JP2014240853A - Liquid crystal display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a liquid crystal display device in which time for work to identify the types of columnar spacers can be reduced during the manufacture of CF substrates or at the occurrence of trouble so as to reduce manufacturing costs.SOLUTION: A liquid crystal display device includes first and second substrates that are arranged opposite to each other, a first columnar spacer that is arranged on the principal surface of the first substrate that is on the side opposite to the second substrate to hold the gap between the first substrate and second substrate, a second columnar spacer that is shorter than the first columnar spacer, and a liquid crystal held between the first and second substrates, where the first substrate is provided in association with one of the first and second columnar spacers and has identification markers to identify the first and second columnar spacers.

Description

  The present invention relates to a liquid crystal display device, and more particularly to a liquid crystal display device including at least two types of columnar spacers having different heights.

  In a general liquid crystal display device, a pair of substrates facing each other is held constant by a spacer, and a liquid crystal is filled between the substrates. One substrate is an active matrix substrate (TFT substrate) in which source wirings and gate wirings cross each other in a lattice shape, and thin film transistors are arranged at the crossing portions.

  The other substrate is a filter substrate on which a color filter (CF) is arranged, and a pixel portion is defined by a black matrix (hereinafter referred to as BM), and R (red), G (green) and B (blue) are defined in the pixel portion. The color filter is formed.

  The distance between two opposing substrates is called the “cell gap”. As a method of maintaining the cell gap, a spherical spherical spacer with a particle diameter of about several μm is dispersed, or columnar protrusions are formed on the substrate. Arrangement of the obtained columnar spacer (PS) is mentioned.

  A configuration using PS is often used because of the advantage of improving the contrast of the liquid crystal display device and reducing the number of manufacturing steps.

  However, in the single PS structure in which the height of the PS is one kind, if the PS is arranged at such a density that increases the strength against the force in the direction of pressing the two substrates (surface pressing strength), the liquid crystal display device becomes low in temperature. When placed, low temperature foaming tends to occur.

  That is, when the liquid crystal display device is placed at a low temperature, all the members constituting the liquid crystal display device try to shrink, but among the members constituting the liquid crystal display device, the shrinkage rate of the liquid crystal material is the largest. Shrinks in the direction of narrowing. However, since the surface pressing strength is high, the deformation of PS cannot follow the narrowing of the gap, the pressure inside the liquid crystal cell of the liquid crystal display device becomes low, and vacuum bubbles (low temperature foaming) are likely to occur in the liquid crystal cell. .

  Conversely, if PS is arranged at such a density that low temperature foaming does not occur, the surface pressing strength may be insufficient.

  Thus, as an improvement in surface pressing strength and a margin increase with respect to low-temperature foaming, for example, Patent Documents 1 and 2 propose a dual PS structure using at least two types of PS having different heights.

  In the dual PS structure, for example, when two types of PS having different heights are used, the higher one is the main PS and the lower one is the sub-PS. The main PS is always in contact with both substrates, and the cell gap ( The distance between the substrates) is held appropriately (predetermined value). On the other hand, the sub-PS is not in contact with one substrate (floating) at normal temperature (a state in which no special external pressure or the like is applied to the panel surface) at normal temperature, and an external pressure or the like is applied to the panel surface. Only when the cell gap is narrower than a predetermined value, such as when the cell gap is smaller than the specified value, such as when the cell gap is applied (surface-pressed state) or when the liquid crystal cell has a negative pressure due to temperature change, the cell Have a role to hold the gap.

  In such a dual PS structure, a type in which the height is changed depending on the presence or absence of a color material under the PS (see Patent Document 1), or the same PS material is used so that the PS height can be freely designed. There is a type that changes only the thickness (see Patent Document 2).

JP-A-2005-122150 JP 2002-341354 A

  In the dual PS structure in which only the height is changed using the same PS material as described above, there is an advantage that it is excellent in cost by separately creating the height using the halftone technology. When this structure is used, the planar shape and the like of the main PS and the sub PS are the same.

  As a result, when the main PS and the sub PS have the same arrangement density, arrangement rule, color material color to be arranged, and the like, they can be distinguished from each other as long as the vicinity of the PS is planarly observed using an optical microscope or the like. difficult.

  Further, in a general dual PS structure, a color material color to be further arranged at a specific position in one pixel region is regularly arranged at the same position, and only a certain proportion of PS is used. In many cases, the main PS is set to the sub PS. Specifically, since setting the main PS to a relatively low density is effective for preventing low-temperature foaming, only the PS at a specific position is set as the main PS at a relatively small ratio, for example, about 10%. , The rest is set to the sub-PS. Even in such a case, in a dual PS structure in which only the height is changed using a PS material, PSs having the same planar shape and the like are simply arranged when viewed on a plane. Difficult to distinguish.

  Therefore, in order to check whether a PS at a certain location is a main PS or a sub PS, it is necessary to be based on design information related to the arrangement of the main PS and the sub PS for each pixel address. Need to get an accurate address.

  For example, in the case of a single CF substrate, it is necessary to count the number of pixels from the edge of the display area that can be used as a reference for position information in planar observation to the position of PS, and it is difficult to determine the type of PS, and the CF substrate There has been a problem that it takes time to determine the type of PS at the time of manufacturing or when trouble occurs.

  The present invention has been made to solve the above problems, and a liquid crystal display device capable of reducing the manufacturing cost by shortening the time for discriminating the PS type when the CF substrate is manufactured or when trouble occurs. The purpose is to provide.

  An aspect of a liquid crystal display device according to the present invention is a liquid crystal display device including a liquid crystal panel for displaying an image, wherein the liquid crystal panel includes first and second substrates disposed opposite to each other, and the first substrate. A first columnar spacer that is disposed on a main surface of the first substrate facing the second substrate and that holds a gap between the first substrate and the second substrate; A second columnar spacer shorter than the first columnar spacer, and a liquid crystal sandwiched between the first and second substrates, wherein the first substrate is one of the first and second columnar spacers. An identification mark is provided in association with one and identifies the first and second columnar spacers.

  According to the liquid crystal display device of the present invention, since the first and second columnar spacers are provided in association with one of the first and second columnar spacers and have the identification mark for identifying the first and second columnar spacers, the plane pattern The type of columnar spacers that are indistinguishable in shape and have different heights can be determined only by plane observation. The manufacturing time can be reduced by shortening the time for discriminating the types of columnar spacers.

It is a top view which shows the whole structure of the liquid crystal panel of the liquid crystal display device which concerns on this invention. It is sectional drawing of the liquid crystal panel of the liquid crystal display device which concerns on this invention. It is a partial top view of the liquid crystal panel of Embodiment 1 which concerns on this invention. It is a fragmentary sectional view of the liquid crystal panel of Embodiment 1 which concerns on this invention. It is a top view which shows the structure of a black matrix. It is a fragmentary top view of the modification of the liquid crystal panel of Embodiment 1 which concerns on this invention. It is a fragmentary top view of the liquid crystal panel of Embodiment 2 which concerns on this invention. It is a fragmentary top view of the liquid crystal panel of Embodiment 3 which concerns on this invention. It is a fragmentary top view of the modification of the liquid crystal panel of Embodiment 3 which concerns on this invention. It is a fragmentary top view of the liquid crystal panel of Embodiment 4 which concerns on this invention. It is a fragmentary top view of the modification of the liquid crystal panel of Embodiment 4 which concerns on this invention. It is a fragmentary top view of the liquid crystal panel of Embodiment 5 which concerns on this invention. 4 is a flowchart illustrating a method for manufacturing a liquid crystal display device according to the present invention.

  Embodiments of the present invention will be described below with reference to the drawings. In order to clarify the explanation, the following description and drawings are omitted or simplified as appropriate. For the sake of clarification, duplicate explanation is omitted as necessary. In addition, what attached | subjected the same code | symbol in each figure has shown the same element, and description is abbreviate | omitted suitably.

<Overall configuration of LCD panel>
Prior to the description of the first embodiment according to the present invention, the overall configuration of the liquid crystal panel 10 will be described with reference to FIGS. 1 and 2.

  FIG. 1 is a plan view showing the overall configuration of the liquid crystal panel 10, and FIG. 2 is a cross-sectional view taken along the line AA in FIG. Here, as an example, a liquid crystal panel in which the operation mode of the liquid crystal is a TN (Twisted Nematic) mode and the switching element is a TFT (Thin Film Transistor) will be described as an example.

  As shown in FIG. 1, the liquid crystal panel 10 is a TFT array substrate (hereinafter referred to as an array substrate) 110 in which TFTs are arranged in an array as switching elements, and a counter substrate disposed to face the TFT array substrate 110. A color filter substrate (hereinafter referred to as a CF substrate) 120 on which a color filter or the like is formed, and a seal pattern 133 that seals a gap between the two are provided. In FIG. 1, the horizontal direction is X and the vertical direction is Y.

  The seal pattern 133 is disposed between the array substrate 110 and the CF substrate 120 so as to surround at least the display region 100 that is a region corresponding to a display surface for displaying an image when the liquid crystal panel 10 is operated. In a space (cell) defined by 133, the array substrate 110, and the CF substrate 120, liquid crystal is injected and sealed by a drop injection (ODF) method.

  Therefore, as shown in FIG. 1, the seal pattern 133 has a closed loop shape and does not have an injection port that is an opening for injecting liquid crystal unlike a liquid crystal panel manufactured by a vacuum injection method. It has a structural feature that a sealing material for sealing the injection port is not provided. The material of the seal pattern 133 is composed of a photo-curing sealant (photo-curing resin) mixed with conductive particles.

  In FIG. 1, in order to illustrate the configuration of the TFT array substrate 110 disposed below the color filter substrate 120, the color filter substrate 120 is mainly illustrated only in the upper left part with the Y direction as the upper side in the drawing. In other areas, the color filter substrate 120 is not shown and the configuration of the TFT array substrate 110 is shown. As an actual configuration, the color filter substrate 120 is provided so as to cover a region DL indicated by a broken line outside a region surrounded by the seal pattern 133.

  In addition, a frame region 101 is arranged so as to surround the outside of the display region 100 in a frame shape. In the drawing, a rectangular area that is to be the display area 100 is surrounded by a dotted line to be a boundary with the frame area 101. The display region 100 and the frame region 101 used here are used on the TFT array substrate 110 of the liquid crystal panel 10, the color filter substrate 120, or the entire region sandwiched between the two substrates. In the book, they are all used with the same meaning.

  As shown in FIG. 2, the TFT array substrate 110 drives the liquid crystal on one main surface (the main surface on the side facing the CF substrate 120) of the glass substrate 111 made of glass which is a transparent substrate. A pixel electrode 113 to which a voltage is applied, a TFT 114 that is a switching element that supplies a voltage to the pixel electrode 113, an insulating film 115 that covers the TFT 114, a plurality of gate wirings 118g that are wirings that supply signals to the TFT 114, a source wiring 118s, and a TFT 114 A signal terminal 116 for receiving a supplied signal from the outside, a transfer electrode (not shown) for transmitting a signal input from the signal terminal 116 to the counter electrode 126 of the color filter substrate 120, and the like are provided. Note that peripheral wiring for transmitting a signal input from the signal terminal 116 to the gate wiring 118g, the source wiring 118s, and the transfer electrode 117 is not shown.

  The TFT 114 is provided in the vicinity of each intersection of the gate wiring 118g and the source wiring 118s in the display region 100 on the TFT array substrate 110, and the pixel electrode 113 is in each pixel region surrounded by the gate wiring 118g and the source wiring 118s. Are arranged in a matrix. Further, the signal terminal 116, the transfer electrode 117, and the peripheral wiring are formed in the frame region 101.

  In addition, an alignment film 112 for aligning liquid crystal is provided in a region corresponding to the display region 100 on the insulating film 115 covering the TFT 114, and a polarizing plate 131 is provided on the other main surface of the glass substrate 111. Yes.

  As shown in FIG. 2, the CF substrate 120 has three primary colors of red (R) and green (on the main surface facing the array substrate 110) on one main surface of a glass substrate 121 that is a transparent substrate. As the G) and blue (B) filters, color filters 124R, 124G, and 124B are provided spaced apart from each other. Further, a black matrix (BM) 125 is provided as a light shielding film for shielding light between the color filters 124 </ b> R to 124 </ b> B or shielding the frame region 101 arranged outside the region corresponding to the display region 100. An alignment film for aligning the liquid crystal on the common electrode 126 is provided on the color filters 124R to 124B and the BM 125 by providing a common electrode 126 for driving the liquid crystal by generating an electric field with the pixel electrode 113 on the array substrate 110. 123, and a polarizing plate 132 is provided on the other main surface of the glass substrate 121 of the CF substrate 120, that is, the main surface opposite to the main surface on which the color filters 124R to 124B, the black matrix 125, and the like are provided. ing. In FIG. 2, the horizontal direction is X and the thickness direction is Z.

  As the color filters 124R to 124B, a color material layer in which a pigment or the like is dispersed in a resin can be selected, and functions as a filter that selectively transmits light in a specific wavelength range such as red, green, and blue.

  The BM 125 is also arranged in the frame area outside the display area 200 in addition to the space between the color filters 124, and is formed over almost the entire frame area in the CF substrate 120. In the frame area unnecessary for display, the BM 125 is included in the CF substrate 120. Light transmission is blocked.

  Further, in the present invention, a dual PS structure is employed in which a cell gap (distance between substrates) is held by two types of columnar spacers (PS) having different heights, and the CF substrate 120 has a columnar shape that is a main PS. A spacer 134m and a columnar spacer 134s, which is a sub-PS, are provided.

  In FIG. 1, the repeating units REP of the columnar spacers 134m and 134s are shown surrounded by a broken line. Further, in Embodiments 1 to 6 described later, an identification mark PSM serving as a mark for arranging the main PS and the sub PS is provided in the repeat unit REP.

  A specific example of the identification mark PSM will be described in the first to sixth embodiments. In FIG. 1, in the pixel in which the columnar spacer 134m described in the first embodiment is arranged, a color material (color filter 124B). In this example, a notch is provided in a part of the identification mark PSM.

  The columnar spacer 134m is normally set to a length that abuts the TFT array substrate 110 and the color filter substrate 120 to maintain the substrate interval at a predetermined value, and the columnar spacer 134s is set to be shorter than the columnar spacer 134m. Normally, the TFT array substrate 110 is not in contact with the TFT array substrate 110. However, when external pressure or the like is applied to the surfaces of the TFT array substrate 110 and the color filter substrate 120, the substrate array becomes narrower than the predetermined value. Abutting against the substrate 110, the distance between the substrates is kept within a certain range. In other words, since the columnar spacer 134s is formed at a lower height than the columnar spacer 134m as the height from the surface of the glass substrate 121, the columnar spacer 134m and the columnar spacer 134s are 2 It will be provided at different heights of each type.

  A liquid crystal layer 130 is held in at least a region corresponding to the display region 100 in the gap between the color filter substrate 120 and the TFT array substrate 110 held by the columnar spacers 134m and the columnar spacers 134s. The pattern 133 is sealed.

  Further, the transfer electrode 117 and the common electrode 126 are electrically connected by conductive particles mixed in the seal pattern 133, and a signal input from the signal terminal 116 is transmitted to the common electrode 123. The conductive particles are preferably those that can be elastically deformed from the viewpoint of the stability of conduction. For example, a spherical resin whose surface is gold-plated may be used.

  In addition to the configuration described above, the liquid crystal panel 10 includes a control board 135 that generates a drive signal, an FFC (Flexible Flat Cable) 136 that electrically connects the control board 135 to the signal terminal 116, and a backlight unit ( Usually, it is arranged outside the TFT array substrate 110 provided on the side opposite to the CF substrate 120 serving as a display surface, facing the main surface of the TFT array substrate 110 (not shown here). In addition, an optical sheet for controlling the polarization state and directivity of light is disposed between the liquid crystal panel 10 and the backlight unit.

  The liquid crystal panel 10 is housed in a casing (not shown) in which an outer portion of the CF substrate 120 in the display area 100 serving as a display surface together with these members is an opening, thereby forming a liquid crystal display device. To do.

  This liquid crystal display device operates as follows. That is, when an electric signal such as an image signal or a control signal is input from the control board 135 which is an external circuit, a driving voltage is applied to the pixel electrode 113 and the common electrode 123, and the direction of liquid crystal molecules changes according to the driving voltage. . As a result, the light transmittance of each pixel is controlled. Then, the light emitted from the backlight unit passes through the TFT array substrate 110, the liquid crystal layer 130, and the CF substrate 120, and is transmitted or blocked to the outside according to the light transmittance of each pixel. A color image or the like is displayed in the area 100.

<Embodiment 1>
The liquid crystal display device according to the first embodiment of the present invention will be described below with reference to FIGS. FIG. 3 is a partial plan view of the CF substrate 120 described with reference to FIGS. 1 and 2 when viewed from the TFT array substrate 110 side. FIG. 4 is a cross-sectional view taken along the line BB in FIG.

  As described above, in the present invention, the dual PS structure in which the cell gap is held by the two types of columnar spacers (PS) having different heights is adopted, and the CF substrate 120 has a columnar shape which is a main PS. A spacer 134m and a columnar spacer 134s which is a sub-PS are provided. FIG. 3 shows a repeating unit REP of the columnar spacers 134m and 134s.

  That is, as shown in FIG. 3, the color filters 124R, 124G, and 124B are arranged so that the color material patterns of the same color are arranged in the X direction, and the columnar spacers 134m and 134s are respectively blue ( B) One color material pattern arranged on a different color material pattern, and in the most recent blue color material pattern arrangement, the color material patterns in which the columnar spacers 134m and 134s are arranged are arranged one by one in the X direction. It is arranged so as to be displaced. For this reason, the repeating unit REP is defined to include two sets of blue color material pattern arrays. In other words, the repeating unit REP is a pixel unit composed of pixels of three colors R, G, and B. Four picture elements in the X direction (4 pixels) and two picture elements in the Y direction (6 Pixels), a total of 8 picture elements, that is, a range of 24 pixel regions. In FIG. 3, the pixel regions of three pixels of three colors R, G, and B constituting one picture element are illustrated by three rectangular regions surrounded by broken lines, and the color filters 124R, The rectangular areas where the color material patterns 124G and 124B are arranged correspond to the pixel areas of the three colors R, G, and B, respectively. Further, as described above, the repeating unit REP is configured by repeating 24 rectangular pixel regions surrounded by the broken line.

  One repeating unit REP is provided with at least one identification mark PSM. In FIG. 3, the identification mark PSM cuts one corner of the blue color material pattern on which the columnar spacer 134m is arranged. It consists of a cutout part NP.

  In order to form the color material pattern so as to have the identification mark PSM, an area where the resist material is irradiated with light or an area where no light is irradiated is defined by an exposure mask in the same manner as in the case of forming a normal color material pattern. Therefore, it is not necessary to increase the number of new processes for manufacturing the CF substrate 120.

  Here, the color material patterns of the color filters 124R, 124G, and 124B are provided so as to cover the opening OP of the black matrix (BM) 125 and the periphery thereof, as shown in FIGS. The columnar spacers 134m and 134s are provided on a portion (light shielding region) that covers the outside of the opening OP of the BM 125 in the color material pattern of the color filter 124B. Similarly, the identification mark PSM is provided so as to cut out a portion covering the outside of the opening OP of the BM 125, and does not affect the display of the liquid crystal display device. FIG. 5 shows the arrangement of the openings OP provided in the BM 125 in a matrix, and the BM 125 has a light shielding region in a region overlapping in a plane excluding the openings OP provided in the matrix. Will form.

  As described above, when there is no difference in the plane pattern shape between the main PS and the sub PS (no distinction is made), and the arrangement density, arrangement rule, and color material color to be arranged are set to be the same. , It is difficult to distinguish between the two near the PS using an optical microscope or the like, but as shown in FIG. 3, by providing the identification mark PSM on the color material pattern in which the columnar spacer 134m is arranged, At the time of planar observation using an optical microscope, it is possible to determine the type of PS having a different height, which cannot be distinguished from the planar pattern shape, only by planar observation.

  The identification mark PSM has been described using the example in which the columnar spacer 134m is disposed in the pixel region. However, the identification mark PSM may be disposed in the pixel region in which the columnar spacer 134s is disposed. In addition, for example, if the color material pattern is formed by a notch NP in which one corner is notched, the pixel region in which the columnar spacer 134m is arranged and the pixel region in which the columnar spacer 134s is arranged are arranged. As long as both are identifiable identification marks PSM, such as by providing notches NP at different corners, both in the pixel area where the columnar spacer 134m is arranged and in the pixel area where the columnar spacer 134s is arranged It may be provided. That is, the identification mark PSM only needs to be provided in a pixel region where at least one of the columnar spacer 134m and the columnar spacer 134s is arranged so that both can be distinguished from each other.

  Further, the separate mark PSM is not limited to the color material pattern of the color filter, and is provided on the CF substrate 120 side such as a black matrix (BM), a common electrode, and an overcoat film (OC film). Any film pattern other than the pattern of the columnar spacers 134m and the columnar spacers 134s may be used as long as the configuration can be visually confirmed and the number of steps for manufacturing the CF substrate 120 is not increased.

<Modification>
FIG. 6 shows the configuration of the color material patterns of the color filters 124R, 124G, and 124B according to the modification of the first embodiment.

  In FIG. 6, the identification mark PSM included in the repetitive unit REP is constituted by a protruding portion DP in which a part of the edge of the blue color material pattern on which the columnar spacer 134m is arranged protrudes in the plane direction.

  Even when the color material pattern is formed so as to have such an identification mark PSM, the region where the resist material is irradiated with light or the region where the light is not irradiated is defined by the exposure mask as in the case of forming the normal color material pattern. Therefore, the number of steps for manufacturing the CF substrate 120 is not increased.

  3 and 6, the color material pattern in which the main PS is arranged is provided with the notch NP or the protrusion DP, but the color material pattern in which the sub PS is arranged has the notch NP or the protrusion DP. It is good also as a structure to provide. In this case as well, the same effect is obtained that the type of PS can be easily discriminated just by observing the planar pattern.

  Further, in the configuration in which the cutout portion NP or the projecting portion DP is provided as the identification mark PSM in the color material pattern in which the main PS shown in FIGS. 3 and 6 is arranged, the identification mark PSM is shown in FIG. Since it is formed so as to overlap the light shielding region formed by the BM 125, the identification mark PSM is not directly recognized and does not affect the display of the liquid crystal display device. In other words, the present invention is not limited to the modes of FIGS. 3 and 6, and the same effect can be obtained if the identification mark PSM is provided so as to overlap the light shielding region formed by the BM 125.

  Further, the present invention is not limited to the provision of the identification mark PSM in the color material pattern in the pixel area in which the main PS and the sub PS are arranged. For example, the pixel adjacent to the pixel in which the main PS and the sub PS are arranged is identified. A mark PSM may be provided. In particular, when it is provided in a pixel adjacent to a pixel in which the main PS or sub PS is arranged, in the vicinity of the side close to the position of the main PS or sub PS in the rectangular region of the adjacent pixel, or in the vicinity of the corner that is also close. By providing, the arrangement density of the main PS and the sub-PS is relatively high, and identification is easy even when both are arranged close to each other. In any case, since the main PS and the sub PS are arranged in the vicinity of the position where the identification mark PSM is arranged, the effect that the type of PS can be easily distinguished is the same.

  Further, the color material patterns of the color filters 124R, 124G, and 124B of the first embodiment have been described using an example in which the color filters 124R, 124G, and 124B are formed from isolated patterns that are divided between pixel regions in the same color. Each of the color material patterns, specifically, the color material patterns of the color filters 124R, 124G, and 124B, may be configured in stripes continuous in the X direction. In the case of such a configuration, it is a little difficult to form the protrusion DP on the color material pattern as the identification mark PSM as in the modification described above, but the notch NP is formed in the color material pattern. When the identification mark PSM is formed to form the identification mark PSM, the rectangular mark region of the rectangular pixel region where the columnar spacer 134m or the columnar spacer 134s is arranged is cut out. Further, since the identification mark PSM may be provided in a pixel adjacent to the pixel where the columnar spacer 134m or the columnar spacer 134s is arranged, the pixel where the columnar spacer 134m or the columnar spacer 134s is arranged straddles between the adjacent pixels. A notch may be formed to form the identification mark PSM.

<Embodiment 2>
In the first embodiment, the configuration in which the identification mark PSM is provided in the color material pattern in which the PS to be identified is arranged has been described. However, as described above, the columnar spacers 134m and 134s are repeatedly arranged in the repeating unit REP. The Therefore, if the repeating unit REP can be determined, the positions of the columnar spacers 134m and 134s can be easily determined.

  Therefore, in the liquid crystal display device according to the second embodiment of the present invention, the identification mark PSM for identifying the delimiter position of the repetition unit REP is arranged at a specific position of the repetition unit REP, and the type of PS based on the identification mark PSM. The structure which can identify is adopted.

  FIG. 7 shows one repeating unit REP in the second embodiment, and a notch NP obtained by notching the corner of the color material pattern at the right end of the array of red color material patterns in the uppermost stage is used as an identification mark PSM. Yes.

  7 is a partial plan view when the CF substrate 120 described with reference to FIGS. 1 and 2 is viewed from the TFT array substrate 110 side, the arrangement of the uppermost red color material pattern is In the plan view of FIG. 1, the red color material pattern is arranged in the lower stage of the repeating unit REP. Accordingly, the identification mark PSM in FIG. 7 is a mark indicating the end of one repeating unit REP.

  By repeating this repeating unit REP over all the display areas, all the pixel arrays are formed, and the delimiter position of the repeating unit REP becomes clear.

  That is, in the example shown in FIG. 7, when the red color material pattern position where the identification mark PSM is arranged is referred to as the first row and the first column (X direction in the figure is the column direction and Y direction is the row direction), By using as a reference, the positions of the columnar spacers 134m and 134s are specified. That is, the columnar spacers 134m are arranged on the color material patterns in the first row, third column and the second row, sixth column, and the columnar spacers 134s are arranged on the color material patterns in the third row, third column, and the fourth row, sixth column. Can be identified.

  Therefore, by searching for an identification mark PSM in the vicinity of the PS to be identified, a total of 24 pixel areas of 4 picture elements (4 pixels) in the X direction and 2 picture elements (6 pixels) in the Y direction as a repetition unit. It is possible to easily determine whether the PS to be identified from the range is the main PS or the sub PS.

<Modification>
FIG. 7 shows an example in which the identification mark PSM is formed by notching the corner of the right color material pattern in the arrangement of the red color material pattern at the uppermost stage of the repeat unit REP. It is not limited to this.

  It may be provided at the corner of another color material pattern that is relatively easy to use as a mark, or may be arranged at the center of the edge or at another specific position. If at least one identification mark PSM is arranged for the repeat unit REP, the delimiter position of the repeat unit REP can be specified based on the design information or the like.

  Further, the identification mark PSM is not limited to the notch NP as long as the position can be confirmed by plane observation, and a part of the edge of the color material pattern described with reference to FIG. 6 protrudes in the plane direction. The portion DP may be provided, or may be formed by changing the pattern shape of a black matrix (BM), a common electrode, an overcoat film (OC film), or the like.

<Embodiment 3>
In the first embodiment, the identification mark PSM is provided in the color material pattern where the PS to be identified is arranged. In the second embodiment, a specific position of the repeating unit REP is determined so that the position of the repeating unit REP can be determined. The configuration in which the identification mark PSM is arranged in the color material pattern has been described. However, by providing the identification mark PSM, the uniformity of the surface state of the color material pattern changes, and the alignment film is formed to make the alignment of the liquid crystal uniform later. There may be a problem with the uniformity of the rubbing process for 123 (FIG. 2).

  That is, in the conventional configuration in which the identification mark PSM is not disposed, only the same rectangular color material pattern is arranged, and the same uneven shape is repeated over the entire surface of the display area. However, the PS forming part is only a local convex part.

  On the other hand, when the identification mark PSM formed by deforming the color material pattern is provided, the portion becomes a local concavo-convex part, and like the PS formation part, the alignment film 123 provided in the upper layer is formed there. In the rubbing process, the contact with the rubbing cloth is not uniform. As a result, the tip of the rubbing cloth is disturbed, and there is a possibility that a desired alignment process cannot be performed. The same applies to the case where the opening of the BM 125 is deformed to form an identification mark, as will be described later.

  When the rubbing process cannot be made uniform in this way, display unevenness is likely to be visually recognized, and the display quality may be reduced. Therefore, it is desirable to arrange the identification mark in a place that is not easily affected by rubbing.

  Therefore, the liquid crystal display device according to the third embodiment of the present invention employs a configuration in which the identification mark is arranged in a place that is not easily affected by rubbing.

  FIG. 8 shows one repeating unit REP when the identification mark PSM described in the first embodiment is made to correspond to the configuration provided in the color material pattern in which the PS to be identified is arranged, and the columnar spacer 134m is arranged. A notch NP obtained by notching one corner of the blue color material pattern is used as the identification mark PSM.

  Here, in FIG. 3, the notch NP is provided at the corner of the edge opposite to the edge of the blue color material pattern on which the column spacer 134m is provided, but in FIG. 8, the column spacer 134m is provided. A notch NP is provided at the corner which is the nearest corner and is downstream of the columnar spacer 134m with respect to the rubbing direction indicated by the arrow Z, and serves as an identification mark PSM. Here, the downstream side in the rubbing direction refers to the tip side of the arrow Z.

  As described above, the PS forming portion is a local convex portion, which acts to disturb the hair end of the rubbing cloth, and in the vicinity of the PS on the downstream side in the rubbing direction, A rubbing process is performed. As a result, in the vicinity of the PS on the downstream side in the rubbing direction, the alignment state of the alignment film surface is not in a desired state and is likely to cause light leakage. Therefore, the BM125 is formed wider to be a light shielding region. The region is not affected by the rubbing, that is, the region is not easily affected by rubbing.

  As described above, by effectively using the region that is not easily affected by rubbing and providing the identification mark PSM, it is possible to suppress the occurrence of light leakage and the like and display unevenness being easily recognized.

  FIG. 9 shows one repeating unit REP in the case of corresponding to the configuration described in the second embodiment in which the identification mark PSM is arranged in a specific color material pattern so that the position of the repeating unit REP can be determined. The identification mark PSM is a corner of the red color material pattern adjacent to the blue color material pattern provided with the columnar spacer 134m, and downstream of the columnar spacer 134m with respect to the rubbing direction indicated by the arrow Z. A notch NP is provided at the corner that becomes the identification mark PSM.

  As described above, the identification mark may be placed anywhere as long as it is not easily affected by rubbing. For example, the color material pattern on which PS is arranged is green, and the identification mark is placed on the color material pattern on which PS is arranged. When green is arranged, the green has a higher transmittance than red and blue, so that unevenness may be easily recognized. In such a case, it is desirable to arrange the identification mark in the color material pattern of another color adjacent to the color material pattern in which the PS is arranged.

  As described above, by disposing the identification mark in consideration of the influence of rubbing, it is possible to prevent the display quality from being lowered without lowering the uniformity of the rubbing process.

  If an overcoat film, which is a flattened film of transparent resin, is formed on the color filters 124R, 124G, and 124B, the local unevenness formed by the identification mark is flattened to some extent. The possibility of lowering the uniformity of the rubbing process is reduced without consideration as in the third embodiment.

<Embodiment 4>
In the first embodiment, the identification mark PSM is provided in the color material pattern where the PS to be identified is arranged. In the second embodiment, a specific position of the repeating unit REP is determined so that the position of the repeating unit REP can be determined. Although the configuration in which the identification mark PSM is arranged in the color material pattern has been described, the liquid crystal display device according to the fourth embodiment of the present invention employs a configuration in which the identification mark PSM is formed by the opening of the BM 125.

  In FIG. 10, the identification mark PSM is changed to the identification mark PSM by changing the shape of the opening of the BM 125 covered with the color material pattern in which the columnar spacers 134m are arranged.

  That is, as shown in FIG. 10, the opening shape of the opening OP1 of the BM 125 covered with the color material pattern in which the columnar spacers 134m are arranged has a trapezoidal shape in which one corner of the rectangle is missing, This is different from the rectangular opening OP of the BM 125 covered with the color material pattern.

  As described above, even when the identification mark PSM is changed by changing the shape of the opening of the BM 125 covered with the color material pattern in which the columnar spacer 134m is arranged, the type of PS having a different height can be determined by plane observation. However, since it is possible to determine the type of PS even from the display surface side of the CF substrate 120, it is possible to perform analysis in the state of the liquid crystal panel when a problem due to PS occurs. Become.

  In the processing of the opening of the BM 125, it is only necessary to create a mask having a pattern shape capable of forming the openings OP1 and OP at the time of mask processing used for patterning of the BM 125, so that the number of manufacturing steps of the CF substrate 120 increases. There is nothing.

  Further, the identification mark PSM may be obtained by changing the shape of the opening of the BM 125 covered with the color material pattern at a specific position of the repeating unit REP so that the position of the repeating unit REP can be determined.

  Thereby, it is possible to easily determine whether the PS to be identified is the main PS or the sub PS by searching for the identification mark PSM in the vicinity of the PS to be identified. Furthermore, since the type of PS can be determined even from the display surface side of the CF substrate 120, analysis in the state of the liquid crystal panel can be performed when a problem caused by PS occurs.

<Modification>
In the liquid crystal display device of the fourth embodiment described above, the configuration of the identification mark PSM is shown by changing the shape of the opening of the BM 125. However, changing the shape of the opening changes the opening area of the BM 125.

  FIG. 11 shows a configuration in which the identification mark PSM is used without changing the shape of the opening. That is, in FIG. 11, the opening OP2 of the BM 125 covered with the color material pattern in which the columnar spacer 134m is arranged is formed at a position slightly shifted from the rectangular opening OP of the BM 125 covered with another color material pattern. Has been.

  That is, the opening OP2 of the BM 125 covered with the color material pattern in which the columnar spacer 134m is arranged is formed at a position shifted in the X direction from the opening OP of the BM 125 covered with the other color material pattern.

  Here, the shift amount of the opening OP2 may be set to a shift amount that allows the opening OP and OP2 to be distinguished at a magnification that allows one repeating unit REP to be accommodated in the field of view of the optical microscope used for observation. The shift amount may be about 1/10 to 2/10 of the length of the long side of the opening OP.

  Further, if the deviation is such a degree, it cannot be visually recognized on the image display, and the quality of the display image is not affected.

  As described above, by adopting a configuration in which the shape of the opening of the BM 125 is not changed, the opening area is not changed, and it is possible to suppress the display image from being affected by the arrangement of the identification mark.

  Further, the present invention is not limited to providing the identification mark PSM by changing the shape of the opening in the pixel region in which the main PS or the sub PS is arranged or by shifting the position of the opening. You may provide the identification mark PSM in the pixel adjacent to the pixel in which PS is arrange | positioned. In particular, when it is provided in a pixel adjacent to a pixel in which the main PS or sub PS is arranged, in the vicinity of the side close to the position of the main PS or sub PS in the rectangular region of the adjacent pixel, or in the vicinity of the corner portion that is also close. By providing, the arrangement density of the main PS and the sub-PS is relatively high, and identification is easy even when both are arranged close to each other. In any case, since the main PS and the sub PS are arranged in the vicinity of the position where the identification mark PSM is arranged, the effect that the type of PS can be easily distinguished is the same.

<Embodiment 5>
In the first to fourth embodiments described above, the identification mark PSM is provided by processing the color material pattern or the opening of the BM 125. However, in the liquid crystal display device according to the fifth embodiment of the present invention, depending on the type of PS. A configuration is adopted in which the positions of PSs in the pixel area where the PSs are arranged are different.

  FIG. 12 shows a pixel area in which the PS is arranged in a pixel in which the blue color material pattern in which the columnar spacer 134m is arranged and a pixel in which the blue color material pattern in which the columnar spacer 134s is arranged are arranged. The arrangement | positioning position from which PS arrangement | positioning differs in is shown. That is, the columnar spacer 134m is a portion that covers the outside of the opening OP of the BM 125 of the blue color material pattern, and has the larger end of the two edge portions in the long side direction of the rectangular color material pattern. It is arrange | positioned in the position near the Y direction lower side of an edge.

  On the other hand, the columnar spacer 134 s is a portion that covers the outside of the opening OP of the BM 125 of the blue color material pattern, and is the end having the larger area of the two edge portions in the long side direction of the rectangular color material pattern. It is arrange | positioned in the position near the Y direction upper side of an edge.

  Note that changing the PS formation position depending on the type of PS may be performed by defining an area where the resist material is irradiated with light or an area where no light is irradiated by the exposure mask, as in the case of normal PS pattern formation. There is no need to add a new process for manufacturing the CF substrate 120.

  As described above, the PS arrangement position in the pixel area where the PS is arranged differs depending on the type of PS, so that the type of PS having a different height can be determined only by planar observation using an optical microscope. Although there is an effect that it becomes possible, there is an advantage that there is no influence on rubbing due to the change of the uneven shape due to the change of the color material pattern, the influence on the aperture ratio due to the change of the BM pattern, etc. Since the color material pattern is the same for each color, there is an advantage that mask replacement is not necessary when the color material pattern is produced.

  In Embodiment 5, the PS type can be identified by changing the PS formation position according to the PS type. However, the positional relationship with the color material pattern and the positional relationship with the opening OP of the BM 125 are as follows. 12 is not limited to the mode shown in FIG. 12, as long as it is possible to identify that the PS is located in a pixel area in which the PS is arranged depending on the type of PS and that it is a different type of PS. In that case, the same effect as in the fifth embodiment can be obtained. However, when the color material patterns of the pixels in which the columnar spacers 134m and the columnar spacers 134s are arranged have different colors, the columnar spacers 134m and the columnar spacers 134s can be easily identified, and the PS arrangement position in the pixel region. It makes no sense to make the distinction different. Therefore, as a precondition for obtaining the same effect as in the fifth embodiment, the pixels in which the columnar spacers 134m and the columnar spacers 134s are arranged have the same specific color, in other words, the columnar spacers 134m and the columnar spacers. It is necessary that the color of the color material pattern provided in each pixel in which the spacer 134s is disposed is the same specific color.

<Manufacturing flow of liquid crystal display device>
A manufacturing method common to the liquid crystal display devices of Embodiments 1 to 5 according to the present invention will be described with reference to FIGS. 1 and 2 and a flowchart shown in FIG.

  Usually, a liquid crystal panel is manufactured by cutting out one or a plurality of liquid crystal panels from a mother substrate larger than the final shape (multiple cutting), and the processes in steps S1 to S9 in FIG. Process.

  First, in a substrate preparation process (not shown), wiring and the like are formed on the mother TFT substrate and the mother CF substrate. That is, in the mother TFT substrate, a process of forming the gate wiring 118g, the source wiring 118s, the TFT 114, the pixel electrode 113, and the like shown in FIG. 1 is performed. These processes are performed for manufacturing a TFT substrate in a general liquid crystal panel. Since it is the same as the method, detailed description regarding the manufacturing method is omitted.

  Further, in the mother CF substrate, a process of forming the color filters 124R, 124G and 124B, BM125, the columnar spacers 134m and 134s having a dual PS structure, and the identification mark PSM shown in FIG. 2 is performed. Is possible by a method of manufacturing a CF substrate in a general liquid crystal panel, and thus a detailed description of the manufacturing method is omitted.

  Here, the columnar spacers 134m and 134s are made only in height by using a halftone technique which is a known method for forming a dual PS structure. The identification mark PSM described using the first to fourth embodiments forms a film formed on the surface of the mother CF substrate, that is, a black matrix (BM), a color material layer, a common electrode, and an overcoat film. In patterning, it can be easily formed by changing the design of an exposure mask or the like that defines the pattern shape.

  Further, when the formation positions of the columnar spacers 134m and 134s described in the fifth embodiment are changed depending on the type of PS, it can be easily handled by changing the mask design of the halftone mask for forming the columnar spacers 134m and 134s. be able to.

  After preparing the mother TFT substrate and the mother CF substrate through the above substrate preparation process, first, in step S1, the alignment film material is transferred to the mother TFT substrate and the mother CF substrate. In this step, an alignment film material is applied to the main surfaces of the mother TFT substrate and the mother CF substrate facing each other. This step includes, for example, a step of applying an alignment film material made of an organic material by a printing method, baking it with a hot plate, and drying.

  Next, in the rubbing step of Step S2, the alignment film material is rubbed and the surface of the alignment film material is aligned to form an alignment film. As shown in FIG. 2, the columnar spacers 134m and 134s formed on the mother CF substrate are also covered with the alignment film, but the alignment film is thinner than the columnar spacers 134m and 134s, so the columnar spacer The alignment film applied on the spacers 134m and 134s is not shown.

  Next, in step S3, the height of the columnar spacer is measured. In the first embodiment, since the columnar spacer is formed on the mother CF substrate, the initial height may be measured on the mother CF substrate. Note that the meaning of measuring the height of the columnar spacers in this step is to determine the amount of liquid crystal dropped when liquid crystal is injected by the drop injection (ODF) method, as will be described later.

  Accordingly, in step S3, the height of the columnar spacer 134m that is the main PS that defines the cell gap related to the volume of the space that fills the liquid crystal is measured. At this time, in the presence of the columnar spacers 134m and the columnar spacers 134s, the identification mark PSM can be used to select the columnar spacers 134m.

  In particular, the measurement accuracy is improved by measuring the heights of the columnar spacers 134m at a plurality of positions in the display area and calculating the average value. In this case, the columnar spacers 134m are identified for efficient sorting. The landmark PSM is effective.

  In addition, although it does not contribute to the determination of the dropping amount of the liquid crystal, in step S3, the height of the columnar spacer 134s that is the sub-PS is also measured to confirm the finish, and thus, the sub-PS formation failure, etc. Defective product inspection (non-defective product / defective product judgment and selection) may be performed.

  In addition, the measurement of the columnar spacers 134m and 134s may be performed at the time of manufacturing the mother CF substrate in the substrate preparation process, not in the above-described process. The identification mark PSM arranged in the form can be effectively used for identifying and selecting the columnar spacers 134m and 134s.

  Next, in the sealing agent application process of step S4, the sealing agent is applied as a printing paste to the main surface of the mother TFT substrate or the mother CF substrate using a screen printing apparatus. The sealant is applied so as to surround the display area of the liquid crystal panel to form a seal pattern 133.

  Next, in the liquid crystal dropping process of step S5, the liquid crystal is dropped into the region surrounded by the seal pattern 133 on the substrate on which the seal pattern 133 is formed. The dropping amount of the liquid crystal is determined based on the height of the columnar spacer 134m that is the main PS measured in step S3.

  Next, in the vacuum bonding process of step S6, the mother TFT substrate and the mother CF substrate are bonded together in a vacuum state to form a mother cell substrate.

  Next, the mother cell substrate is irradiated with ultraviolet rays in the UV (ultraviolet) irradiation process of step S7 to temporarily cure the sealant.

  Thereafter, after-curing is performed by heating in step S8, and the sealing agent is completely cured to obtain a cured seal pattern.

  Next, in the panel cutting process in step S9, the mother cell substrate is cut along the scribe lines to cut into individual liquid crystal panels.

  For each liquid crystal panel divided in step S9, a polarizing plate attaching process in step S10, a control board mounting process in step S11, and the like are executed, and a series of manufacturing processes is completed.

  In addition, a backlight unit is disposed outside the TFT array substrate 110 provided on the side opposite to the CF substrate 120 serving as a display surface via an optical film such as a retardation plate, and is made of resin or metal. The liquid crystal panel 10 and these peripheral members are housed in a housing that is configured, and the liquid crystal display device is completed.

  In the above description, the method of using the identification mark PSM for discriminating between the columnar spacers 134m and the columnar spacers 134s of the present invention will be described by taking as an example the case where it is always used in the standard process of the manufacturing flow of the liquid crystal display device. went. However, as another application example of the present invention, the liquid crystal display device has some trouble such as an abnormal height in the finished state of the columnar spacer 134m or the columnar spacer 134s due to a trouble in manufacturing the mother CF substrate. When the liquid crystal display device is manufactured as a defective product as a result, the identification mark PSM of the present invention can be used effectively also in the PS type discrimination work required as a failure cause analysis process of the defective product. it can.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

  10 liquid crystal panel, 110 TFT array substrate, 120 color filter substrate, 124R, 124G, 124B color filter, 125 black matrix, 134m, 134s columnar spacer.

Claims (9)

A liquid crystal display device having a liquid crystal panel for displaying images,
The liquid crystal panel is
First and second substrates disposed opposite to each other;
A first columnar spacer that is disposed on a main surface of the first substrate facing the second substrate and holds a gap between the first substrate and the second substrate; A second columnar spacer shorter than the first columnar spacer;
A liquid crystal sandwiched between the first and second substrates,
The first substrate is
A liquid crystal display device having an identification mark provided in association with one of the first and second columnar spacers and identifying the first and second columnar spacers. The identification mark is
The film pattern included in a pixel in which one of the first and second columnar spacers is disposed, or a pixel adjacent to the pixel, is provided by making the shape different from other pixels. The liquid crystal display device described. A liquid crystal display device having a liquid crystal panel for displaying images,
The liquid crystal panel is
First and second substrates disposed opposite to each other;
A first columnar spacer that is disposed on a main surface of the first substrate facing the second substrate and holds a gap between the first substrate and the second substrate; A second columnar spacer shorter than the first columnar spacer;
A liquid crystal sandwiched between the first and second substrates,
The first substrate is
A liquid crystal display device having an identification mark for identifying a separation position of the repeating unit for each repeating unit of a pixel in which the combination of the first and second columnar spacers is repeated. The identification mark is
The liquid crystal display device according to claim 3, wherein the film pattern included in at least one pixel in the region of the repeating unit is provided with a shape different from that of other pixels. The liquid crystal panel is
An alignment film for aligning the liquid crystal;
The identification mark is
5. The liquid crystal display according to claim 1, wherein the liquid crystal display is provided at a position near the downstream side of the first or second columnar spacer with respect to a rubbing direction when the alignment film is rubbed. apparatus. The first substrate is
A black matrix that is disposed on the main surface facing the second substrate and that forms a light-shielding region in a region excluding the plurality of openings arranged in a matrix;
The identification mark is
The liquid crystal display device according to claim 1, wherein the liquid crystal display device is formed so as to overlap the light shielding region. The first substrate is
A black matrix that is disposed on the main surface facing the second substrate and that forms a light-shielding region in a region excluding the plurality of openings arranged in a matrix;
The identification mark is
Of the plurality of openings of the black matrix, the shape of one opening included in a pixel in which one of the first and second columnar spacers is arranged or a pixel adjacent to the pixel is changed to another pixel. The liquid crystal display device according to claim 1, wherein the liquid crystal display device is provided in a different shape. The first substrate is
A black matrix that is disposed on the main surface facing the second substrate and that forms a light-shielding region in a region excluding the plurality of openings arranged in a matrix;
The identification mark is
Among the plurality of openings of the black matrix, the position of one opening included in a pixel in which one of the first and second columnar spacers is arranged or a pixel adjacent to the pixel is set as another pixel. The liquid crystal display device according to claim 1, wherein the liquid crystal display device is provided by being shifted with respect to the liquid crystal display device. A liquid crystal display device having a liquid crystal panel for displaying images,
The liquid crystal panel is
First and second substrates disposed opposite to each other;
A first columnar spacer that is disposed on a main surface of the first substrate facing the second substrate and holds a gap between the first substrate and the second substrate; A second columnar spacer shorter than the first columnar spacer;
A liquid crystal sandwiched between the first and second substrates,
The first and second columnar spacers are:
Each arranged in a pixel region of different pixels provided with a specific color material pattern of the same color on the first substrate,
The liquid crystal display device, wherein the first columnar spacer and the second columnar spacer have different arrangement positions in the pixel region of the different pixels arranged therein.

Images