JP2007289826A - Film-forming method, manufacturing method of electro-optical substrate, manufacturing method of electo-optical device, functional film, electo-optical substrate, electo-optical device, and electronic equipment - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a film-forming method which restrains unevenness in film thickness in many respective functional films formed on a substrate; to provide a manufacturing method of an electro-optical substrate, a manufacturing method of an electro-optical device, a functional film, an electro-optical substrate, an electro-optical device, and electronic equipment. <P>SOLUTION: In the film-forming method, a liquid material containing a material for a functional film is arranged both in one or more functional film-forming areas for forming a functional film set in a function valid area on which the functional film on a substrate effectively functions, and in one or more adjustment film-forming areas set in an adjustment area around the function valid area, and then the liquid material is dried in a pressure-reduced environment to form the functional film. In addition, when the total amount of the liquid material arranged in the function valid area and in the adjustment area is a first total amount, the total amount of the liquid material is changed in accordance with the shape of the functional film in its thickness direction, the functional film being formed by drying the liquid material. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a film forming method for forming a functional film such as a light emitting film of an organic electroluminescence (hereinafter referred to as “organic EL”) device, a method for manufacturing an electro-optic substrate having the functional film, and The present invention relates to a method for manufacturing an electro-optical device having the functional film, a functional film, an electro-optical substrate, an electro-optical device, and an electronic apparatus including the electro-optical device.

  Conventionally, as a technique for forming a functional film such as a light emitting film of an organic EL device or a color filter film of a color liquid crystal device, a liquid material containing a functional film material is applied and the liquid material is dried to form a functional film. The technology to do is known. Since the functional film has different characteristics depending on the thickness, a plurality of functional films formed in an organic EL device or the like that need to have the same function (characteristics) are required to have uniform thickness. . For the same reason, each functional film is required to have a uniform thickness in each part of the functional film. However, the functional film formed by drying the liquid material has a thick convex shape at the central portion and a thin concave shape at the central portion, so that the film thickness in the same functional film is not uniform, Due to variations in the concave shape, the film thickness may not be uniform between the functional films.

  For example, in a color filter film of a color liquid crystal device, a color filter film with a non-uniform film thickness differs in transmitted light amount from a color filter film with a uniform film thickness. However, it is different from the luminance of the pixel assuming a color filter film having a uniform film thickness. If the brightness of multiple pixels that make up the minimum unit of an image (hereinafter referred to as “picture element”) deviates from the assumed brightness, the brightness and color of the picture element differ from the brightness and color to be displayed. . When the film thickness is not uniform among a plurality of color filter films formed in one color liquid crystal device, luminance unevenness and color unevenness occur.

  In Patent Document 1, a dummy region is provided around an effective optical region, which is a range in which an effective organic EL layer (light-emitting film) is to be formed, and a composition (liquid material) containing an organic EL material is also provided in the dummy region. A method of disposing and forming an organic EL layer is disclosed. As described in Patent Document 1, when a composition (liquid material) containing an organic EL material is dried, the concentration of the solvent evaporated from the composition is not uniform in the periphery of the range where the composition is disposed. The drying rate tends to be non-uniform due to the tendency to become non-uniform. Thereby, the cross-sectional shape of the cross section in the thickness direction of the organic EL layer formed in the peripheral pixel region is likely to vary among the pixel regions. Since each pixel region in the central part is surrounded by the peripheral part, the concentration of the solvent evaporated from the composition is substantially uniform, and the drying speed is unlikely to be uneven. Thereby, the cross-sectional shape of the organic EL layer formed in the central pixel region in the film thickness direction is unlikely to vary between the pixel regions. According to the method disclosed in Patent Document 1, an effective organic EL layer (light-emitting film) is formed by disposing a composition (liquid material) containing an organic EL material in a dummy region around the effective optical region. Almost all of the range to be formed is a central portion in which the cross-sectional shape of the organic EL layer hardly varies between the pixel regions. Thereby, the cross-sectional shape of the cross section in the thickness direction of the organic EL layer formed in the range is substantially uniform between the pixel regions.

JP 2002-222695 A

  However, the method disclosed in Patent Document 1 can suppress the variation between the pixel regions and can make the shape of the formed organic EL layer substantially uniform between the pixel regions. However, it cannot adjust the drying speed. Therefore, the organic EL layer formed in each pixel region has a problem that the film thickness in the pixel region is not necessarily uniform in each part.

  The present invention solves the above-described problem, and a film forming method capable of suppressing non-uniform thickness of each functional film formed on a substrate, a method for manufacturing an electro-optic substrate, It is an object of the present invention to realize a method for manufacturing an electro-optical device, a functional film, an electro-optical substrate, an electro-optical device, and an electronic apparatus.

  The film forming method according to the present invention is provided in one or more functional film forming regions where a functional film is to be formed, which is set in a functional effective region where the functional film on the substrate functions effectively, and around the functional effective region. Forming a functional film by disposing a liquid material containing a functional film material in one or more adjustment film formation areas set in the adjustment area and drying the liquid material in a reduced pressure environment According to the cross-sectional shape of the cross section in the thickness direction of the functional film formed by drying the liquid material when the total amount of the liquid material disposed in the function effective region and the adjustment region is the first total amount. The total amount of liquid material is changed.

  According to the film forming method of the present invention, when the total amount of the liquid material arranged in the function effective region and the adjustment region is the first total amount, the cross section in the thickness direction of the functional film formed by drying the liquid material The total amount of the liquid material arranged in the function effective region and the adjustment region, that is, the total amount of the liquid material arranged on the substrate is changed according to the cross-sectional shape. In the vacuum drying, the inventors of the present invention have confirmed that the time until drying is completed, that is, the drying speed, differs depending on the total amount of the liquid material arranged on the substrate. In addition, it is known that the cross-sectional shape in the thickness direction of the film formed by drying the liquid material varies depending on the drying speed. According to the film forming method of the present invention, the cross-sectional shape of the functional film is adjusted by changing the amount of the liquid material disposed in the functional effective region and the adjustment region according to the cross-sectional shape of the cross-section in the thickness direction of the functional film. can do. Thereby, it can suppress that a film thickness becomes non-uniform | heterogenous in each functional film formed on a board | substrate.

  In the present invention, the film forming method preferably changes the total amount of the liquid material arranged in the function effective region and the adjustment region by changing the amount of the liquid material arranged in the adjustment region.

  According to this film forming method, the adjustment of the total amount of the liquid material arranged on the substrate can be executed by adjusting the amount of the liquid material arranged in the adjustment region. Since the amount of liquid material placed in the functional film formation region of the functional effective region is not affected, the optimal amount of liquid material is applied to the functional film so as to realize the optimum film thickness for realizing the function that the functional film should have. It can be arranged in the formation region.

  In the present invention, in the film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the amount of the liquid material arranged in the adjustment region is the first arrangement amount is the film thickness on the peripheral side. Is thicker than the film thickness on the center side, it is preferable to dispose more liquid material than the first disposition amount in the adjustment region.

  It has been confirmed by the inventors of the present invention that when the drying speed is high, the formed functional film has a concave shape with a thicker peripheral part than the central part. According to this film forming method, the cross-sectional shape of the functional film when the amount of the liquid material arranged in the adjustment region is the first arrangement amount is such that the film thickness on the peripheral side is thicker than the film thickness on the central side. In some cases, a larger amount of liquid material than the first arrangement amount is arranged in the adjustment region, so that more liquid material is arranged on the substrate, so that it is more dry than when the first arrangement amount is arranged. The speed is slow. Thereby, the cross-sectional shape of the formed functional film can be corrected from a shape in which the film thickness on the peripheral side is thicker than the film thickness on the central side to a form in which the film thickness on the peripheral side is thinner than the film thickness on the central side. . Accordingly, the cross-sectional shape of the cross section in the thickness direction of the functional film to be formed can be made closer to a uniform film thickness from a shape in which the film thickness on the peripheral side is thicker than the film thickness on the central side.

  In the present invention, in the film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the amount of the liquid material arranged in the adjustment region is the first arrangement amount is the film thickness on the peripheral side. Is a shape thinner than the film thickness on the center side, it is preferable to dispose less liquid material than the first disposition amount in the adjustment region.

  It has been confirmed by the inventors of the present invention that when the drying speed is low, the formed functional film has a convex shape whose peripheral part is thinner than the central part. According to this film forming method, the cross-sectional shape of the functional film when the amount of the liquid material arranged in the adjustment region is the first arrangement amount is such that the film thickness on the peripheral side is thinner than the film thickness on the central side. In some cases, the amount of liquid material less than the first arrangement amount is arranged in the adjustment region, so the amount of liquid material arranged on the substrate is reduced, so that the case where the first arrangement amount is arranged is smaller. Increases drying speed. As a result, the sectional shape of the functional film formed in the thickness direction is changed from the shape in which the film thickness on the peripheral side is thinner than the film thickness on the central side to the film thickness on the peripheral side being thicker than the film thickness on the central side. Can be corrected. Therefore, the cross-sectional shape of the cross section in the thickness direction of the functional film to be formed can be made closer to a uniform film thickness from a shape in which the film thickness on the peripheral side is smaller than the film thickness on the central side.

  In the present invention, the film forming method may change the amount of the liquid material arranged in the adjustment region by changing the amount of the liquid material arranged in each adjustment film formation region of the one or more adjustment film formation regions.

  In the present invention, in the film formation method, the planar shape of each of the adjustment film formation regions of the one or more adjustment film formation regions is substantially the same as the planar shape of each of the function film formation regions of the one or more function film formation regions. In one adjustment film formation region, a liquid material of approximately the same amount as the liquid material to be arranged in one functional film formation region is arranged, and by changing the number of adjustment film formation regions in which the liquid material is arranged, You may change the quantity of the liquid material to arrange | position.

  In the present invention, in the film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the total amount is the first total arrangement amount is such that the film thickness on the peripheral side is thicker than the film thickness on the central side. In the case of the shape, it is preferable to dispose more liquid material than the first total disposition amount in the function effective region and the adjustment region.

  It has been confirmed by the inventors of the present invention that when the drying speed is high, the formed functional film has a concave shape with a thicker peripheral part than the central part. According to this film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film when the total amount of the liquid material arranged on the substrate is the first total arrangement amount, the film thickness on the peripheral side is the center side In the case where the shape is thicker than the film thickness, the amount of liquid material larger than the first total arrangement amount is arranged in the function effective region and the adjustment region, so that the total amount of liquid material arranged on the substrate increases. Therefore, the drying speed is slower than when the first total arrangement amount is arranged. Thereby, the cross-sectional shape of the formed functional film can be corrected from a shape in which the film thickness on the peripheral side is thicker than the film thickness on the central side to a form in which the film thickness on the peripheral side is thinner than the film thickness on the central side. . Accordingly, the cross-sectional shape of the cross section in the thickness direction of the functional film to be formed can be made closer to a uniform film thickness from a shape in which the film thickness on the peripheral side is thicker than the film thickness on the central side.

  In the present invention, in the film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the total amount is the first total arrangement amount, the film thickness on the peripheral side is thinner than the film thickness on the central side In the case of a shape, it is preferable to arrange a liquid material less than the first total arrangement amount in the function effective region and the adjustment region.

  It has been confirmed by the inventors of the present invention that when the drying speed is low, the formed functional film has a convex shape whose peripheral part is thinner than the central part. According to this film forming method, the cross-sectional shape of the cross section in the thickness direction of the functional film when the total amount of the liquid material arranged on the substrate is the first total arrangement amount, the film thickness on the peripheral side is the center side When the shape is thinner than the first film thickness, the amount of the liquid material smaller than the first total arrangement amount is arranged in the function effective region and the adjustment region, so that the total amount of the liquid material arranged on the substrate is reduced. Therefore, the drying speed is faster than when the first total arrangement amount is arranged. Thereby, the cross-sectional shape of the formed functional film can be corrected from a shape in which the film thickness on the peripheral side is thinner than the film thickness on the central side to a shape in which the film thickness on the peripheral side is thicker than the film thickness on the central side. . Therefore, the cross-sectional shape of the cross section in the thickness direction of the functional film to be formed can be made closer to a uniform film thickness from a shape in which the film thickness on the peripheral side is smaller than the film thickness on the central side.

  In the present invention, the film forming method preferably changes the total amount by changing the amount of the solvent contained in the liquid material disposed in the function effective region and the adjustment region.

  According to this film forming method, the adjustment of the total amount of the liquid material to be arranged on the substrate can be executed by adjusting the amount of the solvent of the liquid material to be arranged. The amount of material that forms the functional film, which is a solute contained in the liquid material placed in the functional film formation area of the functional effective area, is not affected, so the optimal film thickness is required to realize the function that the functional film should have. A liquid material containing an optimal amount of material can be disposed in the functional film forming region so as to be realized.

  The method for manufacturing an electro-optical substrate according to the present invention is a method for manufacturing an electro-optical substrate having a functional film, and is characterized in that at least one type of functional film is formed using the film forming method described above.

  According to the method for manufacturing an electro-optic substrate according to the present invention, since the functional film is formed using the film forming method capable of performing the uniform film thickness in the functional film, the film thickness in one functional film can be reduced. A suitable electro-optic substrate with small variations can be manufactured. For example, in the case of a color filter substrate, a high-performance electro-optic substrate can be manufactured so that it is easy to accurately display the color and brightness to be displayed.

  A method for manufacturing an electro-optical device according to the present invention is a method for manufacturing an electro-optical device having a functional film, wherein at least one type of functional film is formed using the above-described film forming method.

  According to the method for manufacturing an electro-optical device according to the present invention, the functional film is formed using the film forming method capable of performing the uniform film thickness in the functional film. A suitable electro-optical device with small variations can be manufactured. For example, in the case of an organic EL display device, a high-performance electro-optical device can be manufactured so that it is easy to accurately display the color and brightness to be displayed.

  The functional film according to the present invention is formed using the film forming method described above.

  According to the configuration of the functional film according to the present invention, since the film is formed by using the film forming method capable of performing the uniform film thickness in the functional film, the variation in the film thickness in one functional film is small. . Thereby, the suitable functional film which is easy to implement | achieve the desired function of a functional film is realizable.

  In the present invention, it is preferable that the functional film has a substantially circular or oval shape in plan view.

  When a functional film is formed by drying a liquid material containing a functional film material, the dry state of the liquid material near the edge varies depending on the shape of the edge of the functional film to be formed. For this reason, the thickness of the functional film is partially different depending on the shape of the edge, and the entire thickness is not uniform. For example, since the dry state is different between the side portion and the corner portion of the polygonal functional film, the thickness of the functional film is not uniform between the side portion and the corner portion. According to the configuration of the functional film, since the edges of the functional film are all part of the arc, the shape of the edge is substantially uniform over the entire circumference. Thereby, the dry state is substantially the same over the entire circumference, and the film thickness can be made substantially uniform over the entire circumference. Therefore, since there is little possibility that the shape of the functional film varies, it is possible to realize a functional film that easily realizes a desired function of the functional film.

  The electro-optic substrate according to the present invention is an electro-optic substrate having a functional film, wherein at least one functional film is the functional film described above.

  According to the electro-optical substrate according to the present invention, since at least one type of functional film is a suitable functional film that easily realizes a desired function of the functional film, a suitable electro-optical substrate that easily realizes a desired function. Can be realized.

  An electro-optical device according to the present invention is an electro-optical device including an electro-optical substrate having a functional film, and the electro-optical substrate is the above-described electro-optical substrate.

  According to the electro-optical device according to the present invention, since at least one type of functional film is a suitable functional film that easily realizes a desired function of the functional film, the preferred electro-optical device that easily realizes a desired function. Can be realized.

  An electronic apparatus according to the present invention includes the above-described electro-optical device.

  The electronic apparatus according to the present invention includes a suitable electro-optical device that easily realizes a desired function. Therefore, a suitable electronic apparatus that easily realizes a desired function can be realized.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a film forming method, an electro-optical substrate manufacturing method, an electro-optical device manufacturing method, and a functional film, an electro-optical substrate, and an electro-optical device according to embodiments of the invention will be described with reference to the drawings. . Embodiments of the present invention include a step of manufacturing a color filter substrate of a liquid crystal display panel constituting a liquid crystal display device that is an example of an electro-optical device, and a step of manufacturing an organic EL display device that is an example of an electro-optical device. A film forming method used in the process of forming a functional film will be described as an example.

(First embodiment)
The first embodiment is a process of forming a color element film as a filter film, which is an example of a functional film, in the process of manufacturing a color filter substrate of a liquid crystal display panel constituting a liquid crystal display device, which is an example of an electro-optical device. The film forming method used in the above will be described as an example.

(Configuration of LCD panel)
First, a liquid crystal display panel will be described. FIG. 1 is a schematic view showing the structure of a liquid crystal display panel. FIG. 1A is a plan view of a liquid crystal display panel as viewed from the filter substrate side together with each component, and FIG. 1B shows a cross-sectional shape in the cross section indicated by AA in FIG. It is a schematic sectional drawing shown. In each drawing used in the following description, each layer or member has a different scale so that each layer or member can be recognized on the drawing.

  As shown in FIGS. 1A and 1B, a liquid crystal display panel 10 includes an element substrate 1 having a TFT (Thin Film Transistor) element 3 and a pixel electrode 6b, and a filter substrate having a counter electrode 6a and a color filter 5. 2 and a liquid crystal 8 filled in a gap between the element substrate 1 and the filter substrate 2 bonded by the sealing material 4. The element substrate 1 protrudes in a frame shape slightly larger than the filter substrate 2.

  The element substrate 1 uses a quartz glass substrate having a thickness of about 1.2 mm. The surface of the element substrate 1 includes a pixel electrode 6b constituting a pixel and a TFT element 3 in which one of the three terminals is connected to the pixel electrode 6b. Is formed. The remaining two terminals of the TFT element 3 are connected to a data line (not shown) and a scanning line (not shown) which are arranged in a grid pattern so as to surround the pixel electrode 6b and are insulated from each other. The data line is drawn out in the Y-axis direction and connected to the data line driving circuit unit 9a at the terminal unit 16. The scanning lines are drawn out in the X-axis direction and are individually connected to two scanning line driving circuit units 9b and 9b formed in the left and right frame regions. The input side wirings of each data line driving circuit unit 9 a and scanning line driving circuit unit 9 b are connected to mounting terminals 11 arranged along the terminal unit 16, respectively. In the frame region opposite to the terminal portion 16, a wiring 12 that connects the two scanning line drive circuit portions 9b and 9b is provided.

  The filter substrate 2 uses a glass substrate 2a made of transparent quartz glass having a thickness of approximately 1.0 mm, and is provided with a counter electrode 6a as a common electrode. The counter electrode 6a is electrically connected to the wiring provided on the element substrate 1 side via the vertical conduction parts 14 provided at the four corners of the glass substrate 2a. The wiring is also connected to the mounting terminal 11 provided in the terminal part 16. It is connected. The filter substrate 2 is provided with a color filter 5 in which a color element film 53 is formed at a position facing the pixel electrode 6b.

  An alignment film 7b and an alignment film 7a are formed on the surface of the element substrate 1 facing the liquid crystal 8 and the surface of the filter substrate 2, respectively.

  In the liquid crystal display panel 10, a relay substrate that is electrically connected to an external drive circuit is connected to the mounting terminal 11. An input signal from the external drive circuit is input to each data line drive circuit unit 9a and scan line drive circuit unit 9b, whereby the TFT element 3 is switched for each pixel electrode, and the pixel electrode 6b and the counter electrode 6a During this period, a drive voltage is applied and display is performed.

  Although not shown in FIG. 1, polarizing plates are provided on the front and back surfaces of the liquid crystal display panel 10 to deflect light incident / exited.

(Color filter)
Next, the color filter 5 formed on the filter substrate 2 and the arrangement of the color element films 53 in the color filter 5 will be described. FIG. 2A is a plan view schematically showing a planar structure of an embodiment of a color filter, and FIGS. 2B and 2C are schematic plan views showing an arrangement example of a three-color color filter. .

  As described above, the filter substrate 2 is formed using the glass substrate 2a made of transparent quartz glass having a thickness of approximately 1.0 mm. As shown in FIG. 2A, in the color filter 5, a plurality of color element regions 52 are formed in a dot pattern shape in the filter effective region 52A on the surface of the rectangular glass substrate 2a, in this embodiment, in a dot matrix shape. The color element film 53 is formed in the color element region 52. An adjustment area 152A is set around the filter effective area 52A of the glass substrate 2a. An adjustment color element region 152 having substantially the same shape as the color element region 52 is formed in the adjustment region 152A, and an adjustment color element film 153 equivalent to the color element film 53 is formed in the adjustment color element region 152. Yes. As described above, when the element substrate 1 and the filter substrate 2 are combined, the color element film 53 is opposed to the pixel electrode 6b, and a drive voltage is applied between the pixel electrode 6b and the counter electrode 6a for control. The transmitted light passes through the color element film 53. The color element film 53 is an optical filter, and light transmitted through the color element film 53 becomes light of a color corresponding to the color of the color element film 53. The color element film 53 corresponds to a functional film, the color element area 52 corresponds to a functional film formation area, and the filter effective area 52A corresponds to a function effective area. The adjustment color element region 152 corresponds to the adjustment film formation region, and the adjustment region 152A corresponds to the adjustment region. The filter substrate 2 corresponds to an electro-optical substrate having a functional film.

  As shown in FIGS. 2B and 2C, the color element film 53 is divided by a plurality of partition walls 56 formed in a lattice pattern by a non-translucent resin material and arranged in a dot matrix. For example, the rectangular color element region 52 is filled with a color material. The adjustment color element film 153 is made of the same material as that of the partition wall 56 and is divided by a partition wall 156 (see FIG. 6) formed in the same shape as the partition wall 56, and a plurality of, for example, square adjustments arranged in a dot matrix form. It is formed by filling the color element region 152 with a color material. For example, a liquid material containing a color material constituting the color element film 53 is filled in the color element region 52, and the liquid material is evaporated by evaporating the solvent of the liquid material to dry the liquid material, thereby filling the color element region 52. A color element film 53 is formed. Similarly, the adjustment color element film 153 is prepared by filling the adjustment color element region 152 with a liquid material containing the color material constituting the color element film 53, evaporating the solvent of the liquid material, and drying the liquid material. A film-like adjustment color element film 153 filling the color element region 152 is formed.

  As the arrangement of the color element films 53, for example, a stripe arrangement, a mosaic arrangement, a delta arrangement, and the like are known. As shown in FIG. 2B, the stripe arrangement is an arrangement in which the matrix columns all become the color element films 53 of the same color. The mosaic arrangement is an arrangement in which the color is shifted by one color element film 53 for each horizontal row as shown in FIG. 2C. The three color element films 53 are arranged in three colors. In the delta arrangement, the arrangement of the color element films 53 is different, and in the case of a three-color filter, any three adjacent color element films 53 have different colors.

  In the three-color filter shown in FIGS. 2B and 2C, each of the color element films 53 is a color material of any one of R (red), G (green), and B (blue). Is formed by. A set of color element films 53 each including R (red), G (green), and B (blue) color element films 53R, 53G, and 53B, which are formed adjacent to each other, and is the smallest unit that constitutes an image. A filter of a certain pixel (hereinafter referred to as “picture element filter 54”) is formed. Full color display is performed by selectively allowing light to pass through one or a combination of the color element films 53R, 53G, and 53B in one picture element filter 54. At this time, the partition 56 formed of a resin material having no translucency functions as a black matrix.

(Droplet ejection method and droplet ejection head)
Next, a droplet discharge method used when filling the color element region 52 and the adjustment color element region 152 with a liquid material will be described. Examples of the discharge technique of the droplet discharge method include a charge control method, a pressure vibration method, an electromechanical conversion method, an electrothermal conversion method, and an electrostatic suction method. In the charge control method, a charge is applied to a material with a charging electrode, and the flight direction of the material is controlled with a deflection electrode to be discharged from a discharge nozzle. In addition, the pressure vibration method is a method in which an ultra-high pressure of about 30 kg / cm ² is applied to the material and the material is discharged to the tip side of the discharge nozzle. When no control voltage is applied, the material moves straight and the discharge nozzle When a control voltage is applied, electrostatic repulsion occurs between the materials, and the materials are scattered and are not discharged from the discharge nozzle. The electromechanical conversion method utilizes the property that a piezoelectric element (piezoelectric element) is deformed by receiving a pulse-like electric signal. The piezoelectric element is deformed through a flexible substance in a space where material is stored. Pressure is applied, and the material is extruded from this space and discharged from the discharge nozzle.

  In the electrothermal conversion method, a material is rapidly vaporized by a heater provided in a space in which the material is stored to generate bubbles, and the material in the space is discharged by the pressure of the bubbles. In the electrostatic attraction method, a minute pressure is applied to a space in which a material is stored, a meniscus of material is formed on the discharge nozzle, and an electrostatic attractive force is applied in this state before the material is drawn out. In addition to this, techniques such as a system that uses a change in the viscosity of a fluid due to an electric field and a system that uses a discharge spark are also applicable. The droplet discharge method has an advantage that the use of the material is less wasteful and a desired amount of the material can be accurately disposed at a desired position. Among these, the piezo method has an advantage that it does not affect the composition of the material because it does not apply heat to the liquid material. In the present embodiment, the above piezo method is used from the viewpoint of the high degree of freedom in selecting the liquid material and the good controllability of the droplets.

  Next, a droplet discharge head of a device manufacturing apparatus used when manufacturing a device according to the present invention by a droplet discharge method will be described. This device manufacturing apparatus is a droplet discharge apparatus (inkjet apparatus) that manufactures a device by discharging (dropping) droplets from a droplet discharge head onto a substrate. FIG. 3 is a diagram showing an outline of the appearance of the droplet discharge head. FIG. 3A is a perspective view showing an outline of the appearance of the droplet discharge head, and FIG. 3B is a diagram showing an arrangement of nozzles. As shown in FIG. 3A, the droplet discharge head 62 has, for example, a nozzle row 68 in which a plurality of discharge nozzles 67 are arranged. The number of the discharge nozzles 67 is, for example, 180, the hole diameter of the discharge nozzles 67 is, for example, 28 μm, and the pitch of the discharge nozzles 67 is, for example, 141 μm (see FIG. 3B). A reference direction S shown in FIG. 3A indicates a main scanning direction when the droplet discharge head 62 moves relative to the substrate in order to land the droplet on an arbitrary position on the substrate. Indicates the arrangement direction of the discharge nozzles 67 in the nozzle row 68.

  FIG. 4A is a perspective view showing the structure of the droplet discharge head, and FIG. 4B is a cross-sectional view showing the detailed structure of the discharge nozzle portion of the droplet discharge head. As shown in FIGS. 4A and 4B, each droplet discharge head 62 includes a vibration plate 73 and a nozzle plate 74. Between the vibration plate 73 and the nozzle plate 74, a liquid pool 75 in which a material liquid supplied from a liquid material tank (not shown) through a supply hole 77 is always filled is located. In addition, a plurality of head partitions 71 are located between the diaphragm 73 and the nozzle plate 74. A space surrounded by the diaphragm 73, the nozzle plate 74, and the pair of head partition walls 71 is a cavity 70. Since the cavities 70 are provided corresponding to the discharge nozzles 67, the number of the cavities 70 and the number of the discharge nozzles 67 are the same. The material liquid is supplied from the liquid pool 75 to the cavity 70 via the supply port 76 positioned between the pair of head partition walls 71.

  On the diaphragm 73, the vibrator 72 is positioned corresponding to each cavity 70. The vibrator 72 includes a piezo element 72c and a pair of electrodes 72a and 72b sandwiching the piezo element 72c. By applying a driving voltage to the pair of electrodes 72a and 72b, the liquid material is discharged as droplets from the corresponding discharge nozzle 67. In order to prevent a part of the liquid material discharged from the discharge nozzle 67 from adhering to the nozzle plate 74, a liquid repellent treatment layer 2P having liquid repellency with respect to the liquid material is formed on the outer surface of the nozzle plate 74. Has been.

  The control device (not shown) controls the discharge of the liquid material to each of the plurality of discharge nozzles 67 by controlling the voltage applied to the piezo element 72c, that is, by controlling the drive signal. More specifically, the volume of droplets ejected from the ejection nozzle 67, the number of droplets ejected per unit time, the distance between droplets landed on the substrate, and the like can be changed. For example, by selectively using a discharge nozzle 67 that discharges droplets from among a plurality of discharge nozzles 67 arranged in the nozzle row 68, the length of the nozzle row 68 is within the range in the arrangement direction T. Thus, a plurality of droplets can be discharged simultaneously at the pitch interval of the discharge nozzles 67. In the direction of the reference direction S, the distance between the droplets that have landed on the substrate can be individually changed for each discharge nozzle 67 that discharges the droplet. In addition, the volume of the droplet discharged from each of the discharge nozzles 67 is variable between 1 pl and 300 pl (picoliter).

(Liquid material amount and film thickness)
Next, when the liquid material filled in the color element region 52 is dried under a reduced pressure environment to form the color element film 53, the amount of the liquid material disposed on the glass substrate 2a and the formed color element The relationship with the shape of the film 53 in the thickness direction will be described. FIG. 5A is a graph showing the transition of the pressure of the atmosphere from the start of exhaust, and FIG. 5B is a graph showing the relationship between the amount of liquid material and the central film thickness. FIGS. 5C and 5D are schematic cross-sectional views showing examples of the cross-sectional shape of the color element film.

  The horizontal axis of the graph in FIG. 5A indicates the elapsed time since the start of exhaust for decompression, and the vertical axis indicates the pressure of the atmosphere to be decompressed. A solid line 81 indicates the atmospheric pressure when the adjustment color element region 152 (see FIG. 2) is filled with the same amount of liquid material as the amount filled in the color element region 52. A broken line 82 indicates the pressure of the atmosphere when the adjustment color element region 152 is filled with a liquid material larger than the amount filled in the color element region 52. An alternate long and short dash line 83 indicates the pressure of the atmosphere when the adjustment color element region 152 is filled with a liquid material less than the amount filled in the color element region 52. The drying point 81a, the drying point 82a, and the drying point 83a indicate the time points when the liquid material filled in the color element region 52 is completely dried and the color element film 53 is formed. The amount of liquid material filled in the color element region 52 is the same. Even if the amount of the liquid material filled in the color element region 52 is the same, the time required for drying, that is, the drying speed differs depending on the amount of the liquid material filled in the adjustment color element region 152, and the more liquid material filled, the faster the drying speed. Is slow. Since the amount of the liquid material filled in the color element region 52 is the same, the amount of the liquid material filled in the adjustment color element region 152 is the amount of the liquid material arranged in the adjustment region 152A, and is on the glass substrate 2a. Some of the liquid material placed.

  The horizontal axis of the graph in FIG. 5B indicates the amount of the liquid material filled in the adjustment color element region 152. The vertical axis indicates the film thickness at the center of the formed color element film 53 indicated by the arrow a in FIG. The amount of the liquid material filled in the color element region 52 is the same. Even if the amount of liquid material filled in the color element region 52 is the same, the film thickness at the center of the color element film 53 formed differs depending on the amount of liquid material filled in the adjustment color element region 152, and the adjustment color element region 152 It can be seen that the thicker the liquid material filled in, the thicker the central film thickness. The cross-sectional shape of the color element film 53 is the same as the convex shape shown in FIG. 5D when the central film thickness is large because the amount of liquid material filled in the color element region 52 is the same. When the film thickness at the center is small, it becomes close to a concave shape as shown in FIG. Since the amount of the liquid material filled in the color element region 52 is the same, the amount of the liquid material filled in the adjustment color element region 152 is the amount of the liquid material arranged in the adjustment region 152A, and is on the glass substrate 2a. Some of the liquid material placed.

<Manufacture of filter substrate>
Next, the color element film forming process of the filter substrate 2 will be described with reference to FIG. FIG. 6 is a schematic cross-sectional view showing the color element film forming step of the filter substrate.

  First, as shown in FIG. 6A, partition walls 56 and partition walls 156 are formed on the surface of the glass substrate 2a. The partition wall 56 and the partition wall 156 are formed by, for example, applying a liquid material including the material of the partition wall 56 and the partition wall 156 to the surface of the glass substrate 2a and drying to form a partition film, and performing color etching on the color element region 52 and the adjustment color. It is formed by removing portions such as the element region 152. The glass substrate 2a corresponds to a substrate on which a functional film is formed.

  Next, the glass substrate 2a on which the partition wall 56 and the partition wall 156 are formed is subjected to a surface treatment so that the liquid material can be easily filled. The color element region bottom 52a or the adjustment color element region bottom 152a surrounded by the partition skirt 56a or the partition skirt 156a, the partition side surface 56b, and the partition side surface 156b are lyophilic with respect to the liquid material 530 containing the material of the color element film 53. The partition top 56c and the partition top 156c are processed so as to be liquid repellent with respect to the liquid material 530. By this processing, the liquid material 530 disposed in the color element region 52 or the adjustment color element region 152 becomes easy to become familiar with the color element region 52 or the adjustment color element region 152, and overflows from the color element region 52 or the adjustment color element region 152. It becomes difficult to put out.

  Next, as shown in FIG. 6B, a liquid material 530 containing a color element forming material in each of the plurality of color element regions 52 and the adjustment color element region 152 formed by the partition walls 56 is discharged from the droplet discharge head 62. The droplets are discharged as droplets 530a, and the color element region 52 is filled with the liquid material 530. The adjustment color element region 152 is filled with a larger amount of the liquid material 530 than the amount of the liquid material 530 filled in the color element region 52. The amount of the liquid material 530 filled in the color element region 52 is the same, and when the amount of the liquid material 530 filled in the adjustment color element region 152 increases, the adjustment color element region 152 also has the same amount as the color element region 52. Compared with the case where the liquid material 530 is filled, the amount of the liquid material 530 disposed in the adjustment region 152A increases, and the amount of the liquid material 530 disposed on the glass substrate 2a increases. The amount of the liquid material 530 to be filled is adjusted by adjusting the number of droplets 530a ejected toward the color element region 52 or the adjustment color element region 152.

  Of course, the liquid material 530 containing different color element materials is discharged to each color element region 52 or adjustment color element region 152 where the color element films 53 or adjustment color element films 153 of different colors are formed. For example, in the above-described three-color filter (see FIGS. 2B and 2C), different color elements corresponding to the color element regions 52 in which the color element films 53R, 53G, and 53B of different colors are formed. Three liquid materials 530 containing the material are sequentially filled in the droplet discharge head 62 and discharged. Three liquid materials 530 containing different color element materials are sequentially filled into the droplet discharge head 62 and discharged corresponding to each adjustment color element region 152 where the adjustment color element films 153 of different colors are formed. Alternatively, a plurality of droplet discharge heads 62 may be prepared, and liquid materials 530 containing different color element materials may be filled and discharged.

  Next, the glass substrate 2a is put into a reduced pressure environment, and the liquid material 530 is dried to form the color element film 53 and the adjustment color element film 153. Strictly speaking, the liquid material 530 starts drying from the moment when it is discharged as the droplet 530a from the droplet discharge head 62, but it is almost normal at normal pressure by adjusting the boiling point of the solvent of the liquid material 530 and the like. It can be made to dry in a pressure-reduced state without drying. After the arrangement of the liquid material 530 is completed, it is preferable that the liquid material 530 has a high ratio of the high-boiling solvent whose drying progress is slow so that almost all the drying is performed in the drying process under reduced pressure. .

  As shown in FIG. 6C, the color element film 53 having a substantially flat film thickness and a uniform color element film surface 531 is formed by executing a drying process in a reduced pressure state. When the liquid material 530 of the present embodiment is filled with the liquid material 530 in an amount equal to the amount of the liquid material 530 filled in the color element region 52 in the adjustment color element region 152 and dried, the surface of the liquid material 530 of FIG. It becomes a concave shape like a surface 532 indicated by a two-dot chain line in FIG. The adjustment color element region 152 is filled with a larger amount of the liquid material 530 than the amount of the liquid material 530 filled in the color element region 52, so that the liquid material 530 that fills the color element region 52 in the adjustment color element region 152. The amount of the liquid material 530 disposed in the adjustment region 152A is larger than the case where the liquid material 530 having the same amount as that of the liquid material 530 is filled and dried, and the amount of the liquid material 530 disposed on the glass substrate 2a is increased. The amount increases. As the amount of the liquid material 530 disposed on the glass substrate 2a is increased, the drying speed is decreased as shown in FIG. 5A, and the color element film 53 is formed as shown in FIG. The central film thickness is increased. This corrects the concave shape when the adjustment color element region 152 is filled with the liquid material 530 in an amount equal to the amount of the liquid material 530 filled in the color element region 52 and dried, and the color element film surface 531 is corrected. Is substantially flat and a color element film 53 having a substantially uniform film thickness is formed.

  As shown in FIG. 6C, the color element film 53 is formed, and the color element film forming process of the filter substrate 2 is completed. Further, the process of forming the counter electrode 6a and the alignment film 7a is executed to form the filter substrate 2.

Hereinafter, effects of the first embodiment will be described. According to the first embodiment, the following effects can be obtained.
(1) When the liquid material 530 is filled with the liquid material 530 in an amount equal to the amount of the liquid material 530 filled in the color element region 52 in the adjustment color element region 152 and dried, the film thickness at the center is reduced. It becomes thinner and the cross-sectional shape becomes concave. The adjustment color element region 152 is filled with a larger amount of the liquid material 530 than the amount of the liquid material 530 filled in the color element region 52, so that the liquid material 530 that fills the color element region 52 in the adjustment color element region 152. The amount of the liquid material arranged on the glass substrate 2a is increased as compared with the case where the same amount of the liquid material 530 is filled. When the amount of the liquid material 530 disposed on the glass substrate 2a is increased, the drying speed of the disposed liquid material 530 is decreased, and the film thickness at the center of the color element film 53 is increased. This corrects the concave shape when the adjustment color element region 152 is filled with the liquid material 530 in an amount equal to the amount of the liquid material 530 filled in the color element region 52 and dried, and the film thickness is substantially uniform. A color element film 53 can be formed.

  (2) The amount of light transmitted through the color element film 53 is affected by the thickness of the color element film 53. Since the filter substrate 2 includes the color element film 53 having a substantially uniform film thickness, it is possible to easily form the color element film 53 that can transmit the amount of light that should be transmitted by the color element film 53. Therefore, it is possible to realize a suitable filter substrate 2 that can realize the luminance to be realized by transmitting the amount of light to be transmitted.

  (3) Since the liquid crystal display panel 10 includes the color element film 53 having a substantially uniform film thickness, the color element film 53 that can transmit the amount of light that should be transmitted by the color element film 53 can be easily formed. be able to. Accordingly, it is possible to realize a suitable liquid crystal display panel 10 capable of realizing the luminance to be realized by transmitting the amount of light to be transmitted.

(Second embodiment)
Next, a film forming method, an electro-optical substrate manufacturing method, and an electro-optical device manufacturing method according to the present invention, and a functional film, an electro-optical substrate, and an electro-optical device according to a second embodiment are described. This will be described with reference to the drawings. In this embodiment, a film forming method used in a process of forming a light emitting layer and a hole transport layer, which are examples of functional films, in the process of manufacturing an organic EL display device, which is an example of an electro-optical device, will be described as an example. . Since the droplet discharge device of the present embodiment is substantially the same as the droplet discharge device described in the first embodiment, the description of the droplet discharge device is omitted.

(Configuration of organic EL display device)
First, the configuration of the organic EL display device will be described. FIG. 7 is a schematic front view showing the organic EL display device. FIG. 7A is a schematic front view showing the entire organic EL display device, FIG. 7B is a schematic view showing the arrangement of organic EL elements, and FIG. 7C shows an element substrate. It is a schematic plan view shown. As shown in FIG. 7A, the organic EL display device 100 of this embodiment includes an element substrate 101 having a plurality of organic EL elements 107 that are light emitting elements, and a sealing substrate 109. The organic EL element 107 is a so-called color element, and the organic EL display device 100 includes an organic EL element 107 of three colors, a red element 107R (red), a green element 107G (green), and a blue element 107B (blue). Have. The organic EL element 107 is disposed in the display area 106 and an image is displayed in the display area 106. The display area 106 corresponds to a function effective area.

  For example, as shown in FIG. 7B, the three-color organic EL elements 107 on the element substrate 101 are arranged in a stripe arrangement in which the same-color organic EL elements 107 are arranged in the vertical direction in the drawing. The planar shape of each organic EL element 107 is substantially circular. The arrangement density of the organic EL elements 107 is increased by shifting the organic EL elements 107 arranged in the vertical direction in the figure in the horizontal direction in the figure.

  The element substrate 101 includes a plurality of switching elements 112 (see FIG. 8) as drive elements at positions corresponding to the respective organic EL elements 107. The switching element 112 is, for example, a TFT (Thin Film Transistor) element. In addition, two scanning line driving circuit units 103 and 103 for driving the switching element 112 and one data line driving circuit unit 104 are provided in a portion that is slightly larger than the sealing substrate 109 and extends in a frame shape. Yes. A flexible relay substrate 108 for connecting the drive circuit portions 103 and 104 and an external drive circuit is mounted on the terminal portion 101 a of the element substrate 101. These drive circuit portions 103 and 104 are configured by, for example, forming a low-temperature polysilicon semiconductor layer on the surface of the element substrate 101 in advance.

  As shown in FIG. 7C, an adjustment area 206 is set around the display area 106. The adjustment region 206 includes an adjustment hole transport layer 216 (see FIG. 8) having substantially the same shape as the hole transport layer 116 (see FIG. 8) and the light emitting layer 117 (see FIG. 8) constituting the organic EL element 107, and An adjustment organic EL film 207 having an adjustment light emitting layer 217 (see FIG. 8) is formed.

  FIG. 8 is a cross-sectional view of a main part including the organic EL element of the organic EL display device. The element substrate 101 includes a glass substrate 110, a plurality of switching elements 112 formed on one surface of the glass substrate 110 in the display region 106 (see FIG. 7) set on the glass substrate 110, and switching elements. 112, an insulating layer 111 formed so as to cover 112, a plurality of pixel electrodes 114 formed on the insulating layer 111 and electrically connected to the switching element 112 through the conductive layer 114a, and a plurality of pixel electrodes 114 A bank 115 formed therebetween. Further, a hole transport layer 116 formed on the pixel electrode 114 in a region partitioned by the bank 115 (hereinafter referred to as “pixel region 121”) and a layer stacked on the hole transport layer 116 are formed. The light emitting layer 117 and the counter electrode 118 provided so as to cover the light emitting layer 117 and the bank 115.

  The element substrate 101 is continuous with the bank 115 formed in the display region 106 (see FIG. 7) in the adjustment region 206 (see FIG. 7C) set on the glass substrate 110. 115 has a bank 215 having substantially the same shape as 115. In a region partitioned by the bank 215 (hereinafter referred to as “adjusted pixel region 221”), an adjusted hole transport layer 216 and an adjusted light emitting layer 217 formed on the adjusted hole transport layer 216 are stacked. And are formed. The adjusted hole transport layer 216 and the adjusted light emitting layer 217 constitute the adjusted organic EL film 207.

  In the organic EL display device 100, a sealing substrate 109 is disposed facing the counter electrode 118 of the element substrate 101, and an inert gas 120 is sealed between the counter electrode 118 and the sealing substrate 109. The pixel electrode 114, the hole transport layer 116 surrounded by the bank 115, the light emitting layer 117, and the counter electrode 118 correspond to the organic EL element 107.

  A red light emitting layer 117R (red system), a green light emitting layer 117G (green system), and a blue light emitting layer 117B (blue system) are formed in the pixel region 121 to emit red, green, and blue light, respectively. Element 107R, green element 107G, and blue element 107B are formed. A set of organic EL elements 107 each including one red element 107R, one green element 107G, and one blue element 107B forms a picture element, which is the minimum unit constituting an image. Full color display is performed by selectively emitting light to any one or combination of the red element 107R, the green element 107G, and the blue element 107B in one pixel.

<Manufacture of organic EL elements>
Next, a process of forming the hole transport layer 116 and the light emitting layer 117 constituting the organic EL element 107 in the element substrate 101 of the organic EL display device 100 will be described with reference to FIGS. 9 and 10. FIGS. 9A, 9B, and 9C are schematic cross-sectional views illustrating a process for forming a hole transport layer of the element substrate, and FIGS. 10A, 10B, 10C, and 10D are illustrated. FIG. 4 is a schematic cross-sectional view showing a process for forming a light emitting layer of an element substrate.

  As shown in FIG. 9A, the display region 106 (see FIG. 7C) of the glass substrate 110 on which the switching element 112, the insulating layer 111, the conductive layer 114a, and the pixel electrode 114 are formed. Banks 115 are formed on the surface. Further, a bank 215 is formed on the surface of the adjustment area 206 (see FIG. 7C) around the display area 106. For the banks 115 and 215, for example, a liquid material containing the material of the banks 115 and 215 is applied to the surface of the glass substrate 110 and dried to form a bank film, and the pixel region 121 and the adjustment pixel region 221 are formed by photoetching or the like. Form by removing parts such as. The glass substrate 110 corresponds to a substrate on which a functional film is formed. The element substrate 101 corresponds to an electro-optical substrate having a functional film.

  Next, the glass substrate 110 on which the bank 115 and the bank 215 are formed and cleaned is subjected to a surface treatment so that the liquid material can be easily filled. The bottom of the pixel region 121 or the adjustment pixel region 221 surrounded by the bank 115 or the bank 215 and the side surface of the bank 115 and the bank 215 are lyophilic with respect to the liquid material 560 including the material of the hole transport layer 116. The tops of the banks 115 and 215 are processed so as to be liquid repellent with respect to the liquid material 560. By this processing, the liquid material 560 arranged to be filled in the pixel region 121 or the adjustment pixel region 221 can easily become familiar with the pixel region 121 or the adjustment pixel region 221 and hardly overflow from the pixel region 121 or the adjustment pixel region 221. Become.

  Next, as shown in FIG. 9B, a liquid material 560 containing the material of the hole transport layer 116 is dropped into each of the plurality of pixel regions 121 or the adjustment pixel region 221 formed by the bank 115 or the bank 215. The liquid droplets 560a are discharged from the discharge head 62, and the liquid material 560 is filled in the pixel region 121 and the adjustment pixel region 221. The adjustment pixel region 221 is filled with an amount of the liquid material 560 that is smaller than the amount of the liquid material 560 that fills the pixel region 121. The amount of the liquid material 560 filled in the pixel region 121 is the same, and when the amount of the liquid material 560 filled in the adjustment pixel region 221 decreases, the adjustment material region 221 is also supplied with the same amount of liquid material 560 as the pixel region 121. Compared to the case of filling, the amount of the liquid material 560 disposed in the adjustment region 206 is decreased, and the amount of the liquid material 560 disposed on the glass substrate 110 is decreased. The amount of the liquid material 560 to be filled is adjusted by adjusting the number of droplets 560 a discharged toward the pixel region 121 or the adjustment pixel region 221. The hole transport layer 116 corresponds to a functional film, the pixel region 121 corresponds to a functional film formation region, and the adjustment pixel region 221 corresponds to an adjustment film formation region.

  Next, the glass substrate 110 on which the liquid material 560 is disposed is put into a reduced pressure environment, and the liquid material 560 is dried to form the hole transport layer 116 and the adjusted hole transport layer 216. Strictly speaking, the liquid material 560 starts drying from the moment when it is ejected as the droplet 560a from the droplet ejection head 62. However, by adjusting the boiling point of the solvent of the liquid material 560, the liquid material 560 is almost at normal pressure. It can be made to dry in a pressure-reduced state without drying. After the arrangement of the liquid material 560 is completed, it is preferable that the liquid material 560 has a high ratio of the high-boiling solvent whose drying progress is slow so that almost all drying is performed in the drying step under a reduced pressure environment. .

  As shown in FIG. 9C, the drying step in a reduced pressure state is performed, and the hole transport layer 116 having a substantially flat hole transport layer surface 561 and a substantially uniform film thickness is formed. When the liquid material 560 of this embodiment is filled in the adjustment pixel region 221 with the same amount of the liquid material 560 as the pixel region 121 and the liquid material 560 is dried, the surface has two points in FIG. It has a convex shape like a surface 562 indicated by a chain line.

  The adjustment pixel region 221 is filled with a smaller amount of the liquid material 560 than the amount of the liquid material 560 filled in the pixel region 121, so that the adjustment pixel region 221 has the same amount of the liquid material 560 filled in the pixel region 121. The amount of the liquid material 560 disposed in the adjustment region 206 is reduced and the amount of the liquid material 560 disposed on the glass substrate 110 is decreased as compared with the case where the amount of the liquid material 560 is filled and dried. . Since the amount of the liquid material 560 disposed on the glass substrate 110 is reduced, the drying speed is increased as illustrated in FIG. 5A, and the hole transport layer 116 is illustrated as illustrated in FIG. The film thickness at the center of the film becomes thinner. This corrects the convex shape when the adjustment pixel region 221 is filled with the liquid material 560 in an amount equal to the amount of the liquid material 560 filled in the pixel region 121 and dried, so that the hole transport layer surface 561 is substantially the same. A hole transport layer 116 that is flat and has a substantially uniform film thickness is formed.

  Next, as shown in FIG. 10A, the light emitting layer 117 is formed on the glass substrate 110 on which the hole transport layer 116 and the adjusted hole transport layer 216 are formed. As shown in FIG. 10B, a liquid material 570 containing the material of the light emitting layer 117 in each of the plurality of pixel regions 121 or the adjustment pixel regions 221 formed by the banks 115 or 215 is supplied from the droplet discharge head 62. The liquid material 570 is filled into the pixel region 121 and the adjustment pixel region 221 by discharging as droplets 570a. The adjustment pixel region 221 is filled with a larger amount of the liquid material 570 than the amount of the liquid material 570 filled in the pixel region 121. The amount of the liquid material 570 filled in the pixel region 121 is the same, and when the amount of the liquid material 570 filled in the adjustment pixel region 221 increases, the liquid material 570 of the same amount as the pixel region 121 is also added to the adjustment pixel region 221. Compared to the case of filling, the amount of the liquid material 570 disposed in the adjustment region 206 is increased, and the amount of the liquid material 570 disposed on the glass substrate 110 is increased. The amount of the liquid material 570 to be filled is adjusted by adjusting the number of droplets 570a ejected toward the pixel region 121 or the adjustment pixel region 221. The light emitting layer 117 corresponds to a functional film, the pixel region 121 corresponds to a functional film formation region, and the adjustment pixel region 221 corresponds to an adjustment film formation region.

  Of course, the liquid material 570 containing the material for a different light emitting layer is discharged with respect to each pixel area 121 in which each light emitting layer 117 of a different color is formed. For example, in the above-described color display by the three color light emitting layers (see FIG. 7), the red light emitting layer 117R (red) and the green light emitting layer 117G (green) that respectively emit red, green, and blue light. The liquid material 570 containing the material of each light emitting layer 117 is sequentially filled in the droplet discharge head 62 and discharged into the pixel regions 121 where the blue light emitting layer 117B (blue system) is to be formed. Alternatively, a plurality of droplet discharge heads 62 may be prepared and filled with a liquid material 570 containing a material for the light emitting layer 117 having a different color.

  If the surface treatment performed so that the liquid material 560 becomes easy to become familiar with the pixel region 121 and the adjustment pixel region 221 and does not easily overflow from the pixel region 121 is not effective for the liquid material 570, the liquid material 570 A similar surface treatment is performed before performing the filling. Of course, the processing executed in this case is a surface treatment that makes it easy for the liquid material 570 to become familiar with the pixel region 121 and the adjustment pixel region 221 and not to overflow from the pixel region 121 and the adjustment pixel region 221.

  Next, the glass substrate 110 on which the liquid material 570 is disposed is put into a reduced pressure environment, and the liquid material 570 is dried to form the light emitting layer 117 and the adjusted light emitting layer 217. Strictly speaking, the liquid material 570 starts drying from the moment when it is ejected from the droplet ejection head 62 as the droplet 570a. However, by adjusting the boiling point of the solvent of the liquid material 570, the liquid material 570 is almost at normal pressure. It can be made to dry in a pressure-reduced state without drying. After the arrangement of the liquid material 570 is completed, it is preferable that the liquid material 570 has a high ratio of the high-boiling solvent whose drying progress is slow so that almost all drying is performed in the drying step under a reduced pressure environment. .

  As shown in FIG. 10C, a light emitting layer 117 having a substantially uniform light emitting layer surface 571 and a substantially uniform film thickness is formed by executing a drying process in a reduced pressure state. When the liquid material 570 of this embodiment is filled in the adjustment pixel region 221 with the same amount of the liquid material 570 as the pixel region 121 and the liquid material 570 is dried, the surface has two points in FIG. It has a concave shape like a surface 572 indicated by a chain line.

  The adjustment pixel region 221 is filled with a larger amount of the liquid material 570 than the amount of the liquid material 570 filled in the pixel region 121, so that the adjustment pixel region 221 has the same amount as the amount of the liquid material 570 filled in the pixel region 121. The amount of the liquid material 570 disposed in the adjustment region 206 is increased and the amount of the liquid material 570 disposed on the glass substrate 110 is increased as compared with the case where the amount of the liquid material 570 is filled and dried. . As the amount of the liquid material 570 disposed on the glass substrate 110 is increased, the drying speed is decreased as illustrated in FIG. 5A, and the center of the light emitting layer 117 is illustrated as illustrated in FIG. The film thickness becomes thicker. This corrects the concave shape when the adjustment pixel region 221 is filled with the liquid material 570 having the same amount as the liquid material 570 to be filled in the pixel region 121 and dried, so that the light emitting layer surface 571 is substantially flat. Thus, the light emitting layer 117 having a substantially uniform film thickness is formed.

  As shown in FIG. 10D, the light emitting layer 117 is formed, and the formation process of the hole transport layer 116 and the light emitting layer 117 is completed. Further, the step of forming the counter electrode 118 on the light emitting layer 117 is executed to form the element substrate 101. Furthermore, the sealing substrate 109 is attached, and the above-described relay substrate 108 and the like are mounted to form the organic EL display device 100.

Hereinafter, effects of the second embodiment will be described. According to the second embodiment, the following effects can be obtained.
(1) When the liquid material 560 is filled in the adjustment pixel region 221 with the same amount of the liquid material 560 as the pixel region 121 and dried, the film thickness at the center becomes thick and the cross-sectional shape becomes convex. . The adjustment pixel region 221 is filled with a smaller amount of the liquid material 560 than the amount of the liquid material 560 filled in the pixel region 121, so that the adjustment pixel region 221 has the same amount of the liquid material 560 filled in the pixel region 121. The amount of the liquid material 560 disposed on the glass substrate 110 is reduced as compared with the case where the amount of the liquid material 560 is filled and dried. By reducing the amount of the liquid material 560 disposed on the glass substrate 110, the drying speed is increased, and the film thickness at the center of the hole transport layer 116 is reduced. This corrects the convex shape when the adjustment pixel region 221 is filled with the liquid material 560 in an amount equal to the amount of the liquid material 560 to be filled in the pixel region 121 and dried, thereby correcting the convex shape with a substantially uniform film thickness. A hole transport layer 116 can be formed.

  (2) When the liquid material 570 is filled in the adjustment pixel region 221 with the same amount of the liquid material 570 as the pixel region 121 and the liquid material 570 is dried, the film thickness at the center is reduced and the cross-sectional shape is reduced. It becomes a concave shape. By filling the adjustment pixel region 221 with a larger amount of the liquid material 570 than the amount of the liquid material 570 filling the pixel region 121, the adjustment pixel region 221 is equivalent to the amount of the liquid material 570 filling the pixel region 121. Compared with the case where the liquid material 570 is filled and dried, the amount of the liquid material 570 disposed on the glass substrate 110 is increased. As the amount of the liquid material 570 disposed on the glass substrate 110 is increased, the drying speed is decreased, and the film thickness at the center of the light emitting layer 117 is increased. This corrects the concave shape when the adjustment pixel region 221 is filled with the liquid material 570 having the same amount as the amount of the liquid material 570 to be filled in the pixel region 121 and dried, so that the light emission has a substantially uniform film thickness. Layer 117 can be formed.

  (3) The light emission amount of the organic EL element 107 is affected by the film thicknesses of the hole transport layer 116 and the light emitting layer 117. The element substrate 101 includes the hole transport layer 116 and the light emitting layer 117 having a substantially uniform film thickness, so that the hole transport layer 116 and the light emitting layer 117 that can emit the amount of light to be emitted by the organic EL element 107 are provided. It can be formed easily. Accordingly, it is possible to realize a suitable element substrate 101 that can emit the amount of light to be emitted.

  (4) The light emission amount of the organic EL element 107 is affected by the film thicknesses of the hole transport layer 116 and the light emitting layer 117. The organic EL display device 100 includes the hole transport layer 116 and the light emitting layer that can emit light emitted from the organic EL element 107 by providing the hole transport layer 116 and the light emitting layer 117 having a substantially uniform film thickness. 117 can be formed easily. Accordingly, it is possible to realize a suitable organic EL display device 100 that can emit the amount of light to be emitted.

  (5) The planar shape of the pixel region 121 is circular, and the planar shape of the hole transport layer 116 or the light emitting layer 117 to be formed is circular. Since the edges of the hole transport layer surface 561 or the light emitting layer surface 571 are all part of an arc, the shape of the edge becomes uniform over the entire circumference. This suppresses variations in shape in the thickness direction due to different edge shapes, so that the dry state is substantially the same over the entire circumference, and the film thickness of the hole transport layer 116 or the light emitting layer 117 over the entire circumference. Can be made substantially uniform. In addition, since the variation caused by the difference in the shape of the edge due to the change in the amount of the liquid material 560 or the liquid material 570 is suppressed, the amount of the liquid material 560 or the liquid material 570 is changed. Therefore, it is possible to easily control the film thickness. Therefore, since the hole transport layer 116 or the light emitting layer 117 is less likely to vary in the thickness direction, the hole transport layer 116 or the light emitting layer that easily achieves the desired function of the hole transport layer 116 or the light emitting layer 117 is obtained. Layer 117 can be realized.

(Third embodiment)
Next, an electronic apparatus according to the present invention will be described. The electronic device of the present embodiment is an electronic device including the liquid crystal display device described in the first embodiment or the organic EL display device described in the second embodiment. A specific example of the electronic apparatus of this embodiment will be described.

  FIG. 11A is an external perspective view showing a large-sized liquid crystal television which is an example of an electronic apparatus. As shown in FIG. 11A, a large liquid crystal television 200 that is an example of an electronic device includes a display unit 201. The display unit 201 includes the liquid crystal display panel 10 described in the first embodiment as a display unit.

  FIG. 11B is an external perspective view illustrating an example of a portable information processing device such as a word processor or a personal computer that is an example of an electronic device. In FIG. 11B, the portable information processing device 220 has an information processing device housing 223 and includes an input unit 224 such as a keyboard and a display unit 222. The display unit 222 includes the organic EL display device 100 described in the second embodiment as a display unit that constitutes the display unit 222.

Hereinafter, effects of the third embodiment will be described. According to the third embodiment, the following effects can be obtained.
(1) The large-sized liquid crystal television 200 includes the suitable liquid crystal display panel 10 capable of realizing the luminance to be realized, and thus can realize the liquid crystal television capable of realizing the luminance to be realized and capable of suitable display. .

  (2) The portable information processing device 220 includes the suitable organic EL display device 100 capable of emitting the amount of light to be emitted, so that the portable information processing capable of realizing the amount of light to be realized can be realized. An apparatus can be realized.

  As mentioned above, although preferred embodiment which concerns on this invention was described referring an accompanying drawing, embodiment of this invention is not restricted to the said embodiment. The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the present invention, and can be implemented as follows.

  (Modification 1) In the above-described embodiment, the amount of the liquid material filled in the adjustment color element region 152 or the adjustment pixel region 221 is increased or decreased to change the amount of the liquid material disposed on the glass substrate 2a or the element substrate 101. Although the amount is adjusted, the amount of the liquid material arranged on the glass substrate 2a or the element substrate 101 is adjusted by increasing or decreasing the amount of the liquid material filled in the adjustment color element region 152 or the adjustment pixel region 221. That is not essential. By changing the ratio of the solvent of the liquid material to be filled, the amount of the liquid material may be increased or decreased without changing the amount of the solute that is the material of the color element film 53, the hole transport layer 116, or the light emitting layer 117.

  (Modification 2) In the embodiment described above, the adjustment color element region 152 or the adjustment pixel region 221 is filled with the same liquid material as the color element region 52 or the pixel region 121. Not required. It is not essential to form the adjustment color element film 153, the adjustment hole transport layer 216, or the adjustment light emitting layer 217 in the adjustment color element region 152 or the adjustment pixel region 221. In the adjustment color element region 152 or the adjustment pixel region 221, a liquid composed only of a liquid material solvent may be disposed. Thus, the adjustment color element film 153, the adjustment hole transport layer 216, or the adjustment light emission layer 217 that is not required after the color element film 53, the hole transport layer 116, or the light emission layer 117 is completed is not formed. be able to.

  (Modification 3) In the embodiment described above, the amount of the liquid material to be filled in the adjustment color element region 152 or the adjustment pixel region 221 is increased or decreased to change the amount of the liquid material arranged on the glass substrate 2a or the element substrate 101. Although the amount is adjusted, the amount of the liquid material arranged on the glass substrate 2a or the element substrate 101 is adjusted by increasing or decreasing the amount of the liquid material filled in the adjustment color element region 152 or the adjustment pixel region 221. That is not essential. By making the amount of the liquid material filled in the individual adjustment color element region 152 or the adjustment pixel region 221 constant and increasing or decreasing the number of the adjustment color element regions 152 or adjustment pixel regions 221 filled with the liquid material, the glass substrate 2a. The amount of the liquid material disposed on or on the element substrate 101 may be adjusted.

  (Modification 4) In the embodiment described above, the partition 156 or the bank 215 is provided also in the adjustment region 152A or the adjustment region 206, but it is not essential to provide the partition 156 or the bank 215 also in the adjustment region. An appropriate amount of liquid material may be disposed in an adjustment region that is not partitioned.

  (Modification 5) In the above-described embodiment, the ink jet type droplet discharge head 62 is used to dispose the liquid material. However, it is not essential to use the ink jet type droplet discharge head. For example, any method can be used as long as a minute amount of liquid material can be arranged at a target arrangement position, such as using a microdispenser.

  (Modification 6) In the above-described embodiment, the surface treatment of the glass substrate 2a or the glass substrate 110 is performed after the partition walls 56 or the banks 115 are formed. Not limited to after forming. The lyophilicity or liquid repellency of each part demonstrated by the said embodiment should just be formed.

  (Modification 7) In the embodiment described above, the surface treatment of the glass substrate 2a or the glass substrate 110 is performed to form the lyophilicity or liquid repellency of each part described in the embodiment. It is not essential to execute the process. The lyophilicity or liquid repellency of each part described in the above embodiment may be realized by forming a substrate, a partition wall, or a bank using a material having lyophilicity or liquid repellency with respect to a liquid material. .

  (Modification 8) In the above embodiment, the scanning line driving circuit unit 103 and the data line driving circuit unit 104 are configured by previously forming a low-temperature polysilicon semiconductor layer on the surface of the element substrate 101. However, the present invention is not limited to this, and a driver IC capable of driving the light emitting element may be mounted on the glass substrate in a plane.

  (Modification 9) In the above-described embodiment, the partition walls 56 and 156 and the banks 115 and 215 are formed in advance by partition walls and bank films, and portions such as the color element region 52 and the pixel region 121 are formed from the partition films and bank films. However, the partition walls 56 and 156 and the banks 115 and 215 can be formed directly. For example, the liquid material containing the material of the partition walls 56 and 156 and the banks 115 and 215 is discharged using the droplet discharge head 62 described in the first embodiment, and the partition walls 56 and 156 and the banks 115 and 115 on the substrate are discharged. It can also be formed by selectively disposing at a position where 215 is formed. According to this method, since the material to be removed is not generated, it is possible to prevent the material from being wasted.

  In the above-described embodiments, the color element film of the color filter of the liquid crystal display device and the hole transport layer and the light emitting layer of the organic EL display device have been described as examples of the functional film, but there are various film forming methods according to the present invention. It can be used as a method for forming a functional film. For example, it can be used as a film forming method in which one large functional film is formed on one substrate like an alignment film of a liquid crystal display device. It can also be used as a method for forming a film such as a partition film for forming a partition wall or a bank film for forming a bank.

(A) The top view which shows the structure of a liquid crystal display panel. (B) The schematic sectional drawing in the cross section shown by AA. (A) The top view which shows typically the planar structure of a color filter. (B), (c) The schematic plan view which shows the example of an arrangement | sequence of a 3 color filter. (A) The perspective view which shows the outline | summary of the external appearance of a droplet discharge head. (B) The schematic diagram which shows the arrangement | sequence of a nozzle. (A) The perspective view which shows the structure of a droplet discharge head. (B) Sectional drawing which shows the detailed structure of the discharge nozzle part of a droplet discharge head. (A) The graph which shows transition of the pressure of the atmosphere from exhaust start. (B) A graph showing the relationship between the amount of liquid material and the central film thickness. (C) A schematic sectional view showing an example of a sectional shape of a color element film. (D) A schematic cross-sectional view showing a cross-sectional shape example of a color element film. The schematic cross section which shows the color element film formation process of the filter substrate. (A) The schematic front view which shows the whole organic electroluminescence display. (B) The schematic diagram which shows the arrangement | sequence of an organic EL element. (C) A schematic plan view showing an element substrate. Sectional drawing of the principal part containing the organic EL element of an organic EL display apparatus. The schematic cross section which shows the formation process of the positive hole transport layer of an element substrate. The schematic cross section which shows the formation process of the light emitting layer of an element substrate. (A) The external appearance perspective view which shows a large sized liquid crystal television. (B) The external appearance perspective view which shows an example of a portable information processing apparatus.

Explanation of symbols

  2 ... Filter substrate, 2a ... Glass substrate, 5 ... Color filter, 10 ... Liquid crystal display panel, 52 ... Color element area, 52A ... Filter effective area, 53 ... Color element film, 56, 156 ... Partition, 100 ... Organic EL display Device: 101 element substrate 106 display area 107 organic EL element 110 glass substrate 115, 215 bank 116 hole transport layer 117 light emitting layer 121 pixel area 152 adjustment color Element region, 152A ... adjustment region, 153 ... adjustment color element film, 200 ... large liquid crystal television, 206 ... adjustment region, 207 ... adjustment organic EL film, 216 ... adjustment hole transport layer, 217 ... adjustment light emitting layer, 220 ... mobile phone Type information processing device, 221... Adjustment pixel region, 530, 560, 570... Liquid material.

Claims (16)

The functional film on the substrate is set in a functional effective area where the functional film functions effectively, and is set in one or more functional film forming areas where the functional film is to be formed, and an adjustment area provided around the functional effective area A film forming method for forming the functional film by disposing a liquid material containing the material of the functional film in one or more adjustment film forming regions and drying the liquid material in a reduced pressure environment,
According to the cross-sectional shape of the cross section in the thickness direction of the functional film formed by drying the liquid material when the total amount of the liquid material arranged in the function effective region and the adjustment region is the first total amount And changing the total amount of the liquid material.   2. The film forming method according to claim 1, wherein the total amount of the liquid material disposed in the function effective region and the adjustment region is changed by changing an amount of the liquid material disposed in the adjustment region. 3. .   The cross-sectional shape of the cross section in the thickness direction of the functional film formed when the amount of the liquid material arranged in the adjustment region is the first arrangement amount, the film thickness on the peripheral side is the film thickness on the central side 3. The film forming method according to claim 1, wherein, when the shape is thicker, the liquid material that is larger than the first arrangement amount is disposed in the adjustment region.   The cross-sectional shape of the cross section in the thickness direction of the functional film formed when the amount of the liquid material arranged in the adjustment region is the first arrangement amount, the film thickness on the peripheral side is the film thickness on the central side 3. The film forming method according to claim 1, wherein when the shape is thinner, the liquid material less than the first arrangement amount is arranged in the adjustment region.   The amount of the liquid material to be arranged in the adjustment region is changed by changing the amount of the liquid material to be arranged in each adjustment film formation region of the one or more adjustment film formation regions. 5. The film forming method according to any one of items 1 to 4. The planar shape of each adjustment film formation region of the one or more adjustment film formation regions is substantially the same as the planar shape of each functional film formation region of the one or more function film formation regions, and one adjustment film formation In the region, the liquid material is disposed in approximately the same amount as the liquid material disposed in one functional film formation region,
5. The amount of the liquid material to be arranged in the adjustment region is changed by changing the number of the adjustment film formation regions in which the liquid material is arranged. 5. Film forming method.   When the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the total amount is the first total arrangement amount, the film thickness on the peripheral side is thicker than the film thickness on the central side, 2. The film forming method according to claim 1, wherein the liquid material larger than the first total arrangement amount is arranged in the function effective area and the adjustment area.   When the cross-sectional shape of the cross section in the thickness direction of the functional film formed when the total amount is the first total arrangement amount, the film thickness on the peripheral side is thinner than the film thickness on the central side, The film forming method according to claim 1, wherein the liquid material less than the first total arrangement amount is arranged in the function effective area and the adjustment area.   9. The film forming method according to claim 7, wherein the total amount is changed by changing an amount of a solvent contained in the liquid material arranged in the function effective region and the adjustment region. A method of manufacturing an electro-optic substrate having a functional film,
10. A method for manufacturing an electro-optic substrate, wherein at least one type of the functional film is formed using the film forming method according to claim 1. A method of manufacturing an electro-optical device having a functional film,
10. A method for manufacturing an electro-optical device, wherein at least one type of the functional film is formed by using the film forming method according to claim 1.   A functional film formed by using the film forming method according to claim 1.   It is a functional film of Claim 12, Comprising: The planar shape of the said functional film is a substantially circular shape or a substantially oval shape, The functional film characterized by the above-mentioned. An electro-optic substrate having a functional film,
An electro-optic substrate, wherein the at least one type of functional film is the functional film according to claim 12 or 13. An electro-optical device including an electro-optical substrate having a functional film,
The electro-optical device according to claim 14, wherein the electro-optical substrate is the electro-optical substrate. An electronic apparatus comprising the electro-optical device according to claim 15.