a step of forming a vacant panel by forming a vacant panel by applying a seal resin to at least an outer peripheral portion of a display region of one of the substrates and bonding the two substrates together; and further curing the seal resin. And a liquid crystal injection step of injecting a liquid crystal into the formed empty panel. 33. A method of manufacturing a liquid crystal panel comprising a liquid crystal sandwiched between substrates, wherein a projection spacer for maintaining a constant spacing between the substrates is formed in a display region and a region around which a seal is formed. An object spacer forming step, a sealing resin applying step of applying a sealing resin to an outer peripheral portion of a display area of any of the substrates, a liquid crystal dropping step of dropping a liquid crystal on the substrate coated with the sealing resin, and a dropping of the liquid crystal. A covering step of covering the other substrate while keeping the gas from remaining inside the upper surface of the substrate, and a resin-cured tape for curing the applied sealing resin by a method that does not adversely affect the liquid crystal and bonding the two substrates together. A method of manufacturing a liquid crystal panel. 34. The method for manufacturing a liquid crystal panel according to claim 32, wherein prior to the step of forming the projection spacer, the projection area needs to have a display area and a surrounding area where a seal is formed. A height adjusting film forming step of forming a film for adjusting a difference in height. 35. A height adjusting film forming step for forming at least one of a reflective film, a conductive film, and a color filter, which is also used for forming a color filter and the like. Claim 34
The manufacturing method of the liquid crystal panel described in the above. 36. The method of manufacturing a liquid crystal panel according to claim 34, wherein the step of forming the height adjustment film is a step of forming an alignment film that also serves as an alignment film. 37. A non-contact type alignment treatment step of performing an alignment treatment on the alignment film by irradiating ultraviolet rays or the like after the step of forming the height adjustment film for forming the alignment film and the step of forming the projection spacer thereafter. 4. The method according to claim 3, wherein
7. The method for manufacturing a liquid crystal panel according to 6. 38. The height adjustment film forming step, wherein a resin is used as a material, and the height adjustment film is formed by spin-coating the resin. Claim 3
5. The method for manufacturing a liquid crystal panel according to claim 36 or 37. 39. The step of forming a projecting spacer, wherein the projecting spacer is continuously formed to form a wall in a region where a seal is formed on an outer peripheral portion of the display area, and a small step of forming a projecting spacer also serving as a peripheral wall. Claim 32, Claim 33, Claim 34, characterized by having
Claim 35, Claim 36, Claim 37 or Claim 3
9. The liquid crystal panel according to 8, and a method for manufacturing a liquid crystal panel. 40. A method of manufacturing a liquid crystal panel having a liquid crystal layer held on a substrate, wherein the projections protect the liquid crystal layer from being pressed in a display area on the substrate and also contribute to keeping the thickness of the liquid crystal layer constant. A projecting spacer forming step of forming an object spacer; and a wall-shaped projecting step of forming a wall-shaped projecting element which surrounds and protects the liquid crystal layer around the display area and also contributes to forming the liquid crystal layer. A predetermined liquid filling step of filling a liquid mixture of a polymer-dispersed liquid crystal or a precursor thereof and a resin matrix or a precursor thereof in the formed wall-like projections, and irradiating the filled predetermined liquid crystal with ultraviolet light; A liquid crystal panel comprising a resin serving as a matrix of polymer dispersed liquid crystal droplets by heating, a liquid crystal layer dispersed therein as polymer dispersed liquid crystal droplets, and a matrix forming step. Production method. 41. A method for manufacturing a liquid crystal panel having a liquid crystal layer held on a substrate, wherein the projection on the display region on the substrate protects the liquid crystal layer from being pressed and also contributes to maintaining the thickness of the liquid crystal layer constant. A projecting spacer forming step of forming an object spacer; and a wall-shaped projecting step of forming a wall-shaped projecting element which surrounds and protects the liquid crystal layer around the display area and also contributes to forming the liquid crystal layer. A predetermined liquid filling step of filling a liquid mixture of a liquid crystal or a precursor thereof and a resin film or a precursor thereof to form an upper layer in the formed wall-like projections, and irradiating the filled predetermined liquid crystal with ultraviolet light; A method for manufacturing a liquid crystal panel, comprising: a step of forming a resin that becomes a light-transmitting film above a liquid crystal layer by heating or the like, a liquid crystal layer that becomes a liquid crystal layer below the resin, and an upper film.