JP2610125B2 - Method for manufacturing flexible electro-optical element - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flexible electro-optical element which is integrally processed by roll molding.

[Prior Art] and [Problems to be Solved by the Invention] Conventionally, in the integrated processing by roll molding of a flexible electro-optical element, a predetermined time is required for heating a sealing material and injecting a liquid crystal substance from the continuity of the roll. Therefore, it was necessary to increase the total length of the integrated process. Also, in the step of degassing the cell under vacuum, it has been difficult to continuously process the cell. further,
In a conventional cell, it is difficult to keep the thickness of the liquid layer uniform when bending, and the sealing property of the cell is low.

An object of the present invention is to provide a method for manufacturing a flexible electro-optical element which eliminates the above-mentioned drawbacks of the conventional example, enables simplification and continuation of processing steps, maintains a uniform cell thickness, and has a high sealing property. It is the purpose.

[Means for Solving the Problems] The present invention relates to a method for manufacturing a flexible electro-optical element in which a liquid crystal material is injected between a first substrate and a second substrate, wherein the first substrate has a plurality of substrates. A first step of forming a linear pattern of adjacent thermoplastic resin sealing materials such that adjacent patterns are communicated with each other through a connection path; Adjacent patterns communicate the linear pattern of the mold sealing material by a connecting path, and the sealing material formed on the first substrate when the first substrate is bonded to the second substrate. A second step of forming a position outside the linear pattern, a third step of spraying a spacer on at least one surface of the first substrate and the second substrate, 2 substrates facing each other, 1
A liquid crystal substance in excess of a predetermined amount is dropped inside the cell, which is a region surrounded by the pattern of the substrate, the second substrate, and the thermoplastic resin sealant, and the opposing first substrate and the second substrate are pressed by a pressure roller. A fourth step of causing the liquid crystal material overflowed by the pressure by the roller to be sent to the next cell filled with the liquid crystal material via the connection path at the same time as bonding the second substrate to the second substrate; A fifth step of curing the pattern of each sealant on the second substrate; and a sixth step of cutting the substrate bonded on a cell-by-cell basis. It is a manufacturing method.

As the thermoplastic sealing material used in the present invention, for example, a polyester hot melt adhesive (Aronmelt)
PES), adhesive polyolefin (Admer) and the like. Examples of the electron beam curing type sealing material include epoxy acrylate and epoxy methacrylate.

In the fourth step of the manufacturing method of the present invention, the “predetermined amount” refers to a capacity of a cell which is a region surrounded by a pattern of a thermoplastic resin sealing material on the first substrate and the second substrate.

[Operation] When the first and second substrates are bonded together, the thermoplastic resin sealing material formed on the first substrate is on the inside, and the electron beam-curable sealing material formed on the second substrate is on the outside. Will be placed. For this reason, it is possible to prevent the liquid crystal substance injected into the cell surrounded by the sealing material from reacting with the electron beam curing type sealing material as the outer sealing material. In addition, the double seal configuration described above, for example, a decrease in the sealability due to the revival of the plasticity of the thermoplastic sealant under high-temperature conditions, the other electron beam-curable seal material, such as can be assisted by more secure sealability. Things.

In addition, when the two substrates are pressed and bonded together, the liquid crystal substance is dropped into the cell, which is the area surrounded by the sealant, so that the liquid crystal substance can be injected without using a vacuum and continuous processing can be performed. It becomes possible.

In addition, by dispersing a spacer made of beads or the like in the cell, the cell thickness can be kept uniform. In particular, when the cell is made thin, the cell thickness is maintained by the surface tension of the liquid crystal material, and the cell becomes more uniform. Thickness can be obtained.

Further, since a plurality of cells are formed to communicate with each other via a thin connection path formed of a sealing material, and an excess amount of liquid crystal material is added to the cell when the liquid crystal material is dropped, the excess amount of the liquid crystal material being sufficient to fill the cell. When the sealing material is heated and pressurized after dropping the liquid crystal material, the excess liquid crystal material can move through the narrow connection path, so that no bubbles are trapped and the excess liquid crystal is prevented from protruding outside the cell. it can.

Embodiment FIG. 1 shows the shape of a sealing material on a flexible substrate. As shown in FIG. 1, a sealing material 3 made of an electron beam-curable resin is formed outside a sealing material 2 made of a thermoplastic resin. Adjacent cells in the roll direction of the sealing material formed in each cell unit are electrically connected to each other through the thin connection path 4.

FIG. 2 is an overall configuration diagram showing an example of a method for manufacturing a flexible liquid crystal cell. In FIG. 2, reference numeral 1 denotes a flexible substrate on which a seal pattern of an electron beam-curable resin is printed, and reference numeral 11 denotes a flexible substrate on which a seal pattern of a thermoplastic resin is printed. The used polyester film was used.
Reference numeral 12 denotes a liquid crystal supply device for dropping liquid crystal in a fixed amount. Reference numeral 13 denotes an electron beam curing resin. In this embodiment, a polyester hot melt adhesive (Aron melt PES) is used. Reference numeral 14 denotes a thermoplastic resin. Used epoxy acrylate. Further, 15 is a spacer supply device, 21 is an electron beam curing type resin printing device, 22 is a thermoplastic resin printing device, 23 is a pressure roller, 24 is a hot press roller, and 25 is an electron beam curing device. In FIG. 2, the steps of forming a transparent electrode, an alignment film, and the like and performing an alignment process are omitted.

Next, a manufacturing procedure will be described. First, the flexible substrate 1
A seal pattern of an electron beam-curable resin is formed on the surface of the
A seal pattern of a thermoplastic resin is formed by the printing device 22 on the surface of the substrate. Next, a spacer 8 having a diameter of 8
μm beads are scattered within the frame of the seal pattern.
Next, the substrate 1 and the opposing substrate 11 are bonded to each other with the pressure roller 23 facing each other. At this time, liquid crystal slightly larger than a predetermined amount is dropped from the liquid crystal supply device 12 immediately before the two substrates are bonded. When the liquid crystal is dropped and the cell is pressed by the pressure roller 23, the excess liquid crystal is sent to the next cell through the connection path 4. That is, by expelling bubbles inside the liquid crystal while applying pressure, the liquid crystal is reliably filled in the cell.

Next, when heating and pressurization are performed simultaneously by the hot roller 24 on both substrates that have passed through the pressurizing roller 23, the thermoplastic resin printed on the inside is fused. Thereafter, the electron beam curing device 25 further cures the electron beam curable resin printed on the outside, thereby completing the formation of the upper and lower substrates.

A plurality of liquid crystal cells can be obtained by cutting a series of flexible substrates thus formed at the connection path 4 and sealing the cut portions.

In this embodiment, the heating temperature of the polyester hot melt adhesive is in the range of 100 ° C. to 120 ° C., and the pressure is 2 to 2.
Crimping was performed at 3 kg / cm ² for about 2 to 10 seconds. On the other hand, the irradiation with the electron beam completed the operation in 2 to 5 seconds.

In the above embodiment, an example of a cell using a flexible substrate is described above and below, but a cell may be formed using a hard substrate such as glass or acrylic on one of the substrates.

[Effects of the Invention] As described above, according to the present invention, a double sealing structure of a sealing material of a thermoplastic resin and a sealing material of an electron beam-curing type is employed, so that the sealing material of the electron beam-curing type and the liquid crystal material Does not come into direct contact with the liquid crystal material, so that the reaction between the electron beam-curable sealing material and the liquid crystal material can be prevented, and the thermoplastic sealing material undergoes plastic deformation under high temperature conditions, resulting in distortion caused by this. Thus, the electron beam-curable sealing material can assist the reduced sealing property, so that the reliable sealing property can be maintained in any case.

Further, the liquid crystal material can be injected without using a vacuum step, so that the steps can be simplified and the processing can be continued.

The cell thickness can be kept uniform by the spacers dispersed in the cells.

In addition, a plurality of cells are communicated with each other via a thin connection path formed by a seal material, and an excess amount of liquid crystal material is dropped, so that excess liquid crystal material is sent to the next cell, so that it does not protrude outside the seal pattern. In addition, the contamination of the post-process is minimized, and the waste of the liquid crystal material can be minimized. Further, unnecessary bubbles can be prevented from being taken into the cell.

[Brief description of the drawings]

FIG. 1 is a view showing the shape of a sealing material on a substrate, FIG.
The figure is an overall configuration diagram showing an example of the manufacturing method. 1,11 ... Flexible substrate, 2,3 ... Seal material, 4 ... Connecting path, 12 ... Liquid crystal supply device, 15 ... Spacer supply device, 21 ... Electron beam curable resin printing device, 22 ... Thermoplastic resin, 24 ... Hot press roller, 25 ... Electron beam curing device.

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Fumiko Hashizume 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc. (56) References JP-A-54-126559 (JP, A) JP-A-53 -93858 (JP, A) JP-A-56-97315 (JP, A)

Claims (1)

(57) [Claims] 1. A method of manufacturing a flexible electro-optical element, comprising injecting a liquid crystal material between a first substrate and a second substrate, wherein the first substrate is provided with a plurality of adjacent thermoplastic resin sealing materials. Forming a linear pattern such that adjacent patterns are arranged so as to be communicated with each other by a connecting path; and forming a linear pattern of a plurality of adjacent electron beam-curable sealing materials on a second substrate. Adjacent patterns communicate with each other through a connection path, and are located outside a linear pattern of a sealing material formed on the first substrate when the first substrate is bonded to the second substrate. A second step of forming, a third step of spraying a spacer on at least one surface of the first substrate and the second substrate, the first substrate and the second substrate are opposed to each other, Heatable with first and second substrates A liquid crystal substance in excess of a predetermined amount is dropped inside the cell, which is a region surrounded by the pattern of the plastic resin sealing material, and the opposing first and second substrates are attached to each other with a pressure roller. A fourth step of causing the liquid crystal substance overflowed by the pressure by the roller to be sent to the next cell filled with the liquid crystal substance via the connection path, and for the sealing material on the first and second substrates. A method for manufacturing a flexible electro-optical element, comprising: a fifth step of curing a pattern; and a sixth step of cutting the substrate bonded to each cell.