JP2009237279A - Liquid crystal panel and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve glass strength, to improve durability and to achieve low cost in a liquid crystal panel without adding other processes. <P>SOLUTION: The liquid crystal panel 100 includes: a color filter substrate 120; a switching element substrate 110 provided facing a surface opposite to a display surface 200 of the color filter substrate 120; and a sealing material 130 provided between the color filter substrate 120 and the switching element substrate 110 and sandwiching a liquid crystal 140. The liquid crystal panel further includes, on an end surface of switching element substrate 110, a cut surface separated by applying a stress after forming, on a surface side facing the color filter substrate 120, a cut flaw that serves as a starting point for separation when the switching element substrate 110 is cut out in a predetermined shape from a mother substrate 10 used for taking out the switching element substrate 110. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a liquid crystal panel and a method for manufacturing the liquid crystal panel.

  Usually, a liquid crystal panel is manufactured by cutting out into two pieces of a predetermined size from two bonded mother glass substrates. Cutting is performed by applying a stress to the glass substrate by forming a cutting flaw that becomes a starting point of cutting on the surface of the two mother glass substrates from the front side and the back side of the bonded mother substrate with a scribe wheel, respectively. Is done. Further, as a method for applying stress, there is a case in which a method of cutting by irradiating a laser beam along the formed cutting flaw may be used. In any of these cutting methods, damage such as minute scratches or cracks may enter the cut surface of the substrate, and such scratches or cracks remaining on the substrate end surface grow due to stress applied thereafter. In particular, with recent diversification of applications for liquid crystal panels, the display surface has been deformed into a curved shape with a concave surface or a convex surface, the thin shape has been processed to be extremely thin and lightened by polishing, and the display surface Some of these liquid crystal panels are provided with a touch panel function that is an input function by touching the glass. When these liquid crystal panels are processed into a curved shape, or when touched or pressed from the display surface side, stress is easily generated on the glass. As a result, there was a problem that the liquid crystal panel was damaged starting from the minute scratches and cracks described above.

  Thus, it is desired to improve the strength of the substrate end face, and several methods for improving the strength of the substrate end face of the liquid crystal panel have been proposed. Patent Document 1 discloses a method of reinforcing a glass substrate end face by protecting it with a resin to improve reliability against impact or bending stress. Patent Document 2 discloses a method for preventing cracks caused by impact by melting and extinguishing cracks formed at the time of cutting on a glass substrate end face by heat treatment using a laser.

JP 2004-302133 A Japanese Patent Laid-Open No. 10-111497 (page 3-4, FIG. 1)

  However, in the method of protecting the glass substrate end face of Patent Document 1 with a resin, a new process is required to form the resin, and when the substrate is thin, a resin dripping occurs at the time of application. There is a problem above. Also, the method of melting and extinguishing the cracks in Patent Document 2 with a laser requires a new laser processing step, and a high-power laser irradiation device is required to enable melting of the glass. A high-power laser irradiation apparatus is very expensive, leading to a significant increase in manufacturing cost. As described above, the conventional liquid crystal panel and the manufacturing method thereof have not been suitable for improving both durability and cost reduction.

  The present invention has been made to solve the above-described problems, and can improve the glass cracking strength without adding other processing steps, improve the manufacturing yield, and so on. A liquid crystal panel capable of improving durability and reducing costs and a manufacturing method thereof are obtained.

  In the liquid crystal panel according to the present invention, a first substrate provided with a display surface for displaying an image, a second substrate disposed opposite to the surface of the first substrate opposite to the display surface, A sealing material disposed so as to surround a region corresponding to the display surface between the first substrate and the second substrate and sandwiching the liquid crystal in the region, and at the end surface of the second substrate, the second substrate When the second substrate is cut into a predetermined shape from the mother substrate from which the substrate is taken out, the cut is cut by applying a stress after forming a cutting flaw as a starting point on the surface facing the first substrate. It has a surface.

  According to the liquid crystal panel of the present invention, the glass cracking strength can be improved without adding another processing step, and the durability can be improved and the cost can be reduced.

Embodiment 1.
1 and 2 are schematic diagrams of a liquid crystal panel according to Embodiment 1 of the present invention. Hereinafter, the configuration of the liquid crystal panel will be described with reference to FIGS. FIG. 1 is a plan view showing the entire liquid crystal panel, and FIG. 2 is a cross-sectional view taken along a cross-sectional line AB in FIG. The drawings are schematic and do not reflect the exact size of the components shown. The repeated portion of the display pixel is omitted and the film configuration is partially simplified. Moreover, in the figure, the same code | symbol is attached | subjected to the component same as what was demonstrated in the previous figure, and the description is abbreviate | omitted. The same applies to the following drawings.

Here, to perform the described liquid crystal panel which is operated using a TFT (T hin F ilm T ransistor ) as an example to the switching element. As shown in FIGS. 1 and 2, the liquid crystal panel 100 includes a color filter substrate 120 that is a first substrate having a display surface 200 for displaying an image, and a color filter substrate 120 on the side opposite to the display surface 200. The switching element substrate 110 which is a second substrate disposed to face the surface, and the sealing material 130 disposed so as to surround a region corresponding to the display surface 200 between the color filter substrate 120 and the switching element substrate 110. The sealing material 130 holds the liquid crystal 140 in a region corresponding to the display surface 200 between the color filter substrate 120 and the switching element substrate 110. In addition, the switching element substrate 110 and the color filter substrate 120 are both rectangular with the direction parallel to the double-headed arrow X1-X2 in FIG. 1 as the longitudinal direction. At least, it is formed by cutting out from a mother substrate having an outer shape larger than the predetermined shape. Further, the end faces of all sides of the switching element substrate 110 are formed so as to protrude from the end faces of the sides of the color filter substrate 120. Further, on the end face of the switching element substrate 110, damage dm such as minute scratches and cracks generated when the switching element substrate 110 is cut out from the mother substrate described above remains, and the sectional view of FIG. As shown, it remains mainly on the surface facing the color filter substrate 120.

  The above-described switching element substrate 110 is provided under the alignment film 112 that aligns the liquid crystal 140 in a region corresponding to the display surface 200 on one surface of the glass substrate 111 that is a transparent substrate, and drives the liquid crystal 140. A pixel electrode 113 to which a voltage is applied, a switching element 114 such as a TFT that supplies a voltage to the pixel electrode 113, an insulating film 115 that covers the switching element 114, a gate wiring 116 that is a wiring that supplies a signal to the switching element 114, and a source wiring 117 Further, outside the region corresponding to the display surface 200, a terminal 118 for receiving a signal supplied to the switching element 114 from the outside, and a transfer electrode for transmitting a signal input from the terminal 118 to the counter electrode (see FIG. (Not shown). In addition, a polarizing plate 131 is provided on the other surface of the glass substrate 111.

  On the other hand, the color filter substrate 120 is disposed under one of the alignment film 122 and the alignment film 122 for aligning the liquid crystal 140 on one surface of the glass substrate 121 that is a transparent substrate, and the pixel electrode 113 on the switching element substrate 110. A common electrode 123 that generates an electric field between them and drives the liquid crystal 140, a color filter 124 provided under the common electrode 123, a light shielding layer 125, and the like. In addition, a polarizing plate 132 is provided on the other surface of the glass substrate 121. For the polarizing plate 132, a polarizing plate made of the same material as the polarizing plate 131 is used.

Further, the switching element substrate 110 and the color filter substrate 120 are bonded to each other through a sealant 130 and a spacer (not shown) that keeps the distance between the substrates constant. As the spacer, a granular spacer dispersed on the substrate may be used, or a columnar spacer formed by patterning a resin on one of the substrates may be used. Further, the transfer electrode and the common electrode 123 are electrically connected by a transfer material (not shown), and a signal input from the terminal 118 is transmitted to the common electrode 123. In addition, the driving IC crystal panel 100 for generating a drive signal (I ntegrated C ircuit) control board 135 equipped with such, FFC for electrically connecting the control board 135 to the terminal 118 (F lexible F lat C able ) 136, a backlight unit serving as a light source (usually disposed opposite to the switching element substrate 110 on the opposite side of the display surface 200, but not shown here) and the like. The surface 200 is housed in a housing (not shown) having an open portion. Further, in order to provide a touch panel function for detecting the relative position on the display surface of the contact object that contacts the display surface, a thin plate-shaped touch panel is provided so as to face the display surface 200 on the inside or outside of the housing. You may arrange | position the sensor part of a mechanism.

  The liquid crystal panel 100 operates as follows. For example, when an electric signal is input from the control substrate 135, a driving voltage is applied to the pixel electrode 113 and the common electrode 123, and the direction of the molecules of the liquid crystal 140 changes according to the driving voltage. The light emitted from the backlight unit is transmitted or blocked to the viewer side through the switching element substrate 110, the liquid crystal 140, and the color filter substrate 120, whereby an image or the like is displayed on the display surface 200 of the liquid crystal panel 100. .

The liquid crystal panel 100 is an example and may have other configurations. Operation mode of the liquid crystal panel 100, TN and (T wisted N ematic) mode, STN (S upper T wisted N ematic) mode, may be such a ferroelectric liquid crystal mode, a driving method may be such as a simple matrix or an active matrix A liquid crystal panel using a horizontal electric field method in which the common electrode 123 provided on the color filter substrate 120 is installed on the switching element substrate 110 side and an electric field is applied to the liquid crystal 140 in the horizontal direction between the pixel electrode 113 may be used. . Moreover, although glass was used as an example for the transparent substrate, other materials such as transparent plastic and quartz may be used as long as they are transparent.

  Further, the transfer material can be substituted by omitting conductive particles or the like in the sealing material 130 and can be omitted. Here, the terminal 118 is provided on two sides of the switching element substrate 110 and the control substrate 135 is connected to each of them. However, as in a small liquid crystal panel, the terminal 118 is provided only on one side, Only the control board 135 may be connected. Further, the driving IC may be arranged on the terminal 118 instead of being connected on the control board 135 so that the terminal of the driving IC is directly connected to the terminal 118. Further, in the sealing material 130, an injection port for injecting liquid crystal is not shown, but when a vacuum injection method in which the liquid crystal is injected from the injection port is used as a liquid crystal injection method, the injection port and the injection port are provided. A sealant for sealing is formed. In addition, in the case of using a dropping injection method in which liquid crystals are arranged in droplets and a substrate is bonded and injected in a vacuum, the injection port and the sealing agent can be omitted.

  Next, a method for manufacturing the liquid crystal panel according to the first embodiment will be described with reference to FIGS. Here, as an example of a method of taking out (manufacturing) multiple liquid crystal panels from a mother substrate having a large area, a case where four liquid crystal panels are taken out from a pair of bonded mother substrates will be described. First, FIG. 3 and FIG. 4 are plan views showing a state before and after a pair of mother substrates are bonded to each other, and FIG. 3A shows the color filter substrate taken out. The mother board 20 as the first mother board and FIG. 3B show the mother board 10 as the second mother board from which the switching element board is taken out.

  As shown in FIG. 3A, the mother substrate 20 has four color filter substrates 120a, 120b, 120c and 120d built therein. Further, for example, in the color filter substrate 120a, as described in the description of the configuration, a common electrode, a color filter, and a light shielding layer for driving the liquid crystal are provided in the display region 220a that is a region corresponding to the display surface when the liquid crystal panel is completed. Etc. are built. Although the illustration and description of the color filter substrates 120b to 120d are omitted, the same configuration as the color filter substrate 120a is formed. In addition, since the common electrode, the color filter, the light shielding layer, and the like can be formed in the same manner as a method for manufacturing a color filter substrate in a general liquid crystal panel, a detailed description of the manufacturing method is omitted.

  As shown in FIG. 3B, the mother substrate 10 is formed with four switching element substrates 110a, 110b, 110c, and 110d. Further, for example, as described in the description of the configuration, the switching element substrate 110a drives the liquid crystal to the terminal 118a that receives a signal from the outside or the display area 210a that is an area corresponding to the display surface when the liquid crystal panel is completed. Pixel electrodes, switching elements, various connection wirings and the like are built in. Although the illustration and description of the switching element substrates 110b to 110d are omitted, the same configuration as that of the switching element substrate 110a is formed. Since the fabrication of these terminals and switching elements may be the same as the manufacturing method of a switching element substrate in a general liquid crystal panel, a detailed description of the manufacturing method is omitted.

  Before being bonded to the mother substrate 20 and the mother substrate 10, an alignment film for aligning liquid crystals, a spacer for keeping the distance between the substrates constant, a transfer electrode for transmitting signals between the substrates, and the like (not shown) ) Is formed. Further, as shown in FIG. 3A, on the mother substrate 20, seal materials 130a to 130d for bonding the respective substrates (the seal materials 130b to 130d are omitted in the drawing) are displayed. The liquid crystal 140 is formed so as to surround the display areas 220a to 220d (the display areas 220b to 220d are not shown in the drawing), and is filled in the sealing materials 130a to 130d. It is formed in the form of droplets in a region surrounded by 130a to 130d. Here, the method of filling the liquid crystal 140 using the dropping injection method is taken as an example, and thus formed, but when the vacuum injection method is used, the sealing materials 130a to 130d are not completely closed. A partially opened inlet is formed. Further, in the vacuum injection method, since the liquid crystal 140 is injected from the injection port after the bonding, the liquid crystal 140 forming process described above is omitted.

  The mother substrate 20 and the mother substrate 10 prepared in this way are the switching element substrate 110a with respect to the color filter substrate 120a, and similarly the switching element substrates 110b to 110d with respect to the color filter substrates 120b to 120d. The substrates are arranged to face each other so as to correspond to each other, and are bonded together by the sealing materials 130a to 130d in a vacuum. In this way, as shown in FIG. 4, the mother substrate 20 and the mother substrate 10 are bonded to each other. In the drawing, for the sake of convenience, the mother substrate 20 and the mother substrate 10 are shown in a slightly displaced state, but this is to show that the mother substrate 10 is disposed under the mother substrate 20, , Aligned and pasted so that they almost completely overlap. Further, by being bonded, the liquid crystal 140 in the form of droplets is uniformly spread and filled in the region surrounded by the respective sealing materials 130a to 130d. In order to reduce the weight of the liquid crystal panel, when the substrate is thinned, a thinning process by chemical treatment or physical polishing is performed in the bonded state.

  Subsequently, a cutting process for cutting out four liquid crystal panels from the bonded mother substrate 20 and mother substrate 10 will be described. In the first embodiment, corresponding to four individual liquid crystal panels, there are two stages: a first cutting process for dividing into four parts, and a second cutting process for forming each divided liquid crystal panel into a final shape. Do it separately. First, the first cutting process of dividing into four will be described with reference to FIGS. 4, 5, and 6.

  5A and 5B show cross-sectional views taken along the cross-sectional line CD and the cross-sectional line EF in FIG. In the figure, in the mother substrate 20 and the mother substrate 10, unnecessary portions 150 in the case where the color filter substrates 120a to 120d and the switching element substrates 110a to 110d are cut out are shown shaded. Usually, the cutting of the glass substrate is performed by forming a cutting flaw as a starting point of cutting on the surface of the glass substrate and then applying a stress in the vicinity of the cutting flaw. In the first embodiment, as shown in the cross-sectional view of FIG. 5, the separation of the mother substrate 20 is performed so that the color filter substrates 120a and 120c and the unnecessary portion 150 are removed so as to remove the shaded unnecessary portion 150 described above. The cut flaw SL1 is formed at the boundary between the color filter substrates 120a and 120b and the unnecessary portion 150. Further, the separation of the mother substrate 10 is not a predetermined shape of the switching element substrates 110a to 110d, but the individual switching element substrates 110a and 110c or the switching element substrates 110a and 110b are separated from each other. 110c or switching element substrate 110a and 110b, a cut flaw SL2 is formed near the middle. Further, as apparent from the drawing, the cut scratches SL1 and SL2 are formed on the mother substrate 10 on the surface opposite to the surface facing the mother substrate 10 with respect to SL1 formed on the mother substrate 20. Is formed on the surface opposite to the surface facing the mother substrate 20, respectively.

FIGS. 6A and 6B are plan views from the mother substrate 20 side showing the positions where the cut flaw SL1 and the cut flaw SL2 are formed, and the positions where the cut flaws are formed. Is indicated by a dotted line. As described above, when the mother substrate 20 is divided, the cut scratch SL1 is formed corresponding to the predetermined shape of the color filter substrates 120a to 120d so that the color filter substrates 120a to 120d are cut into a final shape once. . Further, the division of the mother substrate 10 is not a predetermined shape of the switching element substrates 110a to 110d, but a cut flaw SL2 is generated between the individual switching element substrates 110a to 110d so as to separate the individual switching element substrates 110a to 110d. Is formed. After forming the cut flaw SL1 or SL2 in this way, the substrate is divided along the cut flaw by applying a stress in the vicinity of each cut flaw. As a result, it is divided into four parts corresponding to the four individual liquid crystal panels, and the first cutting step is completed.

  The state after the first cutting step performed as described above will be described with reference to FIGS. FIG. 7 shows one liquid crystal panel corresponding to the color filter substrate 120a and the switching element substrate 110a. FIGS. 8A and 8B are sectional lines GH and sectional lines in FIG. A cross-sectional view at J-K is shown. In addition, since the same applies to the liquid crystal panels corresponding to the color filter substrates 120b to 120d and the switching element substrates 110b to 110d, the description will be omitted, and the following also corresponds to the color filter substrate 120a and the switching element substrate 110a. A liquid crystal panel will be described as an example.

  After the first cutting step, as shown in FIGS. 7 and 8, the color filter substrate 120a is cut into a predetermined shape, and the switching element substrate 110a is placed outside the predetermined shape of the switching element substrate 110a. It is cut so as to have a large outer shape provided with an unnecessary portion 150 (shaded area in the figure). Further, damage such as minute scratches and cracks generated in the first cutting process remains on the end face of the substrate. In the color filter substrate 120a, as shown in FIG. 7, damage dm1 due to the cut scratch SL1 remains on all four sides of the outer shape of the color filter substrate 120a. Further, as shown in the cross-sectional view of FIG. 8, the damage dm1 mainly remains on the surface on the side opposite to the surface facing the switching element substrate 110a on the side where the cut scratch SL1 is formed. On the other hand, in the switching element substrate 110a, as shown in FIG. 7, damage dm2 due to the cut flaw SL2 remains on the two sides on the terminal 118a side where the cut surface of the unnecessary portion 150 provided outside is formed. Further, as shown in the cross-sectional view of FIG. 8, the damage dm2 mainly remains on the surface on the side opposite to the surface facing the color filter substrate 120a on the side where the cut scratch SL2 is formed.

  Further, the unnecessary portion 150 provided outside the switching element substrate 110a can be originally removed by forming the cut scratch SL2 in accordance with the outer shape of the switching element substrate 110a, and the second cutting step is unnecessary. is there. However, in the first embodiment, the cutting obtained by dividing the end face of the switching element substrate 110a after forming a cutting flaw as a starting point of the division on the surface of the mother substrate 10 facing the color filter substrate 120a. It needs to be a face. However, since the surface of the mother substrate 10 that faces the color filter substrate 120a is in the region sandwiched between the mother substrate 20 and the mother substrate 10 that face each other before the first cutting step, it is impossible to form a cut flaw. Therefore, in the first cutting step, the cutting is not performed in a final shape, but is cut into a shape in which an unnecessary portion 150 is provided as a margin for performing the second cutting step outside the switching element substrate 110a.

  In the first cutting step, if the surface of the mother substrate 10 facing the color filter substrate 120a can be exposed, it is possible to form a cut flaw in the second cutting step. From this point, it is not essential to divide the mother substrate 10 in the first cutting step. However, the unnecessary portion 150 located between the color filter substrates 120a to 120d is separated from the color filter substrates 120a to 120d by cutting, but there is almost no gap between the cut color filter substrates 120a to 120d. It is relatively difficult to remove. In the first cutting step, the mother substrate 10 is divided and the respective liquid crystal panels are separated, so that the unnecessary portion 150 separated from the mother substrate 20 can be easily removed.

  Subsequently, the second cutting step will be described with reference to FIG. FIG. 9 is a cross-sectional view of FIG. 8 in which a formation position of a cut flaw formed for the second cutting process is additionally shown. As shown in FIG. 9, in the second cutting step, the unnecessary portion 150 provided outside the switching element substrate 110a is removed and the liquid crystal panel is formed into a final shape, so that the color filter substrate 120a and the unnecessary portion 150 are formed. A cut wound SL3 is formed at the boundary. As apparent from FIGS. 5 and 9, the cut flaw SL3 is a portion of the mother substrate 10 that is exposed by removing the opposing mother substrate 20 in the first cutting step of cutting the color filter substrate 120a, that is, the color filter. It is formed on the surface facing the substrate 120a.

  Further, when forming the cut flaw SL3 from the side facing the color filter substrate 120a, the end face of the switching element substrate 110a is used to prevent interference between the end face of the color filter substrate 120a and the scribe wheel that forms the cut flaw. A cut flaw SL3 was formed at a position protruding from the end face of the color filter substrate 120a. Usually, the portion where the terminal 118a is formed has a structure in which the end face of the switching element substrate 110a protrudes from the end face of the color filter substrate 120a in this way, but the structure where the portion where the terminal 118a is not formed protrudes. It was.

  As described above, after forming the cut wound SL3, by applying stress, the switching element substrate 110a having a predetermined shape is cut out as shown in FIG. 10, and the color filter substrate 120a is cut from the mother substrate 20 and the mother substrate 10. And the cutting process of cutting out the liquid crystal panel corresponding to the switching element substrate 110a is completed. Further, in the liquid crystal panel thus formed, as described with reference to FIG. 9, stress is applied after cutting flaws SL3 are formed on the surface side facing the color filter substrate 120a on all four sides of the switching element substrate 110a. As shown in FIG. 10, damage dm3 due to the cut flaw SL3 remains on the end face, and the damage dm3 is formed on the cut flaw SL3. It remains mainly on the side facing the color filter substrate 120a.

  In this way, after the individual liquid crystal panels are divided so as to have a final shape, the polarizing plate is attached in the polarizing plate attaching step, the control substrate is mounted in the control substrate mounting step, and the color filter substrate 120a in the final assembly step. The liquid crystal panel having the same configuration as that of the liquid crystal panel 100 described with reference to FIGS. 1 and 2 is completed by being housed in an open housing having a display surface portion located on the side.

  In the manufacturing method described above, the first cutting step was divided into four corresponding to the four individual liquid crystal panels, and then the second cutting step was performed separately corresponding to the individual liquid crystal panels. However, the order of partial cutting may be changed without being limited to such a procedure. For example, a strip-like shape in which a plurality of liquid crystal panels are connected in a row by first performing division by the first cutting process and removal of unnecessary portions by the second cutting process only in one direction such as the X direction or the Y direction. After that, in another direction, the separation by the first cutting step and the removal of unnecessary portions by the second cutting step may be sequentially performed. In particular, when a large number of liquid crystal panels are taken out from a set of mother substrates, there is a process that can be processed more efficiently when processed in a strip shape. For example, in the case of injecting the liquid crystal through the injection port, it is more efficient to divide only in the injection direction first, inject the liquid crystal in a strip shape, and then perform the division corresponding to each panel to make the liquid crystal injection process more efficient. Can be implemented. Furthermore, in the case of a configuration in which the terminals are arranged only on one side, it is possible to divide only in the terminal arrangement direction first, and to perform the operation inspection process of the liquid crystal panel in a strip shape, and efficiently perform the operation inspection of the liquid crystal panel. The process can be carried out.

  Next, the operation of the liquid crystal panel according to the first embodiment manufactured by the method as described above will be described with reference to FIG. FIG. 11 shows a state in which the pressure PW is applied to the display surface 200 of the liquid crystal panel 100 of the first embodiment. FIG. 11A is a plan view showing the entire panel, and FIG. FIG. 11B is a sectional view taken along the sectional line LM in FIG.

  As shown in the figure, the liquid crystal panel 100 is housed together with the backlight 162 by a mold frame 160 that is a casing that holds the periphery of the liquid crystal panel 100 and a front frame 161 that is a casing in which the display surface 200 is opened. Has been. Further, normally, in the liquid crystal panel 100, since the portion of the display surface 200 is open to the outside of the housing in this way, pressure is often applied to the display surface 200. In addition, when a touch panel function that detects the relative position on the display surface of the contact object that touches the display surface is given, since a contact object such as a finger or a pen is always in contact with the display surface during use, Similarly, pressure is applied to the display surface 200. 11A and 11B show a state in which the pressure PW is applied to the display surface 200 in the direction of the arrow in the drawing. As shown in FIG. 11B, since the liquid crystal panel 100 normally holds a peripheral portion that is not used for display by the casing, when the pressure PW is applied to the display surface 200, the display surface 200 becomes concave. (The curved state in the figure is emphasized for easy understanding of the curved direction). FIG. 11B shows a cross section in the X direction, but the display surface 200 is similarly curved in the direction of the concave surface in the Y direction. However, as the degree of bending, the X direction which is the longitudinal direction of the switching element substrate 110 shown in FIG.

  Further, in the liquid crystal panel 100 of the first embodiment, as described in the description of the manufacturing method, the damage dm1 at the time of cutting in the color filter substrate 120 is the surface side opposite to the surface facing the switching element substrate 110. The damage dm3 at the time of cutting in the switching element substrate 110 mainly remains on the surface side opposite to the surface facing the color filter substrate 120. When a panel in which damage at the time of cutting remains in such a position is curved in a direction in which the display surface 200 becomes concave due to stress from the display surface 200 side, as can be seen from FIG. Also, the portion of the damage dm1 or damage dm3 mainly remaining is deformed in a compressing direction. The main reason that damage such as a minute scratch or crack grows due to stress is that the scratch or crack grows due to expansion due to tensile stress. Therefore, the damage dm1 or damage dm3 does not grow and is unlikely to cause a decrease in strength with respect to the curvature in the direction in which the display surface 200 becomes concave.

  In the liquid crystal panel 100 of the first embodiment, in the liquid crystal panel that is often curved so that the display surface side is concave, the formation of the substrate end face of the liquid crystal panel is performed on both the color filter substrate and the switching element substrate. This is done by forming a cut flaw from the surface side that becomes concave due to the curvature. Therefore, the main damage caused by the cutting flaws does not remain on the surface that becomes convex due to the curve, thereby preventing a decrease in the glass cracking strength due to the growth of damage such as fine scratches and cracks due to the tensile stress due to the curve. it can. As a result, the durability can be improved and the cost can be reduced without adding other processing steps such as special reinforcement processing to the substrate end face.

  In the liquid crystal panel of the first embodiment, the cut flaw SL3 was formed on all four sides of the switching element substrate 110a on the surface facing the color filter substrate 120a, and was divided. However, since the switching element substrate 110a is a rectangle having a longitudinal direction in one direction, the X direction, which is the longitudinal direction, is greatly curved. Considering this point, only the two sides parallel to the longitudinal direction, which are largely curved sides, may be divided by forming a cut flaw SL3 on the side facing the color filter substrate 120a. In particular, when liquid crystal is injected through the injection port, it is easier for the liquid crystal to be drawn during the injection process when the color filter substrate 120a and the switching element substrate 110a do not protrude at the side where the injection port is disposed. Is desirable.

  A modification of the first embodiment having such a configuration will be described with reference to FIG. Here, the change part from the 1st cutting process demonstrated using FIG. 7 is demonstrated. In this modified example, as shown in FIG. 12, cutting is performed so that the unnecessary portion 150 is left only on two sides parallel to the longitudinal direction, and the remaining two sides are cut at positions where the final shape is obtained. In addition, since it is not necessary to form the cut scratch SL3 from the surface facing the color filter substrate 120a, the end surface of the switching element substrate 110a and the end surface of the color filter substrate 120a are the two sides where the terminal 118a is not disposed. The inlet 131a may be formed in the sealing material 130a on this side. After performing the first cutting step in this way, a cut flaw SL3 is formed from the surface facing the color filter substrate 120, and the unnecessary portion 150 is divided. In such a modified example, even in a liquid crystal panel in which liquid crystal is injected using an injection port, the main side due to cutting flaws is formed on the surface side that becomes convex due to the curve, particularly on two sides parallel to the longitudinal direction that are easily damaged by the curve. Since no damage remains, durability can be improved.

  Further, in the liquid crystal panel of the first embodiment, when the cut scratch SL3 is formed from the side facing the color filter substrate 120a, switching is performed to prevent interference between the end surface of the color filter substrate 120a and the scribe wheel. The end surface of the element substrate 110a is configured to protrude from the end surface of the color filter substrate 120a. However, it is not always necessary to adopt such a configuration. When the cut scratch SL3 is formed from the surface facing the color filter substrate 120a, a scribe wheel having a blade only on one side as shown in FIG. By using WH, even if no protrusion is provided on the end face of the switching element substrate 110a, a cut scar is formed on the surface of the switching element substrate 110a that faces the end face of the color filter substrate 120a from the surface facing the color filter substrate 120a. Can be formed.

  By using such a method, the cut flaw SL3 is formed from the side of the surface facing the color filter substrate 120a on all sides of the switching element substrate 110a without providing a protrusion on the end face of the switching element substrate 110a. Thus, it is possible to obtain a structure having a cut surface. As a result, when a liquid crystal injection method using an injection port is used, the liquid crystal can be easily drawn during the process. Further, regardless of which injection method is used, the external shape of the liquid crystal panel can be minimized and the frame can be narrowed. At the same time, the main damage due to the cutting flaws does not remain on the side of the surface that is convex due to the curvature on all sides, so that the durability can be improved.

Embodiment 2.
In the first embodiment, a liquid crystal panel that is normally used in a flat state and is curved in a direction in which the display surface becomes concave when pressure is applied to the display surface has been described. In the second embodiment, An example of application to a curved liquid crystal panel that is manufactured in a curved state and is used as a curved liquid crystal panel that is always curved, particularly a curved liquid crystal panel that is curved in a direction in which the display surface is concave will be described. .

  14A and 14B are schematic views of a liquid crystal panel according to Embodiment 2 of the present invention, in which FIG. 14A is a perspective view showing the entire liquid crystal panel, and FIG. 14B is a cross-sectional line N- in FIG. A cross-sectional view at P is shown. Only the difference from the liquid crystal panel of Embodiment 1 described with reference to FIGS. 1 and 2 will be described. In addition, about the structure which is common in Embodiment 1 demonstrated in FIG.1 and FIG.2, the same code | symbol is attached | subjected and description is abbreviate | omitted.

  As shown in FIG. 14, the liquid crystal panel 101 according to the second embodiment is different in that the switching element substrate 110 and the color filter substrate 120 are curved and the terminal 118 is formed only on one side. The switching element substrate 110 and the color filter substrate 120 are rectangular with the direction of X1-X2 in the drawing as the longitudinal direction as in the first embodiment, and only two sides parallel to the longitudinal direction are curved and deformed. . The bending direction is curved in a direction in which the surface of the switching element substrate 110 facing the color filter substrate 120 is concave. In addition, the end surfaces of the two sides parallel to the longitudinal direction of the switching element substrate 110 that are curved and deformed protrude beyond the end surface of the color filter substrate 120. Furthermore, a terminal 118 is formed on one side of the two non-curved sides of the switching element substrate 110, and the control board 135 is connected to the switching element substrate 110. The positions of the end face 110 and the end face of the color filter substrate 120 are aligned. In the case of injecting liquid crystal from the injection port, an injection port may be formed in the sealing material 130 on the side where the positions of the end faces are aligned.

  Next, a method for manufacturing the liquid crystal panel 101 of the second embodiment will be described. About the manufacturing method of the liquid crystal panel 101 of this Embodiment 2, it is good to perform a 1st cutting process and a 2nd cutting process in the procedure similar to the modification regarding Embodiment 1 demonstrated using FIG. By performing the first cutting step and the second cutting step in this way, the two sides parallel to the longitudinal direction of the switching element substrate 110 are cut by dividing so as to form a cutting flaw from the side facing the color filter substrate 120. An end surface having a surface is formed. A direction in which the surface facing the color filter substrate 120 is a concave surface so that the two sides parallel to the longitudinal direction of the switching element substrate 110 are deformed by bending after the first cutting step and the second cutting step. The switching element substrate 110 is bent. As for the bending method, a method of holding it in a curved state by a housing may be used, different types of polarizing plates 131 and 132 to be attached are used, and one polarizing plate is heated and expanded in the state of being attached. A method may be used in which the stress balance between the switching element substrate 110, the color filter substrate 120, and the polarizing plates 131 and 132 is broken to be bent. In this manner, the liquid crystal panel 101 of the second embodiment is completed by attaching the polarizing plate, connecting the control board, and storing in the housing. In addition, since the connection of the control board and the like may be the same as the manufacturing method of the liquid crystal panel of the first embodiment, the description thereof is omitted.

  In the liquid crystal panel 101 of the second embodiment, in the liquid crystal panel in which the surface facing the color filter substrate of the switching element substrate is curved in a concave direction, the formation of the substrate end surface of the liquid crystal panel is performed by the color filter substrate and the switching Both of the element substrates are formed by forming cut scratches from the side of the surface that becomes concave due to curvature. Therefore, the main damage caused by cutting flaws does not remain on the convex side due to the curve, thereby preventing the glass crack strength from being lowered due to the growth of damage such as fine scratches and cracks due to the tensile stress due to the curve. it can. As a result, it is possible to improve the durability and reduce the cost of the curved liquid crystal panel without adding other processing steps. In addition, as for the parts common to the configuration or the manufacturing method described in the first embodiment or the modification of the first embodiment, the curved liquid crystal panel 101 of the second embodiment is also the first embodiment or the first embodiment. The same effect as that of the first modification can be obtained.

  In the second embodiment, a curved liquid crystal panel in which the substrate is a rectangle having a longitudinal direction in one direction and the curved direction is a direction in which two sides parallel to the longitudinal direction are deformed is taken as an example. I explained. However, the effects of the present invention are not limited to such a configuration. For example, when the substrate shape is not such a shape, or when the position of the end face that causes deformation differs on the end face of the substrate, the formation of the end face of the color filter substrate and the end face of the switching element substrate that is deformed by bending The same effect as that of the second embodiment can be obtained by forming a cutting flaw from the surface side that becomes concave due to bending.

Embodiment 3.
In the second embodiment, among the curved liquid crystal panels, a curved liquid crystal panel that is curved in a direction in which the display surface is concave has been described. However, in the third embodiment, the display surface is convex. An application example to a curved liquid crystal panel curved in a direction will be described.

  15A and 15B are schematic views of the liquid crystal panel according to Embodiment 3 of the present invention. FIG. 15A is a perspective view showing the entire liquid crystal panel, and FIG. 15B is a cross-sectional line Q- in FIG. A cross-sectional view at R is shown. Here, only differences from the liquid crystal panel of the second embodiment described with reference to FIG. 14 will be described. In addition, about the structure which is common in Embodiment 2 demonstrated in FIG. 14, the same code | symbol is attached | subjected and description is abbreviate | omitted.

  In the liquid crystal panel 102 according to the third embodiment, as shown in FIG. 15, the switching element substrate 110 and the color filter substrate 120 are curved in the direction opposite to that of the second embodiment, and the color filter substrate 120 is curved. The difference is that the end face of the side deformed by the protrusion protrudes from the end face of the switching element substrate 110. The switching element substrate 110 and the color filter substrate 120 are rectangular with the direction of X1-X2 in the drawing as the longitudinal direction as in the second embodiment, and only two sides parallel to the longitudinal direction are curved and deformed. . The bending direction is curved in the direction opposite to that of the second embodiment, that is, the direction in which the surface facing the switching element substrate 110 as the first substrate of the color filter substrate 120 as the second substrate is a concave surface. In the third embodiment, the end surfaces of the two sides parallel to the longitudinal direction of the color filter substrate 120 that is curved and deformed protrude from the end surface of the switching element substrate 110. Similarly to the second embodiment, the terminal 118 is formed on one side of the two uncurved sides of the switching element substrate 110 and the control board 135 is connected, and the other terminal 118 is not disposed. In the side, the end face of the switching element substrate 110 and the end face of the color filter substrate 120 are aligned. In the case of injecting liquid crystal from the injection port, an injection port may be formed in the sealing material 130 on the side where the positions of the end faces are aligned.

  Next, a method for manufacturing the liquid crystal panel 102 according to the third embodiment will be described. About the manufacturing method of the liquid crystal panel 101 of this Embodiment 3, the changed part from the manufacturing method of the liquid crystal panel of Embodiment 1 is demonstrated. First, the change part from the 1st cutting process demonstrated using FIGS. 5-8 is demonstrated using FIG.16 and FIG.17. FIG. 16 shows one liquid crystal panel corresponding to the color filter substrate 120a and the switching element substrate 110a after the first cutting step, and FIGS. 17A and 17B are cross-sectional views in FIG. Sectional drawing in ST and sectional line UV is shown.

  The direction in which the cut flaw is formed in the first cutting step is the surface opposite to the surface facing the mother substrate 10 for SL1 formed on the mother substrate 20 as in the first embodiment described with reference to FIG. On the side, SL2 formed on the mother substrate 10 is formed on the surface side opposite to the surface facing the mother substrate 20, respectively. As for the cutting position, as shown in FIGS. 16 and 17 after the first cutting step, the switching element substrate 110a is cut into a predetermined shape, and the color filter substrate 120a is a color filter substrate. The predetermined shape of 120a is cut so as to have a large outer shape in which unnecessary portions 150 (shaded areas in the figure) are provided outside two sides parallel to the longitudinal direction of the color filter substrate 120a. Further, damage such as minute scratches and cracks generated in the first cutting process remains on the end surfaces of the respective substrates. In the color filter substrate 120a, as shown in FIG. 16, two sides perpendicular to the longitudinal direction of the color filter substrate 120a and a cut surface of the unnecessary portion 150 provided outside the color filter substrate 120a are formed on the Y direction positive side. The damage dm1 due to the cut wound SL1 remains in Further, as shown in the cross-sectional view of FIG. 17, the damage dm1 mainly remains on the surface on the side opposite to the surface facing the switching element substrate 110a on the side where the cut scratch SL1 is formed. On the other hand, in the switching element substrate 110a, as shown in FIG. 16, damage dm2 due to the cut wound SL2 remains on all four sides of the outer shape of the switching element substrate 110a. In addition, as shown in the cross-sectional view of FIG. 17, the damage dm2 mainly remains on the surface on the side opposite to the surface facing the color filter substrate 120a on the side where the cut scratch SL2 is formed.

  In the subsequent second cutting step, the unnecessary portion 150 provided outside the color filter substrate 120a is removed, and the liquid crystal panel is formed into a final shape, so that it is cut at the boundary between the color filter substrate 120a and the unnecessary portion 150. A wound SL3 is formed. The cut flaw SL3 is formed on the mother substrate 20 on the surface facing the switching element substrate 110a.

  As described above, after the cut scratch SL3 is formed, the color filter substrate 120a having a predetermined shape is cut out by applying stress, and the color filter substrate 120a and the switching element substrate 110a are supported by the mother substrate 20 and the mother substrate 10. The cutting process for cutting out the liquid crystal panel is completed. In the liquid crystal panel thus formed, as described with reference to FIG. 17, after the cut scratch SL3 is formed on the surface facing the switching element substrate 110a on two sides parallel to the longitudinal direction of the color filter substrate 120a. The end face has a cut surface divided by applying stress, and damage due to the cut flaw SL3 remains on the end face, and the damage caused by the cut flaw SL3 is on the side where the cut flaw SL3 is formed. It remains mainly on the surface facing the certain switching element substrate 110a.

  After performing the first cutting step and the second cutting step, a direction in which the surface facing the switching element substrate 110a is a concave surface so that the two sides parallel to the longitudinal direction of the color filter substrate 120a are deformed by bending, That is, the color filter substrate 120a is bent in a direction in which the display surface side is a convex surface. In this manner, the liquid crystal panel 102 of the third embodiment is completed by attaching the polarizing plate, connecting the control board, bending the board, and storing the board in the housing. Since these steps may be the same as those of the liquid crystal panel manufacturing method of the second embodiment, description thereof is omitted.

  In the liquid crystal panel 102 according to the third embodiment, in the liquid crystal panel curved in a direction in which the surface facing the switching element substrate of the color filter substrate is concave, the longitudinal direction of the color filter substrate which is an end surface that is deformed by the curvature With respect to the end faces of two sides parallel to each other, the substrate end face of the liquid crystal panel is formed by forming a cut flaw from the side of the face that becomes concave due to curvature in both the color filter substrate and the switching element substrate. Therefore, the main damage caused by cutting flaws does not remain on the convex side due to the curve, thereby preventing the glass crack strength from being lowered due to the growth of damage such as fine scratches and cracks due to the tensile stress due to the curve. it can. As a result, it is possible to improve the durability and reduce the cost of the curved liquid crystal panel without adding other processing steps. In addition, as for the parts common to the configuration or the manufacturing method described in the first embodiment, the modified example of the first embodiment, or the second embodiment, the curved liquid crystal panel 102 of the third embodiment also has the same configuration as the first embodiment. 1. The same effect as the modification of the first embodiment or the second embodiment can be obtained.

  In the first embodiment, the modified example of the first embodiment, the second embodiment, and the third embodiment, there is a feature in the method of forming the cut flaw, and therefore, the vicinity of the cut flaw performed after the cut flaw is formed. Although the stress application method is not specifically described, a method in which a plate-shaped break jig is pressed and applied, a method in which stress is applied by heat using a laser, or the like can be appropriately used.

It is a top view of the liquid crystal panel in Embodiment 1 of this invention. It is sectional drawing of the liquid crystal panel in Embodiment 1 of this invention. It is the schematic plan view which showed the mother board | substrate in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic plan view which showed the mother board | substrate in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic sectional drawing which showed the cut | disconnection flaw formation position of the 1st cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic plan view which showed the cutting-scratch formation position of the 1st cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic plan view which showed the 1st cutting process after the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic sectional drawing which showed the 1st cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic plan view which showed the cutting-scratch formation position of the 2nd cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic sectional drawing which showed the 2nd cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic explaining the effect | action of the liquid crystal panel of Embodiment 1 of this invention. It is the schematic plan view which showed the 1st cutting process after the manufacturing process of the liquid crystal panel of the modification of Embodiment 1 of this invention. It is the schematic sectional drawing which showed the modification of the 2nd cutting process in the manufacturing process of the liquid crystal panel of Embodiment 1 of this invention. It is the top view and sectional drawing of a liquid crystal panel in Embodiment 2 of this invention. It is the top view and sectional drawing of a liquid crystal panel in Embodiment 3 of this invention. It is the schematic plan view which showed the 1st cutting process after the manufacturing process of the liquid crystal panel of Embodiment 3 of this invention. It is the schematic sectional drawing which showed the 1st cutting process in the manufacturing process of the liquid crystal panel of Embodiment 3 of this invention.

Explanation of symbols

10, 20 Mother board, 100, 100a to 100d, 101, 102 Liquid crystal panel,
110, 110a-110d switching element substrate,
120, 120a to 120d color filter substrate,
130,130a Sealing material, 140 liquid crystal, 150 Cut off,
200 Display surface, SL1-SL3 Cut wound.

Claims (8)

A first substrate having a display surface for displaying an image; a second substrate disposed opposite to the surface of the first substrate opposite to the display surface; the first substrate and the second substrate; A liquid crystal panel provided with a sealing material disposed so as to surround a region corresponding to the display surface between substrates and sandwiching liquid crystal in the region;
At the end surface of the second substrate, a cutting that becomes a starting point of the division on the surface facing the first substrate when the second substrate is cut into a predetermined shape from the mother substrate from which the second substrate is taken out A liquid crystal panel having a cut surface that is divided by applying a stress after forming a flaw.   The predetermined shape from which the second substrate is cut out is a rectangle having a longitudinal direction in one direction, and the end surface of two sides parallel to the longitudinal direction of the second substrate has the second substrate from the mother substrate. A cutting surface that is divided by applying stress after forming a cutting flaw as a starting point of the dividing on a surface side facing the first substrate when cutting the substrate into a predetermined shape is provided. 1. A liquid crystal panel according to 1.   The liquid crystal panel according to claim 1, further comprising a touch panel mechanism that detects a relative position on the display surface of a contact object that contacts the display surface. A first substrate; a second substrate disposed opposite the first substrate; and an area corresponding to the display surface between the first substrate and the second substrate. A curved liquid crystal panel that is curved in a direction in which a surface of the second substrate facing the first substrate is a concave surface.
In the end surface that is deformed by the curvature of the second substrate,
When the second substrate is cut into a predetermined shape from the mother substrate from which the second substrate is taken out, a stress is applied after forming a cutting flaw as a starting point of the division on the surface facing the first substrate. A liquid crystal panel characterized by having a cut surface divided by.   5. The cut surface formed by dividing the cut surface on the surface of the second substrate facing the first substrate and being divided protrudes from the end surface of the first substrate. A liquid crystal panel according to any one of the above. A first substrate having a display surface for displaying an image; a second substrate disposed opposite to the surface of the first substrate opposite to the display surface; the first substrate and the second substrate; A method of manufacturing a liquid crystal panel comprising a sealing material disposed so as to surround a region corresponding to the display surface between substrates and sandwiching liquid crystal in the region,
Bonding the first mother substrate for taking out the first substrate and the second mother substrate for taking out the second substrate opposite to each other by the sealing material; and the second mother substrate. The first mother substrate is divided by applying stress after forming a cutting flaw that is a starting point of the division on the surface opposite to the surface facing the mother substrate, so that the first mother substrate has a predetermined shape. Cutting out the first substrate;
By applying a stress after forming a cutting flaw that becomes a starting point of the division in the second mother substrate in the portion exposed by removing the first mother substrate facing the first substrate by the step of cutting out the first substrate, Cutting the second mother substrate from the second mother substrate, including a step of cutting the second mother substrate, and cutting out a second substrate of a predetermined shape having a cut surface by the cutting at the end surface;
A method for producing a liquid crystal panel, comprising: The first mother substrate and the second mother substrate are bonded to each other with a sealant, and the first mother substrate is divided into a surface opposite to the surface facing the second mother substrate. A step of dividing the first mother substrate by applying stress after forming a cutting flaw as a starting point and cutting out a first substrate of a predetermined shape from the first mother substrate;
By applying a stress after forming a cutting flaw that becomes a starting point of division on the second mother substrate in the portion exposed by removing the first mother substrate facing the first substrate by the step of cutting out the first substrate, Cutting the second mother substrate from the second mother substrate, including a step of cutting the second mother substrate, and cutting out a second substrate of a predetermined shape having a cut surface by the cutting at the end surface;
The second substrate is placed on the second substrate in such a manner that an end surface of the second substrate having a cut surface formed by cutting that forms a cutting flaw as a starting point of cutting on the surface facing the first substrate is deformed by bending. A step of bending in a direction in which a surface facing one substrate becomes a concave surface;
A method for producing a liquid crystal panel, comprising: The step of cutting out the second substrate of a predetermined shape from the second mother substrate,
A stress is applied to the second mother substrate by applying stress after forming a cutting flaw as a starting point of the division on the surface of the second mother substrate opposite to the surface facing the first mother substrate. The step of dividing into a shape provided with a cutting margin outside the second substrate of the shape,
A stress is applied after forming a cutting flaw that becomes a starting point of division in the exposed portion of the first mother substrate that is removed by the step of cutting out the first substrate of the second mother substrate that is performed thereafter. Cutting the second mother substrate to remove the cutting margin;
A method for manufacturing a liquid crystal panel according to claim 6 or 7, comprising:

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