JP2004145088A - Apparatus and method for manufacturing liquid crystal display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and a method for manufacturing a liquid crystal display device with which a liquid drop including spacers is applied to a substrate so as to be contained in a non-pixel region on the substrate and the liquid crystal display device with high display quality is manufactured. <P>SOLUTION: The substrate 10 is held in a nearly vertically standing state and the liquid drop 15 including the spacers 14 is discharged with a nozzle 13 to the non-pixel region 12 on the substrate 10. The apparatus is constructed in such a way that the substrate 10 is transferred upward with a specified pitch for each discharge process and the discharged liquid drop 15 attached to the substrate 10 has an ellipse like shape along a direction to which the non-pixel region 12 is extended. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for manufacturing a liquid crystal display device, and more particularly, to a liquid crystal display capable of manufacturing a liquid crystal display device having a high display quality by applying a liquid droplet including a spacer so as to fit within a non-pixel region of a substrate. The present invention relates to a device manufacturing apparatus and a manufacturing method.
[0002]
[Prior art]
In the liquid crystal display device, for example, a spherical spacer is arranged between the substrates in order to keep the gap between the substrates constant. As a means for arranging the spacers, there is known a means for spraying the spacers mixed in the carrier solution onto the alignment-treated substrate. The diameter of the spherical spacer formed of resin or glass is about 2 to 6 μm, and a mixed solution of water and isopropyl alcohol is used as the carrier solution.
[0003]
However, in this spray application, the spacers may be unevenly distributed on the substrate. In particular, when a large number of spacers are aggregated in an area used for display (hereinafter, referred to as a “pixel area”), the brightness of the color is increased. However, there has been a problem that the display quality is reduced or color unevenness occurs, thereby deteriorating the display quality.
[0004]
In order to solve such a problem, by using a droplet discharge device, a spacer is accurately discharged and arranged in a region not used for display (hereinafter, referred to as a “non-pixel region (black matrix)”), and A means for improving the contrast of a display device is known (for example, see Patent Document 1). FIG. 12 is a side view schematically showing a state in which spacers are discharged by such a conventional droplet discharge method (so-called ink jet method). FIG. 13 is a plan view showing droplets discharged on the substrate. FIG. 3 is an enlarged plan view illustrating an example of a droplet discharged to a substrate.
[0005]
As shown in FIGS. 12 to 14, the substrate 10 is placed horizontally on a slide table (not shown) formed to be horizontally movable, and a droplet 15 including a spacer 14 is provided above the substrate 10. A nozzle 13 for discharging vertically downward toward a non-pixel region 12 formed between the pixel regions 11 of the substrate 10 is provided.
[0006]
The nozzles 13 are provided in a large number in an inkjet head (not shown) in correspondence with the pitch of the non-pixel region 12, and discharge the droplets 15 from the nozzles 13 while moving the slide table by a predetermined amount. As shown in (1), the droplet 15 is arranged in the non-pixel region 12.
[Patent Document 1]
Japanese Patent Application Laid-Open No. 2002-72218
[Problems to be solved by the invention]
However, the width of the non-pixel region 12 is usually 10 to 20 μm, and the droplet 15 discharged from the nozzle 13 and landed on the non-pixel region 12 has a circular planar shape as shown in FIGS. And its outer diameter is 20 to 50 μm.
[0008]
Therefore, as shown in FIG. 13, the droplet 15 arranged in the non-pixel region 12 does not fit in the non-pixel region 12 but protrudes to the pixel region 11 side, and the spacer 14 is also arranged in the pixel region 11. In some cases. As a result, there is a problem that this is recognized as a light leakage or a black spot, and the brightness of color development of the liquid crystal display device is reduced or color unevenness occurs.
[0009]
The present invention has been made in view of the above, and is an apparatus for manufacturing a liquid crystal display device capable of manufacturing a liquid crystal display device having high display quality by applying a liquid droplet including a spacer so as to be contained in a non-pixel region of a substrate. The purpose is to provide.
[0010]
It is another object of the present invention to provide a method of manufacturing a liquid crystal display device that can apply a liquid droplet including a spacer so as to be contained in a non-pixel region of a substrate and can manufacture a liquid crystal display device with high display quality.
[0011]
[Means for Solving the Problems]
In order to achieve the above object, a liquid crystal display manufacturing apparatus according to the present invention discharges a droplet including a spacer onto a substrate by using a droplet discharging method, and arranges the spacer on the substrate. In the apparatus manufacturing apparatus, a substrate holding means for holding the substrate in an upright state, a nozzle means arranged to face the substrate and discharging the droplet including the spacer to a non-pixel region on the substrate, Scanning means for moving at least one of the substrate and the nozzle means by a predetermined amount, so that the droplets discharged from the nozzle means and adhered to the substrate spread along the direction in which the non-pixel region extends. It discharges.
[0012]
Accordingly, since the substrate is in a standing state, the shape of the droplet attached to the non-pixel region becomes a shape (for example, a vertically long elliptical shape) that expands in the direction in which the non-pixel region extends due to the action of gravity. The width of the droplet becomes smaller. That is, the attached droplets fall within the non-pixel region, do not protrude to the pixel region side, and can prevent the spacer from being arranged also in the pixel region. Therefore, it is possible to prevent light leakage or black spots from being recognized, and it is possible to prevent the brightness of color development of the liquid crystal display device from being reduced and the occurrence of color unevenness.
[0013]
Further, the apparatus for manufacturing a liquid crystal display device according to the present invention includes a substrate angle varying means for arbitrarily changing an installation angle of a substrate. This makes it possible to easily and quickly control the landing angle of the droplet on the substrate, and to utilize the traveling direction component of the momentum of the droplet at the time of landing to combine with the effect of gravity on the droplet, thereby making the ellipse of the droplet The shape can be further elongated so that it can easily fit in the non-pixel region.
[0014]
Further, the apparatus for manufacturing a liquid crystal display device according to the present invention includes a nozzle angle varying means for arbitrarily changing a nozzle installation angle. This makes it possible to easily and quickly control the landing angle of the droplet on the substrate, and to utilize the traveling direction component of the momentum of the droplet at the time of landing to combine with the effect of gravity on the droplet, thereby making the ellipse of the droplet The shape can be further elongated so that it can easily fit in the non-pixel region.
[0015]
Further, in the apparatus for manufacturing a liquid crystal display device according to the present invention, the installation angle of the substrate is any one of 0 to + 80 ° with respect to the vertical direction. The traveling direction component of the momentum of the droplet at the time of landing can be utilized based on the landing angle of the droplet onto the substrate controlled in this manner. Therefore, in combination with the effect of gravity on the droplet, the elliptical shape of the droplet can be promoted to be further elongated, and the droplet can be easily contained in the non-pixel region.
[0016]
Further, in the liquid crystal display device manufacturing apparatus according to the present invention, the installation angle of the nozzle is any one of -70 ° to + 70 ° with respect to the normal line of the substrate. The traveling direction component of the momentum of the droplet at the time of landing can be utilized based on the landing angle of the droplet onto the substrate controlled in this manner. Therefore, in combination with the effect of gravity on the droplet, the elliptical shape of the droplet can be promoted to be further elongated, and the droplet can be easily contained in the non-pixel region.
[0017]
Further, in the manufacturing apparatus of the liquid crystal display device according to the present invention, the position of the nozzle unit is fixed, and the droplet is discharged from the nozzle unit while scanning the substrate upward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0018]
Further, in the manufacturing apparatus of the liquid crystal display device according to the present invention, the position of the substrate is fixed, and droplets are ejected from the nozzle means while scanning the nozzle means downward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0019]
Further, the manufacturing apparatus of the liquid crystal display device according to the present invention is configured to scan the substrate upward and discharge the droplet from the nozzle unit while scanning the nozzle unit downward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0020]
Further, according to a method of manufacturing a liquid crystal display device according to the present invention, in the method of manufacturing a liquid crystal display device in which droplets including spacers are discharged to a substrate by using a droplet discharging method and the spacers are arranged on the substrate, After holding the substrate in an upright state by holding means, the droplets including the spacers are ejected to a non-pixel region on the substrate by nozzle means arranged opposite to the substrate, and the substrate or the nozzle means The spacer is arranged in the non-pixel region by moving at least one of the spacers by a predetermined amount and repeating the droplet discharge process a predetermined number of times.
[0021]
Since the droplets are ejected while the substrate is standing, the shape of the droplets attached to the non-pixel region has a shape (for example, a vertically long elliptical shape) that expands in the direction in which the non-pixel region extends due to the action of gravity. ), And the width of the droplet is reduced. That is, the attached droplets fall within the non-pixel region, do not protrude to the pixel region side, and can prevent the spacer from being arranged also in the pixel region. Therefore, it is possible to prevent light leakage or black spots from being recognized, and it is possible to prevent the brightness of color development of the liquid crystal display device from being reduced and the occurrence of color unevenness.
[0022]
Further, in the method of manufacturing a liquid crystal display device according to the present invention, the position of the nozzle means is fixed, and droplets are ejected from the nozzle means while scanning the substrate upward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0023]
Further, in the method of manufacturing a liquid crystal display device according to the present invention, the position of the substrate is fixed, and droplets are ejected from the nozzle means while scanning the nozzle means downward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0024]
In the method of manufacturing a liquid crystal display device according to the present invention, the substrate is scanned upward, and the nozzle is discharged downward from the nozzle while scanning the nozzle downward. Thereby, the gravity acting on the droplet attached to the non-pixel region is promoted downward, and the shape of the droplet is further elongated vertically, so that the width of the droplet can be reduced.
[0025]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of an apparatus for manufacturing a liquid crystal display device according to the present invention will be described in detail with reference to the drawings. It should be noted that the present invention is not limited by the embodiment.
[0026]
Embodiment 1 FIG.
FIG. 1 is a side view schematically showing a state where a spacer is discharged by the liquid crystal display device manufacturing apparatus according to the first embodiment of the present invention. FIG. 2 is a front view showing the liquid crystal display device manufacturing device. Is a bottom view showing the apparatus for manufacturing a liquid crystal display device, FIG. 4 is a plan view showing droplets discharged on the substrate, and FIG. 5 is an enlarged plan view showing an example of droplets discharged on the substrate. In the following description, the same or corresponding members as those already described are denoted by the same reference numerals, and redundant description will be omitted or simplified.
[0027]
In the invention according to the first embodiment, as shown in FIG. 1, droplets 15 are ejected almost horizontally from the nozzles 13 while the substrate 10 stands almost vertically, and adhere to the non-pixel regions 12 of the substrate 10. The shape of the droplet 15 is formed into a vertically long elliptical shape by the action of gravity so that the width of the droplet 15 is reduced, and the droplet 15 is applied so as to fit within the non-pixel region 12.
[0028]
That is, it is configured such that its own gravity component acts on the droplet 15 attached to the substrate 10 along the direction in which the non-pixel region 12 extends. It should be noted that the above-mentioned elliptical shape does not indicate only a mathematically exact elliptical shape, but may be any shape that fits within the non-pixel region 12.
[0029]
As shown in FIGS. 2 and 3, a liquid crystal display device manufacturing apparatus for discharging a droplet 15 including a spacer 14 to a predetermined position on a substrate 10 holds the substrate 10 in a substantially vertical position, and A stage 16 movably formed in the direction, a base 17 movably holding the stage 16 and the like, a droplet discharge head 18 having a number of nozzles 13, and a droplet discharge head 18 as necessary. A head rotating mechanism 19 that rotates the nozzle 13 to change the direction of the nozzle 13 is provided. The distance between the nozzle 13 and the substrate 10 is kept constant even after the movement of the stage 16. The broken line in FIG. 2 indicates the direction in which the nozzles 13 are arranged, and the arrow a indicates the direction in which the substrate 10 and the stage 16 travel.
[0030]
Further, the spherical spacer 14 formed of resin, glass, ceramic, or the like differs depending on the performance of the liquid crystal display device to be manufactured, but may have a diameter of about 2 to 6 μm, for example. Note that the spacer 14 may have a shape other than a spherical shape as long as it is granular. For example, a spacer having a cylindrical shape and substantially the same diameter and height may be used.
[0031]
Further, as the carrier solution, for example, a mixed solution of water and ethylene glycol (having a viscosity of 10 to 40 mPA · s and a boiling point of about 150 to 250 ° C.) can be used. If so, it is not limited to this, and other solutions may be used. For example, the carrier solution may be one in which the above physical property values can be obtained by adding another solution (for example, 1-decanol or 1-dodecanol) to a mixed solution of water and ethylene glycol. The droplet discharge head 18 discharges the solid spacer 14 from the nozzle 13, and is therefore preferably driven by a piezoelectric element.
[0032]
With the above configuration, as shown in FIGS. 1 and 2, the stage 16 holding the substrate 10 slides upward (in the direction of the arrow a in FIG. 1) and scans, while the stage 16 holding the substrate 10 is moved. A droplet 15 is ejected from the nozzle 13 toward the non-pixel region 12 of the substrate 10 in a substantially vertical state. Then, as shown in FIGS. 4 and 5, the shape of the droplet 15 attached to the non-pixel region 12 becomes a vertically long elliptical shape due to the action of gravity because the substrate 10 is in a substantially vertical state. Becomes smaller.
[0033]
That is, the attached droplets 15 are accommodated in the non-pixel region 12 and do not protrude to the pixel region 11 side, so that the spacer 14 can be prevented from being arranged in the pixel region 11. Therefore, it is possible to prevent light leakage or black spots from being recognized, and it is possible to prevent the brightness of color development of the liquid crystal display device from being reduced and the occurrence of color unevenness.
[0034]
As described above, according to the liquid crystal display device manufacturing apparatus according to the first embodiment, the liquid droplets 15 including the spacers 14 can be applied so as to be contained in the non-pixel regions 12 of the substrate 10, and the liquid crystal with high display quality can be obtained. A display device can be manufactured.
[0035]
In the first embodiment, the position of the droplet discharge head 18 is fixed, and the spacer 14 is discharged while moving the stage 16 holding the substrate 10 upward (in the direction of arrow a in FIG. 1). However, the present invention is not limited to this. For example, the position of the stage 16 holding the substrate 10 is fixed, and the spacer 14 is moved while moving the droplet discharge head 18 downward (in the direction of the arrow b in FIG. 1). It is good also as a structure which discharges.
[0036]
Alternatively, both the droplet discharge head 18 and the stage 16 may be moved in opposite directions (for example, the droplet discharge head 18 is moved downward and the stage 16 is moved upward). The movement direction of the stage 16 or the droplet discharge head 18 is set as described above because the gravity acting on the droplet 15 attached to the non-pixel region 12 is promoted downward, and the shape of the droplet 15 is further elongated. This is because the droplet 15 has an elliptical shape and the width of the droplet 15 is reduced.
[0037]
Embodiment 2 FIG.
In the second embodiment, the installation angle of the substrate 10 and the installation angle of the nozzle 13 at the time of discharging the spacer 14 can be arbitrarily changed. That is, by changing these installation angles, the landing angle of the droplet 15 on the substrate 10 is controlled, and by utilizing the traveling direction component of the momentum of the droplet 15 at the time of landing, the droplet 15 Coupled with the action of gravity, the elliptical shape of the droplet 15 is further promoted to be longer vertically, and it is easy to fit in the non-pixel region 12 (see FIG. 11).
[0038]
Here, FIG. 6 is a side view schematically showing a state in which a spacer is discharged by the liquid crystal display device manufacturing apparatus according to the second embodiment of the present invention, and FIG. 7 is a front view showing the liquid crystal display device manufacturing device. FIG. 8 is a schematic diagram showing the definition of the installation angle of the substrate. 9 is a schematic diagram showing the definition of the nozzle installation angle, FIG. 10 is a table showing the relationship between the substrate and nozzle installation angle and the arrangement state (compatibility) of the spacers, and FIG. FIG. 4 is a plan view showing a droplet that is ejected.
[0039]
That is, as shown in FIG. 7, a manufacturing apparatus for a liquid crystal display device for discharging a droplet 15 including a spacer 14 to a predetermined position on a substrate 10 includes a stage which holds the substrate 10 and is formed to be vertically movable. 16, a base 17 that includes a substrate angle variable mechanism 20 that arbitrarily changes the installation angle of the stage 16 (substrate 10), holds the stage 16, and the like, and a droplet discharge head 18 that includes many nozzles 13. And a nozzle angle variable mechanism 21 for rotating the droplet discharge head 18 and arbitrarily changing the installation angle of the nozzle 13. Note that the arrow a in FIG. 7 indicates the traveling direction of the substrate 10 and the stage 16.
[0040]
The installation angle of the substrate 10 is defined as an angle θ with respect to the vertical direction as shown in FIG. 8, and the installation angle of the nozzle 13 is defined as an angle φ with respect to the normal line of the substrate 10 as shown in FIG. ing. The stage 16 is slid upward for scanning (in the direction of the arrow a in FIG. 6), as in the first embodiment.
[0041]
With the above configuration, as shown in FIG. 10, the installation angle θ of the substrate 10 and the installation angle φ of the nozzle 13 were variously changed, and the angle range in which the spacer 14 was favorably arranged was verified. Compatibility was confirmed in the range indicated by the square frame c. In the drawing, the case where the data conforms is indicated by 、, and the case where the data does not conform is indicated by ×.
[0042]
That is, according to the present invention, the installation angle θ of the substrate 10 is in a range of approximately 0 to + 80 ° with respect to the vertical direction, and the installation angle φ of the nozzle 13 is approximately −70 ° to + 70 ° with respect to the normal line of the substrate 10. It was confirmed that it was effective in the range of °.
[0043]
As described above, according to the liquid crystal display device manufacturing apparatus according to the second embodiment, as shown in FIG. 11, the shape of the droplet 15 attached to the substrate 10 is further elongated vertically along the non-pixel region 12. As a result, the liquid crystal display device can be applied so as to easily fit in the non-pixel region 12, so that a liquid crystal display device with high display quality can be manufactured.
[0044]
In the second embodiment, the position of the droplet discharge head 18 is fixed, and the spacer 14 is discharged while moving the stage 16 holding the substrate 10 upward (in the direction of arrow a in FIG. 6). However, the present invention is not limited to this. For example, the position of the stage 16 holding the substrate 10 is fixed and the spacer 14 is It is good also as a structure which discharges.
[0045]
Alternatively, both the droplet discharge head 18 and the stage 16 may be moved in opposite directions (for example, the droplet discharge head 18 is moved downward and the stage 16 is moved upward). The movement direction of the stage 16 or the droplet discharge head 18 is set as described above because the gravity acting on the droplet 15 attached to the non-pixel region 12 is promoted downward, and the shape of the droplet 15 is further elongated. This is because the droplet 15 has an elliptical shape and the width of the droplet 15 is reduced.
[Brief description of the drawings]
FIG. 1 is a side view schematically showing a state of discharging a spacer.
FIG. 2 is a front view showing an apparatus for manufacturing a liquid crystal display device.
FIG. 3 is a bottom view showing a manufacturing apparatus of the liquid crystal display device.
FIG. 4 is a plan view showing droplets discharged on a substrate.
FIG. 5 is an enlarged plan view illustrating an example of a droplet discharged to a substrate.
FIG. 6 is a side view schematically showing a state of discharging a spacer.
FIG. 7 is a front view illustrating a manufacturing apparatus of the liquid crystal display device.
FIG. 8 is a schematic diagram showing a definition of an installation angle of a substrate.
FIG. 9 is a schematic diagram illustrating a definition of a nozzle installation angle.
FIG. 10 is a table showing an installation angle of a substrate or the like and an arrangement state of a spacer.
FIG. 11 is a plan view showing droplets discharged on a substrate.
FIG. 12 is a side view showing a state of discharging a conventional spacer.
FIG. 13 is a plan view showing droplets discharged on a substrate.
FIG. 14 is an enlarged plan view illustrating an example of a droplet discharged to a substrate.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Substrate 11 Pixel area 12 Non-pixel area 13 Nozzle 14 Spacer 15 Droplet 16 Stage 17 Base 18 Droplet discharge head 19 Head rotation mechanism 20 Substrate angle variable mechanism 21 Nozzle angle variable mechanism

Claims (12)

In a manufacturing apparatus for a liquid crystal display device, a droplet including a spacer is discharged to a substrate using a droplet discharge method, and the spacer is disposed on the substrate.
Substrate holding means for holding the substrate in an upright state,
Nozzle means disposed opposite to the substrate, for discharging the droplets including the spacer to a non-pixel region on the substrate,
Scanning means for moving at least one of the substrate and the nozzle means by a predetermined amount;
With
An apparatus for manufacturing a liquid crystal display device, wherein the droplets discharged from the nozzle means and adhered to the substrate are discharged so as to spread along a direction in which the non-pixel region extends. 2. The apparatus for manufacturing a liquid crystal display device according to claim 1, further comprising a substrate angle changing unit for arbitrarily changing an installation angle of the substrate. 3. The apparatus for manufacturing a liquid crystal display device according to claim 1, further comprising a nozzle angle changing unit for arbitrarily changing an installation angle of the nozzle. The apparatus for manufacturing a liquid crystal display device according to claim 1, wherein an installation angle of the substrate is any angle of 0 to + 80 ° with respect to a vertical direction. The liquid crystal display device according to any one of claims 1 to 4, wherein an installation angle of the nozzle is any one of -70 ° to + 70 ° with respect to a normal line of the substrate. manufacturing device. 6. The liquid crystal display device according to claim 1, wherein the position of the nozzle unit is fixed, and the droplet is discharged from the nozzle unit while moving the substrate upward. apparatus. 6. The liquid crystal display device according to claim 1, wherein the position of the substrate is fixed, and the droplets are ejected from the nozzles while moving the nozzles downward. apparatus. The liquid crystal display device according to any one of claims 1 to 5, wherein the liquid droplet is ejected from the nozzle means while moving the substrate upward and moving the nozzle means downward. Manufacturing equipment. In a method for manufacturing a liquid crystal display device, a droplet including a spacer is discharged to a substrate using a droplet discharge method, and the spacer is disposed on the substrate.
After holding the substrate in an upright state by the substrate holding means,
The droplets including the spacers are ejected to a non-pixel region on the substrate by nozzle means arranged opposite to the substrate,
By moving at least one of the substrate and the nozzle means by a predetermined amount and repeating the droplet discharge process a predetermined number of times, the spacer is arranged in the non-pixel region. Production method. The method according to claim 9, wherein the position of the nozzle unit is fixed, and the droplet is discharged from the nozzle unit while moving the substrate upward. 10. The method according to claim 9, wherein the position of the substrate is fixed, and the droplets are discharged from the nozzle means while moving the nozzle means downward. 10. The method according to claim 9, wherein the liquid droplets are ejected from the nozzle means while moving the substrate upward and moving the nozzle means downward.

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