JP2010204186A - Apparatus, and method for manufacturing color filter, coating device and coating method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus for manufacturing color filter capable of efficiently applying ink while suppressing unevenness of coating amount of ink among pixel areas. <P>SOLUTION: The manufacturing apparatus 10 has an ejection means 20 for applying ink to each pixel area of a substrate 40 while relatively moving only in one direction for the substrate 40. One nozzle group is configured from a plurality of nozzles arrayed side by side in other directions intersecting the one direction. The ejection means includes a plurality of nozzle groups arranged separately in one direction. When relatively moving in one direction, at least two nozzles belonging to different nozzle groups pass through positions facing respective pixel areas. The ink is ejected from at least two nozzles to one pixel area during one time scanning of the ejection means for the substrate and the ink coating to the one pixel area is completed with one time scanning. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a color filter manufacturing apparatus, a color filter manufacturing method, a coating apparatus, and a coating method. More specifically, the present invention relates to an inkjet color filter manufacturing apparatus and a color filter manufacturing method, and an inkjet application apparatus and application method.

  In recent years, with the spread of personal computers and mobile phones, there has been a demand for high-definition and light-weight display devices. The display device is, for example, an LCD (Liquid Crystal Display Panel), a PDP (Plasma Display Panel), or an organic EL (Electro Luminescent Display). In these display devices, so-called color filters can be incorporated as constituent members.

  Various methods such as an inkjet method, a dyeing method, a pigment dispersion method, an electrodeposition method, and a printing method are known as methods for forming a colored layer in a color filter. For example, as disclosed in Patent Document 1, in the ink jet method, ink is applied to an ink receiving layer patterned on a substrate or an opening provided by a light shielding portion on the substrate. As a result, a colored layer is formed.

However, when the colored layer is formed using the ink jet method, there may be a problem in that the amount of ink applied to the pixel regions varies and the chromaticity and luminance differ between pixel regions (colored layers).
JP 2002-221617 A

  According to the coating method disclosed in Patent Document 1, a head that supports a plurality of nozzles arranged in a row is arranged with respect to a substrate only in a main scanning direction perpendicular to the nozzle arrangement direction with respect to the base material. Instead of moving, it also moves relative to the substrate in the sub-scanning direction perpendicular to the main scanning direction. As a result, ink is applied to the same pixel area from different nozzles for each scanning in the main scanning direction. According to such a method, even if the amount of liquid droplets discharged from the nozzles varies from nozzle to nozzle, it is caused by variations in the amount of liquid droplets discharged from each nozzle. The difference in ink application amount can be dispersed and alleviated.

  However, in the method disclosed in Patent Document 1, the head that supports the nozzle scans the substrate a plurality of times, and the color filter cannot be manufactured efficiently. In recent years, there has been an increasing demand for cost reduction of display devices. And since the manufacturing cost of a color filter will occupy a comparatively big ratio among the total manufacturing costs of a display apparatus, reduction of the manufacturing cost of a color filter is also a very important subject now.

  The present invention has been made in consideration of such points, and a color filter manufacturing apparatus capable of efficiently applying ink while suppressing variations in the amount of ink applied between pixel regions, and An object is to provide a method for manufacturing a color filter. Further, in recent years, there has been a demand for further thinning of display devices, and it is not limited to a highly rigid substrate such as glass, and a color filter is manufactured using a thin film-like resin base material. Is being considered. Therefore, it is very convenient if the manufacturing apparatus and the manufacturing method according to the present invention can be suitably applied to such a thin substrate.

  In addition, the present invention provides a coating apparatus and a coating method capable of efficiently coating ink while suppressing variations in coating amount between predetermined regions without being limited to the manufacture of a color filter. For the purpose.

  An apparatus for manufacturing a color filter according to the present invention includes a discharge unit that applies ink to each pixel region of the base material while relatively moving in one direction with respect to the base material including a plurality of pixel regions. A plurality of nozzles that eject the same ink, and a plurality of nozzles arranged side by side in the other direction that intersects the one direction among the nozzles that eject the same ink constitute one nozzle group The ejection unit includes a plurality of nozzle groups arranged separately in the one direction, and each pixel included in the base material when the ejection unit and the base material relatively move in the one direction. At least two nozzles belonging to different nozzle groups pass through the position facing the region, and one image from the at least two nozzles is scanned during one scan of the discharge means with respect to the substrate. Ink is ejected for the region, characterized in that the ink application to the single pixel region is completed in the single scan.

  In the color filter manufacturing apparatus according to the present invention, the number of nozzles included in each nozzle group is the same among the nozzle groups, and a plurality of nozzles included in one nozzle group are included in other nozzle groups. It may be arranged at a position shifted from the plurality of nozzles in the one direction.

  Further, in the color filter manufacturing apparatus according to the present invention, the plurality of nozzles included in each nozzle group are arranged in the other direction over the entire range facing the pixel region to be coated with the ink of the base material. Thus, the application of ink to the substrate may be completed by a single scan of the ejection unit with respect to the substrate.

  Furthermore, in the color filter manufacturing apparatus according to the present invention, each nozzle group is configured as a separate nozzle head, and at least two nozzles belonging to different nozzle groups are one, regardless of the inclination angle of the other direction to the one direction. It may be arranged in a direction.

  Furthermore, the color filter manufacturing apparatus according to the present invention further includes a transport device that transports the base material, and the transport device includes a supply unit and a recovery unit that are spaced apart from each other in the one direction. The application of ink to the base material may be completed while the material advances in the one direction between the supply unit and the recovery unit.

  The color filter manufacturing method according to the present invention is a discharge unit having a plurality of nozzle groups spaced in one direction, and each nozzle group includes a plurality of nozzles arranged side by side in the other direction intersecting the one direction. In a method of manufacturing a color filter by applying ink to a substrate including a plurality of pixel regions using an ejection unit, while relatively moving the ejection unit and the substrate in the one direction. A step of discharging the same ink from the nozzles included in the discharge unit and applying the ink to the pixel region of the base material. In the step of applying the ink, Ink is ejected from at least two nozzles to one pixel area during scanning, and ink application to the one pixel area is completed in one scan. And butterflies.

  In the color filter manufacturing method according to the present invention, the number of nozzles used for applying ink to one pixel region may be the same between the pixel regions.

  In the color filter manufacturing method according to the present invention, the number of droplets ejected from the at least two nozzles used for applying ink to one pixel region may be the same.

  Further, the method of manufacturing a color filter according to the present invention sets the number of ink droplets to be ejected to each pixel area for each of the at least two nozzles used for applying ink to each pixel area. In the step of applying the ink, the ink is ejected from each of the at least two nozzles by the number of droplets set in the step of setting the number of droplets of the ink for the nozzle. You may make it do.

  In such a method of manufacturing a color filter according to the present invention, in the step of setting the number of ink droplets, the amount of droplets of one droplet of ink ejected from each nozzle is a droplet according to the specifications of the nozzle. The amount of ink to be ejected to each pixel region so that the total amount of the ink ejected from the at least two nozzles is the target amount of ink to be applied to each pixel region. The number of drops may be calculated for each of the at least two nozzles.

  Alternatively, in the color filter manufacturing method according to the present invention, in the step of setting the number of ink droplets, the amount of droplets discharged from each nozzle measured in advance is considered, The number of ink droplets to be ejected to each pixel region is such that the total amount of ink ejected from at least two nozzles is a target amount of ink to be applied to each pixel region. It may be calculated for each of the above.

  Alternatively, in the method for manufacturing a color filter according to the present invention, the step of setting the number of ink droplets may be performed in consideration of a target amount of ink to be applied to each pixel region. For each of the at least two nozzles used for coating, setting a standard number of droplets of ink to be ejected to each pixel area; and from each of the at least two nozzles, the standard for the nozzle A step of discharging ink by the number of standard droplets set in the step of setting the number of droplets and measuring the total amount of ink discharged from the at least two nozzles as a standard ink amount, and each nozzle measured in advance Taking into account the amount of one droplet discharged from the nozzle and the measured standard ink amount, the number of the standard droplets set for each of the nozzles is increased or decreased, The number of ink droplets to be ejected to each pixel region is such that the total amount of ink ejected from at least two nozzles is a target amount of ink to be applied to each pixel region. And a step calculated for each of the above. In this color filter manufacturing method, in the step of setting the standard number of droplets of ink, the amount of droplets of one droplet of ink ejected from each nozzle is a droplet amount according to the specifications of the nozzle. Assuming that the total amount of ink ejected from each of the at least two nozzles by the number of standard droplets for that nozzle is the target amount of ink to be applied to each pixel area In addition, the standard droplet number may be calculated for each of the at least two nozzles.

  An application apparatus according to the present invention includes an ejection unit that applies ink to each predetermined region of the base material while relatively moving in one direction with respect to the base material including a plurality of predetermined regions. A plurality of nozzles for ejecting ink and a plurality of nozzles arranged side by side in the other direction intersecting the one direction among the nozzles for ejecting the same ink constitute one nozzle group, and the ejection The means includes a plurality of nozzle groups spaced apart in the one direction, and faces each predetermined region included in the base material when the discharge means and the base material move relative to each other in the one direction. At least two nozzles belonging to different nozzle groups pass through the position where the discharge is performed, and the at least two nozzles perform scanning with respect to one predetermined region during one scan of the discharge means with respect to the base material. Click is ejected, the ink applied to the one predetermined region is equal to or be completed with a single scan.

  In the coating apparatus according to the present invention, the number of nozzles included in each nozzle group is the same among the nozzle groups, and a plurality of nozzles included in one nozzle group includes a plurality of nozzles included in another nozzle group. You may arrange | position in the position shifted | deviated from the nozzle to the said one direction.

  Further, in the coating apparatus according to the present invention, the plurality of nozzles included in each nozzle group is arranged in the other direction over the entire range facing the predetermined area to which the ink of the base material is to be applied. Thus, the ink application to the base material may be completed by a single scan of the ejection unit with respect to the base material.

  Furthermore, in the coating apparatus according to the present invention, each nozzle group is configured as a separate nozzle head, and at least two nozzles belonging to different nozzle groups are arranged in one direction regardless of the inclination angle of the other direction to the one direction. You may be made to be able to be.

  Furthermore, the coating apparatus according to the present invention further includes a transport device that transports the base material, and the transport device has a supply unit and a recovery unit that are spaced apart in the one direction, and the base material is You may make it complete | finish the application of the ink to the said base material, advancing in the said one direction between a supply part and the said collection | recovery part.

  The coating method according to the present invention is a discharge unit having a plurality of nozzle groups spaced in one direction, and each nozzle group includes a plurality of nozzles arranged side by side in the other direction intersecting the one direction. In a method of applying ink to a substrate including a plurality of predetermined regions using a discharge unit, the same is performed from a nozzle included in the discharge unit while relatively moving the discharge unit and the substrate in the one direction. A step of ejecting ink and applying the ink to a predetermined region of the base material, wherein in the step of applying the ink, at least two nozzles perform one predetermined scan during one scan of the discharge means with respect to the base material. Ink is ejected to the region, and ink application to the one predetermined region is completed by the one scanning.

  In the coating method according to the present invention, the number of nozzles used to apply ink to one predetermined area may be the same between the predetermined areas.

  Further, in the coating method according to the present invention, the number of droplets ejected from the at least two nozzles used for coating the ink on one predetermined region may be the same.

  Further, the coating method according to the present invention further includes a step of setting the number of ink droplets to be ejected to each predetermined region for each of the at least two nozzles used for applying the ink to each predetermined region. And in the step of applying the ink, the ink is ejected from each of the at least two nozzles by the number of droplets set in the step of setting the number of droplets of the ink for the nozzle. May be.

  In the step of setting the number of ink droplets of the coating method according to the present invention, the droplet amount of one droplet of ink ejected from each nozzle is the droplet amount according to the specification of the nozzle. Assuming that the total number of inks ejected from the at least two nozzles is a target amount of ink to be applied to each predetermined region, the number of ink droplets to be ejected to each predetermined region is It may be calculated for each of at least two nozzles.

  Alternatively, in the step of setting the number of ink droplets of the coating method according to the present invention, the at least two nozzles are considered in consideration of the droplet amount of one droplet ejected from each nozzle measured in advance. The number of ink droplets to be ejected to each predetermined region is such that the total amount of ink ejected from each of the at least two nozzles is the target amount of ink to be applied to each predetermined region. May be calculated as follows.

  Alternatively, in the step of setting the number of ink droplets of the coating method according to the present invention, the ink application to each predetermined region is performed in consideration of the target amount of ink to be applied to each predetermined region. Setting the standard number of droplets of ink to be ejected to each of the predetermined areas for each of the at least two nozzles used in the process, and from each of the at least two nozzles to the standard liquid A step of ejecting ink by the number of standard droplets set in the step of setting the number of droplets and measuring the total amount of ink ejected from the at least two nozzles as a standard ink amount; and from each nozzle measured in advance Considering the amount of one droplet to be ejected and the measured standard ink amount, the number of the standard droplets set for each of the nozzles is increased or decreased, and the at least two The number of ink droplets to be ejected to each predetermined region is such that the total amount of the ink ejected from each nozzle is the target amount of ink to be applied to each predetermined region. May be included. In the step of setting the standard number of droplets of the ink in this coating method, assuming that the droplet amount of one droplet of ink ejected from each nozzle is the droplet amount according to the specification of the nozzle, When the ink is ejected from each of at least two nozzles by the number of standard droplets corresponding to the nozzle, the total amount of ink ejected is the target amount of ink to be applied to each predetermined region. The number of droplets may be calculated for each of the at least two nozzles.

  Furthermore, in the coating method according to the present invention, the plurality of predetermined regions may be arranged on the substrate such that two adjacent predetermined regions overlap each other at the end portions.

  According to the present invention, it is possible to efficiently apply ink to a predetermined area while suppressing variation in the amount of ink applied between the predetermined areas such as the pixel area.

  Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. In the embodiment described below, as an example, the present invention includes a color filter manufacturing apparatus and a color filter manufacturing method for manufacturing a color filter by applying ink to predetermined pixel regions of a film-like substrate. Apply the invention.

  In the following description and the accompanying drawings, components having substantially the same functional configuration are denoted by the same reference numerals, and redundant description is omitted.

[Configuration of color filter manufacturing equipment]
First, the configuration of the color filter manufacturing apparatus 10 will be described with reference to FIG. FIG. 1 is a diagram schematically showing the configuration of the color filter manufacturing apparatus 10. The color filter manufacturing apparatus 10 includes a support device 15 that supports a substrate 40 to be processed, and an ejection unit (inkjet head) that includes a number of nozzles 21 that eject ink toward the substrate 40 supported by the support device 15. 20.

  As shown in FIG. 1, the color filter manufacturing apparatus 10 includes a transport device that transports the base material 40, and an alignment camera 18 that detects the position coordinates of the base material 40 supported by the support device 15. In addition. The transport device 40 includes a supply unit 26 that supplies the base material 40 to the support device 15, and a recovery unit 27 that recovers the base material 40 from the support device 15. Furthermore, the color filter manufacturing apparatus 10 further includes a control device 12 that is electrically connected to the alignment camera 18, the ejection unit 20, and the transport device 25 and controls the operation of these components.

  Such a color filter manufacturing apparatus 10 is an apparatus for manufacturing a color filter by applying ink to the substrate 40 in a predetermined pattern by discharging ink from the nozzles 21 of the discharge means 20. More specifically, the color filter manufacturing apparatus 10 according to the present embodiment, as shown in FIG. 2, has each pixel region 45 provided by the light shielding portion 41 of the base material 40 having the light shielding portions 41 having a lattice pattern. On the other hand, a color filter is manufactured by applying red, green and blue inks. The pixel arrangement of the color filter shown in FIG. 2 is a so-called stripe arrangement.

  Hereinafter, each component of the color filter manufacturing apparatus 10 will be described in further detail.

  First, the transport device 25 will be described. As described above, the transport device 25 includes the supply unit 26 that supplies the base material 40 and the recovery unit 27 that recovers the base material 40. In the present embodiment, the base material 40 transported by the transport device 25 is a thin film extending in a strip shape, preferably a film having flexibility enough to be wound up as shown in FIG. It is formed by forming the light shielding part 41. In the example shown in FIG. 1, the supply unit 26 of the transport device 25 has a supply core 26 a that winds up the base material 40, and the film-like base material 40 is wound around the supply core 26 a in a roll shape. Can be retained. Similarly, the collection unit 27 of the transport device 25 has a collection core 27 a that winds up the color filter 50 formed by applying ink to the base material 40. And the color filter 50 can be hold | maintained in the state wound up by the collection | recovery core 27a at roll shape.

  Further, as shown in FIG. 1, the transport device 25 has a drive device 28 mechanically coupled to the supply core 26a and the recovery core 27a. The drive device 28 is electrically connected to the control device 12 and rotationally drives the supply core 26 a and the recovery core 27 a based on control from the control device 12. Then, the supply core 26 a and the collection core 27 a are driven to rotate, whereby the base material 40 is supplied from the supply unit 26 and is collected by the collection unit 27 via the support device 15.

  Next, the support device 15 and the alignment camera 18 will be described in detail. As shown in FIG. 1, the support device 15 in the present embodiment is configured as a support stage disposed between the supply unit 26 and the recovery unit 27 of the transport device 25. A guide roller 26 for guiding the base material 40 supplied from the supply unit 26 to the support stage 15 is disposed between the supply unit 26 and the support stage 15 of the transport device 25. Similarly, a guide roller 26 for guiding the base material 40 supplied from the recovery unit 27 to the recovery unit 27 is also disposed between the recovery unit 27 and the support stage 15 of the transport device 25.

  The alignment camera 18 images the base material 40 on the support stage 15. The alignment camera 18 is electrically connected to the control device 12, and the imaging result of the alignment camera 18 is transmitted to the control device 12. In the control device 12, for example, the position coordinates of the base material 40 are detected on the support stage 15 on the basis of a predetermined portion (such as an alignment mark formed on the base material 40) of the base material 40 imaged by the alignment camera 18. .

  The control device 12 controls the transport device 25 based on the specified position coordinates of the base material 40. Thereby, the base material 40 is transported along one direction connecting the supply unit 26 and the recovery unit 27 of the transport device 25 in a stretched state and in a state of being accurately positioned with respect to the support stage 15. Become so.

  Next, the discharge means 20 will be described in detail. The ejection unit 20 is configured to apply ink to each pixel region 45 of the substrate 40 while moving relative to the substrate 40 including the plurality of pixel regions 45.

  The color filter manufacturing apparatus 10 includes a discharge unit 20 that discharges red ink, a discharge unit that discharges green ink, and a discharge unit that discharges blue ink. Each ejection unit has a number of nozzles 21 that eject the same ink. The three discharge means 20 are arranged side by side in the transport direction of the base material 40 on the support stage 15, that is, in one direction described above (see FIG. 2). Note that the three ejection units have the same configuration, although the ejected inks are different. Therefore, in the following description, the discharge means 20 for discharging red ink will be taken as a representative example, and in the drawings, the discharge means for discharging green ink and the discharge means for discharging blue ink are omitted.

  FIG. 2 is a plan view showing the arrangement position of the nozzle 21 with respect to the stage surface of the support stage 15 together with the base material 40 supported on the support stage 15. As shown in FIG. 2, the ejection unit 20 includes a plurality of nozzle groups arranged along the transport direction (one direction described above) of the base material 40 on the support stage 15. In the illustrated example, a total of four nozzle groups including the first nozzle group N-G1, the second nozzle group N-G2, the third nozzle group N-G3, and the fourth nozzle group N-G4 are arranged on the support stage 15. Are arranged along the transport direction (the one direction) of the base material 40.

  As shown in FIG. 2, each of the nozzle groups N-G1 to N-G4 is composed of a large number of nozzles 21 arranged side by side. In the present embodiment, the arrangement direction of the multiple nozzles 21 included in each group is in the other direction that intersects (for example, is orthogonal to) the one direction on the stage surface of the support stage 40, as shown in FIG. Along.

  FIG. 3 is a cross-sectional view along the other direction of the ejection unit 20 that passes through the first nozzle group NG1. As shown in FIG. 3, the first nozzle group N-G1 has a large number (n) of nozzles N-G1-1 to N-G1-n arranged at equal intervals along the other direction. . In addition, although illustration is abbreviate | omitted, 2nd nozzle group N-G2, 3rd nozzle group N-G3, and 4th nozzle group N-G4 are also comprised similarly to 1st nozzle group N-G4. Therefore, the number of nozzles 21 included in each nozzle group N-G1 to N-G4 is the same between the nozzle groups. In addition, the plurality of nozzles 21 included in one nozzle group are arranged at positions shifted in the one direction from the plurality of nozzles 21 included in the other nozzle group.

  As shown in FIG. 3, the ejection unit 20 configured as an ink jet head has an ink supply unit 21 that supplies ink to each nozzle. The ink supply unit 21 includes a chamber filled with ink, an ink pipe for supplying ink to the nozzle 21, a discharge amount control unit that controls the ink discharge amount for each nozzle, and the like. For example, the discharge amount control unit is configured to control the ink discharge amount by controlling the voltage applied to the piezoelectric element provided for each nozzle.

  Note that the nozzle groups N-G1 to N-G4 may be formed integrally or separately. When the nozzle groups N-G1 to N-G4 are integrally formed, the nozzle groups N-G1 to N-G4 may have a common ink supply unit 21. Further, when the nozzle groups N-G1 to N-G4 are formed separately, the nozzle groups N-G1 to N-G4 may have separate ink supply units 21.

[Production method of color filter]
Next, a method for manufacturing a color filter using the color filter manufacturing apparatus 10 having the above configuration will be described.

  First, the base material 40 is supplied from the supply unit 26 of the transport device 25 to the support stage 15. As described above, the supply base material 40 proceeds on the support stage 15 in one direction. On the other hand, as shown in FIG. 1, the discharge means 20 is held stationary above the support stage 15. As a result, the discharge means 20 and the base material 40 are relatively moved in one direction. The position of the ejection unit 20 on the support stage 15 is positioned with respect to the support stage 15 using the alignment camera 18.

  As described above, the ejection unit 20 is configured such that the nozzles 21 belonging to different nozzle groups are arranged along the relative movement direction of the ejection unit 20 and the base material 40. Therefore, when the ejection unit 20 and the base material 40 are relatively moved in one direction, the positions facing the pixel regions 45 included in the base material 40 are set to four positions belonging to different nozzle groups N-G1 to N-G4. The nozzle 21 comes to pass. Therefore, ink is applied to one pixel region 45 from four nozzles 21 belonging to different nozzle groups N-G1 to N-G4 during one scan (relative movement) of the ejection unit 20 with respect to the base material 40. can do.

  In the example shown in FIG. 2, the base material 40 is supplied so that one arrangement direction of the pixel regions 45 of the base material 40 arranged in a lattice pattern is along one direction on the support stage 15. In particular, in the example shown in FIG. 2, the arrangement direction of the columnar pixel regions 45 to which the same color ink of the color filter 50 to be formed as a stripe arrangement is applied is parallel to one direction. . Accordingly, ink can be applied to the plurality of pixel regions 45 belonging to the same pixel column extending in one direction using the same plurality of nozzles 21.

  In this example, the nozzles 21 used for ink application can be allocated to the pixel regions 45 as shown in FIG. Each nozzle 21 has a predetermined number of droplets when the substrate 40 moves relative to the ejection unit 20 and the allocated pixel region 45 passes a predetermined position (for example, a position facing it). Only eject ink. In the example of the setting conditions shown in FIG. 4, the nozzle N-G1-1 belonging to the first group ejects (F1-1) drops of ink to the pixel region R01, and the nozzle N belonging to the second group. -G2-1 ejects (F2-1) drops of ink, nozzle N-G3-1 belonging to the third group ejects (F3-1) drops of ink, and nozzle N-G4 belonging to the fourth group -1 ejects (F4-1) drops of ink. In the example of the setting condition shown in FIG. 4, the nozzle N-G1-7 belonging to the first group ejects (F1-7) drops of ink to the pixel region R33, and the nozzle belonging to the second group. N-G2-7 ejects (F2-7) drops of ink, nozzle N-G3-7 belonging to the third group ejects (F3-7) drops of ink, and nozzle N- belonging to the fourth group G4-7 ejects (F4-7) drops of ink.

  For each of the nozzles 21 used to apply ink to each pixel region 45, the number of ink droplets (F1-1) to (F4-n) to be ejected to each pixel region 45 corresponds to the ink. It is set in advance before the discharging step is performed. A method for setting the number of droplets ejected from each nozzle 21 will be described in detail later.

  As described above, red ink is ejected from the nozzles 21 included in the ejection means 20 while the ejection means 20 and the base material 40 are relatively moved in only one direction, and the red ink is applied to the pixel region 45 of the base material 40. Can be applied. Similarly to the discharge unit 20 that discharges red ink, the discharge unit that discharges green ink and the discharge unit that discharges blue ink, which are disposed at positions shifted in one direction from the discharge unit 20 that discharges red ink, are the same as the discharge unit 20 that discharges red ink. Thus, the ink is applied to the substrate 40. As a result, the color filter 50 formed by applying the red ink, the green ink, and the blue ink to the substrate 40 is produced. The produced color filter 50 is collected by the collection unit 27 of the transport device 26.

  According to the method as described above, during one scan of the substrate 40 of the ejection unit 20, this one time is performed while applying ink to one pixel region 45 using at least two nozzles 21. Thus, the ink application to the one pixel region 45 can be completed.

  In general, even between nozzles 21 of the same specification, the amount of one droplet of ink ejected from each nozzle 21 is actually slightly different. Therefore, when ink is applied to one pixel region 45 using one nozzle 21 and the nozzles 21 that eject ink differ between the pixel regions 45, the same number of droplets from each nozzle 21. The total amount of applied ink differs between the pixel areas 45 from which ink has been ejected.

  In contrast, in the present embodiment, ink is ejected to each pixel region 45 from at least two nozzles 21 belonging to different nozzle groups. That is, in the present embodiment, ink is applied to the pixel region 45 from a plurality of different nozzles 21 for one pixel region 45. In this way, by dispersing the nozzles 21 that apply ink to one pixel region 45, the ink applied to each pixel region 45 due to the difference in the droplet amount of one ink droplet ejected by each nozzle 21. The variation in the total amount can be made uniform effectively.

  Further, as described above, the ink application to one pixel region 45 can be completed by this one scan while applying the ink using at least two nozzles 21. That is, according to the present embodiment, it is possible to apply ink very efficiently while suppressing variations in the amount of ink applied between the pixel regions 45. Thereby, the manufacturing cost of the color filter formed by applying ink to the substrate 40 can be significantly reduced.

  In particular, the plurality of nozzles 21 included in each of the nozzle groups N-G1 to N-G4 may be arranged over the entire range facing the pixel region 45 to which the ink of the base material 40 is to be applied in the other direction. More convenient. That is, it is preferable that the plurality of nozzles 21 included in each of the nozzle groups N-G1 to N-G4 are arranged in a range that covers the entire width of the application region of the base material 40 in the other direction. According to such an arrangement of the nozzles 21, the ink application to the entire region of the substrate 40 can be completed by a single scan of the ejection unit 20 with respect to the substrate 40. According to such a coating method, as shown in FIG. 1, the color filter 50 can be produced by so-called roll-to-roll, and the production efficiency can be greatly improved. Therefore, the coating apparatus (color filter manufacturing apparatus) and the coating method (color filter manufacturing method) according to the present embodiment can be very suitably applied to the manufacture of the color filter 50 using the thin film-like substrate 40.

(First method for setting the number of ejected droplets)
Here, an example of a method for setting the number of droplets (F1-1) to (F4-n) for each of the nozzles 21 will be described. First, a first method for setting the number of droplets based on the specifications of the nozzle 21 will be described. In the first setting method, it is assumed that the droplet amount of one droplet of ink ejected from each nozzle 21 is the droplet amount according to the specification of the nozzle 21. Then, the droplets of ink to be ejected to the pixel region 45 so that the total amount of ink ejected from each nozzle 21 to one pixel region 45 becomes the target amount of ink to be applied to the pixel region 45. A number is calculated for each nozzle 21. Specifically, it can be calculated as follows. In this specification, “to be a target amount (so as to match the target amount)” not only completely matches the target amount, but also approaches the target amount, for example, includes the target amount. Including being within the allowable range.

  First, the target amount W of the total amount of ink to be applied to one pixel area is specified. Then, when the specifications (product standards) for liquid quantification (Ws1-1) to (Ws4-n) for one ink droplet ejected from each nozzle are as shown in FIG. For the region R01, an appropriate number of liquids for each nozzle is calculated so as to satisfy the following formula. In the following expression, “W01” is a target total amount of ink to be applied to the pixel region R01.

W01 [ng]
= (Ws1-1) [ng / drop] x (F1-1) [drop]
+ (Ws2-1) [ng / drop] × (F2-1) [drop]
+ (Ws3-1) [ng / drop] × (F3-1) [drop]
+ (Ws4-1) [ng / drop] × (F4-1) [drop]
Similarly, for example, for the pixel region R33, an appropriate number of liquids for each nozzle is calculated so as to satisfy the following expression. In the following expression, “W33” is the target total amount of ink to be applied to the pixel region R33.

W33 [ng]
= (Ws1-7) [ng / drop] x (F1-7) [drop]
+ (Ws2-7) [ng / drop] × (F2-7) [drop]
+ (Ws3-7) [ng / drop] × (F3-7) [drop]
+ (Ws4-7) [ng / drop] × (F4-7) [drop]
Similarly, the number of droplets ejected from the nozzle 21 used for applying ink to the pixel region 45 can be calculated for the other pixel regions 45.

  As a specific example, the total amount of ink to be applied to the pixel region 45 is all 1000 [ng], and the amount of droplets for one droplet of ink ejected from the nozzle 21 is all 25 in the specification for the nozzle. In the case of [ng / droplet], the number of ink droplets ejected from each nozzle can be set to 10 [droplets] as shown in FIG.

  In the above description, an example in which the amount of ink is specified by information on the weight [ng] has been described, but the present invention is not limited to this. For example, the ink amount is information on the film thickness (average film thickness in the pixel area), information on the chromaticity (chromaticity in the pixel area), information on the volume (volume in the pixel area), information on the maximum film thickness (in the pixel area) (Maximum film thickness), information on luminance (luminance in the pixel area), and the like may be specified.

  Here, the average film thickness in the pixel area is the average film in the pixel area 45 of the colored layer made of the ink applied to the one pixel area 45, based on the target amount of ink to be applied to one pixel area 45. Information shown as thickness. This average film thickness is measured, for example, by measuring the thickness (height) of the colored layer formed in the target pixel region 45 at each position in the pixel region 45 using an electron microscope. It can be calculated by taking the average value of the thicknesses (heights). The in-pixel region chromaticity is information indicating the target amount of ink to be applied to one pixel region 45 as the chromaticity of a colored layer made of ink applied to one pixel region 45. In addition, this chromaticity can be made into the value calculated | required by the measurement of the color coordinate x or y by an xyY color system when using C light source as a light source.

  The volume information (volume in the pixel area) is information indicating the target amount of ink to be applied to one pixel area 45 as the total volume of ink ejected in the pixel area 45. Information on the maximum film thickness (maximum film thickness in the pixel area) is obtained by setting the target amount of ink to be applied to one pixel area 45 as the maximum film thickness of a colored layer made of ink applied to one pixel area 45. This is the information shown. Information on luminance (in-pixel area luminance) is information indicating the target amount of ink to be applied to one pixel area 45 as the luminance in a colored layer made of ink applied to one pixel area 45. . In addition, the brightness | luminance in this case can be made into the value calculated | required from the measurement of the color coordinate Y by xyY color system when C light source is used for a light source.

  In the second and third setting methods of the appropriate number of liquids described below, the amount of ink is specified by information other than information on the weight [ng], as in the first setting method. May be.

(Second method for setting the number of ejected droplets)
Next, a second method for setting the number of droplets (F1-1) to (F4-n) for each nozzle 21 will be described. In the second setting method, the droplet amount of one droplet of ink ejected from each nozzle 21 is measured in advance. That is, the total amount of ink ejected from each nozzle 21 to one pixel region 45 is calculated with respect to the pixel region 45 in consideration of the droplet amount of one droplet ejected from each nozzle 21 measured in advance. The number of ink droplets to be ejected to the pixel region 45 is calculated for each nozzle 21 so that the target amount of ink to be applied is reached. Specifically, it can be calculated as follows.

  First, the target amount W of the total amount of ink to be applied to one pixel region 45 is specified. Then, when the measured values of the liquid quantification (Wr1-1) to (Wr4-n) for one ink droplet ejected from each nozzle 21 are as shown in FIG. 5, for example, for the pixel region R01. Calculates the appropriate number of liquids for each nozzle so as to satisfy the following equation. In the following expression, “W01” is a target total amount of ink to be applied to the pixel region R01.

W01 [ng]
= (Wr1-1) [ng / drop] x (F1-1) [drop]
+ (Wr2-1) [ng / drop] × (F2-1) [drop]
+ (Wr3-1) [ng / drop] × (F3-1) [drop]
+ (Wr4-1) [ng / drop] × (F4-1) [drop]
Similarly, for example, for the pixel region R33, an appropriate number of liquids for each nozzle is calculated so as to satisfy the following expression. In the following expression, “W33” is the target total amount of ink to be applied to the pixel region R33.

W33 [ng]
= (Wr1-7) [ng / drop] x (F1-7) [drop]
+ (Wr2-7) [ng / drop] × (F2-7) [drop]
+ (Wr3-7) [ng / drop] x (F3-7) [drop]
+ (Wr4-7) [ng / drop] × (F4-7) [drop]
Similarly, the number of droplets ejected from the nozzle 21 used for applying ink to the pixel region 45 can be calculated for the other pixel regions 45.

  By the way, in general, when ink is continuously ejected from the nozzle 21, the amount of droplets for one droplet of ink to be ejected can fluctuate greatly at the initial stage of ejection, and thereafter, the droplet for one droplet is discharged. The amount becomes stable (see, eg, FIG. 7). Accordingly, the droplet amount for one ink droplet ejected from each nozzle 21 measured in advance is the droplet amount for one droplet ejected after the initial stage of ejection in which the droplet amount can vary greatly. It is preferably measured. This also applies to the third method for setting the number of ejected droplets described below.

  As a specific method, the total weight of a plurality of droplets ejected continuously from the target nozzle 21 a predetermined number of times is measured, and the average droplet amount for one droplet is calculated from the measured value. As a result, the amount of droplets for one droplet set for each nozzle 21 can be obtained. Here, by setting the “predetermined number of times” to a number (for example, 100,000 shots) that greatly exceeds the number of ejections at the initial stage of ejection in which the amount of droplets for one droplet can vary greatly, The influence of variation can be sufficiently eliminated. In this measurement method, for example, the total amount of a plurality of droplets of ink ejected continuously using a measuring device such as an electronic balance can be measured.

  As another measurement method, it is also possible to actually eject ink droplets from a nozzle to be measured onto one pixel region on the ink repellent substrate and measure the droplet amount for one droplet. According to such a measuring method, the amount of droplets for one droplet is not only the weight of the ejected ink, but also the volume of the ejected ink and the color composed of the ink applied to one pixel region 45. The average film thickness in the pixel area 45 of the layer, the maximum film thickness in the pixel area 45 of the colored layer made of ink applied to one pixel area 45, and the color made of ink applied to one pixel area 45 It can be measured as the chromaticity of the layer or the luminance in the colored layer made of ink applied to one pixel region 45.

  As an example of a method of actually ejecting ink to the pixel region 45 on the substrate 40 and measuring the amount of droplets for one droplet, after droplets are continuously ejected from the nozzle 21 a predetermined number of times. By measuring the amount of one droplet that is continuously ejected, the amount of one droplet can be obtained. Here, the “predetermined number of times” is set to a number exceeding the number of discharges at the initial stage of discharge where the amount of droplets for one droplet can vary greatly, and the number of droplets expected to be ejected based on the nozzle specifications ( More preferably, the value is in the vicinity of the number of droplets calculated by the first setting method described above.

  Specifically, the total amount of ink applied to the pixel area 45 when only 9 droplets are ejected to one pixel area 45 and the pixel area 45 when only 10 droplets are ejected to one pixel area 45. The amount of one droplet can be measured from the difference between the total amount of ink applied to the ink. Alternatively, as another example, by measuring the average droplet amount of a plurality of droplets that are continuously discharged after the droplets are continuously discharged from the nozzle 21 a predetermined number of times, It is also possible to determine the amount of droplets. For example, when only 9 droplets are ejected to one pixel region 45, the total amount of ink applied to the pixel region 45 is applied to the pixel region 45 when only 11 droplets are ejected to one pixel region 45. It is possible to measure the amount of one droplet from the difference between the total amount of ink. As described above, the total amount of ink applied to the pixel region 45 of the substrate 40 is not only as a weight, but as a volume, for example, as an average film thickness of a colored layer made of ink, and as a maximum of a colored layer made of ink. The film thickness can be measured as the chromaticity of the colored layer made of ink or as the luminance of the colored layer made of ink.

  Note that when measuring the amount of one droplet discharged from each nozzle 21, it is the same as the application operation when actually manufacturing a color filter from nozzles other than the nozzle to be measured. It is desirable that ink be ejected. This is to eliminate the influence of the so-called crosstalk phenomenon, which is a variation in the amount of one droplet caused by the presence or absence of ink ejection from the adjacent nozzle. Therefore, it is preferable that the ink ejection from the nozzles other than the measurement nozzle is as much as possible as the ejection when the color filter is actually manufactured.

  In the case of calculating the number of ejected droplets by the second setting method as described above, the following effects can be further expected in addition to the effects obtained by the first setting method described above.

  When ink is ejected from one nozzle 21 having the same specification to one pixel region 45 and the amount of one droplet ejected from each nozzle 21 is unknown, it is applied to the pixel region 45. The adjustment of the total amount of ink is performed only by increasing or decreasing the number of ink droplets ejected from the nozzle 21. Therefore, the minimum adjustable amount of the total ink amount is a droplet amount corresponding to one ink droplet ejected from the nozzle 21. However, when the target amount of ink applied to one pixel region 45 is 1000 ng, in order to obtain a uniform application amount for each pixel region 45, the actual ink application amount in each pixel region 45 is the target amount ± 3 ng. It is desirable to control to about (997 ng to 1003 ng). When ink is ejected from a single nozzle 21 having an ink amount per droplet of about 25 ng to one pixel region 45, the ink application amount in the pixel region 45 is an integer multiple of ± 25 ng. Can only be adjusted. For this reason, the coating amount for each pixel region 45 cannot be made sufficiently uniform.

  On the other hand, according to the second method for setting the number of ejected droplets, the number of ink droplets ejected from one nozzle 21 of the plurality of nozzles 21 is increased by one time. By reducing the number of ink droplets ejected from one nozzle 21 by one time, the amount of one droplet ejected from one nozzle 21 (for example, 26 ng) and ejection from other nozzles 21 The total ink amount applied to the pixel region 45 can be increased or decreased by an ink amount (2 ng = 26 ng−24 ng) corresponding to the difference between the amount of droplets (for example, 24 ng) for one droplet to be applied. . Therefore, the amount of ink applied to one pixel region 45 can be adjusted by an amount corresponding to the difference in the amount of one droplet discharged from each nozzle 21. In theory, the variation in the amount of ink applied to the pixel region 45 due to the difference in the amount of droplets ejected by each nozzle 21 can be eliminated.

(Third method for setting the number of ejected droplets)
Next, a third method for setting the number of droplets (F1-1) to (F4-n) for each of the nozzles 21 will be described. Also in the third setting method, as in the second setting method, the droplet amount of one droplet of ink ejected from each nozzle 21 is measured in advance.

  In the third method of setting the number of ink droplets, a plurality of nozzles 21 used for applying ink to each pixel region 45 in consideration of the target amount of ink to be applied to each pixel region 45. From each of a plurality of nozzles 21 used for applying ink to one pixel region 45, a first step of setting a standard number of ink droplets to be ejected to each pixel region 45 A second step of ejecting ink by the number of standard droplets set for the nozzle 21 and measuring the total amount of ink ejected from the plurality of nozzles 21 as a standard ink amount, and each nozzle 21 measured in advance The number of ink droplets to be ejected to each pixel region 45 is determined with respect to each of the plurality of nozzles 21 in consideration of the droplet amount for one droplet ejected from the nozzle and the measured standard ink amount. A third step calculated by They are out. Hereinafter, each step will be further described in order from the first step.

  In the first step, as shown in FIG. 8, an appropriate number of standard solutions (Fb1-1) to (Fb4-n) are provided for each of the plurality of nozzles 21 used for applying ink to each pixel region 45. Is set. At this time, when ink is ejected from each of the plurality of nozzles 21 that apply ink to one pixel region 45 by the number of standard droplets set for the nozzle 21, the ink is ejected from each of the plurality of nozzles 21. It is preferable that the number of standard droplets is set so that the total amount of ink that is applied becomes the target amount of ink to be applied to the one pixel region 45. As described above, “to be the target amount” not only means that the target amount is completely matched, but also means that the target amount is approached, for example, it is within an allowable range including the target amount. Including.

  For example, as described in the first method for setting the appropriate number of liquids, the droplet amount of one droplet of ink ejected from each nozzle 21 is the droplet amount (Ws1-1) according to the specifications of the nozzle. ) To (Ws4-n), and the total amount of ink ejected from the plurality of nozzles 21 used to apply ink to one pixel region 45 is to be applied to the pixel region 45 The number of standard droplets may be calculated for each of the plurality of nozzles 21 used for applying ink to each pixel region 45 so that the target amount becomes the target amount. In addition, as described in the second method for setting the number of droplets, the droplet amounts (Wr1-1) to (Wr4-n) for one droplet ejected from each nozzle 21 measured in advance are set. In consideration of each pixel, the total amount of ink ejected from the plurality of nozzles 21 used for applying ink to one pixel region 45 becomes the target amount of ink to be applied to the pixel region 45. The standard number of droplets may be calculated for each of the plurality of nozzles 21 used for applying ink to the region 45.

  By the way, it is preferable that the standard number of droplets for each nozzle 21 is set to be equal to or greater than a preset value. The preset value here is a value determined in consideration of variations in the amount of ink droplets at the start of ejection (see FIG. 7). As an example, it is preferable to set the number of standard droplets to 4 or more, which is generally considered that the amount of droplets of one droplet of ink continuously ejected from the nozzle 21 is stable. That is, it is preferable to set the standard number of droplets so that the droplets are ejected from the nozzle 21 until the droplet amount for one droplet becomes stable.

  Next, as a second step, the standard ink amount Wb for each pixel region 45 is measured. As described above, the standard ink amount is a plurality of inks when the ink is ejected from each of the plurality of nozzles 21 that eject ink to one pixel region 45 by the number of standard droplets set for the nozzle 21. This is the total amount of ink ejected from the nozzle 21.

  That is, in this second step, ink is ejected from each of the plurality of nozzles 21 that apply ink to one pixel region 45 by the number of standard droplets set for the nozzle 21, and the discharged ink Actually measure the total amount. However, the total amount of ink ejected can be measured using a measuring device such as an electronic balance, and it is not always necessary to eject ink onto the substrate 40.

  However, as another measurement method, ink is actually applied to one pixel region 45 on the ink-repellent substrate from each of the target nozzles 21 by the number of standard droplets set for the nozzle 21. The total amount of ink ejected and applied in one pixel region 45 may be measured. According to such a measuring method, the total amount of ink (standard ink amount) is determined based on the volume of ejected ink and the average film thickness in the pixel region 45 of the colored layer made of ink applied to one pixel region 45. The maximum thickness of the colored layer made of ink applied to one pixel region 45 in the pixel region 45, the chromaticity of the colored layer made of ink applied to one pixel region 45, or one pixel region It can be measured as the luminance in the colored layer made of the ink applied to 45.

  In the illustrated example, the same nozzle 21 is used for each pixel region 45 included in the same pixel row (for example, pixel examples including the pixel regions R01, R11, R21, R31,...). Ink is discharged. Therefore, if the target amount of ink to be applied to each pixel region 45 included in the same pixel column is the same, the same standard droplet number is set for each nozzle 21 as shown in FIG. Can be done. If the number of standard droplets set for each nozzle 21 is the same, theoretically, the standard ink amounts for the pixel regions 45 belonging to the same pixel column are set to the same value. The measurement of the standard ink amount for the plurality of pixel regions 45 belonging to the same pixel column may be measured for one pixel region 45 in the same pixel column, or within the same pixel column. It is good also as an average value of the some measured value measured with respect to these several pixel area | regions.

  Further, when measuring the standard ink amount, it is desirable that ink is ejected from nozzles other than the nozzle to be measured in the same manner as the application operation in the case of actually manufacturing the color filter 50. This is in order to eliminate the influence of the so-called crosstalk phenomenon caused by fluctuations in the amount of one droplet caused by the presence or absence of ink ejection from adjacent nozzles. Therefore, it is preferable that the ejection of ink from nozzles other than the measurement nozzle is as identical as possible to the ejection when the color filter 50 is actually manufactured.

  Next, as a third step, the droplet amount (Wr1-1) to (Wr4-n) for one droplet measured in advance for each nozzle 21, the standard ink amount Wb measured for each pixel region, Considering the target amount W of the total amount of ink to be applied to one pixel region 45, the total amount of ink ejected from the plurality of nozzles 21 that apply ink to one pixel region 45 becomes the target amount. The number of ink droplets to be ejected to one pixel region 45 is calculated for each of the plurality of nozzles 21.

  As a specific example, first, a target amount W of ink to be applied in one pixel region 45 is compared with a standard ink amount Wb, and a difference between the standard ink amount Wb and the target amount W is calculated. In order to fill the difference between the standard ink amount Wb and the target amount W, the number of standard droplets set for each of the plurality of nozzles 21 is increased or decreased. The increase / decrease in the number of standard droplets is performed in consideration of the droplet amounts (Wr1-1) to (Wr4-n) of one droplet actually measured for each of the plurality of nozzles 21.

  When the measured values of the liquid quantification (Wr1-1) to (Wr4-n) for one ink droplet ejected from each nozzle 21 are as shown in FIG. 5, for example, for the pixel region R01, The appropriate number of liquids for each nozzle is calculated so as to satisfy the following formula. In the following expression, “W01” is a target amount of ink to be applied to the pixel region R01, and “Wb01” is a standard ink amount measured for the pixel region R01.

W01 [ng] -Wb01 [ng / pixel]
= Wr1-1 [ng / drop] × ((F1-1) [drop]-(Fb1-1) [drop]]
+ Wr2-1 [ng / drop] × ((F2-1) [drop]-(Fb2-1) [drop]]
+ Wr3-1 [ng / drop] × ((F3-1) [drop]-(Fb3-1) [drop])
+ Wr4-1 [ng / drop] × ((F4-1) [drop]-(Fb4-1) [drop]]
Similarly, for example, for the pixel region R33, an appropriate number of liquids for each nozzle is calculated so as to satisfy the following expression. In the following expression, “W33” is a target amount of ink to be applied to the pixel region R33, and “Wb33” is a standard ink amount measured for the pixel region R33.

W [ng] -Wb33 [ng / pixel]
= Wr1-7 [ng / drop] x ((F1-7) [drop]-(Fb1-7) [drop])
+ Wr2-7 [ng / drop] × ((F2-7) [drop]-(Fb2-7) [drop]]
+ Wr3-7 [ng / drop] × ((F3-7) [drop]-(Fb3-7) [drop]]
+ Wr4-7 [ng / drop] × ((F4-7) [drop]-(Fb4-7) [drop]]
Similarly, the number of droplets ejected from the nozzle 21 used for applying ink to the pixel region 45 can be calculated for the other pixel regions 45. As a specific example, as shown in FIG. 9, the number of ink droplets ejected from each nozzle 21 can be set.

  When calculating the number of ejected droplets by the third setting method as described above, in addition to the effects obtained by the first setting method and the effects obtained by the second setting method, the following effects are further expected. be able to.

  As described above, when ink is ejected continuously from the nozzle 21, the droplet amount of one droplet of the ejected ink may vary. Further, the fluctuation behavior differs between the nozzles 21. However, typically, as shown in FIG. 7, the amount of droplets for one droplet of ink largely fluctuates in the initial stage of ejection, and stabilizes when the number of ejections exceeds a certain number, for example, 3 times. become.

  In the present embodiment, a standard ink amount corresponding to the total amount of applied ink when each of the plurality of nozzles 21 ejects ink by the number of standard droplets corresponding to the nozzle 21, and one pixel region 45. Based on the target amount of ink to be applied and the amount of one droplet ejected from each nozzle 21, the number of ink droplets to be ejected to one pixel region 45 is determined by a plurality of nozzles 21. Is calculated for each of the above. In other words, the number of standard droplets set for each of the plurality of nozzles 21 is increased or decreased so that the total amount of ink is zero between the target amount and the standard ink amount. The number of ink droplets to be ejected can be calculated for each of the plurality of nozzles 21.

  According to such a calculation method, it is possible to make it difficult to be influenced by fluctuations in the droplet amount at the initial stage of ejection. In particular, if the number of standard droplets is set to the number of droplets that exceeds the number of droplets at the initial stage of ejection, where the droplet volume can vary greatly, the number of droplets can be changed from the number of standard droplets by several droplets ( The total amount of ink applied changes (increases / decreases) from the standard ink amount by an amount obtained as the product of the droplet amount of one ink droplet and the increase / decrease number of the droplet amount in the stable period. It becomes like this. Therefore, if the number of standard droplets and the finally calculated number of ejected droplets are more than the number of ejections at the beginning of ejection, where the amount of droplets for one droplet can vary greatly, The total amount of ink that is actually ejected can be accurately brought close to the target amount of the total amount of ink to be applied to each pixel region 45 by eliminating the influence of fluctuations in the amount of droplets for one droplet. As a result, the ink application amount can be effectively made uniform between the pixel regions 45.

  Specifically, it is generally considered that the standard number of droplets and the finally calculated number of droplets stabilize the amount of droplets for one droplet of ink that is continuously ejected from the nozzle 21. Preferably, it is set to 4 or more. In this case, the total amount of ink applied to each pixel region 45 can be made closer to the target amount with higher accuracy, and the amount of ink applied can be more effectively made uniform between the pixel regions 45.

  Further, in the above-described method, in order to improve the accuracy of the total ink amount applied to one pixel region 45 of the substrate 40, setting of the standard droplet number, measurement of the standard ink amount, and calculation of the number of ejected droplets are performed. May be repeatedly executed. Specifically, the number of droplets calculated based on the standard number of droplets and the standard ink amount in the above-described method is set as the second standard number of droplets, and the second number of droplets is determined based on the second number of standard droplets. The standard ink amount may be measured, and the ejection droplet number may be finally calculated based on the second standard droplet number and the second standard ink amount. Further, the number of ejected droplets may be calculated after the resetting of the standard droplet number and the re-measurement of the standard ink amount are repeated a plurality of times.

  According to such a method, the total amount of ink applied to each pixel region 45 can be brought close to the target amount with high accuracy, and as a result, the amount of ink applied can be made uniform between the pixel regions 45 extremely effectively. Can be made. Actually, when the present inventor conducted an experiment, the total number of inks applied to each pixel region 45 was set to the target amount by resetting the number of standard droplets and re-measuring the standard ink amount twice. We were able to get close with high accuracy. Specifically, ink is applied to one pixel region 45 so as to have an average film thickness of 2.00 μm using four nozzles 21 in which the droplet amount for one droplet is set to about 20 ng. In this case, the average film thickness on one pixel region 45 could be set to the target amount (2.00 μm) ± 0.005 μm.

[Modification]
Various modifications can be made to the above-described embodiment. Hereinafter, an example of modification will be described.

  For example, in the above-described embodiment, an example in which each nozzle group is configured as an integral nozzle head has been described, but the present invention is not limited thereto. As shown in FIG. 10, the nozzle groups N-G1 to N-G4 are configured as separate nozzle heads 22a, 22b, 22c, and 22d, and discharge means 20 that discharges the same ink from the plurality of nozzle heads 22a to 22d. May be formed. In the example shown in FIG. 10, the arrangement pitch Pa of the nozzles 21 in the nozzle groups N-G1 to N-G4 is along the direction orthogonal to the relative movement direction (one direction) between the base material 40 and the discharge means 20. In accordance with the arrangement pitch Pb of the pixel regions 45, the arrangement direction (other direction) of the nozzles 21 is inclined with respect to the direction orthogonal to one direction. And when each nozzle group N-G1-N-G4 is comprised as a separate nozzle head 22a, 22b, 22c, 22d, it is different nozzle group N-G1 irrespective of the inclination angle to one direction of another direction. At least two nozzles 21 belonging to ˜N-G4 can be arranged in one direction. That is, in such a modified example, even if it is necessary to incline the nozzle heads 22a to 22d with respect to the relative movement direction of the base material 40 and the discharge means 20, the discharge means 20 and the base material 40 Are moved relative to each other in the one direction so that at least two nozzles 21 belonging to different nozzle groups N-G1 to N-G4 pass through the positions facing the pixel regions 45 included in the base material 40. be able to. Therefore, regardless of the configuration of the color filter 50 to be manufactured, as described above, ink is applied from at least two nozzles 21 to one pixel region 45 during one scan of the base member 40 of the ejection unit 20. The ink applied to the one pixel region 45 can be completed by one scan. As a result, it is possible to efficiently apply the ink while suppressing variations in the amount of ink applied between the pixel regions 45, and to manufacture a high-quality color filter at low cost.

  In the above-described embodiment, an example in which only one of the many nozzles 21 belonging to one nozzle group ejects ink for each pixel region 45 has been described. However, the present invention is not limited to this, and as shown in FIG. 11, only one of the many nozzles 21 belonging to one nozzle group may eject ink to each pixel region 45. . In the example illustrated in FIG. 11, when the ejection unit 20 moves (scans) relative to the substrate 40, a large number belonging to one nozzle group with respect to one pixel region 45 on the substrate 40. Two of the nozzles 21 face each other, and ink is applied to the same pixel region 45 from the two nozzles belonging to the same nozzle group. In the example shown in FIG. 11, two nozzle groups are arranged along the relative movement direction (one direction) between the base material 40 and the discharge means. As a result, when the ejection unit 20 and the base material 40 move relative to each other in the one direction, the four nozzles pass through the positions facing the pixel regions 45 included in the base material 40.

  Furthermore, in the above-described embodiment, an example in which the arrangement of the pixel regions of the base material 40 is a stripe arrangement has been described. However, the present invention is not limited to this, and the base material 40 of another pixel arrangement (for example, a delta arrangement) is used. The present invention can also be applied to this.

  Furthermore, in the above-described embodiment, the example in which the ejection unit 20 and the base material 40 move relative to each other when the base material 40 moves with respect to the stationary ejection unit 20 has been described, but the present invention is not limited thereto. The base material 40 may be stationary, or both the ejection unit 20 and the base material 40 may be moved.

  Furthermore, in the above-described embodiment, the example in which the ink is applied to the film-like substrate 40 extending in a band shape has been described, but the present invention is not limited thereto. For example, the ink may be applied to a sheet-like base material sucked and held by a support device having a suction function.

  Furthermore, in the above-described embodiment, the example in which the colored layer of the color filter 50 for the display device is formed by applying ink to each of the plurality of pixel regions 45 on the base material 40 has been described. Instead, ink is applied to each of a plurality of predetermined regions (for example, 1 μm square) set on the base material 40 using the above-described coating apparatus (color filter manufacturing apparatus) and coating method (color filter manufacturing method). You may do it. According to such a coating method, a film made of ink can be formed on the substrate 40 when the entire coating region to be coated belongs to any one of the predetermined regions. As an example, the present invention can be applied to the case where an alignment film such as polyimide sandwiching liquid crystal is formed on the surface of the array substrate or the color filter 50 by an ink jet method. In addition, when the predetermined area is set by exclusively dividing the entire coating area, defects such as coating unevenness may occur. As a countermeasure, it is preferable that the end portions of the predetermined regions overlap with each other. In the case where the predetermined region overlaps with another predetermined region adjacent thereto, the ink is overcoated on the overlapping end portion, thereby preventing the occurrence of defects such as coating unevenness. .

  As mentioned above, although one Embodiment by this invention was described referring an accompanying drawing, this invention is not limited to this example. It will be apparent to those skilled in the art that various changes or modifications can be conceived within the scope of the technical idea disclosed in the present application, and these are naturally within the technical scope of the present invention. Understood.

FIG. 1 is a diagram for explaining an embodiment of the present invention, and is a schematic diagram showing a color filter manufacturing apparatus. FIG. 2 is a diagram for explaining the configuration of the ejection means and the ink application method in the color filter manufacturing apparatus shown in FIG. FIG. 3 is a cross-sectional view showing the discharge means. FIG. 4 is a table showing nozzles assigned to apply ink to each pixel area and the number of ink droplets ejected from each nozzle in an example of an ink application method. FIG. 5 is a table showing an example of a droplet amount of one droplet of ink ejected from each nozzle. FIG. 6 is a table showing an example of the number of ink droplets ejected from the nozzles assigned to each pixel region. FIG. 7 is a graph showing the variation in the amount of one ink droplet corresponding to the number of ejections. FIG. 8 is a table corresponding to FIG. 4, showing the nozzles assigned to apply ink to each pixel region and the standard number of ink droplets ejected from each nozzle. is there. FIG. 9 is a table corresponding to FIG. 6, and is a table showing another example of the number of ink droplets ejected from the nozzles assigned to each pixel region. FIG. 10 is a diagram corresponding to FIG. 2 and illustrating a modified example of the ejection unit and the coating method. FIG. 11 is a diagram corresponding to FIG. 2 and is a diagram for explaining another modified example of the ejection unit and the coating method.

DESCRIPTION OF SYMBOLS 10 Color filter manufacturing apparatus 12 Control apparatus 15 Support apparatus (support stage)
18 Alignment camera 20 Discharge means 21 Nozzle 22a, 22b, 22c, 22d Nozzle head 25 Conveying device 26 Supply unit 26a Supply core 27 Collection unit 27a Collection core 40 Base material 41 Light shielding unit 45 Pixel region 50 Color filter

Claims (27)

A discharge means for applying ink to each pixel region of the base material while relatively moving in one direction with respect to the base material including a plurality of pixel regions,
The ejection means has a plurality of nozzles that eject the same ink,
One nozzle group is constituted by a plurality of nozzles arranged side by side in the other direction intersecting the one direction among the nozzles that eject the same ink, and the ejection unit is spaced apart in the one direction. Including a plurality of nozzle groups arranged;
When the ejection unit and the base material move relative to each other in the one direction, at least two nozzles belonging to different nozzle groups pass through positions facing each pixel region included in the base material, Ink is ejected from the at least two nozzles to one pixel area during one scan of the base material of the ejection means, and ink application to the one pixel area is completed by the one scan. A color filter manufacturing apparatus. The number of nozzles included in each nozzle group is the same between the nozzle groups,
2. The color filter manufacturing method according to claim 1, wherein the plurality of nozzles included in one nozzle group are arranged at positions shifted from the plurality of nozzles included in another nozzle group in the one direction. 3. apparatus. The plurality of nozzles included in each nozzle group are arranged in the other direction over the entire range facing the pixel area to which the ink of the base material is to be applied, whereby the base material of the ejection unit The apparatus for producing a color filter according to claim 1, wherein the application of the ink to the substrate is completed by a single scan with respect to the substrate. Each nozzle group is configured as a separate nozzle head,
The color according to any one of claims 1 to 3, wherein at least two nozzles belonging to different nozzle groups can be arranged in one direction regardless of an inclination angle of the other direction in the one direction. Filter manufacturing equipment. Further comprising a transport device for transporting the substrate;
The transport device includes a supply unit and a recovery unit that are arranged apart from each other in the one direction, and the base material is moving in the one direction between the supply unit and the recovery unit. The color filter device according to claim 1, wherein the application of the ink to the substrate is completed. A plurality of discharge means having a plurality of nozzle groups spaced in one direction, wherein each nozzle group is composed of a plurality of nozzles arranged side by side in the other direction intersecting with the one direction. In a method of manufacturing a color filter by applying ink to a base material including a pixel region of
A step of ejecting the same ink from nozzles included in the ejection means while relatively moving the ejection means and the base material in the one direction, and applying ink to the pixel region of the base material,
In the step of applying the ink, ink is discharged from at least two nozzles to one pixel region during one scan of the discharge unit with respect to the base material, and the ink application to the one pixel region is performed by the ink application. A method for producing a color filter, which is completed in one scan. The method of manufacturing a color filter according to claim 6, wherein the number of nozzles used for applying ink to one pixel region is the same between pixel regions. The method for manufacturing a color filter according to claim 6 or 7, wherein the number of droplets ejected from the at least two nozzles used for applying ink to one pixel region is the same. A step of setting, for each of the at least two nozzles used for applying ink to each pixel region, the number of ink droplets to be ejected to each pixel region;
In the step of applying the ink, ink is ejected from each of the at least two nozzles by the number of droplets set in the step of setting the number of droplets of the ink for the nozzle. The manufacturing method of the color filter of Claim 6 or 7. In the step of setting the number of ink droplets, it is assumed that the droplet amount of one droplet of ink ejected from each nozzle is a droplet amount according to the specification of the nozzle, and from the at least two nozzles The number of ink droplets to be ejected to each pixel area is such that the total amount of ink to be ejected is the target amount of ink to be applied to each pixel area. The color filter manufacturing method according to claim 9, wherein the color filter is calculated. In the step of setting the number of ink droplets, the total amount of the ink ejected from the at least two nozzles is determined for each pixel in consideration of the droplet amount of one droplet ejected from each nozzle measured in advance. The number of ink droplets to be ejected to each pixel region is calculated for each of the at least two nozzles so that a target amount of ink to be applied to the region is obtained. 9. A method for producing a color filter according to item 9. The step of setting the number of ink droplets includes:
In consideration of the target amount of ink to be applied to each pixel region, for each of the at least two nozzles used for applying ink to each pixel region, the amount of ink to be ejected to each pixel region Setting the standard number of droplets;
The total amount of ink ejected from each of the at least two nozzles is ejected by the number of standard droplets set in the step of setting the number of standard droplets for the nozzle. Measuring as a standard ink amount,
The number of standard droplets set for each of the nozzles is increased or decreased in consideration of the amount of droplets discharged from each nozzle measured in advance and the measured standard ink amount. Thus, the number of ink droplets to be ejected to each pixel region is such that the total amount of the ink ejected from the at least two nozzles is a target amount of ink to be applied to each pixel region. The method for producing a color filter according to claim 9, further comprising a step of calculating for each of at least two nozzles. In the step of setting the standard number of droplets of ink, it is assumed that the amount of droplets of one droplet of ink ejected from each nozzle is a droplet amount according to the specifications of the nozzles, and the at least two nozzles When the ink is ejected from each of the nozzles by the number of standard droplets corresponding to the nozzle, the total number of ejected inks becomes the target amount of ink to be applied to each pixel region. The method according to claim 12, wherein the manufacturing method is calculated for each of the at least two nozzles. A discharge unit that applies ink to each predetermined region of the base material while relatively moving in one direction with respect to the base material including a plurality of predetermined regions,
The ejection means has a plurality of nozzles that eject the same ink,
One nozzle group is constituted by a plurality of nozzles arranged side by side in the other direction intersecting the one direction among the nozzles that eject the same ink, and the ejection unit is spaced apart in the one direction. Including a plurality of nozzle groups arranged;
When the discharge means and the base material move relative to each other in the one direction, at least two nozzles belonging to different nozzle groups pass through a position facing each predetermined region included in the base material, Ink is ejected from the at least two nozzles to one predetermined area during one scanning of the base material by the ejection means, and ink application to the one predetermined area is completed in one scanning. An applicator characterized by. The number of nozzles included in each nozzle group is the same between the nozzle groups,
The coating apparatus according to claim 14, wherein the plurality of nozzles included in one nozzle group are arranged at positions shifted in the one direction from the plurality of nozzles included in the other nozzle group. The plurality of nozzles included in each nozzle group are arranged in the other direction over the entire range facing the predetermined region to which the ink of the base material is to be applied, whereby the base material of the discharge means The coating apparatus according to claim 14, wherein the application of the ink to the substrate is completed by one scanning with respect to the substrate. Each nozzle group is configured as a separate nozzle head,
The application according to any one of claims 14 to 16, wherein at least two nozzles belonging to different nozzle groups can be arranged in one direction regardless of an inclination angle of the other direction in the one direction. apparatus. Further comprising a transport device for transporting the substrate;
The transport device includes a supply unit and a recovery unit that are arranged apart from each other in the one direction, and the base material is moving in the one direction between the supply unit and the recovery unit. The coating apparatus according to claim 14, wherein the application of the ink to the substrate is completed. A plurality of discharge means having a plurality of nozzle groups spaced in one direction, wherein each nozzle group is composed of a plurality of nozzles arranged side by side in the other direction intersecting with the one direction. In a method of applying ink to a substrate including a predetermined region of
A step of discharging the same ink from a nozzle included in the discharge means while relatively moving the discharge means and the base material in the one direction, and applying the ink to a predetermined region of the base material,
In the step of applying the ink, ink is ejected from at least two nozzles to one predetermined area during one scan of the ejection unit with respect to the base material, and ink application to the one predetermined area is performed A coating method characterized by being completed in one scan. The coating method according to claim 19, wherein the number of nozzles used for applying ink to one predetermined region is the same between the predetermined regions. 21. The coating method according to claim 19 or 20, wherein the number of droplets ejected from the at least two nozzles used to apply ink to one predetermined region is the same. A step of setting, for each of the at least two nozzles used for applying ink to each predetermined region, the number of ink droplets to be ejected to each predetermined region;
In the step of applying the ink, ink is ejected from each of the at least two nozzles by the number of droplets set in the step of setting the number of droplets of the ink for the nozzle. The coating method according to claim 19 or 20. In the step of setting the number of ink droplets, it is assumed that the droplet amount of one droplet of ink ejected from each nozzle is a droplet amount according to the specification of the nozzle, and from the at least two nozzles The number of ink droplets to be ejected to each predetermined region is such that the total amount of ink to be ejected is a target amount of ink to be applied to each predetermined region. The coating method according to claim 22, wherein the coating method is calculated. In the step of setting the number of ink droplets, the total amount of the ink ejected from the at least two nozzles is set to each predetermined amount in consideration of the droplet amount of one droplet ejected from each nozzle measured in advance. The number of ink droplets to be ejected to each predetermined region is calculated for each of the at least two nozzles so that a target amount of ink to be applied to the region is obtained. The coating method according to 22. The step of setting the number of ink droplets includes:
In consideration of the target amount of ink to be applied to each predetermined area, each of the at least two nozzles used for applying ink to each predetermined area is supplied with ink to be discharged to each predetermined area. Setting the standard number of droplets;
The total amount of ink ejected from each of the at least two nozzles is ejected by the number of standard droplets set in the step of setting the number of standard droplets for the nozzle. Measuring as a standard ink amount,
The number of standard droplets set for each of the nozzles is increased or decreased in consideration of the amount of droplets discharged from each nozzle measured in advance and the measured standard ink amount. Thus, the number of ink droplets to be ejected to each predetermined region is set so that the total amount of the ink ejected from the at least two nozzles becomes a target amount of ink to be applied to each predetermined region. The method according to claim 22, further comprising: calculating for each of at least two nozzles. In the step of setting the standard number of droplets of ink, it is assumed that the amount of droplets of one droplet of ink ejected from each nozzle is a droplet amount according to the specifications of the nozzles, and the at least two nozzles When the ink is ejected from each of the nozzles by the number of standard droplets corresponding to the nozzle, the total number of ejected inks becomes the target amount of ink to be applied to each predetermined region. The coating method according to claim 25, wherein the coating method is calculated for each of the at least two nozzles. 27. The plurality of predetermined regions are arranged on the base material such that two adjacent predetermined regions overlap with each other at an end portion thereof. Application method.

Images