JP2015135425A - Manufacturing method of planar display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device capable of preventing occurrence of a defect at a corner edge of a seal material pattern for liquid crystal sealing in the manufacturing method of a planar display device including a step of pressing by releasing decompression after performing lamination via a seal material under the decompression with respect to an array board as a mother board for performing a multi-piece production.SOLUTION: In a step of coating a seal material on a mother bard 10, a coated pattern 11 of a border line dummy seal material extending via an uncut border line 15A is provided between a shelf-shaped part 26 of one display panel area 25 and a display part 27 (non-shelf-shaped part) of the adjacent display panel area 25. This coated pattern 11 is arranged inside the shelf-shaped part 26 in any place other than the place where the shelf-shaped part 26 is brought into contact with a core edge part 29 of the display part 27, and at least a part of the coated pattern is arranged inside the corner edge part 29 of the display part along a round edge part 12B of a rectangular seal material pattern 12 for liquid crystal sealing.

Description

  The present invention relates to a method for manufacturing a flat display device. In particular, the present invention relates to a substrate including an array substrate as a mother substrate for performing multi-cavity processing and a counter substrate, which are bonded together through a sealant under reduced pressure and then pressed by releasing the reduced pressure.

  An active matrix liquid crystal display device, which is the most typical flat display device, generally includes a liquid crystal display panel and a drive system thereof. The liquid crystal display panel is composed of an array substrate and a counter substrate that are bonded to each other via a peripheral sealant, and a liquid crystal layer that is sealed between the substrates by a sealant. Are arranged in a matrix in a display region, switching elements (usually TFTs) and pixel electrodes for each pixel dot (subpixel), and scanning lines and signal lines respectively arranged along the rows and columns of the matrix And.

  In manufacturing a flat display device composed of an array substrate and a counter substrate, in many cases, “multi-face drawing” is performed. That is, as the array substrate and the counter substrate, large substrates corresponding to a large number of liquid crystal display panels called mother substrates are used, and these are bonded together to form a large display panel (referred to as a “multi-panel”). Then, individual liquid crystal display panels are cut out. Specifically, on the mother substrate of the array substrate or the counter substrate, a sealing material is applied so as to surround the image display area of each liquid crystal display panel, and after the liquid crystal material is dropped, it is bonded and cured, so that it can be used for multi-surface processing. Cutting out after obtaining a large panel.

  This sealing material is required to securely seal the liquid crystal material inside, but the width of the sealing material pattern cannot be increased so much in order to make the peripheral non-display area (frame area) as narrow as possible. In the display panel of the “dam & fill” type organic EL display device, the sealing material is also called a dam material, and a sealing transparent resin is dropped instead of dropping the liquid crystal material.

  In Patent Document 1, even when an external force is applied to peel off both substrates, the “extension part” bulges outward at the corner of the seal material pattern in order to prevent the seal material from peeling off. Is proposed. On the other hand, in Patent Document 2, a partition wall is provided at the boundary between the regions of the individual liquid crystal display panels in order to reduce the margin width for absorbing the seal material from spreading outward at the time of bonding pressing. Proposed. This partition is provided on one of the mother substrates at the same time as the columnar spacer. When the individual liquid crystal display panel is cut out from the multi-panel, the partition is cut at the partition.

  On the other hand, in Patent Document 3, in order to cope with the problem that the thickness of the sealing material becomes smaller than a predetermined thickness at the peripheral portion of the multi-chamfer panel, a dummy seal may be provided on the peripheral portion of the mother substrate. Proposed.

JP2009-294601 JP 2006-030440 JP2011-257564

  A display panel of a flat display device is usually provided with a shelf-like portion in which an array substrate protrudes from a counter substrate on at least one side of the rectangle. That is, the display panel includes a display portion (non-shelf-like portion) in which an array substrate and a counter substrate are overlapped via a liquid crystal layer and a sealing material, and a shelf-like portion provided with a driver circuit or a connection terminal group therefor. Consists of. If the drive IC chip is directly mounted (chip-on-array), the drive IC chip is mounted on the shelf. In particular, in a small to medium-sized display panel for a smartphone such as a display area having a diagonal size of 7 inches or less, a relatively wide shelf is provided only on one short side of the rectangle. There are many.

  The process of cutting out individual display panels from a multi-panel layout panel in which the areas corresponding to the individual display panels are arranged vertically and horizontally is generally adjacent to the area that forms the shelf-like part of one display panel after cutting out. And an operation of cutting along the boundary with the area forming the display unit of the display panel after the cutting. On the other hand, in order to cut out individual liquid crystal display panels, for example, a scribe-break method of cleaving by pressing and bending after a scribing operation using a laser or a diamond chip is performed. At the boundary between the shelf-like connecting portion and the adjacent liquid crystal display panel, the sealing material is disposed close to one side, but does not exist on the other side, so the balance is poor. Therefore, the cutting operation may not be performed smoothly.

  If a partition wall as described in Patent Document 2 is provided and cutting is performed at the location of the partition wall, it seems that the balance does not deteriorate. However, if it is attempted to absorb variations in the coating amount of the sealing material, there is a possibility that a gap is generated between the partition wall and the sealing material.

  In view of such a problem, the present inventor attempted to arrange a linear dummy seal material on the side of the shelf-like connecting portion along the boundary. Thereby, basically, problems such as balance at the time of cutting could be solved. However, in further study, when the sealing material is applied in a rectangular shape with rounded corners, the two rectangular sealing material patterns adjacent to each other are surrounded by round corners and straight dummy seals. The present inventors have found that the seal material may have a defect at a portion facing the triangular region. The inventor of the present invention has been diligently studying the cause of this, and the dummy seal material and the rectangular seal pattern are partially connected to each other, and a problem may occur when a triangular isolated gap occurs. I found it. That is, when the mother substrates are bonded together in a vacuum state and then returned to the atmospheric pressure and pressed by the atmospheric pressure, the triangular isolated gaps are left in the vacuum state and are large inside and outside the sealing material. I thought it was because of the pressure difference.

  The present invention applies a sealing material that forms a rectangular liquid crystal sealing sealing material pattern with rounded corners for each display panel to at least one of a mother substrate of an array substrate and a mother substrate of a counter substrate. And a step of performing liquid crystal pressure reduction by, for example, returning to atmospheric pressure after dropping liquid material into each rectangular sealing material pattern and bonding under reduced pressure. An object of the present invention is to provide a device manufacturing method capable of preventing the occurrence of defects at the corners of a sealing material pattern.

  According to a preferred embodiment of the method for manufacturing a flat display device of the present invention, a rectangular shape with rounded corners for individual rectangular display panels is provided on at least one of the mother substrate of the array substrate and the mother substrate of the counter substrate. A step of applying a sealing material to form a sealing material pattern, a step of dropping a liquid material in each sealing material pattern, a step of bonding two mother substrates under reduced pressure, and a step of bonding Including a step of releasing pressure reduction and pressing with atmospheric pressure, and in the step of applying the sealing material, the shelf portion of one display panel and the display portion (non-shelf portion) of another display panel The dummy sealing material application pattern extending along the uncut boundary line is formed, and the dummy sealing material application pattern is a shelf-like shape except where the shelf-like portion and the corner of the display portion are in contact with each other. Place in the department In the portion where the shelf-like portion and the corner portions of the plurality of display portions are combined, at least a part is arranged along the round corner portion of the rectangular sealing material pattern in the corner portion of the display portion. It is characterized by being.

It is a top view perspective view which shows typically the pattern of the sealing material formed on one mother board | substrate by the process of apply | coating the sealing material by the manufacturing method which becomes one Embodiment. After pressing the sealing material of FIG. 1, the laminated cross section is schematically shown in a plan view showing a pattern of the sealing material in a portion (main part) where the corner portion of the shelf portion and the corner portion of the display portion are in contact with each other. It is the partial plane perspective view which added the part shown. FIG. 3 is a partial plan perspective view corresponding to FIG. 2 for a first comparative example. FIG. 4 is a partial plan perspective view corresponding to FIG. 2 for a second comparative example.

  The manufacturing method of the liquid crystal display device which becomes one Embodiment of this invention is demonstrated using FIGS. FIG. 1 schematically shows a state in which a sealing material coating pattern 1 is provided on a first mother substrate 10. FIG. 2 schematically shows the main part of the state after the liquid crystal material 14 is dropped and then pressed in combination with the second mother substrate 31, that is, the multi-chamfer panel 3.

  As shown in FIG. 1, a rectangular liquid crystal sealing sealing material coating pattern 12 is provided for each display panel region 25 on the first mother substrate 10. Specifically, in each display panel region 25, a rectangular coating pattern 12 with rounded corners is provided so as to seal the liquid crystal material 14 after panel assembly so as to surround the display region 18 of the cut-out display panel. . In the illustrated example, a shelf-like portion 26 of each display panel is provided on one short side of the rectangular display panel region 25. That is, each display panel includes a display unit 27 bordered by a liquid crystal sealing seal material and a shelf-like unit 26 for arranging or connecting the drive circuit system.

  As shown in FIG. 1, the asymmetric type is located between the shelf-like portion 26 of one display panel region 25 and the display portion 27 of the display panel region 25 adjacent thereto (between the shelf-like portion and the display portion). The boundary line dummy sealing material coating pattern 11 is linearly provided along the boundary line 15A. As shown in the figure, typically, each display panel area 25 is provided as an individual area divided by a boundary line 15 between grid-like panel areas, and a shelf-like portion 26 is provided for each display panel area 25. Are provided on the same side (the right side in FIG. 1). Therefore, if the shelf-like portion 26 is only on one short side (the right side in FIG. 1), it is parallel to the opposite side (the left side in FIG. 1) of the rectangular mother substrate 10 (the vertical direction in FIG. 1). ), An asymmetric boundary 15 </ b> A between the shelf-like portion and the display portion extends. In addition, a symmetric boundary line 15B between the shelf-like portions and the display portions extends perpendicularly to this (the left-right direction in FIG. 1). Therefore, a plurality of the boundary line dummy seal material coating patterns 11 extend linearly in a direction along one side of the rectangular mother substrate 10 (vertical direction in the drawing of FIG. 1) and are arranged in parallel to each other. Is done. Here, “symmetric type” and “asymmetric type” indicate whether they are shelf-like parts and display parts or not, that is, the sealing material for liquid crystal sealing is the boundary line 15. It represents only whether it exists in the vicinity of both sides.

  The boundary dummy sealing material is a balance when the transparent insulating substrate, particularly the glass substrate, is subjected to deformation at the left and right of the boundary line 15 when the multi-chamfer panel 3 is obtained and then cut by a scribe-break method or a wheel cutter. Is to keep That is, during the cutting operation, a local strain or stress is prevented from being applied to the transparent insulating substrate such as a glass substrate forming the display panel.

  As shown in FIG. 1, the application pattern 11 of the boundary line dummy seal material forms a straight line portion 11 </ b> B and is positioned in the shelf-like portion 26 except for the portions where the corner portions 28 and 29 of the display panel region 25 are in contact with each other. To do. That is, a straight line portion 11B extending in parallel with the asymmetric boundary line 15A between the shelf-shaped portion and the display portion and extending slightly away from the boundary line 15A into the shelf-shaped portion 26 is formed.

  On the other hand, the corner portions (panel corner portions) 28 and 29 of the display panel region 25 are curved and extended toward the display portion 27 at a portion where the corner portions 28 and 29 are in contact with each other. In particular, in the vicinity of the cross-cut portion 17 where the corner portion 28 of the two shelf-like portions 26 and the corner portion 29 of the two display portions 27 are combined, the bay entry portion 11A that enters the display portion 27 side is provided. There is no. The cross-cut portion 17 is a point of intersection where the asymmetric boundary line 15A between the shelf-shaped portion and the display portion and the symmetrical boundary line 15B between the shelf-shaped portions and the display portions intersect. The bay entrance 11A has a bell shape or a Gaussian curve shape in the illustrated example. Each of the bell-shaped inclined portions extends in parallel with the round corner portion 12B of the application pattern 12 of the sealing material for liquid crystal sealing. The bell-shaped top portion smoothly connects the tips of these two inclined portions. Therefore, in the illustrated example, the distance between the application pattern 11 of the boundary line dummy sealing material and the application pattern 12 of the sealing material for liquid crystal sealing is kept substantially constant due to the presence of the bay portion 11A. In the illustrated example, the bay entrance portion 11 </ b> A is located in the corner portion 29 of the display portion 27 in the vicinity of the bell-shaped top portion. In the more specific example shown in the figure, due to the presence of the bay portion 11A, the cross-cut portion 17 is closer to the shelf-like portion 26 than the application pattern 11 of the boundary line dummy seal material, or the application pattern 11 It is located in the vicinity of the edge on the shelf-like part 26 side.

  Application | coating using a dispenser can be easily performed as 11A of bay entrance parts are the bell-shaped smooth curve which continues smoothly from the two linear parts 11B like the example of illustration. However, if it does not overlap with the coating pattern 12 of the sealing material for liquid crystal sealing, the distance from the round corner portion 12B of the coating pattern 12 does not necessarily have to be constant, for example, almost liquid crystal sealing near the top. It may be in contact with the application pattern 12 of the sealing material for a seal. Conversely, the distance from the coating pattern 12 of the sealing material for liquid crystal sealing may gradually open as it approaches the top. In addition, each bay entry part 11A may consist of two linear parts depending on the case. That is, it may have a bent portion at the top and a bent portion between the two straight portions 11B. Moreover, even if each bay entry part 11A has a discontinuous part in the top part etc., it should just be connected in the case of pressing.

  In the illustrated example, the application pattern 11 of the boundary dummy seal material forms a curved portion 11 </ b> C toward the display unit 27 at both ends thereof, that is, along the outer peripheral portion 19 of the mother substrate 10. Specifically, here, it extends in parallel with the round corner portion 12B in the coating pattern 12 of the sealing material for liquid crystal sealing. That is, it extends so that the interval is substantially constant. However, the curved portions 11C at both ends are not necessarily provided. Further, as in the case of the bay entrance portion 11A, the interval may be gradually narrowed toward the tip, or may be gradually widened. Partially, the application pattern of the sealing material for liquid crystal sealing 12 may be substantially in contact with. Moreover, it may consist of a straight part and may include a bent part, and may have a discontinuous part as long as it is connected after pressing. Note that the outer peripheral portion 19 is cut and removed after assembling the multi-chamfer panel 3. That is, it is a portion that is cut and removed by the scribe-break method or the rotating wheel method along the planned cutting line 16 that forms the outline of the entire matrix arrangement in the display panel region 25.

  In the illustrated example, the outer peripheral portion 19 of the first mother substrate 10 is provided with an outer peripheral portion dummy sealing material coating pattern 13. The outer peripheral dummy seal material is provided so that the pressure applied to the liquid crystal sealing seal material at the time of pressing is substantially equal between the portion close to the outer peripheral portion 19 and the inside of the mother substrate 10. Typically, as shown in the drawing, it extends in parallel between the outline of the mother substrate 10 and the planned cutting line 16 and has discontinuous portions 13A at predetermined intervals. This discontinuous portion 13A allows air to pass smoothly during decompression and decompression release.

  Next, the pattern 2 of the sealing material after pressing will be described with reference to FIG. After forming the sealing material coating pattern 1 on the first mother substrate 10 under reduced pressure, the liquid crystal material 14 is dropped into each coating pattern 12 for the liquid crystal sealing sealing material. Then, after the second mother substrate 31 is combined, the pressure reduction is released by releasing the pressure reduction. After the seal material is completely spread by pressing, the seal material is cured by irradiation with light such as ultraviolet rays or heating, whereby the multi-panel panel 3 is obtained.

  In the example shown in FIG. 2, after pressing, the linear portion 11B of the application pattern 11 of the boundary line dummy sealing material and the linear portion 12A of the application pattern 12 of the sealing material for liquid crystal sealing are the asymmetrical boundary line 15A. They are combined at places to form a continuous pattern. Moreover, between the adjacent display parts 27, the linear parts 12A of the application pattern 12 of the sealing material for sealing liquid crystal are joined at the location of the symmetrical boundary line 15B to form a continuous pattern. In particular, in the example shown in FIG. 2, even between the bay portion 11A of the application pattern 11 of the boundary line dummy sealing material and the round corner portion 12B of the application pattern 12 in the two display portions 27, they are continuously joined together. There is a pattern. Accordingly, in each display panel region 25, the width of the sealing material pattern 22 for sealing the liquid crystal is obtained at the panel corner portion 29, which is the corner portion of the display portion 27, except when the display portion is adjacent to the outer peripheral portion 19. Is larger than other parts. That is, when the display panel area 25 is arranged as shown in FIG. 1, the left corner portion 29 in each display panel area 25 is not the leftmost column on the mother board of FIG. When it becomes 3, the reinforced round corner 23 is formed. As a result, in the illustrated example, a narrow gap 24, that is, a region not filled with the sealing material is left only in the vicinity of the apex of the corner of the display panel region.

  The reinforcing round corner portion 23 is considered to have the following significance.

  As described above, after the liquid crystal material 14 is dropped into the application pattern 12 of the rectangular liquid crystal sealing seal material, the pressure is reduced by returning from the reduced pressure to the atmospheric pressure. At this time, the coating pattern 12 of the sealing material for liquid crystal sealing receives pressure from the liquid crystal material 14 that is about to spread from the inside to the outside. However, as a result of pursuing the narrow frame (reduction of the width of the peripheral non-display area) and the reliability of the sealing material to the utmost, the sealing material reaches the boundary line 15 of the panel region as shown in FIG. It will be. However, when the liquid crystal sealing sealant coating pattern 12 spreads out by pressing, it collides with the borderline dummy sealant coating pattern 11 on one short side (left side in the figure) of the rectangle, On the long side (upper and lower sides in the figure), it collides with the adjacent coating pattern 11. For this reason, the pressure of the liquid crystal material 14 that is about to spread tends to concentrate on the round corner portion 12A that can be pushed and spread into the corner gap. Such concentrated pressure can also act in the thickness direction and in the direction of peeling off the sealing material.

  On the other hand, when releasing the reduced pressure and performing the clamping, the air flowing in from the discontinuous portion of the outer peripheral dummy sealing material flows into the interior of the multi-faced panel 3 before curing through the region of the row of the shelf-like portions 26. To do. As a result, on the inside of the sealing material pattern 22 for sealing the liquid crystal filled with the liquid crystal material, the pressing force due to the atmospheric pressure outside the mother substrates 10 and 31 continues to act, whereas the sealing material pattern for sealing the liquid crystal On the outside of 22, such a pressing force does not act. Therefore, based on such a pressure difference, in particular, a kind of peeling force can act on the corner portion of the sealing material pattern 22 for sealing liquid crystal.

  Therefore, as shown in FIG. 2, when the sealing materials are combined at the boundary line 15 of the panel region at the time of pressing, the panel corner portion 29 that is composed of the corner portion of the display portion 27 and is adjacent to the shelf portion 26. Thus, the concentration of the internal pressure of the layer of the liquid crystal material 14 and the action of the peeling force based on the air flowing between the mother substrates 10 and 31 occur simultaneously. The reinforced round corner portion 23 prevents a sealing failure from occurring in the sealing material pattern of the display panel product due to such an action. The reinforcing round corners 23 are formed only at the two corners of the sealing material pattern 22 for sealing the liquid crystal, but the internal pressure of the liquid crystal material layer does not concentrate at the other corners. In the coating pattern 12 of the sealing material for liquid crystal sealing, any one of the straight portions 12A following the corner portion 12B can be relatively freely expanded into the shelf portion 26. This is because stress concentration on 12B does not occur. The same applies to the case where the corner portion 12B is adjacent to the outer peripheral portion 19 because the straight portion 12A can be pushed and extended to the outer peripheral portion.

  In one specific example, the first mother substrate 10 is an array substrate mother substrate, and the second mother substrate 31 is a counter substrate mother substrate. Here, the array substrate is manufactured by, for example, a film forming operation by a low-temperature polysilicon method, and thereby a drive circuit system can be built in the shelf-like portion 26. The manufactured display panel has a display area 18 having a diagonal dimension of 3 to 7 inches, for example, about 5 inches, and an aspect ratio of 16/9, and is a display for mobile terminals such as smartphones and in-vehicle devices. It is used as Each mother substrate is, for example, of the fourth generation (about 680 × 880 mm) to the sixth generation (about 1,500 mm × 1,800 mm). For example, the display panel region has 70 to 80 to 280 to 320 display panels. The sealing material is applied, for example, by moving the dispenser nozzle in a single stroke using a robot arm. The application of the sealing material, the dropping of the liquid crystal material, and the bonding of the second mother substrate 31 are performed under a vacuum of 1 to 100 Pa, and the release of the reduced pressure is performed by flowing air into the reduced pressure chamber at once. The sealing material is cured by, for example, heating at 120 to 130 ° C. after performing temporary curing by ultraviolet irradiation. After the multi-sided substrate 3 is completed in this manner, cutting is performed at the boundary line 15 and the outer cutting planned line 16 by a scribe-break method or the like. Finally, the display panel is obtained by cutting off the portion of the counter substrate that is derived from the mother substrate and covers the shelf 26. In this separation, since the removed portion is discarded, it is not necessary to provide a sealing material pattern on both sides of the separation line.

  On the other hand, in the above specific example, the width of the sealing material pattern 22 for sealing liquid crystal and the width of the dummy dummy sealing material 21 are 0.3 to 0.7 mm, for example, 0.5 mm, and the distance between the substrates is 2 to 6 μm. For example, the width of the shelf-like portion 26 is 10 to 30 mm, for example, 20 mm. The round corner portion 23 of the sealing material pattern 22 for liquid crystal sealing has a radius of curvature of the inner edge of 0.3 to 1.5 mm, for example, 0.5 mm. Moreover, in the application pattern 11 of the dummy sealing material, the distance from the bay entrance dimension of the bay entrance portion 11A, that is, the line connecting the center line of the straight portion 11B, to the center line at the apex of the bay entrance portion 11A is 0.3 to 0.8 mm. For example, 0.6 mm.

  Next, the manufacturing method of the 1st and 2nd comparative example is demonstrated using FIG. 3 and 4, respectively.

  In the first comparative example, when the boundary line dummy seal material is applied, it is applied only to the portion of the straight portion 11A in FIG. 1, and a discontinuous portion is formed instead of the bay portion 11A. When application is performed with a dispenser nozzle, when the dispenser nozzle is lowered to bring the liquid dripping portion into contact with the mother substrate 10 and when the liquid dripping portion is separated from the mother substrate 10 by using the dispenser nozzle, Since the amount of the sealing material that shifts to is larger than that at other locations, in the pattern after coating, the coating amount at the locations corresponding to both ends of the linear portion 11A is somewhat increased. That is, both ends of each coating pattern on the obtained straight line segment are slightly swollen. Therefore, after the pressing, as shown in FIG. 3, the obtained boundary line dummy sealing material 21 ′ is interrupted in the vicinity of the cross cutting line 17 and the end of the line segment pattern is wide. . On the other hand, as shown in FIG. 3, the sealing material pattern 22 for liquid crystal sealing does not have the reinforcing round corner portion 23 but has a constant width including the round corner portion 23 '.

  FIG. 3 schematically shows the problems of the first comparative example. As described above, if the decompressed state of the chamber is released and the pressure-tightening by the atmospheric pressure is started, the panel corner 29 by the display unit 27 is located at the round corner of the liquid crystal sealing sealant pattern. Due to the internal pressure of the liquid crystal material and the pressure difference from the liquid crystal material placement location due to the inflow of air, a force that separates the mother substrates 10 and 31 from each other acts. As shown in FIG. 3, the sealing material pattern 22 for sealing a liquid crystal is not combined with other sealing material patterns only at the round corners 23 '. Therefore, depending on the conditions, as shown in FIG. 3, a partial seal peeling 41 occurs at the outer portion of the round corner portion 23 ′. The problem in the comparative example of FIG. 3 can also be prevented by increasing the width of the round corner when applying the liquid crystal sealing sealant. However, if it does in this way, it will be thought that the process of application | coating becomes remarkably complicated compared with said embodiment. In particular, in order to locally increase the width of the coating pattern by application using a dispenser nozzle, it is necessary to control the increase of the discharge amount locally or the movement speed of the dispenser nozzle to be slow, and the seal Due to the thixotropy of the material, it is difficult to apply with a predetermined width. On the other hand, in the above embodiment, the liquid crystal sealing sealing material and the boundary line dummy sealing material may be provided by application with a uniform width.

  In the second comparative example described with reference to FIG. 4, in applying the boundary line dummy sealing material, a bay portion, a curved portion, and a discontinuity portion are not provided, and the linear shape is continuous along the asymmetric boundary line 15A. Only applied. Similarly, the entire boundary line dummy sealing material 21 ″ obtained after the pressing is one continuous straight line. In the illustrated example, as in the case of the above-described embodiment, the liquid crystal sealing sealing material patterns 22 of the adjacent display portions are aligned with each other at the symmetrical boundary line 15B, and the liquid crystal sealing sealing material pattern 22 is combined. And the boundary line dummy sealing material 21 '' are combined with each other at the location of the asymmetrical boundary line 15A. Then, as shown in the figure, the round corner portions 23 ′ of the two liquid crystal sealing sealing material patterns 22 and the linear field dummy sealing material 21 ″ are arranged at the place where the panel corner portions 29 of the two display portions meet. A substantially triangular closed space 24 '' surrounded by is formed.

  Even if the decompression is canceled after the liquid crystal material is dropped and the counter substrate is bonded, the inside of the gap 24 ″ remains in a decompressed state for at least a while. Further, as described above, since only the portion of the round corner portion 23 ′ is not combined with the other sealing material pattern, the internal pressure of the liquid crystal material layer tends to concentrate on the round corner portion 23 ′. Therefore, as schematically shown in FIG. 4, leakage 42 of the liquid crystal material 14 occurs depending on conditions.

  In the description of the above embodiment and the description of the comparative example, it has been described that the shelf-like portion 26 is provided on the one short side of the display panel region 15, but even if it is provided on the one long side, it is quite complete. It is the same. Further, in the description of the above embodiment, the application pattern 11 of each dummy sealing material has been described as being provided in a single continuous line, but for example, even if there is a discontinuity in the linear portion 11B, It is sufficient that the cutting operation is not hindered. In the above description of the embodiment, it has been described that the dummy seal material is provided on the outer peripheral portion of the mother substrate and the multi-chamfer panel, but this outer peripheral dummy seal material may be omitted depending on circumstances.

  In the above description of the embodiment, the case where only the same display panel is obtained from one multi-panel is described. However, for example, a plurality of types of display panels having different dimensions can be obtained. In this case, the shelf portion of one large display panel region and the display portions of two small display panel regions may be adjacent to each other with one asymmetric boundary line 15A interposed therebetween. Also in this case, similarly, the boundary line dummy sealing material can have a pierced portion into the corners of the two display portions at the location of the three-way cut portion. On the other hand, in the description of the above embodiment, it has been described that the pressure reduction is released and the pressure is reduced by the atmospheric pressure. However, the atmospheric pressure when the pressure reduction is released does not have to be the atmospheric pressure, and the pressure is slightly lower than the atmospheric pressure. However, the pressure may be higher than atmospheric pressure. In addition, it has been described that the sealing material is applied and the liquid crystal material is dropped under reduced pressure. For example, these are performed under atmospheric pressure, and degassing is performed under reduced pressure, and then the other mother substrate is bonded under reduced pressure. It may be. Since the width of the sealing material may vary, the liquid crystal sealing material pattern 22 and the boundary line dummy sealing material 21 reach the boundary line 15 and are combined with the pattern of the adjacent sealing material. It may be only a part of.

  In the above description of the embodiment, the method for manufacturing a liquid crystal display panel has been described. However, the method can be similarly used for a method for manufacturing an organic EL display panel. In this case, the sealing material is also called a dam material, and a transparent resin for sealing can be dropped instead of dropping the liquid crystal material.

1 ... Application pattern of sealing material; 10 ... First mother substrate;
11 ... Application pattern of boundary dummy sealing material; 11A ... Bay entry part;
11B ... linear part; 12 ... application pattern of sealing material for liquid crystal sealing;
12A: Round corner portion; 12B: Straight portion;
13 ... Application pattern of outer peripheral dummy seal material; 13A ... Interrupted portion;
14 ... Liquid crystal material; 15 ... Border between panel regions;
15A: An asymmetric boundary line between a shelf portion and a display portion between adjacent panel regions;
15B ... Symmetric boundary lines between the shelf-like portions and the display portions between adjacent panel regions;
16 ... Scheduled cutting line of outer peripheral part; 17 ... Cross cutting part where shelf-like part and display part are combined;
18 ... display area; 19 ... outer periphery of mother board;
2 ... Sealing material pattern after pressing; 21 ... Border dummy sealing material;
22 ... Sealing material pattern for liquid crystal sealing; 23 ... Reinforcing round corners; 24 ... Corner gaps;
25 ... Individual display panel area; 26 ... Shelf-shaped part; 27 ... Display part;
28 ... Panel corner angle by shelf-like part; 29 ... Panel corner angle by display part;
3 ... Multi-sided panel; 31 ... Second mother substrate; 41 ... Seal peeling;
42 ... Liquid crystal leaks

Claims (3)

Applying a sealing material on at least one of the mother substrate of the array substrate and the mother substrate of the counter substrate so as to form a rectangular sealing material pattern with rounded corners for each rectangular display panel; and A step of dropping a liquid material in the sealing material pattern, a step of bonding the two mother substrates under reduced pressure after the dropping, and a step of releasing the reduced pressure after bonding and pressing with the pressure of the atmosphere In a manufacturing method of a flat display device including:
In the step of applying the sealing material, a dummy sealing material application pattern extending along an uncut boundary line between the shelf portion of one display panel and the display portion of the other display panel is formed,
The application pattern of the dummy sealing material is arranged in the shelf-like portion except where the corner portion of the shelf-like portion and the corner portion of the display portion are in contact with each other, and the corner-like portions of the shelf-like portion and the plurality of display portions are arranged. A method of manufacturing a flat display device, wherein at least a part is disposed along the round corners of the rectangular sealing material pattern in the corners of the display unit at the place where the two are combined.   After the pressing, the dummy sealing material pattern and the rectangular sealing material pattern are combined with each other at the position of the uncut boundary line, and the rectangular sealing material pattern is The method for manufacturing a flat display device according to claim 1, wherein the display portions of display panels adjacent to each other are combined with each other at other uncut boundary lines.   The portion disposed along the rounded corner of the rectangular sealing material pattern in the application pattern of the dummy sealing material has a smooth curved shape that is smoothly continuous with other portions. A method for manufacturing the flat display device according to 1 or 2.

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