JP2009198546A - Discharge pattern creation method, ink discharge device, color filter produced using the same, and organic functional element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce deviation in the use of nozzles by suppressing line-like color unevenness generated in the progressing direction of the nozzles in an ink discharge device. <P>SOLUTION: A method is provided for creating a discharge pattern C<SB>uv</SB>, in the ink discharge device provided with: a substrate having X×Y pieces of cells; a mean for holding the quantity C<SB>uv</SB>of the ink to be discharged to the cells at the positions (u, v) to a memory, as a discharge pattern; and a mechanism where the cells on the substrate and nozzle heads provided with a plurality of nozzles are aligned, and then ink is discharged from the nozzles based on the discharge pattern. A Bernoulli trial in which, in the case the unit of the discharge quantity of each nozzle is denoted as d and m<SB>uv</SB>is denoted as a positive integer satisfying ¾C<SB>uv</SB>¾<d×m<SB>uv</SB>, while p=¾C<SB>uv</SB>¾/(d×m<SB>uv</SB>) is the probability of success and m<SB>uv</SB>is the frequency of trials, is performed, and, when the frequency of the successes is n, the initial C<SB>uv</SB>is substituted with C<SB>uv</SB>'=(the sign of C<SB>uv</SB>)n×d. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for generating data relating to the amount of ink ejection used to form a pattern in which unevenness is not noticeable by an ink ejection device.

  The size of color filter substrates used in liquid crystal displays is increasing year by year. Conventionally, the method of repeating a photolithography process using a pigment-dispersed resist has been the mainstream, but in recent years, in order to reduce the cost of the color filter, in recent years, an inkjet method (hereinafter referred to as an ink jet method) that can form each colored layer of the color filter simultaneously. (Referred to as “ink ejection method”) is also regarded as an effective method.

  In the ink ejection method, the substrate surface is generally partitioned by partition walls so that different color inks ejected on the substrate do not mix. Colored ink corresponding to each color of the color filter is discharged from the nozzle of the nozzle head into the opening (hereinafter referred to as a cell). At this time, it is believed that the color filter color unevenness is reduced and the quality of the color filter can be manufactured as the variation in the filling amount of the ink discharged to each cell is smaller.

  On the other hand, the pattern pitch of a color filter tends to become finer year by year as the resolution and capacity of an image display device or the like in which the color filter is built is increased. Therefore, since the cell size applied by the ink discharge device is also small, it is necessary to control the discharge amount of ink from the individual nozzles and the nozzle head that bundles them with high accuracy so that the entire head is uniform. There is. In addition, for speeding up, a nozzle head for each color is provided, and a plurality of such sets are stacked.

  However, since the amount of ink ejected from each nozzle varies, it is inevitable that even if a large number of inks are bundled to form a nozzle head, there will be a difference in the ejection amount. Since the amount of ink ejected from each nozzle is very small and the number of nozzles allocated to each cell is as small as several, the variation is relatively large.

  In general, since the same amount of ink is filled in each nozzle head, even if the same number of inks are ejected from nozzles belonging to different nozzle heads, the amount of ink filling in the cell differs for each nozzle head. The amount of ink ejected for each nozzle head can be regarded as being fixed with a certain variation. This state is maintained to a considerable extent in the traveling direction of the nozzle head.

  If the ink discharge device is provided with a plurality of sets, with three color nozzle heads as one set, it differs from the total liquid amount of continuous cells (hereinafter referred to as cell lines) from which ink was discharged by the same nozzle head set. A difference occurs in the total liquid amount in the cell line formed by the nozzle headset. As a result, there is a problem that when the nozzle head is moved, and after that, once discharging is finished and moved again in the horizontal direction and the re-discharging operation is repeated, it appears visually as uneven color.

The above unevenness is produced by ink ejection of an organic EL element in which a partition wall is previously formed on a substrate and one or more organic functional layers are stacked in the opening, or an organic functional element such as an organic solar cell. It also occurs when you do. For example, in an organic EL element, when functional inks of a hole transport material and a light emitting material are ejected from an ink ejection device, the organic EL element as a whole has a low image quality with noticeable light emission unevenness.

  In order to solve the simple ink discharge amount variation or the above problems, a circuit device that can change the drive voltage value for each nozzle is incorporated in order to suppress the discharge amount variation for each nozzle. A method of reducing color unevenness by using after adjusting the discharge amount and adjusting the discharge amount is disclosed (Patent Document 1).

  However, as described in Patent Document 1, in order to change and correct the drive voltage value for each nozzle, the degree of variation of each nozzle, when adjacent nozzles discharge at the same timing, or discharge If it is not, it is necessary to grasp all the effects of crosstalk that the discharge amount is different. For this reason, there is a problem that a great deal of time and materials are wasted because the discharge is performed many times, the measurement is performed each time, and the operation is performed until there is no discharge variation of each nozzle.

Another problem with the ink ejection apparatus relates to the frequency of use of nozzles assigned to individual cells. If the nozzle is used in a biased manner, the service life will be shortened. The nozzles to be used are determined by the cell size and pitch, the minimum ink discharge amount and the total discharge amount, etc., but not all the nozzles allocated in each region can be used and are not optimal. . Generally speaking, considering long-term stable use such as nozzle clogging due to overuse, it is desirable to use them equally based on some kind of law rather than arbitrarily selecting them.
JP 2004-90621 A “Probability Theory and Its Applications I”, Chapter VI, W.W. By Ferrer, Kinokuniya, 1971

  In view of the above-described points, the present invention first provides an ink for removing the vertical stripes of color unevenness caused by the amount of ink ejected from a plurality of adjacent nozzles being constant in the traveling direction of the nozzles. The first problem is to provide a method for providing variation in the amount of discharge. However, the method of the present invention is not only to electrically adjust the discharge amount of each nozzle as described above, but also to provide a method that can be easily achieved in a short time. The second problem is to provide a method that can efficiently use the nozzles assigned to the cells evenly and stably and as a nozzle head for a long period of time. It is an object of the present invention to provide a high-quality color filter and an organic functional element that do not have a glare using an ink ejection device in which these are achieved.

A first invention for achieving the above object is a substrate having X × Y cells divided into X rows and Y columns by a partition, and the amount of ink to be ejected to a cell at a position (u, v). Means for holding _Cuv as a discharge pattern in a memory and a mechanism for discharging ink from the nozzle based on the discharge pattern _Cuv after _aligning a cell on the substrate and a nozzle head having a plurality of nozzles wherein a method for generating ejection pattern C _uv, the unit discharge amount of the nozzle d, the m _uv in the ink ejection device including a | when the <positive integer satisfying d × m _uv, | C _uv When Bernoulli trials are performed with p = | C _uv | / (d × m _uv ) as the probability of success and m _uv is the number of trials, and the number of successes is n, the initial C _uv is represented by C _uv '= (C _uv sign) discharge pattern characterized by substituting n × d It is a generation method. (Where u and v are positive integers satisfying 1 ≦ u ≦ X and 1 ≦ v ≦ Y).

When the original data of the ink discharge amount is modulated for each cell by this pattern generation method, the amount of ink to be discharged for each adjacent cell in the cell line extending in the traveling direction of the nozzle head can be given.

According to a second aspect of the present invention, there is provided a discharge pattern generation in which the replaced ink amount C _uv ′ according to the first aspect is distributed as a discharge amount C _uv ′ (γ) of k nozzles for discharging ink to the cell. In this method, when the unit of the discharge amount of the nozzle is d and m _uv is the smallest positive integer satisfying | C _uv '| <k × d × m _uv , p = | C _uv | / (k Xd × m _uv ) is the probability of success and m _uv is the number of trials, and when the number of successes is n, C _uv ′ (γ) = (sign of C _uv ) n × d This is a discharge pattern generation method characterized by the above. (Where γ = 1, 2,..., K).

If the total amount of ink to be ejected assigned to each cell by the method according to claim 1 is assigned to the nozzles belonging to the cell by this method, the nozzles can be used evenly without deviation.

  In the invention of claim 3, the random number used when calculating the number of times of success is a uniform random number R (j) (0 ≦ R (j) <1) or a long-period component of the uniform random number. It is a corrected random number.

  According to the present invention, when a uniform random number having a large number of cells (number of pixels) and several million or more is used, it is possible to avoid problems caused by periodicity in the uniform random number. By correcting the long-period component of the uniform random number, the ink discharge amount distribution has no periodicity, so that a natural liquid crystal display without glare can be realized.

The invention according to claim 4 is the above-described ejection pattern generation method, wherein the ejection pattern C _uv is constant for each column.

The invention according to claim 5 is the above-described ejection pattern generation method, wherein the ejection pattern C _uv is obtained by calculating a difference between an ideal value and an actual measurement value of the ink ejection amount for each column.

The inventions according to claims 4 and 5 limit the discharge pattern C _uv as the initial data necessary for the first ink discharge to special but realistic data in the column direction. By adopting the data, it is possible to quickly give variation to the discharge amount. Also, an ideal discharge amount distribution can be reached quickly.

  A sixth aspect of the present invention is an ink ejection apparatus comprising the ejection pattern conversion method described above.

  A seventh aspect of the present invention is a color filter manufactured by the ink ejection apparatus according to the present invention.

  The invention of claim 8 is an organic functional element manufactured by the ink ejection apparatus according to the present invention.

According to the present invention, the color unevenness of the vertical stripes inevitably generated when the ink discharge amount becomes constant in the traveling direction of the head, and the variation is consciously given when the ink discharge amount is along the traveling direction. Therefore, it can be completely inconspicuous. Further, it is possible to easily reach an ideal ink discharge amount distribution in a short time. Another effect is that the nozzles that eject ink are used so as not to be biased by statistical operations, and can be used stably for a long time. By these, it is possible to realize a color filter without color unevenness and glare, or an organic functional element without light emission unevenness.

  First, the schematic configuration of the ink ejection apparatus according to the present invention will be described in detail with reference to FIG. 1 and other FIGS. 2 to 4. FIG. 1 schematically shows the overall configuration of the ink ejection apparatus. The ink ejection apparatus includes a head unit 2 in which a plurality of nozzle heads 1 in which a large number of ejection nozzles 5 are regularly arranged in a plurality of rows (FIG. 2) are arranged. In order to form a color filter, the nozzle head 1 is assigned to each color (for example, red, blue, and green), and these three heads are used as one unit in a state where several units are juxtaposed or stacked.

  The substrate table 3 is movable in a sub-scanning direction (X) 12 that is orthogonal to the main scanning direction (Y) 11 and is further rotatable in the θ direction (in the YZ plane). Since it can be rotated in the θ direction, the partition wall of the substrate placed on the substrate mounting table and the head unit 2 can be aligned in parallel, and the ink can be ejected with the width of the head unit 2 by operating in the sub-scanning direction 12. It can be carried out. After the head unit 2 ejects ink for a predetermined distance in the Y direction, the substrate stage 3 is moved in the sub main scanning direction (X) 12 to perform further ink ejection, thereby ejecting ink to all necessary portions. The substrate table 3 includes an adsorption mechanism (not shown), and the substrate is firmly fixed.

  The ink ejection apparatus includes a head controller 4 as a central part that drives and controls the head unit. The head controller 4 has (a) ejection pattern information and (b) nozzle head parameter information as information necessary for driving each part of the apparatus. The discharge pattern information part (a) is composed of information related to the position of the head and nozzles and information related to the ink discharge amount of the nozzles.

  Information on the position includes information on the substrate on which ink is ejected (partition pitch, coloration pattern, etc.), information on the arrangement of nozzles belonging to each head (two-dimensional pitch of the nozzles in FIG. 2), and the relative position of the heads Information on the relationship and how the substrate is moved.

The information related to the ink discharge amount is an appropriate unit that represents the amount of ink to be discharged for each nozzle belonging to the head unit. If an arbitrary area for discharging ink on the substrate is a set of (X × Y) cells, which nozzle of which head covers which position (u, v) cell is determined in advance. (Where u = 1, 2,..., X, v = 1, 2,..., Y, and u and v are parameters indicating the cell number). Therefore, the total amount of ink ejected for each cell at the position (u, v) is _defined as C _uv and the ejection pattern information C _uv . Further, if the number of nozzles assigned to the cell is k, C _uv is further divided into k pieces of information C _uv (γ) (γ = 1, 2,..., K) and is stored in the memory of the head controller. Retained. Actually, the ejection pattern information C _uv (γ) is transferred from the head controller 4 to each nozzle at the time of ejection, and ejection is performed based thereon. Note that it is not necessary to cover the entire allowable range for the range of u and v, and it may be a part of the substrate.

  The nozzle head parameter information (b) is necessary for controlling the amount of ink ejected from the nozzle for each nozzle head. Ink is released using the piezo effect, but its amount and strength are controlled by voltage. If the drive voltages of all the nozzle heads are set to the same value, there is a difference in the amount of liquid ejected from each head, so that ink cannot be ejected uniformly into the substrate. This is information for setting and adjusting an optimum voltage value for each nozzle head.

Furthermore, in the ink ejection apparatus of this example, whether or not ink has been dropped from a nozzle of a predetermined head to a target cell based on the position information can be observed with a provided camera. Therefore, the consistency with the discharge pattern C _uv is checked.
_uv and C _uv (γ) are provided for actual use.

Now, the ink ejection device repeats the same during operation whether the amount of ink is electrically set or whether C _uv (γ) is further set as in this example. While it is not impossible to apply feedback during operation to asymptotically reach the target value, it is generally not done. Therefore, prior to the _actual operation, it is necessary to set C _uv and C _uv (γ) to optimum values that are inconspicuous in color unevenness.

FIG. 3 schematically shows the moving direction of the substrate on which ink is ejected and the nozzle head. Assuming that the nozzle head moves in the Y direction 11, when the nozzle head reaches the lower side, the nozzle head shifts in the X-axis direction 12 and scans the upper side again to discharge. That is, the same set of nozzles may be moved in different positions in the X-axis direction 12. As a result, the distribution of the discharged liquid amount in the Y-axis direction is the same in the separated cell lines 13 and 13 ′, which is the cause of the vertical streak-like color unevenness 14. There is a possibility that this can be avoided by mechanically shifting the head, changing the amount of discharged liquid, or varying the data of C _uv (γ). The present invention is avoided as follows.

The amount of liquid droplets that can be dropped from the nozzle can be set within a certain range, but is generally several picoliters and cannot be made too small. In this specification, this minimum value is represented by d. The ejection pattern C _uv (γ) may be the number of droplets in units of d (hereinafter also referred to as the number of drops) or the amount of ink. Further, it may be an amount including a certain positive / negative offset value. What is necessary is just to mutually convert into the unit suitable for a drive by appropriate data processing. The number of nozzles k is approximately several. This is determined in accordance with the number of nozzles per unit area, the cell opening area, the position information described above, and the like.

Before determining the optimized ejection pattern C _uv and C _uv (gamma) the actual use when driving, the ejection pattern C _uv as the initial data, the state actually is as previously described are considered constant in the Y direction So set it like that. This state is a state having vertical stripe-like color unevenness, and is schematically shown in FIG. Of course, there may be some variation in the Y direction. The problem is that the same condition occurs periodically in the X direction. The number of blocks forming the column in the Z direction in FIG. 4A corresponds to the ink amount C _uv as the ejection pattern C _uv .

  Giving variation within the column means converting the state shown in FIG. 4A to the state shown in FIG. In the present invention, a so-called Bernoulli trial was adopted for this conversion (Non-Patent Document 1). The procedure is described below.

Consider that C _uv as initial data is once taken out of the box and returned to the original box. In returning, C _uv is divided into units of unit amount d and then returned to units of plate d (shown in a state where one block is divided into three at the broken line portion in FIG. 4A). ) When the remainder is not divisible by d, it is increased or decreased by one unit d. Here, d is an amount of a unit dropped from the nozzle, but it is not necessarily limited to this at this stage. When the number of operations (trial) for returning represented by m _uv, m _uv is the product of d and a positive integer m _uv is, | C _uv | if the larger can be set to any value (| C _uv | <D × m _uv ). In addition, || is an absolute value symbol.

Using C _uv , d, and m _uv defined above, a real number p = | C _uv | / (d × m _uv ) can be defined (0 ≦ p <1). Next, a uniform random number R (j) is generated m _uv times (0 ≦ R (j) <1). This m _uv random number is compared with p, and the number of times that the random number is smaller than p is defined as n. In that case, n d is returned to the original box. This is a Bernoulli trial for determining the success probability when the probability of success is p and the probability of failure is (1-p).

When returning by this procedure, the average of the return amount is n × d (= p × m _uv × _{d≈C uv} ) which is the same as the original value. The maximum value is d × m _uv , which varies as a whole around C _uv . The distribution of n is given by the binomial distribution of the following equation (1).

従って、分散などの平均量はこれから計算できる。同様な手順を所望のセルすべてで繰り返す。それによって指定されたすべてのセルに対し、Ｘ、Ｙ方向で相関のないバラツキを付与でき、上記値でＣ_uvを置換することで新しいインキ吐出パターンＣ_uv’を生成できる。乱数との比較は本例のようにセルごとに行ってもよいし、セルラインごとにあるいはまったくランダムに行っても構わない。

Therefore, the average amount such as variance can be calculated from this. A similar procedure is repeated for all desired cells. Accordingly, non-correlated variations in the X and Y directions can be given to all the specified cells, and a new ink ejection pattern C _uv ′ can be generated by replacing C _uv with the above values. Comparison with random numbers may be performed for each cell as in this example, or may be performed for each cell line or at random.

This is the method according to claim 1 for imparting variation to each cell while keeping the total amount substantially constant. Actually, as described above, C _uv can be considered constant in the cell line in the Y direction (v direction), so m _uv may be constant regardless of the value of v. However, it is not necessary to do so. The combination of the substrate and the device that is inherent habit, it may also be m _uv vary from cell (u, v) on the basis of experiments, may be changed along a certain direction, same for C _uv It is. The magnitude of the positive integer m _uv need not be set so as to greatly exceed | C _uv |. If it is set to a large value, the variation width will be widened, but it is desirable to set it to an appropriate value within a range where it is not possible to visually recognize the variation.

In some cases, C _uv may be negative. This corresponds to a case where the ink discharge amount is reduced, but after calculating by applying the above procedure to the absolute value of C _uv , it may be finally made negative. This is the reason why the absolute values are given in claims 1 and 2. Incidentally, C _uv code = C _uv / | written as well | C _uv.

The content of claim 2 is a method of allocating the total discharge amount for each cell to which the variation is given in the above procedure to the nozzles assigned to the cell. The way of allocation is basically the same as that of claim 1 above. The difference from claim 1 is that when C _uv is set to k, the number of nozzles used for ejection is changed to n × d / k ( _{≈C uv} / k). In this case, it is necessary to set d as a unit of the amount of liquid dropped by the nozzle. Furthermore, the positive integer m _uv is preferably set to a minimum value. Sorting is performed by k nozzles in a cell, and it is necessary to repeat it in all desired cells.

  Regarding the uniform random number R (j) used for selection, attention is paid to the periodicity when j is large (several millions or more) since the number used is enormous. This is the content of claim 3. Specifically, N (> several million) random numbers of R (j) are Fourier transformed with respect to N to obtain R (q). That is, R ′ (q) is obtained by removing some of the low wavelength components (q≈0) from R (q), and R (j) is obtained by inverse Fourier transform. It is desirable to vary the amount to be removed. Since there is no periodicity due to random numbers in ink ejection, a color filter with less glare can be manufactured and a good liquid crystal display can be obtained.

  Since the contents of claim 4 have been described above, an initial data setting method for obtaining a higher quality image related to claim 5 will be additionally described. Due to the variation in the discharge amount for each nozzle, the influence of crosstalk, etc., the total amount of ink discharged in each actual cell line or cell is deviated from the ideal total amount. The total amount of liquid discharged can be estimated by observing and evaluating the actual number of drops. Furthermore, by correcting this value with actual values such as film thickness, chromaticity, and luminance, it is possible to optically estimate the ideal amount for each cell line or for each cell.

Therefore, the difference between the ideal total liquid amount of each cell and the measured amount is set as the initial ejection pattern C _uv . When the procedure of claim 1 is applied to the discharge pattern C _uv , the modulated C _uv ′
Get. The result and the original liquid amount are added together to form a new C _uv . If the amount of liquid is negative, all of the steps are included in this procedure as described above. Thereby, an ideal discharge pattern can be reached quickly. By repeating this procedure recursively, an ideal ejection pattern is reached.

  As described above, according to the method of the present invention, the color unevenness between the cell lines or between the pixels is not accompanied by the complicated work of measuring the variation in the discharge amount for each nozzle and correcting the discharge amount for each nozzle. Can be reduced.

  Next, an example of ink ejection by the ejection device of the present invention will be described. First, element technologies common to the color filter and the organic functional element will be described.

  The substrate is used as a support substrate from which ink is discharged. For example, a known transparent substrate material such as a glass substrate, a quartz substrate, a plastic substrate, or a dry film can be used, although the type of substrate differs depending on the target optical element. Among them, the glass substrate is excellent in transparency, strength, heat resistance, and weather resistance in color filter and organic EL device applications.

  The partition wall has a function of dividing the surface of the substrate into a plurality of regions and preventing color mixture of ink ejected in each of the many regions. In order to prevent color mixing, it is desirable to use a partition that exhibits a certain ink repellency. For example, a method of forming partition walls with a resin composition containing an ink repellent agent, a method of performing plasma treatment on the partition walls of the resin composition, or forming a partition wall with a photocatalyst layer to impart ink repellency can be exemplified. Further, in the display, the contrast of the display screen can be improved by providing a light shielding property to the partition walls. The partition walls can be produced by a known method such as a printing method or a photolithography method.

  Next, the manufacturing method of an organic functional element is demonstrated. When manufacturing an organic EL element, an organic solar cell, or an organic semiconductor, first, a partition is formed on a substrate. It can be manufactured by ejecting a desired organic functional layer onto a substrate using the ink ejection device of the present invention, wherein the ink contains an organic light emitting material. The ink can contain an organic light emitting material, a solvent, and a resin binder as necessary.

  Organic light emitting materials include coumarin, perylene, pyran, anthrone, porphyrene, quinacridone, N, N'-dialkyl substituted quinacridone, naphthalimide, N, N'-diaryl substituted pyrrolopyrrole, iridium Organic light-emitting materials that are soluble in organic solvents such as complex systems, those in which the organic light-emitting materials are dispersed in polymers such as polystyrene, polymethyl methacrylate, and polyvinyl carbazole, polyarylene-based, polyarylene vinylene-based, and polyfluorene-based materials High molecular organic light-emitting materials such as those based on the above-mentioned types.

Next, a color filter manufacturing method will be described as an example of implementation.
First, a partition is manufactured. A black photosensitive resin composition having the following composition ratio was prepared as a photosensitive resin composition containing an ink repellent material. As the substrate, non-alkali glass (1737: manufactured by Corning Co., Ltd.) was used, and this black photosensitive resin composition was applied thereon by spin coating, and prebaked on a hot plate at a temperature of 90 ° C. for 1 minute. A film having a thickness of 2.0 μm was formed on the substrate.

[Composition of black photosensitive resin composition]
Cyclohexanone (boiling point 155.7 ° C.) 80 parts by weight Cresol-novolak resin: EP4050G (manufactured by Asahi Organic Materials Co., Ltd.) 15 parts by weight melamine resin: MW30 (manufactured by Sanwa Chemical Co., Ltd.) 5 parts by weight Carbon pigment: MA -8 (manufactured by Mitsubishi Materials Corporation) 23 parts by weight Dispersant: Solsperse 5000 (manufactured by Geneca Corporation) 1.4 parts by weight Compound having radical polymerizability: trimethylolpropane triacrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd.) 5 Part by weight Photopolymerization initiator: Irgacure 369 (manufactured by Ciba Specialty Chemicals) 2 parts by weight Fluorine-containing compound: Modiper F-600 (manufactured by NOF Corporation, mass average molecular weight 35000) 5 parts by weight.

Subsequently, using a photomask having a lattice pattern, an exposure process of 100 mJ / cm ² was performed with an ultrahigh pressure mercury lamp, and further, a development process and a drying process were performed to obtain a desired partition wall pattern. The cell opening is 330 μm in the X direction and 110 μm in the Y direction. The number of cells was X = 11080 and Y = 1920.

  Preparation of the coloring ink was carried out by adding 0.75 parts by weight of azobisisobutylnitrile under a nitrogen atmosphere and reacting under the conditions of 70 ° C. for 5 hours to produce an acrylic copolymer resin.

[Composition of colored ink composition]
Methacrylic acid 20 parts by weight Methyl methacrylate 10 parts by weight Butyl methacrylate 55 parts by weight Hydroxyethyl methacrylate 15 parts by weight Butyl lactate 300 parts by weight Propylene glycol monomethyl so that the obtained acrylic copolymer resin is 10% by weight Dilution with ether acetate gave a diluted solution of acrylic copolymer resin.

  Add 19.0 g of color pigment and 0.9 g of polyoxyethylene alkyl ether as a dispersant to 80.1 g of this diluted solution, and knead with three rolls to obtain red, green and blue colored varnishes. It was. As a red pigment, Pigment Red 177, Pigment Green 36 as a green pigment, and Pigment Blue 15 as a blue pigment were used.

  Propylene glycol monomethyl ether acetate is added to each colored varnish so that the pigment concentration is 12 to 15% by weight and the viscosity is 15 cps, and red, green and blue colored inks are obtained. It was.

  A colored layer was formed using the ink ejection apparatus having the configuration shown in FIG. Here, the ideal total liquid amount M of each cell is 420 pl, and the discharge amount d of the unit drop is 6 pl.

  Next, a program for determining the number of drops of each cell described in claims 1 to 3 was incorporated in the head controller 4 (see FIG. 1) of the ink ejection apparatus, and an ejection experiment was conducted. The number of nozzles per cell was eight.

Table 1 shows, for each cell line in the Y direction, the difference between the measured value of the average total liquid amount per cell before the adjustment according to the present invention and the theoretical total liquid amount. The ideal total liquid amount was calculated based on the ink material based on the ink amount necessary for obtaining a desired chromaticity in the color filter. Further, the chromaticity of the color filter actually produced was measured for each cell to determine the difference from the target chromaticity, and this was converted into the liquid volume to determine the difference from the total liquid volume. The number of increase / decrease drops in each cell is determined by the relationship between this difference and the unit drop discharge amount 6 pl. Here, as described above, since the chromaticity of the cell is substantially constant in the cell line in the Y direction, C _uv and m _uv are constant in the cell line. In this example, the minimum value of m _uv is adopted for each cell line.

  The numerical values in the lower part of Table 1 are the results of the adjustment described in claim 5. As a result of the adjustment, it is clear that the average total liquid volume of each cell line is closer to the theoretical total liquid volume.

Here, from Table 1, in cell line 2, the difference between the average total liquid volume and the theoretical total liquid volume is 7.1 pl, and the minimum value of m _uv is 2. In this case, the success probability p is p = 0.5917, and the theoretical value of the number of cells where the success count n is 2 and the number of cells where n = 1 is obtained based on this. Table 2 is a table comparing the theoretical values with the number of cells actually reduced by 2 drops and the number of cells reduced by 1 drop by comparing the random numbers with the method of the present invention. As a result, it can be seen that the theoretical value and the calculation result by the random number almost coincide with each other, and as a result, as shown in Table 1, an average total liquid volume close to the theoretical total liquid volume was obtained. As a result of this adjustment, a color filter with reduced color unevenness as a whole was obtained. In addition, by selecting the nozzles using random numbers, the effect of reducing the vertical stripe color unevenness was increased, and the long-term stability of the head was also effective.

以上のように、ノズルごとの吐出量のバラツキを測定して、ノズルごとに機械的電気的に吐出量を制御することなく、短時間で各着色層のセルごとの適切な吐出量のバラツキを付与することによって、色ムラのないカラーフィルタを製造することができた。同じ手順を有機ＥＬ素子及び有機太陽電池等の有機機能性素子のインキ吐出に際し、適用することで理想とする各インキの分布を達成できる。

As described above, the variation in the discharge amount for each nozzle is measured, and the variation in the appropriate discharge amount for each cell of each colored layer can be achieved in a short time without mechanically and electrically controlling the discharge amount for each nozzle. By applying, a color filter having no color unevenness could be produced. By applying the same procedure to ink ejection of organic functional elements such as organic EL elements and organic solar cells, it is possible to achieve an ideal distribution of each ink.

Schematic which shows the example of a whole block diagram of the ink discharge apparatus of this invention. The figure explaining arrangement | positioning of the nozzle at the time of seeing a part of nozzle head from the nozzle side front. The figure which illustrates typically the relative moving direction of a head with respect to a board | substrate, and the direction of vertical stripe unevenness. The figure which illustrates typically the state which has a straight line | wire nonuniformity, and the state which provided the variation of this invention.

Explanation of symbols

1. Nozzle head 2, nozzle head unit 3, substrate stand 4, head control unit 5, nozzle 6, assigned nozzle 11, main scanning direction of nozzle head (Y direction)
12. Nozzle head sub-scanning direction (X direction)
13, 13 ', cell line 14, vertical streaky color unevenness

Claims (8)

A substrate having X × Y cells divided into X rows and Y columns by a partition, means for holding in a memory an amount C _uv of ink to be discharged to a cell at position (u, v), and the substrate Generation of the ejection pattern C _uv in an ink ejection apparatus having a mechanism for ejecting ink from the nozzles based on the ejection pattern C _uv after _{aligning the} upper cell and a nozzle head having a plurality of nozzles When the unit of the discharge amount of the nozzle is d and m _uv is a positive integer that satisfies | C _uv | <d × m _uv , p = | C _uv | / (d × m _uv ) Probability of success, Bernoulli trial with m _uv as the number of trials is performed, and when the number of successes is n, the original C _uv is replaced with C _uv ′ = (sign of C _uv ) n × d A method for generating a discharge pattern. (Where u and v are positive integers satisfying 1 ≦ u ≦ X and 1 ≦ v ≦ Y). A method for generating a discharge pattern according to claim 1, wherein the amount C _uv ′ of the replaced ink is distributed as a discharge amount C _uv ′ (γ) of k nozzles for discharging ink to the cell. When the unit of the discharge amount is d and m _uv is the smallest positive integer satisfying | C _uv '| <k × d × m _uv , p = | C _uv | / (k × d × m _uv ) An ejection pattern characterized by C _uv ′ (γ) = (sign of C _uv ) n × d when Bernoulli trials are performed with the probability of success, m _uv as the number of trials, and the number of successes is n. Generation method. (Where γ = 1, 2,..., K).   The random number used when calculating the number of successes is a uniform random number R (j) (0 ≦ R (j) <1) or a random number obtained by correcting the long-period component of the uniform random number. The ejection pattern generation method according to claim 1, wherein the ejection pattern generation method is characterized by the following. The ejection pattern generation method according to claim 1, wherein the ejection pattern C _uv is constant for each column. The ejection pattern generation according to any one of claims 1 to 3, wherein the ejection pattern C _uv is obtained by calculating a difference between an ideal value and an actual measurement value of the ink ejection amount in units of columns. Method.   An ink discharge apparatus comprising the discharge pattern generation method according to claim 1.   A color filter manufactured by the ink ejection device according to claim 6.   An organic functional element produced by the ink ejection apparatus according to claim 6.

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