JP2012255882A - Method for manufacturing liquid crystal display device, liquid crystal display device, and mother substrate pair - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress decrease in a yield.SOLUTION: A liquid crystal display device includes: a first substrate, which includes a mounting part formed between an effective part constituting an active area and a substrate end extending in a first direction, and includes a bank formed in a row with the mounting part in the first direction; a second substrate, which faces the effective part and exposes the mounting part and the bank; a sealing material, which is disposed in a periphery of the effective part, forming a liquid crystal injection port in an opposite side to the substrate end across the effective part, and which laminates the first substrate and the second substrate forming a cell gap; and a liquid crystal layer held in the cell gap.

Description

  Embodiments described herein relate generally to a method for manufacturing a liquid crystal display device, a liquid crystal display device, and a mother substrate pair.

  Liquid crystal display devices are utilized in various fields as display devices for OA equipment such as personal computers and televisions, taking advantage of features such as light weight, thinness, and low power consumption. In recent years, liquid crystal display devices are also used as mobile terminal devices such as mobile phones, display devices such as car navigation devices and game machines.

  In the case where a plurality of liquid crystal display panels are collectively formed using a large mother substrate, it is required to take out more liquid crystal display panels. In recent years, each region taken out as a liquid crystal display panel tends to be formed close to a mother substrate. For this reason, when each region is cleaved, undesired cracks or chipping of the substrate may occur, leading to a decrease in yield.

JP 2006-184671 A

  An object of the present embodiment is to provide a method of manufacturing a liquid crystal display device, a liquid crystal display device, and a mother substrate pair that can suppress a decrease in yield.

According to this embodiment,
A first mounting portion, a first effective portion, a first array region having a first side serving as a boundary line on the opposite side of the first mounting portion across the first effective portion; a second mounting portion; A second effective part, a second side that coincides with the first side on the opposite side of the second effective part across the second mounting part, and the second mounting part along the second side And a first mother substrate having a second array region having island-shaped banks, and a first sealing material is disposed around the first effective portion in the first array region of the first mother substrate. At the same time, both end portions of the first sealing material are drawn out toward the banks of the second array region to form first liquid crystal injection holes, and the second effective region is formed in the second array region of the first mother substrate. A second sealing material is disposed around the second portion and second at both ends of the second sealing material. After forming the crystal injection port and disposing the second mother substrate on the side of the first mother substrate on which the first sealing material and the second sealing material are disposed, the first sealing material and the second sealing material are Curing is performed to form a mother substrate pair in which the first mother substrate and the second mother substrate are bonded together, the first mother substrate is divided along the boundary line, and the first mother substrate is divided into the first mother substrate and the second mother substrate. The first cover part located on the first mounting part is removed, and the second cover part located on the second mounting part of the second mother board is pulled out to the second array region from the boundary line. Further, there is provided a method for manufacturing a liquid crystal display device, wherein the first sealing material is removed.

According to this embodiment,
A liquid crystal display device manufactured by the above-described method for manufacturing a liquid crystal display device and including at least a part of the bank is provided.

According to this embodiment,
A first substrate including a mounting portion formed between an effective portion forming an active area and a substrate end extending along a first direction; and a bank formed side by side with the mounting portion in the first direction; A second substrate facing the effective portion and exposing the mounting portion and the bank; and a liquid crystal injection port disposed on the opposite side of the substrate end with the effective portion disposed around the effective portion. There is provided a liquid crystal display device comprising: a sealing material for bonding the first substrate and the second substrate in which a cell gap is formed; and a liquid crystal layer held in the cell gap.

According to this embodiment,
A first mounting area, a first active area, and a first array area having a first side serving as a boundary on the opposite side of the first mounting section across the first effective section; a second mounting section; A second active area, a second side that coincides with the first side on the opposite side of the second active area across the second mounting part, and a line with the second mounting part along the second side A first mother substrate having a second array region having island-shaped banks; and disposed at the periphery of the first effective portion in the first array region of the first mother substrate and having both ends thereof A first seal member that is drawn toward the bank of the second array region and forms a first liquid crystal injection port; and is disposed around the second effective portion in the second array region of the first mother substrate. The second liquid crystal injection port at both ends A mother substrate pair comprising: a second sealing material to be formed; and a first mother substrate and a second mother substrate bonded together by the first sealing material and the second sealing material are provided. The

FIG. 1 is a plan view schematically showing the configuration of the liquid crystal display device according to the present embodiment. FIG. 2 is a cross-sectional view schematically showing a cross-sectional structure when the liquid crystal display panel including the bank shown in FIG. 1 is cut along line II-II. FIG. 3 is a view for explaining the method of manufacturing the liquid crystal display panel in the present embodiment, and is a plan view for explaining a step of preparing a first mother substrate. FIG. 4 is a view for explaining the method of manufacturing the liquid crystal display panel in the present embodiment, and is a plan view for explaining the step of arranging the sealing material. FIG. 5 is an enlarged plan view of a region B including the bank and the first sealing material shown in FIG. FIG. 6 is a cross-sectional view schematically showing a cross-sectional structure when the first mother board including the bank and the first sealing material shown in FIG. 5 is cut along the line VI-VI. FIG. 7 is a diagram for explaining a method of manufacturing a liquid crystal display panel according to the present embodiment, and a cross-section for explaining a process of forming a mother substrate pair in which a first mother substrate and a second mother substrate are bonded together. FIG. FIG. 8 is a cross-sectional view schematically showing a cross-sectional structure when a region including the bank and the first sealing material is cut in the mother substrate pair shown in FIG. FIG. 9 is a cross-sectional view schematically showing a cross-sectional structure of the panel after the mother substrate pair shown in FIG.

  Hereinafter, the present embodiment will be described in detail with reference to the drawings. In each figure, the same reference numerals are given to components that exhibit the same or similar functions, and duplicate descriptions are omitted.

  FIG. 1 is a plan view schematically showing a configuration of a liquid crystal display device 1 in the present embodiment.

  That is, the liquid crystal display device 1 includes an active matrix type liquid crystal display panel LPN.

  The liquid crystal display panel LPN includes an array substrate AR, a counter substrate CT arranged to face the array substrate AR, a seal material SE for bonding the array substrate AR and the counter substrate CT, an array substrate AR, and a counter substrate CT. And a liquid crystal layer LQ held in the cell gap formed between the two.

  The liquid crystal display panel LPN includes a substantially rectangular active area ACT for displaying an image. This active area ACT is composed of a plurality of pixels PX arranged in an m × n matrix (where m and n are positive integers).

  The liquid crystal display panel LPN has a quadrangular shape and extends along the first direction X along the first side S1 and the second side S2, and along the second direction Y orthogonal to the first direction X. The third side S3 and the fourth side S4 are extended. Both the array substrate AR and the counter substrate CT have a quadrangular shape. The array substrate AR has substrate ends corresponding to the first side S1, the second side S2, the third side S3, and the fourth side S4, respectively. The counter substrate CT has substrate ends respectively corresponding to the first side S1, the third side S3, and the fourth side S4, and is further positioned on the active area ACT side than the position immediately above the second side S2. It has a substrate end CTE.

  The array substrate AR includes an effective portion EF that forms the active area ACT, and an extending portion ARE that extends outward from the substrate end CTE along the first direction X of the counter substrate CT. That is, the extending part ARE is formed between the substrate end of the array substrate AR corresponding to the second side S2 and the effective part EF (or between the substrate end CTE of the counter substrate CT). The array substrate AR includes a mounting portion MT and a bank BK formed side by side along the first direction X in the extending portion ARE. The counter substrate CT is opposed to the effective portion EF of the array substrate AR and exposes the mounting portion MT and the bank BK in the extending portion ARE.

  The bank BK is formed in an island shape. In the illustrated example, two banks BK are formed in an island shape in the extending part ARE, and are arranged along the second side S2 (or the first direction X). Further, these banks BK are formed in the vicinity of an almost intermediate position along the first direction X of the second side S2. The two illustrated banks BK may be connected. In such a case, one bank BK is formed in an island shape in the extension ARE.

  The mounting unit MT includes a plurality of pads PD. As a signal source for supplying a signal necessary for displaying an image in the active area ACT, for example, the flexible printed circuit board 2 is connected to the pad PD of the mounting unit MT. Note that a driving IC chip may be mounted on the mounting unit MT as another signal source. In the illustrated example, in the extension part ARE, two mounting parts MT are formed on both sides of the bank BK. Such mounting parts MT and banks BK are arranged along the second side S2 (or the first direction X).

  The seal material SE is disposed around the active area ACT (or the effective portion EF of the array substrate AR) between the array substrate AR and the counter substrate CT, and is formed in a substantially rectangular frame shape in the illustrated example. Yes. This seal material SE is placed on the opposite side of the substrate end of the array substrate AR corresponding to the second side S2, that is, on the first side S1 side, across the active area ACT (or the effective portion EF of the array substrate AR). A liquid crystal injection port LI for injecting a liquid crystal material is formed. Such a liquid crystal injection port LI is formed by pulling out both end portions of the sealing material SE toward the first side S1. Note that both end portions of the sealing material SE are located on the same straight line as the bank BK along the second direction Y. Such a liquid crystal injection port LI is sealed with a sealing material LS.

  The configuration of each pixel PX is, for example, as follows. That is, the array substrate AR is connected to the gate line GL extending along the first direction X, the source line SL extending along the second direction Y, the gate line GL, and the source line SL in the effective portion EF. Switching element SW, pixel electrode EP connected to switching element SW, and the like. The gate wiring GL and the source wiring SL are each drawn out to the outside of the effective part EF and connected to each pad PD of the mounting part MT. The counter electrode ET facing the pixel electrode EP via the liquid crystal layer LQ may be provided on the array substrate AR or may be provided on the counter substrate CT.

  The liquid crystal mode is not particularly limited, and a mode mainly using a vertical electric field or an oblique electric field, such as a TN (Twisted Nematic) mode, an OCB (Optically Compensated Bend) mode, or a VA (Vertical Aligned) mode, or an IPS (In-Plane) mode. A mode mainly using a lateral electric field such as a switching) mode and an FFS (Fringe Field Switching) mode can be applied.

  FIG. 2 is a cross-sectional view schematically showing a cross-sectional structure when the liquid crystal display panel LPN including the bank BK shown in FIG. 1 is cut along line II-II. Here, only parts necessary for the description are shown in a simplified manner.

  The array substrate AR is formed using an insulating substrate 10 such as a glass substrate. In the effective portion EF, the switching element SW, the first interlayer insulating film 11, the second interlayer insulating film 12, and the like formed on the insulating substrate 10, The pixel electrode PE, the first alignment film AL1, and the like are provided. For example, the first interlayer insulating film 11 is interposed between a gate wiring and a source wiring (not shown). That is, the gate wiring is disposed between the insulating substrate 10 and the first interlayer insulating film 11, and the source wiring is disposed between the first interlayer insulating film 11 and the second interlayer insulating film 12.

  The switching element SW is, for example, a bottom gate type or top gate type thin film transistor (TFT), and includes a semiconductor layer made of polysilicon or amorphous silicon. The first interlayer insulating film 11 is formed of an inorganic material such as silicon nitride (SiN) or silicon oxide (SiO). Such a first interlayer insulating film 11 extends from the effective portion EF to the extending portion ARE. The second interlayer insulating film 12 is formed on the first interlayer insulating film 11. Such a second interlayer insulating film 12 is an organic film colored in red, green, and blue, which is a color filter, or a transparent organic film, and is formed of an organic material.

  The pixel electrode PE is formed on the second interlayer insulating film 12. The pixel electrode PE is electrically connected to the switching element SW through a contact hole formed in the second interlayer insulating film 12. The first alignment film AL1 is formed on the surface of the array substrate AR that faces the counter substrate CT, and extends over substantially the entire effective portion EF. The first alignment film AL1 covers the pixel electrode PE and the like.

  Although the structure of the counter substrate CT is not described in detail, the counter substrate CT is formed using an insulating substrate such as a glass substrate, and includes a black matrix, a color filter, an overcoat layer, a second alignment film AL2, and the like as necessary. The second alignment film AL2 is formed on the surface of the counter substrate CT facing the array substrate AR.

  The columnar spacers SP arranged between the array substrate AR and the counter substrate CT form a cell gap for holding the liquid crystal layer LQ. In the illustrated example, the columnar spacer SP is provided on the array substrate AR side, is formed on the second interlayer insulating film 12, and is covered with the first alignment film AL1. Note that the columnar spacer SP may be provided on the counter substrate CT side.

  The array substrate AR includes a first interlayer insulating film 11, a bank BK, and the like formed on the insulating substrate 10 in an extending portion ARE extending outward from the substrate end CTE of the counter substrate CT. The first interlayer insulating film 11 functions as a base film of the bank BK. The bank BK is formed on the first interlayer insulating film 11 similarly to the second interlayer insulating film 12 of the effective portion EF.

  The bank BK is formed of the same organic material as the second interlayer insulating film 12. For example, when the second interlayer insulating film 12 is a transparent organic film, the bank BK is formed of a transparent organic material. In addition, when the second interlayer insulating film 12 is a color filter, the bank BK has a colored layer colored in a low visibility (or low specific visibility), for example, an organic colored in blue. It is desirable to form by material.

  In addition, although it showed with the broken line in the figure, the convex body CV may be arrange | positioned in the position which approached the effective part EF side on the bank BK. Such a convex body CV is formed of the same material as the columnar spacer SP. In the configuration in which the columnar spacer SP is provided on the array substrate AR side, the convex body CV may be disposed on the bank BK. In the configuration in which the columnar spacer SP is provided on the counter substrate CT side, the convex body CV does not remain on the bank BK.

  Below, the manufacturing method of the liquid crystal display panel LPN in this embodiment is demonstrated. Here, a manufacturing method that employs so-called multiple chamfering that collectively forms a plurality of liquid crystal display panels LPN using a large substrate will be described.

  FIG. 3 is a view for explaining a method of manufacturing the liquid crystal display panel LPN in the present embodiment, and is a plan view for explaining a step of preparing the first mother substrate SUB1.

  As shown in the drawing, first, a first mother substrate SUB1 for forming the array substrate AR is prepared. Such a first mother substrate SUB1 is formed using, for example, a large glass substrate. The first mother substrate SUB1 includes a plurality of array regions A,. Each of these array regions A has a quadrangular shape and corresponds to a region where the array substrate AR is formed. These array regions A are aligned in the first direction X and aligned in the second direction Y.

  Such an array region A includes a first array region A1 and a second array region A2. The second array area A2 is adjacent to the first array area A1 in the second direction Y. A thick line in the drawing showing the array region A is a planned cutting line CA for cutting the first mother substrate SUB1 when the individual array substrate AR is cut out from the first mother substrate SUB1 later. That is, each array area A corresponds to an inner area surrounded by the planned cutting line CA. Such a cleaving line CA has a lattice shape.

  Further, in the first mother substrate SUB1 shown here, there is no gap between the adjacent array regions A. That is, the adjacent array areas A are in contact with each other, and the planned cutting line CA is a boundary line between the adjacent array areas A. For example, the cutting planned line CA12 that is a boundary line between the first array region A1 and the second array region A2 becomes the first side S1 of the array substrate AR corresponding to the first array region A1, and the second array region A2 The second side S2 of the array substrate AR corresponding to. That is, the second side S2 of the array substrate AR corresponding to the second array region A2 coincides with the first side S1 of the array substrate AR corresponding to the first array region A1.

  Each array region A includes a mounting part MT and an effective part EF. Each mounting portion MT includes a plurality of pads as described above, although detailed illustration is omitted. Although not shown in detail, each effective portion EF includes various interlayer insulating films, switching elements, and pixel electrodes as described above. Of the array region A, the first array region A1 and the second array region A2 will be described more specifically.

  The first array region A1 includes a first mounting part MT1 and a first effective part EF1. Further, the first array region A1 includes a first side S1 serving as a boundary line with the second array region A2 on the opposite side of the first mounting portion MT1 across the first effective portion EF1.

  The second array area A2 includes a second mounting part MT2 and a second effective part EF2. The second array region A2 is a boundary line with the first array region A1 on the opposite side of the second effective portion EF2 across the second mounting portion MT2, and the first side of the first array region A1. A second side S2 that coincides with S1 is provided. Further, the second array region A2 includes island-shaped banks BK aligned with the second mounting portion MT2 along the second side S2. Such a bank BK is formed simultaneously with the formation of the second interlayer insulating film of the second effective EF2. The bank BK and the second mounting part MT2 in the second array region A2 are located between the second effective part EF2 and the first effective part EF1. Although not shown, when the array substrate includes a columnar spacer, the convex body CV is simultaneously formed on the bank BK when the columnar spacer is formed on the second interlayer insulating film.

  Although not shown, on the other hand, a second mother substrate SUB2 for forming the counter substrate CT is prepared. The second mother substrate SUB2 is formed using a substrate having the same dimensions as the first mother substrate SUB1. In the configuration in which the counter substrate includes columnar spacers, the convex body CV is simultaneously formed when the columnar spacers are formed.

  FIG. 4 is a view for explaining a method of manufacturing the liquid crystal display panel LPN in the present embodiment, and is a plan view for explaining a step of arranging the seal material SE.

  As illustrated, the sealing material SE is disposed on the first mother substrate SUB1. Each sealing material SE is arranged around the effective portion EF in each of the array regions A, and forms a liquid crystal injection port LI that communicates with each effective portion EF. Each liquid crystal injection port LI is formed by pulling out each sealing material SE beyond a boundary line (or a planned cutting line CA) with the adjacent array region A. Each sealing material SE is formed in a substantially rectangular frame shape, and is separated from other adjacent sealing materials SE.

  Such a seal material SE includes a first seal material SE1 formed in the first array region A1 and a second seal material SE2 formed in the second array region A2. The second sealing material SE2 is separated from the first sealing material SE1. Between the first seal material SE1 and the second seal material SE2, the second mounting portion MT2 formed in the second array region A2 is located.

  The first sealing material SE1 is disposed around the first effective portion EF1. Both end portions of the first sealing material SE1 are respectively drawn out toward the bank BK of the second array region A2 beyond the planned cutting line CA12 that is a boundary line between the first array region A1 and the second array region A2. One liquid crystal inlet LI1 is formed.

  Similarly, the second sealing material SE2 is arranged around the second effective portion EF2, and the second liquid crystal injection port LI2 is formed at both ends thereof.

  Each of these sealing materials SE is formed of, for example, a resin material such as an ultraviolet curable resin or a thermosetting resin. Such a sealing material SE may be formed by screen printing, or may be applied and formed by drawing with a dispenser.

  At this time, the positional relationship between the bank BK of the second array region A2 and the first sealing material SE1 in the region B surrounded by the broken line in the drawing will be described more specifically.

  FIG. 5 is an enlarged plan view of the region B including the bank BK and the first seal material SE1 illustrated in FIG.

  One end of the first sealing material SE1 is bent substantially perpendicularly from the first direction X to the second direction Y in the first array region A1, and passes over the planned cutting line CA12 and above the bank BK in the second array region A2. To the seal end set position CSP set to.

  In the illustrated example, a convex body CV extending along the first direction X is disposed on the bank BK. Here, four rows of convex bodies CV are shown. These convex bodies CV are arranged on the second effective portion EF side on the bank BK. The seal end point setting position CSP is set closer to the cutting line CA12 than the convex body CV.

  The bank BK and the convex body CV serve as a barrier when the first seal material SE1 spreads in the second direction Y, and suppresses the spread toward the second effective portion EF2.

  Here, the width W1 along the first direction X of the bank BK is wider than the width W2 along the first direction X of the first seal material SE1 drawn onto the bank BK. For this reason, when the first seal material SE1 that has reached the bank BK is about to spread in the second direction Y, the first seal material SE1 before riding on the bank BK is expanded along the first direction X. , It is possible to suppress the spread in the second direction Y.

  Moreover, the width along the first direction X of the convex body CV is also wider than the width W2 along the first direction X of the first sealing material SE1. For this reason, even if the first sealing material SE1 reaches the convex body CV, first, the first sealing material SE1 is expanded along the first direction X in which the convex body CV extends, so that the second direction Y It becomes possible to suppress the spread to. Further, even if the first sealing material SE1 gets over the convex body CV located on the cutting line CA12 side, each of the convex bodies CV formed over a plurality of rows similarly applies the first sealing material SE1. Since it spreads in the 1st direction X, it becomes possible to suppress the spread to the 2nd direction Y.

  Further, since the width W1 of the bank BK is wider than the width W2 of the first seal material SE1, when the first seal material SE1 is pulled out on the bank BK, a part of the first seal material SE1 is above the bank BK. Can be prevented from falling off. Further, when the first sealing material SE1 is spread on the first direction X by securing the margin of the bank BK on both sides of the first sealing material SE1 when the first sealing material SE1 is drawn on the bank BK. It is possible to prevent a part of the bank BK from dropping off from the bank BK.

  The distance L along the second direction Y from the planned cutting line CA12 to the bank BK is shorter than the depth D along the second direction Y of the bank BK. This will be described with reference to FIG.

  FIG. 6 is a cross-sectional view schematically showing a cross-sectional structure when the first mother substrate SUB1 including the bank BK and the first sealant SE1 shown in FIG. 5 is cut along the VI-VI line.

  The first interlayer insulating film 11 serving as the base film of the bank BK extends over the first array region A1 and the second array region A2. As described above, since the first seal material SE1 is assumed to spread in the second direction Y, the plurality of rows of convex bodies CV are each in the order of several tens of μm in order to prevent the spread to the second effective portion EF2. The depth D of the bank BK is set while ensuring a space to be arranged with an interval of.

  On the other hand, there is a possibility of shifting to the first array region A1 side or the second array region A2 side at the time of actual cutting with respect to the cutting planned line CA12 at the design time. Therefore, the bank BK is arranged with a margin with respect to the planned cutting line CA12 at the time of design. When attention is paid to the adhesive force with the first seal material SE1, the adhesive force between the first interlayer insulating film 11 and the first seal material SE1 is stronger than the adhesive force between the bank BK and the first seal material SE1. Since the first sealing material SE1 drawn to the second array area A2 side from the cleaving line CA12 should be removed after the cleaving, the region having a relatively strong adhesive force with the first sealing material SE1 is as small as possible. It is desirable. For this reason, it is desirable that the distance L from the planned cutting line CA12 to the bank BK is as small as possible. As the inventors have examined, the depth D of the bank BK is set to be several times the distance L from the planned cutting line CA12 to the bank BK.

  Further, the adhesive force between the bank BK and the first interlayer insulating film 11 is weaker than the adhesive force between the bank BK and the first seal material SE1. As a matter of course, the adhesive force between the bank BK and the first interlayer insulating film 11 is weaker than the adhesive force between the first sealing material SE1 and the first interlayer insulating film 11. For this reason, the first sealing material SE1 spread on the bank BK can be easily removed when cleaving. This will be described in more detail in the cleaving step.

  FIG. 7 is a diagram for explaining a method of manufacturing the liquid crystal display panel LPN in the present embodiment, and describes a process of forming a mother substrate pair SS in which the first mother substrate SUB1 and the second mother substrate SUB2 are bonded together. It is sectional drawing for doing. Here, a cross section including the first array region A1 and the second array region A2 is illustrated.

  As illustrated, the second mother substrate SUB2 is disposed on the side of the first mother substrate SUB1 where the first seal material SE1, the second seal material SE2, and the like are disposed. That is, the second mother substrate SUB2 is disposed on each sealing material SE disposed on the first mother substrate SUB1. Then, the first mother substrate SUB1 and the second mother substrate SUB2 are pressurized so that a predetermined cell gap is formed between each array region A of the first mother substrate SUB1 and the second mother substrate SUB2. Then, in a state where a desired cell gap is formed between the first mother substrate SUB1 and the second mother substrate SUB2, each sealing material SE is cured, and the first mother substrate SUB1 and the second mother substrate SUB2 are bonded. A combined mother substrate pair SS is formed.

  Thereafter, the first mother substrate SUB1 and the second mother substrate SUB2 may be polished as necessary.

  Thereafter, as shown in the figure, in the mother substrate pair SS, the cutting is performed on all the cutting planned lines CA including the cutting planned line CA12 of the first mother substrate SUB1, and the cutting is performed on the cutting planned line CC of the second mother substrate SUB2. To do. Thereby, the first mother substrate SUB1 is divided into the respective array regions A including the first array region A1 and the second array region A2 along the boundary line. Further, all the cover parts including the first cover part CR1 located on the first mounting part MT1 and the second cover part CR2 located on the second mounting part MT2 are removed from the second mother substrate SUB2. The

  FIG. 8 is a cross-sectional view schematically showing a cross-sectional structure when a region including the bank BK and the first seal material SE1 is cut in the mother substrate pair SS shown in FIG.

  As illustrated, in the mother substrate pair SS in which the second mother substrate SUB2 is bonded to the first mother substrate SUB1, the first seal material SE1 spreads in the second direction Y during pressurization, and the first seal material SE1 is It extends to the convex body CV side from the seal end setting position CSP. In the illustrated example, the first sealing material SE1 reaches the convex body CV located closest to the first array region A1 among the plurality of rows of convex bodies CV.

  In this state, after the first sealing material SE1 is cured, the first mother substrate SUB1 is cleaved along the cleaving planned line CA12 to divide the first array region A1 and the second array region A2, and the second The mother substrate SUB2 is cleaved along the cleaving line CC, and the second cover portion CR2 is removed. When removing the second cover portion CR2, the first seal material SE1 drawn out to the second array region A2 from the planned cutting line CA12 is also removed at the same time. This will be described with reference to FIG.

  FIG. 9 is a cross-sectional view schematically showing the cross-sectional structure of the panel after the mother substrate pair SS shown in FIG. 8 is cleaved along the cleaved lines CA12 and CC.

  Here, four panels (a) to (d) are shown. Each panel is opposed to the array substrate AR corresponding to the second array region A2 cut out from the first mother substrate SUB1 and the second cover substrate CR2 cut out from the second mother substrate SUB2 facing the second array region A2. The substrate CT is bonded to the second sealing material SE2.

  In the panel shown in (a), the first seal material SE1 that has been placed on the first interlayer insulating film 11 and the bank BK is removed together with the second cover portion CR2. In such a panel, substantially the entire bank BK remains on the first interlayer insulating film. Further, a part of the convex body CV above the bank BK may be removed together with the first seal material SE1, and in this case, only the side close to the second seal material SE2 may remain. obtain.

  In the panel shown in (b), the first seal material SE1 is removed together with the second cover portion CR2, but a part of the bank BK on which the first seal material SE1 is mounted is also removed. Therefore, it is different from the panel shown in FIG. Even in such a panel, a part of the convex body CV on the bank BK may be removed together with the first seal material SE1.

  In the panel shown in (c), the first seal material SE1 is removed together with the second cover portion CR2, but all the convex bodies CV on the bank BK are also removed at the same time. It is different from the panel shown in a).

  In the panel shown in (d), the first seal material SE1 is removed together with the second cover portion CR2, but a part of the bank BK on which the first seal material SE1 is mounted is also removed. Furthermore, it differs from the panel shown in (a) in that all the convex bodies CV on the bank BK are also removed at the same time.

  Note that when the first seal material SE1 is removed together with the second cover portion CR2, the entire bank BK on which the first seal material SE1 is riding may be removed at the same time. In this case, neither the bank BK nor the convex body CV remains on the panel after the cleaving.

  The panels shown in (c) and (d) are formed with a configuration in which all the convex bodies CV are provided on the counter substrate CT. Further, even when all the convex bodies CV are provided in the array substrate AR, when all the convex bodies CV are bonded to the first seal material SE1, the first seal material SE1 is removed. , All the convex bodies CV may be removed.

  The panel thus cut is sealed with a sealing material LS after injecting a liquid crystal material from the liquid crystal injection port LI. Thereby, the liquid crystal display panel LPN in which the liquid crystal layer LQ is held between the array substrate AR and the counter substrate CT is manufactured.

  According to the above-described liquid crystal display panel LPN, the protrusion of the sealing material SE to the adjacent array region A in the manufacturing process can be suppressed by the bank BK and the convex body CV. It is possible to reduce the amount of protrusion. In addition, the area where the adhesive force with the protruding seal material SE is strong (area where the first interlayer insulating film 11 is bonded) is very small, and the ratio of the area where the adhesive force with the seal material SE is weak (area where the bank BK is bonded) is Is higher. For this reason, it becomes possible to easily remove the sealing material SE adhered to the cover CR at the time of cleaving from the array substrate AR side. Therefore, when removing the cover portion CR, it is possible to suppress the occurrence of chipping or cracking of the substrate due to the strong adhesive force with the sealing material SE. As a result, it is possible to suppress a decrease in yield.

  As described above, according to this embodiment, it is possible to provide a method for manufacturing a liquid crystal display device, a mother substrate pair, and a liquid crystal display device that can suppress a decrease in yield.

  In addition, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

DESCRIPTION OF SYMBOLS 1 ... Liquid crystal display device LPN ... Liquid crystal display panel AR ... Array substrate CT ... Opposite substrate LQ ... Liquid crystal layer SE ... Sealing material LI ... Liquid crystal injection port EF ... Effective part SUB1 ... First mother substrate SUB2 ... Second mother substrate SS ... Mother Board pair

Claims (15)

A first mounting portion, a first effective portion, a first array region having a first side serving as a boundary line on the opposite side of the first mounting portion across the first effective portion; a second mounting portion; A second effective part, a second side that coincides with the first side on the opposite side of the second effective part across the second mounting part, and the second mounting part along the second side Preparing a first mother substrate having a second array region having island-shaped banks;
A first sealing material is disposed around the first effective portion in the first array region of the first mother substrate, and both end portions of the first sealing material are drawn out toward the banks of the second array region, respectively. To form a first liquid crystal inlet,
A second sealing material is disposed around the second effective portion in the second array region of the first mother substrate and a second liquid crystal injection port is formed at both ends of the second sealing material;
After the second mother substrate is disposed on the first mother substrate on the side where the first sealing material and the second sealing material are disposed, the first sealing material and the second sealing material are cured, and the first mother Forming a mother substrate pair by bonding the substrate and the second mother substrate;
Dividing the first mother substrate along the boundary line;
Removing the first cover portion located on the first mounting portion of the second mother substrate;
Removing the first sealing material drawn to the second array region from the boundary line together with the second cover portion located on the second mounting portion of the second mother substrate;
A method for manufacturing a liquid crystal display device.   The method for manufacturing a liquid crystal display device according to claim 1, further comprising: a convex body extending in a first direction parallel to the boundary line is disposed on the bank.   The method of manufacturing a liquid crystal display device according to claim 2, wherein the convex body is disposed on the second effective portion side on the bank.   4. The liquid crystal display according to claim 2, wherein a width along the first direction of the bank is wider than a width along the first direction of the first sealing material drawn on the bank. Device manufacturing method.   The distance from the said boundary line along the 2nd direction orthogonal to the said boundary line to the said bank is shorter than the depth along the 2nd direction of the said bank, The any one of Claim 1 thru | or 4 characterized by the above-mentioned. The manufacturing method of the liquid crystal display device of description.   6. The bank according to claim 1, wherein the bank is formed on a base film extending over the first array region and the second array region of the first mother substrate. The manufacturing method of the liquid crystal display device of description.   The method of manufacturing a liquid crystal display device according to claim 6, wherein a first adhesive force between the bank and the base film is weaker than a second adhesive force between the bank and the first sealing material.   8. The liquid crystal display device according to claim 6, wherein a first adhesive force between the bank and the base film is weaker than a third adhesive force between the first sealing material and the base film. Method.   The method for manufacturing a liquid crystal display device according to claim 1, wherein the bank is formed of an organic material.   A liquid crystal display device manufactured by the method for manufacturing a liquid crystal display device according to claim 1, comprising at least a part of the bank.   A liquid crystal display device manufactured by the method for manufacturing a liquid crystal display device according to claim 2, comprising at least a part of the convex body disposed on the bank. A first substrate including a mounting portion formed between an effective portion forming an active area and a substrate end extending along a first direction; and a bank formed side by side with the mounting portion in the first direction; ,
A second substrate facing the effective portion and exposing the mounting portion and the bank;
A sealing material that is disposed around the effective portion, forms a liquid crystal injection port on the opposite side of the substrate end across the effective portion, and bonds the first substrate and the second substrate with a cell gap formed therebetween; ,
A liquid crystal layer held in the cell gap;
A liquid crystal display device comprising: A first mounting area, a first active area, and a first array area having a first side serving as a boundary on the opposite side of the first mounting section across the first effective section; a second mounting section; A second active area, a second side that coincides with the first side on the opposite side of the second active area across the second mounting part, and a line with the second mounting part along the second side A second array region comprising island banks, a first mother substrate comprising:
The first mother substrate is disposed around the first effective portion in the first array region, and both end portions thereof are drawn out toward the bank in the second array region to form a first liquid crystal injection port. A first sealing material to
A second sealing material disposed around the second effective portion in the second array region of the first mother substrate and forming a second liquid crystal injection port at both ends thereof;
A second mother substrate bonded to the first mother substrate by the first sealing material and the second sealing material;
A mother board pair comprising:   The mother substrate pair according to claim 13, further comprising a convex body disposed on the bank on the second effective portion side and extending in a first direction parallel to the boundary line.   15. The mother substrate pair according to claim 13, wherein the bank is formed of an organic material.

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