JP2008225082A - Substrate for color filter, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a substrate for color filter with which a liquid crystal display device having a uniform cell gap can be formed, and a manufacturing method thereof. <P>SOLUTION: The substrate for color filter is provided with: a transparent substrate, a light shield part formed in a pattern shape on a pixel display region of the transparent substrate; a colored layer formed at an opening part comparted by the light shield part; a spacer for pixel display region formed on the light shield part; and an external bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a color filter substrate used for manufacturing a liquid crystal display device and a manufacturing method thereof.

  In a liquid crystal display device, a color filter and a liquid crystal driving side substrate are opposed to each other, a liquid crystal compound is sealed between them to form a thin liquid crystal layer, and the liquid crystal alignment in the liquid crystal layer is electrically controlled by the liquid crystal driving side substrate. Then, display is performed by selectively changing the amount of transmitted light or reflected light of the color filter.

  Such a liquid crystal display device has various driving methods such as a static driving method, a simple matrix method, and an active matrix method. Recently, an active matrix method or a simple matrix method is used as a flat display for a personal computer or a portable information terminal. Color liquid crystal display devices using liquid crystal panels are rapidly spreading.

  FIG. 6 shows an example of an active matrix liquid crystal display panel. In the liquid crystal display device 101, the color filter 11 and the TFT array substrate 12 which is a liquid crystal driving side substrate are opposed to each other, and a gap portion 13 of about 1 μm to 10 μm is provided. Is sealed with a sealing material 14 (for example, Patent Document 1). The color filter 11 includes a light shielding portion 16 formed in a predetermined pattern on the transparent substrate 15 to shield the boundary between the colored layers 17, and a plurality of colors (usually red (R) and green (G). , Three primary colors of blue (B)) are arranged in a predetermined order, an overcoat layer 18 and a transparent electrode film 19 are stacked in this order from the side close to the transparent substrate.

  On the other hand, the TFT array substrate 12 has a structure in which TFT elements are arranged on a transparent substrate and a transparent electrode film is provided (not shown). An alignment film 20 is provided on the inner surface side of the color filter 11 and the TFT array substrate 12 facing the color filter 11. A color image is obtained by controlling the light transmittance of the liquid crystal layer behind the colored layer.

  Here, the thickness of the gap 13, that is, the cell gap (gap distance between the color filter and the liquid crystal driving side substrate) is the thickness of the liquid crystal layer itself, preventing display unevenness such as color unevenness and contrast unevenness and uniform display. In order to provide a color liquid crystal display device with good display performance such as high-speed response, high contrast ratio, and wide viewing angle, it is necessary to maintain the cell gap constant and uniform.

  As a method for maintaining the cell gap, for example, as shown in FIG. 6, a large number of spherical or rod-like particle spacers 21 made of glass, alumina, plastic, or the like are scattered in the gap 13 as spacers. There is a method of injecting liquid crystal by bonding the color filter 11 and the TFT array substrate 12 together. In this method, the cell gap is determined and maintained with the size of the bead spacer portion.

  For example, as shown in FIG. 7, a method of forming a columnar spacer portion 22 having a height corresponding to the cell gap on the inner surface side of the color filter 11 and on the light shielding portion 16 (non-display region) is also common. (For example, Patent Document 2). Such a columnar spacer portion 22 is formed by applying a photocurable resin to a uniform thickness on a transparent substrate of a color filter and curing the resulting coating film by pattern exposure by photolithography. Formed.

  Further, a method of applying a bead spacer forming coating solution containing beads and a binder on a light shielding portion of a color filter substrate by an ink jet method to form a bead spacer only on the light shielding portion is also considered.

  Here, in recent years, there has been a demand for an increase in the area of liquid crystal display devices, and an increase in the area of substrates and the like used for color filters has been achieved. At the same time, there is a need to improve the manufacturing efficiency of liquid crystal display devices. For example, a color filter substrate in which a plurality of color filters are provided on one substrate, and a plurality of liquid crystal driving wirings on one substrate are provided on multiple surfaces. The liquid crystal driving side substrate attached is arranged so that each color filter and each liquid crystal driving wiring face each other to perform cell assembly, and then the multi-sided liquid crystal display device assembled with the cell is cut to separate each liquid crystal A method of manufacturing a display device is also used. As described above, when the substrate to be used is enlarged, the cell for sealing the liquid crystal by bonding the color filter substrate and the liquid crystal driving side substrate, regardless of which method is used. When assembling, a uniform gap could not be maintained, and there were cases where the manufactured liquid crystal display device had display unevenness or display failure. This is because the spacer portion is not formed outside the pixel display region such as the color filter forming substrate, so that the gap between the color filter substrate 9 and the liquid crystal driving side substrate 12 is increased as shown in FIG. This is because the substrate cannot be within the predetermined range and the substrate is bent.

  Thus, for example, a method has been proposed in which columnar spacers are formed using a photocurable resin outside the pixel display region of the liquid crystal display device to prevent the substrate from being bent during the cell assembly. However, when the columnar spacer is formed using the photo-curing resin, the columnar spacer cannot be formed at a desired height due to the shape of the base of the region where the columnar spacer is formed, and the columnar spacer. Has a problem that it is difficult to make the cell gap uniform in the liquid crystal display device because it is less deformable by pressure. This is because, for example, when columnar spacers are collectively formed in the pixel display region and the outer region, as shown in FIG. 9, photocuring is performed on the region where the large area pedestal 30a and the like are formed. The film thickness of the curable resin 31 is different from the film thickness of the photocurable resin 31 formed on the small area pedestal 30b or the like. Accordingly, the height of the columnar spacers formed by patterning this photocurable resin varies.

JP-A-8-194216 JP 2001-159707 A

  Therefore, it is desired to provide a color filter substrate capable of forming a liquid crystal display device having a uniform cell gap and a method for manufacturing the same.

  The present invention provides a transparent substrate, a light-shielding portion formed in a pattern on the pixel display area of the transparent substrate, a colored layer formed in an opening defined by the light-shielding portion, and the light-shielding portion. There is provided a color filter substrate comprising: a pixel display region spacer, and an outer bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder.

  According to the present invention, since the outer bead spacer is formed, the distance between the color filter substrate and the liquid crystal driving side substrate is within a certain range even when outside the pixel display region when assembling the cells. It is possible to reduce the amount of bending of the substrate. In addition, the outer bead spacer is usually elastic and can be deformed when pressure is applied. Therefore, there is some variation in the height of the outer bead spacer. However, it is possible to make the gap between the color filter substrate and the liquid crystal driving side substrate uniform over the entire surface of the liquid crystal display device by applying pressure during the cell assembly.

  In the above invention, the pixel display region spacer contains beads and a binder, and the beads contained in the outer bead spacer have an average particle diameter of beads contained in the pixel display region spacer. It is preferable that the average particle size of is larger. Since the pixel display region spacer is formed on the light-shielding portion and the outer bead spacer is formed on the transparent substrate, the average particle diameter of the beads contained in the outer bead spacer is By making it larger than the average particle diameter of the beads contained in the pixel display region spacer, the distance from the transparent substrate surface to the outer bead spacer surface and the distance from the transparent substrate surface to the pixel display region spacer surface This is because the distance can be made equal.

  In the said invention, it is preferable that the surface is made liquid-repellent at least in the area | region in which the said outside bead spacer is formed of the said transparent substrate. As a result, when forming the outer bead spacer, the outer bead spacer forming coating solution can be prevented from spreading and becoming lower in height. This is because a bead spacer can be formed.

  In the present invention, the beads contained in the outer bead spacer are preferably plastic beads. This is because the outer bead spacer can have elasticity, and the intended cell gap can be realized.

  In the said invention, it is preferable that the said plastic bead contains the divinylbenzene polymer. The divinylbenzene polymer has a suitable specific gravity in the coating solution for forming the outer bead spacer for forming the outer bead spacer and has a high sphericity, so that the height of the outer bead spacer is high. This is because there can be little variation.

  The present invention also provides a transparent substrate, a light-shielding portion formed in a pattern on the pixel display area of the transparent substrate, a colored layer formed in an opening defined by the light-shielding portion, and the light-shielding portion. A method for manufacturing a color filter substrate, comprising: a pixel display region spacer formed on the transparent substrate; and an outer bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder. There is provided a method for producing a substrate for a color filter, comprising a step of forming an outer bead spacer, wherein a bead spacer is formed after forming the light shielding portion and / or the colored layer.

  According to the present invention, since the outer bead spacer forming step for forming the outer bead spacer is included, the liquid crystal display device is manufactured using the color filter substrate manufactured according to the present invention. In addition, the distance between the color filter substrate and the liquid crystal drive side substrate can be kept constant, and a high-quality liquid crystal display device free from display unevenness can be manufactured.

  In the above invention, the outer bead spacer forming step is preferably performed by a discharge method. This is because the color filter substrate can be efficiently manufactured.

  The present invention also provides a liquid crystal display device using the color filter substrate. According to the present invention, since the color filter substrate is used, a liquid crystal display device having a uniform cell gap between the color filter substrate and the liquid crystal driving side substrate can be obtained.

  According to the present invention, there is an effect that a gap between the color filter substrate and the liquid crystal driving side substrate can be made a color filter substrate that can be uniform over the entire surface of the liquid crystal display device.

  The present invention relates to a color filter substrate used for forming a liquid crystal display device and a manufacturing method thereof. Each will be described separately below.

A. Color Filter Substrate First, the color filter substrate of the present invention will be described. The color filter substrate of the present invention is used for forming a liquid crystal display device, and is a color filter substrate used for forming one liquid crystal display device, that is, for example, transparent as shown in FIG. It may have only one pixel display region 10 on the substrate 1 and may be a color filter substrate used for forming a plurality of liquid crystal display devices at one time, that is, for example, as shown in FIG. A multi-sided substrate in which a plurality of pixel display regions 10 are provided on a transparent substrate 1 may be used.

  The color filter substrate of the present invention includes a transparent substrate, a light-shielding portion formed in a pattern on the pixel display region of the transparent substrate, a colored layer formed in an opening defined by the light-shielding portion, It has a pixel display area spacer formed on the light shielding portion and an outer bead spacer formed outside the pixel display area of the transparent substrate and containing beads and a binder. The color filter substrate of the present invention includes, as shown in FIG. 2, for example, a transparent substrate 1, a light shielding portion 2 formed on a pixel display region (region indicated by a in the drawing) of the transparent substrate 1, The colored layer 3 formed in the opening b defined by the light shielding portion 2, the pixel display region spacer 4 formed on the light shielding portion 2, and the outside of the pixel display region a of the transparent substrate 1. The outer bead spacer 5 is provided.

  Here, the pixel display region in the present invention refers to a region used for displaying an image when used in a liquid crystal display device in a color filter substrate, and includes a colored layer and the colored layer. An area where a light shielding portion for partitioning is formed. In the present invention, a pixel display region also includes a region generally referred to as a frame light-shielding portion in which a light-shielding portion is formed in a frame shape around a colored layer. Further, the position where the outer bead spacer is formed is not particularly limited as long as it is outside the pixel display region. When the cell is assembled by bonding the color filter substrate and the liquid crystal driving side substrate together. In addition, it is formed at a position where at least the cell gap of the pixel display region is uniform. In general, the outer bead spacer is formed in a region other than a region where a sealing material for bonding the color filter substrate and the liquid crystal driving side substrate is applied.

  As described above, when the spacer is formed only in the pixel display area of the color filter substrate, when the cell is assembled by bonding the color filter substrate and the liquid crystal drive side substrate, On the outside, the distance between the color filter substrate and the liquid crystal driving side substrate becomes narrow, and the substrate is bent. Therefore, there has been a problem that the cell gap in the liquid crystal display device cannot be made uniform. In addition, it has been devised to form columnar spacers outside the pixel display region. In this case, it is difficult to form the columnar spacers at a uniform height, and the columnar spacers generally apply pressure. Even in such a case, since the deformability is small, it is difficult to assemble the cells so that the cell gap is uniform over the entire surface of the liquid crystal display device.

On the other hand, in the present invention, since the outer bead spacer is formed outside the pixel display region, the color filter substrate and the liquid crystal driving side substrate are formed outside the pixel display region when the cells are assembled. This distance can be within a certain range, and the substrate is less likely to be bent. Furthermore, the outer bead spacer contains beads, and since the beads generally have elasticity, for example, the height between the outer bead spacer and the pixel display region spacer is slightly higher. Even if there is variation, the beads can be deformed by following the pressure applied when assembling the cells, and the gap between the color filter substrate and the liquid crystal drive side substrate is the liquid crystal display device. It becomes possible to make it uniform on the entire surface.
Hereinafter, the color filter substrate of the present invention will be described in detail for each configuration.

1. First, the outer bead spacer used in the present invention will be described. The outer bead spacer used in the present invention is formed on a transparent substrate described later, and contains beads and a binder. The outer bead spacer is a region outside the pixel display region when the color filter substrate and the liquid crystal drive side substrate are assembled into a cell, and the color filter substrate and the liquid crystal drive side substrate. This is used to support these substrates so that the distance between them is constant.

  In the present invention, the shape of the outer bead spacer is not particularly limited as long as the distance between the color filter substrate and the liquid crystal driving side substrate can be kept constant during cell assembly. Absent. For example, as shown in FIG. 3, a circular shape, a rectangular shape, or the like may be formed outside the pixel display region 10 in a dot shape with a predetermined interval. In the present invention, since the outer bead spacer is preferably formed using an ink jet method, it is particularly preferable that the outer bead spacer is formed in a circular shape.

In the present invention, the outer for total 2000μm ² ~100000μm ² about the area of the bead spacers formed on 1000μm angle, at a density such that among others 5000μm ² ~60000μm ² mm, an outer bead spacers formed It is preferable that Since the outer bead spacers are formed at such a density, when forming a liquid crystal display device using the color filter substrate of the present invention, the gap between the color filter substrate and the liquid crystal driving side substrate. This is because it can be kept constant.

  Further, the interval between adjacent outer bead spacers may be the same as or different from the pitch at which the pixel display region spacers formed in the pixel display region are formed. .

  Further, the height of the outer bead spacer is usually determined by the particle size of the contained beads. In the present invention, it is preferably about 1 μm to 10 μm, more preferably about 3 μm to 7 μm. This is because it is possible to maintain a good gap between the color filter substrate and the liquid crystal drive side substrate during cell assembly.

The beads contained in the outer bead spacer are not particularly limited as long as they are compatible with the binder described later, and are the same as those used as a bead spacer in a general color filter. Can be used. For example, porous, non-porous and hollow bodies of inorganic compounds such as glass, silica and metal oxides (MgO, Al ₂ O ₃ ), polystyrene, polyethylene, polypropylene, polyester, polyacryl, nylon, divinyl Plastics such as benzene polymer and silicone resin can be used. In addition, the surface of such a bead may be subjected to a surface treatment in order to improve the adhesiveness with the binder.

  In the present invention, among the above, beads made of plastic are preferably used from the viewpoint of the elasticity of the beads, and it is particularly preferable to use beads containing a divinylbenzene polymer. This is because the divinylbenzene polymer has good sphericity and can have a suitable specific gravity in the binder.

  Here, the shape of the bead is not particularly limited, and a bead having the same shape as that used for a bead spacer in a general color filter can be used. From the viewpoint of controlling the thickness, it is preferably spherical. In this case, the average particle size is usually about 1 μm to 10 μm, and preferably about 3 μm to 7 μm. In the present invention, when the pixel display region spacer described later contains beads, the average particle size of the beads contained in the outer bead spacer is the average of the beads contained in the pixel display region spacer. It is preferable to be larger than the particle size. Since the pixel display region spacer is formed on the light-shielding portion, and the outer bead spacer is formed on the transparent substrate, the average particle diameter of the beads contained in the outer bead spacer Is larger than the average particle diameter of the beads contained in the pixel display region spacer, the distance from the transparent substrate surface to the outer bead spacer surface, and the transparent substrate surface to the pixel display region spacer surface. This is because the distance up to can be made equal. The average particle size is enlarged by scanning electron microscope or optical microscope, respectively, for the particle size of beads contained in 10 adjacent outer bead spacers or 10 adjacent pixel display region bead spacers. The particle diameter of the beads is an arithmetic average value.

  The binder is not particularly limited as long as it has curability and can fix the beads. For example, it may be a thermosetting resin, or may be photocured. Resin may be used. Specific examples include acrylic resins, epoxy resins, melamine resins, and the like.

  Moreover, in this invention, it is preferable that the binder contains about 75 mass%-about 95 mass%, especially about 85 mass%-about 90 mass% in solid content of the said outside bead spacer. This is because the outer bead spacer as described above can be formed.

  In addition, as a method for forming the outer bead spacer, an outer bead spacer forming coating liquid in which the above-described binder and beads are appropriately mixed with an additive, a solvent, or the like as necessary is applied using, for example, a dispenser. And a method of coating by a discharge method such as coating by an inkjet method. In the present invention, it is preferable to use an inkjet method among the discharge methods. This is because it is possible to efficiently form the outer bead spacer at the target position. The solvent, additive, etc. used in the coating solution for forming the outer bead spacer are appropriately selected according to the type of the binder, and are the same as those used for general inkjet inks. be able to.

2. Transparent substrate Next, the transparent substrate used in the present invention will be described. The transparent substrate used in the present invention is not particularly limited as long as it is usually used for a color filter. A rigid material, or a transparent flexible material having flexibility, such as a transparent resin film or an optical resin plate, can be used.

  Here, in the present invention, it is preferable that the surface of the transparent substrate in the region where the outer bead spacer is formed is liquid repellent. Thus, when forming the outer bead spacer, the outer bead spacer forming coating liquid is less likely to spread and wet, and the outer bead spacer is precisely defined in the target region. This is because can be formed. Here, “being made liquid-repellent” means having low lyophilicity with respect to the bead spacer-forming coating solution used when forming the outer bead spacer. It shall be.

  The contact angle with the liquid on the surface of the transparent substrate having the liquid repellency is such that the contact angle with a liquid of 40 mN / m is 30 ° or more, and especially the contact angle with a liquid with a surface tension of 40 mN / m is 50 The contact angle with a liquid having a surface tension of 40 mN / m is particularly preferably 70 ° or more. The contact angle with pure water is preferably 90 ° or more, and more preferably 100 ° or more.

  The method for subjecting the transparent substrate to a liquid repellent treatment will be described in detail in “B. Method for manufacturing substrate for color filter” described later.

3. Next, the light shielding part used in the present invention will be described. The light shielding portion used in the present invention is formed in a pattern on a transparent substrate described later.

  The type of the light shielding part is not particularly limited. For example, a metal thin film such as chromium having a thickness of about 1000 to 2000 mm is formed by a sputtering method, a vacuum vapor deposition method, or the like, and the thin film is patterned to form the light shielding part. The part may be formed. As the patterning method, a normal patterning method such as sputtering can be used.

  Alternatively, a method may be used in which a layer containing light-shielding particles such as carbon fine particles, metal oxides, inorganic pigments, and organic pigments in a resin binder is formed in a pattern. As the resin binder to be used, polyimide resin, acrylic resin, epoxy resin, polyacrylamide, polyvinyl alcohol, gelatin, casein, cellulose, or a mixture of one or more resins, photosensitive resin, or O / A W emulsion type resin composition, for example, an emulsion of a reactive silicone can be used. The thickness of such a resin light-shielding part can be set within a range of 0.5 μm to 10 μm. As a method for patterning such a resin light shielding portion, a generally used method such as a photolithography method or a printing method can be used.

  As will be described later in “B. Manufacturing Method of Color Filter Substrate”, when the surface of the light-shielding portion is directly subjected to liquid repellency and the pixel display region spacer is formed on the light-shielding portion, the above-described light shielding. The part is preferably a resin light-shielding part.

4). Next, the colored layer used in the present invention will be described. The colored layer used in the present invention is formed in the opening section partitioned by the light shielding section. Such a colored layer is usually formed of three colors of red (R), green (G), and blue (B). The colored pattern shape in the colored layer can be a known arrangement such as a stripe type, a mosaic type, a triangle type, a four-pixel arrangement type, and the colored area can be arbitrarily set.

  Here, the colored layer used in the present invention can be formed by a material or a forming method used for a colored layer of a known color filter, and thus detailed description thereof is omitted here.

5. Pixel Display Area Spacer Next, the pixel display area spacer used in the present invention will be described. The pixel display region spacer used in the present invention is formed on the light shielding portion, and can maintain a constant gap between the color filter and the liquid crystal driving side substrate when the liquid crystal display device is formed. If it is a thing, the kind in particular will not be limited. For example, it may be a columnar spacer formed by patterning a photosensitive resin by a photolithography method or the like, or a bead spacer formed by applying a coating solution for forming a spacer containing beads and a binder by a discharge method or the like. It may be.

  In the present invention, a bead spacer is particularly preferable among the above. In this case, it is possible to adjust the gap between the color filter in the pixel display region and the liquid crystal driving side substrate when assembling the cells due to the elasticity of the beads.

  Here, the width of the pixel display region spacer is appropriately selected depending on the width of the light shielding portion or the like. For example, when the pixel display region spacer is a bead spacer, the diameter of the circle is 15 μm. It is preferable that the thickness is about ˜50 μm. This is because the luminance of the color filter can be reduced less due to the presence of the pixel display region spacer, and a color filter substrate capable of forming a high-luminance liquid crystal display device can be obtained. .

The height of the pixel display region spacer is preferably about 1 μm to 8 μm, more preferably about 2 μm to 6 μm. As the area of a region each of the pixel display area spacers are formed, 500μm ² ~8000μm ² about, among others 700μm ² ~2800μm ² mm, it is preferable that there is a particular 1250μm ² ~1600μm ² about. Thereby, it is possible to reduce the luminance of the color filter due to the presence of the pixel display region spacer, and it is possible to provide a color filter substrate capable of forming a high luminance liquid crystal display device. .

In the present invention, total 2000μm ² ~96000μm ² about the area of the pixel display area spacer formed 1000μm angle, among others as a 5000μm ² ~60000μm ² mm, the number is adjusted for the pixel display region A spacer is preferably formed. Since the pixel display region spacers are formed at such a density, when the color filter substrate of the present invention is used in a liquid crystal display device, the gap between the color filter substrate and the liquid crystal driving side substrate is used. This is because it can be kept constant.

  The pixel display region spacer can maintain a uniform gap between the color filter substrate and the liquid crystal drive side substrate when a liquid crystal display device is formed using the color filter substrate of the present invention. If it is, the material etc. will not be specifically limited, According to the kind of said pixel display area spacer, it selects suitably. When the pixel display region spacer is a bead spacer, it can be formed by the same method using the same material as the outer bead spacer described above. The average particle size of the beads contained in the pixel display region spacer is preferably about 1 μm to 8 μm, and more preferably about 2 μm to 6 μm. This is because the distance from the transparent substrate surface to the upper surface of the outer bead spacer and the distance from the transparent substrate surface to the pixel display region spacer surface can be made uniform.

6). Next, the color filter substrate of the present invention will be described. The substrate for a color filter of the present invention is not particularly limited as long as it has the above-described transparent substrate, light-shielding portion, coloring layer, pixel display region spacer, and outer bead spacer, and is oriented as necessary. You may have various members, such as a film | membrane and a transparent electrode layer. Since such various members can be the same as those used for a general color filter substrate, description thereof is omitted here.

B. Next, a method for manufacturing a color filter substrate of the present invention will be described. The method for producing a color filter substrate of the present invention includes a transparent substrate, a light-shielding portion formed in a pattern on the pixel display region of the transparent substrate, and a colored layer formed in an opening partitioned by the light-shielding portion. And a pixel display region spacer formed on the light-shielding portion, and an outer bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder. The method further comprises a step of forming an outer bead spacer for forming the outer bead spacer after forming the light-shielding portion and / or the colored layer.

  For example, as shown in FIG. 4, the color filter manufacturing method of the present invention forms the light shielding portion 2 on the pixel display area a of the transparent substrate 1 (FIG. 4A), and then outside the pixel display area a. The outer bead spacer 5 may be formed on the pixel display region a of the transparent substrate 1, for example, as shown in FIG. After forming the light-shielding part 2 and forming the colored layer 3 in the opening section defined by the light-shielding part 2 (FIG. 5A), the outer side where the outer bead spacer 5 is formed outside the pixel display area a. The method may also include a bead spacer forming step (FIG. 5B). In the present invention, a pixel display region spacer may be formed on the light shielding portion before the outer bead spacer forming step.

According to the present invention, since the outer bead spacer forming step for forming the outer bead spacer is included, the liquid crystal display device is manufactured using the color filter substrate manufactured according to the present invention. In addition, the distance between the color filter substrate and the liquid crystal drive side substrate can be kept constant, and a high-quality liquid crystal display device free from display unevenness can be manufactured.
Hereinafter, the outer bead spacer forming step will be described.

a. Outside Bead Spacer Forming Step The outside bead spacer forming step in the present invention is a step of simultaneously forming outside bead spacers outside the pixel display region of the transparent substrate. Here, in the present invention, as long as the outer bead spacer can be formed on the transparent substrate, the method is not particularly limited, but the outside of the pixel display area of the transparent substrate is not limited. After the lyophobic treatment, a bead spacer forming coating solution is preferably applied to form an outer bead spacer.

  The method for lyophobic treatment of the surface of the transparent substrate is not particularly limited, for example, a method of forming a liquid repellent layer having liquid repellency on the surface of the transparent substrate, for example, a resin-made transparent substrate, For example, a method of irradiating with plasma using a fluorine compound as an introduction gas to make it liquid repellent can be used.

  Specifically, as a method of making the surface of the transparent substrate lyophobic by forming a lyophobic layer on the transparent substrate, a repellency made of fluorocarbon generally used for forming the lyophobic layer is used. For example, a liquid layer or a liquid repellent layer containing a silane compound having a liquid repellent organic group may be formed on a transparent substrate. Examples of the silane compound include organopolysiloxane and the like, and for example, those similar to those described in JP-A No. 2001-272774 can be used.

  The region for forming the liquid repellent layer is not particularly limited as long as it is a region where the outer bead spacer is formed. For example, the liquid repellent layer may be formed on the entire surface of the transparent substrate. A liquid repellent layer may be formed on only a part of the transparent substrate. Further, the method for forming the liquid repellent layer is not particularly limited, and may be a general coating method such as a spin coating method or a die coating method, or a chemical vapor deposition method such as a plasma CVD method or a thermal CVD method. A phase deposition method (CVD) method may be used. Further, for example, a method of immersing the color filter substrate in a liquid repellent layer forming coating solution for forming the liquid repellent layer, and self-organizing the liquid repellent layer on the surface of the transparent substrate. Also good.

  The film thickness of the liquid repellent layer is appropriately selected depending on the type of the liquid repellent layer and the like, but is usually about 0.001 μm to 1.0 μm, and more preferably 0.001 μm to 0.500 μm, especially 0.00. It is preferable to be about 001 μm to 0.100 μm.

  Further, as a method for lyophobic treatment of the transparent substrate surface by irradiating the resin transparent substrate surface with plasma, specifically, a method of irradiating the transparent substrate surface with plasma using a fluorine compound as an introduction gas is used. be able to. This utilizes the fact that fluorine can be introduced into an organic substance when plasma irradiation is performed using a fluorine compound as an introduction gas. The plasma irradiation may be performed in a vacuum, for example, or may be performed under atmospheric pressure. The region to be irradiated with plasma is not particularly limited as long as it irradiates at least the region where the outer bead spacer is formed. For example, the entire region of the transparent substrate may be used. Only the region of the part may be used.

Examples of the fluorine compound of the introduced gas used when the plasma is irradiated include carbon fluoride (CF ₄ ), fluorine nitride (NF ₃ ), sulfur fluoride (SF ₆ ), C ₂ Cl ₃ F ₃ , and C _{2. F 6, C} 3 F _6, and the like. Moreover, the irradiation condition of the plasma to be irradiated is appropriately selected depending on the irradiation apparatus or the like.

  Here, in the present invention, the plasma irradiation is preferably plasma irradiation under atmospheric pressure. This is because an apparatus for decompression or the like is not necessary, which can be preferable in terms of cost, manufacturing efficiency, and the like. The irradiation conditions of such atmospheric pressure plasma can be as follows. For example, the power output can be the same as that used in a general atmospheric pressure plasma irradiation apparatus. At this time, the distance between the plasma electrode to be irradiated and the surface of the transparent substrate is preferably about 0.2 mm to 20 mm, and more preferably about 1 mm to 5 mm. Furthermore, the flow rate of the fluorine compound used as the introduction gas is preferably about 1 L / min to 100 L / min, and more preferably about 5 L / min to 50 L / min. In this case, the transport speed of the transparent substrate is 0.1 m. / Min to about 10 m / min, especially about 0.5 m / min to 5 m / min is preferable.

  The presence of fluorine introduced on the surface of the transparent substrate is measured by measuring the proportion of fluorine element in the total elements detected from the surface of the transparent substrate in an analysis using an X-ray photoelectron spectrometer (XPS: ESCALAB 220i-XL). This can be confirmed. At this time, the proportion of the fluorine is preferably 10% or more.

  In the present invention, the region where the outer bead spacer is formed in the transparent substrate by the liquid repellency treatment has a contact angle with a liquid having a surface tension of 40 mN / m of 30 ° or more, and in particular, the surface tension is 40 mN. The contact angle with a / m liquid is preferably 50 ° or more, and the liquid repellent treatment is particularly preferably performed so that the contact angle with a liquid with a surface tension of 40 mN / m is 70 ° or more. Accordingly, when forming the outer bead spacer, the bead spacer forming coating liquid can be prevented from spreading and forming the outer bead spacer in a desired region at a uniform height. Because it becomes possible. The contact angle with the liquid is measured using a contact angle measuring device (CA-Z type, manufactured by Kyowa Interface Science Co., Ltd.) (dropping a droplet from a microsyringe). 30 seconds later), and the result can be obtained or graphed.

  Further, in the present invention, as the method for forming the bead spacer, a bead spacer forming coating solution in which a binder and beads are appropriately mixed with an additive, a solvent or the like as necessary, a method using a dispenser, an ink jet method, or the like. For example, it can be formed by coating by a discharge method. In the present invention, application by an ink jet method can be particularly preferred from the standpoint of production efficiency.

  The beads and binder used in the bead spacer-forming coating solution can be the same as those described in “A. Color filter substrate” described above. Solvents, additives, and the like are appropriately selected in accordance with the type of binder and the like, and can be the same as those used for general inkjet inks.

b. Other steps In the present invention, in addition to the outer bead spacer forming step, various steps such as a light shielding part forming step, a colored layer forming step, a pixel display region spacer forming step, and an alignment film forming step are performed as necessary. You may have. Further, after the outer bead spacer forming step, there may be a step of lyophilicizing the surface of the transparent substrate other than the region where the outer bead spacer is formed. When the pixel display region spacer is a bead spacer containing beads and a binder, it is preferable to form a pixel display region spacer by subjecting the surface of the light shielding portion to a liquid repellent treatment. This is because the pixel display region spacer can be formed with high definition in the target region. The liquid repellent treatment method and the pixel display region spacer formation method can be the same as the method performed in the outer bead spacer formation step. Further, the liquid repellent treatment of the light shielding part may be performed simultaneously with the liquid repellent treatment of the transparent substrate described above.

  In addition, about the said light-shielding part formation process, colored layer formation process, alignment film formation process, etc. which are performed in this invention, it can be made to be the same as each process performed at the time of manufacture of the board | substrate for general color filters.

C. Next, the liquid crystal display device of the present invention will be described. The liquid crystal display device of the present invention is characterized by using the color filter substrate described above. In the present invention, the configuration is not particularly limited as long as the color filter substrate is used, and the configuration can be the same as that of a general liquid crystal display device. Specifically, it may be one having the color filter substrate, a liquid crystal driving side substrate disposed opposite to the substrate, and liquid crystal sealed between the opposite substrates. When the color filter substrate is a multi-sided substrate, the liquid crystal display device of the present invention can be obtained by cutting the multi-sided liquid crystal display device in which cells are assembled into individual liquid crystal display devices. .

  According to the present invention, since the color filter substrate having the outer bead spacer is used, when the color filter substrate and the liquid crystal driving side substrate are assembled into a cell, the color filter can be used even outside the pixel display region. The distance between the substrate for use and the liquid crystal drive side substrate can be set within a certain range. Therefore, the gap between the color filter substrate and the liquid crystal drive side substrate is uniform over the entire surface of the liquid crystal display device, and a high-quality liquid crystal display device free from display unevenness can be obtained.

  Note that the liquid crystal layer, the liquid crystal driving side substrate, and the like used in the present invention can be the same as those used in a general liquid crystal display device, and thus description thereof is omitted here.

  The present invention is not limited to the above embodiment. The above-described embodiment is an exemplification, and the present invention has substantially the same configuration as the technical idea described in the claims of the present invention, and any device that exhibits the same function and effect is the present invention. It is included in the technical scope of the invention.

The following examples illustrate the present invention more specifically.
[Example]
(Light shielding part forming step and colored layer forming step)
A color filter substrate having a base material made of a glass substrate, a light-shielding portion formed in a pattern on the base material, and a colored layer formed in an opening defined by the light-shielding layer was prepared.

(Liquid repellent treatment)
A coating solution for forming a liquid repellent layer having the following composition was applied so as to cover the light shielding portion of the color filter substrate and the colored layer, and then dried at 120 ° C. for 2 minutes. Subsequently, this color filter substrate was heated at 180 ° C. for 10 minutes to form a liquid repellent layer having a thickness of 0.04 μm.

<Liquid repellent layer forming coating solution>
The following materials were stirred at room temperature for 24 hours and then diluted to 1% by mass with PGMEA.
N-Hexyltrimethoxysilane (LS-3130 manufactured by Shin-Etsu Chemical Co., Ltd.)
17.0% by mass
・ Tetramethoxysilane (TSL8114 GE Toshiba Silicone Co., Ltd.)
56.3 mass%
・ 5mM hydrochloric acid 26.7% by mass

(Pixel display region spacer forming step and outer bead spacer forming step)
On the pixel display area of the color filter substrate described above, a spacer portion-forming coating solution A having the following composition was applied drop by drop (15 pl) at an interval of 170 μm. Subsequently, on the outside of the pixel display area other than the seal portion, a spacer portion-forming coating solution B having the following composition was applied drop by drop (15 pl) with an interval of 170 μm, and a hot plate at 80 ° C., It was dried for 10 minutes and then heated in an oven at 230 ° C. for 30 minutes. As a result, a pixel display region spacer containing an average of 10 beads having an average particle size of 3.5 μm on the pixel display region and an average of 10 beads having an average particle size of 5.0 μm outside the pixel display region. The outer bead spacer contained was obtained.
<Spacer part forming coating liquid A>
-Thermosetting resin: Acrylic resin (main component glycidyl methacrylate) 5.0 wt%
・ Diluting solvent: 94.0 wt% mixed liquid of butyl carbitol acetate, dimethyl malonate, and triacetin
・ Bead: Micropearl (manufactured by Sekisui Chemical Co., Ltd .: average particle size 3.5 μm) 1.0 wt%
<Spacer part forming coating solution B>
-Thermosetting resin: Acrylic resin (main component glycidyl methacrylate) 5.0 wt%
・ Diluting solvent: 92.0 wt% of a mixed solution of butyl carbitol acetate, dimethyl malonate and triacetin
・ Beads: Micropearl (manufactured by Sekisui Chemical Co., Ltd .: average particle size 5.0 μm) 3.0 wt%

[Comparative example]
A color filter substrate was prepared in the same manner as in the example except that columnar spacers were formed instead of the outer bead spacers.

[Evaluation]
The color filter substrate and the liquid crystal drive side substrate formed in the above examples and comparative examples were assembled into a cell to form a liquid crystal display device. In the color filter substrate formed according to the example, the cell gap between the color filter substrate and the liquid crystal driving side substrate could be made uniform. On the other hand, in the color filter substrate formed by the comparative example, the height of the columnar spacers varies, and the cell gap between the color filter substrate and the liquid crystal driving side substrate cannot be made uniform, and the cell assembly A defect occurred.

It is explanatory drawing for demonstrating the board | substrate for color filters of this invention. It is a schematic sectional drawing which shows an example of the board | substrate for color filters of this invention. It is explanatory drawing for demonstrating the board | substrate for color filters of this invention. It is process drawing which shows an example of the manufacturing method of the color filter of this invention. It is process drawing which shows the other example of the manufacturing method of the color filter of this invention. It is explanatory drawing for demonstrating the conventional substrate for color filters. It is explanatory drawing for demonstrating the conventional substrate for color filters. It is explanatory drawing for demonstrating the conventional substrate for color filters. It is explanatory drawing for demonstrating the conventional substrate for color filters.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Transparent substrate 2 ... Light-shielding part 3 ... Colored layer 4 ... Pixel display area spacer 5 ... Outer bead spacer a ... Pixel display area b ... Opening

Claims (8)

  A transparent substrate, a light-shielding portion formed in a pattern on the pixel display region of the transparent substrate, a colored layer formed in an opening defined by the light-shielding portion, and a pixel display formed on the light-shielding portion A color filter substrate comprising: a region spacer; and an outer bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder.   The pixel display region spacer contains beads and a binder, and the average particle size of beads contained in the outer bead spacer is larger than the average particle size of beads contained in the pixel display region spacer. The color filter substrate according to claim 1, wherein the substrate is larger.   3. The color filter substrate according to claim 1, wherein a surface of the transparent substrate in which at least the outer bead spacer is formed has a liquid repellency. 4.   4. The color filter substrate according to claim 1, wherein the beads contained in the outer bead spacer are plastic beads. 5.   The color filter substrate according to claim 4, wherein the plastic beads contain a divinylbenzene polymer. A transparent substrate, a light-shielding portion formed in a pattern on the pixel display region of the transparent substrate, a colored layer formed in an opening defined by the light-shielding portion, and a pixel display formed on the light-shielding portion A method for producing a color filter substrate, comprising: a region spacer; and an outer bead spacer formed outside the pixel display region of the transparent substrate and containing beads and a binder,
A method for producing a substrate for a color filter, comprising a step of forming an outer bead spacer after forming the light shielding portion and / or the colored layer.   The method for manufacturing a color filter substrate according to claim 6, wherein the outer bead spacer forming step is performed by a discharge method.   A liquid crystal display device using the color filter substrate according to any one of claims 1 to 5.

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