JP4023287B2 - Manufacturing method of liquid crystal display device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a liquid crystal display device, and more particularly, to a liquid crystal display device with high display quality, which can apply a droplet including a spacer so as to be contained in a non-pixel region of a substrate.
[0002]
[Prior art]
In the liquid crystal display device, for example, spherical spacers are arranged between the substrates in order to keep the gap between the substrates constant. As means for arranging the spacers, there is known a means for spraying the spacers mixed in the carrier solution onto the alignment-treated substrate. The diameter of the spherical spacer formed of resin or glass is about 2 to 6 μm, and a mixed solution of water and isopropyl alcohol is used as the carrier solution.
[0003]
However, in this spraying, the spacers may be unevenly distributed on the substrate. In particular, when a large number of spacers aggregate in an area used for display (hereinafter referred to as a “pixel area”), the brightness of color development is increased. There is a problem that the display quality is reduced, uneven coloring occurs, and the display quality is lowered.
[0004]
In order to solve such problems, by using a droplet discharge device, spacers are accurately discharged and arranged in a region not used for display (hereinafter referred to as “non-pixel region (black matrix)”), and liquid crystal Means for improving the contrast of a display device are known (for example, see Patent Document 1). FIG. 5 is a side view schematically showing how the spacers are ejected by such a conventional droplet ejection method (so-called inkjet method), FIG. 6 is a plan view showing the droplets ejected on the substrate, and FIG. FIG. 5 is an enlarged plan view showing an example of droplets ejected onto a substrate.
[0005]
As shown in FIG. 5 to FIG. 7, the substrate 10 is horizontally placed on a slide table (not shown) formed to be horizontally movable, and a droplet 15 including a spacer 14 is placed above the substrate 10. A nozzle 13 for discharging vertically downward toward a non-pixel region 12 formed between the pixel regions 11 of the substrate 10 is provided.
[0006]
A large number of nozzles 13 are provided in an inkjet head (not shown) corresponding to the pitch of the non-pixel regions 12, and by ejecting droplets 15 from the nozzles 13 while moving the slide table by a predetermined amount, FIG. As shown in FIG. 5, the droplet 15 is disposed in the non-pixel region 12.
[Patent Document 1]
JP 2002-72218 PR [0007]
[Problems to be solved by the invention]
However, the width of the non-pixel region 12 is normally 10 to 20 μm, and the liquid droplet 15 ejected from the nozzle 13 and landed on the non-pixel region 12 has a circular planar shape as shown in FIGS. The outer diameter is 20 to 50 μm.
[0008]
Therefore, as shown in FIG. 6, the droplet 15 disposed in the non-pixel region 12 does not fit in the non-pixel region 12 and protrudes to the pixel region 11 side, and the spacer 14 is also disposed in the pixel region 11. May end up. As a result, this is recognized as light loss or a black spot, and there is a problem that the brightness of color development of the liquid crystal display device is reduced or color unevenness occurs.
[0009]
In order to solve the above problems, the applicant of the present application has proposed an apparatus for manufacturing a liquid crystal display device as shown in FIGS. That is, this liquid crystal display manufacturing apparatus is configured such that the installation angle of the substrate 10 and the installation angle of the nozzle 13 can be arbitrarily changed when the spacers 14 are discharged. By changing these installation angles, the landing angle of the droplet 15 on the substrate 10 is controlled, the traveling direction component of the momentum of the droplet 15 at the time of landing is utilized, and the action of gravity on the droplet 15 is As a result, the shape of the droplet 15 becomes a shape that spreads along the direction in which the non-pixel region 12 extends (for example, a vertically long ellipse shape), and easily fits in the non-pixel region 12 (FIGS. 10 and 11). reference).
[0010]
More specifically, as shown in FIG. 9, the liquid crystal display manufacturing apparatus includes a stage 16 that holds the substrate 10 and is movable in the vertical direction (inclination direction of the substrate 10). A substrate angle variable mechanism 20 that arbitrarily changes the installation angle of the (substrate 10), a base 17 that holds the stage 16 and the like, a droplet discharge head 18 that includes a large number of nozzles 13, and a droplet discharge head The nozzle angle changing mechanism 21 is configured to rotate the nozzle 18 and arbitrarily change the installation angle of the nozzle 13. Arrows a in FIGS. 8 and 9 indicate the moving scanning directions of the substrate 10 and the stage 16 when the position of the droplet discharge head 18 is fixed. Note that this apparatus is configured such that when the position of the substrate 10 is fixed, the position of the droplet discharge head 18 can be moved and scanned in the direction of the arrow b in FIG. 8 (the direction parallel to the substrate 10).
[0011]
However, it is conceivable that the gravity component acting on the droplet 15 becomes excessive, and as shown in FIGS. 12 and 13, the outflow or interference of the droplet 15 occurs in the extending direction of the non-pixel region 12. In such a case, even if the droplet 15 is initially arranged in the non-pixel region 12, it will protrude to the pixel region 11 side due to the outflow and interference, and as a result, this will be recognized as light leakage or a black spot. In other cases, the brightness of the color of the liquid crystal display device may decrease or color unevenness may occur.
[0012]
8 is a side view schematically showing how the spacers are discharged by the liquid crystal display manufacturing apparatus proposed by the applicant of the present application. FIG. 9 is a front view showing the liquid crystal display manufacturing apparatus. Fig. 11 is a plan view showing droplets discharged onto the substrate, Fig. 11 is an enlarged plan view showing an example of droplets discharged onto the substrate, and Fig. 12 shows the outflow and interference state of the droplets discharged onto the substrate. FIG. 13 is an enlarged plan view showing an example of a droplet interference state.
[0013]
The present invention has been made in view of the above, and can apply a droplet including a spacer so as to be contained in a non-pixel region of a substrate, and prevent the applied droplet from flowing out and interfering with the substrate. An object of the present invention is to provide a method for manufacturing a liquid crystal display device with high display quality.
[0014]
[Means for Solving the Problems]
In order to achieve the above-described object, a method of manufacturing a liquid crystal display device according to the present invention uses a droplet discharge unit to discharge a droplet including a spacer to a region that is not used for display of the substrate, and the spacer is transferred to the substrate. In the manufacturing method of the liquid crystal display device formed by disposing on,
In the region not used for display of the substrate, the droplet discharge position is defined, and the droplets discharged from the droplet discharge means and disposed on the substrate are in the extending direction of the region not used for display. Protruding portions are provided to partition so as not to flow out and interfere with each other.
[0015]
When a droplet is ejected to the area defined by the convex part of the substrate, the non-pixel area is partitioned by this convex part. ) ・ Can prevent interference. At this time, the droplets have a shape that spreads along the extending direction of the non-pixel region (for example, an elliptical shape), and the spacers are arranged according to the shape, so that the liquid droplets are not unevenly distributed in the non-pixel region. Each droplet that spreads along the extending direction of the non-pixel region is blocked by the convex portion to prevent the droplets from flowing into each other.
[0016]
That is, the arranged droplets are accommodated between the convex portions of the non-pixel region and do not protrude to the pixel region side, so that the spacer can be prevented from being arranged also in the pixel region. Therefore, it is possible to prevent the light from being recognized as a light spot or a black spot, and the brightness of color development of the liquid crystal display device is not reduced, and color unevenness does not occur.
[0017]
Another embodiment of the present invention is a liquid crystal display formed by discharging a droplet including a spacer to a region not used for display on a substrate by using a droplet discharge unit, and disposing the spacer on the substrate. In the manufacturing method of the apparatus, the droplet discharge position is defined, and a convex portion is provided in the region not used for the display so that the spacer disposed on the substrate does not protrude into the region used for the display. It is characterized by that.
Another embodiment of the present invention is a liquid crystal display formed by discharging a droplet including a spacer to a region not used for display on a substrate by using a droplet discharge unit, and disposing the spacer on the substrate. In the device manufacturing method, the spacer is provided by ejecting the liquid droplets in a region partitioned by a convex portion provided in a region not used for the display.
Another embodiment of the present invention is formed by discharging a carrier solution mixed with a spacer to a region not used for display on a substrate using a droplet discharge means, and disposing the spacer on the substrate. In the manufacturing method of the liquid crystal display device, the carrier solution discharge position is defined, and the carrier solution including the spacer discharged to the substrate is not used for the display so as not to protrude into a region used for display. It is characterized by having convex portions that divide the region.
Another embodiment of the present invention is a liquid crystal display formed by discharging a droplet including a spacer to a region not used for display on a substrate by using a droplet discharge unit, and disposing the spacer on the substrate. In the manufacturing method of the apparatus, the discharge position of the droplet is defined, and the droplet discharged to the region not used for the display and the other droplet discharged to the region not used for the display do not interfere with each other As described above, a convex portion is provided in a region not used for the display.
Also according to each aspect as described above, since the spacer can be prevented from being arranged also in the pixel region, it can be prevented from being recognized as a light loss or a black spot, and the brightness of the color of the liquid crystal display device is reduced. There will be no uneven coloring.
In the liquid crystal display device according to the present invention, the convex portion is formed by forming a resist film in a non-pixel region and then exposing the resist film. Thereby, a convex part can be formed easily.
[0018]
In the liquid crystal display device according to the present invention, the convex portion is formed by applying a cured resin to a non-pixel region by a droplet discharge means and curing. Thereby, a convex part can be formed easily and rapidly.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a liquid crystal display device manufacturing apparatus according to the present invention will be described in detail below with reference to the drawings. Note that the present invention is not limited to the embodiments.
[0020]
FIG. 1 is a plan view showing a liquid crystal display device provided with a convex portion in a non-pixel region according to an embodiment of the present invention, FIG. 2 is a cross-sectional view showing the convex portion, and FIG. FIG. 4 is an enlarged plan view showing an example of a droplet discharged onto a substrate. In the following description, members that are the same as or correspond to those already described are denoted by the same reference numerals, and redundant description is omitted or simplified.
[0021]
On the substrate 10 of the liquid crystal display device according to the present embodiment, as shown in FIGS. 1 and 2, a plurality of convex portions 22 are formed at a predetermined pitch along the extending direction in the non-pixel region 12. Has been. The convex portions 22 are erected on the non-pixel region 12 so as to correspond to the arrangement pitch of the droplets 15, and the arranged droplets 15 flow out toward the adjacent droplets 15 (liquid dripping). A non-pixel region 12 is partitioned so as not to interfere.
[0022]
The shape of the convex portion 22 may be a polygonal shape as well as a rectangular shape as in the illustrated example. Further, the height of the convex portion 22 is formed lower than that of the pixel region 11. The protrusion 22 can be easily formed by, for example, forming a resist film on the non-pixel region 12 of the substrate 10 and then exposing it. The resist may be JNPC-80 manufactured by JSR, and the developer may be NMD-W.
[0023]
Further, the convex portion 22 can also be formed by an ink jet (droplet discharge) method. For example, a predetermined amount of ultraviolet curable resin is applied to the non-pixel region 12 by an ink jet (droplet discharge) method and is cured by irradiating ultraviolet rays, or similarly, a thermosetting resin is applied to the non-pixel region. It can also be formed by applying to 12 and heat-curing. Furthermore, a solvent that does not cure can be used as long as it has a physical property that does not interfere with the droplet 15 until the spacer 14 is fixed.
[0024]
When the droplet 15 is ejected between the convex portions 22 of the substrate 10 configured as described above by the droplet ejection device proposed by the applicant of the present invention shown in FIG. 8, this convexity is obtained as shown in FIG. Since it is partitioned by the portion 22, it is possible to prevent the arranged droplets 15 from flowing out (spilling) and interfering with each other toward the adjacent droplets 15. Then, as shown in FIG. 4, the spacers 14 are arranged without uneven distribution in the non-pixel region 12 according to the elliptical shape of the droplet 15.
[0025]
That is, the arranged droplets 15 are accommodated between the convex portions 22 of the non-pixel region 12 and do not protrude to the pixel region 11 side, and the spacer 14 can be prevented from being arranged also in the pixel region 11. Therefore, it is possible to prevent the light from being recognized as a light spot or a black spot, and the brightness of color development of the liquid crystal display device is not reduced, and color unevenness does not occur.
[0026]
The spherical spacers 14 formed of resin, glass, ceramic, or the like may vary depending on the performance of the liquid crystal display device to be manufactured, but may have a diameter of about 2 to 6 μm, for example. The spacer 14 may have a shape other than a spherical shape as long as it is granular. For example, a cylindrical shape having a diameter and a height substantially equal to each other can be used.
[0027]
As the carrier solution, for example, a mixed solution of water and ethylene glycol (having a viscosity of about 10 to 40 mPA · s and a boiling point of about 150 to 250 ° C.) can be used, but the spacer 14 can be appropriately disposed. As long as it is present, it is not limited to this, and other solutions may be used. For example, this carrier solution may be one in which the above physical property values can be obtained by adding another solution (for example, 1-decanol or 1-dodecanol) to a mixed solution of water and ethylene glycol. Moreover, since the droplet discharge head 18 discharges the spacer 14 which is a solid substance from the nozzle 13, what is driven by a piezoelectric element is preferable.
[0028]
As described above, according to the liquid crystal display device according to this embodiment, the droplets 15 including the spacers 14 can be applied so as to fit within the non-pixel regions 12 of the substrate 10 and the applied droplets flow out. And a liquid crystal display device with high display quality can be obtained.
[0029]
As shown in FIG. 8, the present invention was applied to an example in which the liquid crystal display device manufacturing apparatus of the present applicant applied the substrate 10 and the nozzles 13 to incline and eject the droplets 15. The present invention is not limited, and the present invention can also be applied to a case where the substrate 10 is disposed almost horizontally and only the nozzle 13 is inclined to discharge.
[Brief description of the drawings]
FIG. 1 is a plan view showing a liquid crystal display device having a convex portion in a non-pixel region.
FIG. 2 is a cross-sectional view showing a convex portion.
FIG. 3 is a plan view showing droplets discharged onto a substrate.
FIG. 4 is an enlarged plan view showing an example of liquid droplets discharged onto a substrate.
FIG. 5 is a side view schematically showing a state of discharging a conventional spacer.
FIG. 6 is a plan view showing droplets discharged onto a substrate.
FIG. 7 is an enlarged plan view showing an example of liquid droplets discharged onto a substrate.
FIG. 8 is a side view schematically showing a state of discharging.
FIG. 9 is a front view showing an apparatus for manufacturing a liquid crystal display device.
FIG. 10 is a plan view showing droplets discharged onto a substrate.
FIG. 11 is an enlarged plan view showing an example of droplets discharged onto a substrate.
FIG. 12 is a plan view showing the outflow and interference state of liquid droplets discharged onto a substrate.
FIG. 13 is an enlarged plan view showing an example of a droplet interference state.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Substrate 11 Pixel area 12 Non-pixel area 13 Nozzle 14 Spacer 15 Droplet 16 Stage 17 Base 18 Droplet discharge head 19 Head rotation mechanism 20 Substrate angle variable mechanism 21 Nozzle angle variable mechanism 22 Projection

Claims (7)

In a method of manufacturing a liquid crystal display device formed by discharging droplets including spacers to a region not used for display on a substrate using droplet discharge means, and disposing the spacers on the substrate.
In the region not used for display of the substrate, the discharge position of the droplet is defined, and the droplets discharged from the droplet discharge means and disposed on the substrate are in the extending direction of the region not used for display. A method for manufacturing a liquid crystal display device , comprising a convex portion for partitioning so as not to flow out and interfere. In a method of manufacturing a liquid crystal display device formed by discharging droplets including spacers to a region not used for display on a substrate using droplet discharge means, and disposing the spacers on the substrate.
  In addition to defining a discharge position of the droplets, a convex portion is provided in a region not used for display so that the spacer disposed on the substrate does not protrude into a region used for display. A method for manufacturing a liquid crystal display device. In a method of manufacturing a liquid crystal display device formed by discharging droplets including spacers to a region not used for display on a substrate using droplet discharge means, and disposing the spacers on the substrate.
  A method of manufacturing a liquid crystal display device, wherein the spacer is provided by ejecting the droplets in a region partitioned by a convex portion provided in a region not used for the display. In a manufacturing method of a liquid crystal display device formed by discharging a carrier solution mixed with a spacer to a region not used for display on a substrate using a droplet discharge means, and disposing the spacer on the substrate.
  Protrusions that define the discharge position of the carrier solution and that partition the region that is not used for display so that the carrier solution that includes the spacer discharged to the substrate does not protrude into the region that is used for display. A method for manufacturing a liquid crystal display device. In a method of manufacturing a liquid crystal display device formed by discharging droplets including spacers to a region not used for display on a substrate using droplet discharge means, and disposing the spacers on the substrate.
  In addition to defining the discharge position of the liquid droplets, the liquid droplets discharged to the area not used for the display and the other liquid droplets discharged to the area not used for the display do not interfere with each other. A method of manufacturing a liquid crystal display device, comprising a convex portion in an unused area. The convex portions, after forming the resist film in a region that is not used for the display, The method according to any one of claims 1 to 5, characterized in that formed by exposing them. The convex portions, The method according to any one of claims 1 to 5, characterized in that formed by coating and cured in a region that is not used for the display by the liquid droplet discharging means a cured resin .

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