JP2007065653A - Liquid crystal display device and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a liquid crystal display device which is repaired to minimize a decrease in visual appreciation due to foreign matter left in a liquid crystal panel in such a case and to provide a manufacturing method of the same. <P>SOLUTION: The liquid crystal display device includes a first substrate 100 and a second substrate 110 which have pluralities of pixel areas formed at mutually corresponding positions and are arranged opposite each other, a liquid crystal display layer 130 formed between the first substrate 100 and second substrate 110, a microhole 120 formed in the back side of one of the first substrate 100 and the second substrate 110 corresponding to the foreign matter 121 left between the first substrate 100 and the second substrate 110, and a substance layer 125 which is formed in the microhole 120 and has such an optical density value that a bright point generated by the foreign matter 121 is blocked according to the light intensity of the bright point. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a liquid crystal display device, and more particularly, to a liquid crystal display device repaired so as to minimize a decrease in visual sensation caused by foreign matter when the foreign matter remains in the liquid crystal panel, and a method for manufacturing the same. It is.

  Recently, as the information society has developed, the demand for display devices has increased in various forms. Furthermore, in response to such demands, LCD (Liquid Crystal Display), PDP (Plasma Display Panel), ELD (Electro Luminescent Display), VFD (Vacuum Fluorescent Display) and other flat display devices are available. Some of them are already used as display devices in various devices.

  Among the above flat panel display devices, at present, LCDs are the most used as mobile image display devices instead of CRT (Cathode Ray Tube) due to the features and advantages such as excellent image quality, light weight, thinness, and low power consumption. It is used. In addition to mobile applications such as notebook computer monitors, LCDs have also been developed for television and computer monitors that receive and display broadcast signals.

  Since the above liquid crystal display device is used in various devices as a general screen display device, while maintaining features such as light weight, thinness, and low power consumption, it has high definition, high brightness, and large area. A quality image must be realized.

  Hereinafter, a conventional liquid crystal display device will be described with reference to the drawings.

  FIG. 1 is an exploded perspective view showing a general liquid crystal display device.

  As shown in FIG. 1, the liquid crystal display device is injected between a first substrate 1 and a second substrate 2 bonded together with a predetermined space, and between the first substrate 1 and the second substrate 2. And the liquid crystal layer 3.

  More specifically, the first substrate 1 includes a plurality of gate lines 4 arranged in one direction with a predetermined interval in order to define the pixel region P, and a direction perpendicular to the gate lines 4. Includes a plurality of data lines 5 arranged at a predetermined interval. In addition, a pixel electrode 6 is formed in each pixel region P, and a data signal of the data line 5 is applied to each pixel electrode 6 at an intersection between the gate line 4 and the data line 5 by a signal applied to the gate line 4. A thin film transistor T to be applied is formed.

  The second substrate 2 is formed with a black matrix layer 7 for blocking the light except for the pixel region P. The portions corresponding to the pixel regions have R, G for expressing the hue. B color filter layer 8 is formed, and a common electrode 9 for generating an image is formed on the color filter layer 8.

  In the liquid crystal display device as described above, the liquid crystal of the liquid crystal layer 3 formed between the first substrate 1 and the second substrate 2 is aligned by the electric field between the pixel electrode 6 and the common electrode 9. An image can be displayed by adjusting the amount of light transmitted through the liquid crystal layer 3 depending on the degree of orientation of the liquid crystal layer 3.

  Such a liquid crystal display device is called a TN (Twisted Nematic) mode liquid crystal display device. In addition to the TN mode liquid crystal display device, a lateral electric field (In-Plane Switching: IPS) mode liquid crystal display device using a horizontal electric field has been developed. In a lateral electric field (IPS) mode liquid crystal display device, a pixel electrode and a common electrode are formed in parallel in the pixel region of the first substrate with a predetermined distance therebetween, so that a lateral electric field is formed between the pixel electrode and the common electrode. (Horizontal electric field) is generated, and the liquid crystal layer is aligned by the lateral electric field.

  Hereinafter, the cause of the bright spot observed in a general liquid crystal display device will be described.

  FIG. 2 is a plan view showing a case where foreign matter is generated in a general liquid crystal display device, and FIG. 3 is a cross-sectional view of FIG.

  As shown in FIG. 2 and FIG. 3, the liquid crystal display device realized in the TN mode includes the first substrate 1 and the second substrate 2 facing each other and the first substrate 1 as described with reference to FIG. A pixel electrode 6 formed for each pixel region and a common electrode 9 formed on the entire surface of the second substrate 2 are configured. A black matrix layer 7 corresponds to the non-pixel area on the second substrate 2 and a color filter layer 8 corresponds to the pixel area.

  In the TN mode liquid crystal display device formed as described above, when the conductive foreign material 21 remains in a predetermined portion on the pixel electrode 6, the foreign material 21 comes into contact with the common electrode 9 of the second substrate 2. Thus, the pixel electrode 6 on the first substrate 1 and the common electrode 9 on the second substrate 2 in contact with the foreign substance 21 are electrically connected to each other. Such foreign matter 21 is a particle that remains on the first substrate 1 or the second substrate 2 as a residue remaining in the chamber after the step of etching the metal or the transparent electrode and is not removed even after cleaning. . In particular, when the foreign material 21 remains in the formation portion of the pixel electrode 6, the common electrode 9 and the pixel electrode 6 on the upper and lower portions thereof are conducted, and the pixel electrode 6 and the common electrode corresponding to the portion where the conductive foreign material 21 remains are provided. No. 9 has a problem that it is always in a shot state.

  In this case, in a TN mode liquid crystal display device that is generally driven in a normally white mode, the corresponding portion of the pixel electrode 6 is always in a white state regardless of whether or not a voltage is applied to the pixel electrode 6. In particular, it is observed as a bright spot under a black state condition where a voltage is applied. In addition, a bright spot is generated by an electrical short circuit or disconnection.

  On the other hand, even when the foreign material 21 is not conductive or the liquid crystal display device is not in the TN mode, an alignment film is formed on each uppermost layer facing the first substrate 1 and the second substrate 2, and this is rubbed. When the foreign material 21 remains, the alignment process is not performed smoothly unlike the other parts, and this part is observed as a light leakage defect. In the liquid crystal display device, light leakage occurs due to the non-uniform alignment region, and this light leakage causes a bright spot by disturbing the light transmittance of the liquid crystal 3.

  In general, when realizing a high gray (white state), a portion where one region appears dark due to light leakage is called a dark spot, and when realizing a low gray (black state), a portion where one region appears bright due to light leakage Is called a bright spot. At this time, the human eye reacts more sensitively to the bright spot in the darker state than the dark spot in the brighter state, so when determining whether or not the liquid crystal panel is defective, the bright spot is more defective than the dark spot. Are given stricter standards. Therefore, it is necessary to provide a method for minimizing the panel defect rate due to the occurrence of bright spots.

  In the conventional liquid crystal display device, when a defect occurs in each thin film of the first substrate 1 and the second substrate 2, the corresponding thin film is deposited again by a rework process, or the corresponding part is formed using a laser or the like. A repair process is performed.

  However, when performing the above-described rework process or repair process, as shown in FIGS. 2 and 3, the foreign material 21 remains between the first substrate 1 and the second substrate 2, but the foreign material 21 remains. If the 1st board | substrate 1 and the 2nd board | substrate 2 are joined in a state, rework will become impossible and repair will also become difficult. For example, even in the case of a short circuit or disconnection on the circuit, when repair is performed using a laser, repair often fails.

  In the conventional liquid crystal display device and the repair method as described above, when foreign matter remains between the upper and lower substrates inside the liquid crystal panel, the brightness varies depending on the mode. Defects occur. When the liquid crystal panel is manufactured, if foreign matter remains on the thin film in the array process of each substrate before the upper and lower substrates are bonded together, a rework process for re-depositing the corresponding thin film is performed, or the corresponding part The foreign matter can be easily removed by repairing. However, if the foreign matter is not removed through these processes, or if the upper and lower substrates of the liquid crystal panel are bonded together while leaving the foreign matter generated in the cleaning process, etc., the defect of the bright spots generated by this The fact is that there is no solution to this.

  An object of the present invention is to solve the above-described problems, and an object of the present invention is to provide a liquid crystal display device that can be repaired so as to minimize a decrease in visual sensation caused by foreign matter remaining in the liquid crystal panel. It is in providing the manufacturing method.

  In order to achieve the above object, a liquid crystal display device according to the present invention includes a first substrate and a second substrate, each of which has a plurality of pixel regions formed at portions corresponding to each other, and is disposed to face each other, and the first substrate. One of the first substrate and the second substrate corresponding to the liquid crystal layer formed between the second substrate and the foreign matter remaining between the first substrate and the second substrate. And a light blocking material layer that is formed inside the microhole and blocks the starting point according to the light intensity of the bright spot generated by the foreign matter. It is characterized by that.

  The light blocking material layer has an optical density value of 0.01 to 10.0.

  The light blocking material layer is made of a pigment material.

  The microhole is formed in a size corresponding to a predetermined pixel region where the foreign matter remains.

  The micro hole is formed in a size of a part of the pixel region according to the generation site of the foreign matter.

  It further includes a polarizing plate formed on each back surface of the first substrate and the second substrate.

  The polarizing plate includes a hole of the same size at a portion corresponding to the microhole, and the hole is filled with a light blocking material layer that blocks a bright spot generated by the foreign matter.

  According to another aspect of the present invention, there is provided a method of manufacturing a liquid crystal display device according to the present invention, comprising: a first substrate and a second substrate having a plurality of pixel regions defined at opposing portions; the first substrate; Preparing a liquid crystal panel including a liquid crystal layer filled between the second substrates, detecting a pixel area where foreign matter of the liquid crystal panel is generated, and detecting light intensity of a bright spot generated by the foreign matter; Forming a microhole on the back side of one of the first substrate and the second substrate constituting the liquid crystal panel corresponding to the generation site of the bright spot, and in the microhole, And a step of filling a light blocking material layer that blocks the bright spot according to the light intensity of the bright spot.

  Also, the step of preparing the liquid crystal panel includes preparing a liquid crystal panel having a first polarizing plate and a second polarizing plate attached to the back surfaces of the first substrate and the second substrate, and forming the microhole. Corresponding to the generation site of the bright spot, either the first substrate or the second substrate constituting the liquid crystal panel, and the first polarizing plate or the second polarized light attached thereto. A microhole having a predetermined thickness is formed from the back side including the plate.

  In the step of forming the microhole, any one of the first substrate and the second substrate is formed to have a predetermined thickness using any one of a micro drill, a milling machine, an ultrasonic device, and a laser. The micro holes are formed by removing only the micro holes.

  The step of filling the light blocking material layer includes leaving the light blocking material layer so as to cover the entrance surface of the microhole, and then covering the back surface of the substrate including the periphery of the microhole with a vacuum cap. The micro-hole is filled with the light-blocking material layer using a pressure difference between the outside of the light-blocking material layer and the inside of the microhole.

  The light blocking material layer is made of a photocurable pigment material. In this case, the method further includes the step of curing the pigment material after the step of filling the light blocking material layer. The step of curing the pigment material is performed by irradiating ultraviolet rays through an ultraviolet lamp.

  The liquid crystal display device and the manufacturing method thereof according to the present invention have the following effects.

  In the liquid crystal display device and the manufacturing method thereof according to the present invention, a microhole having a predetermined depth from the back surface (front surface) of one of the upper and lower substrates corresponding to the site where the bright spot is generated as a repair process for the bright spot. In this microhole, a light blocking material layer corresponding to the light intensity of the corresponding bright spot is applied. As a result, when actually driven, the repaired portion becomes extremely black even on a gray screen. Since it is not observed, the visual feeling can be improved. In addition, a light blocking material layer to which an appropriate optical density value is applied is formed in the microhole, and generation of bright spots due to foreign matters is completely blocked on the front surface, and a predetermined amount of light incident from the side is transmitted. Thus, it is possible to prevent adjacent pixels from being blocked by the side surface of the microhole. Further, repair is possible even when a polarizing plate is attached to the liquid crystal panel. Furthermore, the production yield of a liquid crystal panel can be increased by making a defective panel in which a bright spot is generated in a black state into a non-defective product by repair processing.

  Hereinafter, a liquid crystal display device and a manufacturing method thereof according to the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 4 is a cross-sectional view showing a liquid crystal display device according to the present invention.

  As shown in FIG. 4, the liquid crystal display device according to the present invention includes a first substrate 100 and a second substrate 110 on which a thin film transistor array and a color filter array are formed to face each other, and the first substrate 100 and the second substrate. And a liquid crystal layer 130 filled between the substrates 110. In addition, a foreign substance 121 remains in a predetermined portion between the first substrate 100 and the second substrate 110, and correspondingly, the first substrate 100 or the first substrate 100 in the portion corresponding to the bright spot generated by the foreign matter 121 is stored. A microhole 120 having a predetermined depth h is formed on the back side of the two substrates 110, and an optical density (Optical Density) that blocks the bright spot in accordance with the light intensity of the corresponding bright spot is formed in the microhole 120. A light blocking material layer 125 having an OD value is formed.

  As shown in the drawing, the inside of the microhole 120 can be filled only with a light blocking material layer 125 that blocks the bright spot according to the light intensity of the corresponding bright spot. A light blocking material layer 125 for blocking the bright spot is formed at a predetermined thickness (h1 <h) in the microhole 120 from the bottom of the microhole 120 (side closer to the inner surface of the substrate), and the remaining microholes 120 are formed. It is also possible to fill the inside with a transparent substance.

  The light blocking material layer 125 may be formed of a light blocking material having an optical density value with different ratios of blocking light according to the value. In the former case, by adjusting the optical density value of the light blocking material layer 125, the light emitted from the front is blocked, and the light incident from the side surface through the light blocking material layer 125 in the microhole 120 is only an appropriate amount. Make it transparent. In the latter case, the same effect can be obtained by appropriately adjusting the predetermined thickness h1 of the light blocking material layer 125.

  Here, in the latter case, the light blocking substance layer 125 in the microhole 120 is made of a material having an optical density value with a good light blocking property, and the predetermined thickness at this time is the front light passing through the foreign matter 121. The thickness is such that it can be completely blocked. As the material forming the light blocking material layer 125 whose optical density value is adjusted as described above, a pigment material can be cited. The optical density value of this pigment material varies depending on the intensity of the bright spot. For example, the optical density value of the same black pigment as the black matrix layer is adjusted to about 3.4 μm, and the optical density value of the light blocking material layer 125 is adjusted to about 3.4 μm.

On the other hand, the optical density (OD) indicates the intensity ratio of transmitted light to incident light. In other words, this is expressed as follows:
OD = log ₁₀ (Iin / Iout)
Here, Iin is the intensity of incident light, and Iout is the intensity of outgoing light. As can be seen from this mathematical formula, a high optical density value (OD value) means that the light is well blocked (the light absorption is good), and a low optical density value is relatively transparent. It means that there is much light quantity. In the case of a thin film, a difference occurs in the amount of light emitted (or the amount of light absorption) depending on the thickness, so in general, the intensity of incident light and transmitted light with a thickness of 1 μm is calculated, and the corresponding optical density value (/ μm Calculated in units of

  As described above, in the liquid crystal display device according to the present invention, the reason for filling the light blocking material layer 125 in consideration of the optical density value in the microhole 120 is, for example, a portion where a weak bright spot with low light intensity is generated. In addition, when completely black pigment is filled with a very high optical density value, the black spots repaired on the gray screen may appear dark, so the black pigment has no relation to the light intensity of the bright spot. This is in order to eliminate the decrease in visual acuity that occurs when the light is blocked by only.

  Therefore, in the liquid crystal display device according to the present invention, when repairing the bright spot generated by the foreign substance 121, the light blocking having an optical density value that can block the corresponding bright spot according to the light intensity of the corresponding bright spot. The material layer 125 blocks the corresponding bright spot. In this case, in the bright spot inspection stage, if the light intensity differs for each bright spot when a plurality of bright spots are generated, the light intensity of each bright spot area and each bright spot is judged at the same time, and the part corresponding to each bright spot area The microhole 120 is formed in at least one of the first substrate 100 and the second substrate 110.

  Meanwhile, the thin film transistor array formed on the first substrate 100 includes a gate line (not shown) and a data line (not shown) that intersect with each other to define a pixel region, and an intersection of the gate line and the data line. A thin film transistor formed in the portion, and a pixel electrode 106 formed in the pixel region.

  Further, the color filter array formed on the second substrate 110 includes a black matrix layer 111 formed corresponding to a region (gate line, data line, thin film transistor forming portion) excluding the pixel region, and a pixel region. A color filter layer 112 formed corresponding to the region and a common electrode 113 formed on the entire surface of the second substrate 110 are included.

  The liquid crystal display device shown in FIG. 4 relates to the TN mode, and a microhole is formed in a portion corresponding to the foreign matter of the present invention, and the optical density corresponding to the light intensity of the bright spot due to the foreign matter is formed inside the microhole. A structure filled with a light blocking material having a value can be applied in other modes such as the IPS mode.

  In this case, in the IPS mode liquid crystal display device, except that the pixel electrode and the common electrode are alternately formed in the pixel region of the first substrate, and an overcoat layer is formed instead of the common electrode of the second substrate, The structure is similar to that of the above-described TN mode liquid crystal display device.

  5A to 5D are process cross-sectional views illustrating a method for manufacturing a liquid crystal display device according to the present invention.

  As shown in FIG. 5A, a first substrate 100 and a second substrate 110 on which a thin film transistor array and a color filter array are formed to face each other, and a liquid crystal filled between the first substrate 100 and the second substrate 110. A liquid crystal panel including the layer 130 is prepared. The constituent elements forming the thin film transistor array and the color filter array in the liquid crystal panel differ depending on whether the liquid crystal display device is in the TN mode or the IPS mode, and in the illustrated drawings, description will be made based on the TN mode.

  Here, a pixel electrode 106 is formed on the first substrate 100 corresponding to each pixel region, and on the second substrate 110, a black matrix layer 111 corresponding to a region excluding each pixel region, and each A color filter layer 112 corresponding to each region including the pixel region and a common electrode 113 formed on the entire surface of the second substrate 110 are formed.

  The liquid crystal panel formed as described above applies voltage signals to the pixel electrode 106 and the common electrode 113, respectively, and is in a black state (in this case, the liquid crystal panel is in a normally white mode and exhibits a black state when a voltage is applied). In other words, the site where the bright spot is generated by the foreign matter 121 is inspected with the liquid crystal panel. In this case, the light intensity of the bright spot is determined together with the site where the bright spot is generated, and a substance having an optical density value sufficient to block the corresponding bright spot is prepared according to the information.

  The liquid crystal panel shown in FIG. 5A shows an inverted state, and shows a substrate surface on which a microhole is to be formed after inspection of a foreign matter by a bright spot. In FIG. 5A, the inversion was performed as described above in order to form the microhole from the first substrate 100, that is, the back surface of the first substrate 100. In this case, it is also possible to perform a microhole forming process on the upper second substrate 110 corresponding to the foreign substance 121 site without inverting the liquid crystal panel.

  The generation site of the foreign matter 121 is a portion where a bright spot is observed in an inspection process for applying a voltage to give a black state condition and inspecting the bright spot of the liquid crystal panel. To the site.

  Next, as shown in FIG. 5B, the portion corresponding to the foreign substance 121 from the back side of the first substrate 100 is wide enough to include the generation site of the bright spot induced by the foreign substance 121 using the micro drill 150 and a predetermined width. The microhole 120 is formed by drilling at a depth of.

  The microhole 120 may be formed in a size corresponding to a predetermined pixel region where the foreign matter 121 remains, or may be formed in a size of a part of the pixel region corresponding to only the portion where the foreign matter 121 is generated. You can also.

  The microhole 120 is formed by drilling a predetermined depth from the back surface of the first substrate 100 using not only the above-described microdrill 150 but also a milling machine, a laser, or an ultrasonic machine. In this case, when the micro drill is used, the shape of the micro hole 120 is such that the moving direction of the micro drill is a vertical direction, and the cross-sectional shape of the micro hole after the micro drilling is close to a circular shape. Is used, the moving direction of the milling is up / down, left / right, and front / rear direction, and the cross-sectional shape of the microhole can be arbitrarily designated. In addition, when a laser or ultrasonic equipment is used, the thickness and shape are determined by the irradiation area or projection area and intensity. When the thickness of the first substrate 100 is 0.5 to 0.7 mm, the thickness of the microhole 120 is about half of the thickness of the first substrate 100, or around that. For example, the thickness of the first substrate 100 remaining on the microhole 120 side is preferably about 0.05 to 0.2 mm. At this time, when a backlight unit (not shown) is located on the lower side of the first substrate 100, the microhole 120 is adjusted in thickness and width in consideration of the amount of light that escapes to the side surface in addition to the front surface. It is formed.

  As shown in FIG. 5C, an optical density value corresponding to the light intensity of the bright spot by the corresponding foreign substance 121 is present inside the microhole 120 using a long nozzle 155 that enters the inside of the microhole 120 ( A light blocking material 125a (having an optical density value enough to block the bright spot) is filled. In this case, the light blocking material 125a is a liquid and photocurable material, and for example, a pigment material is considered. When filling the liquid light blocking material 125a, the nozzle 155 is placed inside the microhole 120 as much as possible, and is filled from the bottom without generating bubbles. After the injection of the light blocking material 125 a is completed inside the microhole 120, the tube of the nozzle 155 is taken out from the microhole 120.

  On the other hand, when the tube of the nozzle 155 enters near the bottom of the microhole 120, in addition to the light blocking material 125a having an optical density value corresponding to the light intensity of the bright spot, a separate transparent material layer (not shown) is shown. The light blocking material 125a does not remain on the wall surface filled with the transparent material layer, and transmitted light passing through the side surface through the transparent material layer is transmitted to the upper portion with a small blocking rate.

  Meanwhile, the light blocking material 125a having an optical density value corresponding to the light intensity of the bright spot may be formed by directly dotting in the microhole 120 using an ink jet device instead of the nozzle 155. Is possible.

  As shown in FIG. 5D, the light blocking material 125a filled in the microhole 120 is cured through the ultraviolet lamp 160 to form a cured light blocking material layer 125. When the light blocking material 125a remains in a liquid state, this curing process is performed in order to eliminate the risk that the material filled in the microhole 120 may be pulled out by reversal or movement or attached to the back surface of the lower substrate 100 or the like. Is.

  Here, when the light blocking material layer 125 is formed at the bottom of the microhole 120 with a thickness of a part of the microhole 120, after filling the transparent material into the remaining microhole 120 again after the curing process, A step of curing this is further performed.

  As described above, after the repair process is completed, a process of attaching a first polarizing plate and a second polarizing plate (not shown) to the back surfaces of the first substrate 100 and the second substrate 110 of the liquid crystal panel is further performed.

  Hereinafter, another method for forming a light blocking material layer having an optical density value for blocking a bright spot in the microhole 120 will be described.

  6A and 6B are diagrams illustrating various methods for forming a light blocking material layer having an optical density value for blocking a bright spot in the microhole 120 of the present invention.

  As shown in FIG. 6A, the light blocking material layer 125 can be formed by spraying the light blocking material 125 a through the spray 156 into the microhole 120. In this case, after the light blocking material 125a forming the light blocking material layer 125 is placed in the inner container of the spray 156, the spray is sprayed on the back side of the substrates 100 and 110 on which the microholes 120 are formed. The spray 156 is accurately aligned with the microhole 120, and the light blocking material 125a that has been sprayed and remains on the substrate 100, 110 is removed from the surface of the substrate 100, 110 by wiping or sucking, and only the microhole 120 is irradiated with light. The blocking substance 125a is left.

  Although not shown, the step of filling the light blocking material layer into the microhole 120 is performed using a light blocking material 125a that forms the light blocking material layer 125 inside the microhole 120 using an inkjet device (not shown). It is also possible to dot. In this case, the ink jet apparatus is made to accurately correspond to the microhole 120, and the light blocking material 125a is filled in the microhole 120.

  In addition, as shown in FIG. 6B, the step of filling the light blocking material layer into the microhole includes leaving the light blocking material 125a so as to cover the entrance surface of the microhole 120, and then the substrate 100 including the peripheral portion of the microhole, The back surface of 110 may be covered with a vacuum cap 158, and the inside of the microhole 120 may be filled with the light blocking material 125 a due to a pressure difference between the outside of the light blocking material layer and the inside of the microhole 120.

  Hereinafter, a method for manufacturing a liquid crystal display device according to another embodiment of the present invention will be described with reference to the drawings.

  FIG. 7 is a process cross-sectional view illustrating a method of manufacturing a liquid crystal display device according to another embodiment of the present invention.

  The liquid crystal display device in which the repair process according to another embodiment of the present invention is performed shows a case where the repair process is performed after the polarizing plate is formed.

  That is, as shown in FIG. 7, a liquid crystal panel used in a method of manufacturing a liquid crystal display device according to another embodiment of the present invention includes a first substrate 100 and a second substrate 110 that are formed to face each other, and these A liquid crystal layer 130 filled between the first substrate 100 and the second substrate 110, a foreign substance 121 remaining in a predetermined portion on the pixel electrode 106 formed on the first substrate 100, and the first substrate 100 and the second substrate. 110 includes a first polarizing plate 141 and a second polarizing plate 142 formed on the back surface of 110.

  Here, the first substrate 100 includes a gate line (not shown) and a data line (not shown) that intersect with each other to define a pixel region, and a thin film transistor formed at an intersection of the gate line and the data line. (Not shown) and a pixel electrode 106 formed in the pixel region.

  The second substrate 110 is formed on the entire surface of the second substrate 110, the black matrix layer 111 formed corresponding to the area excluding the pixel area, the color filter layer 112 formed corresponding to the pixel area. The common electrode 113 is included.

  As described above, the light intensity of the bright spot at the site where the foreign matter is generated is determined through the bright spot inspection in the black state of the formed liquid crystal panel.

  Next, a microhole 120 having a predetermined depth is formed on the back surface of the corresponding portion of the first substrate 100 or the second substrate 110 corresponding to the portion where the foreign matter 121 remains, and the bright spot light caused by the foreign matter is formed inside the microhole 120. The light blocking material layer 125 having an optical density value corresponding to the strength is filled and cured. In this case, the liquid crystal panel is in a state in which the first polarizing plate 141 and the second polarizing plate 142 are attached to the upper and lower portions thereof, and the microhole 120 is a polarizing plate attached to the substrate on which the microhole 120 is formed. At the same time, the substrate is formed by removing a predetermined thickness, and the light blocking substance having an optical density value corresponding to the light intensity of the bright spot is filled in the removed portion of the polarizing plate.

  For the formation of the microhole 120 as described above, all the methods used for forming the microhole described above can be applied.

  The method for manufacturing a liquid crystal display device according to the present invention is a method applicable not only to the TN mode and the IPS mode but also to various drive modes. By repairing a defect of a bright spot induced by a foreign substance, A liquid crystal panel can be improved.

  In the liquid crystal display device according to the present invention, a light blocking material having an optical density value corresponding to the light intensity of the corresponding bright spot is applied as a repair process for the bright spot, and the brightness of the bright spot is weak. A material having a small optical density value is used for the light source, and a material having a large optical density value is used when the brightness of the bright spot is strong. Therefore, when actually driving, the repaired part is not observed to be particularly black even on the gray screen, so that the visual feeling can be improved relatively compared to the method of repairing only the black pigment with respect to the bright spot. it can.

It is the disassembled perspective view which showed the general liquid crystal display device. It is the top view which showed the case where the foreign material generate | occur | produced in the general liquid crystal display device. FIG. 3 is a cross-sectional view of FIG. 2. It is sectional drawing which showed the liquid crystal display device which concerns on this invention. It is process sectional drawing which showed the manufacturing method of the liquid crystal display device which concerns on this invention. It is process sectional drawing which showed the manufacturing method of the liquid crystal display device which concerns on this invention. It is process sectional drawing which showed the manufacturing method of the liquid crystal display device which concerns on this invention. It is process sectional drawing which showed the manufacturing method of the liquid crystal display device which concerns on this invention. It is the figure which showed the various methods of forming the material layer which has the optical density value which blocks a bright spot in the microhole of this invention. It is the figure which showed the various methods of forming the material layer which has the optical density value which blocks a bright spot in the microhole of this invention. It is process sectional drawing which showed the manufacturing method of the liquid crystal display device which concerns on other embodiment of this invention.

Explanation of symbols

100 first substrate, 106 pixel electrode, 110 second substrate, 111 black matrix layer, 112 color filter layer, 113 common electrode, 120 microhole, 121 foreign material, 125 light blocking material layer, 125a light blocking material, 130 liquid crystal layer, 141 1st polarizing plate, 142 2nd polarizing plate, 150 micro hole, 155 nozzle, 160 UV lamp.

Claims (14)

A plurality of pixel regions are formed in portions corresponding to each other, and a first substrate and a second substrate disposed opposite to each other;
A liquid crystal layer formed between the first substrate and the second substrate;
Microholes formed on the back side of either the first substrate or the second substrate in response to foreign matter remaining between the first substrate and the second substrate;
A liquid crystal display device comprising: a light blocking material layer formed inside the microhole and blocking the bright spot according to the light intensity of the bright spot generated by the foreign matter. The liquid crystal display device according to claim 1, wherein the light blocking material layer has an optical density value of 0.01 to 10.0.   The liquid crystal display device according to claim 2, wherein the light blocking material layer is made of a pigment material.   The liquid crystal display device according to claim 1, wherein the micro hole is formed in a size corresponding to a predetermined pixel region where the foreign matter remains.   The liquid crystal display device according to claim 1, wherein the micro hole is formed with a size of a part of the pixel region in accordance with a generation site of the foreign matter.   The liquid crystal display device according to claim 1, further comprising a polarizing plate formed on each of the back surfaces of the first substrate and the second substrate. The polarizing plate includes a hole of the same size at a portion corresponding to the microhole,
The liquid crystal display device according to claim 6, wherein the hole is filled with a light blocking material layer that blocks a bright spot generated by the foreign matter. Providing a liquid crystal panel including a first substrate and a second substrate having a plurality of pixel regions defined in mutually facing portions, and a liquid crystal layer filled between the first substrate and the second substrate; ,
Detecting a pixel area where the foreign matter of the liquid crystal panel is generated and a light intensity of a bright spot generated by the foreign matter;
Forming a microhole on the back side of one of the first substrate and the second substrate forming the liquid crystal panel corresponding to the generation site of the bright spot;
Filling the microhole with a light blocking material layer that blocks the bright spot according to the light intensity of the bright spot. A method for manufacturing a liquid crystal display device, comprising: The step of preparing the liquid crystal panel includes preparing a liquid crystal panel in which a first polarizing plate and a second polarizing plate are respectively attached to the back surfaces of the first substrate and the second substrate.
In the step of forming the microhole, the first substrate or the second substrate constituting the liquid crystal panel, and the first substrate attached to the first substrate, which form the liquid crystal panel, correspond to the generation site of the bright spot. 9. The method of manufacturing a liquid crystal display device according to claim 8, wherein microholes having a predetermined thickness are formed from the back side including the polarizing plate or the second polarizing plate.   In the step of forming the microhole, any one of the first substrate and the second substrate is formed to have a predetermined thickness using any one of a micro drill, a milling machine, an ultrasonic device, and a laser. The method for manufacturing a liquid crystal display device according to claim 8, wherein the microhole is formed by removing only the microhole.   The step of filling the light blocking material layer includes leaving the light blocking material layer so as to cover the entrance surface of the microhole, and then covering the back surface of the substrate including the periphery of the microhole with a vacuum cap. 10. The liquid crystal according to claim 8, wherein the light blocking material layer is filled in the microhole using a pressure difference between the outside of the light blocking material layer and the inside of the microhole. Manufacturing method of display device.   10. The method of manufacturing a liquid crystal display device according to claim 8, wherein the light blocking material layer is made of a photocurable pigment material.   The method according to claim 12, further comprising the step of curing the pigment material after the step of filling the light blocking material layer. The method of claim 13, wherein the step of curing the pigment material is performed by irradiating ultraviolet rays.

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