JP2002169166A - Liquid crystal display, method for manufacturing the same and equipment applying image display - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress peeling of a columnar resin pattern and to decrease display irregularities by improving the adhesion degree of the columnar resin pattern to a substrate. SOLUTION: In the liquid crystal display device, a resin film 15 is formed on a TFT array substrate 10 where a switching active element 4 to drive a pixel electrode is formed, and the switching active element 4 is brought into contact with a pixel electrode 2 formed on the resin film 15 through a contact hole 12, formed in the resin film 15. A columnar resin pattern 17 is formed to cover the contact hole 12 part, while the pattern fills the whole or a part of the contact hole 12, so that the columnar resin pattern 17 is formed overlapping the contact hole 12 part; and the adhesion degree of the columnar resin pattern 17 to the substrate is improved, as well as the level difference on the substrate surface is decreased, to prevent disturbance in the alignment of the liquid crystal caused by the level difference. Thus, high display quality without irregularities can be realized.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a liquid crystal display device, a method of manufacturing the same, and an image display application device.

[0002]

2. Description of the Related Art Liquid crystal display devices are widely used as main display devices, especially for applications requiring small size and light weight. The liquid crystal display device, as shown in FIG.
Array substrate 11 on which switching active elements 4 for driving pixel electrodes are formed, and color filter patterns 5
The liquid crystal 8 is located between the color filter substrate 10 on which the
Is a liquid crystal display device in which is encapsulated.

[0003]

In recent years, large monitors,
2. Description of the Related Art With an attempt to apply a liquid crystal to a device field in which a CRT has been conventionally used, such as a television application, a further improvement in performance of a liquid crystal display device is required. In particular, when applying liquid crystal panels to medical applications such as radiographic display and Internet commerce, high brightness, high definition, and
There is a demand for a high-quality liquid crystal panel having no display unevenness.
However, in a conventional liquid crystal panel, it is difficult to achieve both high luminance and high definition because of light shielding by a black matrix formed in a color filter. In addition, display unevenness was observed due to the bite spacers used for controlling the panel gap being cut into the color filter film, and the performance was not sufficient for use in the above applications.

Under such a background, a flattening resin film or a color filter pattern is formed on a TFT array substrate on which a switching active element for driving a pixel electrode is formed for the purpose of achieving both high luminance and high definition. Attempts have been made to form In order to improve the uniformity of the panel gap, a columnar resin pattern for forming a panel gap is previously formed on a counter substrate such as a TFT array substrate or a color filter substrate on which switching active elements for driving pixel electrodes are formed. Active attempts are being made to form them.

However, it has been found that fine display unevenness occurs in a panel formed by combining these two techniques.

As a result of investigations to solve such problems, it has been found that display unevenness is caused by the following phenomenon.

[0007] This is due to gap variation due to peeling of the columnar resin pattern.

Accordingly, an object of the present invention is to improve the degree of adhesion of a columnar resin pattern to a substrate, thereby suppressing peeling of the columnar resin pattern and reducing display unevenness, a method of manufacturing the same, and a method of manufacturing the same. Provide display application equipment.

[0009]

According to a first aspect of the present invention, there is provided a liquid crystal display device in which a switching active element for driving a pixel electrode is formed.
A resin film is formed on an FT array substrate, and the switching active element and a pixel electrode formed on the resin film are contacted by a contact hole formed in the resin film. A liquid crystal display device in which a columnar resin pattern for forming a panel gap is formed between an opposing substrate and a liquid crystal is sealed in the panel gap, wherein all or a part of the contact hole is filled. In this state, the columnar resin pattern is formed so as to cover the contact hole portion.

As described above, since the columnar resin pattern is formed so as to cover the contact hole portion in a state where the contact hole is completely or partially filled, the columnar resin pattern is formed on the contact hole portion in an overlapping manner. The degree of adhesion of the columnar resin pattern to the substrate is improved, and at the same time, the level difference on the substrate surface is reduced, and the liquid crystal alignment disorder due to the level difference is prevented. Thereby, it is possible to realize high display quality without unevenness.

The liquid crystal display device according to the second aspect is the first aspect.
In the above, the resin film is a color filter. Since the resin film is a color filter as described above, the effect of claim 1 can be obtained in a color filter on array type liquid crystal display device.

The liquid crystal display device according to the third aspect is the first aspect.
In this case, (contact hole diameter) <(columnar resin pattern diameter). Thus, (contact hole diameter) <
Since the columnar resin pattern has a diameter of (columnar resin pattern), the columnar resin pattern has a stronger attachment strength to the array substrate side and does not peel off.

According to a fourth aspect of the present invention, there is provided a liquid crystal display device.
In this case, (contact hole diameter) <(columnar resin pattern diameter). Thus, (contact hole diameter) <
Since the columnar resin pattern has a diameter of (columnar resin pattern), the columnar resin pattern has a stronger attachment strength to the array substrate side and does not peel off.

According to a fifth aspect of the present invention, there is provided a liquid crystal display device.
5. The liquid crystal display device according to claim 1, wherein the liquid crystal display method is a TN method. Thus, the present invention can be applied to a liquid crystal display device in which the liquid crystal display method is the TN method.

[0015] The liquid crystal display device according to the sixth aspect is the first aspect.
5. The liquid crystal display device according to claim 1, wherein the liquid crystal display system is an IPS system. Thus, the present invention can be applied to a liquid crystal display device in which the liquid crystal display method is the IPS method.

According to a seventh aspect of the present invention, there is provided a liquid crystal display device.
The liquid crystal display device according to any one of claims 1 to 4, wherein an alignment treatment is performed by optical alignment. As described above, the present invention can be applied to a liquid crystal display device that performs alignment processing by optical alignment.

In the method of manufacturing a liquid crystal display device according to the present invention, a resin film is formed on a TFT array substrate on which switching active elements for driving pixel electrodes are formed, and contact holes formed in the resin film are formed. The TFT array substrate so that the switching active element is brought into contact with a pixel electrode formed on the resin film, and the contact hole portion is covered with all or part of the contact hole. A columnar resin pattern for forming a panel gap is formed between the substrate and a counter substrate facing the same.

As described above, in a state where the contact holes are completely or partially filled, a panel gap is formed between the TFT array substrate and the opposing substrate facing the TFT array substrate so as to cover the contact holes. Since the columnar resin pattern is formed, the degree of adhesion of the columnar resin pattern to the substrate is improved, and at the same time, the level difference on the substrate surface is reduced, and the liquid crystal alignment disorder due to the level difference is prevented. Thereby, it is possible to realize high display quality without unevenness.

An image display application device according to a ninth aspect has the liquid crystal display device according to any one of the first to seventh aspects. As described above, since the liquid crystal display device according to any one of claims 1 to 7 has the liquid crystal display device according to any one of claims 1 to 7, it can be applied to an image display application device that requires a high-quality liquid crystal panel with high brightness, high definition, and no display unevenness. Available.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described with reference to FIG. FIG. 1 is a sectional view showing the structure of the liquid crystal display device according to the first embodiment of the present invention.

As shown in FIG. 1, this liquid crystal display device
A flattening resin film 15 is formed on a TFT array substrate 11 on which a switching active element 4 for driving a pixel electrode (transparent electrode 2) is formed, and switching is performed by a contact hole 12 formed in the flattening resin film 15. Active element 4
And the pixel electrode 2 formed on the flattening resin film 15, and a columnar resin for forming a panel gap between the TFT array substrate 11 and the opposing substrate (color filter substrate 10) opposed thereto. This is a configuration in which a pattern 17 is formed and the liquid crystal 8 is sealed in the panel gap. The columnar resin pattern 17 is formed so as to cover a portion of the contact hole 12 in a state where the columnar resin pattern 17 is completely or partially filled.

In this case, the array substrate 11 on which the flattening resin film 15 is formed and the color filter substrate 10 are subjected to an alignment process,
The cell gap is controlled by the columnar resin patterns 17 arranged at a constant density, and the two substrates 10 and 11 that have been subjected to the above-mentioned orientation treatment are adhered to each other by the sealant 9.
Thus, the liquid crystal 8 is sealed. 2,
2 'is a transparent electrode, 3 and 3' are polyimide alignment films, 5 is a color filter pattern, and 6 is a black matrix. The columnar resin pattern 17 is formed in the contact hole 1.
2 are formed such that (contact hole diameter) <(columnar resin pattern diameter). That is, the columnar resin pattern 17 is formed integrally with the base end portion 17a embedded in the contact hole 12, and the diameter of the columnar resin pattern 17 formed above the contact hole 12 is formed larger than the diameter of the contact hole 12. You.

Next, a method of manufacturing the liquid crystal display device will be described. Flattening resin film 15 on TFT array substrate 11
Is formed, and the switching active element 4 is brought into contact with the pixel electrode 2 formed on the flattening resin film 15 by the contact hole 12 formed in the flattening resin film 15,
A columnar resin pattern 17 is formed so as to cover the contact hole 12 site.

A second embodiment of the present invention will be described with reference to FIG. FIG. 2 is a sectional view showing the structure of the liquid crystal display device according to the second embodiment of the present invention. As shown in FIG. 2, this liquid crystal display device is different from the first embodiment in that
This is a color filter on array type liquid crystal display device in which a color filter pattern is not provided on the counter substrate side but a color filter pattern is provided instead of the flattening resin film.

In this case, the color filter patterns 5 and 6 are formed on the TFT array substrate, the color filter on array substrate 13 and the opposing substrate 14 are subjected to an orientation treatment, and the cell gap is formed by the columnar resin patterns 17 arranged at a constant density. The two substrates 13 and 14 to be subjected to the alignment treatment are adhered to each other by a sealing agent 9 and the liquid crystal 8 is sealed by the sealing agent 9. In the figure, 2 and 2 'are transparent electrodes, 3 and 3' are polyimide alignment films, and 6 is a black matrix. Further, the columnar resin pattern 17 is formed on the contact hole 12 similarly to the first embodiment.
It is formed so that (contact hole diameter) <(columnar resin pattern diameter).

Next, a method for manufacturing the liquid crystal display device will be described. The color filter pattern 5 is formed on the TFT array substrate 11, and the switching active element 4 is brought into contact with the pixel electrode 2 formed on the color filter pattern 5 through the contact hole 12 formed in the color filter pattern 5. A columnar resin pattern 17 is formed so as to cover the holes 12.

[0027]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 of the present invention will be described. TF
A flattening resin film (PC335, JSR
After forming the pattern, a pixel ITO electrode pattern is formed by vapor deposition. Next, a columnar resin (NN700, manufactured by JSR Corporation) pattern for forming a panel gap is overlapped with the contact hole portion of the flattening film pattern and formed at a density of two per three pixels (FIG. 1). . At this time, (contact hole diameter) <(columnar resin pattern diameter)
Design a pattern so that After forming an alignment film pattern on the substrate and subjecting the substrate to an alignment process by rubbing, the substrate is bonded to a counter color filter substrate similarly subjected to the alignment process via a sealing resin to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

Embodiment 2 of the present invention will be described. T
A color resist (CM7000, CM7000,
After applying a spin coat method, exposing and developing a color filter pattern, a pixel ITO electrode pattern is formed by vapor deposition. Next, a columnar resin (N
An N700 (manufactured by JSR Corporation) pattern is superposed on the contact hole portion of the color filter pattern and formed at a density of two per three pixels (FIG. 2). At this time, the pattern is designed so that (contact hole diameter) <(columnar resin pattern diameter). After forming an alignment film pattern on the substrate and subjecting it to an alignment treatment by rubbing, the substrate is similarly bonded to a counter substrate to which the alignment treatment is performed via a sealing resin to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

Next, Comparative Example 1 will be described. As shown in FIG. 3, a flattening resin film (PC
After forming the pattern 15 (335, manufactured by JSR Corporation), the pixel ITO electrode pattern 2 is formed by vapor deposition. Next, a columnar resin for forming a panel gap (NN700, JS
R (manufactured by R. Co., Ltd.) and the flattening film pattern 1
3 so as not to overlap with the contact hole 12
Pixels are formed at a density of two. At this time, the pattern is designed so that (contact hole diameter) <(columnar resin pattern diameter). After forming an alignment film pattern 3 on the substrate 11 and performing an alignment process by rubbing, the substrate 11 is bonded to a counter color filter substrate 10 that is similarly subjected to the alignment process via a sealing resin 9 to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

Next, Comparative Example 2 will be described. As shown in FIG. 4, a color resist (C
M7000, manufactured by Fuji Film Ohlin Co., Ltd.) by spin coating, exposure and development to form a color filter pattern 5 and then a pixel ITO electrode pattern 2
Is formed by vapor deposition. Next, a columnar resin (NN700, manufactured by JSR Corporation) pattern 7 ′ for forming a panel gap is formed at a density of two per three pixels so as not to overlap the contact hole 12 of the color filter pattern 5. I do. At this time, the pattern is designed so that (contact hole diameter) <(columnar resin pattern diameter). After forming an alignment film pattern 3 on the substrate 13 and performing an alignment process by rubbing, the substrate 13 is bonded to a counter substrate 14 that is similarly subjected to the alignment process via a sealing resin 9 to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

Next, Comparative Example 3 will be described. A flattening resin film (PC335, JSR Corporation) on a TFT array substrate
After the pattern is formed, a pixel ITO electrode pattern is formed by vapor deposition. Next, a columnar resin (NN700, manufactured by JSR Corporation) pattern for forming a panel gap is overlapped on the contact hole portion of the flattening film pattern.
Two pixels are formed in three pixels. At this time, the pattern is designed so that (contact hole diameter)> (columnar resin pattern diameter). After forming an alignment film pattern on the substrate and subjecting the substrate to an alignment treatment by rubbing, the substrate is bonded to a counter color filter substrate similarly subjected to the alignment treatment via a sealing resin to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

Next, a comparative example 4 will be described. A color resist pattern (CM7000, manufactured by Fuji Film Orin Co., Ltd.) is applied on a TFT array substrate by spin coating, and is exposed and developed to form a color filter pattern, and then a pixel ITO electrode pattern is formed by vapor deposition. . Next, a columnar resin (NN70) for forming a panel gap is used.
0, manufactured by JSR Corporation) pattern is superimposed on the contact hole portion of the color filter pattern, and 2
It is formed at the density of individual pieces. At this time, (contact hole diameter)
The pattern is designed so that> (columnar resin pattern diameter). After forming an alignment film pattern on the substrate and subjecting the substrate to an alignment treatment by rubbing, the substrate is similarly bonded to a counter substrate to be subjected to the alignment treatment via a sealing resin to form an empty cell. After injecting liquid crystal into the empty cell by a vacuum injection method, sealing is performed to produce a liquid crystal panel. The display unevenness of the liquid crystal panel is visually evaluated. Table 1 shows the results.

[0033]

[Table 1]

In this embodiment, since the part of the columnar resin pattern 17 is also filled in the part of the contact hole 12, the mounting strength of the columnar resin pattern 17 on the array substrate side is higher (the bite is better). Therefore, it is advantageous in mechanical strength and is also preferable in improving long-term reliability.

In the case of a small and high-definition liquid crystal panel, the characteristics are remarkably improved, and the disadvantage of the present invention in terms of cost can be covered.

The liquid crystal display system is a TN system,
The present invention can be applied to an IPS liquid crystal display device. Further, an alignment treatment may be performed by optical alignment (rubbingless; not aligned by mechanical means).

When the number of spacers (per unit area) of the columnar resin pattern is too large, there is a problem that low-temperature bubbles are generated. When the number is too small, a gap change due to a temperature change causes a problem in display performance. Therefore, the number of spacers in the columnar resin pattern has an optimum value depending on the conditions of the liquid crystal material, the material of the spacer, the configuration of the liquid crystal panel, and the like. I have.

Further, an image display application device can be configured using the liquid crystal display device having the above configuration.

[0039]

According to the liquid crystal display device of the first aspect of the present invention, the columnar resin pattern is formed so as to cover the contact hole portion in a state where the contact hole is completely or partially filled. A columnar resin pattern is formed on the hole portion so as to be superimposed thereon, so that the degree of adhesion of the columnar resin pattern to the substrate is improved, and furthermore, the step on the substrate surface is reduced, and the liquid crystal alignment disorder due to the step is prevented. Thereby, it is possible to realize high display quality without unevenness.

According to the second aspect, since the resin film is a color filter, the effect of the first aspect can be obtained in a color filter on array type liquid crystal display device.

According to claim 3, (contact hole diameter) <
Since the columnar resin pattern has a diameter of (columnar resin pattern), the columnar resin pattern has a stronger attachment strength to the array substrate side and does not peel off.

In claim 4, (diameter of contact hole) <
Since the columnar resin pattern has a diameter of (columnar resin pattern), the columnar resin pattern has a stronger attachment strength to the array substrate side and does not peel off.

According to the fifth aspect, the liquid crystal display method is T
The present invention can be applied to an N-type liquid crystal display device.

In claim 6, the liquid crystal display system is I
It can be applied to a liquid crystal display device of the PS system.

According to the seventh aspect, the present invention can be applied to a liquid crystal display device which performs alignment processing by optical alignment.

According to the manufacturing method of the liquid crystal display device of the present invention, the TFT array substrate and the TFT array substrate are opposed to each other so as to cover the contact hole portion in a state where the contact hole is completely or partially filled. Since the columnar resin pattern for forming the panel gap is formed between the substrate and the opposite substrate, the degree of adhesion of the columnar resin pattern to the substrate is improved, and further, the step on the substrate surface is reduced, and the liquid crystal alignment disorder due to the step is reduced. To prevent Thereby, it is possible to realize high display quality without unevenness.

According to the image display application device of the ninth aspect of the present invention, since the liquid crystal display device of the first, second, third, fourth, fifth, sixth or seventh aspect is provided, high brightness, high definition, and It can be used for image display application equipment requiring a high-quality liquid crystal panel with no display unevenness.

[Brief description of the drawings]

FIG. 1 is a sectional view of a liquid crystal display device according to a first embodiment of the present invention.

FIG. 2 is a sectional view of a liquid crystal display device according to a second embodiment of the present invention.

FIG. 3 is a cross-sectional view of the liquid crystal display device of Comparative Example 1.

FIG. 4 is a cross-sectional view of a liquid crystal display device of Comparative Example 2.

FIG. 5 is a sectional view of a conventional liquid crystal display device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1, 1 'Glass substrate 2, 2' Transparent electrode 3, 3 'Orientation film 4 Switching active element 5 Color filter pattern 6 Black matrix 8 Liquid crystal 9 Sealant 10 Color filter substrate 11 Array substrate 12 Contact hole 15 Flattening resin film 17 Columnar resin pattern

Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat II (reference) G09F 9/30 338 G09F 9/30 338 F term (reference) 2H089 LA09 LA10 LA11 LA12 LA16 LA19 MA03X 2H090 MB01 MB12 2H091 FA02Y FB02 FD06 FD12 GA06 GA07 GA08 GA13 GA16 HA07 HA18 LA02 LA13 LA30 2H092 JA46 JB58 NA04 NA18 PA03 PA08 QA07 QA18 5C094 AA03 AA42 AA43 AA55 BA03 BA43 BA44 CA19 CA23 DA13 DA15 EA03 EA04 EA07 EC03 ED02 FA02 FB01 FB01FB

Claims (9)

[Claims] 1. A resin film is formed on a TFT array substrate on which a switching active element for driving a pixel electrode is formed, and the switching active element and the resin film are formed by contact holes formed in the resin film. A pixel electrode formed above is contacted to form a columnar resin pattern for forming a panel gap between the TFT array substrate and an opposing substrate facing the TFT array substrate, and a liquid crystal is sealed in the panel gap. A liquid crystal display device, wherein the columnar resin pattern is formed so as to cover a contact hole portion in a state where the contact hole is entirely or partially filled. 2. The color filter according to claim 1, wherein the resin film is a color filter.
The liquid crystal display device as described in the above. 3. The liquid crystal display device according to claim 1, wherein (contact hole diameter) <(columnar resin pattern diameter). 4. The liquid crystal display device according to claim 2, wherein (contact hole diameter) <(columnar resin pattern diameter). 5. The liquid crystal display device according to claim 1, wherein the liquid crystal display system is a TN system. 6. The liquid crystal display device according to claim 1, wherein the liquid crystal display system is an IPS system. 7. The liquid crystal display device according to claim 1, wherein an alignment process is performed by optical alignment. 8. A resin film is formed on a TFT array substrate on which a switching active element for driving a pixel electrode is formed, and the switching active element and the resin film are formed by contact holes formed in the resin film. The pixel electrode formed above is brought into contact with the TFT array substrate and the opposing substrate facing the TFT array substrate so as to cover the contact hole portion in a state where all or part of the contact hole is filled. A method for manufacturing a liquid crystal display device, comprising forming a columnar resin pattern for forming a panel gap. 9. An image display application device having the liquid crystal display device according to claim 1.