JP3880606B2 - Manufacturing method of color filter, manufacturing method of display panel, manufacturing method of information processing device including display panel, manufacturing method of liquid crystal display panel, manufacturing method of information processing device including liquid crystal display panel - Google Patents

Description

The present invention is a manufacturing method and a liquid crystal display panel of a liquid crystal display panel with a manufacturing method and color filter of the color filter for producing a color filter by coloring by ejecting ink toward a colored article by an ink jet head The present invention relates to a method for manufacturing an information processing apparatus provided .

  In general, a liquid crystal display device is mounted on a personal computer, a word processor, a pachinko game machine, an automobile navigation system, a small television, and the like, and the demand is increasing in recent years. However, liquid crystal display devices are expensive and demands for cost reduction of liquid crystal display devices are increasing year by year.

  The color filter constituting the liquid crystal display device is configured by arranging pixels such as red (R), green (G), and blue (B) on a transparent substrate, and further, display contrast is provided around these pixels. In order to increase the brightness, a black matrix for light shielding is provided.

  Conventionally, pigment dispersion methods, dyeing methods, electrodeposition methods, printing methods and the like are known as methods for producing color filters.

  In the pigment dispersion method, a photosensitive resin layer in which a pigment is dispersed is formed on a glass substrate, and the process of obtaining a monochromatic pattern by patterning this layer is repeated three times for each of the R, G, and B colors. To form.

  In the dyeing method, a layer of a water-soluble polymer material, which is a dyeing material, is formed on a glass substrate, formed into a desired pattern by photolithography, and the glass substrate is immersed in a dyeing basket. A color filter is formed by repeating the process of obtaining a colored pattern three times for each of the R, G, and B colors.

  The electrodeposition method is a process in which a transparent electrode pattern is formed on a glass substrate, and the glass substrate is immersed in an electrodeposition coating solution containing a pigment, a resin, an electrolytic solution, etc., and a single color is electrodeposited. A color filter is formed by repeating three times for each B3 color and firing.

  In the printing method, the R, G, and B colors are separately applied by repeating printing using a material in which a pigment is dispersed in a thermosetting resin, and then the resin is thermoset.

  What is common to these four methods is that the same process needs to be repeated three times in order to color the R, G, and B3 colors, and since the number of processes is large, the yield decreases and the cost increases. , And the like.

  Furthermore, the electrodeposition method is difficult to apply to the TFT because the shape of the pattern that can be formed is limited. Also, the printing method has disadvantages such as poor resolution and difficulty in dealing with pattern miniaturization.

  Therefore, in order to make up for these drawbacks, a technique for forming a color filter pattern by ejecting ink onto a glass substrate with an inkjet head has been proposed.

With regard to such an ink jet method, for example, in Japanese Patent Application Laid-Open No. 59-75205, ink containing three colors of R, G, and B is ejected onto a substrate by an ink jet method, and each ink is dried. It has been proposed to form a colored image portion. In such an ink jet method, it is possible to form each pixel of R, G, and B at once, and a great simplification of the manufacturing process and a great cost reduction effect can be obtained.
JP 59-75205 A JP-A-8-240803

  However, in the production of a color filter by the ink jet method, as shown in FIG. 11, when the pixels on the same column or row in one screen are continuously colored at a time, the color in the screen is changed. There was a problem that unevenness may occur.

This is considered to be caused by various non-uniformities in ink discharge as described below.
(1) Variation in the amount of ink ejected at one time (2) Variation in diameter when the ejected ink spreads on the substrate (3) Variation in positional relationship of the ink spread on the substrate with respect to the pixels Of these, (1) is visually perceived as the color density of each pixel is different, and (2) and (3) are macroscopic due to the difference in color uniformity within the pixel. The unevenness is visually recognized when the color depth of the pixels seen in FIG.

  The reason why these appear to be uneven will be described with reference to FIG.

  FIG. 17 shows the color filter pixels and the absorbance distribution of the cross section (for convenience of explanation, a single color filter is shown).

  In FIG. 17, the pixel 1 has the same absorbance distribution within the pixel as the pixels 2, 4, and 5, but the absorbance is low as a whole. This is caused by the above (1). On the other hand, since the landing positions of the pixels 3 are shifted to the left, the average of the absorbance in the pixels is the same as that of the pixels 2, 4, and 5, but the distribution is different. This occurs due to the above (2) and (3). In this example, since the right side of the pixel 3 is bright, the entire pixel 3 is recognized brighter than the pixels 2, 4, and 5 by human eyes and may appear uneven.

  These non-uniformity of ink ejection exists not only for ink ejected by the same nozzle, but also between nozzles.

  For this reason, in order to speed up a coloring process, it becomes a problem especially when coloring using a some nozzle.

  On the other hand, as described in JP-A-8-240803, there has been proposed a method of dispersing nonuniformity by limiting the order of coloring pixels.

  However, this method has a problem in that it is difficult to reduce the time required for the coloring step because the order of coloring the pixels is limited.

  Accordingly, the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a color filter manufacturing method capable of manufacturing a color filter with little color unevenness in a short time.

Another object of the present invention is to provide a method for manufacturing a liquid crystal display panel including a color filter manufactured by the above manufacturing method and a method for manufacturing an information processing apparatus including a liquid crystal display panel .

In order to solve the above-described problems and achieve the object, a method for manufacturing a color filter according to the present invention includes ejecting a plurality of colors of red, green, and blue toward an object to be colored by an ink jet head. A method of manufacturing a color filter by coloring each pixel of a colored body, the step of measuring the color density of the pixel multiple times, and adjusting the color density variation between pixels based on the results of the multiple measurements Thus, the color density variation between pixels to be colored red is 5% or less, the color density variation between pixels to be colored green is 10% or less, and the color between pixels to be colored blue There is a step of coloring so that the density variation is 3% or less, and the frequency of adjusting the color density variation is changed according to the color.

  In the color filter manufacturing method according to the present invention, the variation in the ink discharge amount per one time of the ink discharge nozzles of the ink jet head is greater than 3%.

  In the color filter manufacturing method according to the present invention, the variation in the ink discharge amount per one time of the ink discharge nozzles of the ink jet head is 15 to 20%.

The color filter manufacturing method according to the present invention is characterized in that the frequency of adjusting the color density variation is changed for each color according to the color density variation defined for each of red, green, and blue. .

In the color filter manufacturing method according to the present invention, the color density variation adjustment is executed based on an average of the results of the plurality of measurements .

  In the color filter manufacturing method according to the present invention, when each pixel is colored n times (n is a positive integer) in the coloring step, the color density variation between the pixels in each coloring is red. The pixel is colored so that it becomes less than √n times 5% of the pixel, less than √n times less than 10% in the case of the green pixel, and less than √n times of 3% in the case of the blue pixel.

  Further, in the method for manufacturing a color filter according to the present invention, when the object to be colored is a substrate having a diagonal dimension of 200 mm or more, a variation in color density between pixels to be colored in red is 2.5% or less, Coloring is performed so that a variation in color density between pixels to be colored green is 6% or less, and a variation in color density between pixels to be colored blue is 1.5% or less.

  In the color filter manufacturing method according to the present invention, when each pixel is colored n times (n is a positive integer) in the coloring step, the color density variation between the pixels in each coloring is red. In the case of a pixel of 2.5%, √n times or less of 2.5%, in the case of a green pixel, √n times or less of 6%, and in the case of a blue pixel, 1.5% of √n times or less Features.

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

  The display panel manufacturing method according to the present invention is manufactured by ejecting a plurality of colors of red, green, and blue toward an object to be colored by an inkjet head to color each pixel of the object to be colored. A method of manufacturing a display panel provided with a color filter comprising: a step of preparing a color filter manufactured by the above manufacturing method; the prepared color filter; and a light amount changing unit capable of changing a light amount. And a step of integrating.

  Further, a method of manufacturing an information processing apparatus including a display panel is a method of manufacturing an information processing apparatus including a display panel, the step of preparing the display panel manufactured by the above manufacturing method, and the preparation Connecting the display panel and image signal supply means for supplying an image signal to the display panel.

  In addition, the method for manufacturing a liquid crystal display panel according to the present invention is manufactured by ejecting a plurality of colors of red, green, and blue toward an object to be colored by an ink jet head and coloring each pixel of the object to be colored. A method of manufacturing a liquid crystal display panel provided with the prepared color filter, the step of preparing a color filter manufactured by the above manufacturing method, and the step of encapsulating liquid crystal between the prepared color filter and the counter substrate And.

  A method of manufacturing an information processing apparatus including a liquid crystal display panel according to the present invention is a method of manufacturing an information processing apparatus including a liquid crystal display panel, and the liquid crystal display panel manufactured by the above manufacturing method is prepared. And a step of connecting the prepared liquid crystal display panel and an image signal supply means for supplying an image signal to the liquid crystal display panel.

  According to the present invention, since there is no restriction on the coloring order, a simple stage operation is sufficient, and a color filter can be manufactured in a short time.

  In addition, since the optimum variation range for each color has been clarified, it is possible to achieve both manufacturing cost and quality. For example, as described in the above embodiment, in a color filter manufacturing apparatus in which repeated measurement is performed and variation in color density is controlled by the number of repetitions, distinction by color is performed by setting the number of measurements for each color. Compared with the case where there is not, it is possible to achieve both higher manufacturing cost and quality.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  Note that the color filter defined in the present invention includes a colored portion and an object to be colored, and can obtain output light whose characteristics are changed with respect to input light.

  FIG. 1 is a schematic diagram showing the configuration of a color filter manufacturing apparatus using an ink jet method, and shows a state during the coloring process.

  In FIG. 1, 51 is an apparatus base, 52 is an XYθ stage disposed on the base 51, 53 is a color filter substrate set on the XYθ stage 52, 54 is a color filter formed on the color filter substrate 53, 55 Is a head unit comprising red, green and blue inkjet heads for coloring the color filter 54 and a head mount 55a for supporting them, 58 is a controller for controlling the overall operation of the color filter manufacturing apparatus 90, and 59 is a controller. A display unit 60 indicates a keyboard which is an operation unit of the controller.

  The head unit 55 is detachably attached to the support portion 90a of the color filter manufacturing apparatus and is mounted so that the rotation angle can be adjusted in a horizontal plane.

  FIG. 2 is a configuration diagram of the control controller of the color filter manufacturing apparatus 90. 59 is a teaching pendant serving as input / output means of the controller 58, 62 is a display unit for displaying information such as the progress of manufacturing and the presence or absence of head abnormality, and 60 is an operation unit for instructing the operation of the color filter manufacturing apparatus 90. (Keyboard).

  58 is a controller for controlling the overall operation of the color filter manufacturing apparatus 90, 65 is an interface for transferring data to and from the teaching pendant 59, 66 is a CPU for controlling the color filter manufacturing apparatus 90, and 67 is for operating the CPU 66. ROM for storing a control program for storing, RAM for storing abnormal information and the like, 70, an ejection control unit for controlling ejection of ink into each pixel of the color filter, and 71, XYθ of the color filter manufacturing apparatus 90 A stage control unit 90 for controlling the operation of the stage 52 is connected to the controller 58 and represents a color filter manufacturing apparatus that operates in accordance with the instructions.

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

  In FIG. 3, the ink jet head IJH is generally configured by a heater board 104 that is a substrate on which a plurality of heaters 102 for heating ink is formed, and a top plate 106 placed on the heater board 104. . A plurality of discharge ports 108 are formed in the top plate 106, and a tunnel-like liquid path 110 communicating with the discharge ports 108 is formed behind the discharge ports 108. Each liquid path 110 is isolated from an adjacent liquid path by a partition wall 112. Each liquid passage 110 is commonly connected to one ink liquid chamber 114 at the rear thereof, and ink is supplied to the ink liquid chamber 114 via an ink supply port 116, and the ink is supplied from the ink liquid chamber 114. The liquid is supplied to each liquid passage 110.

  The heater board 104 and the top plate 106 are aligned so that each heater 102 comes to a position corresponding to each liquid passage 110 and assembled in a state as shown in FIG. Although only two heaters 102 are shown in FIG. 3, the heaters 102 are arranged one by one corresponding to the respective liquid paths 110. When a predetermined drive pulse is supplied to the heater 102 in the assembled state as shown in FIG. 3, the ink on the heater 102 boils to form bubbles, and the ink is discharged from the ejection port 108 by the volume expansion of the bubbles. Extruded and discharged. Accordingly, it is possible to adjust the bubble size by controlling the drive pulse applied to the heater 102, for example, by controlling the magnitude of the electric power, and the volume of ink ejected from the ejection port can be freely controlled. it can.

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

  In the color filter of the present invention, a translucent substrate is preferable as the substrate, and a glass substrate is generally used. However, a glass substrate is acceptable as long as it has necessary characteristics such as transparency and mechanical strength as a color filter for liquid crystals. It is not limited to. 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 that can be cured by light irradiation or light irradiation and heating is applied to the substrate 1 on which the black matrix 2 is formed, and is pre-baked as necessary to form the resin layer 3. It forms (FIG.4 (b)). The resin layer 3 can be formed by any coating method such as spin coating, roll coating, bar coating, spray coating, and dip coating, and is not particularly limited.

  Next, a portion 5 (non-colored portion) that does not absorb ink by curing a part of the resin layer by performing pattern exposure in advance on the portion of the resin layer that is shielded by the black matrix 2 using a photomask 4. After forming (FIG. 4C), each of R, G, and B is colored at once using an inkjet head (FIG. 4D), and the ink is dried as necessary.

  As the photomask 4 used for pattern exposure, a photomask 4 having an opening for curing a light shielding 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 at the portion in contact with the black matrix. Therefore, it is preferable to use a mask having an opening narrower 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 ink and solid ink can be used.

  As the curable resin composition used in the present invention, any resin composition can be used as long as it has ink acceptability and can be cured by light irradiation or at least one of light irradiation and heating. Examples thereof include acrylic resins, epoxy resins, silicon resins, hydroxypropyl cellulose, hydroxyethyl cellulose, cellulose derivatives such as methyl cellulose, carboxymethyl cellulose, and modified products thereof.

  It is also possible to use a photoinitiator (crosslinking agent) in order to advance the crosslinking reaction of these resins by light or light and heat. As the photoinitiator, dichromate, bisazide compound, radical initiator, cationic initiator, anionic initiator and the like can be used. Moreover, these photoinitiators can be mixed or used in combination with other sensitizers. Furthermore, a photoacid generator such as an onium salt can be used in combination as a crosslinking agent. In order to further advance the crosslinking reaction, heat treatment may be performed after the light irradiation.

  The resin layer containing these compositions is extremely excellent in heat resistance, water resistance, etc., and can sufficiently withstand high temperatures in a post-process or a cleaning process.

  As the ink jet system used in the present invention, a bubble jet (registered trademark) type using an electrothermal transducer as an energy generating element, a piezo jet type using a piezoelectric element, or the like can be used. Can be set arbitrarily.

  In this example, a black matrix is formed on the substrate. However, the black matrix is formed on the resin layer after forming a curable resin composition layer or after coloring. There is no particular problem, and the form is not limited to this example. Moreover, as a formation method thereof, it is preferable to form a metal thin film on a substrate by sputtering or vapor deposition, and patterning by a photolithography process, but it is not limited to this.

  Next, the curable resin composition is cured by light irradiation only, heat treatment only, or light irradiation and heat treatment (FIG. 4E), and a protective layer 8 is formed as necessary (FIG. 4F). In the figure, hν represents the intensity of light, and in the case of heat treatment, heat is applied instead of hν.The protective layer 8 has a second resin composition of photocuring type, thermosetting type or photothermal combination type. It can be formed by vapor deposition or sputtering using an inorganic material, has transparency when used as a color filter, and sufficiently withstands subsequent ITO formation process, alignment film formation process, etc. If possible, it can be used.

  5 to 7 are cross-sectional views showing the basic configuration of a color liquid crystal display device 30 incorporating the above-described color filter.

  A color liquid crystal display device is generally formed by combining a color filter substrate 1 and a counter substrate 21 and enclosing a liquid crystal compound 18. A TFT (Thin Film Transistor) (not shown) and transparent pixel electrodes 20 are formed in a matrix on the inside of one substrate 21 of the liquid crystal display device. In addition, a color filter 54 is installed 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 in the BM (black matrix) on-array type liquid crystal panel, it is formed on the opposite TFT substrate side (see FIG. 6). Further, an alignment film 19 is formed in the planes of both substrates, and liquid crystal molecules can be aligned in a certain direction by rubbing the alignment film 19. Further, polarizing plates 11 and 22 are adhered to the outside of each glass substrate, and the liquid crystal compound 18 is filled in a 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 liquid crystal compound is displayed by functioning as an optical shutter that changes the transmittance of the backlight light. I do.

  Further, as shown in FIG. 7, a colored portion may be formed on the pixel electrode 20 so as to function as a color filter. That is, the colored portion constituting the color filter is not limited to being formed on the glass substrate. In the format shown in FIG. 7, there are a case where an ink receiving layer is formed on the pixel electrode and ink is applied to the receiving layer, and a case where resin ink mixed with a color material is directly irradiated on the pixel electrode. is there.

  An example in which such a liquid crystal display device is applied to an information processing device will be described with reference to FIGS.

  FIG. 8 is a block diagram showing a schematic configuration when the above-described liquid crystal display device is applied to an information processing apparatus having functions as a word processor, personal computer, facsimile apparatus, and copying apparatus.

  In the figure, reference numeral 1801 denotes a control unit that controls the entire apparatus, which includes a CPU such as a microprocessor and various I / O ports, and outputs control signals and data signals to each unit, and control signals and data signals from each unit. To control. A display unit 1802 displays various menus, document information, image data read by the image reader 1807, and the like on the display screen. Reference numeral 1803 denotes a transparent pressure-sensitive touch panel provided on the display unit 1802. By pressing the surface with a finger or the like, item input, coordinate position input, or the like on the display unit 1802 can be performed.

  Reference numeral 1804 denotes an FM (Frequency Modulation) sound source unit that stores music information created by a music editor or the like as digital data in a memory unit 1810 or an external storage device 1812, and performs FM modulation by reading out from the memory or the like. is there. An electric signal from the FM sound source unit 1804 is converted into an audible sound by the speaker unit 1805. A printer unit 1806 is used as an output terminal of a word processor, a personal computer, a facsimile machine, and a copying machine.

  Reference numeral 1807 denotes an image reader unit that photoelectrically reads and inputs document data. The image reader unit 1807 is provided in the document transport path, and reads various documents in addition to facsimile documents and copy documents.

  Reference numeral 1808 denotes a facsimile transmission / reception unit for facsimile transmission of original data read by the image reader unit 1807 and reception and decoding of a transmitted facsimile signal, and has an interface function with the outside. Reference numeral 1809 denotes a telephone unit having various telephone functions such as a normal telephone function and an answering machine function.

  Reference numeral 1810 denotes a memory unit including a system program, a manager program, other application programs, a ROM that stores character fonts, a dictionary, and the like, an application program loaded from an external storage device 1812, document information, and a video RAM. .

  Reference numeral 1811 denotes a keyboard unit for inputting document information and various commands.

  An external storage device 1812 uses a floppy (registered trademark) disk, a hard disk, or the like as a storage medium. The external storage device 1812 stores document information, music or voice information, a user application program, and the like.

  FIG. 9 is a schematic overview of the information processing apparatus shown in FIG.

  In the figure, reference numeral 1901 denotes a flat panel display using the above-mentioned liquid crystal display device, which displays various menus, graphic information, document information, and the like. On the display 1901, coordinate input and item designation input can be performed by pressing the surface of the touch panel 1803 with a finger or the like. Reference numeral 1902 denotes a handset used when the apparatus functions as a telephone. The keyboard 1903 is detachably connected to the main body via a cord, and can perform various document functions and various data input. The keyboard 1903 is provided with various function keys 1904 and the like. Reference numeral 1905 denotes an insertion slot for a floppy (registered trademark) disk into the external storage device 1812.

  Reference numeral 1906 denotes a paper placement unit on which a document read by the image reader unit 1807 is placed. The read document is discharged from the rear of the apparatus. In facsimile reception or the like, printing is performed by the ink jet printer 1907.

  When the information processing apparatus functions as a personal computer or a word processor, various types of information input from the keyboard unit 1811 are processed by the control unit 1801 according to a predetermined program and output to the printer unit 1806 as an image.

  When functioning as a receiver of a facsimile apparatus, facsimile information input from a FAX transmission / reception unit 1808 via a communication line is received and processed by a control unit 1801 according to a predetermined program and output to a printer unit 1806 as a received image.

  When functioning as a copying apparatus, the original is read by the image reader unit 1807, and the read original data is output as a copy image to the printer unit 1806 via the control unit 1801. When functioning as a receiver of a facsimile machine, document data read by the image reader unit 1807 is transmitted by the control unit 1801 according to a predetermined program, and then transmitted to the communication line via the FAX transmission / reception unit 1808. The

  Note that the above-described information processing apparatus may be an integrated type in which an ink jet printer is built in the main body as shown in FIG. 10, and in this case, it becomes possible to further improve portability. In the figure, parts having the same functions as those in FIG.

  FIG. 11 is a diagram showing a coloring method of the color filter, and one of the color filters formed on the same substrate in FIG. 1 is viewed from above.

  Each element in FIG. 11 will be described in order from the lower layer. Reference numeral 101 denotes a color filter substrate (corresponding to the substrate 1 in FIG. 4), and reference numeral 102 denotes a black matrix (corresponding to the black matrix 2 in FIG. 4) formed on the color filter substrate 101, which has a light shielding property. Reference numeral 103 denotes an opening provided in the black matrix 102 (corresponding to the light transmission portion 7 in FIG. 4). An ink receiving layer (corresponding to the resin layer 3 in FIG. 4) is formed on the black matrix 102 and colored with ink. In the ink receiving layer, a portion (corresponding to the non-colored portion 5 in FIG. 4) which becomes water-repellent by ultraviolet irradiation is formed in a stripe shape between openings adjacent in the horizontal direction of the black matrix 102. Reference numeral 104 denotes a colored portion of the ink receiving layer. As shown in FIG. 12, inks landed on the receiving layer are mixed with each other and spread in a range as indicated by 104 in FIG. 11. Reference numeral 55 denotes an ink jet head unit for coloring a color filter as shown in FIG. 1, and is provided with a separate ink jet head 55b, 55c, 55d for each color (red R, green G, blue B). The inkjet heads 55b, 55c, and 55d have a plurality of nozzles (not shown) in the longitudinal direction, and are inclined and installed in a plane parallel to the substrate 101 so that the nozzle pitch matches the pixel pitch of the colored portion. The inkjet head unit 55 discharges ink while being scanned in the direction indicated by the arrow A relative to the substrate 101, and colors each pixel column.

  By using such a color filter manufacturing apparatus, manufacturing a color filter intentionally added with an element that is expected to cause unevenness, and checking whether the uneven color is visually recognized in the manufactured color filter, the unevenness The principle of generation was clarified.

The following two factors were predicted as the cause of unevenness.
(1) Variation in average value of absorbance in pixels from pixel to pixel (2) Variation in absorbance distribution in pixels from pixel to pixel Hereinafter, the average value of absorbance in pixels is described as a color density.

  The color filter actually manufactured has 22 pairs of 3 pixels of red, green and blue in the horizontal direction, and a range of about 65 pixels in the vertical direction, and 2 sets of red located in the center of the horizontal direction. The color density and the ink landing position are intentionally changed in three vertical pixel portions of green and blue (hereinafter referred to as a central pixel row). FIG. 16 is an enlarged view of the central portion in the horizontal direction of the color filter, and squares written as R, G, and B are pixel portions colored in red, green, and blue, respectively.

  In addition, in order to eliminate the influence of the difference in the discharge amount and landing position for each nozzle, coloring was performed using only a single nozzle. For this reason, since the time during which uniform discharge can be sustained with a single nozzle is restricted, only a small range of coloring can be performed as described above.

  As for the color density of the central pixel row, the ink amount per unit area was made smaller than that of the other portions by intentionally extending the ink landing interval as compared with the other portions. In addition, the dispersion of the landing position was realized by adjusting the positional relationship between the stage and the head and landing on the position intentionally shifted to the right from the center of the opening of the black matrix of each color.

  The results of this experiment are shown in FIG.

  In FIG. 13, the horizontal axis shows the deviation of the landing position of the central pixel row, and the vertical axis shows how much the coloring density of the central pixel row is higher or lower than the other parts in percentage (see FIG. 16). (corresponding to x), a range indicated as an ok region in FIG. 13 is a range in which a color filter having no color unevenness and mixed colors is obtained.

The following three conclusions were obtained from this experiment.
(1) The color density is dominant with respect to invisible color unevenness.
(2) The displacement of the landing position mainly affects the color mixture (mixing of ink with the colored portion of the adjacent color), and does not significantly affect the presence or absence of color unevenness.
(3) The limit value of the variation in the color density whether the color unevenness is visible or not varies depending on the color.

  Therefore, it was found that a color filter having no color unevenness can be realized by controlling the color density variation for each color.

  The boundary between the ok area and the NG area in FIG. 13 represents a limit that a skilled worker cannot discriminate unevenness under the condition that the unevenness can be most easily discriminated (entirely, a single color lighting state, a dark room). In particular, some unevenness is allowed. Therefore, based on the experimental results in an environment assuming a normal use state, the limit of the variation in the color density of each color where no practical unevenness was visible was obtained.

For the following two reasons, it is appropriate to use the standard deviation instead of the minimum and maximum values for the evaluation of the color density variation.
(1) Unlike the above experiment in which the variation in color density is intentionally created, the variation in color density has a distribution close to a normal distribution in an actual color filter.
(2) When the color density of a small number of pixels protrudes from other parts, the pixels appear as bright spots or black defects that appear as dark spots, and unevenness is not recognized.

  Therefore, in this specification, the standard deviation of the distribution of the entire filter surface of the set of average values of the absorbance of each part in each pixel is referred to as color density variation.

  The variation in color density obtained from the above and showing no practical unevenness was as follows.

Red: 5% or less Green: 10% or less Blue: 3% or less Therefore, by limiting the density variation between pixels of each color to the above value or less, it is possible to manufacture a color filter in which color unevenness is not noticeable in practice. .

  The color density (average value of absorbance inside the pixel) is measured with a measuring device using the line CCD camera shown in FIG. 14, and the pixel portion is divided into about 3 μm squares, and the absorbance of each portion is obtained. The average value of the whole pixel was calculated.

  In addition, the measurement accuracy of 1% or less was ensured by removing the disturbance at the time of measurement by measuring several times.

  By the way, in the above experiment, since the range of the colored portion (screen size of the color filter) is small compared to a color filter for general personal computers, the color unevenness is more easily seen than a general color filter. There was concern about the possibility of the difference.

  Therefore, using the color filter manufacturing apparatus shown in FIG. 1, changes in the visibility of unevenness due to screen dimensions were confirmed.

  The actual confirmation method is to use color filters with diagonal dimensions of 264 mm (10.4 inches) and 307 mm (12.1 inches), which are widely used as displays for personal computers, with various variations in the ink amount. The variation of the color density was created and no unevenness was seen. Furthermore, by covering a part of the outer periphery of these color filters, color filters having various screen dimensions were made approximately, and an allowable range of variation in ink amount in color filters having various screen dimensions was obtained.

From this experiment, the following results were obtained.
(1) In a color filter having a diagonal dimension of 200 mm or less, the tolerance of the variation in coloring density at which unevenness cannot be seen decreases as the screen size increases.
(2) In a color filter having a diagonal size of 200 mm or more, the tolerance of variation in coloring density where unevenness is not visible is hardly affected by the size of the screen.
(3) In the above color filter having a diagonal size of 200 mm or more, the range of variation in the color density where no unevenness is practically visible is less than the value shown below.

Red: 2.5%
Green: 6%
Blue: 1.5%
The color filter actually manufactured is a color filter having diagonal lengths of 264 mm (10.4 inches) and 307 mm (12.1 inches) in which colored portions of 400 pixels vertically and 600 pixels horizontally are arranged in stripes.

  The ink jet head used was a head having 1408 nozzles in total, and each color was colored using a total of 207 nozzles for every 5 nozzles. Further, in order to align the nozzle pitch and the pixel interval, the head was tilted in a plane parallel to the substrate.

  Further, since the total length of the head was about 1/4 of the lateral length of the color filter, coloring was performed by dividing all pixels into four areas from the left.

  Further, the ink jet head was scanned five times for each divided region, and coloring of one pixel was completed with five times of coloring. At this time, the stage was driven so that the nozzles for coloring the same pixel in each scan were shifted by 30 nozzles.

  As an actual coloring pattern, the ink landing interval is controlled for each nozzle in accordance with the ejection amount of each nozzle so that the ink amount per unit area of each pixel becomes equal (referred to as shading correction). Alternatively, instead of controlling the ink landing interval, the ink discharge amount per nozzle of the inkjet head may be made uniform for each nozzle (referred to as bit correction). Alternatively, the above bit correction and shading correction may be combined.

  FIG. 18 is a diagram illustrating a state of the color filter immediately after coloring. In particular, as shown in FIG. 18, when a region including a plurality of pixels is colored in a continuous manner, the amount of ink per unit area of the pixels in the region can be controlled with high accuracy by shading correction. It is possible to make the variation in the color density equal to or less than the variation in the discharge amount of each nozzle. For this reason, even if the variation in the ink discharge amount of each ink nozzle is larger than 3%, the variation in color density between pixels of each color is 5% or less in red, 10% or less in green, and 3% or less in blue. It can be a range.

In this control, the discharge amount of each nozzle was measured using a measuring instrument shown in FIG.
In FIG. 14, reference numeral 501 denotes an image processing apparatus that measures density, and 502 denotes a personal computer (hereinafter referred to as PC) that controls the image processing apparatus 501 and the XY control stage 504. 503 is an optical microscope, 504 is an XY control stage that continuously moves each part of the measurement object to the field of view of the microscope, 505 is a CCD camera that captures an image of the measurement object into the image processing apparatus, and 506 is below the XY control stage 504. It is the transmitted light source installed in. The stage surface of the XY control stage 504 is made of glass at the center, and the measurement object can be taken into the color CCD camera 505 by transmission illumination using the transmission light source 506. The PC 502 controls the XY control stage 504 and the image processing apparatus 501.

  In addition, as a measurement sample, a stripe pattern similar to a color filter is formed for each color on a color filter substrate 210 on which a black matrix is not formed as shown in FIG. A colored one was used. The same nozzle direction and the different nozzle direction in the figure indicate the extending direction of the line pattern by the ink ejected from the same nozzle and the alignment direction of the line pattern by the ink ejected from the different nozzle, respectively.

  The measurement principle of this measurement system will be described. When the line pattern is divided into minute regions, it is derived from Lambert-Beer's law that the absorbance of that portion is proportional to the volume of ink absorbed in that portion. Therefore, a value proportional to the volume of ink contained in the line pattern can be obtained by integrating the absorbance with respect to the line pattern. As a result, the ejection amount of the nozzle that has drawn each line, or the ink amount per unit area of each pixel of the created color filter is obtained as a relative value of each nozzle or pixel.

  Since a random noise component exists in this measurement result, a plurality of measurements are performed, and the ink amount per unit area is controlled using the average value of each measurement result. For this reason, by changing the number of times of measurement, the variation in the color density of each pixel changes as a result, and when the number of times of measurement is increased, the variation in the color density of each pixel becomes smaller.

  Here, in order to reduce the density variation of the colored pixels to red: 2.5%, green: 6%, blue: 1.5% or less, the drive signal of the inkjet head, the nozzle hole dimensions, etc. It is necessary to control the ejection amount by adjustment or the control of the ink landing interval. In this embodiment, the number of times to obtain the measurement accuracy required for this control is six. That is, in this embodiment, the data for suppressing the density unevenness to the above value is obtained by measuring the density of the line pattern and calculating the ink discharge amount of each nozzle six times or more and taking the average. The required accuracy can be obtained, and the color filter can be evenly colored by only the ejection control of the inkjet head without being limited by the coloring order as in the prior art.

Incidentally, since the different by color density variations in color pixel invisible unevenness, above required measurement accuracy varies according to the color. For this reason, in the above example, the number of measurements for the three colors is the same as the color that required the most number of measurements (in the above example, blue was 6), but the most For colors other than those requiring the number of times of measurement, a smaller number may be used. That is, the number of measurements may be changed for each color. In this case, since the total number of measurements for the three colors is reduced, the overall time required for manufacturing the color filter can be further reduced.

  In the present embodiment, the number of times of color density measurement is changed for each color as the step of changing the number of repetitions included in the processing step for adjusting the ink amount per unit area of the pixel of the color filter for each color.

  In addition, as a means for measuring the color density, a general means for measuring the color density such as a spectroscopic microscope may be used.

  Further, the density variation of the colored portion is also caused by the difference between the discharge amount of each nozzle when the color density is measured and the discharge amount when actually manufacturing the color filter. This difference generally increases in proportion to the frequency of discharge from the time when the color density is measured to the time when the color filter is manufactured. For this reason, if the color filter continues to be manufactured and the difference in the discharge amount exceeds the allowable value, the density variation of the colored portion is measured again, and the measurement result is used to control the discharge amount or the ink landing interval. It becomes necessary to perform control.

With regard to this, when paying attention to the difference for each color, the density variation range of the colored pixels that do not appear uneven varies depending on the color. Therefore, the above density variation is measured, and the ejection amount control or the ink landing interval control is performed. It can be seen that the frequency at which is required also varies depending on the color. Therefore, most often, to determine the concentration variation, possible to control the landing interval of the discharge amount control or ink in accordance with the required color (usually the blue), measuring the concentration variation for the other colors However, it is only necessary to control the ejection amount or the ink landing interval, but as another method, it is possible to perform the other colors with less frequency. In this case, the effect that the time required for manufacturing the color filter is further shortened can be obtained.

  Hereinafter, the coloring performed in this embodiment in a plurality of times will be described.

  Usually, the density variation in the colored part is the measurement noise when adjusting the color density of the line pattern, the deviation of the discharge amount of each nozzle between when the color density is measured and when the color filter is actually manufactured, etc. Caused by. Therefore, the inventors of the present application investigated the characteristics of these measurement noise and ejection amount deviation. As a result, they all showed random behavior, and for this reason, it was found that the distribution of the color density of each nozzle after the color density adjustment was almost normal.

  Therefore, when the standard deviation of the color density distribution of each nozzle is σ, when the same pixel is colored with different n nozzles, the standard deviation of the color density distribution of each pixel is σ / √n from the central limit theorem. Become.

  Also in the color filter of this embodiment, when the variation in color density of each pixel is within the above range, the color density variation due to each nozzle unit is approximately √n (in this case, n = 5) times the above value. Met.

  That is, by coloring each pixel in a plurality of times (n times), the variation in pixel density can be reduced to 1 / √n compared to the case where the pixels are colored once.

  Note that, as described in this embodiment, in general, in order to reduce the variation in the color density, a decrease in productivity such as an increase in the number of measurements is caused. On the other hand, when manufacturing is actually performed, there are various disturbance factors during manufacturing. For this reason, when the target value of the variation in the color density is set as small as possible, it is clear that the probability of falling within the variation range shown in the present invention is high, and production can be performed with a high yield. That is, productivity and yield are in a trade-off relationship.

  For this reason, the optimum value regarding the target value of the variation range of the color density needs to be determined in consideration of productivity and yield.

  Note that the present invention can be applied to modifications or variations of the above-described embodiment without departing from the spirit of the present invention.

  For example, in recent years, there is a panel in which a color filter is provided on the TFT array side, but the color filter defined in this specification is an object to be colored that is colored with a coloring material, and whether or not it is on the TFT array side. Regardless of whether or not.

  The present invention includes means (for example, an electrothermal converter or a laser beam) that generates thermal energy as energy used for ejecting ink, particularly in an ink jet recording system, and the state of ink by the thermal energy. A printing apparatus that causes a change has been described, but according to such a system, higher recording density and higher definition can be achieved.

  As its typical configuration and principle, for example, those performed using the basic principle disclosed in US Pat. Nos. 4,723,129 and 4,740,796 are preferable. 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, it is arranged corresponding to the sheet or liquid path holding the liquid (ink). By applying at least one drive signal corresponding to the recording information and applying a rapid temperature rise exceeding the film boiling to the electrothermal transducer, the thermal energy is generated in the electrothermal transducer, and the recording head This is effective because film boiling occurs on the heat acting surface of the liquid, and as a result, bubbles in the liquid (ink) corresponding to the drive signal on a one-to-one basis can be formed. By the growth and contraction of the bubbles, liquid (ink) is ejected through the ejection opening to form at least one droplet. When the drive signal is pulse-shaped, the bubble growth and contraction is performed immediately and appropriately, and thus it is possible to achieve the discharge of liquid (ink) with particularly excellent responsiveness.

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

  As the configuration of the recording head, in addition to the combination configuration (straight liquid flow path or right-angle liquid flow path) of the discharge port, the liquid path, and the electrothermal transducer as disclosed in each of the above-mentioned specifications, the heat acting surface The configurations using US Pat. No. 4,558,333 and US Pat. No. 4,459,600, which disclose a configuration in which is disposed in a bending region, are also included in the present invention. In addition, Japanese Patent Application Laid-Open No. 59-123670, which discloses a configuration in which a common slot is used as a discharge portion of an electrothermal transducer, or an opening that absorbs a pressure wave of thermal energy is discharged to a plurality of electrothermal transducers. A configuration based on Japanese Patent Laid-Open No. 59-138461 disclosing a configuration corresponding to each part may be adopted.

  Furthermore, 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 satisfied by a combination of a plurality of recording heads as disclosed in the above specification. Either a configuration or a configuration as a single recording head formed integrally may be used.

  In addition, the ink is integrated into the replaceable chip type recording head or the recording head itself, which can be electrically connected to the apparatus main body and supplied with ink from the apparatus main body by being attached to the apparatus main body. A cartridge type recording head provided with a tank may be used.

  In addition, it is preferable to add a recovery means for the recording head, a preliminary auxiliary means, etc. provided as a configuration of the recording apparatus of the present invention, since the effects of the present invention can be further stabilized. Specifically, capping means, cleaning means, pressurizing or suction means for the recording head, preheating means using a heating element different from this, or a combination thereof, or recording is used. Performing a preliminary discharge mode for performing another discharge is also effective for performing stable recording.

  In the embodiments of the present invention described above, the ink is described as a liquid. However, even if the ink is solidified at room temperature or lower, the ink softened or liquefied at room temperature may be used. It is sufficient if the ink sometimes forms a liquid.

  In addition, it is solidified in a stand-by state in order to actively prevent temperature rise by heat energy as energy for changing the state of ink from the solid state to the liquid state, or to prevent ink evaporation. Ink that is liquefied by heating may be used. In any case, by applying heat energy according to the application of thermal energy according to the recording signal, the ink is liquefied and liquid ink is ejected, or when it reaches the recording medium, it already starts to solidify. The present invention can also be applied to the case of using ink having the property of liquefying for the first time. In such a case, the ink is held as a liquid or solid in a porous sheet recess or through-hole as described in JP-A-54-56847 or JP-A-60-71260, It is good also as a form which opposes with respect to an electrothermal converter. In the present invention, the most effective one for each of the above-described inks is to execute the above-described film boiling method.

It is the schematic which shows the structure of one Embodiment of the manufacturing apparatus of a color filter. It is a figure which shows the structure of the control part which controls operation | movement of the manufacturing apparatus of a color filter. It is a figure which shows the structure of the inkjet head used for the manufacturing apparatus of a color filter. It is the figure which showed the manufacturing process of a color filter. It is sectional drawing which shows an example of the basic composition of the color liquid crystal display device incorporating the color filter of one Embodiment. It is sectional drawing which shows the other example of the basic composition of the color liquid crystal display device incorporating the color filter of one Embodiment. It is sectional drawing which shows the further another example of the basic composition of the color liquid crystal display device incorporating the color filter of one Embodiment. It is the figure which showed the information processing apparatus in which a liquid crystal display device is used. It is the figure which showed the information processing apparatus in which a liquid crystal display device is used. It is the figure which showed the information processing apparatus in which a liquid crystal display device is used. It is the schematic of the coloring method of a color filter. It is the schematic of the coloring part of the color filter immediately after coloring. It is a figure which shows the relationship between color irregularity, coloring density, and landing deviation. It is the schematic of a coloring density measuring machine. It is a figure which shows the line pattern for the ink discharge amount measurement of a nozzle. It is the figure which showed the state which colored the pixel row partially changing the density. It is a figure for demonstrating the cause in which the nonuniformity of a color filter is visible. It is a figure which shows the mode of the color filter immediately after coloring.

Explanation of symbols

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

Claims (13)

A method for producing a color filter by discharging ink of a plurality of colors of red, green, and blue toward an object to be colored by an inkjet head and coloring each pixel of the object to be colored,
Measuring the color density of the pixel multiple times;
By adjusting the color density variation between pixels based on the results of the plurality of measurements, the color density variation between pixels to be colored red is 5% or less, and the color density between pixels to be colored green The step of coloring so that the variation in color density is 10% or less and the variation in color density between pixels to be colored blue is 3% or less,
A method for producing a color filter, wherein the frequency of adjusting the variation in the color density is changed according to the color.   The method for producing a color filter according to claim 1, wherein the variation in the amount of ink discharged per time of the ink discharge nozzles of the inkjet head is greater than 3%.   The method for producing a color filter according to claim 2, wherein a variation in the ink discharge amount per one time of the ink discharge nozzles of the inkjet head is 15 to 20%.   2. The method of manufacturing a color filter according to claim 1, wherein the frequency of adjusting the color density variation is changed for each color according to the color density variation defined for each of red, green, and blue. The color filter manufacturing method according to claim 1, wherein the adjustment of the variation in the color density is performed based on an average of the results of the plurality of measurements .   When each pixel is colored n times (n is a positive integer) in the coloring step, the color density variation between the pixels in each time of coloring is 5% or less √n times or less in the case of a red pixel, green 2. The method for producing a color filter according to claim 1, wherein the color filter is colored so as to be 10% of √n times or less in the case of a blue pixel, and 3% of √n times or less in the case of a blue pixel.   When the object to be colored is a substrate having a diagonal dimension of 200 mm or more, the variation in color density between pixels to be colored red is 2.5% or less, and the variation in color density between pixels to be colored green 2. The method for producing a color filter according to claim 1, wherein the color filter is colored so that a variation in color density between pixels to be colored blue is 1.5% or less.   When each pixel is colored n times (n is a positive integer) in the coloring step, the color density variation between the pixels in each time of coloring is less than √n times 2.5% for red pixels The color filter according to claim 7, wherein the color filter is colored so that √n times or less of 6% for green pixels and √n times or less 1.5% for blue pixels. Method.   2. The color filter according to claim 1, wherein the inkjet head is a head that ejects ink using thermal energy, and includes a thermal energy generator for generating thermal energy applied to the ink. 3. Production method. A method of manufacturing a display panel including a color filter manufactured by discharging ink of a plurality of colors of red, green, and blue toward an object to be colored by an inkjet head and coloring each pixel of the object to be colored. And
Preparing a color filter manufactured by the manufacturing method according to any one of claims 1 to 9,
Integrating the prepared color filter and a light amount changing means capable of changing the light amount;
A method of manufacturing a display panel, comprising: A method of manufacturing an information processing apparatus including a display panel,
Preparing a display panel manufactured by the manufacturing method according to claim 10;
Connecting the prepared display panel and image signal supply means for supplying an image signal to the display panel;
A method for manufacturing an information processing apparatus provided with a display panel. A method of manufacturing a liquid crystal display panel including a color filter manufactured by discharging ink of a plurality of colors of red, green, and blue toward an object to be colored by an inkjet head and coloring each pixel of the object to be colored. There,
Preparing a color filter manufactured by the manufacturing method according to any one of claims 1 to 9,
Sealing the liquid crystal between the prepared color filter and the counter substrate;
A method for producing a liquid crystal display panel, comprising: A method for manufacturing an information processing apparatus including a liquid crystal display panel,
Preparing a liquid crystal display panel manufactured by the manufacturing method according to claim 12;
Connecting the prepared liquid crystal display panel and image signal supply means for supplying an image signal to the liquid crystal display panel;
A method for manufacturing an information processing apparatus provided with a liquid crystal display panel.

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