JP2971589B2 - Manufacturing method of color filter - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a color filter, and more particularly, to a method for manufacturing a color filter used for a flat display such as a liquid crystal display, an imager such as a CCD, or a color sensor with high accuracy and efficiency. The present invention relates to a method of manufacturing a color filter which can be easily obtained.

[0002]

2. Description of the Related Art For example, a color filter in which fine stripes of a plurality of colors are formed on a transparent substrate is mounted on an image pickup tube of a color video camera. In a liquid crystal display (LCD), a color filter is used in both the active matrix system and the simple matrix system in order to respond to the recent demand for colorization. For example, in an active matrix type liquid crystal display using a thin film transistor (TFT), a color filter, a liquid crystal cell, and a backlight are main members, and the color filters are three primary colors of red (R), green (G), and blue (B). The liquid crystal operates as a shutter by turning on / off an electrode corresponding to each pixel of R, G, B, and light is transmitted through each pixel of R, G, B to perform color display. . The color mixing is visually performed on the retina by the principle of additive color mixing in which liquid crystal shutters corresponding to pixels of two or more colors are opened and mixed to show different colors.

[0003] The color filters used as described above have been conventionally manufactured by means such as a dyeing method and a dispersion method. The production of color filters by the conventional dyeing method
Gelatin, casein, a coating solution obtained by adding a photosensitive agent such as dichromate to a hydrophilic resin such as polyvinyl alcohol is applied on a transparent glass substrate by a spin coating method or the like,
Next, exposure and development are performed using a mask having a predetermined pattern, and thereafter, dyeing with a dye is performed to form a first colored layer. Thereafter, an anti-dye layer is provided on the first colored layer to prevent double dyeing, and then a second colored layer and a third colored layer are formed in the same manner as the formation of the first colored layer. As a result, a color filter having R, G, and B colored layers on a transparent glass substrate could be obtained.

In the production of a color filter using a conventional dispersion method, a photosensitive liquid in which a coloring agent such as a dye, an organic pigment, or an inorganic pigment is dispersed in a transparent photosensitive resin is applied on a transparent glass substrate. To form a photosensitive resin layer. Next, a mask having a predetermined pattern is placed on the photosensitive resin layer,
Exposure and development are performed to form a first colored layer. Similarly, a second color layer and a third color layer were formed to obtain a color filter having R, G, and B color layers.

[0005]

However, both the dyeing method and the dispersion method require a mask in which an opening pattern of a predetermined shape for each of the R, G, and B colored layers is formed with high accuracy.
Such a mask is expensive, and it is necessary to perform multiple exposures on the object to be exposed, such as a photosensitive resin layer, using each mask. There is also a problem that the accuracy is lowered or an apparatus for accurately arranging the mask is required, which causes an increase in manufacturing cost.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described circumstances, and is intended to provide a color filter used for a flat display such as a liquid crystal display, an imager such as a CCD, or a color sensor with high precision and efficiency. An object of the present invention is to provide a method for manufacturing a color filter that can be obtained.

[0007]

In order to achieve the above object, the present invention relates to a method of manufacturing a color filter having a colored layer composed of a plurality of colored patterns, the method comprising the steps of: A photosensitive layer is formed by applying the photosensitive layer to a surface of the transparent substrate by irradiating a light beam for exposure at a predetermined incident angle to the lenticular lens from a lenticular lens disposed on the other surface of the transparent substrate. The step of forming a colored pattern by exposing and developing with the above pattern is repeated for the required number of colors while changing the incident angle stepwise to form a colored layer.

In a method of manufacturing a color filter having a colored layer composed of a plurality of colored patterns, a photosensitive material for dyeing is applied to one surface of a transparent substrate to form a photosensitive layer. The photosensitive layer is exposed and developed in a predetermined pattern by irradiating the lenticular lens with a light beam for exposure at a predetermined incident angle from the lenticular lens side disposed on the surface, and then dyed with a dye and colored. The step of forming a pattern is repeated for the required number of colors while changing the incident angle stepwise to form a colored layer.

[0009]

A light beam for exposure applied to a lenticular lens at a predetermined angle of incidence is transmitted through a transparent substrate to expose a photosensitive layer made of a pigment-dispersed photosensitive material or a photosensitive material for dyeing in a predetermined pattern, and When the photosensitive layer is made of a pigment-dispersed photosensitive material, a colored pattern is formed by performing development thereafter, and when the photosensitive layer is made of a photosensitive material for dyeing, the colored pattern is developed by performing development and dyeing with a dye thereafter. By forming and repeating this, a color filter having a coloring layer having a desired coloring pattern can be obtained.

[0010]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of a lenticular lens used for manufacturing a color filter according to the present invention.
In FIG. 1, the lenticular lens 1 has a base 1a.
It has such a shape that a plurality of convex portions 1b are formed on one surface. Such a lenticular lens 1
In the above, the width of the convex portion 1b is preferably about 0.2 to 0.6 mm, and the width of each colored pattern of the color filter is determined by the width of the convex portion 1b as described later. Such a lenticular lens 1 is made by polishing a glass material or molding a transparent resin such as an acrylic resin.

According to the present invention, a high-precision color filter is produced without performing a complicated mask operation or the like by exposing from the transparent substrate side using the lenticular lens as described above. Next, an example of manufacturing a color filter using the dispersion method according to the present invention will be described with reference to FIGS. First, the lenticular lens 1 is placed on the transparent substrate 2
And a red pigment-dispersed photosensitive material is applied to the other surface of the transparent substrate 2 to form a photosensitive layer 3 having a thickness of about 0.5 to 2 μm (FIG. 2A). Next, when an exposure light beam is irradiated from the lenticular lens 1 side at a predetermined incident angle, the exposure light beam is condensed by each convex portion 1b of the lenticular lens 1 and a predetermined portion of the photosensitive layer 3 (the width W of the convex portion 1b). 2) is exposed, and only the strip-shaped exposed portion 3a is cured (FIG. 2).
(B)). Then, development is performed to remove the unexposed portions of the photosensitive layer 3, thereby forming a red pattern 6R (FIG. 2C). Next, a photosensitive material 3 is formed by applying a green pigment-dispersed photosensitive material on the transparent substrate 2 on which the red pattern 6R is formed, and the incident angle of the exposure light beam to the lenticular lens 1 is changed to change the red pattern 6R. The strip-shaped portion 3b (having a width w corresponding to 1/3 of the width W of the convex portion 1b) is exposed so as to be adjacent to (FIG. 3A). Then, development is performed to remove the unexposed portions of the photosensitive layer 3, whereby a green pattern 6G is formed (FIG. 3B). Next, a photosensitive material 3 is formed by applying a blue pigment-dispersed photosensitive material on the transparent substrate 2 on which the red pattern 6R and the green pattern 6G are formed, and the incident angle of the exposure light beam to the lenticular lens 1 is changed. The band-shaped portion 3c (the width W of the convex portion 1b is 1) between the red pattern 6R and the green pattern 6G.
(Having a width w corresponding to / 3) (FIG. 3)
(C)). After that, the photosensitive layer 3
The blue pattern 6B is formed by removing the unexposed portion of (3) (FIG. 3D).

When a white plate glass is used as the transparent substrate 2 as will be described later, the lenticular lens 1 is removed from the white plate glass on which the colored layer 6 composed of each of the colored patterns 6R, 6G and 6B is formed. The protective layer 8 and the transparent common electrode 9 cover the colored layer 6 as shown in FIG.
And a color filter can be provided. Also,
Similarly, when a nitrocellulose film is used as the transparent substrate 2 as described later, a colored layer 6 composed of 6R, 6G, and 6B colored patterns is separately prepared and adhered to the transparent substrate, and then the lenticular lens is formed from the nitrocellulose film. 1 is removed, and a protective layer and a transparent common electrode are provided so as to cover the colored layer 6 to form a color filter.

In the above example, the lenticular lens 1 is used.
Exposure by changing the incident angle of the exposure light beam to
Each of the R, 6G, and 6B colored patterns is formed. Before the formation of each of the colored patterns, the photosensitive layer formed by applying a black pigment-dispersed photosensitive material is formed between the above-mentioned colored patterns (band-like). The exposed portions 3a, 3b and 3c) may be exposed to form a black matrix in advance. in this case,
The change of the incident angle of the exposure light beam to the lenticular lens 1 is performed in three steps in forming the black matrix and three steps in forming each of the colored patterns 6R, 6G, and 6B.
It is a stage. As described above, the present invention does not require a highly accurate photomask or a device for accurately arranging the photomask at a predetermined position of the photosensitive layer 3, and reduces the incident angle of the exposure light beam to the lenticular lens 1. A high-precision color filter can be manufactured only by changing stepwise.

Next, an example of manufacturing a color filter using the dyeing method according to the present invention will be described with reference to FIG. First, the lenticular lens 1 is disposed on one side of the transparent substrate 2,
On the other surface of the transparent substrate 2, a photosensitive material for dyeing is applied to form a photosensitive layer 3 having a thickness of about 0.3 to 2 μm (FIG. 5A). Next, when an exposure light beam is irradiated from the lenticular lens 1 side at a predetermined incident angle, the exposure light beam is condensed by each convex portion 1b of the lenticular lens 1 and a predetermined portion of the photosensitive layer 3 (the width W of the convex portion 1b). Is exposed, and only the strip-shaped exposed portion 3a is cured (FIG. 5B). Then, while performing development to remove the unexposed portion of the photosensitive layer 3,
A red pattern 6R is formed by dyeing the cured remaining portion with a red dye (FIG. 5C). Next, a dye-resisting layer 4 is provided on the transparent substrate 2 on which the red pattern 6R is formed to prevent dyeing twice, and then a photosensitive material for dyeing is applied again to form a photosensitive layer 3, and a lenticular layer is formed. The red pattern 6 is changed by changing the incident angle of the exposure light beam to the lens 1.
R (the width W of the convex portion 1b is 1
(Having a width w corresponding to / 3) (FIG. 5)
(D)) Thereafter, development is performed to remove the unexposed portions of the photosensitive layer 3, and the cured remaining portions are dyed with a green dye to form a green pattern 6R. Further, after providing the anti-staining layer 4 on the transparent substrate 2 on which the red pattern 6R and the green pattern 6G are formed, a photosensitive material for dyeing is applied again to form the photosensitive layer 3, and the lenticular lens 1 The strip 3c sandwiched between the red pattern 6R and the green pattern 6G by changing the incident angle of the exposure light beam
Exposure is performed (having a width w corresponding to 1/3 of the width W of the convex portion 1b) (FIG. 5E). Thereafter, development is performed in the same manner to remove unexposed portions of the photosensitive layer 3 and dye the remaining cured portion with a blue dye to form a blue pattern 6B.

The transparent substrate 2 may be a rigid material such as quartz glass, pyrex glass, or synthetic quartz plate, or a flexible resin such as a transparent resin film such as a nitrocellulose film or an optical resin plate. A material or the like can be used. Among these, white sheet glass (7059 glass manufactured by Corning Incorporated) is a material having a low coefficient of thermal expansion, excellent in dimensional stability and workability in high-temperature heat treatment, and has an active matrix LC.
Suitable for D color filters.

As the pigment-dispersed photosensitive material, known pigment-dispersed photosensitive materials which have been conventionally used can be used. For example, a coloring agent such as an organic pigment or an inorganic pigment is added to a polyimide resin, an acrylic resin, a polyvinyl alcohol-based resin or the like. Are dispersed. Further, as a photosensitive material for dyeing in which a photosensitive agent is added to a hydrophilic resin, a material obtained by adding a photosensitive agent such as dichromate to a hydrophilic resin such as gelatin, casein, or polyvinyl alcohol can be used. still,
Additives such as an antistatic agent and a wetting agent may be added to the pigment-dispersed photosensitive material and the dyeing photosensitive material.

In order to apply the above-described pigment-dispersed photosensitive material or photosensitive material for dyeing onto the transparent substrate 2, a known method such as a spin coating method can be used. As a light source used for exposing the photosensitive layer 3, an ultra-high pressure mercury lamp,
Xenon lamps, fluorescent lamps and the like can be mentioned. The irradiation amount in the exposure is preferably about 10 to 100 mW / cm ² . As the dye for dyeing the photosensitive material for dyeing cured by exposure, a known dye used in a conventional dyeing method can be used.

The protective layer 8 provided so as to cover the color layer 6 of the color filter is for the purpose of smoothing the surface of the color filter, and is made of acrylic resin, urethane resin, epoxy resin or the like. Can be formed. The thickness of the protective layer is preferably about 0.2 to 10 μm.
Further, as the transparent common electrode 9, an indium tin oxide (ITO) film can be used. The ITO film can be formed by a known method such as an evaporation method and a sputtering method, and the thickness is preferably about 200 to 2000 °.

Next, the present invention will be described in more detail with reference to experimental examples. (Experimental example 1) Using 7059 glass (thickness = 1.1 mm) manufactured by Corning Co., Ltd. as a transparent substrate and the following red pigment-dispersed photosensitive material as a pigment-dispersed photosensitive material, transparent by a spin coating method (rotation speed = 1000 rpm). A photosensitive layer (thickness = 1 μm) was formed on the substrate.

(Red pigment-dispersed photosensitive material) Chromophtal red BRN / 10% PVA = 3/10 2 parts by weight PVA / SbQ (1.4 mol% introduced) 10 parts by weight Pure water 10 parts by weight Next, a lenticular lens having the following specifications is used as shown in FIG.
As shown in the figure, the surface was bonded to the surface of the 7059 glass on which the photosensitive layer was not formed via a urethane resin.

[0021] Next, the photosensitive layer was exposed to ultraviolet light from the lenticular lens side. The incident angle of the ultraviolet rays on the lenticular lens was 0 °. The light source for exposure is an ultra-high pressure mercury lamp, and the irradiation amount is 10 at a wavelength of 365 nm.
mW / cm ² . By such an ultraviolet exposure, the photosensitive layer was exposed in a band shape having a width of 0.1 mm at intervals of 0.3 mm. Next, the unexposed photosensitive layer was removed by water development to form a red pattern on the transparent substrate. The resolution at this time was 5 μm in line & space.

Next, a photosensitive layer was formed on a transparent substrate having a red pattern formed thereon using the following green pigment-dispersed photosensitive material in the same manner as described above. (Green pigment-dispersed photosensitive material) ・ Lionol green 2Y-301 / 10 wt% PVA = 1/10 2 parts by weight ・ PVA / SbQ (1.5 mol% introduced) 10 parts by weight ・ Pure water 10 parts by weight The photosensitive layer was exposed by irradiating ultraviolet rays from the lenticular lens side at an incident angle of 30 °. By such an ultraviolet exposure, a region adjacent to the red pattern of the photosensitive layer was exposed in a band shape having a width of 0.1 mm. Then, the unexposed photosensitive layer was removed in the same manner as the red pattern to form a green pattern on the transparent substrate.

Further, a photosensitive layer was formed on a transparent substrate on which a red pattern and a green pattern were formed by using the following blue pigment-dispersed photosensitive material in the same manner as described above. (Blue pigment-dispersed photosensitive material) Fastogen Blue GNPS / 10% PVA = 1/10 3 parts by weight PVA / SbQ (1.5 mol% introduced) 10 parts by weight Pure water 10 parts by weight The photosensitive layer was exposed by irradiating ultraviolet rays from the lenticular lens side at an incident angle of -30 °. In this case, the ultraviolet irradiation direction and the ultraviolet irradiation direction in the above-described green pattern formation are symmetric with respect to the length direction of the convex portion of the lenticular lens. By such an ultraviolet exposure, a region between the red pattern and the green pattern of the photosensitive layer was exposed in a strip shape. Then, the unexposed photosensitive layer was removed in the same manner as in the red pattern to form a blue pattern on the transparent substrate. Thereby, a colored layer having a colored pattern of red (R), green (G), and blue (B) was formed. Thereafter, the lenticular lens was removed from the 7059 glass (transparent substrate).

Next, a protective layer was formed so as to cover the colored layer formed as described above. This protective layer is formed by spin coating using a urethane-based resin and has a thickness of about 1 μm.
m. Further, a transparent common electrode (ITO) having a thickness of about 1000 A is formed on the protective layer by an ion plating method.
A film was formed to obtain a color filter. (Experimental example 2) A transparent substrate (7059) was produced in the same manner as in Experimental example 1.
(Glass), a photosensitive layer was formed using the following black pigment-dispersed photosensitive material.

(Black pigment-dispersed photosensitive material) Carbon black / 10% PVA = 1/10 3 parts by weight PVA / SbQ (3 mol% introduced) 10 parts by weight Pure water 10 parts by weight Fig. 2 (A)
As shown in the figure, the surface of the 7059 glass on which the photosensitive layer was not formed was bonded via an acrylic resin.

[0026] Next, the photosensitive layer was exposed to ultraviolet light from the lenticular lens side. The incident angles of the ultraviolet rays to the lenticular lens were set to three stages of 0 °, 30 °, and -30 °. An ultra-high pressure mercury lamp was used as a light source for exposure, and the irradiation amount at one time was 30 mW / cm ² at a wavelength of 365 nm. By such UV exposure, the photosensitive layer is 0.1 m
It was exposed in a 0.02 mm wide strip at intervals of m. next,
The unexposed photosensitive layer was removed by development to form a black matrix pattern on the transparent substrate.

Next, a colored layer having a red (R), green (G), and blue (B) coloring pattern was formed on the transparent substrate on which the black matrix pattern was formed in the same manner as in Experimental Example 1. Next, the lenticular lens used in Example 1 was bonded to form a colored pattern in a region between the black matrix patterns in a repeating order of red, green, and blue. The angle of incidence of ultraviolet irradiation from the lenticular lens side is 0 ° when forming a red pattern, 30 ° when forming a green pattern, and -30 when forming a blue pattern.
゜

Thereafter, the lenticular lens was removed from the 7059 glass, and the protective layer and the I
A color filter was obtained by forming a TO film. (Experimental Example 3) Using a nitrocellulose film (thickness = 0.1 μm) as a transparent substrate, a lenticular lens was adhered to the other surface of the nitrocellulose film in the same manner as in Experimental Example 1, and the same as in Experimental Example 1. A colored layer having a colored pattern of red (R), green (G), and blue (B) was formed.

Next, an adhesive (epoxy) of 1 μm was applied to one side of 7059 glass (thickness = 1.1 mm) manufactured by Corning Incorporated.
And the colored layer formed on the nitrocellulose film was adhered to the pressure-sensitive adhesive layer, and the lenticular lens was removed from the nitrocellulose film. Then, a protective layer and an ITO film were formed in the same manner as in Experimental Example 1 to obtain a color filter. (Experimental Example 4) Spin coating method (rotation speed = 1) using 7059 glass (thickness = 1.1 mm) manufactured by Corning Co., Ltd. as a transparent substrate and the following photosensitive material for staining as a photosensitive material for staining.
300 r.pm) on a transparent substrate with a photosensitive layer (thickness =
1.5 μm).

(Photosensitive material for dyeing) Casein: 10 parts by weight Ammonium dichromate: 0.1 parts by weight Pure water: 50 parts by weight Next, in the same manner as in Experimental Example 1, 7 lenticular lenses were used.
It was bonded to the surface of the 059 glass on which the photosensitive layer was not formed via epoxy.

Next, the photosensitive layer was exposed to ultraviolet light from the lenticular lens side. The incident angle of the ultraviolet rays on the lenticular lens was 0 °. The light source for exposure was an ultra-high pressure mercury lamp, and the irradiation amount was 30 mJ / cm ² at a wavelength of 365 nm. By such an ultraviolet exposure, the photosensitive layer was exposed in a band shape having a width of 0.1 mm at intervals of 0.3 mm. Next, after the unexposed photosensitive layer was removed by hot water development, the cured remaining portion was dyed with a red dye (Kayal Milling Red RS manufactured by Nippon Kayaku Co., Ltd.) to form a red pattern on the transparent substrate. The line width at this time is
It was 100 μm.

Next, after applying the following anti-staining layer (thickness: 0.1 μm) on the transparent substrate on which the red pattern is formed, a photosensitive material for dyeing is applied in the same manner as described above to form the photosensitive layer. Formed. (Coating liquid for anti-dye layer) Urethane resin: 1 part by weight Ethyl cellosolve acetate: 12 parts by weight Next, the photosensitive layer was exposed to ultraviolet rays from the lenticular lens side at an incident angle of 30 °. By such an ultraviolet exposure, a region adjacent to the red pattern of the photosensitive layer was exposed in a band shape having a width of 0.1 mm. Then, after removing the unexposed photosensitive layer in the same manner as the red pattern, the cured remaining portion was dyed with a green dye (Brilliant India Blue manufactured by Hoechst) to form a green pattern on the transparent substrate.

Further, an anti-staining layer and a photosensitive layer were formed on the transparent substrate on which the red and green patterns were formed in the same manner as described above. The photosensitive layer was exposed by irradiating ultraviolet rays from the lenticular lens side at an incident angle of -30 °. In this case, the ultraviolet irradiation direction and the ultraviolet irradiation direction in the above-described green pattern formation are symmetric with respect to the length direction of the convex portion of the lenticular lens. By such an ultraviolet exposure, a region between the red pattern and the green pattern of the photosensitive layer was exposed in a strip shape. Then, after removing the unexposed photosensitive layer in the same manner as the red pattern, the cured remaining portion was dyed with a blue dye (Kayal Sayanin 6B manufactured by Nippon Kayaku Co., Ltd.) to form a blue pattern on the transparent substrate. . Thereby, a colored layer having a colored pattern of red (R), green (G), and blue (B) was formed.

Thereafter, the lenticular lens was removed from the 7059 glass, and the protective layer and the I
A color filter was obtained by forming a TO film.

[0035]

As described in detail above, according to the present invention, a highly accurate photomask and a device for accurately arranging the photomask at a predetermined position of the photosensitive layer are not required. A high-precision color filter can be manufactured only by changing the incident angle of the exposure light beam stepwise, and the manufacturing process can be simplified and the manufacturing cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of a lenticular lens used for manufacturing a color filter according to the present invention.

FIG. 2 is a process diagram illustrating a method of manufacturing a color filter according to the present invention.

FIG. 3 is a process diagram illustrating a method of manufacturing a color filter according to the present invention.

FIG. 4 is a schematic sectional view showing an example of a color filter manufactured according to the present invention.

FIG. 5 is a process chart for explaining another example of the method for manufacturing a color filter according to the present invention.

[Explanation of symbols]

 Reference Signs List 1 lenticular lens 2 transparent substrate 3 photosensitive layer 6 colored layer 6R, 6G, 6B colored pattern

Claims (4)

(57) [Claims] 1. A method for manufacturing a color filter having a colored layer comprising a plurality of colored patterns, wherein a pigment-dispersed photosensitive material is applied to one surface of a transparent substrate to form a photosensitive layer, Forming a colored pattern by irradiating a light beam for exposure at a predetermined incident angle to the lenticular lens from the lenticular lens side disposed on the surface and exposing and developing the photosensitive layer in a predetermined pattern, A method for manufacturing a color filter, wherein a colored layer is formed by repeating the required number of colors while changing the incident angle stepwise. 2. A method for manufacturing a color filter comprising a colored layer comprising a plurality of colored patterns, wherein a photosensitive material for dyeing is applied to one surface of a transparent substrate to form a photosensitive layer, The photosensitive layer is exposed and developed in a predetermined pattern by irradiating the lenticular lens with a light beam for exposure at a predetermined incident angle from the lenticular lens side disposed on the surface, and then dyed with a dye and colored. A method for manufacturing a color filter, wherein a step of forming a pattern is repeated for a required number of colors while changing the incident angle stepwise to form a colored layer. 3. The method according to claim 1, wherein the transparent substrate is a glass substrate, and the lenticular lens is removed from the glass substrate after forming the colored layer. 4. The method according to claim 1, wherein the transparent substrate is a nitrocellulose substrate, the colored layer is formed on the glass substrate after the colored layer is formed, and then the lenticular lens is removed from the nitrocellulose substrate. Item 3. The method for producing a color filter according to item 1 or 2.