JP2013195609A - Color filter formation substrate and liquid crystal display unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a color filter formation substrate having a columnar spacer obtained by forming a columnar shape by a pigmented layer and covering the columnar shape with an OC layer, cell-assembled with a TFT substrate to form a liquid crystal display unit, as a liquid crystal display unit such as a smart phone in which high definition display is required, the color filter formation substrate capable of preventing coloring dust being dust on top of the pigmented layer of the columnar spacer from flowing into a liquid crystal, even under oscillation.SOLUTION: A color filter formation substrate for a liquid crystal display unit has a columnar spacer obtained by arranging pigmented layers of respective colors for color filter formation and a black matrix on one surface of a transparent substrate and laminating two or more pigmented layers from among the pigmented layers of respective colors for color filter formation on the black matrix to form a columnar shape and covering the laminated layers with an OC layer. The pigmented layer of the transparent substrate positioned farthest away from the columnar spacer is recessed on a side not being a transparent substrate side, toward the transparent substrate side.

Description

  The present invention relates to a color filter forming substrate and a liquid crystal display device, and more particularly, to a color filter forming substrate for a liquid crystal display device in which columnar spacers are formed with colored layers of colors for color filters.

A liquid crystal display device for color display (also referred to as a liquid crystal panel) simply includes a TFT substrate (TFT; Thin Film Transistor) provided with a thin film transistor (TFT) and a scanning electrode, and a colored layer for each color filter. The arranged color filter forming substrate (also referred to as CF forming substrate) is opposed to each other, the liquid crystal is sealed between both substrates, and further, a deflection plate is disposed outside the TFT substrate and the color filter forming substrate, The backlight part is arranged outside the TFT substrate, and the light from the backlight part is displayed through a color filter (hereinafter also referred to as CF) composed of colored layers of each color. The light passing through the color filter is on-off controlled using a liquid crystal as a switching element for each pixel.
In such a liquid crystal display device, conventionally, in order to maintain the thickness of the liquid crystal layer (also referred to as a cell gap), the distance between the two substrates is usually kept constant between the TFT substrate and the color filter forming substrate. In order to maintain this, plastic beads with a uniform particle size were scattered between the two substrates as spacers for spacing control (referred to as bead spacers), but the uniform distribution of the beads was difficult, and there was a problem of bead movement. There are problems such as cell gap unevenness due to agglomeration and contrast decrease due to alignment disorder around beads, and in recent years, when forming a color filter forming substrate by forming a colored layer for each color filter by photolithography, Colored layers for each color filter are stacked to form a columnar shape, and an OC layer (also called an overcoat layer) is used to form a columnar spacer. It has come to so that.

For example, as shown in a partial cross section in FIG. 6A, the color filter forming substrate 110 is formed by stacking three colored layers (113R, 113G, and 113B) to form a column shape, and an OC layer (over layer). A columnar spacer 115 is formed by covering with a coating layer 114.
Then, cells are assembled by the color filter forming substrate 110 and the TFT substrate 120, and the liquid crystal 130 is sealed to form a liquid crystal display device.
However, in such a liquid crystal display device, when the cell is assembled by the color filter forming substrate 110 and the TFT substrate 120, when subjected to vibration due to transportation or the like, as shown in FIG. The protrusion 121a on the side penetrates the OC layer 114 covering the colored layer 113B of the columnar spacer 115, reaches the colored layer 113B, scrapes the colored layer 113B, and the colored dust particles flow into the liquid crystal 130, resulting in poor display. There was a case.
In such a case, conventionally, as shown in FIG. 6C, the OC of the columnar spacer 115 is used in order to prevent the colored dust that is the waste (also referred to as debris) of the colored layer 113 </ b> B from flowing into the liquid crystal 130. By increasing the width size of the colored layer 113B on the layer 114 side, the OC layer 114 is prevented from being thinned due to the leveling action when the OC layer 114 is formed by a die coating method or the like, and the OC layer 114 is slightly thickened. In this way, it was formed.
Here, W1 <W2.
In addition, the shape of each colored layer forming the columnar shape is usually a circular shape or a square shape.
In addition, the OC layer 114 of the columnar spacer 115 usually has a Vickers hardness of 60 or more and a film thickness of 0.2 μm or more to withstand a pressing force caused by frictional force due to rubbing treatment or vibrations such as conveyance or carrying. Is preferable, and more preferably 0.3 μm. (See Patent Document 1)
Further, the protrusion 121a on the TFT substrate 120 side is an electrode portion for controlling a voltage applied to the liquid crystal, and the columnar spacer 115 on the color filter forming substrate 110 side is firmly attached to the TFT substrate 120 side.

However, smartphones (also called multi-function mobile phones or high-function mobile phones) and tablet-type multi-function terminals are expected to spread rapidly, and display devices for these terminal devices (hereinafter referred to as mobile electronic devices). However, the line width of the black matrix of the color filter forming substrate has been further reduced.
For this reason, it is necessary to reduce the width of the columnar spacer formed in the black matrix region, and the width size of the uppermost colored layer 113B farthest from the transparent substrate 111 on the OC layer 114 side of the columnar spacer 115 is increased, so that the die coating is performed. It has become impossible to prevent the OC layer 114 from being thinned due to a leveling action when the OC layer 114 is formed by a method or the like.

JP 2010-286639 A

As described above, in the color filter forming substrate having the columnar spacers formed by stacking the colored layers of the respective colors and covered with the OC layer, the liquid crystal is formed by assembling cells between the color filter forming substrate and the TFT substrate. In the case of a display device, particularly in the case of a liquid crystal display device that requires high-definition display such as a smartphone, the projection on the TFT substrate side penetrates the OC layer of the columnar spacer and vibrates the top colored layer by vibration. There is a problem that colored dust, which is a waste of the layer, flows into the liquid crystal and causes a display defect, and this countermeasure has been demanded.
The present invention corresponds to this, and is a color filter forming substrate having a columnar spacer formed by laminating colored layers of respective colors and covered with an OC layer. In the case of a liquid crystal display device, it is intended to provide a color filter forming substrate that can prevent colored dust, which is scrap of the uppermost colored layer of the columnar spacer, from flowing into the liquid crystal even when subjected to vibration. is there.
In particular, even when a liquid crystal display device that requires high-definition display such as a smartphone is used, even if it receives vibration, colored dust that is waste of the uppermost colored layer of the columnar spacer is prevented from flowing into the liquid crystal. An object of the present invention is to provide a color filter forming substrate.
At the same time, an object of the present invention is to provide a liquid crystal display device capable of preventing the colored dust, which is the waste of the colored layer of the columnar spacers, from flowing into the liquid crystal even when subjected to vibration in the assembled state of the cells.

The color filter forming substrate of the present invention has a color filter forming color layer and a black matrix on one surface of a transparent substrate, and the color filter forming color layer on the black matrix. A color filter forming substrate for a liquid crystal display device, in which two or more colored layers are laminated to form a columnar shape, and columnar spacers covered with an OC layer (also referred to as an overcoat layer or a protective layer) are provided. The colored layer farthest from the transparent substrate of the columnar spacer is characterized in that the side that is not on the transparent substrate side is recessed on the transparent substrate side.
And it is said color filter formation board | substrate, Comprising: It is used for the liquid crystal display device of a smart phone (it is also called a multifunctional mobile phone or a high-functionality mobile phone) and a tablet-type multifunctional terminal.
In addition, any one of the color filter forming substrates described above is characterized in that it is for an IPS (In Plane Switching) type liquid crystal display device that controls liquid crystal display by a lateral electric field method.
Here, the “shape recessed on the transparent substrate side” includes both a shape in which the colored layer farthest from the transparent substrate of the columnar spacer is recessed and does not penetrate, and a shape that penetrates recessed.
In addition, as described above, the “spacer” here is a thickness of a liquid crystal layer (cell) in a liquid crystal display device in which a cell is assembled by a color filter forming substrate and a TFT substrate to seal liquid crystal. It is a spacer for holding a gap.

  The liquid crystal display device of the present invention is characterized by using any of the color filter forming substrates described above.

(Function)
The color filter forming substrate of the present invention is a color filter forming substrate having a columnar spacer formed by laminating colored layers of respective colors and having a columnar spacer covered with an OC layer. And providing a color filter forming substrate capable of preventing the colored dust from the colored layer forming the columnar spacers from flowing into the liquid crystal even when subjected to vibration in a state where the liquid crystal display device is assembled with the cells. It is possible.
Specifically, a colored layer for forming a color filter and a black matrix are arranged on one surface of a transparent substrate, and two of the colored layers for forming a color filter are arranged on the black matrix. A color filter forming substrate for a liquid crystal display device in which a columnar spacer is formed by laminating the above colored layers to form a columnar shape and covering with an OC layer (also referred to as an overcoat layer or a protective layer), This is achieved because the colored layer farthest from the transparent substrate of the columnar spacer has a shape in which the side that is not the transparent substrate side is recessed toward the transparent substrate side.
As described above, in a conventional liquid crystal display device, when a color filter forming substrate used is a columnar spacer formed by stacking a colored layer and then covering with an OC layer to form a columnar spacer, a TFT substrate When the cell device is assembled into a display device, the OC layer of the columnar spacer of the color filter forming substrate facing the projection of the TFT substrate is damaged by vibrations in transportation and carrying, and further, the farthest from the transparent substrate of the color filter forming substrate. If the uppermost colored layer of the columnar spacer is shaved, the shavings may become colored floating foreign matter (also called colored dusting matter) and enter the liquid crystal layer, resulting in a display defect due to the colored floating foreign matter.
On the other hand, in the color filter forming substrate of the present invention, the uppermost colored layer forming the columnar spacer farthest from the transparent substrate of the color filter forming substrate is recessed on the transparent substrate side on the non-transparent substrate side. Due to the shape, when the OC layer is formed by application of a die coater or the like, the OC material for forming the OC layer flows into the recessed portion (hereinafter also referred to as a depression), and the OC layer is formed in the recessed depression. When used in a display device, the thickness of the OC layer that is in close contact with the protrusions of the TFT substrate can be increased, so that the protrusions of the TFT substrate are the most from the transparent substrate of the color filter forming substrate. As a result, it is possible to prevent the uppermost colored layer of the separated columnar spacer from being scraped, and as a result, the display defect caused by the colored floating foreign material of the uppermost colored layer of the conventional columnar spacer is prevented. It is assumed that can be prevented.
And when it is used for a liquid crystal display device of a smart phone (also called a multi-function mobile phone or a high-function mobile phone) or a tablet-type multi-function terminal that requires high definition, the width of the black stripe itself is due to high definition. Since it is required to be small, it is necessary to reduce the width of the colored layer to be laminated on the columnar spacers disposed thereon, but this case can be dealt with and is particularly effective.
In a high-definition display device such as a smartphone, the line width of the black matrix is small, and the colored layer is placed inside the area of the lower colored layer in the order of stacking on the black matrix of the color filter forming substrate. Therefore, the width of the uppermost colored layer of the columnar spacer on the black matrix is further reduced.
In addition, the color filter forming substrate can cope with a pressing force of a touch panel type, and an IPS (abbreviation of In Plane Switching) method for controlling a liquid crystal display by a horizontal electric field method in which display quality is not affected by the pressing force of the touch panel type. This is even more effective when used for a liquid crystal display device.

  The liquid crystal display device of the present invention has such a configuration, so that even if the cell is assembled with the color filter forming substrate and the TFT substrate, the colored dust particles in the colored layer forming the columnar spacers are not affected by vibration. It is supposed that it can be prevented from flowing into the liquid crystal.

In this way, the present invention is a color filter forming substrate having a columnar spacer formed with a colored layer and covered with an OC layer. In the case of a liquid crystal display device that requires high-definition display such as a smartphone, it is possible to prevent the colored dust that is the waste of the uppermost colored layer of the columnar spacer from flowing into the liquid crystal even when subjected to vibration. A color filter forming substrate can be provided.
At the same time, it is possible to provide a liquid crystal display device that can prevent the colored dust of the uppermost colored layer forming the columnar spacer from flowing into the liquid crystal even when subjected to vibration in the assembled state.

FIG. 1A is a schematic sectional view of a part of a first example of an embodiment of a color filter forming substrate of the present invention, and FIG. 1B is a diagram of the first example shown in FIG. It is a schematic sectional drawing of the liquid crystal display device using a color filter formation board | substrate. FIG. 2A is a schematic sectional view of a part of a second example of the embodiment of the color filter forming substrate of the present invention, and FIG. 2B is a diagram of the second example shown in FIG. It is a schematic sectional drawing of the liquid crystal display device using a color filter formation board | substrate. FIG. 3A to FIG. 3F are process cross-sectional views illustrating manufacturing steps of the color filter forming substrate of the first example shown in FIG. 1A and the liquid crystal display device shown in FIG. is there. FIG. 4A is a schematic diagram for explaining a method of forming a recess, FIG. 4B is a diagram showing a cross section of the recess after development, and FIG. 4C is a diagram of another recess. It is the schematic for demonstrating the formation method. It is the figure which showed the manufacture flow of the color filter formation board | substrate of a 1st example, and the manufacture flow of the liquid crystal display device using the color filter formation board | substrate of a 1st example. FIG. 6A is a schematic cross-sectional view showing a conventional color filter forming substrate, and FIG. 6B is a diagram showing a projection of a TFT substrate due to vibration in a cell assembly using the conventional color filter forming substrate. FIG. 6C is a diagram showing a state where the colored layer of the columnar spacer has been reached. FIG. 6C is a diagram in which the width of the colored layer farthest from the transparent substrate of the columnar spacer is increased and the OC is increased. It is sectional drawing corresponding to thickening the thickness of a layer.

First, the 1st example of embodiment of the color filter formation board | substrate of this invention is demonstrated based on FIG.
The color filter forming substrate 10 of the first example is provided with a colored layer (13R, 13G, 13B) for forming a color filter and a black matrix 12 on one surface of a transparent substrate 11, and on the black matrix 12. A smartphone (multi-function mobile phone) provided with a columnar spacer 15 formed by laminating three colored layers of the respective color layers for forming the color filter to form a column shape and covered with the OC layer 14 This is a color filter forming substrate for a liquid crystal display device of a tablet-type multifunction terminal.
The cross section of the liquid crystal display device using the color filter forming substrate 10 of the first example is as shown in FIG.
In the color filter forming substrate 10 of the first example, as shown in FIG. 1A, the colored layer 13B farthest from the transparent substrate 11 of the columnar spacer 15 is transparent on the surface that is not on the transparent substrate 11 side. When the OC layer 14 is coated and formed by die coating or the like without being penetrated into the substrate side 11, the concave portion (also referred to as a depression) 13 a is not formed in the concave portion as compared with the shape without the concave portion 13 a. An OC material for forming an OC layer can be stored.
For this reason, when the cell is assembled with the TFT substrate, the projection 21a of the TFT substrate does not reach the colored layer 13B farthest from the transparent substrate 11 of the columnar spacer 15 even when subjected to vibration in transportation or carrying. The colored dust in the colored layer 13R does not flow into the liquid crystal 30 and the display quality is not deteriorated.
In particular, the color filter forming substrate 10 of the first example can be used for a liquid crystal display device of a smartphone (also referred to as a multi-function mobile phone or a high-function mobile phone) and a tablet-type multi-function terminal that require high definition.
Note that when the liquid crystal display device is an IPS (abbreviation of In Plane Switching) method for controlling liquid crystal display by a horizontal electric field method, the liquid crystal alignment is not easily disturbed, and is particularly effective for a touch panel type.

Next, the material of each part will be described.
<Transparent substrate 11>
As the transparent substrate 11 used in the first example, those conventionally used for color filters can be used, such as quartz glass, Pyrex (registered trademark) glass, synthetic quartz plate, and the like that are not flexible. An inorganic substrate, and a transparent transparent resin substrate such as a transparent resin film and an optical resin plate can be exemplified. In particular, an inorganic substrate is preferably used, and a glass substrate among inorganic substrates is preferable. Is preferably used.
Furthermore, it is preferable to use an alkali-free type glass substrate among the glass substrates.
The alkali-free glass substrate is superior in dimensional stability and workability in high-temperature heat treatment, and does not contain an alkali component in the glass. Therefore, the base of a color filter forming substrate for an active matrix type color liquid crystal display device is used. It is because it can be used suitably as a material.
As the substrate, a transparent transparent substrate is usually used.

<Colored layer of black matrix 12>
As the colored layer of the black matrix 12, generally, a pigment (pigment) such as carbon black or a black colorant such as a dye dispersed in a binder resin is used, and a film thickness for obtaining an optical density of 4.0 or more is used. To do.
When a photolithography method is used as a method for forming the light-shielding colored layer, the binder resin is, for example, a photosensitive resin having a reactive vinyl group such as an acrylate, methacrylate, polyvinyl cinnamate, or cyclized rubber. Resin is used.
In this case, a photopolymerization initiator may be added to the photosensitive resin composition for forming a black matrix containing a black colorant and a photosensitive resin, and further, if necessary, a sensitizer, a coatability improver, A development improver, a crosslinking agent, a polymerization inhibitor, a plasticizer, a flame retardant, and the like may be added.
In addition, when using a printing method or an inkjet method as the method for forming the light-shielding colored layer, examples of the binder resin include polymethyl methacrylate resin, polyacrylate resin, polycarbonate resin, polyvinyl alcohol resin, polyvinyl pyrrolidone resin, and hydroxyethyl cellulose. Examples thereof include resins, carboxymethyl cellulose resins, polyvinyl chloride resins, melamine resins, phenol resins, alkyd resins, epoxy resins, polyurethane resins, polyester resins, maleic acid resins, polyamide resins and the like.

<Colored layers 13R, 13G, 13B of color filter forming substrate 10>
In this example, the colored layers for forming the color filters are the three colored layers of the red colored layer 13R, the green colored layer 13G, and the blue colored layer 13B.
The colored layer of each color is obtained by dispersing or dissolving a colorant such as a pigment or dye of each color in a binder resin, and is formed by a photolithography method (also referred to as a photolithography method).
As the binder resin used in the colored layer, for example, a photosensitive resin having a reactive vinyl group such as acrylate, methacrylate, polyvinyl cinnamate, or cyclized rubber is used.
In this case, a photopolymerization initiator may be added to the photosensitive resin composition for forming a colored part containing a colorant and a photosensitive resin, and further, a sensitizer, a coating property improver, and a development as necessary. You may add an improving agent, a crosslinking agent, a polymerization inhibitor, a plasticizer, a flame retardant, etc.
The thickness of the colored layer of each color is usually set to about 1 μm to 5 μm.
The color of the colored layer is not particularly limited as long as it includes at least three colors of red, green, and blue. For example, three colors of red, green, and blue, or red, green, blue, and yellow Or five colors such as red, green, blue, yellow, and cyan.
Examples of the colorant used in the red (also referred to as R) colored layer include perylene pigments, lake pigments, azo pigments, quinacridone pigments, anthraquinone pigments, anthracene pigments, and isoindoline pigments. Can be mentioned.
These pigments may be used alone or in combination of two or more.
Examples of the colorant used in the green (also referred to as G) colored layer include phthalocyanine pigments such as halogen polysubstituted phthalocyanine pigments or halogen polysubstituted copper phthalocyanine pigments, triphenylmethane basic dyes, and isoindoline pigments. Examples thereof include pigments and isoindolinone pigments.
These pigments or dyes may be used alone or in combination of two or more.
Examples of the colorant used in the blue (also referred to as B) coloring layer include copper phthalocyanine pigments, anthraquinone pigments, indanthrene pigments, indophenol pigments, cyanine pigments, dioxazine pigments, and the like. .
These pigments may be used alone or in combination of two or more.

<OC layer (also referred to as protective layer) 14 of color filter forming substrate>
Examples of the material of the OC layer 14 include a thermosetting resin composition and a photocurable resin composition. The photo-curable resin composition is preferable for cutting into pieces after imposing the color filter-formed substrate on the surface.
The OC photocurable resin composition is the same as the binder resin used for the color layers for forming the color filter, for example, acrylate, methacrylate, polyvinyl cinnamate, or cyclized rubber. A photosensitive resin having a reactive vinyl group such as a system is used.
In this case as well, a photopolymerization initiator may be added to the photosensitive resin composition for forming colored portions containing the photosensitive resin, and further, a sensitizer, a coating property improver, and a development improver as necessary. Further, a crosslinking agent, a polymerization inhibitor, a plasticizer, a flame retardant and the like may be added.
In the first example, the color filter forming substrate 10 is impositioned to form the colored layers 13R, 13G, 13B and the frame portion 12A, and then the OC layer resin composition is applied by a die coating method. .
In addition, in order to separate the OC layer between each color filter substrate and separate into individual pieces at the cut, the OC resin composition is applied as a photocurable resin composition, dried after being applied, Although only predetermined areas are selectively irradiated with light and developed to form cuts, the method for forming the OC layer is not limited to this.
Examples of the thermosetting resin composition for the OC layer include those using an epoxy compound and those using a thermal radical generator.
Examples of the epoxy compound include known polyvalent epoxy compounds that can be cured by a carboxylic acid or an amine compound. Examples of such an epoxy compound include “Epoxy resin handbook” edited by Masaki Shinbo, published by Nikkan Kogyo Shimbun. (1987) and the like, and these can be used.
The thermal radical generator is at least one selected from the group consisting of persulfates, halogens such as iodine, azo compounds, and organic peroxides, more preferably azo compounds or organic peroxides.
Examples of the azo compound include 1,1′-azobis (cyclohexane-1-carbonitrile, 1-[(1-cyano-1-methylethyl) azo] formamide, 2,2′-azobis- [N- (2-propenyl). ) -2-methylpropionamide], 2,2′-azobis (N-butyl-2-methylpropionamide), 2,2′-azobis (N-cyclohexyl-2-methylpropionamide) and the like, Examples of the organic peroxide include di (4-methylzenzoyl) peroxide, t-butylperoxy-2-ethylexanate, 1,1-di (t-hexylperoxy) cyclohexane, 1,1-di ( t-butylperoxy) cyclohexane, t-butylperoxybenzoate, t-butylperoxy-2-ethylhexyl monocarbonate, t-butyl Examples include til-4,4-di- (t-butylperoxy) butanate and dicumyl peroxide.

Next, an example of manufacturing the color filter forming substrate 10 of the first example shown in FIG. 1A and an example of manufacturing a liquid crystal panel using the first color filter forming substrate 10 shown in FIG. A brief description will be given based on FIG. 3 showing a sectional view of each process and FIG. 5 showing a process flow.
In FIG. 5, S0 to S10 indicate processing steps.
First, a transparent substrate 11 serving as a base of a color filter forming substrate of the present invention is prepared in advance (S0), and a black matrix 12 is formed on the side of the transparent substrate on which a colored layer for each color is to be formed. I do. (FIG. 3A, S0 to S1 in FIG. 5)
Here, a black colored layer in which a pigment, dye or the like is mixed and dispersed in an ultraviolet curable photosensitive resin is applied to one surface of a transparent substrate, and the black matrix 12 is formed into a predetermined shape by photolithography.
The black matrix 12 is a portion in which lines are arranged in the vertical direction and the horizontal direction, and a portion surrounded by these is a colored pixel.
Next, a red colored layer in which pigments and dyes are mixed and dispersed in an ultraviolet curable photosensitive resin is applied to the surface of the transparent substrate on which the black matrix 12 is formed, and is formed into a predetermined shape by photolithography. Thus, a first colored layer (also referred to as a red colored layer or R layer) 13R is formed. (FIG. 3B, S2 in FIG. 5)
Here, the first colored layer 13R for the color filter is formed, and a colored layer portion including the first colored layer 13R for forming the columnar spacer 15 is formed.
Next, a green colored layer in which pigments and dyes are mixed and dispersed in an ultraviolet curable photosensitive resin is applied to the surface of the glass substrate on which the black matrix 12 and the first colored layer 13R are formed. A second colored layer (also referred to as a green colored layer or G layer) 13G is formed in a predetermined shape by a photolithography method. (FIG. 3C), S3 in FIG. 5)
Here, the second colored layer 13G for the color filter is formed, and a colored layer portion including the second colored layer 13R for forming the columnar spacer 15 is formed.
Next, the black colored layer 12 of the glass substrate, the first colored layer 13R, and the second colored layer 13G were formed from the blue colored layer in which pigments and dyes were mixed and dispersed in the ultraviolet curable photosensitive resin. A third colored layer (also referred to as a blue colored layer or B layer) 13B is formed by applying to the side surface and forming a predetermined shape by photolithography. (FIG. 3 (d)), S4 in FIG. 5)
Here, the third colored layer 13B for the color filter is formed, and a colored layer portion composed of the third colored layer 13B for forming the columnar spacer 15 is formed.
The surface of the third colored layer 13 </ b> B for forming the columnar spacer 15 on the side that is not on the transparent substrate 11 side is a recessed shape without penetrating the transparent substrate side 11.
Next, an OC layer is applied to the entire surface on which the first colored layer 13R, the second colored layer 13G, and the third colored layer 13B are formed by a die coating method, and is dried and cured as necessary. The color filter forming substrate of the example is prepared. (FIG. 3 (e), S5 to S6 in FIG. 5)

The exposure in the photolithographic method for forming the first colored layer to the third colored layer is performed by using a predetermined photomask for forming each colored layer and an ultraviolet curable colored layer for forming each colored layer. The gap (about 100 to 200 μm) is separated and proximity exposure (also referred to as proximity exposure) is performed with predetermined exposure light.
In the case of forming the first colored layer 13R and the second colored layer 13G, the photomask used for exposure has an opening in the region where the colored layer of the columnar spacer 15 is formed and the region where the colored layer for the color filter is formed. Thus, a transmissive region is formed, and other regions are shielded from light so as to be a light-shielded region.
A photomask used here is also called a binary mask.
Further, in the case of forming the third colored layer 13B, the surface of the columnar spacer 15 on the side that is not on the transparent substrate 11 side of the third colored layer 13B has a recessed shape without penetrating the transparent substrate side 11, As shown in FIG. 4A, in the photomask 51, an exposure light transmitting halftone film 54 that transmits exposure light at a predetermined rate is formed in a region where the recessed portion of the columnar spacer 15 is exposed. Thus, a semi-transmissive region is formed, and the other photomask region corresponding to the formation region of the third colored layer 13B is opened to be a transmissive region, and the other is a light-shielding region.
A photomask used here is also referred to as a gradation mask.
A region exposed through the halftone film 54 becomes a concave portion 13a having a concave shape as shown in FIG.
The exposure light transmittance of the halftone film 54 is appropriately adjusted according to the depth of the recess 13a.
The method for forming the recess 13a is not limited to this.
For example, in the halftone film 54 region of FIG. 4 (a), as shown in FIG. 4 (c), a line & space pattern that is not resolved even if exposed by a line 52a made of a light-shielding film is provided. Alternatively, a concave portion having the same concave shape as that of the halftone film can be obtained by arranging a dot pattern made of a light-shielding film that is not resolved even when exposed to light.

The color filter forming substrate of the first example manufactured in this way (FIG. 3E, S6 in FIG. 5) and the TFT substrate (S7 in FIG. 5) to be bonded to form a liquid crystal display device. ) Is prepared in advance.
Then, an ultraviolet curable sealant is applied to the seal area on the outer periphery of the color filter forming substrate of the first example by a dispenser or printing to a predetermined height, and liquid crystal is further disposed by a dropping method. Thereafter, bonding to the TFT substrate is performed. (S8 to S9 in FIG. 5)
At the time of bonding, the sealing material is cured by irradiating the sealing material in the sealing region with ultraviolet rays from the transparent substrate 11 side.
In this manner, a liquid crystal display device using the first color filter forming substrate is manufactured. (FIG. 3 (f), S10 in FIG. 5)

Next, a second example of the embodiment of the color filter forming substrate of the present invention will be described.
The second example is the same as the first example except that the shape of the columnar spacer of the first example is changed.
In the color filter forming substrate 10A of the second example, as shown in FIG. 2A, the colored layer 13B farthest from the transparent substrate 11 of the columnar spacer 15 is transparent on the surface that is not on the transparent substrate 11 side. As in the case of the first example, when the OC layer 14 is applied and formed by die coating or the like in the shape of being recessed through the substrate side 11, the OC layer 14 is formed in the recess compared to the configuration without the recess 13 a. The OC material can be stored.
For this reason, as in the case of the first example, when the cell is assembled with the TFT substrate, the projection 21a of the TFT substrate is colored farthest from the transparent substrate 11 of the columnar spacer 15 even when it is subjected to vibration during transportation or carrying. It does not reach the layer 13B, so that the colored dust in the colored layer 13R does not flow into the liquid crystal 30 to deteriorate the display quality.
As in the case of the first example, it can be used for a liquid crystal display device of a smart phone (also referred to as a multi-function mobile phone or a high-function mobile phone) requiring high definition or a tablet-type multi-function terminal.
The production of the color filter forming substrate 10A of the second example shown in FIG. 2A is different from the production method of the first example except that exposure is performed by changing the photomask when forming the uppermost colored layer to be laminated. Is basically the same as the manufacturing method of the first example.
Here, the recessed part which penetrated is formed by exposing the recessed shape of the colored layer of a columnar spacer using the opening pattern which resolves which opened the light shielding film.
The liquid crystal display device shown in FIG. 2B using the color filter forming substrate 10A of the second example can be manufactured in the same manner as in the case of the first example.

The color filter forming substrate of the present invention is not limited to the above.
For example, in the first example and the second example, the colored layer for forming the columnar spacer is formed by laminating three colored layers. However, the colored layer is formed by laminating two colored layers. Also good.
In the case where four color layers are used for the color filter forming substrate, the color layers for forming the columnar spacers may be laminated with the four color layers.
The shape of each colored layer forming the columnar shape is usually a circular shape or a quadrangular shape, and in the case of the first example and the second example, it is such a shape, but is not limited thereto.
In addition, when forming the colored layer for forming the color filter of each color by the photolithography method, it seems impossible to form the columnar spacer with the colored layer of one color.
In the first example and the second example, the colored layers forming the columnar spacers are the three colored layers, the red colored layer 13R, the green colored layer 13G, and the blue colored layer in order from the transparent substrate side. Although the colored layer 13B is used, the stacking order is not limited to this.
Moreover, the recessed part of a recessed shape is not limited to the above.
For example, a part of the concave shape of the uppermost colored layer of the columnar spacer may be penetrated and partly not penetrated.

Next, the liquid crystal display device shown in FIGS. 1B and 2B will be briefly described. The liquid crystal display device shown in FIG. 1B is an IPS-type liquid crystal panel in which a color filter forming substrate 10 and a TFT substrate 20 are arranged with a liquid crystal 30 therebetween, and in brief, a common electrode formed on the TFT substrate 20. By applying a voltage between the pixel electrode and the pixel electrode, an electric field is formed substantially in parallel with the interface of the color filter forming substrate 10 or the TFT substrate 20, and the liquid crystal molecules in the gap portion between the two substrates It is polarized and rotated in a plane parallel to the substrate 20, and the polarization axis of the light from the light source is rotated, so that this pixel is turned on.
In this way, a color image is obtained by controlling the light transmittance of each of the pixels colored in each color or the liquid crystal layer 30 behind the color filter forming substrate 10.
Here, a color filter forming substrate 10 which is a display side substrate and the TFT substrate 20 are opposed to each other, and a gap portion of about 1 to 10 μm is provided, and the liquid crystal 30 is filled in the gap portion. It has a sealed structure.
An alignment film is provided on the inner surface side of the color filter forming substrate 10 and the TFT substrate 20 opposed thereto.
In addition, deflecting plates are disposed outside the color filter forming substrate 10 and the TFT substrate 20, respectively.
The color filter forming substrate 10 may be provided with a retardation layer (optical compensation layer) (not shown) between the transparent substrate 11 and the OC layer 14 from the viewpoint of improving display characteristics.
The liquid crystal display device shown in FIG. 2B is the same as the liquid crystal display device shown in FIG. 1B except that the color filter forming substrate shown in FIG.

[Example]
The present invention will be further described with reference to examples.
Example 1
In Example 1, the color filter forming substrate shown in FIG. 1A and the liquid crystal display device shown in FIG. 1B are manufactured by the processing flow shown in FIG.
Hereinafter, a description will be given based on FIG.
Here, as described below, a photocurable curable resin composition A is prepared, and the prepared curable resin composition A is used for forming a color filter of each color in a color filter forming substrate. A curable resin composition, a green curable resin composition, a blue curable resin composition, and a curable resin composition for a black matrix portion are prepared, and using these, a photolithography method is performed for each curable resin composition. Then, each colored resin layer was formed to produce a color filter forming substrate 10.
In Example 1, the black matrix 12 has a thickness of 2.0 μm and a width of 80.0 μm. In the spacer 15, the first colored layer 13R has a thickness of 2.8 μm, a width of 60.0 μm, and the second colored layer 13G has a thickness. The thickness of the third layer colored layer 13B, which is the uppermost layer, is 1.5 μm, the width W0 is 30.0 μm, the width Wa of the recess 13a is 20.0 μm, and the depth at which the recess 13a is recessed is 1.7 μm, the width is 45.0 μm The thickness was 1.0 μm.
Here, each colored layer forming the columnar spacer has a circular shape.

(Preparation of curable resin composition A)
The polymerization tank is charged with 63 parts by weight of methyl methacrylate (MMA), 12 parts by weight of acrylic acid (AA), 6 parts by weight of 2-hydroxyethyl methacrylate (HEMA), and 88 parts by weight of diethylene glycol dimethyl ether (DMDG). After stirring and dissolving, 7 parts by weight of 2,2′-azobis (2-methylbutyronitrile) was added and dissolved uniformly.
Then, it stirred at 85 degreeC under nitrogen stream for 2 hours, and also was made to react at 100 degreeC for 1 hour.
7 parts by weight of glycidyl methacrylate (GMA), 0.4 parts by weight of triethylamine, and 0.2 parts by weight of hydroquinone were further added to the resulting solution, and the mixture was stirred at 100 ° C. for 5 hours to obtain a copolymer resin solution ( A solid content of 50%) was obtained.
Next, the following materials were stirred and mixed at room temperature to obtain a curable resin composition A.
-Copolymer resin solution (solid content 50%): 16 parts by weight-Dipentaerythritol pentaacrylate (Sartomer SR399)
: 24 parts by weight-Orthocresol novolak type epoxy resin (Epicoat Shell Epoxy Co., Ltd. Epicoat 180S70): 4 parts by weight-2-Methyl-1- (4-methylthiophenyl) -2-morpholinopropan-1-one: 4 parts by weight Parts ・ Diethylene glycol dimethyl ether: 52 parts by weight

<Light-shielding colored resin material (curable resin composition) for forming the black matrix 12 of the color filter forming substrate>
The components of the following amounts were sufficiently mixed to obtain a light-shielding colored layer composition.
Black pigment dispersion 1: 42 parts by weight Curable resin composition A: 20 parts by weight Diethylene glycol dimethyl ether: 38 parts by weight The black pigment dispersion 1 here is mixed with the following components and is sufficiently mixed in a bead mill. To prepare a dispersion.
・ Black pigment (black pigment)
Resin-coated carbon black (MS18E manufactured by Mitsubishi Chemical Corporation): 20 parts by weight Polymer dispersion material (Big Chemie Japan, Ltd. Disperbyk
111)
: 5 parts by weight-Solvent (diethylene glycol dimethyl ether): 75 parts by weight

Each color resin material (curing resin composition) for the color filter was also prepared by mixing the components in the following amounts and sufficiently dispersing in a sand mill.
<Red curable resin composition>
C. I. Pigment Red 177: 3 parts by weight C.I. I. Pigment Red 254: 4 parts by weight-Polysulfonic acid type polymer dispersant: 3 parts by weight-Curable resin composition A: 23 parts by weight-3-methoxybutyl acetate: 67 parts by weight <Green curable resin composition>
C. I. Pigment Green 58: 7 parts by weight C.I. I. Pigment Yellow 138: 1 part by weight-Polysulfonic acid type polymer dispersant: 3 parts by weight-Curable resin composition A: 22 parts by weight-3-methoxybutyl acetate: 67 parts by weight <Blue curable resin composition>
C. I. Pigment Blue 15: 6: 5 parts by weight-Polysulfonic acid type polymer dispersant: 3 parts by weight-Curable resin composition A: 25 parts by weight-3-methoxybutyl acetate: 67 parts by weight

A black matrix was formed on one surface of the color filter forming substrate as follows.
(Formation of black matrix 12)
A curable resin composition for forming the black matrix 12 having the above composition was applied on a transparent substrate (manufactured by Asahi Glass Co., Ltd., AN material) by a spin coating method, and then dried in an oven at 70 ° C. for 3 minutes.
Next, a photomask is placed at a distance of 100 μm from the coating film of the curable resin composition for forming the black matrix 12 and corresponds to a colored layer forming region using a 2.0 kW ultrahigh pressure mercury lamp by a proximity aligner. Only the area to be irradiated was irradiated with ultraviolet rays for 10 seconds.
Subsequently, it was immersed in a 0.05 wt% potassium hydroxide aqueous solution (liquid temperature 23 ° C.) for 1 minute and developed with alkali to remove only the uncured portion of the coating film of the curable resin composition for forming the black matrix 12. .
Thereafter, the substrate was left in an atmosphere of 230 ° C. for 15 minutes to perform heat treatment to form the black matrix 12 over the entire display region.

Next, the colored layer for each color filter of the color filter forming substrate was formed as follows.
(Formation of red colored layer 13R)
On the side of the transparent substrate 11 on which the black matrix 12 was formed, the red curable resin composition having the above composition was applied by spin coating, and then dried in an oven at 70 ° C. for 3 minutes.
Next, a photomask is placed at a distance of 100 μm from the coating film of the red curable resin composition, and ultraviolet rays are applied only to the region corresponding to the colored layer formation region using a 2.0 kW ultrahigh pressure mercury lamp by a proximity aligner. Irradiated for 10 seconds.
Subsequently, it was immersed in 0.05 wt% potassium hydroxide aqueous solution (liquid temperature 23 degreeC) for 1 minute, and alkali development was carried out, and only the uncured part of the coating film of a red curable resin composition was removed.
Thereafter, the substrate was left in an atmosphere of 230 ° C. for 15 minutes to perform heat treatment, thereby patterning the red colored layer 13R in the red color filter forming region and the columnar spacer forming region in the display region.
The film thickness of the colored layer 13R formed in the pixel region and serving as the red color filter portion was 3.5 μm.
(Formation of green colored layer 13G)
Next, using the green curable resin composition having the above composition, in the same process as the formation of the red colored layer 13R, the coating film thickness is changed, and the colored layer that is formed in the pixel region and becomes the green color filter portion The green colored layer 13G was formed by patterning in the green color filter forming region and the columnar spacer forming region in the display region so that the film thickness of 13G was 3.5 μm.
(Formation of blue colored layer 13B)
Further, using the blue curable resin composition having the above composition, the coating film is formed in the same process as that for forming the red relief pattern except that the photomask (tone mask) shown in FIG. The thickness of the colored layer 13B that is formed in the pixel region and becomes the blue color filter portion is changed to 3.5 μm by changing the thickness, and the blue color filter forming region and the columnar spacer forming region in the display region are blue. The colored layer 13B was formed by patterning.
Here, the recess 13a is formed with the exposure light transmittance of the halftone film 54 shown in FIG.
The depth of the recess of the recess 13a was 1.0 μm.

(Formation of OC layer 14)
After forming the blue colored layer 13B as described above, the above-mentioned curable resin composition A is applied and dried on the side of the transparent substrate 11 on which the colored layer is formed by a die coating method, and the dried coating film has a thickness of 2 μm. The coating film was formed.
A photomask is placed at a distance of 100 μm from the coating film of the curable resin composition A, and an ultraviolet ray is applied only to a region corresponding to the region where the OC layer 14 is formed using a 2.0 kW ultrahigh pressure mercury lamp by a proximity aligner. Irradiated for 2 seconds.
Next, it was immersed in a 0.05 wt% aqueous potassium hydroxide solution (liquid 23 ° C.) for 1 minute and alkali developed to remove only the uncured portion of the coating film of the curable resin composition.
Thereafter, the substrate was left to stand in an atmosphere at 230 ° C. for 15 minutes to perform heat treatment, thereby forming the OC layer 14.
The thickness of the CO layer 14 in the recess 13a could be 1.5 μm or more.
In this way, the color filter forming substrate 10 shown in FIG.

(Creation of liquid crystal display device)
An alignment film (SE-6210, manufactured by Nissan Chemical Industries, Ltd.) was formed on the surface of the color filter forming substrate 10 obtained as described above on the colored layer forming side, and then a rubbing treatment was performed.
Next, after forming an alignment film on the TFT substrate on which the TFT is formed and performing a rubbing treatment, a required amount of IPS liquid crystal is dropped, and the color filter is overlaid, and UV curable resin (Three Bond Co., Ltd., Three Bond) is added. 3025) is used as a sealing material, and a cell is assembled by exposing with a dose of 400 mJ / cm ² while applying a pressure of 0.3 kgf / cm ^{2 at} room temperature, and a polarizing plate, a backlight unit, and a cover glass are assembled. The liquid crystal display device was obtained by installing.
In this way, the liquid crystal display device shown in FIG. 1B was manufactured.

Next, the manufactured liquid crystal display device is subjected to display after a vibration test in which an acceleration force of 1.5 G to 2.0 G is applied in the XY direction (plane direction) and the Z direction (direction perpendicular to the plane). In the visual observation, the display quality was not deteriorated by the colored dust of the third colored layer of the columnar spacer farthest from the transparent substrate 11 of the color fill forming substrate.
Normally, an acceleration force of less than 1.5 G is applied to the vibration in transporting and carrying the liquid crystal display device.
After the vibration test, the liquid crystal display device was disassembled and the state of the columnar spacer in contact with the TFT substrate was observed with a cross-sectional SEM, optical microscope, etc., but it was confirmed that the third colored layer was not scraped. It was done.

10, 10A Color filter forming substrate 11 Transparent substrate 12 Black matrix 13a, 13b Recess (also referred to as a depression)
13R first colored layer (also referred to as red colored layer)
13G second colored layer (also referred to as green colored layer)
13B Third colored layer (also called blue colored layer)
13B1 Photosensitive resin layer 14 (for forming the third colored layer) OC layer (also referred to as protective layer)
15 Columnar spacer 20 TFT substrate 21 Transparent substrate 21a Protrusion 30 Liquid crystal 50 Photomask 51 Transparent substrate 52 Light shielding film 52a Line 52b Space 53 Transmission region 54 Halftone film 110 Color filter forming substrate 111 Transparent substrate 112 Black matrix 113R First coloring Layer (also called red colored layer)
113G second colored layer (also referred to as green colored layer)
113B Third colored layer (also called blue colored layer)
114 OC layer (also called protective layer)
115 Columnar spacer 120, 120A TFT substrate 121 Transparent substrate 121a Protrusion 130 Liquid crystal

Claims (4)

  A colored layer for forming a color filter and a black matrix are arranged on one surface of a transparent substrate, and two or more colored layers of the colored layers for forming a color filter are formed on the black matrix. A color filter forming substrate for a liquid crystal display device in which a columnar spacer is formed by laminating and providing a columnar spacer covered with an OC layer, and the colored layer farthest from the transparent substrate of the columnar spacer is The color filter forming substrate, wherein the side that is not on the transparent substrate side has a shape recessed toward the transparent substrate side.   It is a color filter formation board | substrate of Claim 1, Comprising: It is for liquid crystal display devices of a smart phone or a tablet type multifunction terminal, The color filter formation board | substrate characterized by the above-mentioned.   3. The color filter forming substrate according to claim 1, wherein the color filter forming substrate is for an IPS (In Plane Switching) type liquid crystal display device that controls liquid crystal display by a horizontal electric field method. Color filter forming substrate.   A liquid crystal display device comprising the color filter forming substrate according to claim 1.

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