JP2009053371A - Color filter, liquid crystal display apparatus equipped therewith and manufacturing method of color filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a color filter which has a colored layer constituted by repeatedly arranging colored parts of three colors in order and which leaks no light from the colored part of any color when used in combination with a liquid crystal display apparatus. <P>SOLUTION: In the color filter 10, the colored layer 11 constituted by arranging a colored part 12(R) of a first color, a colored part 12(B) of a second color, and a colored part 12(G) of a third color in this order with at least one direction as a repeating direction is directly or indirectly provided on an upper surface of a base material 16 having a light translucent region where visible light is transmitted and visible light passing through the light translucent region is colored in three colors. In this color filter, an outline shape of a perpendicular cross-section obtained by cutting colored parts 12 of the first color to the third color respectively in the repetition direction has substantially no inclination biassed toward one direction. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention is a color filter having three colored portions exemplified by red (R), green (G), blue (B), cyan (C), magenta (M), yellow (Y) and the like, The present invention relates to a liquid crystal display device including this as a display-side substrate and a method for manufacturing a color filter.

  At present, liquid crystal display devices capable of color display (color liquid crystal display devices) are widely used. On the viewer side of a general color liquid crystal display device, a color filter in which colored portions corresponding to pixels (dots) are finely patterned is provided as a display side substrate, and a liquid crystal drive substrate including a liquid crystal drive electrode is provided. A liquid crystal cell is formed by sandwiching driving liquid crystal molecules between them, and this is switched for each pixel to switch between bright display (white display) and dark display (black display). In a typical color filter, colored portions of three colors corresponding to the three primary colors of red (R), green (G), and blue (B) are repeatedly arranged side by side in stripes at each pixel width. A transparent colored layer is formed. Three pixels (dots) of R, G, and B constitute one picture element (pixel), and each picture element can perform color display by the additive color mixing method.

Further, in addition to the RGB additive color mixing method, by arranging the three colored portions of cyan (C), magenta (M), and yellow (Y), color display by the subtractive color mixing method becomes possible.
Note that the colored layer may be patterned in a matrix in two vertical and horizontal directions or patterned in two oblique directions, in addition to repeating the stripe-shaped colored portions side by side as described above.

  Specifically, for example, when the colored portion is formed in a stripe pattern of three colors, the first color is 1,4,7,11,..., 3n + 1 from the end within the effective display area where color display is performed. ., 3n + 2 in the second color, 3, 6, 9, 12, .., 3n + 3 in the third color The colored part is arranged.

The above three-color colored portions can be applied to the colored material of each color directly on a light-transmitting substrate or indirectly through a light-shielding black matrix or other underlayer using a photolithography method or an inkjet method. In general, the coating is formed in the repeated direction.
In the case of the photolithography method, a coloring material is applied over the entire surface so as to cover the effective display area, mask exposure and unnecessary portions are etched away, and colored portions of each color are formed in a single step.
In the case of the inkjet method, fine nozzles that discharge coloring materials of respective colors are provided side by side in the repeating direction, and the nozzles that are applied in the direction in which the stripes are extended are applied simultaneously on the base material. Can do.

As described above, the ink jet method has an advantage that the coloring material can be applied on demand at a desired scheduled application position without waste, but is applied such that undulation or unevenness occurs on both width sides in the application direction. There is a problem that it is difficult to increase the resolution of the colored portion.
Particularly in recent years, in order to improve the aperture ratio in the effective display area of a liquid crystal display device, it has been required to form a black matrix that partitions colored portions narrower than in the past, and the coating resolution of the colored portions is low. In this case, there is a problem that color mixing occurs in the light transmission region. For this reason, a photolithography method with high coating resolution is suitably used for forming the colored portion.

  In recent years, as an optical element used for a liquid crystal display device or the like, an optical element having a retardation layer between substrates has been developed in order to expand a viewing angle (for example, Patent Document 1 below). Such an optical element is formed by applying crosslinkable liquid crystal molecules directly on a colored layer of a color filter or indirectly through another layer such as an alignment film and fixing the liquid crystal molecules in a state of being aligned in a desired direction. A phase difference layer (in-cell phase difference layer) is provided. For example, an in-cell retardation layer in which crosslinkable liquid crystal molecules are aligned perpendicularly to the color filter compensates for the viewing angle of a polarizing plate arranged in a crossed Nicols state on the forefront side and the back side of the liquid crystal display device. In addition to functioning as a C plate, it can also serve as a protective layer that physically protects the colored layer. Further, since the in-cell retardation layer is sandwiched between the display side substrate and the liquid crystal driving substrate (in-cell side) together with the driving liquid crystal molecules, there is an advantage that the in-cell retardation layer is physically protected and hardly absorbs moisture.

JP 2004-240102 A

  However, in recent years, there has been a demand for higher brightness and higher quality of liquid crystal displays, and in-cell phase difference type color filters in which colored portions are formed with a high resolution by a photolithography method are also required to block visible light. The problem of light leakage in which a small amount of transmitted light occurs during display has been recognized as a problem to be improved. In particular, when the protective layer that has been generally provided between the color filter and the driving liquid crystal molecules is omitted in order to reduce the thickness of the liquid crystal display device, the above problem of light leakage is significant.

  Therefore, the present inventor has studied in detail the cause of the light leakage of the color filter. As a result, it has been found that light leakage may occur only for a specific color among the three colored portions constituting the colored layer of the color filter. The light leakage in the specific colored portion has caused the light leakage of the conventional color filter.

  The present invention has been made to solve the above problems, that is, when a color filter including a colored layer in which three colored portions are repeatedly arranged in order is used in combination with a liquid crystal display device. It is an object of the present invention to provide a color filter in which light leakage does not occur from any colored portion. Another object of the present invention is to provide a method for producing such a color filter using a photolithography method, and a liquid crystal display device provided with such a color filter.

  In making the present invention, as a result of intensive investigation of the cause of the above problems by the present inventors, among the three colored layers that are formed by repeating the three photolithography steps, the coloring applied the second time In the portion (second color coloring portion), more specifically, on the side adjacent to the colored portion (first color coloring portion) coated and formed for the first time among the second color coloring portions, from the liquid crystal display device It was found that light leakage occurred. Therefore, when the outer shape of the vertical cross section obtained by cutting the colored portion of each color in the repeating direction (hereinafter sometimes referred to as the width direction) is measured with a three-dimensional measuring instrument, only the colored portion of the second color is one side. It was found that it was a left-right asymmetrical shape inclined in the direction.

FIG. 12 is a schematic diagram relating to a vertical cross section of the colored layer 11 coated and formed on the upper surface of the light-transmitting substrate 16, and corresponds to a measurement result obtained by a three-dimensional measuring device. In the drawing, the dimension in the thickness (vertical direction in the figure) direction is enlarged with respect to an actual colored layer. The horizontal direction in the figure is the repeating direction of the colored portion. In addition, the figure also shows a state in which the liquid crystal molecules 50 applied on the colored layer 11 are vertically aligned. The colored portion 12 (R) of the first color is red, the colored portion (B) of the second color is blue, and the colored portion 12 (G) of the third color is green, and these are arranged in this order by photolithography. Is formed by coating. That is, the red colored portion 12 (R) is obtained by the first photolithography process, the blue colored portion 12 (B) is obtained by the second photolithography process, and the green colored portion 12 (G) is obtained by the third photolithography process. Are repeatedly applied to the base material 16 every two rows.
In the drawing, each colored portion has a stripe shape extending in the front-rear direction of the paper surface, and represents a state in which a boundary between the colored portions is partitioned by a black matrix (BM) 14. The width of the light transmitting region opened between the adjacent BMs 14 corresponds to the pixel width of the liquid crystal display device.

In such a colored layer 11, when liquid crystal molecules 50 such as driving liquid crystal molecules and crosslinkable liquid crystal molecules are applied directly on the upper surface or indirectly through an alignment film (not shown), the first color and the third color are applied. As for the colored portions 12 (R) and 12 (G), the orientation of the liquid crystal molecules 50 existing on the colored layer interface side is bilaterally symmetric (Sy), and the liquid crystal molecules 50 located thereabove are also based on the continuous elastic body theory. Align vertically.
The outer portions of the colored portions 12 (R) and 12 (G) are formed with convex portions 22 and 23 having the same height at both ends in the width direction by riding on the BM 14 and the adjacent colored portion, and the center is flat. It has a symmetrical shape. For this reason, although the vertical alignment of the liquid crystal molecules 50 is tilted to the inside of the pixel in the vicinity of the protrusions 22 and 23, the alignment of the liquid crystal molecules 50 on the colored layer interface side is balanced left and right in the pixel unit. The liquid crystal molecules 50 do not have alignment defects.

  On the other hand, in the colored portion 12 (B) of the second color, the alignment of the liquid crystal molecules 50 is balanced left and right (Sy) on the right side in the drawing, which is the side adjacent to the colored portion 12 (G) of the third color. However, the liquid crystal molecules 50 are tilted in one direction (in the case of the right side in the figure) on the left side of the drawing adjacent to the colored portion 12 (R) of the first color, and the liquid crystal molecules 50 existing thereabove. Is also asymmetric (Asy), resulting in poor alignment. For this reason, when the alignment defect occurs in the driving liquid crystal molecules, the transmitted light is not switched as expected, and a desired phase difference cannot be obtained in the liquid crystal cell. Therefore, light leakage occurs during dark display. . In addition, even when the above alignment defect occurs in the crosslinkable liquid crystal molecules, a desired viewing angle improvement effect cannot be obtained by the in-cell retardation layer formed by immobilizing the molecules, and light leakage also occurs during dark display.

The present inventor further studied and found a mechanism in which such an orientation failure occurs only in the colored portion of the second color. A conventional method for producing a three-color filter will be described with reference to FIGS.
FIG. 2A is a schematic diagram showing the first photolithography process. The light is applied to the entire surface of the base material 16 (only the upper surface is shown in the figure (b) and below) on which the BM 14 is optionally formed in a stripe shape or a matrix shape with a pixel width therebetween or to cover the effective display area. A first color coloring material 18 (R), which is a curable coloring resist material, is applied. Further, as shown in the figure, a photomask 20 in which a mask opening 21 is formed corresponding to the planned formation position of the colored portion 12 (R) of the first color is placed facing the base material 16, and further the photomask 20 Actinic radiation such as ultraviolet rays is exposed to the coloring material 18 (R) via Only the portion of the coloring material 18 (R) that has ridden on the BM 14 bulges. In general, the colored portion 12 is formed thicker than the BM 14. In addition, the bulging does not occur when the BM 14 is not formed on the upper surface of the base material 16.
FIG. 4B shows a state in which the unexposed portion is removed by etching the colored material 18 (R) after exposure to leave the first-color colored portion 12 (R) remaining. In the colored portion 12 (R), convex portions 22 are formed at both ends in the width direction riding on the BM 14, and a flat portion 24 is formed at the center. In the case of a color filter not provided with the BM 14 as described above, the convex portion 22 does not occur and the colored portion 12 (R) is formed flat.

FIG. 4C is a schematic diagram showing the second photolithography process. That is, using the base material 16 including the colored portion 12 (R) of the first color obtained as described above as a base layer, the colored material 18 (B) of the second color, which is a colored resist material, is applied to the entire surface, and the second A state in which ultraviolet exposure is performed through a photomask 20 in which a mask opening 21 is formed facing a predetermined formation position of the colored portion 12 (B), that is, a position adjacent to the colored portion 12 (R) of the first color. Is shown. The coloring material 18 (B) bulges out at the portion riding on the BM 14 and the coloring portion 12 (R).
FIG. 4D shows a state in which the coloring material 18 (B) is etched and the second colored portion 12 (B) remains. The colored portion 12 (B) is formed adjacent to one side (right side in the figure) of the colored portion 12 (R) of the first color, and is adjacent to the colored portion 12 (R) (in the drawing) On the left side, a higher convex portion 23 is formed, and on the opposite side, a lower convex portion 22 is formed. In addition, the outer shape of the cross section of the colored portion 12 (G) is formed with an inclined portion 25 that descends from the left to the right in the drawing in the center of the width. This is because the colored layer 12 (R) is already thick only on one side (left side in the figure) of the width direction of the pixel in the base layer to which the coloring material 18 (B) of the second color is applied. The other side (right side in the figure) is only provided with a thin BM 14 and the applied height of the applied coloring material 18 (B) is adjacent to the colored portion 12 (R). This is because it becomes higher on the side to be performed.

FIG. 4E is a schematic diagram showing the third photolithography process. That is, the third color coloring material 18 (G), which is a colored resist material, is applied to the entire surface of the base material 16 including the first color and second color coloring portions 12 (R), 12 (B), A state is shown in which the mask opening 21 is opposed to the unformed regions of the colored portions 12 (R) and 12 (B) and the ultraviolet exposure is performed. The heights of the end portions of the colored portions 12 (B) and 12 (R) that are already formed on the left and right of the planned formation position of the colored portion 12 (G) are the same at the convex portion 22.
FIG. 5F shows a state in which the coloring material 18 (G) is etched and the third colored portion 12 (G) remains. High convex portions 23 equivalent to the left side of the colored portion 12 (B) are formed at both ends of the colored portion 12 (G). Thus, the colored layer 11 including the first to third colored portions 12 (R), 12 (B), and 12 (G) is formed.

  As described above, regarding the colored portion 12 (R) of the first color and the colored portion 12 (G) of the third color, the state of the base layer in the region to be cured by ultraviolet rays is the same in both sides in the width direction of the pixel. Therefore, even when the convex portions 22 and 23 are formed at both ends, the height of the outer shape is equal on the left and right sides, and a flat portion 24 is formed at the center of the width to be symmetrical. On the other hand, for the colored portion 12 (B) of the second color, the colored portion 12 (R) is already cured and formed on one side in the width direction of the planned formation region, and this does not exist on the other side. The outer shape is inclined downward from the one side to the other side and becomes asymmetrical.

The present invention has been made to solve the problem of alignment failure of liquid crystal molecules due to the above-mentioned left-right asymmetry of the colored portion, and is a cross section in the width direction of the first to third colored portions constituting the colored layer. By making the outer shape into a predetermined shape, the orientation of the liquid crystal molecules applied thereon is improved for each pixel.
In addition, a more specific first feature of the present invention for realizing this is that even when a colored portion is already formed only on one side adjacent in the width direction as shown in FIG. This is based on the technical idea of preventing the coloring material applied on the surface of the coloring material from riding on the material as shown in FIG. Similarly, the second feature is that, when a colored portion is already formed on only one side in the width direction, the opposite side in the width direction in anticipation of the height of the next applied coloring material riding on the colored portion. This is based on the technical idea that the protrusions are formed in advance. Other technical features will be apparent from the following description.

That is, the color filter according to the present invention is
(1) A colored layer in which colored portions of the first to third colors are arranged in this order with at least one direction as a repetitive direction is provided directly or indirectly on the upper surface of a base material having a light transmission region through which visible light is transmitted. In the color filter that colors the visible light transmitted through the light transmission region into three colors,
A color filter characterized in that the outline shape of the vertical section obtained by cutting the colored portions of the first to third colors in the repetitive direction is not substantially inclined in one direction;
(2) The color filter as described in (1) above, wherein the outer shapes of the colored portions of the first to third colors are substantially symmetrical.
Is the gist.

In the present invention, as a more specific embodiment of the color filter,
(3) The color filter according to (1) or (2), wherein the colored portion of at least two of the three colors has a hydrophobic upper surface;
(4) The color filter according to (3) above, wherein the at least two colored portions include a hydrophobic material;
(5) The color filter according to (3), wherein a hydrophobic layer having hydrophobicity is formed on an upper surface of the colored portion of at least two colors;
(6) Between the colored layer and the base material, the upper end height is flush with the upper surface of the colored portion of the first color in the boundary region between the colored portion of the second color and the colored portion of the third color. A color filter as described in (1) or (2) above, wherein a projecting portion formed on the surface is provided;
(7) A light-shielding black matrix that partitions the colored portions of the first to third colors from each other is provided between the colored layer and the base material,
The color filter according to (6), wherein the protrusion is provided between the black matrix and the colored layer;
(8) A light-blocking black matrix that partitions the colored portions of the first to third colors from each other is provided between the colored layer and the base material,
In the above (6), the protrusion is made of a colorless transparent material or a transparent material of the same color as the second color and is provided adjacent to the colored portion of the second color with respect to the black matrix. The described color filter;
(9) The color filter according to any one of (1) to (8), wherein the colored portion of the first color is formed at an extreme end in the repetition direction in an effective display region formed on the base material. ;
(10) Any one of (1) to (9) above, wherein a retardation layer in which a polymerizable liquid crystal compound is fixed in an aligned state is laminated directly on the upper surface of the colored layer or indirectly through an alignment film A color filter according to claim 1;
However, the object of the present invention can be achieved.

The liquid crystal display device of the present invention is
(11) The color filter according to any one of the above (1) to (10) and a liquid crystal driving substrate including a liquid crystal driving electrode are opposed to each other with the colored layer and the liquid crystal driving electrode inside, and between them A liquid crystal display device encapsulating driving liquid crystal molecules;
Is the gist.

In addition, the method for producing a color filter according to the present invention includes:
(12) The method for producing a color filter according to (1) or (2) above,
Applying the coloring material of the first color in the effective display area preliminarily formed on the base material, patterning this by a photolithography method to form the colored portion of the first color;
The coloring material of the second color is applied by an inkjet method at a position within the effective display area and adjacent to the first coloring portion in the repeating direction. Forming a colored portion;
The third color coloring material is applied in the effective display area and patterned by a photolithography method so that the third color is positioned adjacent to both the first colored portion and the second colored portion. Forming a colored portion of
A method for producing a color filter, comprising:
(13) The method for producing a color filter according to (1) or (2) above,
Applying the coloring material of the first color having hydrophilicity in the effective display area planned to be formed on the base material, and patterning this by a photolithography method to form the colored portion of the first color;
Forming a hydrophobic layer having hydrophobicity directly or indirectly on the upper surface of the colored portion of the first color;
In the effective display area including the formation area of the hydrophobic layer, the coloring material of the second color having hydrophilicity is applied, and this is patterned by a photolithography method, and the first coloring portion is Forming the colored portion of the second color at a position adjacent to the repeating direction;
Removing the hydrophobic layer from the colored portion of the first color;
The third color coloring material is applied in the effective display area and patterned by a photolithography method so that the third color is positioned adjacent to both the first colored portion and the second colored portion. Forming a colored portion of
A method for producing a color filter, comprising:
(14) The method for producing a color filter according to (1) or (2), wherein the colored portions of the first to third colors are formed by a photolithography process twice for each color, and the following (i) Of the steps (vi)
After performing steps (i) and (ii) in this order,
Performing step (iii) alone, or simultaneously performing steps (iii) and (iv), or after step (iv),
Furthermore, the remaining steps are performed in an arbitrary order.
(I) The coloring material of the first color is applied in an effective display area that is preliminarily formed on the substrate, and this is patterned by a photolithography method, so that 6n + 1 in the repeating direction (n is an integer of 0 or more) Forming the colored portion of the first color at a second position;
(Ii) applying the second color coloring material in the effective display area and patterning the second color coloring material by a photolithography method to form the second color coloring portion at the 6n + 3rd position in the repeating direction;
(Iii) A step of applying the third color coloring material in the effective display area and patterning it by a photolithography method to form the third color coloring portion at the 6n + 5th position in the repeating direction;
(Iv) A step of applying the third color coloring material in the effective display area and patterning the third color coloring material by a photolithography method to form the third color coloring portion at the 6n + 2nd position in the repeating direction;
(V) applying the coloring material of the first color in the effective display area and patterning the coloring material by a photolithography method to form the colored portion of the first color at the 6n + 4th position in the repeating direction;
(Vi) applying the second color coloring material in the effective display area and patterning the second color coloring material by a photolithography method to form the second color coloring portion at the 6n + 6th position in the repetition direction;
Is the gist.

  In the present invention, the “outer shape” of the vertical cross section cut in the repeating direction (width direction) of the colored portion refers to the contour on the upper surface side of the colored portion, that is, the opposite surface side of the substrate. In addition, the outer shape of the colored portion without particular notice means an outer shape of a vertical cross section obtained by cutting the colored portion in a repeating direction.

  Further, in the present invention, the outline shape of the cross section in the width direction of the colored portion is “substantially not inclined in one direction”, specifically, directly above the colored portion or an alignment film or the like. To the extent that when liquid crystal molecules for driving or crosslinkable liquid crystal molecules are disposed indirectly through another layer, the liquid crystal molecules cause alignment defects in the effective display area and at positions exposed from light-shielding areas such as a black matrix. This means a state in which the tilt is not shown in one direction. As a more desirable example of such a state, in addition to the case where the entire outer shape of the colored portion is flat, even if the outer shape has a convex portion or an inclination, a flat portion is present at the center of the width of the outer shape or in the vicinity thereof. Including the case where it is formed. Specifically, in the above outline, when the slope of the approximate curve obtained by sampling within the range of 35% on one side (70% on both sides) from the center of the width at every predetermined interval includes different signs, excluding zero slope Excluding cases where the slope in the range is positive or negative only. That is, when the gradient is only zero or positive, or only zero or negative, the outer shape of the colored portion of the pixel is inclined substantially in one direction. The sampling interval can be about 20 to 40 equally in the width direction within the range of 70% on both sides.

Further, in the present invention, “substantially left-right symmetric”, which is a more preferable aspect of the state in which the outer shape of the cross section in the width direction of the colored portion is “substantially not inclined in one direction”, is specifically Specifically, in addition to the above, (a) when the width of the colored portion (pixel width) is 150 μm or less, the height difference between both ends in the width direction is 2500 mm or less, and (b) when the pixel width is 150 μm or more. It means that the difference in height between both ends in the width direction is 1700 mm or less, and includes both cases where both sides are raised with respect to the width center, when both are lowered, and when one is raised and the other is lowered.
A commercially available three-dimensional measuring device such as a fine shape measuring instrument ET4000L (manufactured by Kosaka Laboratory) can be used for measuring the outer shape of the colored portion.
In addition, since the alignment defect of the liquid crystal molecules within the pixel width becomes more noticeable as the pixel width becomes larger, in the present invention, the allowable value of the height difference at both ends in the case of (b) is set as in the case of (a). It is more severe than that.

  In the constituent layers constituting the color filter of the present invention, “upper”, “upper”, “upper surface”, or “lower”, “lower”, “lower surface”, etc. Means the relative positional relationship of the layers constituting the layer, and does not mean up and down relative to the direction of gravity.

  In the present invention, the “effective display area” means an area where transmitted light is emitted / incident and a predetermined display or observation is performed. For example, when the present invention is used in a liquid crystal display device, an image in the device is displayed. It means the area corresponding to the display area.

  In the color layer of the color filter of the present invention, the outer shape of the cross section of each colored portion constituting the color layer is not substantially inclined in one direction. Therefore, for example, a liquid crystal display using the color filter of the present invention as one substrate When the device is formed, there is no possibility that the driving liquid crystal molecules and the crosslinkable liquid crystal molecules that face the colored layer directly or indirectly cause poor alignment due to the inclination of the cross-sectional outline. Therefore, the liquid crystal display device configured using the color filter of the present invention can provide a high-quality display without causing a problem of light leakage in dark display.

  Specifically, in the case of driving the driving liquid crystal molecules on the colored layer according to the present invention, the horizontal / vertical alignment in the pixel is favorably performed on the interface side of the colored layer, so that it passes through the liquid crystal cell. A desired phase difference amount can be given to the transmitted light. Conventionally, a protective layer that has been applied between the colored layer and the driving liquid crystal molecules to flatten the upper surface of the colored layer can be omitted by replacing the protective layer with an in-cell retardation layer. Can contribute to cost reduction.

The same applies to the case where the crosslinkable liquid crystal molecules applied on the colored layer of the present invention are aligned vertically or horizontally and fixed to form a retardation layer. The alignment property of the crosslinkable liquid crystal molecules is improved, and a desired phase difference amount is given to the transmitted light passing therethrough, so that the viewing angle expansion effect of the liquid crystal display device can be obtained as desired.
Also in this case, the protective layer for flattening the upper surface of the colored layer can be omitted or significantly reduced in thickness, which can contribute to thinning of the liquid crystal cell.

FIG. 1A shows a color filter 10 provided with a preferred colored layer 11 having the above-described effects of the present invention on a base material 16 and cut in the repeating direction of colored portions 12 (R), (B), and (G). It is a vertical cross-sectional schematic diagram.
On the base material 16, BM14 is arrange | positioned by the pitch corresponding to a pixel width at stripe form or a grid | lattice form, and the said pixel is formed by fixing and forming the colored part 12 (R)-(G) between adjacent BM14. Color red (R), blue (B), and green (G). Three adjacent colored portions are combined to form one picture element. When the color filter 10 is used in a liquid crystal television as an example of a liquid crystal display device, each picture element is on the order of several tens to several hundreds of μm, and generally smaller than this when used in a mobile phone display screen.

FIG. 4B is a schematic diagram showing a preferred outer shape of the colored portion 12. The colored portion 12 has a width of 35% on one side and 70% on both sides from the center of the width (CL) in addition to the case where the entire outer shape is flat, as well as the case where there is an ascending (shown) or descending gradient at both ends in the width direction. When the slope of the approximate curve connecting the upper surface positions sampled by dividing the flat portion 24 corresponding to the range (0.35 W) into 20 to 40 parts in the width direction has both positive and negative, the outer shape is substantially It can be said that it is not inclined in one direction.
In particular, when the BM 14 is formed on both sides in the width direction of the colored portion 12 as in the case shown in the drawing, or when another colored portion is previously formed at a position adjacent to the width direction, the colored portion 12 is formed. Ride on this, and convex portions 22a and 22b may be formed on both sides. Also in such a case, if the inclination of the outline within the width of the flat portion 24 corresponding to 35% width on one side from the width center (CL) is reversed from positive to negative, or from negative to positive, directly or indirectly on the upper surface of the colored portion 12. The alignment of the liquid crystal molecules 50 applied to the liquid crystal is balanced within the pixel, and the problem of light leakage of the liquid crystal display device is reduced.

Further, as a more preferable outer shape of the colored portion 12, also in the colored portion 12 in which the convex portions 22a and 22b are formed at both ends in the width direction, the height difference (H) between the convex portions 22a and 22b is not more than a predetermined value. For this reason, the outer shape is substantially symmetric, and the orientation of the liquid crystal molecules 50 is further balanced within the pixel.
The height difference (H) between the protrusions 22a and 22b is 2500 mm or less when the pixel width (W) is relatively small, less than 150 μm, and 1700 mm or less when the pixel width (W) is relatively large, 150 μm or more. A suitable value is set. When the pixel width is large, the effect of canceling the balance of the alignment of the liquid crystal molecules 50 in the vicinity of the projections 22a and 22b with the entire liquid crystal molecules 50 within the pixel width is weakened. Requires a tighter tolerance (1700 mm).
In order to achieve the above object of the present invention, the height of the convex portions formed at both ends in the width direction of the colored portion 12 is not a problem, and it is preferable that the difference in height (H) between both ends is small. Therefore, even when the high convex portions 23a and 23b are formed on both sides of the colored portion 12 by riding on the colored portions of other colors provided in advance on both sides in the width direction, the height difference (H) is preferable as described above. As long as the value is satisfied, the entire pixel does not have a problem of light leakage due to poor alignment. Even if the alignment of the liquid crystal molecules 50 existing in the vicinity of the convex portions 23a and 23b becomes locally poor, the outer shape of the colored portion is bilaterally symmetric like the colored portion 12 (G) in FIG. This is because the problem of light leakage does not occur in units.

  In the description of the present invention, for the sake of convenience, a subscript (R) meaning red is attached to the coloring material and colored portion of the first color, blue is meant for the second color (B), and the third color is concerned. Is attached with (G) meaning green, but the selection of the three colors constituting the colored layer and the arrangement order thereof are not limited to this. Those skilled in the art can easily implement the present invention based on the following explanations even when the selection of the three colors of coloring materials and the order of coating are different.

Hereinafter, a method for manufacturing a color filter will be described in which the outer shape of the cross section in the width direction of the colored portion is preferably substantially symmetric without being inclined substantially in one direction as described above.
The production method according to the present invention is roughly classified as follows: (1) A climbing prevention method for preventing a colored material applied next from running on a colored portion that is already provided adjacent to only one side in the width direction. ;
(2) A projection forming method in which a projection is formed in advance on the other side in anticipation of a height at which the applied coloring material rides on a colored portion that is also provided adjacent to one side;
(3) In order to avoid the state in which the colored layer is already formed only on one side in the width direction of the undercoat layer to which the coloring material is applied, the three-color coloring material is artificially even-numbered (six colors) A six-color patterning method, in which it is regarded as a coloring material and patterned in a jumping manner;
(4) a post-treatment method in which the applied coloring material or a colored portion obtained by curing the material is formed into a desired shape by post-treatment;
There are four types.
Hereinafter, each method will be described in order.

<(1) How to prevent getting on>
As already described with reference to FIG. 13, when the coloring material 18 (B) of the second color is applied on the base material 16 on which only the coloring portion 12 (R) of the first color is applied and formed, the coloring portion 12 There is a problem that the cross-sectional outline of the colored portion 12 (B) of the second color is inclined in one direction by riding on (R). In order to prevent this in the present invention, at least one of (i) the upper surface of the colored portion 12 (R) of the first color and the colored material 18 (B) of the second color applied on the surface is hydrophobic. (Ii) A high-resolution photolithography method is used to fix the colored portion 12 (R) of the first color and the colored portion 12 (G) of the third color, and the colored material 18 (B ) Is applied by using one of two means of using an inkjet method.

  For the sake of convenience, the order of the coloring materials applied to the substrate 16 in this embodiment is as follows: the first color coloring material 18 (R), the second color coloring material 18 (B), and the third color coloring material 18 ( G).

Here in general,
(A) Affinity of both when a hydrophilic coloring material is applied to the hydrophilic upper surface of the colored portion,
(Ii) Affinity of both when the hydrophobic coloring material is applied to the hydrophilic upper surface of the colored portion,
(U) Affinity of both when a hydrophilic coloring material is applied to the hydrophobic upper surface of the colored portion,
(E) Affinity of hydrophobic coloring material applied to the hydrophobic upper surface of the colored part,
When the magnitude relation of is compared, the relation of the following expression (1) is obtained.

(Formula 1)
(A)>(E)>(I)> (U) (1)

  Note that there is a positive correlation between the affinity and the running height of the coloring material. In other words, when other coloring materials are applied to the base layer on which the colored portion is already formed adjacent to one side in the width direction, both the colored portion and the colored material are hydrophilic in the conventional color filter. It was common to be. For this reason, the colored portion 12 (R) of the first color is formed thick on one side in the width direction with respect to the planned formation region of the colored portion 12 (B) of the second color, and the substrate 16 is formed on the other side. In the case of an underlayer that is exposed or formed with a thin BM 14, when the second color coloring material 18 (B) is applied thereon, the running to one side (first color side) is outstanding. The high convex part 23 was formed.

Of the above (i), as a method of hydrophobizing the upper surface of the colored portion 12 (R) of the first color,
(I-1) A method in which a hydrophobic material is mixed with the coloring material 18 (R) of the first color and both the upper surface and the inside of the colored portion 12 (R) are made hydrophobic (first embodiment), or ( i-2) Method of depositing and forming a hydrophobic layer having hydrophobicity on the upper surface of the colored portion 12 (R) on the colored portion 12 (R) obtained by patterning and fixing the hydrophilic coloring material 18 (R) ( Second embodiment),
Can be taken.
The second color coloring portion 12 (B) and the third color coloring portion 12 (G) can be selected in a plurality of ways depending on whether they are hydrophobic or hydrophilic.

[First Embodiment: Regarding (i-1) above]
In the first embodiment,
(I-1a) The colored portion 12 (R) of the first color is made hydrophobic and the colored material 18 (B) of the second color is made hydrophilic;
(I-1b) The colored portion 12 (R) of the first color is made hydrophilic and the colored material 18 (B) of the second color is made hydrophobic;
(I-1c) The first colored portion 12 (R) and the second colored material 18 (B) are both hydrophobic;
You can choose three ways.

By setting the above (i-1a) or (i-1b), the end height of the second color coloring material 18 (B) is reduced on one side adjacent to the first color coloring portion 12 (R). The second colored portion 12 (B) is symmetrical in the width direction by leveling with the other end height not previously provided with the colored portion, that is, the vertical cross section of the colored portion. The outer shape does not substantially tilt in one direction.
Moreover, by setting it as said (i-1c), compared with the conventional color filter which stands in the relationship of said (a), the edge part side height in the colored part 12 (B) of the 2nd color is reduced similarly, By leveling with the height of the end on the other side, the problem of light leakage in the colored portion 12 (B) of the second color can be reduced.

In the case of the above (i-1a), if the coloring material 18 (G) of the third color is made hydrophilic, the coloring material 12 (G) of the third color obtained by patterning the coloring material 18 (G) by the photolithography method A problem arises that a high convex portion is formed only on the side adjacent to the two-color colored portion 12 (B), and the outer shape of the third-color colored portion 12 (G) is inclined in one direction. End up. On the side adjacent to the colored portion 12 (R) of the first color, the third color (hydrophilicity) has a polarity different from that of the first color (hydrophobic). The third color coloring material 18 (G) has a smaller ride due to the above relationship, whereas the second color (hydrophilicity) has the same polarity and the above (a) has the best mutual affinity. This is because the ride will also increase.
Therefore, in the case of (i-1a), the coloring material 18 (G) of the third color is made hydrophobic, and the affinity with the colored portion 12 (B) of the second color can be lowered due to the relationship (ii) above. preferable.

  In order to make the coloring material 18 hydrophobic, a hydrophobic material such as a fluororesin may be mixed therein.

  In the case of the above (i-1b), the third color material 18 (G) is made hydrophobic, so that the relationship (ii) is established on the side adjacent to the first color, and the second color is changed. Therefore, the height of the third color coloring portion 12 (G), which is fixed on the side, is leveled at both ends in the width direction, and the vertical cross section of the pixel is The outer shape does not substantially tilt in one direction.

In the case of the above (i-1c), the coloring material 18 (G) of the third color may be hydrophilic or hydrophobic. When this is hydrophilic, the adjacent height to the first color and the adjacent side of the second color have the above relationship (iii) and the ride height is equal. Further, even when this is hydrophobic, the adjacent height to the first color and the adjacent side to the second color are equal to each other in the width direction, and the ride heights on both sides in the width direction are equal.
However, by making the coloring material 18 (G) of the third color hydrophilic, the height of both ends of the colored portion 12 (G) is further reduced based on the relationship of the above (U) and the above formula (1), and light transmission is achieved. This is preferable because the width of the flat portion 24 (see FIG. 13) formed in the region is increased and the orientation of the liquid crystal molecules 50 becomes better.

  Therefore, in the colored layer of the present embodiment, it is preferable that at least two of the three colors are hydrophobic, and it is particularly preferable that only two of these are hydrophobic.

[Second Embodiment: Regarding (i-2) above]
In the color filter according to the second embodiment, the hydrophobic layer is applied to the upper surface of the colored portion 12 formed by fixing the hydrophilic coloring material 18 so that the coloring filter 18 can be applied to the coloring material 18 of another color to be applied next. The affinity is reduced based on the above formula (1). Specifically, the coloring material 18 (R) of the first color in the above (i-1a) and (i-1c) is made hydrophilic, and the upper surface of the colored portion 12 (R) formed by pattern-fixing this is hydrophobic. A layer may be formed.

  In forming a hydrophobic layer on the upper surface of the colored portion 12, a method of hydrophobizing the colored portion 12 itself on the upper surface by subjecting the colored portion 12 to atmospheric pressure plasma treatment in a fluorine gas atmosphere, and a hydrophobic property such as a fluororesin There is a method of producing a hydrophobic film by applying a hydrophobic ink containing a material to the upper surface of the colored portion 12 and drying and fixing it.

  In this case, the selection of the hydrophilicity / hydrophobicity of the coloring materials 18 (B) and (G) of the second color and the third color is the same as described above. Therefore, in the colored layer of the present embodiment, it is preferable that the upper surface of the colored portion of at least two of the three colors is hydrophobic, and it is particularly preferable that only the upper surface of only two colors is hydrophobic.

  The purpose of forming a hydrophobic layer on the upper surface of the colored portion 12 to make the region hydrophobic is to reduce the affinity with the coloring material 18 of other colors applied thereon, This is to prevent the formation of a high convex portion at the end portion of the colored portion 12 of another color formed adjacently. Accordingly, the hydrophobic layer may be formed on the entire upper surface of the colored portion 12 or may be formed only on one side of the upper surface of the colored portion 12 adjacent to the other color.

Moreover, in this embodiment, you may remove the hydrophobic layer formed in the upper surface of the coloring part 12 of a predetermined color in a subsequent process. Specifically, according to the following steps.
A manufacturing process of the color filter 10 according to the present embodiment is shown in FIG.

  As a first step, hydrophilic coloring material 18 (R) having a predetermined thickness is applied so as to cover the effective display area that is preliminarily formed on the base material 16 by the BM 14 (see FIG. a)), this is patterned by a photolithography method, and the colored portion 12 (R) of the first color is fixedly formed ((b) in the figure). Since the formed colored portion 12 (R) of the first color is applied on the base material 16 in which the BMs 14 are equally formed on both sides in the width direction, the outer shape is a low convex portion 22a on both sides in the width direction. 22b is formed, and a flat portion 24 is formed in the vicinity of the center of the width to be symmetrical.

As a second step, a hydrophobic hydrophobic layer 26 is formed on the entire upper surface of the first color coloring portion 12 (R) or on the planned formation side of the second color coloring portion 12 (B) on the upper surface. (FIG. (C)). It is preferable that the hydrophobic layer 26 is not formed on the surface of the BM 14. Therefore, when the hydrophobic layer 26 in this embodiment is obtained by hydrophobizing the upper surface of the colored portion 12 (R), which is a resin material, by atmospheric pressure plasma treatment in a fluorine gas atmosphere, the BM 14 is not hydrophobized by the treatment. A metal thin film having a light-shielding property or a light-absorbing property such as a metal chromium thin film or a tungsten thin film may be patterned on the substrate 16 in advance.
The hydrophobic layer 26 is formed only on the upper surface of the colored portion 12 (R) only on the side adjacent to the planned formation region of the colored portion 12 (B) of the second color even if it is formed as shown in the figure. May be.

  As a third step, the second color coloring material 18 (B) is applied with a predetermined thickness so as to cover the effective display area including the coloring portion 12 (R), and this is patterned by a photolithography method to be second. The colored portion 12 (B) is fixedly formed ((d) in the figure). At this time, since the upper surface of the colored portion 12 (R) of the first color is hydrophobic at least on the side adjacent to the second color, the colored material 18 (B) of the second color is not applied onto the hydrophobic layer 26. It will be struck, or it will be a slight ride-up height, and it will ride on only BM14 substantially. Therefore, the outer shape of the colored portion 12 (B) of the second color formed by exposing and curing the coloring material 18 (B) of the second color through the mask opening 21 and further etching away is substantially biased in one direction. It becomes symmetric without being (FIG. (E)).

  As the fourth step, the hydrophobic layer formed on the upper surface of the colored portion 12 (R) of the first color is removed. Thereby, the upper surface of the colored portion 12 (R) of the first color becomes hydrophilic. However, when the hydrophobic layer is formed only on the second color adjacent side of the upper surface of the colored portion 12 (R) of the first color, this step is unnecessary because the third color adjacent side is originally hydrophilic. It is.

  As a fifth step, the third color coloring material 18 (G) is applied with a predetermined thickness so as to cover the effective display area including the colored portions 12 (R) and (B) of the first color and the second color. (Figure (f)), this is patterned by a photolithographic method, and the colored portion 12 (G) of the third color is fixedly formed (figure (g)). At this time, since the upper surfaces of both the first color coloring portion 12 (R) and the second color coloring portion 12 (B) are hydrophilic, the third color coloring material 18 (G) is present on both sides in the width direction. A relatively high convex portion 23 is formed on the colored portions, and a flat portion 24 is formed at the center of the width.

  By the above, the cross-sectional outline shape of the colored part 12 of the 1st color thru | or 3rd color in the colored layer 11 can be made bilaterally symmetrical, without substantially biasing in one direction.

  As shown in the present embodiment, by applying a color material of another color in a state where a layer having a polarity different from that of the color material 18 constituting the color part 12 is formed on the upper surface of the color part 12, the first color is applied. Even if the colored material thus fixed and the colored material applied later have the same polarity, the colored material applied later can be prevented from running. When this is applied to the first color coloring material 18 (R) and the second color coloring material 18 (B), the outer shape of the third color coloring portion 12 (G) is symmetrical in the width direction. For this purpose, it is necessary to make the polarities of at least the upper surfaces of the colored portions 12 (R) and (B) adjacent to both sides in the width direction equal.

There are two such methods, one of which is that after applying the second color coloring material 18 (B) to the hydrophobic layer formed on the upper surface of the first color coloring portion 12 (R) as in this embodiment. And it is good to remove before application of coloring material 18 (G) of the 3rd color. When removing the hydrophobic layer, only the colored portion 12 (R) of the first color, or both the colored portions (R) and (B) of the first color and the second color are approximately equal to the formation thickness of the hydrophobic layer. The upper surface may be shaved.
Secondly, after fixing the colored portion 12 (B) of the second color, a hydrophobic layer is also laminated thereon. That is, the upper surfaces of the colored portions 12 (R) and (B) of the first color and the second color are both made hydrophobic, so that the colored material 18 (G) of the third color rides on both sides in the width direction. Are equally suppressed.

  In the case of the color filter 10 of the present embodiment, both ends of the first color coloring portion 12 (R) and the second color coloring portion 12 (B) are substantially ridden only on the BM 14, and the third color coloring portion. Reference numeral 12 (G) denotes a shape that rides on the colored portion 12 of another color that has already been formed. Therefore, among the repeated direction (width direction) of the colored portion in the effective display area, the colored portion (first color or second colored colored portion (R in this embodiment) that is applied first or second at the extreme end. ), (B)), and the third colored portion (the third colored portion (G) in this embodiment) is preferably applied second or third from the end.

[Third Embodiment: Regarding (ii) above]
As a method for solving the problem of the present invention in which the colored portion 12 formed by fixing the coloring material 18 is asymmetrical due to the base on which the coloring material 18 is applied protruding greatly only on one side in the width direction, In the present embodiment, the photolithography method is used for the coating formation of the colored portions 12 (R), (G) of the first color and the third color, and the coloring material 18 (B) of the second color is applied. An ink jet method is used. Thereby, it is possible to achieve both high resolution of the colored portion 12 by the photolithography method and left-right symmetry of the application shape of the coloring material 18 by the ink jet method.

FIG. 3 shows a manufacturing process of the color filter 10 according to the present embodiment.
FIG. 4A shows the entire upper surface or at least the effective display area of the upper surface of the base material 16 in which the first to third color scheduled formation positions 13 (R), (B), and (G) are partitioned by the BM 14. A state in which the coloring material 18 (R) of the first color is applied so as to cover and ultraviolet rays are irradiated to the planned formation position 13 (R) of the first color through the mask opening 21 of the photomask 20 is shown.

  FIG. 5B shows a state in which the unexposed portion in the mask exposure is removed by etching to leave the colored portion 12 (R) of the first color. The colored portion 12 (R) has both ends in the width direction running on the BM 14 to form a relatively low convex portion 22, and a flat portion 24 is formed therebetween, so that the outer shape is substantially symmetrical. .

In FIG. 8C, the second color coloring material 18 (B) is applied to the second color scheduled formation position 13 (B) by the ink jet method, and is cured by heating or exposure, so that the second color of the second color is formed. The state which produced the colored part 12 (B) is shown.
Coloring of the second color between the BMs 14a and 14b arranged on both sides of the predetermined formation position 13 (B) of the second color by an ink jet method capable of applying the coloring material 18 to an arbitrary position on the substrate 16 on demand. By applying the material 18 (B), the outer shape of the colored portion 12 (B) of the second color is symmetrized without being affected by the colored portion 12 (R) of the first color that has already been fixedly formed. can do.

In the present embodiment, the coloring material 18 (B) of the second color is applied so as to ride on the BMs 14a and 14b. Thereby, in the adjacent region of the BMs 14a and 14b at the planned formation position 13 (B), no color loss occurs in which white light is transmitted without being colored.
However, in order to prevent the second color coloring material 18 (B) from riding on the first color coloring portion 12 (R) and achieve the object of the present invention, the second color coloring material 18 ( B) is preferably not in contact with the colored portion 12 (R) of the first color, and is applied so as to be in contact with only the inside of the vertical surfaces of the BMs 14a and 14b in the light transmission region sandwiched between the BMs 14a and 14b. Also good.

  In FIG. 6D, a third color coloring material 18 (G) is applied onto the base material 16, and ultraviolet rays are irradiated to the planned formation position 13 (G) of the third color through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (G) bulges due to its viscosity in the formation region of the colored portions 12 (R) and (B) of the BM 14 and the first and second colors.

  FIG. 4E shows a state in which the unexposed portion of the coloring material 18 (G) is removed by etching, and the third color coloring portion 12 (G) remains on the substrate 16. The colored portion 12 (G) has a large ride on the BM 14 and the colored portion 12 (B) of the second color on the second color adjacent side (left side in the drawing) in the width direction, while the first color adjacent side. As for (right side in the figure), the BM 14 and the colored portion 12 (R) are both ridden greatly to form a relatively high convex portion 23, the outer shape is substantially symmetrical, and the flat portion 24 is formed at the center. ing.

  As in the color filter 10 of the present embodiment, only the colored portion 12 (B) of the second color is applied and formed by the inkjet method, so that it is not affected by the colored portion 12 (R) of the first color. In addition, the third color coloring portion 12 (G) is also mounted on the first color and the second color coloring portions 12 (R) and (B) already formed on both sides thereof by approximately equaling each color. The outer shape of the colored portion 12 is not substantially biased in one direction.

<(2) Method for forming protrusions>
[About the fourth to sixth embodiments]
Solves the problem of light leakage caused by the outer shape being inclined in one direction substantially in one of the three colored portions to be applied sequentially on the substrate. As a second method, among the planned formation regions of the second color coloring portion 12 (B), the first color coloring portion 12 on the side adjacent to the third color coloring portion 12 (G). A protrusion forming method in which the protrusion 15 having the same height as the upper surface of (R) is formed in advance will be described.
That is, the second color material 18 (B) is expected to run on the first color side in advance, and the protruding portion 15 is erected on the third color side so that the same level of running occurs. . Accordingly, the colored portion 12 (B) of the second color is equally laid on both sides of the width direction, one on the colored portion 12 (R) of the first color and the other on the protruding portion 15. The outer shape of this is substantially bilaterally symmetric, that is, it is not substantially biased in one direction.
In addition, the third color coloring material 18 (G) also has almost the same height on the protrusion 15 and the first color coloring portion 12 (R) on both sides in the width direction. The colored portion 12 (G) is also substantially symmetrical.

  Therefore, in the present invention, the lower end of the colored layer 11, that is, the upper end height of the protrusion 15 provided between the base material 16 and the colored layer 11 is flush with the upper surface of the colored portion 12 (R) of the first color. The outer shapes of the colored portions 12 (B) and (G) of the second color and the third color to be formed are not substantially biased in one direction, and as a result, the upper side of the colored layer 11 The liquid crystal molecules 50 that are directly or indirectly applied to the liquid crystal molecules 50 and are aligned in a predetermined direction do not cause alignment defects in units of pixels. In other words, the above-mentioned flushness means that the upper end of the protrusion 15 and the colored portion of the first color are used as long as the object of the present invention is achieved that the liquid crystal display device using the color filter of the present invention does not have the problem of light leakage. It will be apparent to those skilled in the art that the top surface of 12 (R) is the same height, and that it does not require that both be the same height with mathematical rigor.

As the position where the protruding portion 15 is erected, the second color may be the center of the width direction in the boundary region between the colored portion 12 (B) of the second color and the colored portion (G) of the third color. It may be on either the side or the third color side. In order to make the outer shape of the colored portion 12 (B) of the second color and the colored portion 12 (G) of the third color equal, a protrusion at the center of the boundary region of the colored portions 12 (B) and (G) 15 may be erected.
When the planar shape of the colored portion 12 of each color is a strip shape and the colored layer 11 is a stripe shape, the protruding portion 15 is also a strip shape. Moreover, when the planar view shape of the colored portion 12 of each color is rectangular or triangular and the colored layer 11 is in a matrix shape, the protrusions 15 are also arranged in a matrix shape.

As to whether the protrusion 15 is light (visible light) transmissive or light-shielding, whether or not the light-shielding BM 14 that separates the colored portions 12 is provided on the substrate 16, and the protrusion 15 is provided. It is selected depending on whether or not it is arranged at a position covered by the BM 14.
That is, for the color filter 10 that does not have the BM 14 that separates the colored portions 12, in order to prevent the light shielding portion from being formed in the effective display area by the protrusion 15, the protrusion 15 is made of a light-transmitting resin material or the like. It is preferable to produce by.
On the other hand, in the case of the color filter 10 including the BM 14 between the colored portions 12, particularly between the colored portion 12 (B) of the second color and the colored portion (G) of the third color, When the protruding portion 15 is erected, it does not matter whether the protruding portion 15 is light transmissive or light shielding. Further, in the case of the color filter 10 including the BM 14 and the protrusion 15 is erected while being exposed to the light transmission region, the protrusion 15 is a colorless transparent material such as an acrylate resin or an epoxy resin, Or it is good to produce with the transparent material of the same color system as the coloring part corresponding to the said exposure area | region.
Here, the protrusion 15 has the same color system as that of the colored portion 12. In the bright display by the liquid crystal display device using the color filter 10, a color shift occurs in the color display in the picture element including the protrusion 15 in the pixel. This means that the hues are close enough to be invisible to the observer.
In addition, since the visible light passing through the color filter 10 is colored twice at the projection 15 and the coloring portion 12, when the projection 15 is made of a colored transparent material having the same color as the coloring portion 12, The visible light passing through the projection 15 and the convex portions 22a and 22b formed thereon is colored in the same manner as the visible light passing through the flat portion 24 with the coloring density lower than that of the colored portion 12. It is preferable to adjust so that.

Hereinafter, as a fourth embodiment,
(Iii-1) A method for producing the colored layer 11 for realizing the present invention in the color filter 10 having no BM 14 will be described with reference to FIG.
Next, as a fifth embodiment,
(Iii-2) A method (ii-2) for producing the colored layer 11 provided with the protrusion 15 in the light shielding area of the BM 14 in the color filter 10 of the present invention including the BM 14 will be described with reference to FIG. To do.
Furthermore, as a sixth embodiment,
(Iii-3) A color filter 10 of the present invention including the BM 14, and a method (ii-3) for producing the colored layer 11 in which the protruding portion 15 is erected in the light transmission region exposed from the BM 14 will be described with reference to FIG. I will explain.

(Fourth embodiment: (iii-1) above)
FIG. 4A is a cross-sectional view showing a state in which a protrusion 15 made of a colorless and transparent material is erected on the upper surface of the light-transmitting substrate 16. As will be described later, the protrusion 15 is located at the boundary between the second color coloring portion 12 (B) and the third color coloring portion 12 (G). Moreover, it is preferable to make it colorless and transparent so that visible light may not be given a color other than desired.

  The base material 16 is preliminarily formed with coating positions of the colored portions 12 (R), (B), (G) of the first color to the third color using alignment marks (not shown). Yes. That is, the planned formation position 13 (R) of the colored portion 12 (R) of the first color, the planned formation position 13 (B) of the colored portion 12 (B) of the second color, and the colored portion 12 (G) of the third color. The planned formation position 13 (G) is repeatedly virtually divided side by side in the width direction of the base material 16. The protrusion 15 is disposed between the planned formation positions 13 (B) and 13 (G).

  In FIG. 6B, the first color coloring material 18 (R) is applied so as to cover the entire upper surface or at least the effective display area of the upper surface of the substrate 16, and the first color is scheduled through the mask opening 21 of the photomask 20. A state in which ultraviolet rays are pattern-irradiated at the formation position 13 (R) is shown.

FIG. 5C shows a state in which the unexposed portion in the mask exposure is removed by etching to leave the first colored portion 12 (R). The colored portion 12 (R) is flat in the width direction like the upper surface shape of the substrate 16, and the entire outer shape is the flat portion 24.
As shown in the drawing, the upper end height of the protrusion 15 is flush with the upper surface of the colored portion 12 (R) of the first color. In other words, the protrusion 15 is erected on the base material 16 in the initial state shown in FIG. 5A so as to have a height equal to the predetermined coating thickness of the colored portion 12 (R). .

  In FIG. 4D, the second color coloring material 18 (B) is applied onto the base material 16, and ultraviolet rays are irradiated to the second color scheduled formation position 13 (B) through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (B) bulges due to its viscosity in the formation region of the coloring portion 12 (R) and the protruding portion 15.

  FIG. 4E shows a state in which the unexposed portion of the coloring material 18 (B) is removed by etching, and the second color coloring portion 12 (B) remains on the substrate 16. The colored portion 12 (B) has the first color adjacent side (left side in the figure) on the colored portion 12 (R) in the width direction, and the third color adjacent side (right side in the figure) is the protrusion 15. A relatively low convex portion 22 is formed on each of them, the outer shape is substantially symmetrical, and a flat portion 24 is formed at the center.

  In FIG. 5F, a third color coloring material 18 (G) is applied onto the base material 16, and ultraviolet rays are irradiated to the planned formation position 13 (G) of the third color through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the colored material 18 (G) bulges due to its viscosity in the formation region of the colored portions 12 (R), (B) and the protruding portion 15.

  FIG. 4G shows a state in which the unexposed portion of the coloring material 18 (G) is removed by etching, and the third color coloring portion 12 (G) is formed on the substrate 16. The colored portion 12 (G) rides the second color adjacent side (left side in the figure) on the protrusion 15 and the colored portion 12 (B) in the width direction, and the first color adjacent side (right side in the figure). A relatively low convex portion 22 is formed on the colored portion 12 (R), the outer shape is substantially symmetrical, and a flat portion 24 is formed at the center.

  As described above, in the color filter 10 according to the present embodiment, the protrusion 15 is erected in advance between the planned formation position 13 (B) for the second color and the planned formation position 13 (G) for the third color. Thus, the running of the coloring materials 18 (B) and (G) applied thereon is controlled as desired, and the heights of both ends of the colored portions 12 (B) and (G) fixedly formed are made substantially equal. Therefore, the outer shape is symmetric.

(Fifth embodiment: (iii-2) above)
FIG. 5A shows a case where a light-shielding BM 14 is applied and formed on the upper surface of a light-transmitting substrate 16 in a stripe shape or a matrix shape, and the colored portions 12 (R), (B), (G) shows a state where the scheduled formation positions 13 (R), (B), (G) are partitioned. Further, a projection 15 is provided on the BM 14 between the planned formation position 13 (B) for the second color and the planned formation position 13 (G) for the third color.
That is, the protrusion 15 is disposed in the light shielding area by the BM 14. Therefore, the protrusion 15 may be a light transmissive material or a light shielding material, and its color is also arbitrary.

  In FIG. 6B, the first color coloring material 18 (R) is applied so as to cover the entire upper surface or at least the effective display area of the upper surface of the substrate 16, and the first color is scheduled through the mask opening 21 of the photomask 20. A state in which ultraviolet rays are pattern-irradiated at the formation position 13 (R) is shown.

FIG. 5C shows a state in which the unexposed portion in the mask exposure is removed by etching to leave the first colored portion 12 (R). The colored portion 12 (R) has both ends in the width direction running equally on the BM 14, a relatively low convex portion 22 is formed to protrude, and a flat portion 24 is formed therebetween, so that the outer shape is substantially symmetrical. Yes.
As shown in the figure, the height of the upper end of the protrusion 15 erected on the BM 14 is the upper surface and the surface of the convex portion 22 riding on the BM 14 out of the colored portion 12 (R) of the first color. It is one. In other words, the height obtained by subtracting the coating thickness of the BM 14 from the height of the upper surface on the side adjacent to the second color in the colored portion 12 (R) formed in advance is equal to the height of the protrusion 15 itself. Thus, the protrusion 15 is erected on the BM 14 in the initial state shown in FIG.

  In FIG. 4D, the second color coloring material 18 (B) is applied onto the base material 16, and ultraviolet rays are irradiated to the second color scheduled formation position 13 (B) through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (B) bulges due to its viscosity in the formation region of the BM 14, the first color coloring portion 12 (R), and the protrusion 15.

  FIG. 4E shows a state in which the unexposed portion of the coloring material 18 (B) is removed by etching, and the second color coloring portion 12 (B) remains on the substrate 16. The colored portion 12 (B), on the side adjacent to the first color in the width direction (left side in the figure), largely rides on the BM 14 and the colored portion 12 (R) that is already fixedly formed, while the third color Also on the adjacent side (right side in the figure), a relatively high convex portion 23 is formed by greatly climbing over the BM 14 and the protruding portion 15, the outer shape is substantially symmetric, and a flat portion 24 is formed in the center. Yes.

  In FIG. 5F, a third color coloring material 18 (G) is applied onto the base material 16, and ultraviolet rays are irradiated to the planned formation position 13 (G) of the third color through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (G) bulges due to its viscosity in the formation region of the BM 14, the colored portions 12 (R), (B) of the first color and the second color, and the protruding portion 15.

  FIG. 4G shows a state in which the unexposed portion of the coloring material 18 (G) is removed by etching, and the third color coloring portion 12 (G) is formed on the substrate 16. The colored portion 12 (G) has a second color adjacent side (left side in the figure) on the BM 14 and the protrusion 15 in the width direction, and the first color adjacent side (right side in the figure) A relatively high convex portion 23 is formed on both the BM 14 and the colored portion 12 (R), and the outer shape is substantially symmetrical and a flat portion 24 is formed at the center.

As described above, in the color filter 10 according to the present embodiment, the protrusion 15 is provided in advance on the BM 14 that partitions the planned formation position 13 (B) of the second color and the planned formation position 13 (G) of the third color. By doing so, the running of the coloring materials 18 (B) and (G) applied thereon is controlled as desired, and the heights of both ends of the colored portions 12 (B) and (G) fixedly formed are set. The outer shape is made symmetric with respect to each other. Further, since the protrusion 15 is disposed in the light shielding region by the BM 14, the material does not need to be a transparent material, and it can be made of the same light shielding material as the BM 14. That is, in the present embodiment, the protrusion 15 and the BM 14 may be manufactured integrally.
Specifically, only for the BM 14 that partitions the planned formation position 13 (B) of the second color and the planned formation position 13 (G) of the third color, the outer shape thereof is stepped, L-shaped, tapered, By making the upper end height higher than that of other BMs 14 by making it a thick rectangular shape or the like, the function of the protrusions 15 can be given to the BM 14.
Therefore, in such a case, the BM 14 may be formed by coating a black resin material on the substrate 16 by a printing method such as a photolithography method or a flexographic printing method. This is because the BM 14 can be formed thick and can be adjusted to a desired outer shape.

(6th embodiment: About said (iii-3))
FIG. 6A shows a case where a light-shielding BM 14 is applied and formed on the upper surface of a light-transmitting substrate 16 in a stripe shape or a matrix shape, and the colored portions 12 (R), (B), (G) shows a state where the scheduled formation positions 13 (R), (B), (G) are partitioned. Further, a protrusion adjacent to the second color planned formation position 13 (B) side with respect to the BM 14 between the second color planned formation position 13 (B) and the third color planned formation position 13 (G). Part 15 is erected.
That is, the protrusion 15 is disposed in the light transmission region exposed from the BM 14. Therefore, the protrusion 15 needs to be a light-transmitting material, and its color is colorless or the same color as the second color.

  In FIG. 6B, the first color coloring material 18 (R) is applied so as to cover the entire upper surface or at least the effective display area of the upper surface of the substrate 16, and the first color is scheduled through the mask opening 21 of the photomask 20. A state in which ultraviolet rays are pattern-irradiated at the formation position 13 (R) is shown.

FIG. 5C shows a state in which the unexposed portion in the mask exposure is removed by etching to leave the first colored portion 12 (R). The colored portion 12 (R) has both ends in the width direction running equally on the BM 14, a relatively low convex portion 22 is formed to protrude, and a flat portion 24 is formed therebetween, so that the outer shape is substantially symmetrical. Yes.
As shown in the figure, the height of the upper end of the protrusion 15 that is erected adjacent to the BM 14 is the upper surface of the convex portion 22 that rides on the BM 14 among the colored portions 12 (R) of the first color. It is the same. In other words, in the initial state shown in FIG. 5A, the height of the upper surface on the side adjacent to the second color and the height of the protrusion 15 are equal in the colored portion 12 (R) that has been coated and formed in advance. The protrusion 15 is erected adjacent to the BM 14.

  In FIG. 4D, the second color coloring material 18 (B) is applied onto the base material 16, and ultraviolet rays are irradiated to the second color scheduled formation position 13 (B) through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (B) bulges due to its viscosity in the formation region of the BM 14, the first color coloring portion 12 (R), and the protrusion 15.

FIG. 4E shows a state in which the unexposed portion of the coloring material 18 (B) is removed by etching, and the second color coloring portion 12 (B) remains on the substrate 16. In the width direction, the colored portion 12 (B) largely rides on the BM 14 and the colored portion 12 (R) that is already fixedly formed on the first color adjacent side (left side in the figure), while the third color Also on the adjacent side (right side in the figure), a relatively high convex portion 23 is formed by greatly climbing on the protrusion 15, the outer shape is substantially symmetrical, and a flat portion 24 is formed at the center.
Further, the third color adjacent side (right side in the drawing) of the colored portion 12 (B) of the second color reaches the BM 14 beyond the protruding portion 15. As a result, a colored portion 12 (B) serving as a base of a coloring material 18 (G) of a third color described later is applied and formed on the BM 14.

  In FIG. 5F, a third color coloring material 18 (G) is applied onto the base material 16, and ultraviolet rays are irradiated to the planned formation position 13 (G) of the third color through the mask opening 21 of the photomask 20. Indicates the state of As shown in the drawing, the coloring material 18 (G) bulges due to its viscosity in the formation region of the BM 14, the colored portions 12 (R), (B) of the first color and the second color, and the protruding portion 15.

  FIG. 4G shows a state in which the unexposed portion of the coloring material 18 (G) is removed by etching, and the third color coloring portion 12 (G) is formed on the substrate 16. The colored portion 12 (G) has a second color adjacent side (left side in the drawing) on the BM 14 and the second colored colored portion 12 (B) in the width direction, while the first color adjacent side ( As for the right side in the figure, the BM 14 and the colored portion 12 (R) are both ridden greatly to form a relatively high convex portion 23, the outer shape is substantially symmetrical, and the flat portion 24 is formed at the center. Yes.

  As described above, in the color filter 10 according to the present embodiment, the protrusion 15 is provided adjacent to the BM 14 that partitions the planned formation position 13 (B) of the second color and the planned formation position 13 (G) of the third color. Also, the outer shape of the colored portion 12 of each color can be made substantially symmetrical.

  In the present embodiment, the protrusions 15 may be erected on both sides in the width direction so as to sandwich the BM 14 that partitions the scheduled formation positions 13 (B) and 13 (G). That is, the first protrusion 15 made of a colored transparent material that is colorless and transparent or of the same color as the second color is disposed on the side adjacent to the second color of the BM 14, and colorless and transparent on the side adjacent to the third color of the BM 14. Or you may arrange | position the 2nd projection part 15 (not shown) which consists of a colored transparent material of the same color system as a 3rd color.

  In the colored layer 11 of the first to eighth embodiments, of the three colored portions 12 (R), (B), and (G) that are repeatedly arranged in the width direction, the color that is fixedly formed first. It is preferable that the colored portion is located at the extreme end in the repeating direction in the effective display area formed on the substrate. That is, the colored layer 11 of each of the above embodiments is common in that the height of the underlying layer on which both ends in the width direction of the colored portions 12 of the respective colors constituting the same are made equal, but is the extreme end of the effective display area. In some cases, the colored portions 12 are arranged side by side only on one side in the repeating direction, and the colored portions 12 are not arranged on the other side. Therefore, the colored portion 12 located at the extreme end is convex only on the one side. This is because there is a possibility of projecting greatly.

FIG. 7 is a process diagram showing a state in which the colored layer 11 is produced by arranging the three colored portions 12 (R), (B), and (G) in the width direction (left-right direction in the drawing).
In each of the above-described embodiments, as shown in FIG. 6A, the BMs 14 are dispersedly arranged on the upper surface of the base material 16 so that the effective display area 28 and the planned formation positions 13 (R), (B), (G) of the respective colors Is partitioned. In the case of the drawing, the colored portions 12 are repeatedly arranged in order of blue, green, and red in order from the left end of the effective display area 28. Accordingly, the red colored portion 12 is located at the right end of the effective display area 28.

  As the formation position of the colored portion 12 of the first color that is fixedly formed first, the most end of the effective display area 28 is preferable as described above. Accordingly, as shown in FIG. 4B, the colored portion 12 (R) is fixed as the first colored portion at one end in the width direction of the effective display area 28 (the right end is selected in the same figure). Is formed.

Here, in the case of the colored layer 11 according to the first to sixth embodiments, when the colored portion 12 fixedly formed second is green, which is the second color from the right end, the colored portion fixedly formed last is blue, There is a possibility that the outer shape of the colored portion 12 (B) becomes asymmetrical at the left end of the effective display area 28. At the left end of the effective display area 28, there is no other colored portion 12 on the left side of the effective display area 28. Therefore, the end portion of the effective display area 28 is relatively large with only the green colored portion 12 (G) positioned second from the left end. This is because the high convex portion 23 is formed.
Therefore, as the second color, as shown in FIG. 5C, it is preferable to select the colored portion 12 to be arranged at the other end in the width direction of the effective display area 28 (the left end in the figure). As for the leftmost pixel, since the colored portions 12 of other colors are not fixedly formed on either side of the pixel, the colored portion 12 (B) rides only on the BM 14 and the outer shape is substantially symmetrical. .
Further, the colored portion 12 (B) formed at a position other than the left end of the effective display area 28 also has a substantially symmetrical outer shape by the action of the methods of the first to sixth embodiments.

  That is, in the first to sixth embodiments, it is preferable to select colors arranged at both ends of the effective display area 28 as the first colored portion 12 and the second colored portion 12.

<(3) Six-color patterning method>
[About the seventh and eighth embodiments]
Solves the problem of light leakage caused by the outer shape being inclined in one direction substantially in one of the three colored portions to be applied sequentially on the substrate. As a third method, there is a six-color patterning method in which three-color coloring materials are regarded as pseudo-even-numbered (six-color) coloring materials and patterned in a jumping manner.
That is, in the present embodiment, a colored portion is not formed at a position where a colored portion is already formed only on one side adjacent in the width direction, and a colored portion is formed on both sides in the width direction. In either case, a new colored portion is fixedly formed only at a position where this is not formed. Such a method is impossible by patterning by three times (odd number of times) of photolithography, but this is considered by virtually considering the three color materials as six colors and performing the photolithography process twice for each color. It becomes possible.

  That is, for example, in the case of an RGB three-color filter, red (R) → blue (B) → green (G) → red (R) → blue (B) → green (G)... The coloring portion 12 is changed to red 1 (R1) → blue 1 (B1) → green 1 (G1) → red 2 (R2) → blue 2 (B2) → green 2 (G2) → red 1 (R1). Assuming that red 1 is applied in the order of 6n + 1, blue 1 is applied 6n + 2, green 1 is applied 6n + 3, red 2 is applied 6n + 4, blue 2 is applied 6n + 5, and green 2 is applied 6n + 6. n is an integer of 0 or more. However, the term “first” does not necessarily mean the end in the width direction of the effective display area where the colored portions 12 are repeatedly arranged.

Here, if the 6n + 1th (red 1) is applied first, then the 6n + 3th (green 1) or 6n + 5th (blue 2) is applied.
Subsequently, 6n + 2 (blue 1) or 6n + 4 (green 2), which is between the already applied colored parts, is applied, or 6n + 5th (blue 2) where the colored parts are not yet applied on both sides. ) Or 6n + 3rd (green 1).
In the same manner, a position where a colored portion is already formed on both sides or a position where no colored portion is formed on both sides is selected and a new colored portion is patterned by a photolithography method. Good.

Specifically, the following three coating orders can be taken.
(Iv-1) 6n + 1th (red 1) → 6n + 3th (green 1) → 6n + 5th (blue 2) In this order, the remaining colored portions (blue 1, red 2, green 2) are arbitrarily ordered thereafter. Apply.
(Iv-2) 6n + 1 (red 1) → 6n + 3 (green 1) in order, then 6n + 2 (blue 1) and 6n + 5 (blue 2) are applied simultaneously, and then in any order Apply the remaining colored parts (red 2, green 2).
(Iv-3) 6n + 1 (red 1) → 6n + 3 (green 1) → 6n + 2 (blue 1) → 6n + 5 (blue 2) , Apply green 2).

However, in the above (iv-1) to (iv-3), red 1 is applied to the first and green 1 is applied to the second. As described above, blue 2 may be applied next to red 1, but blue 2 (6n + 5th) is the mirror surface target position of green 1 (6n + 3) with respect to red 1; When blue 2 is applied, the subsequent colored portions may also be applied to the positions of the above (iv-1) to (iv-3) and the mirror surface with reference to red 1.
That is, in the present invention in which the selection of the three colors of the coloring material and the arrangement order thereof are arbitrary, the colored portion at the 6n + 1 position is applied first, and the colored portion at the 6n + 3 position is applied second. Then, it is obvious to those skilled in the art that the expression means that the colored portion at the position 6n + 1 is applied first and the colored portion at the position 6n + 5 is applied secondly. is there.

(About the seventh embodiment)
The steps (iv-1) and (iv-2) will be described with reference to FIG.
FIG. 6A shows a state in which a colored portion 12 (R1) corresponding to red 1 is applied and formed by a photolithography method at the 6n + 1th position. Note that the left end of the figure is the 6n + 1 position, and is set to the 6n + 2 position, 6n + 3 position,..., 6n + 6 position toward the right.
In addition, BM14 is arrange | positioned on the base material 16, and the scheduled formation position of the coloring part of each color is divided. Accordingly, the colored portion 12 (R1) has both sides in the width direction riding on the BM 14 and the relatively low convex portions 22 are formed equally, and the outer shape thereof is formed symmetrically.

FIG. 6B shows a state in which the colored portion 12 (G1) corresponding to green 1 is applied and formed by the photolithography method at the 6n + 3rd position following FIG.
FIG. 6C shows a state where the colored portion 12 (B2) corresponding to blue 2 is applied and formed by the photolithography method at the 6n + 5th position, following FIG.
As a result, all the colored portions 12 are first applied at odd positions. The colored portions 12 (G1) and (B2) both have the same height on both ends of the BM 14 to form a relatively low convex portion 22, and the outer shape is substantially symmetrical.

  (D-1) shows a state in which the colored portion 12 (B1) corresponding to blue 1 is applied and formed by the photolithography method at the 6n + 2nd position, following (c) in FIG. However, since both blue 1 and blue 2 are blue, the colored portion that is both blue at the 6n + 2 and 6n + 5 positions following (b) without passing through the state of FIG. 12 (B1) and the colored portion 12 (B2) can be simultaneously formed by photolithography. As a result, the number of repetitions of the photolithography method can be reduced by one.

  (D-2) and (d-3) of FIG. 6 show that the colored portion 12 (R2) corresponding to red 2 is continuously formed by the photolithography method at the 6n + 4th position when the state shown in FIG. The coated state and the state where the colored portion 12 (G2) corresponding to green 2 is coated at the 6n + 6th position after the state of FIG.

  FIG. 6E-1 shows a state in which the colored portion 12 (R2) corresponding to red 2 is applied by the photolithography method at the 6n + 4th position following FIG. Following 2), the colored portion 12 (B1) corresponding to blue 1 is applied at the 6n + 2nd position.

  (E-2) shows a state in which the colored portion 12 (G2) corresponding to green 2 is applied by the photolithography method at the 6n + 6th position following FIG. (D-1), or (d− The state where the colored portion 12 (B1) corresponding to blue 1 is applied to the 6n + 2nd position following 3) is shown.

  FIG. 6E-3 shows a state where the colored portion 12 (G2) corresponding to green 2 is applied by the photolithography method at the 6n + 6th position after FIG. 6D-2, or FIG. Following 3), the colored portion 12 (B1) corresponding to blue 1 is applied at the 6n + 4th position.

  Since all of the colored portions 12 (B1), (R2), and (G2) ride on the colored portions 12 that are previously formed on both sides in the width direction, relatively high convex portions 23 are formed at both ends in the width direction. However, since the heights at both ends are equal, the outer shape is substantially symmetrical.

  FIG. 5F shows a state where the colored layer 11 is manufactured by coating all the colored portions 12 by the photolithography method. As shown in the figure, the colored portion 12 located at the 6n + 1, 6n + 3, 6n + 5th position has a relatively low convex portion 22 protruding on the BM 14 on both sides thereof in the width direction, and is located at the 6n + 2, 6n + 4, 6n + 6th position The colored portions 12 that run on the BM 14 and the other colored portions 12 on both sides of the colored portions 12 run equally on the left and right in the width direction so that relatively high convex portions 23 are formed so that the outer shape of each colored portion 12 is substantially symmetrical. Become.

(About the eighth embodiment)
The step (iv-3) will be described with reference to FIG.
FIGS. 7A and 7B are common to the seventh embodiment. FIG. 8C shows a state in which the colored portion 12 (B1) corresponding to blue 1 is applied and formed at the 6n + 2 position by the photolithography method, following FIG.
FIG. 4D shows a state where the colored portion 12 (B2) corresponding to blue 2 is applied and formed by the photolithography method at the 6n + 5th position following FIG.
FIG. 8E-1 shows a state where the colored portion 12 (R2) corresponding to red 2 is applied and formed at the 6n + 4th position by the photolithography method, following FIG.
FIG. 8E-2 shows a state where the colored portion 12 (G2) corresponding to the green 2 is applied and formed by the photolithography method at the 6n + 6th position, following FIG.
FIG. 5F shows a state where the colored layer 11 is manufactured by coating all the colored portions 12 by the photolithography method.

  As described above, after the 6n + 1th and 6n + 3th, the colored portion 12 located at the 6n + 2nd is formed, and among the 6n + 4 to 6th, the 6n + 5th in which the state of the underlayer is the same on both sides in the width direction By forming the colored portions 12 on the outer surfaces, the outer shapes of all the colored portions 12 constituting the colored layer 11 can be made substantially symmetrical. In this embodiment, the colored portions 12 (B1) and (B2) corresponding to blue 1 and blue 2 from the state of FIG. The state shown in FIG.

<(4) Post-processing method>
[About the ninth embodiment]
Solves the problem of light leakage caused by the outer shape being inclined in one direction substantially in one of the three colored portions to be applied sequentially on the substrate. As a fourth method, there is a processing method for eliminating the unevenness by applying post-processing to the applied coloring material or a colored portion obtained by curing the applied coloring material.
Specifically, as such a method, (v-1) a method of smoothing the coloring material 18 generated by riding on the colored portion 12 of another color formed on the substrate 16, or (v-2) fixed formation The method of deleting the protrusion of the convex parts 22 and 23 from the colored part 12 made can be mentioned.
Specifically, as the above (v-1), an uncured coloring material 18 may be leveled with a doctor blade, or the viscosity of the coloring material 18 may be adjusted as desired.
Specifically, as the above (v-2), a method of crushing the projected portions 22 and 23 by pressing the coated colored layer 11 or a rubbing treatment on the surface of the colored layer 11 to project the projected portions 22 and 23. Can be mentioned.

<About color filters>
Hereinafter, the configuration of the color filter of the present invention will be described in more detail.
FIG. 10 is a schematic cross-sectional view of a color filter 10 including the colored layer 11 according to the present embodiment. The laminated structure of the color filter 10 and preferred materials for each structure will be described below.

As described above, the color filter 10 of the present embodiment has a light-shielding BM 14 that partitions and forms an effective display region and pixels on the upper surface (upper side in the drawing) of the light-transmitting substrate 16, and adjacent BMs 14. A colored layer 11 in which three colored portions 12 (R), (B), and (G) are repeatedly arranged in the width direction (left and right direction in the figure) is provided so as to straddle.
On the upper surface of the colored layer 11, there is laminated a retardation layer 30 formed by cross-linking and fixing the polymerizable liquid crystal molecules aligned in a predetermined direction. As shown in the figure, in the color filter 10 of the present embodiment, the liquid crystal molecules 50 (polymerizable liquid crystal molecules 32) constituting the retardation layer 30 are vertically aligned, and the molecular axes thereof are oriented in the normal direction of the substrate 16. ing.
A horizontal alignment film 34 for aligning driving liquid crystal molecules constituting the liquid crystal cell is laminated on the upper surface of the retardation layer 30.

(About the base material)
The substrate 16 is preferably configured to have optical isotropy, and a glass substrate, a film, or the like having optical transparency can be arbitrarily used. In particular, when the color filter of the present invention is used in a liquid crystal display device, the base material is preferably alkali-free glass. The thickness of the substrate is, for example, about 5 μm to 3 mm depending on the application.

(About black matrix)
In the color filter of the present invention, when forming the BM, for example, a metal thin film having a light-shielding property or a light-absorbing property such as a metal chromium thin film or a tungsten thin film is formed on a substrate in a rectangular lattice shape or a stripe shape. Alternatively, it can be formed by patterning in a triangular lattice pattern or the like. Moreover, it is also possible to form by printing an organic material such as a black resin in a predetermined shape by a transfer method or the like.

  In the present invention, except for the fifth and sixth embodiments, BM formation is arbitrary. However, even if alignment failure occurs in the critical region between the colored portions due to the presence of the BM, if the alignment failure region is within the BM region in plan view, transmission through the alignment failure region is attempted. Since light is blocked, it is preferable in that light leakage and coloring problems can be prevented from appearing on the display panel.

The manufacturing method example of BM will be described in more detail. After the prepared black matrix material is washed on the glass substrate according to a conventional method, it is applied to a thickness of 3.0 μm by spin coating, at 90 ° C. for 3 minutes. Pre-baking, exposing a predetermined pattern (100 mJ / cm ² ), spray development using 0.05% KOH aqueous solution for 60 seconds, and post-baking at 200 ° C. for 30 minutes to produce a black matrix substrate Can do. Further, the black matrix forming step may be performed by etching a substrate on which metal chromium or the like is vapor-deposited on a transparent base material in advance.

(About coloring parts and coloring materials)
The three colored portions in the present invention are red, blue, and green as exemplified above, and yellow, cyan, magenta, and the like can be appropriately selected and used. Hereinafter, the red, blue, and green coloring portions and the coloring materials of the respective colors will be described.

1) Red colored portion The coating thickness of the red colored material 18 (R) forming the red colored portion 12 (R) varies depending on the required color reproducibility and the composition of the red colored portion to be laminated. In general, the thickness of the red colored portion is preferably in the range of 1 μm to 4 μm, more preferably in the range of 1 μm to 3 μm. When the film thickness is thicker than the above range, for example, curing and patterning by photolithography method is not successful, and fine unevenness is generated on the colored portion surface, or the shape becomes reverse tapered, which is not preferable. If it is thinner than the above range, it is difficult to obtain the required high color purity, which is not preferable.

  The red colored portion formed in the present invention is generally composed of a red pigment, a yellow pigment, a binder, a dispersant, and other additives. Although the kind of binder changes with the manufacturing method of a red colored part, in this invention, it is preferable on the property of invention that a red colored part is formed by photolithography methods, such as a pigment dispersion method. Therefore, in the present invention, a UV curable resin is used as the binder resin.

  In addition, the said pigment may use what was surface-treated, such as a rosin process, an acidic group process, a basic process, and a pigment derivative process, as needed. Further, as a dispersant necessary for dispersing the pigment, styrene / butyl styrene copolymer, long-chain polyaminoamide phosphate, polyamide, high molecular weight polycarboxylate, oleylamine acetate, tetraalkylammonium salt, oleic acid Sodium, oleic acid amino oleate, phosphate ester salt, alkylbenzene sulfonate, etc. can be mentioned. Such a dispersant can be contained in the range of 30 to 100 parts by weight with respect to 100 parts by weight of the pigment.

  As the UV curable resin, examples of the binder resin component include monomers having an acidic group such as (meth) acrylic acid, maleic anhydride, styrenesulfonic acid, styrene, α-methylstyrene, ethyl (meth) acrylate. And a copolymer obtained by copolymerizing a monomer such as (meth) acrylamide.

Moreover, you may add a photoinitiator as another additive, Specifically, a halomethylated triazine derivative, a halomethylated oxadiazole derivative, an imidazole derivative, a benzophenone derivative etc. are mentioned. These photopolymerization initiators are compounds capable of generating radicals that polymerize a polymerizable group of a photopolymerizable monomer with ultraviolet rays, and are used alone or in combination.
Furthermore, examples of the photopolymerizable monomer include isobutyl acrylate, t-butyl acrylate, stearyl acrylate, 2-methoxyethyl acrylate, and 3-methoxybutyl acrylate.

  Specific examples of the solvent used for the red coloring material include diisopropyl ether, n-pentane, diethyl ether, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, methyl 3-ethoxypropionate, diglyme, and butyl carbitol. And organic solvents such as

  In addition, various additives can be added to the red colored portion of the present embodiment as necessary, for example, a sensitizer, a coatability improver, a development improver, a crosslinking agent, a polymerization inhibitor, You may contain a plasticizer, a flame retardant, etc. In addition, about the addition of the various additives added to the said pigment, it is the same also about the other pigment mentioned later.

2) Green coloring part Although the coating-film thickness of the green coloring material 18 (G) which forms the green coloring part 12 (G) changes with required color reproducibility and the composition of the green coloring part laminated | stacked, it is different. Generally, the film thickness of the green colored portion is usually in the range of 1 μm to 4 μm, preferably in the range of 1 μm to 3 μm. The reason for this range is the same as the reason for the red colored portion, and a description thereof will be omitted here.

The green colored portion formed in the present invention is formed by applying a green coloring material and drying it, followed by pattern exposure and development in the same manner as the above layer. The coating material is mainly composed of a binder resin such as a green pigment, a yellow pigment, and a UV curable resin, and a solvent.
Since the yellow pigment, binder resin, paint solvent, and other additives to be added are the same as those described in the above layer, description thereof is omitted here.

3) Blue colored portion The coating thickness of the blue colored material 18 (B) forming the blue colored portion 12 (B) varies depending on the required color reproducibility and the composition of the green colored portion to be laminated. In general, the thickness of the blue colored portion is usually in the range of 1 μm to 4 μm, preferably in the range of 1 μm to 3 μm. The reason for this range is the same as the reason for the red colored portion, and a description thereof will be omitted here. A purple pigment may be added to the blue colored portion in order to adjust the color tone.
Further, the binder resin, the solvent for paint, and other additives to be added are the same as those described in the above layer, and thus the description thereof is omitted here.

(About retardation layer)
As a kind of the retardation layer that can be formed by designing the alignment direction of the crosslinkable liquid crystal material constituting the retardation layer 30 in a desired direction, the liquid crystal molecules are vertically aligned (homeotropic alignment) and fixed. Thus, there is a so-called positive C plate in which the optical axis of the liquid crystal molecules faces the normal direction of the retardation layer and has an extraordinary ray refractive index larger than the ordinary ray refractive index in the normal direction of the retardation layer. In another aspect, the retardation layer 30 is a so-called positive layer in which the optical axis of liquid crystal molecules is parallel to the retardation layer and has an extraordinary ray refractive index larger than the ordinary ray refractive index in the in-plane direction of the retardation layer. A plate may be sufficient. Furthermore, by making the optical axis of the liquid crystal molecules parallel to the phase difference layer and adopting a cholesteric orientation having a helical structure in the normal direction, the entire phase difference layer has an extraordinary ray refractive index smaller than the ordinary ray refractive index. It may be a so-called negative C plate that is in the normal direction of the retardation layer. Further, the discotic liquid crystal having negative birefringence anisotropy may be a negative A plate having its optical axis in the in-plane direction of the retardation layer. Still further, the retardation layer 30 may be inclined with respect to the layer, or may be a hybrid alignment plate whose angle changes in a direction perpendicular to the layer.

  The retardation layer 30 may be a layer made of any one of the positive or negative C plate, A plate, or hybrid alignment plate described above, but is a layer formed by combining these layers. Also good. For example, the retardation layer 30 may be configured by sequentially laminating a positive A plate and a positive C plate on the upper surface of the substrate 16. Alternatively, a positive A plate may be first formed on the upper surface of the substrate 16, then the colored layer 11 described above may be formed, and a positive C plate may be further formed on the upper surface of the colored layer 11. A positive or negative C plate, A plate, or hybrid alignment plate that can be used as the retardation layer 30 can be appropriately formed on the transparent colored layer by a conventionally known method.

  Specifically, in order to form the retardation layer 30, first, a liquid crystal composition contained in a crosslinkable liquid crystal material is applied onto a substrate to form a liquid crystal coating film. For the application of the liquid crystal composition, for example, gravure printing method, offset printing method, relief printing method, screen printing method, transfer printing method, electrostatic printing method, plateless printing method, gravure coating method, roll Coating methods such as coating methods, knife coating methods, air knife coating methods, bar coating methods, dip coating methods, kiss coating methods, spray coating methods, die coating methods, comma coating methods, ink jet methods, spin coating methods, slit coating methods, etc. Or a combination of these methods can be used as appropriate.

  Subsequently, the solvent component is removed by drying under reduced pressure, and the crosslinkable liquid crystal material contained in the liquid crystal coating film is oriented in a desired direction, and then irradiated with ultraviolet rays, electron beams, or the like, or irradiated with heat. A cross-linkable liquid crystal material oriented in the direction can be polymerized to form a retardation layer. However, the method for forming the retardation layer in the present invention is not limited to this, and is a conventionally known method, in which the crosslinkable liquid crystal is polymerized and fixed on the base material surface in a desired direction. Any method may be adopted as long as it can be used.

  For example, when the liquid crystal coating film is to be the retardation layer 30 having a function as a positive C plate, the crosslinkable liquid crystal materials are polymerized by homeotropic alignment of the crosslinkable liquid crystal material in the liquid crystal coating film. Giving homeotropic alignment to a crosslinkable liquid crystal material means that the liquid crystal coating film is heated by means of heating with infrared rays, etc., and the temperature of the liquid crystal coating film is changed so that the crosslinkable liquid crystal contained therein has a liquid crystal phase. The temperature (liquid crystal phase temperature) is equal to or higher than the temperature at which the crosslinkable liquid crystal becomes the isotropic phase (liquid phase).

In addition, polymerization (crosslinking polymerization) between crosslinkable liquid crystal materials provided with alignment in the liquid crystal coating film is to irradiate the surface of the liquid crystal coating film with light having a photosensitive wavelength of a photopolymerization initiator contained in the liquid crystal composition. You can proceed with. At this time, the wavelength of light applied to the liquid crystal coating film is appropriately selected according to the absorption wavelength of the liquid crystal composition, but is generally about 200 to 500 nm. The light applied to the liquid crystal coating film is not limited to monochromatic light, and may be light having a certain wavelength range including the photosensitive wavelength of the photopolymerization initiator. In addition, in making the liquid crystal coating film into the retardation layer 30, the liquid crystal coating film is irradiated with light to advance the crosslinking polymerization reaction of the crosslinkable liquid crystal material, and the liquid crystal coating film is further baked using an oven or the like. It may be done. By performing such baking, the polymerization reaction of the crosslinkable liquid crystal material included in the retardation layer 30 can be promoted.
As described above, the crosslinkable liquid crystal material contained in the liquid crystal coating film is polymerized to form the retardation layer 30 in which the crosslinkable liquid crystal material is fixed in a desired orientation.

<Crosslinkable liquid crystal material>
As a liquid crystal material for constituting the retardation layer 30, a nematic liquid crystal having a rod-like structure is used as a liquid crystal material having positive birefringence anisotropy, and a liquid crystal material having negative birefringence anisotropy is used. A discotic liquid crystal having a disk-like structure can be used. These liquid crystal materials include liquid crystal monomers, liquid crystal oligomers, or liquid crystal polymers. In the present invention, these liquid crystal materials may be collectively referred to as liquid crystal molecules for convenience.

  It is a polymerizable liquid crystal molecule, particularly a cross-linkable liquid crystal monomer, which is polymerized and cured by irradiation with ionizing radiation such as ultraviolet rays and electron beams in that it can be cured while maintaining the alignment state of the liquid crystal molecules. It is preferable to use one. Since retardation amount and alignment characteristics are determined by the birefringence Δn of the liquid crystal molecules and the thickness of the retardation layer, Δn is preferably about 0.03 to 0.15.

More specifically, the liquid crystal material contained in the liquid crystal composition used for forming the retardation layer has an unsaturated double bond in its molecular structure and is three-dimensionally crosslinked in a liquid crystal state. Thus, a polymerizable liquid crystal material capable of fixing the liquid crystal structure is conceivable. Here, as the polymerizable liquid crystal material, compounds included in the following (Chemical Formula 1) to (Chemical Formula 11) can be used alone or in combination of two or more. In the case of the liquid crystalline monomer represented by the general formula (Formula 11), X is preferably 4 to 6 (integer). Here, since the retardation amount and the alignment characteristics are determined by the birefringence Δn and the film thickness of the liquid crystal molecules, Δn is preferably about 0.03 to 0.20, more preferably about 0.05 to 0.15.
The liquid crystal material can be applied by being dissolved in various organic solvents. The organic solvent is not particularly limited as long as the liquid crystal material is dissolved, but it is preferable that the organic solvent can be uniformly coated on the substrate. In addition, when the substrate is given water / oil repellency, or when the added surfactant has strong water / oil repellency, UV cleaning and plasma treatment should be performed as long as the vertical alignment ability is not hindered. It is also possible to improve paintability.

  Moreover, it is preferable to mix | blend a photoinitiator in the said liquid crystal composition in the range which does not impair the alignment of a liquid crystal molecule, and the radical polymerization initiator which generate | occur | produces a free radical by the energy of an ultraviolet-ray is preferable. As a compounding quantity of a photoinitiator, it is about 0.01%-15% (mass reference | standard with respect to a liquid-crystal composition), More preferably, it is about 0.5%-10% (same).

  Specific examples of the photopolymerization initiator include benzyl (also referred to as bibenzoyl), benzoin isobutyl ether, benzoin isopropyl ether, benzophenone, benzoylbenzoic acid, methyl benzoylbenzoate, 4-benzoyl-4'-methyldiphenyl sulfide, benzylmethyl Ketal, dimethylaminomethylbenzoate, 2-n-butoxyethyl-4-dimethylaminobenzoate, isoamyl p-dimethylaminobenzoate, 3,3′-dimethyl-4-methoxybenzophenone, methylobenzoyl formate, 2-methyl- 1- (4- (methylthio) phenyl) -2-morpholinopropan-1-one, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butan-1-one, 1- (4 -Dodecylpheny ) -2-hydroxy-2-methylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1- (4-isopropylphenyl) -2- Hydroxy-2-methylpropan-1-one, 2-chlorothioxanthone, 2,4-diethylthioxanthone 2,4-diisopropylthioxanthone, 2,4-dimethylthioxanthone, isopropylthioxanthone, 1-chloro-4-propoxythioxanthone, etc. be able to.

(About liquid crystal display devices)
A liquid crystal display device 51 using the color filter 10 of the present invention will be described with reference to FIG.
FIG. 11 is a schematic cross-sectional view of a liquid crystal display device 51 including the color filter 10 of the present invention. As the liquid crystal display device 51, a so-called IPS driving method is exemplified, but other driving methods such as an MVA driving method and an OCB driving method may be used.

In the liquid crystal display device 51, the color filter 10 is incorporated as a display-side substrate on the viewer side (upper side in the figure) facing the viewer.
On the other hand, a driving liquid crystal layer 40 and a liquid crystal driving substrate 71 are provided on the color filter 10 so as to be stacked below the backlight (not shown) side far from the observer.
The liquid crystal driving substrate 71 includes a glass substrate 76, a liquid crystal driving circuit 73 provided on the surface of the in-cell side, that is, the driving liquid crystal layer 40, and a liquid crystal driving electrode 72 whose applied voltage is controlled thereby. The liquid crystal driving electrode 72 is formed in a comb-like pattern for each pixel defined by the BM 14.
Further, a horizontal alignment film (not shown) for horizontally aligning the liquid crystal molecules 50 (driving liquid crystal molecules 41) is applied to the in-cell side surface of the liquid crystal driving electrode 72.

  The driving liquid crystal layer 40 including the driving liquid crystal molecules 41 is sealed in a sealed space surrounded by the phase difference layer 30, the liquid crystal driving substrate 71, and the seal 48, and applied to the panel in-plane direction from the liquid crystal driving electrode 72. The driving liquid crystal molecules 41 are switching driven by the voltage. In order to secure a desired thickness of the driving liquid crystal layer 40, a plurality of columnar bodies are generally formed between the color filter 10 and the liquid crystal driving substrate 71, but this is illustrated in FIG. Omitted.

  The liquid crystal display device 51 includes a linearly polarizing plate 81, a retardation film 82 having an optical compensation function as a positive A plate, a retardation layer 30, a driving liquid crystal layer 40, a linearly polarizing plate 83, and a backlight in order from the observer side. Are arranged, and bright display and dark display are performed by controlling transmission or blocking of backlight light for each picture element. Note that the linearly polarizing plate 81 and the linearly polarizing plate 83 are disposed so that the transmission axis directions are orthogonal to each other.

(Example 1)
(1. Adjustment of substrate)
A glass substrate (7059 glass manufactured by Corning Co., Ltd.) as a base material subjected to a cleaning process and a photoresist for colored portions of three colors of BM and red (R), green (G), and blue (B) were prepared. . And the photoresist for coloring part was apply | coated for each color as shown below on the glass substrate upper surface, and the colored layer was laminated | stacked and formed on the base material. The composition of each photoresist will be described later.

(2. Adjustment of coloring material)
A pigment-dispersed photoresist was used as a coloring material for BM and each region. The pigment-dispersed photoresist uses a pigment as a coloring material, adds beads to a dispersion composition (containing a pigment, a dispersant, and a solvent), disperses them with a disperser for 3 hours, and then removes the beads. And a clear resist composition (polymer, monomer, additive, disclosure agent and solvent). Its composition is shown below. A paint shaker was used as the disperser.

(3. Creation of BM)
First, a BM photoresist prepared as follows is applied to a glass substrate by a spin coating method, pre-baked (pre-baked) at 90 ° C. for 3 minutes, and exposed using a mask formed in a predetermined pattern. (100 mJ / cm ² ), followed by spray development using 0.05% KOH aqueous solution for 60 seconds, followed by post-baking (baking) at 200 ° C. for 30 minutes, width 20 μm, thickness 1.2 μm The base material (BM forming base material) on which BM was formed was produced.

(4. Creation of colored layer)
On the BM forming substrate, a pattern is designed so that a line having a width of 200 μm and a length of 4 cm is 300 rows × 1 column, and colored portions are formed in order of red, blue, and green in order from the end. Each colored portion was created as follows. It should be noted that, in relation to the BM, the design was made so that both ends of the above-mentioned line exist at positions where the BM is lifted.

  In this example, the effect of the present invention by the color filter 10 according to the seventh embodiment is verified. Therefore, the three colored portions consisting of red, blue, and green are virtually regarded as six colors, and red is assigned to 6n + 1 and 6n + 4th (where n is an integer of 0 or more, the same applies hereinafter), and 6n + 2 and 6n + 5th. Place blue and 6n + 3 and 6n + 6th green.

First, a red (R) pigment-dispersed photoresist is applied onto the surface of the BM-forming substrate by spin coating, dried under reduced pressure to 130 Pa, pre-baked at 80 ° C. for 5 minutes, UV exposure (300 mJ / cm ² ) was performed using a photomask for stripe pattern in which the mask opening was patterned so that a red colored portion was formed on the 6n + 1th line with the first end of the region being the first. . Further, spray development using a 0.1% KOH aqueous solution was performed for 60 seconds, followed by post-baking (baking) at 200 ° C. for 60 minutes, and a red (R) film having a thickness of 2.6 μm at a predetermined position with respect to the BM pattern. ) A colored portion pattern was formed. In addition, the said film thickness is the thickness of the red (R) coloring part in BM non-formation position, and the film thickness in the both ends which got on BM was about 3.5 micrometers.

Subsequently, using a method similar to the method for forming the pattern of the red (R) colored portion, except for using a photomask in which the mask opening is patterned so that the colored portion is formed 6n + 3rd, green (G) A colored part was created.
Subsequently, using a method similar to the method for forming the pattern of the red (R) colored portion, except that a photomask having a mask opening patterned so that the colored portions are formed at the 6n + 2 and 6n + 5th positions is used. (B) A colored part was created.
Subsequently, red (R) is used by using the same method as the method for forming the pattern of the red (R) colored portion except that a photomask having a mask opening patterned to form the 6n + 4th colored portion is used. A colored part was created.
Finally, except for using a photomask in which the mask opening is patterned so that the 6n + 6th colored portion is formed, green (G) is formed using the same method as the method for forming the red (R) colored portion pattern. A colored part was created.
In this way, a color filter in which a transparent colored layer constituted by repeatedly arranging BM, a red colored portion, a blue colored portion, and a green colored portion in this order on a glass substrate was prepared. It was.

<Photoresist for black matrix>
Black pigment: 14.0 parts by weight (TM Black # 95550 manufactured by Dainichi Seika Kogyo Co., Ltd.)
・ Dispersant ・ ・ ・ ・ 1.2 parts by weight (Disperbyk 111 manufactured by Big Chemie)
・ Polymer 2.8 parts by weight (VR60 manufactured by Showa Polymer Co., Ltd.)
・ Monomer: 3.5 parts by weight (SR399, manufactured by Sartomer)
・ Additives: 0.7 parts by weight (L-20, manufactured by Soken Chemical Co., Ltd.)
Photopolymerization initiator: 1.6 parts by weight (2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone-1)
-Photopolymerization initiator: 0.3 parts by weight (4,4'-diethylaminobenzophenone)
-Photopolymerization initiator: 0.1 part by weight (2,4-diethylthioxanthone)
・ Solvent: 75.8 parts by weight (ethylene glycol monobutyl ether)

<Red (R) colored portion photoresist>
Red pigment: 4.8 parts by weight (CIPR254 (Chromophthal DPP Red BP manufactured by Ciba Specialty Chemicals))
・ Yellow pigment: 1.2 parts by weight (CI PY139 (PASFOL Yellow D1819 manufactured by BASF))
・ Dispersant ... 3.0 parts by weight (Solsparse 24000 manufactured by Zeneca Corporation)
-Monomer: 4.0 parts by weight (SR399 manufactured by Sartomer Co., Ltd.)
-Polymer 1 ... 5.0 parts by weight-Photopolymerization initiator ... 1.4 parts by weight (Irgacure 907 manufactured by Ciba Geigy)
・ Photopolymerization initiator: 0.6 parts by weight (2,2′-bis (o-chlorophenyl) -4,5,4 ′, 5′-tetraphenyl-1,2′-biimidazole)
・ Solvent: 80.0 parts by weight (propylene glycol monomethyl ether acetate)

<Green (G) Colored photoresist>
Green pigment: 3.7 parts by weight (CIPG7 (Seika Fast Green 5316P manufactured by Dainichi Seika))
・ Yellow pigment ... 2.3 parts by weight (CI PY139 (Pariotor Yellow D1819 manufactured by BASF))
・ Dispersant ... 3.0 parts by weight (Solsparse 24000 manufactured by Zeneca Corporation)
-Monomer: 4.0 parts by weight (SR399 manufactured by Sartomer Co., Ltd.)
-Polymer 1 ... 5.0 parts by weight-Photopolymerization initiator ... 1.4 parts by weight (Irgacure 907 manufactured by Ciba Geigy)
・ Photopolymerization initiator: 0.6 parts by weight (2,2′-bis (o-chlorophenyl) -4,5,4 ′, 5′-tetraphenyl-1,2′-biimidazole)
・ Solvent: 80.0 parts by weight (propylene glycol monomethyl ether acetate)

<Blue (B) Colored photoresist>
Blue pigment: 4.6 parts by weight (CI PB15: 6 (BASF Heliogen Blue L6700F))
・ Purple pigment: 1.4 parts by weight (CI PV23 (Clariant Foster Palm RL-NF))
・ Pigment derivative ... 0.6 parts by weight (Zeneca Co., Ltd. Solsperse 12000)
・ Dispersant: 2.4 parts by weight (Solsparse 24000 manufactured by Zeneca)
-Monomer: 4.0 parts by weight (SR399 manufactured by Sartomer Co., Ltd.)
-Polymer 1 ... 5.0 parts by weight-Photopolymerization initiator ... 1.4 parts by weight (Irgacure 907 manufactured by Ciba Geigy)
・ Photopolymerization initiator: 0.6 parts by weight (2,2′-bis (o-chlorophenyl) -4,5,4 ′, 5′-tetraphenyl-1,2′-biimidazole)
・ Solvent: 80.0 parts by weight (propylene glycol monomethyl ether acetate)

  In the present specification, the polymer 1 described above is a copolymer of benzyl methacrylate: styrene: acrylic acid: 2-hydroxyethyl methacrylate = 15.6: 37.0: 30.5: 16.9 (molar ratio). 16.9 mol% of 2-methacryloyloxyethyl isocyanate is added to 100 mol%, and the weight average molecular weight is 42500.

(Formation of retardation layer)
A retardation layer was formed on the upper surface of the transparent colored layer by the method described below.

<Formation of vertical alignment film>
First, in order to form a so-called positive C plate as a retardation layer on the transparent colored portion, a vertical alignment film was first formed.
Specifically, using JALS2021 (manufactured by JSR Co., Ltd.) as an alignment film material, patterning is performed on the above color filter by flexographic printing, and then baking is performed at 200 ° C. for 1 hour, thereby achieving a vertical alignment of 600 mm in thickness. A base substrate provided with a film was obtained. In this case, a protective layer made of a transparent resin may be provided between the colored layer and the alignment film. This is because the step of the color filter is relaxed and more reliable liquid crystal alignment is possible.

<Preparation of Liquid Crystal Composition Containing Crosslinkable Liquid Crystal Material>
A liquid crystal composition containing a crosslinkable liquid crystal material constituting the retardation layer was prepared as follows.
As a polymerizable liquid crystalline monomer molecule showing a nematic liquid crystal layer, 20 parts by weight of the compound represented by the above (Chemical Formula 11) (wherein X is 6) and a photopolymerization initiator (“Irgacure 907” manufactured by Ciba Geigy Co., Ltd.) ] 0.8 parts by weight, 59.2 parts by weight of chlorobenzene as a solvent, and 20 parts by weight of a solution obtained by diluting the above-mentioned vertical alignment film forming solution JALS-2021-R2 to 12.5% with diethylene glycol dimethyl ether. A liquid crystal composition was prepared.

<Formation of retardation layer>
Next, the prepared liquid crystal composition was placed on a spin coater (manufactured by MIKASA, “trade name 1H-360S”), and the liquid crystal composition prepared in advance was dried. The upper surface of the alignment film was spin-coated so that the subsequent film thickness was about 1.5 μm. In this embodiment, the spin coating method is applied. However, the present invention is not limited to this as long as it can be uniformly applied on the substrate, and may be die coating, slit coating, or a combination thereof. There is no particular limitation.
Subsequently, the substrate is dried under reduced pressure to 130 Pa, and then heated on a hot plate at 100 ° C. for 3 minutes to remove the remaining solvent and to align the liquid crystalline monomer contained in the liquid crystal solution in the vertical direction. The alignment of the liquid crystal molecules was confirmed by visually confirming the liquid crystal transition point at which the film formed by the above became transparent from white. Subsequently, under a nitrogen atmosphere, the entire surface of the liquid crystal coating film is irradiated with ultraviolet rays (20 mW / cm ² , 365 nm, 10 nm) using an ultraviolet irradiation device (“TOSCURE 751” manufactured by Harrison Toshiba Lighting Co., Ltd.) having an ultrahigh pressure mercury lamp. Second), the crosslinkable liquid crystalline molecules constituting the liquid crystal layer were three-dimensionally crosslinked and cured. A curing reaction was completed by heating and baking on a 230 ° C. hot plate for 60 minutes, and a retardation layer of a positive C plate having a thickness of 1.45 μm was obtained.

(Comparative Example 1)
Photo in which the mask opening is patterned so that the colored portion is formed 3n + 1 after the red colored portion is formed so that the colored portion is formed in order of red, blue, and green, and then the colored portion is formed 3n + 1. The color is the same as in Example 1 except that the blue colored portion is formed using a mask and then the green colored portion is formed using a photomask having a mask opening patterned to form the 3n + 3 colored portion. A filter was prepared and used as Comparative Example 1.

(Evaluation 1) Light Leakage Evaluation In order to evaluate the performance of whether or not light leakage is prevented when light is transmitted through the color filter, light leakage of Example 1 was evaluated by the following method.

  In the state which applied the light of the sample of Example 1 created as mentioned above in the state which set the polarization microscope CPX31-P by Olympus Co., Ltd. to the cross Nicol state, and sandwiched the color filter of Example 1 on the polarizing plate. The substrate was rotated and the presence or absence of light leakage was observed with the naked eye. As a result, no light leakage was observed in the entire region of Example 1.

  For Comparative Example 1, a sample was formed in the same manner as in Example 1, and then light leakage was evaluated. As a result, light leakage was confirmed in the blue colored portion applied second. In the pixel corresponding to the blue colored portion, in more detail, the light leakage was remarkably confirmed on the side adjacent to the red colored portion applied first.

(Evaluation 2) Measurement of front luminance Front luminance was measured using a luminance measurement system constructed with a luminance measuring device, a color filter with a retardation layer, a polarizing plate, and a light irradiation unit that irradiates light.

  In the luminance measurement system, the luminance measuring device detects light that has passed through the color filter with a retardation layer sandwiched in a polarizing plate crossed Nicol state among the light emitted from the light irradiation unit, and the light sensor detects And a measuring unit that measures the luminance based on the received signal. Specifically, “BM-9” manufactured by Topcon Corporation was used as a luminance measuring instrument for measuring luminance.

  Using the above luminance measurement system, the front luminance was measured as follows. First, a color filter with a retardation layer is arranged with two polarizing plates sandwiched in a crossed Nicol state, a light irradiation part is arranged outside the first polarizing plate, and a liquid crystal is sandwiched with a color filter with a retardation layer. An optical sensor was disposed at a position facing the thickness direction of the layer and outside the second polarizing plate.

Next, light is emitted from the light irradiating unit toward the liquid crystal display device, and the light that has passed through the cell from the position outside the second polarizing plate and has passed through the first polarizing plate is detected by the optical sensor. The amount of brightness (luminance) was measured by the measurement unit, and the front luminance was measured. As a result of the above measurement, the front luminance of Example 1 was 0.21 [cd / m ² ].

Also in Comparative Example 1, as in Example 1, front luminance was measured according to the above evaluation 2. As a result, the front luminance of Comparative Example 1 was 0.41 [cd / m ² ].

  From the results of the above evaluations 1 and 2, the color filter of the present invention does not cause light leakage when transmitting light. For example, when used as a substrate on one side of a liquid crystal display, a high-quality image is obtained. It is possible to provide. Further, it was also confirmed by the front luminance of evaluation 2 that there was no light leakage in the color filter of the present invention.

(Example 2)
In order to verify the effect of the present invention by the color filter 10 according to the second embodiment, the colored portion photoresist and the black matrix photoresist of three colors of red, blue, and green were prepared in the same manner as in Example 1 above. The BM and the colored portion were fixedly formed by a photolithography method with the same coating thickness, thereby producing a three-color colored layer in a stripe shape on the glass substrate.

In the colored layer, the first end of the pixel region is the first, the red colored portion is arranged at the 3n + 1th position, the blue colored portion is arranged at the 3n + 2nd position, and the green colored portion is arranged at the 3n + 3rd position.
In addition, as described in the second embodiment, the upper surface of the red colored portion applied first is changed to a hydrophobic layer by performing atmospheric pressure plasma treatment in a fluorine gas atmosphere, and is applied second. The blue colored photoresist material to be worked was applied.
Further, after the blue colored portion was fixedly formed, the upper surface of the red colored portion and the blue colored portion was cut to a thickness of 0.2 μm by performing plasma etching in an oxygen gas atmosphere, and the hydrophobic layer was deleted.
From this state, a green colored photoresist material was applied, and a green colored portion was fixedly formed at a predetermined position to obtain a colored layer.

  Thereafter, the vertical alignment film and the retardation layer were formed in the same manner as in Example 1.

When the optical evaluation by evaluation 1 and evaluation 2 was performed about the present Example, in the light leakage evaluation of evaluation 1, light leakage was not confirmed in the blue coloring part applied 2nd.
In addition, the measurement result of the front luminance in Evaluation 2 was 0.19 [cd / m ² ].
From the above, it was confirmed that the effect of the present invention to solve the problem of light leakage in the color filter according to this example was confirmed.

(Example 3)
In order to verify the effect of the present invention by the color filter 10 according to the fifth embodiment, the above-mentioned Example 2, the red, blue, and green color portion photoresist and the black matrix photoresist were adjusted, and the same The BM and the colored part were fixedly formed by a photolithography method at the positions and the coating thickness, thereby producing three-color colored layers in a stripe shape on the glass substrate.

In the colored layer, the first end of the pixel region is the first, the red colored portion is arranged at the 3n + 1th position, the blue colored portion is arranged at the 3n + 2nd position, and the green colored portion is arranged at the 3n + 3rd position.
In addition, a protrusion having a width of 5.0 μm and a thickness of 2.3 μm was formed in a stripe shape at the center in the width direction on the upper surface of the BM partitioning the 3n + 2 and 3n + 3th. As a result, the height from the upper surface of the glass substrate to the upper end of the protruding portion is 3.5 μm, which is flush with the end height that rides on the BM among the red (R) colored portions that are fixedly formed.

  In the same manner as in Example 2, three colored portions were fixedly formed by photolithography on a glass substrate on which such BM and protrusions had been formed in advance, thereby producing a colored layer according to this example.

  Thereafter, the vertical alignment film and the retardation layer were formed in the same manner as in Examples 1 and 2.

When the optical evaluation by evaluation 1 and evaluation 2 was performed about the present Example, in the light leakage evaluation of evaluation 1, light leakage was not confirmed in the blue coloring part applied 2nd.
The measurement result of the front luminance in Evaluation 2 was 0.22 [cd / m ² ].
From the above, it was confirmed that the effect of the present invention to solve the problem of light leakage in the color filter according to this example was confirmed.

(A) is the vertical cross-sectional schematic diagram which cut the color filter 10 of this invention in the repeating direction of coloring part 12 (R), (B), (G). (B) is a schematic diagram showing a preferred outer shape of the colored portion 12. (A)-(g) shows the preparation process of the color filter 10 concerning 2nd embodiment. (A)-(e) shows the preparation process of the color filter 10 concerning 3rd embodiment. (A)-(g) shows the preparation process of the color filter 10 concerning 4th embodiment. (A)-(g) shows the preparation process of the color filter 10 concerning 2nd embodiment. (A)-(g) shows the preparation process of the color filter 10 concerning 2nd embodiment. (A)-(d) is process drawing which shows the state which arranges and arranges the colored part 12 (R), (B), (G) of three colors in the width direction, and produces the colored layer 11. FIG. (A)-(f) shows the manufacturing process of the color filter 10 concerning 7th embodiment. (A)-(f) shows the manufacturing process of the color filter 10 concerning 8th embodiment. 2 is a schematic cross-sectional view of the color filter 10. FIG. 3 is a schematic cross-sectional view of a liquid crystal display device 51 including a color filter 10. FIG. It is the schematic diagram regarding the vertical cross section of the conventional colored layer 11 coated and formed on the upper surface of the transparent base material 16. FIG. (A)-(f) shows the preparation method of the conventional three-color color filter.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Color filter 11 Colored layer 12 Colored part 13 Planned formation position 14 Black matrix (BM)
DESCRIPTION OF SYMBOLS 15 Protrusion part 16 Base material 18 Coloring material 20 Photomask 21 Mask opening 22, 23 Convex part 24 Flat part 25 Inclined part 26 Hydrophobic layer 28 Effective display area 30 Phase difference layer 40 Drive liquid crystal layer 41 Drive liquid crystal molecule 50 Liquid crystal molecule 51 Liquid crystal Display device 71 Liquid crystal drive substrate 72 Liquid crystal drive electrode

Claims (14)

A colored layer in which colored portions of the first to third colors are arranged in this order with at least one direction as a repetitive direction is provided directly or indirectly on the upper surface of a base material having a light transmission region through which visible light is transmitted, In a color filter that colors visible light transmitted through a light transmission region into three colors,
A color filter characterized in that none of the outline shapes of the vertical cross sections obtained by cutting the colored portions of the first to third colors in the repeating direction are substantially inclined in one direction.   2. The color filter according to claim 1, wherein the outer shapes of the colored portions of the first to third colors are substantially bilaterally symmetric.   The color filter according to claim 1 or 2, wherein at least two colored portions of the three colors have a hydrophobic upper surface.   The color filter according to claim 3, wherein the at least two colored portions include a hydrophobic material.   The color filter according to claim 3, wherein a hydrophobic layer having hydrophobicity is formed on an upper surface of the at least two colored portions.   Between the colored layer and the substrate, formed at the boundary area between the colored portion of the second color and the colored portion of the third color at the upper end height flush with the upper surface of the colored portion of the first color The color filter according to claim 1, wherein a protruding portion is provided. Provided between the colored layer and the substrate, a light-shielding black matrix that partitions the colored portions of the first to third colors from each other,
The color filter according to claim 6, wherein the protrusion is provided between the black matrix and the colored layer. Provided between the colored layer and the substrate, a light-shielding black matrix that partitions the colored portions of the first to third colors from each other,
The protrusion is made of a colorless transparent material or a transparent material of the same color as the second color, and is provided adjacent to the colored portion of the second color with respect to the black matrix. Color filter.   The color filter according to any one of claims 1 to 8, wherein the colored portion of the first color is formed at an extreme end in the repetition direction in an effective display area formed on the base material.   The color filter according to any one of claims 1 to 9, wherein a retardation layer in which a polymerizable liquid crystal compound is fixed in an aligned state is laminated directly on the upper surface of the colored layer or indirectly through an alignment film.   The color filter according to any one of claims 1 to 10 and a liquid crystal driving substrate including a liquid crystal driving electrode are opposed to each other with the colored layer and the liquid crystal driving electrode inside, and driving liquid crystal molecules are enclosed therebetween. A liquid crystal display device. It is a manufacturing method of the color filter of Claim 1 or 2, Comprising:
Applying the coloring material of the first color in the effective display area preliminarily formed on the base material, patterning this by a photolithography method to form the colored portion of the first color;
The coloring material of the second color is applied by an inkjet method at a position within the effective display area and adjacent to the first coloring portion in the repeating direction. Forming a colored portion;
The third color coloring material is applied in the effective display area and patterned by a photolithography method so that the third color is positioned adjacent to both the first colored portion and the second colored portion. Forming a colored portion of
In this order, a method for manufacturing a color filter. It is a manufacturing method of the color filter of Claim 1 or 2, Comprising:
Applying the coloring material of the first color having hydrophilicity in the effective display area planned to be formed on the base material, and patterning this by a photolithography method to form the colored portion of the first color;
Forming a hydrophobic layer having hydrophobicity directly or indirectly on the upper surface of the colored portion of the first color;
In the effective display area including the formation area of the hydrophobic layer, the coloring material of the second color having hydrophilicity is applied, and this is patterned by a photolithography method, and the first coloring portion is Forming the colored portion of the second color at a position adjacent to the repeating direction;
Removing the hydrophobic layer from the colored portion of the first color;
The third color coloring material is applied in the effective display area and patterned by a photolithography method so that the third color is positioned adjacent to both the first colored portion and the second colored portion. Forming a colored portion of
In this order, a method for manufacturing a color filter. 3. The method for producing a color filter according to claim 1, wherein the colored portions of the first to third colors are formed by a photolithography process twice for each color, and the following steps (i) to (vi): Out of
After performing steps (i) and (ii) in this order,
Performing step (iii) alone, or simultaneously performing steps (iii) and (iv), or after step (iv),
Furthermore, the remaining steps are performed in an arbitrary order.
(I) The coloring material of the first color is applied in an effective display area that is preliminarily formed on the substrate, and this is patterned by a photolithography method, so that 6n + 1 in the repeating direction (n is an integer of 0 or more) Forming the colored portion of the first color at a second position;
(Ii) applying the second color coloring material in the effective display area and patterning the second color coloring material by a photolithography method to form the second color coloring portion at the 6n + 3rd position in the repeating direction;
(Iii) A step of applying the third color coloring material in the effective display area and patterning it by a photolithography method to form the third color coloring portion at the 6n + 5th position in the repeating direction;
(Iv) A step of applying the third color coloring material in the effective display area and patterning the third color coloring material by a photolithography method to form the third color coloring portion at the 6n + 2nd position in the repeating direction;
(V) applying the coloring material of the first color in the effective display area and patterning the coloring material by a photolithography method to form the colored portion of the first color at the 6n + 4th position in the repeating direction;
(Vi) applying the second color coloring material in the effective display area and patterning the second color coloring material by a photolithography method to form the second color coloring portion at the 6n + 6th position in the repetition direction;

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