JP2008242058A - Manufacturing method of color filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To coat a target pixel with a desired amount of coloring agent droplets without causing any defect. <P>SOLUTION: In response to reaching of discharge nozzles (50) above a BM grating (21), discharge nozzles (50) which are disposed inside the internal wall of the BM grating (21) by ≥0.8 time as large as the radius of a coloring agent droplet under flying are put in operation in order to coat a pixel (22) defined by the BM grating (21) of a transparent substrate (2) with the necessary number of coloring agent droplets. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a color filter by operating a discharge nozzle while moving an inkjet head and applying a colorant to a transparent substrate.

In recent years, the demand for personal computers and color liquid crystal displays has increased, and the size of displays has increased.
Conventionally, as a color filter manufacturing apparatus provided conventionally, an apparatus using a spin coater or a manufacturing process mainly including photolithography using a coater has been mainly used.

  However, in recent years, a color filter manufacturing apparatus using an inkjet head having a plurality of discharge nozzles has been attracting attention in consideration of the fact that cost reduction and consideration for the environment have been strongly desired (Patent Document 1). , Patent Document 2 and Patent Document 3).

And if a color filter is manufactured with the color filter manufacturing apparatus using an inkjet head, it can enjoy the advantage that the quantity of a resist and a coloring agent can be reduced, and the advantage that chemical processing, such as development, can be made unnecessary.
JP-A-9-203803 JP 2002-62422 A Japanese Patent Laid-Open No. 9-230129

  FIG. 1 is a plan view showing the concept of the positional relationship between a head in which nozzles are arranged in a row and a BM substrate, and FIG. 2 is a longitudinal sectional view thereof. In this figure, for convenience of explanation, the size of the BM lattice is enlarged.

  Since BM lattices generally have various types of sizes and shapes depending on product specifications such as liquid crystal panels, the smaller the nozzle pitch of the inkjet head, the more pixels are embedded in the various shapes of the BM lattice. The degree of freedom of nozzle selection becomes high, and it becomes possible to perform discharge precisely aiming at a predetermined position in the pixel.

  Thus, a composite head composed of nozzles of fine pitch as shown in FIG. 10, for example, is used for coating on a large substrate by means for increasing the nozzle pitch density and means for elongating the head.

  On the other hand, there is a limit to increasing the nozzle pitch density, and preparing a dedicated inkjet head that matches the BM lattice pattern is not only costly, but also causes time loss due to color filter type switching. Therefore, a general-purpose inkjet head must be used to some extent.

  Liquid crystal screens such as mobile phones are a few inches and are small in size. If you aim at the center of the pixels defined by the BM grid of the color filter, the entire screen will spread and spread, but in the case of a large screen TV color filter. The size of the pixels partitioned by the BM grid is as large as several to a dozen times as large as the droplet diameter, so the degree of freedom of the landing position increases, but if the landing position is wrong, the following color mixing and shading differences occur. Become.

  Taking a 32-inch television as an example, the size of one pixel is about 100 μm wide × 320 μm high when the pixel sizes of RGB are the same. If a pixel is filled with a droplet having a droplet diameter of about 40 μm during flight, it is theoretically possible with 3 to 4 droplets of ink if it is selectively applied so that the landing positions do not overlap. The required amount of ink is determined by required specifications such as ink properties, filter effect, and pixel surface condition, and usually several times as many droplets are required. On the other hand, since a general-purpose inkjet head is used, the pitch of the discharge nozzles is determined, and the discharge nozzles that can be used without a margin are limited in the current situation.

  In addition, since a limited discharge nozzle is used, if the selection of the discharge nozzle is incorrect, it will overflow into the adjacent pixel, resulting in a color mixture or shade difference with the color of the adjacent pixel, and conversely a position that is too far from the pixel boundary for fear of color mixing. When the colorant is landed on the surface, the colorant does not reach the pixel boundary and white spots occur.

  Further, when the side surface of the BM grid is lyophobic, white spots are likely to occur, and when the upper surface of the BM grid is lyophilic, color mixing and density differences between adjacent pixels are likely to occur. Become.

  Also, in the coating method in which the ejection nozzle is arranged so as to be orthogonal to the short side of the pixel that is normally employed and the inkjet head is moved in parallel with the long side of the pixel, the short side of the normal RGB pixel is the long side. Therefore, the ratio of the number of discharge nozzles that can be selected is reduced, and time and labor are easily wasted in adjusting the discharge head position and the pixel pitch.

  In addition, when a color filter is manufactured by a color filter manufacturing apparatus using an ink jet head, since the absolute amount of the colorant droplet is as small as the order of picoliters, the ratio of the surface area of the droplet increases, and each colorant liquid Drop drying speed is extremely fast.

  Therefore, when the time interval from the application of a certain colorant droplet to the application of the next colorant droplet to the pixels defined by the BM lattice of the transparent substrate becomes longer, the previously applied colorant The droplets were dried, and it was difficult to bond together with the colorant that had landed later, resulting in uneven coating of the colorant, and uneven coating.

  The present invention has been made in view of the above-described problems, and it is possible to increase the selection range of the discharge nozzle corresponding to the target pixel and to prevent color mixture and white spot, and into the pixel. By shortening the droplet application time, it is possible to prevent uneven coating and uneven coating, and to eliminate time loss and to provide an inexpensive color filter manufacturing method.

  The present invention uses a plurality of discharge nozzles (50) of an ink jet head (5) in which a plurality of discharge nozzles (50) are arranged substantially linearly, using a BM lattice (21) on a transparent substrate (2). In the color filter manufacturing method in which a necessary number of colorant droplets are applied to the partitioned pixel (22), the flying droplet radius (r) of the colorant discharged from the discharge nozzle from the pixel (22) boundary. The color filter manufacturing method is characterized in that all the required number of liquid droplets are landed at a position 0.8 times or more inside.

Usually, the landing radius (R) of the colorant discharged from the discharge nozzle is the radius of the droplet during flight (r).
2 to 5 times the size of the BM grid, and if it hits the position of the condition of this claim 1, it seems that the BM grid overflows to the adjacent pixels. It has been found that if it is more than 0.8 times the flying droplet radius (r), it will not overflow to adjacent pixels. This increased the selection range of the discharge nozzle.

  Here, at least one colorant droplet having a distance between the droplet landing position and the short side boundary of the pixel (22) of 1.3 times or less of the droplet landing radius (R) is present on each of the short sides. It is preferable to exist above.

  When a droplet lands near the previously landed droplet, the droplets try to combine with each other and are attracted to the previously landed droplet. Under the condition of several to twenty drops, the distance between the droplet landing position and the pixel (22) short side border is 1.3 times or less of the droplet landing radius (R) regardless of the landing order. It was found that white spots on the short side do not occur if there is a droplet landing at a distance of.

  It is preferable that the side surface of the BM lattice (21) on the transparent substrate (2) is lyophilic and the upper surface is lyophobic.

  It has been found that if this condition is satisfied, it is possible to surely eliminate color mixing and shading due to overflowing adjacent pixels and to prevent white spots.

  The plurality of ejection nozzles (50) are arranged in parallel to the long sides of the pixels (22) partitioned by the BM lattice (21) on the transparent substrate (2), and the ink jet head (5) is disposed on the pixels (22). It is preferable to apply the necessary number of colorant droplets to the pixel (22) with the plurality of discharge nozzles while moving so as to be orthogonal to the long side.

  By satisfying this condition, it is possible to increase the usage ratio of the discharge nozzles, increase the accuracy of the movement direction of the inkjet head, and shorten the time by preprogramming the nozzle selection for the pixels at the time of product type switching. It became possible to connect.

  It is preferable to apply the necessary number of colorant droplets to the pixels (22) within 10 seconds. By satisfying this condition, the colorant droplets that have landed first do not dry, and a predetermined number of subsequent droplets are landed to prevent uneven application of the colorant. It became possible to prevent the bias.

  More preferably, the necessary number of colorant droplets is applied to the pixel (22) within one second. By satisfying this condition, drying of the colorant droplets can be further suppressed, and uneven application of the colorant and unevenness of the coating film can be further suppressed.

  The colorant droplets preferably contain 50 to 88% by weight of a colorant drying inhibiting solvent, and the vaporizing pressure of the colorant drying inhibiting solvent is preferably 20 to 30 ° C. and a vapor pressure of 2 to 200 Pa.

  The colorant used in the color filter contains an organic solvent. By satisfying the conditions for this drying-inhibiting solvent, it is possible to easily prevent uneven coating of the colorant and to prevent uneven coating. It has become possible.

  Usually, the landing radius (R) of the colorant droplet discharged from the discharge nozzle is about 2 to 5 times larger than the droplet radius (r) during the flight, and is located at the position of the condition of the present invention. If landing, it seems that the neighboring pixels overflow from the BM grid. However, the present inventors have found that if the landing position from the BM grid is more than 0.8 times the flying droplet radius (r), the neighboring pixels I discovered that it was not overflowing. This increased the selection range of the discharge nozzle.

  When a droplet lands near the previously landed droplet, the droplets try to combine with each other and are attracted to the previously landed droplet. Under the condition of several to twenty drops, the distance between the droplet landing position and the pixel (21) short side boundary is 1.3 times or less the droplet landing radius (R) regardless of the landing order. It was found that white spots on the short side do not occur if there is a droplet landing on the surface.

  Since the side surface of the BM lattice (21) on the transparent substrate (2) is lyophilic and the upper surface is liquid repellent, it is possible to reliably eliminate color mixing and light / dark differences caused by overflowing adjacent pixels. It was found that it was possible to prevent white spots.

  A plurality of discharge nozzles (50) are arranged in parallel to the long sides of the pixels (22) partitioned by the BM lattice (21) on the transparent substrate (2), and the inkjet head (5) is arranged to be the length of the pixels (22). By applying the necessary number of colorant droplets to the pixel (22) with a plurality of discharge nozzles while moving so as to be orthogonal to the sides, the use ratio of the discharge nozzles can be increased and inkjet It is possible to shorten the time by preprogramming the nozzle selection for the pixel at the time of switching the product type while maintaining the accuracy of the head moving direction.

  Applying the required number of colorant droplets to the pixel (22) within 10 seconds, more preferably within 1 second, the previously landed colorant droplets will not dry out. In addition, by landing a predetermined number of subsequent droplets, it becomes possible to prevent uneven application of the colorant and to prevent uneven coating.

  The coloring agent droplet contains 50 to 88% by weight of the coloring agent drying inhibiting solvent, and the coloring agent drying inhibiting solvent has a vapor pressure of 2 to 200 Pa at 20 to 30 ° C., further preventing uneven coating of the coloring agent. In addition, it is possible to easily prevent unevenness of the coating film, to form a colorant layer having a uniform film thickness, and to improve the uniformity of chromaticity, which is an important quality of a color filter. Play.

  According to the present invention, it is possible to eliminate a time loss such as switching between types at a low cost and to manufacture a high quality color filter.

  Hereinafter, an embodiment of a color filter manufacturing method of the present invention will be described in detail with reference to the accompanying drawings.

  1 and 2 are schematic views showing the positional relationship between the inkjet head and the BM lattice (21) formed on the glass substrate.

  A method for reducing the inkjet nozzle arrangement and the nozzle pitch (P) will be described below.

  By using n (n = 2 to N, etc.) heads 1 as shown in FIG. 3 and shifting them in parallel by a pitch of P / n and integrating them as shown in FIGS. A head having a nozzle density corresponding to nozzles having a pitch of P / n can be made by arranging the nozzles in the direction perpendicular to the moving direction of the head.

  Further, when the head is lengthened, it can be generally realized by arranging the heads in a staggered arrangement as shown in FIG.

  In this way, an ink head that is optimal for the shape and pattern of the target color filter substrate may be configured.

  FIG. 14 is a schematic diagram showing a color filter manufacturing apparatus to which the color filter manufacturing method of the present invention is applied, and FIG. 15 is a schematic diagram showing in detail the configuration of the main part.

  This color filter manufacturing apparatus supports a suction table (3), a coating gantry (4), a camera gantry (6), and the like on a machine base 1.

  The suction table (3) holds the glass substrate (2) by suction. In order to achieve the positioning of the glass substrate (2), the suction table (3) is rotationally driven by a driving mechanism and a guide mechanism (not shown), and Y Driven in the direction.

  The coating gantry (4) holds the inkjet head (5) and is driven in the X direction by a driving mechanism and a guide mechanism (not shown) to apply a colorant (color material) to the glass substrate (2). Is done. Moreover, in order to adjust the relative position with respect to a glass substrate (2), it drives to a Z direction and a Y direction by the drive mechanism and guide mechanism which are not shown in figure.

  The camera gantry (6) detects alignment positions and shapes of pixels and colorants of the black matrix of the alignment camera (7), (8) and the glass substrate (2) for alignment of the glass substrate (2). The scan camera (9) is held, and is driven in the X direction by a drive mechanism and a guide mechanism (not shown) for alignment and pixel detection. Further, the alignment cameras (7), (8) and the scan camera (9) are driven in the Y direction by a drive mechanism and a guide mechanism (not shown).

  The alignment cameras (7) and (8) detect marks (not shown) on the glass substrate (2), and the suction table (3) is based on the mark detection results by the alignment cameras (7) and (8). By rotating and / or moving in the Y direction, alignment of the glass substrate (2) can be achieved.

  X and Y represent directions orthogonal to each other set to define a plane parallel to the upper surface of the glass substrate (2) held by suction by the suction table (3), and Z is defined by X and Y. The direction orthogonal to the formed plane is shown.

  Therefore, by operating the inkjet head (5) while moving the coating gantry (4), it is possible to apply a colorant to the glass substrate (2) and manufacture a color filter.

  Moreover, it is preferable to set the moving speed of the coating gantry (4) (moving speed of the inkjet head (5)) to 50 to 200 mm / sec and apply the colorant to the glass substrate (2) in one scan. The production efficiency of the filter can be increased.

  This configuration includes a main tank (51) for storing the colorant, a communication path (52) for leading the colorant from the main tank (51), an open / close valve (53) interposed in the communication path (52), A sub-tank (54) in which the colorant is supplied to the upper part through the communication path (52), an inkjet head (5) from which the colorant is guided from the lower part of the sub-tank (54), and an opening / closing valve (56). A pressure regulator (58) for applying pressure to the main tank (51) through the communication passage (57), an air vent valve (59) communicated with the upper part of the sub tank (54), and an upper part and a lower part of the sub tank (54). And a casing member (55) that surrounds the sub tank (54) to form a negative pressure chamber.

Therefore, after the open / close valve (53) is opened and the colorant is supplied from the main tank (51) to the sub tank (54), the open / close valve (53) is closed and the discharge nozzle of the inkjet head (5) is operated. Thus, the colorant can be discharged.
The colorant is a mixture of a resin, a drying inhibiting solvent, a pigment, and if necessary, another solvent, a curing agent, a dispersant, and other additives, and is partitioned by a BM lattice (21). After being sprayed onto the pixel (22), it can be cured by drying, heating, or irradiating with energy rays such as ultraviolet rays to form a pixel of a color filter. Here, examples of the resin include, but are not limited to, acrylic resin, alkyd resin, melamine resin, epoxy resin, polyvinyl alcohol, phenol resin, polyamide, polyamideimide, and polyimide.

  Among these, the polyimide resin is preferable, it may be in the state of polyamic acid which is a polyimide precursor, and the solubility is improved by introducing a polar group such as hydroxyl group or sulfonyl group into the skeleton. Polyimide may be used. The polyamic acid can be obtained by the reaction of a tetracarboxylic dianhydride and a diamine, and any aliphatic, alicyclic, aromatic or fluorine-containing one can be used. Moreover, when siloxane diamine is used as a part of diamine, the adhesiveness with an inorganic substrate can be made favorable. Siloxane diamine is usually used in an amount of 1 to 20 mol% in the total diamine. If the amount of siloxane diamine is too small, the effect of improving the adhesiveness is not exhibited, and if it is too large, the heat resistance is lowered. Specific examples of the siloxane diamine include bis-3- (aminopropyl) tetramethylsiloxane.

An acrylic resin is also preferably used and is not particularly limited, but a copolymer of an unsaturated carboxylic acid and an ethylenically unsaturated compound can be preferably used. Examples of the unsaturated carboxylic acid include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid, vinyl acetic acid, and acid anhydrides. These may be used alone or in combination with other copolymerizable ethylenically unsaturated compounds. Specific examples of the copolymerizable ethylenically unsaturated compound include methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-propyl acrylate, isopropyl acrylate, n-propyl methacrylate, and methacrylic acid. Isopropyl acrylate, n-butyl acrylate, n-butyl methacrylate, sec-butyl acrylate, sec-butyl methacrylate, iso-butyl acrylate, iso-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate N-pentyl acrylate, n-pentyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, benzyl acrylate, benzyl methacrylate and other unsaturated carboxylic acid alkyl esters, styrene, p-methyls Rene, aromatic vinyl compounds such as o-methylstyrene, m-methylstyrene and α-methylstyrene, unsaturated carboxylic acid aminoalkyl esters such as aminoethyl acrylate, unsaturated carboxylic acid glycidyl esters such as glycidyl acrylate and glycidyl methacrylate, Carboxylic acid vinyl esters such as vinyl acetate and vinyl propionate, vinyl cyanide compounds such as acrylonitrile, methacrylonitrile, and α-chloroacrylonitrile, aliphatic conjugated dienes such as 1,3-butadiene and isoprene, acryloyl groups at the terminals, Alternatively, macromonomers such as polystyrene, polymethyl acrylate, polymethyl methacrylate, polybutyl acrylate, polybutyl methacrylate, and polysilicone having a methacryloyl group And the like, but not limited thereto.
And it is preferable that it is resin which has heat resistance. In addition, the resin needs to be highly transparent in the visible region.

  The dye may be either a dye or a pigment. However, considering heat resistance, the pigment is preferably a pigment, and more preferably an organic pigment. When representative organic pigments that can be used in the colorant are represented by color index numbers, red pigments include Pigment Red 9, 97, 122, 123, 144, 149, 166, 168, 177, 190, 192, 209, and 215. 216, 224, 254, and the like. Examples of the green pigment include Pigment Green 7, 10, 36, and 47. Examples of the blue pigment include Pigment Blue 15: 3, 15: 4, 15: 6, and 21. , 22, 60, 64 and the like. The pigment may be subjected to surface treatment such as rosin treatment, acidic group treatment, basic treatment and the like, if necessary.

  As the solvent, a drying inhibiting solvent is preferable. The drying inhibiting solvent here has an effect of preventing clogging of the head and not solidifying even when the colorant lands on the substrate. The clogging of the head can be determined by whether or not the colorant can be discharged intermittently, for example, after stopping the discharge for 5 seconds. In addition, when the coloring agent has landed on the substrate, it is not solidified that the substrate after landing is wiped off with a cotton swab without heating and drying, and the coloring agent adheres to the swab. It can be confirmed with.

  As such a drying inhibiting solvent, a solvent having a saturated vapor pressure in the range of 20 to 30 ° C. is preferably in the range of 2 to 200 Pa, and more preferably in the range of 2 to 50 Pa. If the saturated vapor pressure is less than 2 Pa, there is a problem that the pre-drying time becomes long, it takes a long time until the substrate can be transported, and the tact time becomes slow. If the saturated vapor pressure exceeds 200 Pa, the colorant This is not preferable because the drying speed is higher than the wetting and spreading speed in the pixel, and unevenness is likely to occur, and the problem of clogging of the head occurs. These drying inhibiting solvents are preferably contained in an amount of 50 to 88% by weight based on the total amount of the colorant. If it is less than 50% by weight, the effect of the drying-inhibiting solvent is reduced and head clogging is likely to occur, which is not preferable. If it is more than 88% by weight, the necessary amount of solids such as pigments and resins can be secured. This is because it becomes difficult to obtain a desired color as a color filter.

  Examples of such a drying inhibiting solvent include benzyl ethyl ether, dihexyl ether, acetonyl acetone, isophorone, caproic acid, caprylic acid, 1-octanol, 1-nonanol, benzyl alcohol, benzyl acetate, ethyl benzoate, and oxalic acid. Diethyl, diethyl maleate, N-methylpyrrolidone, ethylene carbonate, propylene carbonate, phenyl cellosolve acetate, methyl benzoate, ethyl benzoate, diethyl malonate, β-propiolactone, γ-butyrolactone, γ-valerolactone, δ-valerolactone , Γ-caprolactone, ε-caprolactone, diacetone alcohol, tripropylene glycol methyl ether, dipropylene glycol n-propyl ether, dipropylene glycol n-butyl ether Le, tripropylene glycol n- butyl ether, propylene glycol phenyl ether, 1,3-butylene glycol diacetate. Among these drying inhibiting solvents, dipropylene glycol n-butyl ether and γ-butyrolactone are preferred from the viewpoint of good drying inhibiting effect and pigment dispersibility, and dipropylene glycol n-butyl ether is more preferred. Moreover, two or more types of these drying inhibiting solvents can be mixed, and further, other solvents having no effect of the drying inhibiting solvent can be included.

  Other organic solvents are not particularly limited, and for example, methyl cellosolve, ethyl cellosolve, methyl carbitol, ethyl carbitol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl Ethers, (poly) alkylene glycol ether solvents such as diethylene glycol monomethyl ether, or fats such as propylene glycol monoethyl ether acetate, ethyl acetoacetate, methyl-3-methoxypropionate, 3-methyl-3-methoxybutyl acetate Aliphatic esters such as ethanol, butanol, 3-methyl-3-methoxybutanol, cyclopentanone, Examples include ketones such as clohexanone, amide polar solvents such as N-methyl-2-pyrrolidone, N, N-dimethylacetamide and N, N-dimethylformamide, and aromatic hydrocarbons such as toluene and xylene. It is not limited to these.

  In any case, it has a saturated vapor pressure of 2 to 200 Pa at 20 to 30 ° C. (normally used temperature range), and the colorant preferably contains 50 to 88% by weight of the drying inhibiting solvent. .

  11 and 12 are schematic views showing the relationship between the BM lattice (21) formed on the glass substrate (2), the pixels (22) partitioned by the BM lattice, and the discharge nozzle (50) of the inkjet head (5). is there.

  As can be seen from FIGS. 11 and 12, the plurality of discharge nozzles (50) arranged in series in the inkjet head (5) are arranged so as to be parallel to the long side of the pixel (22) of the glass substrate (2). is doing.

  FIG. 13 is a flowchart for explaining an embodiment of the color filter manufacturing method of the present invention.

  In step SP1, the inkjet head 5 is moved in a direction (X direction) orthogonal to the long side of the pixel (22) of the glass substrate (2). In step SP2, the pixel (22) of the glass substrate (2) is moved. Wait until the discharge nozzle (50) of the inkjet head (5) reaches the upper position, and in step SP3, select to land at a position within 0.8 or more of the radius of the colorant droplet in flight from the inner wall of the pixel (22) The discharge nozzles (50) thus operated are sequentially operated to apply the necessary number of colorant droplets to the pixels (22) partitioned by the BM lattice (21) of the glass substrate (2). It is determined whether or not the required number of colorant droplets have been normally applied to the pixel (22). If it is determined that it is not normal, in step SP5, for the product, the content is recorded in the management information of the immediately preceding product, and the subsequent processing is performed in the subsequent process. The management information of the individual nozzles is updated, and the production is continued while maintaining the optimum application control, or the production process is temporarily stopped to perform the maintenance process of the application apparatus. If it is determined to be normal, the process of step SP1 is performed.

  The flying droplet radius (r) of the colorant is determined in consideration of the discharge amount obtained by an off-line apparatus (not shown) and the flying droplet as a sphere, and considering the specific gravity of the colorant.

Further, the relationship between the landing radius (R) of the colorant and the discharge amount is also obtained in advance by an offline apparatus. These relationships may be appropriately implemented as necessary.
In addition, the selection of a discharge nozzle that lands on a position inside 0.8 times or more of the flying droplet radius (r) and a discharge nozzle that is within 1.3 times the landing diameter (R) from the short side is mounted on the apparatus. The scan camera (9) is used to detect the BM edge position that is the boundary with the pixel portion (22) of the BM grid (21), and from the inkjet head (5) on the glass substrate without the BM grid (21). A discharge nozzle selection program that detects the landing position and the landing diameter (R) of the discharged colorant droplets, and is pre-configured from the relationship between the BM edge position, the landing position of the colorant droplets, the landing diameter, and the discharge amount Is used to select the discharge nozzle corresponding to each pixel (22). These calibrations may be appropriately performed as necessary.

  In order to prevent white spots in the entire pixel (22), the conditions of claims 1 and 2 of the present invention are obeyed, and the adjacent landing position distance of the discharge nozzle to the pixel (22) is also determined as a colorant. It is important to keep it within twice the landing radius (R).

  Since the ejection nozzles are selected as described above, the necessary number of colorant droplets are applied to the pixels (22) partitioned by the BM grid (21) of the glass substrate (2) at a predetermined position. In addition, it is possible to uniformly apply a colorant droplet amount of a desired color to the target pixel (22) without causing problems such as white spots.

  In addition, in the process of step SP3, the inkjet head configuration and movement in the X direction in consideration of the pitch of the ejection nozzle and the ejection amount so that the desired application amount for each pixel (22) is completed within 10 seconds. As speed. Furthermore, it is more preferable to apply the desired application amount to each pixel (22) within 1 second. In these cases, drying of the colorant droplets can be suppressed, and uneven application of the colorant and unevenness of the coating film can be suppressed.

  In addition, since the BM lattice (21) on the glass substrate is provided with liquid repellency on the upper surface, a predetermined coating amount calculated corresponding to the solid content concentration of the colorant in the pixel (22). Normally, even if a coating agent having a coating amount several times the volume of the pixel (22) calculated from the height of the BM grid (21) is applied, the colorant overflows to adjacent pixels to prevent problems such as color mixture and shade differences. It is possible to do.

  Furthermore, since the BM lattice (21) on the glass substrate has a lyophilic side surface, it is possible to prevent white spots on the short side boundary of the pixel (22).

  Next, an embodiment in which a color filter is actually created will be described.

  The present invention will be specifically described based on the following examples, but the present invention is not limited thereto.

Example 1
A. Preparation of light shielding layer material (BM-1) 50 parts by weight of bisphenol A type liquid epoxy resin (R-140p, manufactured by Mitsui Oil Co., Ltd.), 30 parts by weight of carbon powder (MA-8, manufactured by Mitsubishi Materials), and 20 parts by weight of toluene are mixed. As a result, a light shielding layer material (BM-1) was obtained.
B. Preparation of liquid repellent layer material (PP-1) o-naphthoquinonediazide / phenol novolac positive photosensitive agent (Microposit RC100, Shipley) 60 parts by weight, “Thinner” C (Shipley) 20 parts by weight, fluorine-based interface 5 parts by weight of an activator (EF-123A, Tochem Products) and 5 parts by weight of (F179, Dainippon Ink) were mixed to obtain a liquid repellent layer material (PP-1).
C. Preparation of color ink (INK-1R, INK-1G, INK-1B) 5 parts by weight of red pigment PR177, 1 part by weight of polymer dispersant “Solsperse” 24000 (Avicia), acrylic copolymer solution (“Cyclomer”) P "ACA-250, Daicel Chemical Industries) 5 parts by weight, epoxy resin" Epicoat "828 (Oka Shell Co., Ltd.) 3 parts by weight, dipropylene glycol n-butyl ether 86 parts by weight are dispersed and mixed, and red color ink (INK- 1R) was obtained. Similarly, a green color ink (INK-1G) was obtained using the green pigment PG36 instead of the red pigment, and a blue color ink (INK-1B) was obtained using the blue pigment PB15 instead of the red pigment.
D. Production of BM lattice On a 0.7 mm-thick glass substrate “1737” manufactured by Corning Japan Co., Ltd., the light shielding layer material (BM-1) produced in A above was applied with a spinner so that the film thickness after heat treatment was 1.5 μm. Thus, a coating film was formed. The coating film was dried in an oven at 100 ° C. for 10 minutes, and then a liquid repellent layer material (PP-1) was applied thereon with a spinner so that the film thickness after heat treatment was 0.5 μm. Dry in oven for 10 minutes. Using a UV exposure machine “PLA-501F” manufactured by Canon Inc., exposure was performed at 100 mJ / cm ² (ultraviolet intensity of 365 nm) through a photomask pattern in which BM remained in a lattice shape at the periphery of each color pixel. After exposure, the film was immersed in a developer composed of a 2.0% aqueous solution of sodium hydroxide and patterned. Next, after heating at 100 ° C. for 20 minutes, it was immersed in toluene for 1 minute, and the light shielding layer was patterned by etching. After patterning, heat curing was performed at 230 ° C. for 30 minutes to prepare a BM lattice. At this time, the line width of the light shielding layer was 25 μm, the length in the longitudinal direction of the inner wall of the pixel partitioned into BM was 320 μm, and the length in the lateral direction was 100 μm.
E. Production of Color Filter Example 1
Red, green, and blue color inks (INK-1R, INK-1G, and INK-1B) were ejected and colored on the pixel portion of the substrate with BM manufactured in D above using an inkjet ejector. The colorant (color ink) droplet radius (r) during flight was 20 μm, the discharge nozzle position used was 50 μm on the inner side of the inner wall of the BM grid, and the required number of colorants were applied for 5 seconds. After coloring, it was heated and cured at 230 ° C. for 30 minutes to produce a color filter.

  The obtained color filter was evaluated according to the following criteria.

◎ Overall uniform and no unevenness observed ○ Some level of unevenness is observed with careful observation, but no problem at all △ Some unevenness due to liquid bias is observed, but overall it is clean Things x Ink overflow, white spots, and noticeable unevenness were observed, which were inappropriate as the quality of the color filter. Good without white spots and ink overflow of the pixels, and good with no appearance irregularities. The results are summarized in Table 1.

@ 0001
Examples 2-3
A color filter was produced in the same manner as in Example 1 except that the discharge nozzle position used was changed to 30 μm (Example 2) and 20 μm (Example 3) on the inner side of the inner wall of the BM grid. Both were good with no white spots on the pixels or ink overflow, and good with no appearance irregularities.

Example 4
A color filter was produced in the same manner as in Example 3 except that the nozzle setting was changed and the droplet radius (r) during flight was changed to 15 μm. The pixel was satisfactory with no white spots or ink overflow, and was satisfactory without uneven appearance.

Example 5
A color filter was produced in the same manner as in Example 2 except that the nozzle setting was changed and the droplet radius (r) during flight was changed to 30 μm. The pixel was satisfactory with no white spots or ink overflow, and was satisfactory without uneven appearance.

Examples 6-10
The ink ejection timing is changed, and the application time is 15 seconds (Example 6), 10 seconds (Example 7), 8 seconds (Example 8), 3 seconds (Example 9), 1 second (Example 10). A color filter was produced in the same manner as in Example 2 except that. Here, in the case where the coating time was as long as 15 seconds (Example 6), a slight unevenness that appears to be caused by the ink evaporation rate being faster than the ink coating time was observed, whereas the coating time was In 10 seconds to 1 second (Examples 7 to 10), almost no unevenness was observed. In particular, when the coating time was 1 second (Example 10), no unevenness was observed and the color filter had excellent quality.

Example 11
C. Preparation of color ink (INK-2R, INK-2G, INK-2B) 5 parts by weight of red pigment PR177, 1 part by weight of polymer dispersant “Solsperse” 24000 (Avicia), acrylic copolymer solution (“Cyclomer”) P "ACA-250, Daicel Chemical Industries) 5 parts by weight, epoxy resin" Epicoat "828 (Oka Shell Co., Ltd.) 3 parts, and propylene glycol methyl ether acetate 86 parts by weight are dispersed and mixed to produce a red color ink (INK-2R). ) Similarly, a green color ink (INK-2G) was obtained using the green pigment PG36 instead of the red pigment, and a blue color ink (INK-2B) was obtained using the blue pigment PB15 instead of the red pigment.

E. Production of color filter A color filter was produced in the same manner as in Example 2 except that the color ink (INK-2R, INK-2G, INK-2B) produced in C was used. Due to the high evaporation rate of the ink, some unevenness due to the unevenness of the liquid was observed, but the whole was clean.

Comparative Example 1
A color filter was produced in the same manner as in Example 1 except that the position of the discharge nozzle from the inner wall of the BM lattice was 15 μm. Ink climbing on the BM lattice, ink bias, and the like were observed, and the quality of the color filter was significantly impaired.

Comparative Example 2
A color filter was produced in the same manner as in Example 5 except that the position of the discharge nozzle from the inner wall of the BM lattice was 20 μm. Ink climbing on the BM lattice, ink bias, and the like were observed, and the quality of the color filter was significantly impaired.

It is a schematic plan view which shows the positional relationship of a head and BM grating | lattice (21) formed in the glass substrate. It is a schematic longitudinal cross-sectional view which shows the positional relationship of a head and BM grating | lattice (21) formed in the glass substrate. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows an inkjet nozzle arrangement | sequence. It is the schematic which shows the structure of a composite inkjet head. It is the schematic which shows the structure of a composite inkjet head. It is a schematic plan view which shows the positional relationship of a composite inkjet head and BM grating | lattice (21) formed in the glass substrate. It is a schematic longitudinal cross-sectional view which shows the positional relationship of a composite inkjet head and BM grating | lattice (21) formed in the glass substrate. It is a flowchart explaining one Embodiment of a color filter manufacturing method. It is a schematic perspective view which shows a color filter manufacturing apparatus. It is the schematic which shows the principal part of a color filter manufacturing apparatus.

Explanation of symbols

2 Glass substrate 5 Inkjet head 21 BM grid 22 Pixel 50 Discharge nozzle

Claims (7)

  Pixels partitioned by the BM lattice (21) on the transparent substrate (2) using the plurality of discharge nozzles (50) of the inkjet head (5) in which the plurality of discharge nozzles (50) are arranged substantially linearly. In the color filter manufacturing method in which the number of colorant droplets necessary for (22) is applied, the flying droplet radius (r) of the colorant ejected from the ejection nozzle from the boundary of the pixel (22) is 0.8. A method for producing a color filter, wherein all the required number of droplets are landed at a position more than double the inner position.   At least one or more colorant droplets having a distance between the droplet landing position and the pixel (22) short side boundary of not more than 1.3 times the droplet landing radius (R) are present on both short sides. The color filter manufacturing method according to claim 1.   The method for producing a color filter according to claim 1 or 2, wherein a side surface of the BM lattice (21) on the transparent substrate (2) is lyophilic and an upper surface is lyophobic. .   The plurality of ejection nozzles (50) are arranged in parallel to the long sides of the pixels (22) partitioned by the BM lattice (21) on the transparent substrate (2), and the ink jet head (5) is disposed on the pixels (22). The colorant droplets required for the pixels (22) are applied by the plurality of discharge nozzles while moving so as to be orthogonal to the long sides of the plurality of discharge nozzles. Color filter manufacturing method.   The color filter manufacturing method according to any one of claims 1 to 4, wherein a necessary number of colorant droplets are applied to the pixels (22) within 10 seconds.   The color filter manufacturing method according to any one of claims 1 to 4, wherein a necessary number of colorant droplets are applied to the pixel (22) within one second. The colorant droplets contain 50 to 88% by weight of a colorant drying inhibiting solvent, and the colorant drying inhibiting solvent has a vapor pressure of 2 to 200 Pa at 20 to 30 ° C. Item 7. A method for producing a color filter according to any one of Items 6 to 8.

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