JP2007156182A - Spacer arranging method and liquid crystal display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a spacer arranging method in which a plurality of predetermined single spacers are arranged at respective places on a substrate, and also to provide a liquid crystal display device by the same. <P>SOLUTION: The spacer arranging method includes a sticking stage of sticking spacer-containing liquid 20 which contains coupling spacers 230 formed by previously coupling a plurality of single spacers and a fixing stage of fixing the coupling spacers 230 in the stuck spacer-containing liquid on the substrate 100. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a spacer arrangement method and a liquid crystal display device.

  In manufacturing a liquid crystal display or the like, a spacer arrangement method is known in which a spacer-containing liquid in a head container is ejected as droplets from the opening of the head container and adhered to a desired location on a substrate. By drying the droplets after the droplets are attached, the spacers in the droplets are fixed on the substrate.

  When the spacers are arranged on the substrate in this way, the number of spacers in the ejected droplets is set to a predetermined number, for example, one, and the predetermined number of spacers is set to the substrate. It is desirable to place it in the desired location above.

Conventionally, a single spacer is uniformly dispersed in a spacer-containing liquid, and the concentration of the single spacer in the spacer-containing liquid is appropriately adjusted, whereby a single spacer in a droplet discharged from the opening of the head container is used. The number of one spacer was adjusted to about one.
JP 2004-145101 A

  By the way, recently, when it is required to arrange a plurality of predetermined single spacers, for example, 2, 3, 4, 5, 6 in one place on the substrate. There is. In this case, it is necessary to include a plurality of predetermined single spacers in one discharged droplet.

  However, it has been difficult to accurately include a plurality of predetermined single spacers in a droplet. For example, even if the spacer concentration in the spacer-containing liquid in which single spacers are dispersed is adjusted to a concentration such that an average of four single spacers are included in one droplet, four single spacers are not included. Droplets, such as those containing one or zero single spacers, are generated with considerable probability. Therefore, it is difficult to arrange a predetermined plurality of single spacers at one place on the substrate.

  The present invention has been made in view of the above problems, and provides a spacer arrangement method capable of arranging a plurality of predetermined single spacers at various locations on a substrate, and a liquid crystal display device obtained thereby. Objective.

  The spacer arrangement method according to the present invention includes an adhesion step of adhering a spacer-containing liquid containing a bonding spacer formed by previously bonding a plurality of single spacers onto a substrate, and the bonding spacer in the adhering spacer-containing liquid on the substrate. An adhering step for adhering.

  According to the present invention, since the bonding spacer formed by previously bonding a plurality of single spacers is included in the spacer-containing liquid, the bonding spacer is directly fixed to the substrate by the fixing process. Therefore, by appropriately adjusting the number of single spacers in the coupling spacer, a predetermined plurality of single spacers can be easily arranged at each location on the substrate.

  Here, in the attaching step, it is preferable to form droplets of the spacer-containing liquid and attach the droplets onto the substrate.

  In the spacer-containing liquid, each binding spacer behaves as one particle. Therefore, by appropriately adjusting the concentration of the combined spacer in the spacer-containing liquid, including one combined spacer in the formed droplets allows a single spacer to be dispersed without being bonded in the droplet. It is much easier than containing a plurality of these.

  In particular, in the attaching step, it is preferable to discharge droplets toward the substrate from the opening of the head container that can move relative to the substrate.

  According to this, it is possible to easily dispose the spacer-containing liquid droplets at each desired location on the substrate.

  On the other hand, in the attaching step, the spacer-containing liquid droplets may be sprayed on the substrate. In the attaching step, a liquid film of the spacer-containing liquid may be formed on the substrate.

  According to these, the liquid film or droplet of the spacer-containing liquid can be easily attached on the substrate.

  Moreover, it is preferable to dry the spacer containing liquid in the fixing step.

  When the spacer-containing liquid is dried, the bonding spacer in the spacer-containing liquid can be easily fixed to the substrate.

  In particular, when the surface of the bonding spacer is formed of a resin, or when the functional group capable of bonding to the substrate is bonded to the surface of the bonding spacer, the spacer is very well formed by drying the liquid around the spacer. It can be fixed against.

  On the other hand, when the surface of the bonding spacer is formed of a resin that is cured by light irradiation, in the fixing process, the bonding spacer in the spacer-containing liquid is in contact with the surface of the substrate with respect to the bonding spacer. It is also preferable to irradiate light.

  According to this, since the surface of the coupling spacer in contact with the substrate in the spacer-containing liquid is cured by light, the coupling spacer can be fixed to the substrate without drying the spacer-containing liquid.

  Further, in the fixing step, only the part of the substrate is irradiated with light through the mask, so that the bonding spacer in the spacer-containing liquid existing on the part of the substrate can be fixed to the substrate.

  According to this, it is preferable that a part of the substrate, that is, the bonding spacer in the spacer-containing liquid existing on a desired place is selectively fixed to the substrate. In this case, the droplets may be dried by infrared light, or the coupling spacer may be cured and fixed by light for curing the coupling spacer.

  In addition, when the coupling spacer is a single spacer previously bonded with a thermoplastic binder, or the surface of each single spacer is formed of a thermoplastic resin, and the bonding spacer is a surface of the single spacer. It is preferable that they are directly bonded together by heating. Such a coupling spacer is easy to manufacture.

  In addition, when such a coupling spacer is used, after the fixing process, another substrate is stacked on the substrate via the coupling spacer, and the coupling spacer can be heated in the stacking process. .

  In this case, since the bonding spacers are heated, the single spacers in each bonding spacer can be rearranged. In particular, a three-dimensional bonding spacer in which four or more single spacers are bonded is fixed to the substrate. Even in this case, the single spacers of the coupling spacers are rearranged to a thickness corresponding to one layer between the pair of substrates, so that the distance between the substrates, for example, the color filter and the driving substrate can be easily made uniform.

  A liquid crystal display device according to the present invention includes a liquid crystal driving substrate having pixel electrodes, a color filter disposed opposite to the liquid crystal driving substrate, and a spacer disposed between the liquid crystal driving substrate and the color filter. Is a coupling spacer formed by coupling a plurality of single spacers.

  Since such a liquid crystal display device has a coupling spacer, the spacer is difficult to move, and further, the spacer is not easily crushed by local pressure.

  According to the present invention, a plurality of predetermined single spacers can be arranged at various locations on the substrate, and an excellent liquid crystal display device can be realized.

  Hereinafter, preferred embodiments of a spacer arranging method and a liquid crystal display device according to the present invention will be described with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant descriptions are omitted. In the drawings, the dimensional ratio does not necessarily match that described.

(First embodiment)
In the present invention, a combined spacer formed by combining a plurality of single spacers is prepared, and a spacer-containing liquid containing the combined spacer is ejected as droplets from the opening of the head and adhered onto the color filter. Then, the TFT substrate is placed on the color filter. Details will be described below.

(Bonding spacer creation process)
First, as shown in FIG. 1A, a single spacer 220 is prepared. The material of the single spacer 220 is not particularly limited, and for example, silicon oxide particles such as silica, plastic particles such as silicon modified polymer, and the like can be used. Further, the particle size of the single spacer 220 is not particularly limited, and can be, for example, about 1 to 7 μm.

  In addition, the surface of the single spacer 220 is formed of a resin such as a polymer, or an alignment film formed on the surface of the TFT substrate on the surface of the single spacer to align liquid crystal, or a color filter (particularly an alignment film). It is preferable that a functional group that can be bonded to, for example, an epoxy group, a glycidyl group, an oxetane group, an acid anhydride group, a lactone group, an amide group, a carboxyl group, or the like can be bonded to the color filter to increase the adhesion. .

  For example, when the surface of the single spacer 220 is formed of resin, the adhesion between the single spacer and the color filter or the alignment film on the surface of the TFT substrate can be further enhanced by heat or the like during drying described later. Examples of the resin include a thermoplastic resin, a thermosetting resin, and a resin that is cured by light irradiation, such as a visible light curable resin, an ultraviolet curable resin, and an infrared curable resin. Here, even if the whole single spacer is formed from resin, only the surface layer may be formed from resin. Even if the surface of the single spacer has the above-mentioned functional group, the single spacer 220 and the alignment film on the surface of the color filter or TFT substrate are formed by chemical bonding between the functional group and the alignment film on the surface of the color filter or TFT substrate. It can improve the adhesion. Further, in the case of a resin that is cured by light irradiation, it can be fixed to the color filter or the alignment film on the surface of the TFT substrate by the light irradiation.

  Subsequently, a plurality of single spacers 220 are combined to form a combined spacer 230 as shown in FIGS. The number of the single spacers 220 included in the coupling spacer 230 may be plural, for example, 2, 3, 4, 6, etc.

  Although the manufacturing method of the joint spacer 230 is not specifically limited, A well-known granulation method can be used. Specifically, for example, a dish type granulator, a fluidized bed granulation coating apparatus, a granulation apparatus using a spray dryer, or the like can be used. Also, a dispersing agent is dissolved in the liquid, and a fixing resin (which may be dissolved or dispersed smaller than the spacer) and a spacer (the fixing agent may be chemically treated in the spacer) are dispersed. Then, the solubility parameter of the solution may be changed and granulated. Alternatively, the solution may be dried (may be freeze-dried), and then pulverized and classified to obtain the same size.

  In particular, by using a binder, the coupling spacer 230 can be suitably formed regardless of the material of the single spacer 220. The binder is not particularly limited, but it is particularly preferable to use a thermoplastic binder. As thermoplastic binder, for example, acrylic resin, polyester resin, polyether resin, polyolefin wax, polyvinyl pyrrolidone, vinyl acetate resin, polyvinyl ether resin, etc., almost no spacer-containing liquid (does not affect LCD reliability) Degree) or a resin that does not dissolve at all. Further, such a resin may be provided with a functional group that reacts with particles by applying heat, or a functional group that prevents alignment disorder of the liquid crystal. An example of a coupling spacer 230 in which three single spacers 220 are coupled by a binder 235 is shown in FIG.

  Further, the coupling spacer 230 can be formed without using a binder. For example, when the surfaces of the single spacers 220 are formed of a thermoplastic resin, the surfaces of the single spacers 220 can be directly bonded to each other by stirring the single spacers 220 while heating, The coupling spacer 230 can be generated without using a binder.

  Examples of the coupling spacer 230 formed by coupling the single spacers 220 without using the binder 235 are shown in FIGS. 1 (b) and 1 (d) are coupling spacers 230 in which three single spacers 220 are coupled, FIG. 1 (c) is a coupling spacer 230 in which two single spacers 220 are coupled, and FIG. e) is an example of a coupling spacer 230 in which four single spacers 220 are coupled, and FIG. 1F is an example of a coupling spacer 230 in which six single spacers 220 are coupled.

  Here, in the aggregate of the coupling spacers 230 formed by the granulation method as described above, the number of the single spacers 220 included in each coupling spacer 230 is not so uniform, so the aggregate of the coupling spacers 230 after granulation. Is preferably classified. The classification method is not particularly limited. For example, a classification method using sedimentation of granulated particles due to a specific gravity difference such as multi-cyclone or standing in liquid, a classification method using hydrodynamic chromatography, mesh, sieve And a classification method using a membrane or the like. By this, it is possible to obtain an aggregate of coupling spacers 230 including a high proportion of coupling spacers 230 formed by coupling a plurality of predetermined single spacers 220.

  Specifically, for example, on a number basis, the total number of coupling spacers 230 including a plurality of predetermined single spacers 220 is 90% or more, preferably 95% or more. It is preferable to create an aggregate of coupling spacers 230 that exhibits a sharp distribution.

  And the aggregate | assembly of the coupling spacer 230 obtained in this way is disperse | distributed in a spacer carrier liquid, and the spacer containing liquid in which the coupling spacer 230 was disperse | distributed is obtained. Here, the coupling spacer 230 is dispersed in the liquid as if it were one particle. Note that the concentration of the coupling spacer 230 in the spacer-containing liquid is adjusted to a concentration such that one coupling spacer 230 is included in the volume V of the liquid droplets ejected from the opening (described later in detail) of the head container. In the present embodiment, a case will be described in which a spacer-containing liquid including a combined spacer in which three spacers are combined as shown in FIG.

  As the spacer carrier liquid 11 in which the bonding spacer 230 is dispersed, for example, a mixed liquid of water and IPA can be used. Moreover, a dispersing agent can also be used as needed.

(Arrangement process)
Subsequently, a droplet 200 is formed from the spacer-containing liquid 12 using the spacer arrangement device 1 as shown in FIG. 2, and the droplet is attached to the surface of the color filter 100.

  First, examples of the spacer arrangement device 1 and the color filter 100 will be described.

(Spacer placement device)
The spacer arrangement device 1 is a device that ejects a spacer-containing liquid from the head device 41 to the upper color filter 100 and attaches droplets of the spacer-containing liquid to the lower surface of the color filter 100.

  The spacer arrangement device 1 mainly includes a stirring tank 20 that stirs the spacer-containing liquid 12, and a head device 41 that ejects the spacer-containing liquid 12 supplied from the stirring tank 20 toward the upper color filter 100 as droplets 200. And a substrate moving unit 80 that moves the color filter 100 above the head device 41 and a controller 90 that controls the head device 41, the substrate moving unit 80, and the like.

  The head device 41 has a box-like head container 42 extending in the width direction of the color filter 100. A large number of openings 37 are formed in a row at a predetermined pitch 37P on the upper surface of the head container. The arrangement direction of the openings 37 is parallel to the width direction of the color filter and is perpendicular to the moving direction of the color filter.

  Here, the diameter of the opening 37 can be, for example, about 10 to 50 μm. Further, the pitch 37P of the openings 37 can be set to, for example, about 100 μm.

  A hammer 52 and a piezo element 54 are provided in the head container 42 in order from the top. The bottom of the piezo element 54 is fixed to the bottom of the head container 42. The piezo element 54 is connected to the controller 90 and expands and contracts in accordance with a signal from the controller 90. The hammer 52 is fixed on the piezo element 54. The upper surface of the hammer 52 faces each opening 37 from below and is spaced apart from each opening 37 by a predetermined distance.

  When the piezo element 54 extends upward in response to a signal from the controller 90, the hammer 52 moves upward. Accordingly, the spacer-containing liquid 12 in the vicinity of the opening 37 is pushed out of the opening 37 by the upper end surface 52d of the hammer 52, and the droplet 200 of the spacer-containing liquid 12 is ejected upward.

  The agitation tank 20 includes an agitation blade 17 rotated by a motor 17a, and agitates the spacer-containing liquid 12 in which the above-described coupling spacer 230 is dispersed to disperse the coupling spacer 230 in the spacer carrier liquid 11. The stirring strength is set to a strength that does not break the bonding of the bonding spacer 230.

  One end of the head container 42 is connected to the stirring tank 20 by a line L1. The other end of the head container 42 is connected to the agitation tank 20 by a line L2 including a circulation pump 70. The circulation pump 70 sucks the spacer-containing liquid in the head container 42 and discharges it into the stirring tank 20. Correspondingly, the spacer-containing liquid 12 in the stirring tank 20 is supplied into the head container 42 via the line L1.

  The substrate moving unit 80 includes a substrate suction unit 82 and a substrate moving unit 84. The substrate suction unit 82 supports the color filter 100 by sucking the color filter 100 above the head device 41 by static electricity or reduced pressure. Here, the substrate suction unit 82 supports the color filter 100 so that the depressions 160 a of the upper film 160 (described later in detail) of the color filter 100 are directed downward and parallel to the arrangement direction of the openings 37.

  The substrate moving unit 84 horizontally moves the substrate suction unit 82 that has sucked the color filter 100 in the color filter moving direction, that is, the direction orthogonal to the width direction of the color filter. That is, the color filter 100 and the opening 37 of the head device 41 move relatively along the surface of the color filter 100. Further, the substrate moving unit 84 can move the color filter 100 in the width direction of the color filter by a predetermined distance so that the color filter 100 can be aligned. The substrate moving unit 84 is preferably a linear motor type that can move the color filter 100 with high accuracy.

  The controller 90 is a computer device that performs processing based on a predetermined program. The controller 90 is connected to the substrate moving unit 80, the piezo element 54, the circulation pump 70, and the motor 17a, and controls the driving thereof.

(Color filter)
Next, an example of a color filter as a substrate to which droplets are to be attached will be described with reference to FIG. The color filter 100 in which the droplet 200 is to be disposed includes a transparent substrate 110, a black matrix 120, a red coloring portion 130R, a green coloring portion 130G, a blue coloring portion 130B, and an upper film 160.

  The transparent substrate 110 is a transparent flat plate made of glass or the like.

  The black matrix 120 is a film made of a material that blocks visible light. Examples of the material of the black matrix 120 include metal materials such as chromium and chromium / chromium oxide, and resin materials. The black matrix 120 has a lattice shape or a stripe shape, and has a large number of openings 120p. The width 120W of the black matrix can be set to about 5 to 30 μm, for example. The height 120H of the black matrix can be set to about 0.1 to 2 μm, for example.

  The red coloring portion 130 </ b> R, the green coloring portion 130 </ b> G, and the blue coloring portion 130 </ b> B are sequentially arranged in each opening 120 p of the black matrix 120. Each of the red coloring portion 130R, the green coloring portion 130G, and the blue coloring portion 130B is made of a transparent coloring material that can selectively transmit visible light of each color. For example, a transparent coloring resin can be used. The width 130W of each coloring part 130R, 130G, 130B can be 5-100 micrometers, for example. The height 130H of each coloring part 130R, 130G, 130B can be set to 1 to 2 μm, for example.

  Here, the height 130H of the colored portions 130R, 130G, and 130B is sufficiently higher than the height 120H of the black matrix 120.

  An upper film 160 is formed over the colored portions 130R, 130G, and 130B and the black matrix 120. The upper film 160 is a laminated body having a transparent flattening film (not shown), a transparent electrode film 140, an alignment film 150, and the like that are provided in order from the transparent substrate 110 side.

  The transparent electrode film 140 is a common electrode that should be disposed facing a pixel electrode (described later in detail) of a liquid crystal driving substrate for driving a liquid crystal display, and is formed of a transparent conductive material such as ITO. The thickness of the transparent electrode film 140 is, for example, about 0.1 μm.

  The alignment film 150 aligns the liquid crystal in a desired direction, and can be formed of, for example, a resin material such as polyimide. The thickness of the alignment film 150 is, for example, about 0.1 μm.

  Then, corresponding to the level difference between the upper surface of the black matrix 120 and the upper surfaces of the colored portions 130R, 130G, and 130B, the surface of the color filter 100, that is, the surface of the upper film 160 is depressed on the black matrix 120. A portion 160a is formed. The black matrix 120 has a lattice shape or a stripe shape, and the recessed portion 160 a has a groove shape along the black matrix 120. Further, the end portions of the colored portions 130R, 130G, and 130B on the black matrix 120 side are raised.

  For example, such a color filter 100 is formed by forming the black matrix 120 on the transparent substrate 110 by a photolithography method or the like and then sequentially forming the colored portions 130R, 130G, and the like in the openings 120p of the black matrix 120 by the photolithography method or the like. 130B is formed to be higher than the black matrix 120, and then a transparent electrode film 140 having a predetermined thickness is formed on the black matrix 120 and the colored portions 130R, 130G, and 130B by a sputtering method, a vapor deposition method, and the like. Further, an alignment film material such as polyimide resin is applied on the transparent electrode film 140 to a predetermined thickness to be solidified, and the surface thereof is rubbed to form the alignment film 150.

(Droplet ejection and adhesion)
Next, the droplet ejection and adhesion process will be described. In the present embodiment, as shown in FIG. 2, while moving the color filter 100 in the color filter moving direction, the droplet 200 is repeatedly ejected from each opening 37 of the head container 42, and the rows (a plurality of droplets 200 ( By repeatedly attaching (line) to the substrate surface (see FIG. 3), as shown in FIGS. 4 and 5, a plurality of droplets 200 are attached to the surface of the color filter 100 in a matrix.

  Here, the movement of the color filter 100 is controlled by controlling the substrate moving unit 80 and the piezo element 54 so that the droplet 200 adheres to the depression 160a in the surface of the upper film 160. The pitch 37 </ b> P of the droplets 200 on each recess 160 a corresponds to the pitch 37 </ b> P of the openings 37 of the head container 42.

  The diameter of the droplet 200 on the color filter 100 can be, for example, about 50 to 100 μm. Therefore, the volume V of the droplet 200 is, for example, about 10 to 100 pL. Here, as described above, the concentration of the coupling spacer 230 in the spacer-containing liquid 12 in the head container 42 is approximately one coupling spacer 230 in the volume V of the droplet 200, for example, 0.9 to 1.1. The concentration is about one. Therefore, most of the droplets 200 discharged from the opening 37 of the head container 42 include only one coupling spacer 230 as shown in FIGS.

  Since each coupling spacer 230 is a combination of a desired plurality of single spacers 220, a predetermined plurality of single spacers 220 are arranged at desired locations on the color filter.

  Here, the fact that approximately one coupling spacer is included in the droplet 200 will be described in detail with reference to FIG. FIG. 6 shows a case where the bonding spacer 230 is dispersed as a single particle in the spacer-containing liquid 12, and the concentration of the bonding spacer 230 is approximately 1 in A: the volume V of the droplet, and B: the volume of the droplet. FIG. 6 is an example of a graph showing the frequency distribution of the number of coupling spacers 230 included in one droplet 200 that is actually ejected when it is set to be about three in V. FIG. Further, this graph shows that the single spacer 220 is dispersed as a single particle in the spacer-containing liquid 12, and the concentration of the single spacer 220 is about 1 in A: the volume V of the droplet, and B: It is also a graph showing the frequency distribution of the number of single spacers 220 included in one droplet 200 that is actually ejected when the number of droplets is set to about 3 in the volume V of the droplet.

  When the single spacer 220 is dispersed as a single particle in the spacer-containing liquid 12 as in the prior art, the concentration of the single spacer 220 in the spacer-containing liquid 12 is determined as a droplet as shown in FIG. Even if the concentration is set so that three single spacers 220 are included in the volume V of the liquid, the frequency distribution of the number of single spacers 220 in the droplet 200 becomes broad and the single in the droplet 200 is single. The number of spacers 220 tends to vary greatly.

  However, when the bonding spacer 230 formed by combining a plurality of predetermined single spacers 220 as a single particle is dispersed in the spacer-containing liquid 12 as in this embodiment, the bonding spacer 230 is It behaves as if it is one particle. When the concentration of the coupling spacer 230 in the spacer-containing liquid 12 is set to a concentration at which one coupling spacer 230 is contained in the volume V of the droplet, as shown in FIG. Only one coupling spacer 230 can be included in the 200 with considerable probability. This is because when the single spacer 220 is dispersed as a single particle in the spacer-containing liquid 12 and the concentration of the single spacer 220 is set to a concentration of one single spacer 220 in the droplet volume V, the comparison is made. This is in common with the fact that one single spacer 220 is included in the droplet 200 with high accuracy.

  Therefore, according to the present embodiment, the droplet 200 including a predetermined plurality of single spacers 220 can be arranged at each location on the color filter 100.

(Fixing process)
Subsequently, the coupling spacer 230 in the droplet 200 is fixed to the color filter 100. The fixing method is not particularly limited, and examples thereof include heating with an infrared lamp and the like, and drying methods such as blowing. When the droplet 200 is dried, the coupling spacer 230 in the droplet 200 is fixed on the color filter 100 as shown in FIG. At this time, normally, the coupling between the single spacers 220 of the coupling spacer 230 is hardly broken.

  Here, as shown by a dotted line in FIG. 4, in order to prevent the coupling spacer 230 </ b> A from adhering to an unintended place when the droplet 200 </ b> A adheres to an unintended place, as shown in FIG. 8. In addition, it is preferable to irradiate the color filter 100 with infrared rays through a mask M in which portions corresponding to the depressions 160a and the black matrix 120 are openings OP. Then, as shown in FIG. 9, the liquid on the portion corresponding to the opening OP is dried and the coupling spacer 230 is selectively fixed at the place, while the droplet 200 </ b> A that is not irradiated with infrared rays is not dried. It is possible to extremely effectively prevent the coupling spacer 230A from being fixed other than intended. In this case, after the desired coupling spacer 230 is fixed, as shown in FIG. 10, when a liquid such as a solvent of a spacer-containing liquid is caused to flow down from the nozzle 480 to the surface of the color filter, the coupling spacer that has not been fixed. Only 230A can be removed from the color filter. Note that the non-fixed coupling spacer 230A may be removed by blowing off with a gas or the like or immersing in a liquid.

  In the process of fixing by drying, regardless of whether the droplet 200 is in an upward state or a downward state, each single spacer 220 of the coupling spacer 230 finally comes into contact with the color filter 100. Become. In the present embodiment, in particular, a coupling spacer 230 in which three single spacers are coupled is used. Usually, after drying, any single spacer 220 of the coupling spacer 230 contacts the surface of the color filter 100, that is, At the time of fixing, the height of the coupling spacer 230 is the same as the height of the single spacer 220.

  Also, the bonding spacer can be fixed by a method other than drying. For example, when the surface of the coupling spacer 230 is a resin that is cured by light irradiation, such as a visible light curable resin, an ultraviolet curable resin, an infrared curable resin, or the like, the coupling spacer 230 in the droplet 200 is the color filter 100. The coupling spacer 230 can be fixed onto the color filter 10 by irradiating light that cures the resin in contact with the surface. In this case, drying is not always necessary. Further, it is preferable to irradiate light through the mask M in order to prevent the coupling spacer 230A from adhering to an unintended place. Further, the unfixed coupling spacer 230A may be removed as described above.

  At the same time as fixing by curing, or after fixing by curing, the color filter 100 is irradiated with infrared rays through the mask M, and the liquid around the coupling spacer 230G is dried to bond the coupling spacer 230G and the color filter 100. It is also possible to increase the fixing force.

(Drive substrate stacking process)
Subsequently, as shown in FIG. 11, a liquid crystal driving substrate 400 having a pixel electrode 402 (for example, a TFT element) is mounted on the color filter 100 via a coupling spacer 230. The liquid crystal driving substrate 400 is obtained by providing a pixel electrode 402, an alignment film 403, and the like on a glass substrate 401.

  In addition, the connection between the color filter 100 and the liquid crystal driving substrate 400 is not a single spacer 220 as in the prior art, but a combination of a plurality of single spacers 220 whose number is controlled with higher accuracy. Since they are respectively supported by the spacers 230, the panel GAP becomes uniform and the display becomes clean. Moreover, since it is an aggregate | assembly, it becomes difficult to move a spacer, and it is hard to occur that a spacer is crushed by local pressurization.

  Thereafter, if the liquid crystal is filled between the liquid crystal driving substrate 400 and the color filter 100, the liquid crystal display device 300 is completed. Note that the liquid crystal may be dropped on the color filter 100 before the liquid crystal driving substrate 400 is placed on the color filter 100.

  As described above, according to the present embodiment, the spacer-containing liquid 12 including the coupling spacer 230 formed by coupling a plurality of single spacers 220 is used. It behaves as if it is one particle. Then, by adjusting the concentration of the coupling spacer 230 in the spacer-containing liquid 12, it is easy to contain one coupling spacer 230 in the discharged droplet 200. Therefore, the predetermined plurality of single spacers 220 are arranged at desired positions of the color filter with higher accuracy than in the past.

(Second Embodiment)
Next, the second embodiment will be described. In the present embodiment, as shown in FIG. 1E, a coupling spacer 230 in which four coupling spacers are sterically coupled is used. In this case, the state shown in FIG. 12 is obtained after the droplets are attached and dried as described above. After that, the color filter 100 is overlaid on the color filter 100, and the coupling spacer 230 is sandwiched between the color filter 100 and the liquid crystal driving substrate 400, thereby applying a predetermined stress to the coupling spacer 230. The bonds between the single spacers 220 are released, and the single spacers 220 constituting the combined spacers 230 are rearranged into one layer. As a result, as shown in FIG. 11, the distance between the color filter 100 and the liquid crystal drive substrate 400 is defined by the height of the single spacer 220.

  Here, when the coupling spacer 230 is a unit in which the single spacers 220 are coupled to each other via a thermoplastic binder 235, or the surface of each single spacer 220 is formed of a thermoplastic resin. In the case where the surfaces of the single spacers 220 are directly bonded to each other by heating, the single spacers 220 are heated with a relatively weak stress by heating the bonding spacer 230 with an infrared lamp or the like in this overlapping step. The spacers can be easily rearranged, and the single spacers 220 can be bonded again by the thermoplastic resin in the rearranged state to form the combined spacers.

(Third embodiment)
Subsequently, a third embodiment according to the present invention will be described. In the third embodiment, as shown in FIG. 13, the spray device 2 having the droplet spray nozzle 202 is used on the color filter 100 instead of the spacer arrangement device 1 as in the first embodiment and the second embodiment. A large number of droplets 200 are deposited by spraying.

  For example, a two-fluid nozzle can be used as the droplet spray nozzle 202. A blower 204 is connected to the droplet spray nozzle 202 via a line L20, and a pump 206 and a stirring tank 20 similar to the first embodiment are connected via a line L22. The pump 206 supplies the spacer-containing liquid 12 to the droplet spray nozzle 202, and the blower 204 supplies air to the droplet spray nozzle 202, so that a large number of spacer-containing liquid droplets 200 are output from the droplet spray nozzle 202. It is formed. The large number of droplets 200 adheres to the surface of the color filter 100 arranged to face the droplet spray nozzle 202. Note that the spray conditions such as the orifice diameter of the droplet spray nozzle 202, the spacer-containing liquid and the air pressure are set so that the droplet diameter has a desired size. Each droplet 200 preferably includes one coupling spacer 230.

  In such a spraying method, it is difficult to control the attachment position of the droplet 200 on the color filter 100 as in the first embodiment, and the droplet 200 including the coupling spacer 230 is, as shown in FIG. The color filter 100 is arranged almost randomly. The coupling spacer 230 in the droplet 200 is classified into a coupling spacer 230G arranged on the black matrix 120 and a coupling spacer 230H arranged on a portion other than the black matrix 120.

  Subsequently, through a mask M as shown in FIG. 8, that is, a striped mask M in which the portion corresponding to the black matrix 120 of the color filter 100 is an opening OP and the other portion is a light shielding portion. Light is applied to the black matrix 120 of the color filter 100. Then, while the coupling spacer 230G on the black matrix 120 is fixed on the black matrix 120, no light is irradiated on the portion other than the black matrix 120, so the coupling spacer 230H on the portion other than the black matrix 120 is colored. It does not adhere to the filter 100.

  Examples of the fixing method include a method of drying a liquid with infrared rays and a method of irradiating light for curing the bonding spacer, as in the first embodiment.

  Then, after the coupling spacer 230G on the black matrix 120 is fixed to the color filter, the unfixed coupling spacer 230H is removed from the color filter surface by running water or the like, as in the first embodiment, as shown in FIG. In addition, the coupling spacer 230G can be selectively disposed on the black matrix 120.

  Thereafter, an overlapping process may be performed as in the first embodiment or the second embodiment.

(Fourth embodiment)
In this embodiment, as shown in FIGS. 16 and 17, not the droplet 200 but the liquid film 210 of the spacer-containing liquid 12 is attached on the color filter 100. Specifically, the liquid film 210 of the spacer-containing liquid 12 can be formed on the color filter 100 using various known coating apparatuses. For example, the liquid film 210 can be formed using the die coater 3 shown in FIG. The liquid film 210 can also be formed by spraying droplets with a spray nozzle as in the third embodiment for a sufficiently long time.

  When such a liquid film 210 is formed, as shown in FIGS. 16 and 17, the coupling spacers 230 are arranged almost randomly on the color filter 100 in the liquid film 210. Here, it is assumed that the coupling spacer disposed on the black matrix 120 is 230G, and the coupling spacer disposed on the portion other than the black matrix 120 is 230H.

  Thereafter, light may be irradiated through the mask M as in the third embodiment. The coupling spacer 230G may be fixed to the color filter 100 by drying the liquid around the coupling spacer 230G on the black matrix 120 with infrared rays, and the surface of the coupling spacer 230G is cured with light to bond the coupling spacer 230G and the color. The filter 100 may be fixed. Then, after fixing, the unfixed coupling spacer 230H may be removed by washing or the like. As a result, as shown in FIG. 15, the coupling spacer 230 is selectively disposed on the black matrix 120. Thereafter, an overlapping process may be performed as in the first embodiment or the second embodiment.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation aspect is possible. For example, the number of single spacers 220 included in each coupling spacer 230 is not particularly limited as long as it is plural, and may be two, or may be several tens if there is no problem in discharging from the opening 37.

  In the above embodiment, the droplet 200 is discharged upward from the opening 37 of the head container 42, but may be discharged downward or sideways.

  In addition, the relationship between the width of the opening OP of the mask M and the width of the place (for example, the black matrix) where the coupling spacer 230 is to be disposed may be approximately the same, and the type of light (ultraviolet / visible light / Infrared: Linearity varies depending on the type), distance between mask and color filter, degree of unevenness of color filter, how light reaches from color source to color filter (parallel light or convergent light) Accordingly, the relationship between the width OPW of the opening OP (see FIG. 8) and the width of the place where the spacer is to be disposed (for example, 120 W in FIG. 3) can be arbitrarily set appropriately. Usually, (the width of the opening) ≦ (the width of the place where the spacer is to be disposed) may be satisfied.

  In manufacturing other than color filters, for example, TFT substrates, liquid crystal display elements that require cell gaps with spherical spacers, optical devices such as multimode optical waveguides and connectors that require gap control, etc. Of course, it is possible to use the method of each of the above-described embodiments to arrange the spacers on the substrate or the like during manufacturing.

  Thus, according to the present invention, since a desired plurality of single spacers can be arranged on the substrate, it is possible to manufacture a liquid crystal display or the like having higher functions.

FIG. 1 is a schematic diagram illustrating a single spacer and a coupling spacer formed by coupling a single spacer. FIG. 2 is a schematic configuration diagram of an example of a spacer spraying device used in the present embodiment. FIG. 3 is a cross-sectional view of an example of a color filter used in the present embodiment. FIG. 4 is a top view showing a state in which droplets are dispersed on the color filter. 5 is a VV arrow view of FIG. FIG. 6 shows that when the concentration of the single spacer or the combined spacer in the spacer-containing liquid is A: about 1 in the droplet volume and B: about 3 in the droplet volume, It is a graph which shows the frequency distribution of the number of the single spacer contained in a droplet, or a coupling spacer. FIG. 7 is a cross-sectional view showing a state where the droplets of the color filter of FIG. 4 are dried. FIG. 8 is a top view showing the mask M having the opening OP. 9 is an arrow view showing a state after the color filter of FIG. 4 is dried by irradiating light through the mask M, and the location corresponds to the VIII-VIII plane of FIG. . FIG. 10 is a cross-sectional view showing a state in which the unfixed coupling spacer is removed from the color filter in the state shown in FIG. FIG. 11 is a cross-sectional view showing a state where the liquid crystal driving substrate is placed on the color filter. FIG. 12 is a cross-sectional view showing a state in which a coupling spacer obtained by coupling four single spacers is fixed on the color filter. FIG. 13 is a conceptual diagram showing a spacer-containing droplet spraying method according to the third embodiment. FIG. 14 is a plan view showing a state in which droplets adhere on the color filter. FIG. 15 is a plan view showing a state where the coupling spacer is selectively fixed on the black matrix. FIG. 16 is a conceptual cross-sectional view showing a spacer-containing liquid film forming method according to the fourth embodiment. FIG. 17 is a plan view showing a state in which a liquid film is attached on the color filter.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 12 ... Spacer containing liquid, 37 ... Opening, 42 ... Head container, 100 ... Color filter (substrate), 200 ... Droplet (spacer containing liquid), 202 ... Pixel electrode, 210 ... Liquid film (spacer containing liquid), 220 ... Single spacer 230... Binding spacer 300. Liquid crystal display device 400. Liquid crystal driving substrate (other substrate).

Claims (13)

An adhesion step of adhering a spacer-containing liquid containing a bonding spacer formed by previously bonding a plurality of single spacers onto the substrate;
An adhering step of adhering the bonded spacer in the adhering spacer-containing liquid to the substrate.   The spacer placement method according to claim 1, wherein in the attaching step, droplets of the spacer-containing liquid are formed and the droplets are attached on the substrate.   The spacer placement method according to claim 2, wherein, in the attaching step, the droplets are ejected toward the substrate from an opening of a head container that is movable relative to the substrate.   The spacer placement method according to claim 2, wherein in the attaching step, droplets of the spacer-containing liquid are sprayed on the substrate.   The spacer arrangement method according to claim 1, wherein in the attaching step, a liquid film of the spacer-containing liquid is formed on the substrate.   The spacer arrangement method according to claim 1, wherein the spacer-containing liquid is dried in the fixing step.   The spacer arrangement | positioning method of Claim 6 by which the surface of the said coupling spacer is formed with resin, or the functional group which can be couple | bonded with a board | substrate is couple | bonded with the surface of the said coupling spacer. The surface of the coupling spacer is formed of a resin that is cured by light irradiation,
6. The spacer arrangement method according to claim 1, wherein, in the fixing step, the light is applied to the bonding spacer in a state where the bonding spacer in the spacer-containing liquid is in contact with the surface of the substrate. .   In the fixing step, only a part of the substrate is irradiated with light through a mask to fix a bonding spacer in a spacer-containing liquid existing on the part of the substrate to the substrate. The spacer arrangement method according to any one of the above.   The spacer arrangement method according to any one of claims 1 to 9, wherein the coupling spacer is obtained by previously coupling the single spacers with a thermoplastic binder.   The surface of each single spacer is formed of a thermoplastic resin, and the bonding spacer is obtained by directly bonding the surfaces of the single spacers in advance by heating. Spacer placement method. After the fixing step, further comprising a stacking step of stacking another substrate on the substrate via the coupling spacer,
The spacer arrangement method according to claim 10 or 11, wherein the coupling spacer is heated in the overlapping step. A liquid crystal driving substrate having a pixel electrode, a color filter disposed opposite to the liquid crystal driving substrate, and a spacer disposed between the liquid crystal driving substrate and the color filter,
The liquid crystal display device, wherein the spacer is a combined spacer formed by combining a plurality of single spacers.

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