JP3347709B2 - Method for manufacturing color filter and method for manufacturing liquid crystal display device - 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 and an apparatus for adjusting the warpage of an ink jet head, a method for manufacturing a color filter, and a method for manufacturing a liquid crystal display.

[0002]

2. Description of the Related Art In recent years, the development of personal computers,
In particular, with the development of portable personal computers, the demand for liquid crystal displays, especially color liquid crystal displays, tends to increase. However, for further widespread use, it is necessary to reduce the cost of the liquid crystal display, and in particular, there is an increasing demand for reducing the cost of a color filter having a high specific gravity. Conventionally, various methods have been tried to satisfy the above-mentioned requirements while satisfying the required characteristics of the color filter, but a method for satisfying all the required characteristics has not yet been established. The respective methods will be described below. The first method is a pigment dispersion method. In this method, a photosensitive resin layer in which a pigment is dispersed is formed on a substrate, and a monochromatic pattern is obtained by patterning the photosensitive resin layer. Further, by repeating this process three times, R,
G and B color filter layers are formed.

[0003] The second method is a dyeing method. In the dyeing method, a water-soluble polymer material, which is a material for dyeing, is applied on a glass substrate, and is patterned into a desired shape by a photolithography process. Get a pattern. This is repeated three times to form R, G, B color filter layers.

As a third method, there is an electrodeposition method. In this method, a transparent electrode is patterned on a substrate, and immersed in an electrodeposition coating solution containing a pigment, a resin, an electrolytic solution, and the like to electrodeposit a first color. This process is repeated three times to form R, G, and B color filter layers, and finally fired.

As a fourth method, there is a printing method. In this method, a pigment is dispersed in a thermosetting resin, R, G, and B are separately applied by repeating printing three times, and then the resin is thermoset to form a colored layer. In any method, a protective layer is generally formed on the colored layer.

The common features of these methods are R,
In order to color the three colors G and B, the same process needs to be repeated three times, which increases the cost. In addition, there is a problem that the yield decreases as the number of steps increases.
Further, in the electrodeposition method, since a pattern shape that can be formed is limited, it is difficult to apply the current technology to a TFT. In the printing method, it is difficult to form a fine pitch pattern due to poor resolution and smoothness.

To compensate for these drawbacks, Japanese Patent Application Laid-Open No.
JP-A-5205, JP-A-63-235901 and JP-A-1-217320 disclose a method of manufacturing a color filter using an ink jet system. These methods are R (red), G (green), B
An ink containing three (blue) dyes is jetted onto a light-transmissive substrate by an inkjet method, and each ink is dried to form a colored image portion. In such an ink-jet method, each of the R, G, and B pixels can be formed at a time, so that a great simplification of the manufacturing process and a great cost reduction effect can be obtained.

[0008]

As one of such ink-jet systems, a so-called bubble jet (registered) for ejecting ink by causing ink to boil by heat energy to generate air bubbles and expanding and discharging the ink by volume expansion of the air bubbles. (Trademark) system. When such a bubble jet method is used for an ink jet head, the temperature of the head increases due to the generated thermal energy. Such a rise in temperature causes the head to thermally expand, causing a positional shift of the ink discharge nozzle. In particular, recently, a method of using a long head in which a large number of nozzles are arranged, scanning the head in a direction substantially orthogonal to the arrangement direction of the nozzles, and coloring a large number of pixel rows at a time has been used. And the positional deviation of the nozzle due to the longitudinal extension of the head has become an important problem.

[0009] In the long head as described above,
It is difficult to manufacture a head such that a large number of nozzles are arranged in a straight line in the order of μm. In particular, when a high degree of ink landing accuracy is required, such as in the manufacture of color filters, the nozzle position accuracy must be reduced. Improvement is becoming an important issue.

Accordingly, the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to arrange nozzles of a long ink jet head with high accuracy in a straight line.

[0011]

Means for Solving the Problems The above-mentioned problems are solved,
In order to achieve the object, a color filter according to the present invention is provided.
Manufacturing method, a plurality of ink ejection ports are arranged in the longitudinal direction.
Inkjet head using
By discharging ink from the head to the substrate, multiple pixels are
This is a method of manufacturing a color filter by coloring.
The warpage of adjusting the warpage of the inkjet head
In the adjusting step and the warpage adjusting step, the warpage is adjusted.
From the broken inkjet head to the substrate
A coloring process of coloring a plurality of pixels by discharging
The inkjet head has an inkjet head.
The plate for adjusting the warpage of the pad
Attached along the length of the plate
A plurality of first screw holes are formed in the hand direction,
The ink jet head has a hole corresponding to the first screw hole.
A second screw smaller than the first screw hole at a corresponding position;
A hole is formed, and in the warpage adjustment step, the first
A second screw screwed into the second screw hole through the screw hole of
Screw into the second screw hole, thereby
Move the jet head toward the plate
Operation, and screwing the first screw hole into the first screw hole.
By screwing the first screw that fits,
The head in the direction away from the plate.
By performing at least one of the actions
It is characterized in that the warpage of the inkjet head is adjusted .

Further, the color filter of the present invention
In the manufacturing method, the warpage adjusting step may include the step of
Imaging multiple ink ejection ports of the jet head with a camera
Monitoring the plurality of imaged ink ejection ports
And displaying a plurality of images displayed on the monitor.
While observing the position of the ink discharge port,
Correcting the warpage of the pad .

Further, the color filter of the present invention
In the manufacturing method, the warpage adjusting step may include the step of
Imaging multiple ink ejection ports of the jet head with a camera
Monitoring the plurality of imaged ink ejection ports
And displaying a plurality of images displayed on the monitor.
While observing the position of the ink discharge port,
Correcting the warpage of the pad .

Further, the color filter of the present invention
In the manufacturing method, the heat capacity of the plate
It is characterized in that the heat capacity is not less than twice and not more than four times the heat capacity of the jet head .

Also, the color filter according to the present invention
In the manufacturing method , the inkjet head is a head that ejects ink using thermal energy,
It is characterized by having a thermal energy generator for generating thermal energy given to the ink.

Further, the color filter according to the present invention
In the manufacturing method, the pixel is formed on the substrate.
It is characterized by being a region partitioned by a black matrix .

Further, a method of manufacturing a liquid crystal display device according to the present invention is a method of manufacturing a liquid crystal display device having a color filter manufactured by discharging ink from an ink jet head toward a substrate. The method includes a step of manufacturing a color filter by a manufacturing method, and a step of sealing a liquid crystal compound between the counter substrate facing the color filter and the manufactured color filter.

[0018]

[0019]

[0020]

[0021]

[0022]

[0023]

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a schematic diagram showing the configuration of an embodiment of a color filter manufacturing apparatus.

In FIG. 1, reference numeral 51 denotes an apparatus mount; 52, an XYθ stage disposed on the mount 51; 53, a color filter substrate set on the XYθ stage 52;
Is a color filter formed on the color filter substrate 53, 55 is R (red) for coloring the color filter 54,
G (green) and B (blue) ink jet heads; 58, a controller for controlling the overall operation of the color filter manufacturing apparatus 90; 59, a teaching pendant (personal computer) as a display unit of the controller; 60, a teaching pendant 59; The keyboard as an operation unit is shown.

FIG. 2 is a configuration diagram of a control controller of the color filter manufacturing apparatus 90. 59 is a teaching pendant which is an input / output means of the controller 58;
Reference numeral denotes a display unit for displaying information such as the progress of manufacturing and whether or not the head is abnormal. Reference numeral 60 denotes an operation unit (keyboard) for instructing the operation of the color filter manufacturing apparatus 90 and the like.

Reference numeral 58 denotes a controller for controlling the overall operation of the color filter manufacturing apparatus 90; 65, an interface for transferring data to and from the teaching pendant 59; 66, a CPU for controlling the color filter manufacturing apparatus 90; ROM, which stores a control program for operating the printer, 68, a RAM for storing production information and the like, 70, a discharge control unit for controlling discharge of ink into each pixel of the color filter, 71, a color filter manufacturing apparatus A stage control unit 90 for controlling the operation of the 90 XYθ stage 52 is connected to the controller 58, and shows a color filter manufacturing apparatus that operates according to the instruction.

Next, FIG. 3 is a view showing the structure of the ink jet head 55 used in the color filter manufacturing apparatus 90 described above. In FIG. 1, three inkjet heads are provided corresponding to three colors of R, G, and B,
Since these three heads have the same structure, FIG. 3 shows only one of the three heads as a representative structure.

In FIG. 3, the ink jet head 55
Is schematically composed of a heater board 104 as a substrate on which a plurality of heaters 102 for heating ink are formed, and a top plate 106 overlaid on the heater board 104. A plurality of discharge ports 108 are formed in the top plate 106, and a tunnel-shaped liquid path 110 communicating with the discharge ports 108 is formed behind the discharge ports 108. Each liquid channel 110 is separated from an adjacent liquid channel by a partition 112. Each liquid path 110 is commonly connected to one ink liquid chamber 114 at the rear thereof, and ink is supplied to the ink liquid chamber 114 through an ink supply port 116. The liquid is supplied to each of the liquid paths 110.

The heater board 104 and the top plate 106
Each heater 102 is positioned so as to come to a position corresponding to each liquid path 110, and assembled in a state as shown in FIG.
Although only two heaters 102 are shown in FIG. 3, one heater 102 is
Are arranged one by one. Then, when a predetermined drive pulse is supplied to the heater 102 in an assembled state as shown in FIG. 3, the ink on the heater 102 boils to form bubbles, and the ink expands from the ejection openings 108 by volume expansion of the bubbles. Extruded and discharged. Therefore, it is possible to control the driving pulse applied to the heater 102, for example, by controlling the magnitude of the electric power, to adjust the size of the bubble,
The volume of the ink ejected from the ejection port can be freely controlled.

In this embodiment, a glass substrate is generally used as the substrate 1. However, the substrate 1 is not limited to a glass substrate as long as it has necessary characteristics such as transparency and mechanical strength as a color filter for liquid crystal. Absent.

Next, FIG. 4 is a diagram showing an example of a manufacturing process of a color filter.

FIG. 4A shows a glass substrate 1 provided with a light transmitting portion 7 and a black matrix 2 as a light shielding portion. First, a resin composition curable by light irradiation or light irradiation and heating and having an ink receptivity is applied onto the substrate 1 on which the black matrix 2 is formed, and prebaked as necessary to form a resin layer 3 ′. Is formed (FIG. 4B). For forming the resin layer 3 ', a coating method such as spin coating, roll coating, bar coating, spray coating, dip coating, or the like can be used, and there is no particular limitation.

Next, a portion of the resin layer, which is shielded from light by the black matrix 2, is subjected to pattern exposure in advance using a photomask 4 'to cure a portion of the resin layer and not absorb the ink. Uncolored portions) are formed (FIG. 4 (c)), and then each color of R, G, B is colored at a time using an ink jet head (FIG. 4 (d)), and the ink is dried if necessary. .

As the photomask 4 'used at the time of pattern exposure, a photomask 4' having an opening for curing a light-shielded portion by a black matrix is used. At this time, it is necessary to apply a relatively large amount of ink in order to prevent color loss of the colorant in a portion in contact with the black matrix. Therefore, it is preferable to use a mask having an opening smaller than the (light-shielding) width of the black matrix.

As the ink used for coloring, both dye-based and pigment-based inks can be used, and both liquid inks and solid inks can be used.

As the curable resin composition used in the present invention, any resin can be used as long as it has an ink receiving property and can be cured by at least one of light irradiation and heating. Examples include acrylic resins, epoxy resins, silicone resins, cellulose derivatives such as hydroxypropylcellulose, hydroxyethylcellulose, methylcellulose, and carboxymethylcellulose, and modified products thereof.

It is also possible to use a photoinitiator (crosslinking agent) to cause these resins to undergo a crosslinking reaction by light or light and heat. As a photoinitiator, dichromate,
Bisazide compounds, radical initiators, cationic initiators, anionic initiators and the like can be used. These photoinitiators can be used as a mixture or in combination with other sensitizers. Further, a photoacid generator such as an onium salt can be used in combination as a crosslinking agent. Note that heat treatment may be performed after light irradiation in order to further promote the crosslinking reaction.

The resin layer containing these compositions is extremely excellent in heat resistance, water resistance and the like, and can sufficiently withstand a high temperature or a washing step in a later step.

As the ink jet system used in the present invention, a bubble jet type using an electrothermal converter as an energy generating element can be used, and the coloring area and the coloring pattern can be arbitrarily set.

Next, the curable resin composition is cured only by light irradiation, heat treatment alone, or light irradiation and heat treatment (FIG. 4E), and a protective layer 8 is formed as necessary (FIG. 4E).
(F). In the drawing, hν indicates the intensity of light, and in the case of heat treatment, heat is applied instead of the light of hν. The protective layer 8 can be formed using a second resin composition of a photo-curing type, a thermo-setting type or a combination of light and heat, or can be formed by vapor deposition or sputtering using an inorganic material. Any material can be used as long as it has the transparency in this case and can sufficiently withstand the subsequent ITO forming process, alignment film forming process, and the like.

In this embodiment, an example is shown in which a resin composition is formed on a substrate. However, ink may be applied directly to the substrate as described below.

That is, using the ink jet method, R, G, and B inks are applied so as to fill a light transmitting portion between black matrices constituting a light shielding portion. The R, G, and B patterns may be formed in a so-called casting shape. Further, it is preferable that the printing is performed within a range where the respective color inks do not overlap on the black matrix.

As the ink to be used, any dye or pigment can be used as long as it can be cured by application of energy such as light or heat, and both liquid ink and solid ink can be used. It is essential that the ink contains a photo-curable component or a thermo-curable component or a component curable by both light and heat,
As such a component, various commercially available resins and curing agents can be used, and the component is not particularly limited as long as it does not cause a problem such as fixation in the ink. Specifically, acrylic resins, epoxy resins, melamine resins, and the like are suitably used.

FIGS. 5 and 6 are sectional views showing the basic structure of a color liquid crystal display device 30 incorporating the above-described color filter.

The color liquid crystal display device is generally formed by combining the color filter substrate 1 with the counter substrate 21 and enclosing the liquid crystal compound 18. A TFT (Thin Film Transistor) is provided inside one substrate 21 of the liquid crystal display device.
r) (not shown) and transparent pixel electrodes 20 are formed in a matrix. In addition, a color filter 54 is provided inside the other substrate 1 so that RGB color materials are arranged at positions facing the pixel electrodes, and a transparent counter electrode (common electrode) 16 is formed on the entire surface. Is done. The black matrix 2 is usually formed on the color filter substrate 1 side (see FIG. 5), but is formed on the opposite TFT substrate side in a BM (black matrix) on-array type liquid crystal panel (see FIG. 6). Further, an alignment film 19 is formed in the planes of both substrates, and rubbing the alignment film 19 allows liquid crystal molecules to be aligned in a certain direction. A polarizing plate 1 is provided outside each glass substrate.
The liquid crystal compound 18 is filled in the gap (about 2 to 5 μm) between these glass substrates.
In addition, a combination of a fluorescent lamp (not shown) and a scattering plate (not shown) is generally used as the backlight, and the display is performed by making the liquid crystal compound function as an optical shutter that changes the transmittance of the backlight light. I do. next,
A coloring process of a color filter when the manufacturing method of the present embodiment is applied will be described.

First, the XY of the color filter manufacturing apparatus 90
The glass substrate 53 is set on the θ stage 52. After the positioning is properly performed, the color filter forming region (colored region) of the glass substrate 53 is moved to a position immediately below the inkjet head 55, and
The ink is ejected while the XYθ stage 52 and the glass substrate 53 are relatively scanned by the XYθ stage 52, thereby coloring each pixel of the color filter.

FIG. 7 shows the relationship between the glass substrate 53 and the head 55a of the ink jet head 55 that discharges red (R) ink during this coloring.

In FIG. 7, the head 55a is, for example,
The nozzles 313 are arranged at intervals of 70.5 μm, and when this is used to color a color filter in which the R, G, and B pixels 314 are arranged in order at intervals of 100 μm, for example, red nozzles arranged at intervals of 300 μm are used. It is necessary to align the position of the nozzle with the pixel. Therefore, the nozzles of the head 55a are used every five nozzles, and the head 55a is used at an angle of 31.7 ° with respect to the scanning direction. In this way, 5
Coloring can be performed when the nozzle at the nozzle position comes directly above the red pixel. Such a relationship is represented by the red head 55
The same applies to the other heads 55b and 55c as well as a.

Next, FIG. 8 is a rear view showing a structure which suppresses a rise in the temperature of the ink jet head, which is a characteristic part of the present embodiment. FIG. 9 is a side view of FIG. It is. Here, the inkjet head 55a that discharges red ink will be described, but the other heads 55b and 55c have the same configuration.

The ink jet head 55a of this embodiment
Employs a so-called bubble jet method in which bubbles are generated in ink by thermal energy and the ink is pushed out and ejected by the growth of the bubbles. Therefore, the temperature of the inkjet head rises due to its own heat generation. And
This rise in temperature causes thermal expansion of the ink jet head and changes the distance between the nozzles. For example,
In the present embodiment, the inkjet head 55a
The temperature rise of about 5 ° C. occurs when the ink is continuously ejected by itself. The inkjet head 55a has a main body made of an aluminum alloy and has a total length of about 100 in the longitudinal direction.
When the temperature rises by 5 ° C., the distance between the nozzles at both ends in the longitudinal direction increases by about 10 μm. When the position of the nozzle changes by 10 μm in this way, when the color filter is colored, color mixing with adjacent pixels of different colors may occur. In order to prevent the occurrence of color mixing, it is necessary to suppress the nozzle misalignment to about 3 μm or less.

In this embodiment, as shown in FIGS. 7 and 8, a plate 120 having a heat capacity of about 2 to 4 times the heat capacity of the ink jet head 55a is attached to the back of the ink jet head 55a. The heat capacity of the combined head and plate is three times or more that of the inkjet head 55a alone.
5 times. In this way, the temperature rise of the ink jet head is 1/3 to 1/5 that of the head alone.
Thus, the amount of change in the space between the nozzles at both ends in the longitudinal direction of the inkjet head is about 2 μm to 3 μm. As a result, a head that enables coloring without causing color mixture is realized. In addition, as a material of the plate 120, an aluminum alloy, stainless steel, or the like is preferable in terms of easy processing and low cost.

Next, FIG. 10 is a partial sectional view of FIG. 8 viewed from below. Plate 120 used in this embodiment
Also has a function of correcting the warpage of the inkjet head 55a. A structure for correcting this warpage will be described with reference to FIGS.

8 and 10, the plate 12
0 is fixed to the main body 56 of the inkjet head 55a by three bolts 122. Around the female screw portion 56b to which the three bolts 122 of the main body 56 are screwed, a flat portion 56a slightly higher than other portions of the main body 56 is provided.
Are formed, and the plate 120 is formed by the flat portion 56.
a.

On the other hand, a plurality of screw holes 120a are formed in an intermediate portion of the plate 120 at a position where the bolt 122 is mounted. The screw hole 120a is, for example, an M4 screw hole. Then, two types of bolts 124 and 126 are mounted in the screw holes 120a. The bolt 124 is, for example, an M4 screw that is just screwed into the screw hole 120a.
By screwing the bolt 124 into the screw hole 120a, the tip of the bolt 124 contacts the surface of the head main body 56, and pushes the head main body 56 away from the plate 120 to shift the nozzle in the direction of arrow A shown in FIG. Can be done. The bolt 126 is, for example, a screw hole 120.
M3 bolt that can be freely inserted with a gap in a
By screwing the bolt 126 into the M3 screw hole 56c formed in the head main body 56, the head main body 56 is drawn in a direction approaching the plate 120, and the nozzle can be shifted in the direction of arrow B shown in FIG. By selectively mounting the bolts 124 that are just screwed into the respective screw holes 120a or the bolts 126 that are freely inserted into the screw holes 120a, the nozzle position at the position of the screw holes is moved in the direction of arrow A or the direction of arrow B. Can be done. Thereby, the slight warpage of the ink jet head 55a at the time of manufacture can be arbitrarily corrected.

FIG. 11 is a diagram for explaining a specific method of adjusting the ink jet head 55a.

The ink jet head 55a is the same as that shown in FIG.
As shown in FIG. 11A, at the time of manufacture, it has a slight warp (in FIG. 11A, the warp is emphasized and greatly shown). This warp is applied to the bolt 12 shown in FIG.
4 or 126 is replaced as appropriate, and correction is made by pushing and pulling the ink jet head against the plate 120. At this time, as shown in FIG. 11 (a), operations such as slightly pulling, largely pulling, slightly pressing, and largely pressing are combined according to the magnitude of the warp, and the head is straightened as shown in FIG. 11 (b). To correct the condition.

By performing such a correction, at the time of manufacture, ± 10 μm as shown by a solid line in FIG.
The head having the above-mentioned warpage can be corrected to a warp of about ± 2 μm as shown by a dashed line in FIG.

When correcting the warpage, as shown in FIG. 13, the nozzle holes of the ink jet head 55a are
Enlarged by a microscope 200, captured by a television camera 202, displayed on a monitor 206 via an image processing device 204,
Correction work is performed while observing the position of the nozzle hole.

In this manner, an ink jet head having a slight warp during manufacturing can be corrected to a state in which the nozzles are arranged in a straight line with a very small deviation of about ± 2 μm.

FIG. 14 is a view showing a modified example of the plate. As shown in FIG.
By forming 30, the heat dissipation is improved, and the temperature rise of the head can be further suppressed.

Also, by making the plate black,
The radiation of heat is improved, and the effect of suppressing the temperature rise of the head is further enhanced.

Next, a description will be given of the accuracy of adjusting the warpage of the ink-jet head when a color filter is manufactured by discharging ink onto the glass substrate while causing the ink-jet head to scan relative to the glass substrate.

The inventor of the present application suffered from the problem of color mixing, in which the colors of adjacent pixels were mixed, which is unique to the ink jet system, when producing a color filter by the ink jet system.

Therefore, in order to clarify the cause of the color mixture, the glass substrate 53 is moved so that the ink jet head scans obliquely with respect to the longitudinal direction of the pixel during ink ejection as shown in FIG. And the deviation amount (Δx) of the ink dot when the color mixture starts and the diameter CL of the ink dot.
An experiment for examining the relationship between the pixel width and the pixel width GL was performed.

A plurality of nozzles eject ink, that is, inks having different diameters upon impact are ejected, and the pixel width (the distance GL between the centers of adjacent black matrices 2a and 2b) is obtained.
While repeating coloring to different pixels, the pixel width becomes GL,
When the diameter of the dot formed by the landed ink is CL and the deviation amount of the landed position in the pixel width direction is Δx, it has been found that when GL <CL + Δx, the possibility of color mixing sharply increases. Conversely, it has been found that if Δx ≦ GL-CL is satisfied, color mixing is extremely unlikely to occur.

When coloring pixels at different pitch intervals during the production of a color filter, it is possible to flexibly cope with various color filters by using the head obliquely as shown in FIG. Is known.

The inventor of the present application makes the ink land on the glass substrate 53 before the ejected ink becomes spherical, so that landing deviation due to ink skewing or the like is less likely to occur, and a more accurate landing position is achieved. The fact that the accuracy can be realized is shown in Japanese Patent Application No. 7-195235. At this time, by examining the landing positions of the ink, it was found through experiments that the landing positions of the ink substantially coincided with the positions of the holes of the ink discharge nozzles of the inkjet head, as shown in FIG.

That is, it has been found from these experiments that the positional accuracy of the nozzle holes of the head is dominant in the likelihood of color mixing in the ink jet head.

As described above, the inventor of the present invention has shown that, as shown in FIGS. 15 and 17, GL is the pixel width (the distance between the centers of the widths of adjacent black matrices), and CL is the dot formed by the ink that has landed. Is the diameter of the nozzle, y1 is the amount of deviation of the nozzle from the ideal straight line (approximate straight line obtained by the least squares method) in the direction perpendicular to the ideal straight line where the nozzles are aligned when the head is not warped, and y2 is the head. When there is no warpage, the amount of deviation from the ideal straight line in which the nozzles are lined up to the negative side in the direction orthogonal to the ideal straight line, θ is the tilt angle of the head with respect to the direction orthogonal to the head scanning direction, and Δx is the scanning direction. It has been found that the following equation holds when the amount of displacement of the ink dots in the direction orthogonal to the width (pixel width direction) is set.

Y = y1 + y2 Δx = y · sin θ Δx ≦ GL-CL That is, y · sin θ ≦ GL-CL y ≦ (GL-CL) / sin θ (where 0 ° <θ <90 °) (1) The diameter CL of the dot formed by the landed ink referred to in the above is the diameter of the ink spread on the undivided elemental glass or the glass coated with the ink receiving layer, and the ink spreads before drying. In a head having a plurality of irregular nozzles, the largest landing diameter is defined as CL.

Therefore, a color filter without color mixture can be manufactured by correcting the amount of displacement y of the nozzle of the warped head so as to satisfy the above equation (1) by the correction method described above. . Alternatively, a color filter without color mixture can be manufactured by coloring a color filter using a head whose nozzle displacement amount y satisfies Expression (1) regardless of whether the warpage is corrected. .

Needless to say, although the nozzle position slightly shifts in the nozzle row direction during the manufacture of the head, at least the amount of deviation of the nozzle position in the direction orthogonal to the nozzle row needs to satisfy Expression (1). .

In equation (1), 0 ° <θ <90 °, but from the viewpoint of manufacturing efficiency, it is common to use 0 ° <θ ≦ 45 °.

In the experiment by the present inventor, the pixel width GL was 102.5 μm and the landing diameter CL was 85 μm.
4-inch long head of 60 dpi (nozzle number 1408)
And every 5 nozzles) was used at an angle of θ = 29.27 °.

At this time, since the variation on the positive side and the negative side from the ideal straight line of the nozzle were substantially equal, y1 =
As y2, y ≦ ± {(102.5-85) / sin 29.27 °} /
2 Therefore, y ≦ ± 17.9 μm.

The inventor of the present application has assumed that the margin of the accuracy of the apparatus is ± 10 μm, and the warpage of the head is ± 8 μm.
The head was adjusted as described below to perform coloring. As a result, a color filter having no color mixture could be manufactured. Equation (1) is an equation on the assumption that a margin such as the accuracy of the apparatus is zero. If there is a margin, the margin amount is subtracted from the value calculated from equation (1) as described above. Is adjusted so that the amount of warpage of the head is equal to or less than the calculated value.

FIG. 18 is a diagram for explaining a positional shift in a head unit combining short heads. Also in this example, the nozzle shift amount y is set so as to satisfy the equation (1). I just need.

FIG. 19 is a diagram showing the relationship between the pixels of the color filter and the ink dots, and FIG. 20 is a diagram showing the limit of color mixing when coloring the color filter.

As described above, according to the above-described embodiment, by mounting a plate having a large heat capacity to the ink jet head, it is possible to suppress a rise in the temperature of the ink jet head, to prevent misalignment of nozzles, and to perform color mixing. A color filter free of defects can be manufactured.

Further, a screw hole is formed in the plate, and a screw hole one size smaller than the screw hole is formed in the head main body side. By selectively mounting bolts, the head can be moved both in the direction away from the plate and in the direction approaching the head at the position of each screw hole, and it is possible to correct the head warpage, so that the nozzle An inkjet head that is precisely aligned on a straight line is provided.

Further, a color filter free from color mixture can be manufactured by using a head whose nozzle displacement satisfies the expression (1).

The present invention can be applied to a modification or a modification of the above embodiment without departing from the gist of the invention.

The present invention is particularly provided with a means (for example, an electrothermal converter or a laser beam) for generating thermal energy as energy used for ejecting ink even in an ink jet recording system. The printing apparatus of the type that causes a change in the state of the ink has been described.
High definition can be achieved.

The typical configuration and principle are described in, for example, US Pat. Nos. 4,723,129 and 4,740.
It is preferable to use the basic principle disclosed in the specification of Japanese Patent No. 796. This method can be applied to both the so-called on-demand type and continuous type. In particular, in the case of the on-demand type, liquid (ink)
By applying at least one drive signal corresponding to the recorded information and providing a rapid temperature rise exceeding the film boiling to the electrothermal transducer arranged corresponding to the sheet or the liquid path holding the Since thermal energy is generated in the electrothermal transducer and film boiling occurs on the heat-acting surface of the recording head, bubbles in the liquid (ink) corresponding to this drive signal on a one-to-one basis can be formed. It is valid. By discharging the liquid (ink) through the discharge opening by the growth and contraction of the bubble, at least one droplet is formed. When the drive signal is formed into a pulse shape, the growth and shrinkage of the bubble are performed immediately and appropriately, so that the ejection of the liquid (ink) having particularly excellent responsiveness can be achieved, which is more preferable.

As the pulse-shaped drive signal, those described in US Pat. Nos. 4,463,359 and 4,345,262 are suitable. Further, if the conditions described in US Pat. No. 4,313,124 relating to the temperature rise rate of the heat acting surface are adopted, more excellent recording can be performed.

As the configuration of the recording head, in addition to the combination of the discharge port, the liquid path, and the electrothermal converter (linear liquid flow path or right-angle liquid flow path) as disclosed in the above-mentioned respective specifications, A configuration using U.S. Pat. No. 4,558,333 or U.S. Pat. No. 4,459,600, which discloses a configuration in which a heat acting surface is arranged in a bent region, is also included in the present invention. In addition, for multiple electrothermal transducers,
JP-A-59-123670 which discloses a configuration in which a common slot is used as a discharge part of an electrothermal transducer, and JP-A-59-123670 which discloses a configuration in which an opening for absorbing a pressure wave of thermal energy corresponds to a discharge part. A configuration based on 138461 may be adopted.

Further, as a full-line type recording head having a length corresponding to the width of the maximum recording medium that can be recorded by the recording apparatus, the length is determined by combining a plurality of recording heads as disclosed in the above-mentioned specification. This may be either a configuration satisfying the above requirements or a configuration as a single recording head formed integrally.

In addition, the print head is replaceable with a print head of a replaceable chip type, which can be electrically connected to the main body of the apparatus or supplied with ink from the main body of the apparatus, or is integrated with the print head itself. Alternatively, a cartridge type recording head provided with an ink tank may be used.

It is preferable to add recovery means for the recording head, preliminary auxiliary means, and the like provided as components of the recording apparatus of the present invention since the effects of the present invention can be further stabilized. . If these are specifically mentioned, capping means for the recording head, cleaning means, pressurizing or suction means, preheating means using an electrothermal transducer or another heating element or a combination thereof, and printing Performing a preliminary ejection mode for performing another ejection is also effective for performing stable printing.

In the embodiments of the present invention described above, the ink is described as a liquid. However, an ink which solidifies at room temperature or lower, or an ink which softens or liquefies at room temperature may be used. It is only necessary that the ink be in a liquid state when the recording signal is applied.

In addition, in order to positively prevent the temperature rise due to thermal energy as energy for changing the state of the ink from the solid state to the liquid state, the temperature is positively prevented.
Alternatively, in order to prevent evaporation of the ink, an ink which solidifies in a standing state and liquefies by heating may be used. In any case, the application of heat energy causes the ink to be liquefied by application of the heat energy according to the recording signal and the liquid ink to be ejected, or to start to solidify when reaching the recording medium. The present invention is also applicable to a case where an ink having a property of liquefying for the first time is used. In such a case, as described in JP-A-54-56847 or JP-A-60-71260, the ink is held in a liquid state or a solid state in the concave portion or through hole of the porous sheet. It is good also as a form which opposes an electrothermal transducer. In the present invention, the most effective one for each of the above-mentioned inks is to execute the above-mentioned film boiling method.

[0094]

As described above, according to the present invention, the nozzles of a long ink jet head can be accurately aligned in a straight line.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing a configuration of an embodiment of a color filter manufacturing apparatus.

FIG. 2 is a diagram illustrating a configuration of a control unit that controls the operation of the color filter manufacturing apparatus.

FIG. 3 is a diagram illustrating a structure of an ink jet head used in a color filter manufacturing apparatus.

FIG. 4 is a view showing another example of the manufacturing process of the color filter.

FIG. 5 is a cross-sectional view illustrating a basic configuration of a color liquid crystal display device incorporating a color filter according to an embodiment.

FIG. 6 is a cross-sectional view illustrating a basic configuration of a color liquid crystal display device incorporating a color filter according to an embodiment.

FIG. 7 is a diagram showing an example of how to color a color filter.

FIG. 8 is a diagram illustrating a state where a plate is attached to the inkjet head.

FIG. 9 is a side view of FIG. 8 as viewed from the left side.

FIG. 10 is a partial sectional view of FIG. 8 as viewed from below.

FIG. 11 is a diagram for explaining a specific method for correcting the warpage of the inkjet head.

FIG. 12 is a diagram illustrating warpage amounts of an inkjet head before and after correction.

FIG. 13 is a diagram illustrating a configuration of an apparatus for observing a warpage of an inkjet head.

FIG. 14 is a view showing a modification of the plate.

FIG. 15 is a diagram for explaining a method of calculating the amount of displacement of ink dots that causes color mixing.

FIG. 16 is a diagram showing a relationship between an ink landing position and a nozzle position.

FIG. 17 is a diagram for explaining nozzle displacement in the pixel width direction due to head warpage.

FIG. 18 is an explanatory diagram of a position shift in a head unit in which a head having a short length is combined.

FIG. 19 is a diagram illustrating a relationship between pixels of a color filter and ink dots.

FIG. 20 is a diagram illustrating a limit of color mixing when coloring a color filter.

[Explanation of symbols]

 52 XYθ stage 53 Glass substrate 54 Color filter 55 Coloring head 58 Controller 59 Teaching pendant 60 Keyboard

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-3-227634 (JP, A) JP-A-5-104354 (JP, A) JP-A-8-27011 (JP, A) 46759 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B41J 2/01 B41J 2/44 B41J 2/45 B41J 2/455 G02B 5/20 101 G02F 1/1335 505

Claims (7)

(57) [Claims] A plurality of ink ejection ports are arranged in a longitudinal direction.
Inkjet head using
By discharging ink from the head to the substrate, multiple pixels are
This is a method of manufacturing a color filter by coloring.
I, warpage adjustment Engineering for adjusting a warp of said ink jet head
And the ink whose warpage has been adjusted in the warpage adjusting step.
Eject ink from the jet head toward the substrate
And a coloring step of coloring a plurality of pixels, the ink-jet head, the ink jet f
The plate for adjusting the warpage of the pad
A plurality of first screw holes in the longitudinal direction.
Is formed, and the ink jet head is
Is the first screw at a position corresponding to the first screw hole.
A second screw hole smaller than the hole is formed, and in the warp adjustment step, the second screw hole is formed through the first screw hole.
A second screw screwed into the second screw hole is inserted into the second screw hole.
Screwing the inkjet head into the front
Movement in a direction to approach the plate,
Attach the first screw screwed into the first screw hole to the first screw hole.
To move the inkjet head to the
At least in the movement to move away from the rate
By performing one operation, the ink jet head is
The color filter is characterized by adjusting the warpage of the color filter.
Manufacturing method . 2. The method according to claim 1 , wherein the step of adjusting the warpage includes the step of
Multiple outlets of the printhead are ± 2 μm from a predetermined straight line
The inkjet head so that it is aligned within
2. The warpage of the hand is adjusted.
Manufacturing method of color filter . 3. The ink jet printer according to claim 1 , wherein
Of imaging multiple ink ejection ports of a printhead with a camera
And the plurality of imaged ink ejection ports are displayed on a monitor.
Displaying the plurality of inks displayed on the monitor.
While observing the position of the ejection port, the inkjet head
Correcting the warpage of the object.
3. The method for producing a color filter according to 1 or 2 . 4. The heat capacity of the plate is equal to the ink capacity.
That more than twice the heat capacity of Ettoheddo is 4 times or less
A color according to any one of claims 1 to 3, characterized in that:
Filter manufacturing method . 5. The inkjet head according to claim 1, wherein the inkjet head uses thermal energy to discharge the ink, and includes a thermal energy generator for generating thermal energy to be applied to the ink. 5. The method for producing a color filter according to any one of 4. 6. The pixel according to claim 6, wherein the pixel is a pixel formed on the substrate.
It is characterized by being an area partitioned by a rack matrix
The color filter according to any one of claims 1 to 5,
Manufacturing method . 7. A method of manufacturing a liquid crystal display device having a color filter manufactured by towards the ink jet head to the substrate to discharge ink, by the method according to any one of claims 1 to 6 A method for manufacturing a liquid crystal display device, comprising: a step of manufacturing a color filter; and a step of sealing a liquid crystal compound between a counter substrate facing the color filter and the manufactured color filter.