JP4945981B2 - Printed matter and manufacturing method thereof. - Google Patents
Printed matter and manufacturing method thereof. Download PDFInfo
- Publication number
- JP4945981B2 JP4945981B2 JP2005275238A JP2005275238A JP4945981B2 JP 4945981 B2 JP4945981 B2 JP 4945981B2 JP 2005275238 A JP2005275238 A JP 2005275238A JP 2005275238 A JP2005275238 A JP 2005275238A JP 4945981 B2 JP4945981 B2 JP 4945981B2
- Authority
- JP
- Japan
- Prior art keywords
- ink layer
- partition wall
- partition
- correction
- substrate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Description
本発明は、隔壁と、この隔壁の区切られた領域に設けられたインキ層を含む印刷物およびその製造方法に関する。印刷物として、例えばインキ層として着色インキ層を備えたカラーフィルタを挙げることができる。また、印刷物として、例えばインキ層として有機発光層又は／及び正孔輸送層を備えた有機エレクトロルミネッセンス素子を挙げることができる。その他、印刷物として回路基板、薄膜トランジスタ、マイクロレンズ、バイオチップ等を挙げることができる。 The present invention relates to a printed matter including a partition and an ink layer provided in a region where the partition is partitioned, and a method for manufacturing the printed matter. As a printed material, for example, a color filter provided with a colored ink layer as an ink layer can be exemplified. Moreover, as a printed matter, for example, an organic electroluminescence device including an organic light emitting layer and / or a hole transport layer as an ink layer can be exemplified. In addition, examples of the printed material include a circuit board, a thin film transistor, a microlens, and a biochip.
近年、パーソナルコンピュータや、薄型カラーテレビの発達に伴い、カラーＬＣＤの需要が増加しており、特に、後者は大型化が進展している。しかしながら、基板の大型化に対して、ＬＣＤやカラーフィルタ工程で高い歩留りを維持する事は困難であり、加えて、部材の中でもコスト比重が高いＣＦは、カラーＬＣＤの普及に向け、一層のコストダウンが要求されている。 In recent years, with the development of personal computers and thin color televisions, the demand for color LCDs has increased. In particular, the latter has been increasing in size. However, it is difficult to maintain a high yield in the LCD and color filter processes as the substrate size increases, and in addition, among the components, CF, which has a high cost ratio, further increases the cost of spreading color LCDs. Down is requested.
カラーフィルタは、透明基板上に、カラー表示に不可欠な、例えば、Ｒ（赤）、Ｇ（緑）、Ｂ（青）各色の着色インキ層と、カラーＬＣＤの表示コントラスト向上目的で設けられる金属皮膜やＢｋ（黒）の隔壁を、所定のパターンに配列したものであり、多くの製造方法が知られている。以下に幾つかの方法を説明する。 For example, R (red), G (green), and B (blue) colored ink layers on a transparent substrate, and a metal film provided for the purpose of improving the display contrast of a color LCD. And Bk (black) barrier ribs are arranged in a predetermined pattern, and many manufacturing methods are known. Several methods are described below.
カラーフィルタの製造方法として染色法、顔料分散法、電着法、印刷法などが挙げられる。染色法は、透明基板上に染色性高分子材料を塗布し、所定形状にフォトリソ法でパターニングした後、染色液に浸漬して着色する工程をＲ、Ｇ、Ｂ各色で繰り返し、着色インキ層を形成する方法である。顔料分散法は、透明基板上に顔料を分散した感光性樹脂材料を、スピンコーターなどで塗布後、フォトリソ法でパターニングする工程を、Ｒ、Ｇ、Ｂ各色で繰り返し、着色インキ層を形成する方法である。電着法は、透明基板上に透明電極パターンを形成した後、顔料、樹脂、電解液等の入った電着塗装液に浸漬して電着する工程を各色で繰り返し、着色インキ層を得る方法である。印刷法は、顔料が分散された熱硬化型インキを、パターニングされた印刷板に転移させた後、透明基板上に、直接印刷若しくは、オフセット印刷によってパターン形成する工程を各色で繰り返して、着色インキ層を形成する方法である。必要に応じて、これらの方法による着色インキ層形成前に、透明基板上にＣｒ等の金属膜や黒色顔料からなる隔壁パターンが形成される。 Examples of the method for producing the color filter include a dyeing method, a pigment dispersion method, an electrodeposition method, and a printing method. In the dyeing method, a process of applying a dyeable polymer material on a transparent substrate, patterning it into a predetermined shape by a photolithographic method, and then immersing and coloring in a dyeing solution is repeated for each color of R, G, and B, and a colored ink layer is formed. It is a method of forming. The pigment dispersion method is a method in which a photosensitive resin material in which a pigment is dispersed on a transparent substrate is applied with a spin coater or the like and then patterned with a photolithographic method to repeat a color ink layer for each color of R, G, and B. It is. The electrodeposition method is a method in which after forming a transparent electrode pattern on a transparent substrate, the process of dipping in an electrodeposition coating solution containing a pigment, resin, electrolytic solution, etc. and electrodeposition is repeated for each color to obtain a colored ink layer. It is. In the printing method, after a thermosetting ink in which a pigment is dispersed is transferred to a patterned printing plate, a process of forming a pattern by direct printing or offset printing on a transparent substrate is repeated for each color, and coloring ink is used. A method of forming a layer. If necessary, a partition wall pattern made of a metal film such as Cr or a black pigment is formed on the transparent substrate before forming the colored ink layer by these methods.
前記の方法によって、カラーフィルタの製造は可能であるが、良好な色特性や、位置精度、コストなどから、現状は、顔料分散法が多く用いられている。しかし、いずれの製造方法を採用したとしても、基板の大型化に伴うカラーフィルタ面内のゴミや異物の増加によって、隔壁や着色インキ層においてピンホールや異物による欠陥の数も増加している。そのため、高品質のカラーフィルタを製造することが困難になり、大型基板使用などの材料コスト上昇と合わせて考慮すると、漸進的なコスト低減が難しい状況になりつつある。 Although a color filter can be manufactured by the above-described method, the pigment dispersion method is often used at present because of good color characteristics, positional accuracy, cost, and the like. However, regardless of which manufacturing method is employed, the number of defects due to pinholes and foreign matters in the partition walls and the colored ink layer is increasing due to an increase in dust and foreign matters in the color filter surface accompanying the increase in size of the substrate. For this reason, it is difficult to manufacture a high-quality color filter, and considering the increase in material costs such as the use of a large substrate, it is becoming difficult to gradually reduce costs.
このようなことから、カラーフィルタの製造方法において、隔壁および着色インキ層に発生する欠陥を高精度かつ迅速に修正する工程が重要となっている。以下で、従来のカラーフィルタの製造方法において、着色インキ層の欠陥を修正する技術について述べる。 For this reason, in the manufacturing method of the color filter, a process of correcting defects generated in the partition walls and the colored ink layer with high accuracy and speed is important. Hereinafter, a technique for correcting a defect in a colored ink layer in a conventional color filter manufacturing method will be described.
従来は、カラーフィルタの製造方法において、隔壁の修正および着色インキ層の修正は、それぞれ修正に適した方法が異なることから各々独立して行なわれていた。つまり、欠陥検査を別々に行い、まず基板上に隔壁を形成した後、隔壁の検査・修正を行い、その後欠陥部に、着色インキ層を形成し、また着色インキ層の検査・修正をしていた。
修正の具体的手段として、針の先端に適切な色濃度を有するインキを付け、欠陥部（修正部ともいう。）に塗布して乾燥させる方法（特許文献１参照）、感光性着色フィルムを修正部に熱転写し、露光・現像・乾燥させる方法（特許文献２参照）、レーザー照射で異物を除去した後再度着色する方法（特許文献３参照）が知られている。しかし、これらの方法は、部材のコストが高かったり、修正の微調整が難しかったり、また著しく時間がかかるという問題があった。また、隔壁が黒色である場合、欠陥の検査は目視では非常に困難になり、隔壁の欠陥の修正が難しいという問題があった。
Conventionally, in the color filter manufacturing method, the correction of the partition walls and the correction of the colored ink layer have been performed independently because the methods suitable for the correction are different. In other words, defect inspection is carried out separately, and after first forming the partition on the substrate, the partition is inspected and corrected, and then a colored ink layer is formed on the defective portion, and the colored ink layer is inspected and corrected. It was.
As specific means for correction, a method of applying ink having an appropriate color density to the tip of the needle, applying the ink to a defective portion (also referred to as a correction portion), and drying (see Patent Document 1), correcting the photosensitive colored film There are known a method in which heat transfer is performed to a part and exposure, development, and drying are performed (see Patent Document 2), and a method of coloring again after removing foreign matters by laser irradiation (see Patent Document 3). However, these methods have a problem that the cost of members is high, fine adjustment of correction is difficult, and it takes a considerable time. Further, when the partition walls are black, it is very difficult to inspect the defects visually, and it is difficult to correct the defects of the partition walls.
また、インキ吐出印刷装置により着色インキ層を修正する方法が知られている（特許文献４、５参照）。この方法によると、欠陥部に対して高速なインキ吐出が可能であり修正時間も早く、また、欠陥部へのインキを重ね打ちするため、塗布量増加させて色濃度を上げる場合でも微調整に優れ、短時間の修正が可能という長所を有する。そして、隔壁および着色インキ層の修正をインキ吐出印刷装置により順次行えば、効率よく一度の工程でカラーフィルタの欠陥部の修正ができるようにも思われる。
しかし、インキ吐出印刷装置による修正は、インキ吐出印刷方式により形成された部分の欠陥の修正にのみ適していた。隔壁や着色インキ層を、インキ吐出印刷方式以外の方法（例えば顔料分散法等）で形成した場合、インキと隔壁、着色インキ層間の表面張力差から、修正インキが、ピンホール等色ヌケ部から周辺部へと流動し易く、必要な色濃度を得難かった。
このため、着色インキ層がインキ吐出印刷方式で形成される場合であっても、隔壁を顔料分散法、又は印刷、転写等インキ吐出印刷方式以外の方法により形成した場合は、インキ吐出印刷方式による修正により効率よく一度の工程でカラーフィルタの欠陥部の修正することはできなかった。
However, the correction by the ink discharge printing apparatus is only suitable for correcting the defect of the portion formed by the ink discharge printing method. When partition walls and colored ink layers are formed by methods other than the ink ejection printing method (for example, pigment dispersion method), the correction ink is removed from the color missing parts such as pinholes due to the difference in surface tension between the ink and the partition walls and the colored ink layers. It was easy to flow to the peripheral part and it was difficult to obtain the required color density.
For this reason, even when the colored ink layer is formed by an ink discharge printing method, when the partition wall is formed by a method other than the ink discharge printing method such as a pigment dispersion method or printing or transfer, the ink discharge printing method is used. Due to the correction, the defective portion of the color filter could not be corrected efficiently in one step.
本発明は、前記課題を解決するためになされたものであり、その課題とするところは、基板と、基板上にパターン状に設けられた隔壁と、この隔壁によって区切られた開口部に設けられたインキ層を含む印刷物を、インキ吐出印刷装置を用いて製造する方法において、隔壁とインキ層の欠陥の修正を一度の工程で行い、高品質な印刷物を効率よく製造する方法を提供することである。 The present invention has been made to solve the above-mentioned problems, and the object of the present invention is to be provided in a substrate, a partition wall provided in a pattern on the substrate, and an opening section partitioned by the partition wall. In a method for producing printed matter including an ink layer using an ink ejection printing device, a defect is corrected in a partition wall and an ink layer in one step, and a method for efficiently producing high-quality printed matter is provided. is there.
ところで、本発明者らは、基板上に隔壁を設け、その後隔壁の欠陥を検査・修正することなく、隔壁によって区切られた開口部にインキ吐出印刷装置により着色インキ層を形成した。そして、隔壁形成後に形成した着色インキ層の白抜け欠陥から、隔壁の欠陥を判別し、さらに複数の修正手段を有する修正装置により修正すると、基板上の着色インキの白抜け欠陥と隔壁の欠陥を、同一のワーク上で一度の工程で、修正することができることを見出した。本発明はこのような知見に基づいてなされたもので、請求項１に記載の発明は、基板と、この基板上にパターン状に設けられた隔壁と、この隔壁によって区切られた開口部に設けられたインキ層とを含む印刷物の製造方法において、少なくとも、
（ａ）基板上に隔壁樹脂を塗布する工程と、
（ｂ）この基板の隔壁樹脂が塗布された面を、隔壁パターン状に露光する工程と、
（ｃ）この基板を現像し、隔壁を形成する工程と、
（ｄ）この基板を加熱し、隔壁を熱硬化させる工程と、
（ｅ）この基板の隔壁の開口部に形成された領域に、インキ吐出印刷装置を用いてインキを吐出しインキ層を形成する工程と、
（ｆ）このインキ層の異物、ピンホールからなる欠陥を検出する工程と、
（ｇ）この検出結果から異物、ピンホールからなる欠陥を分類してＮＧ規格となる欠陥位置情報を記録する工程と、
（ｈ）この隔壁の欠陥部分を修正する工程と、を行うことを特徴とする印刷物の製造方法である。
請求項２に記載の発明は、
（ｈ）この隔壁の欠陥部分を修正する工程が、
（ｈ１）この隔壁の欠陥部に隔壁と同じ材料を被覆形成する工程と、
（ｈ２）この隔壁を熱硬化若しくは光硬化させる工程と、
（ｈ３）紫外〜赤外レーザ光の照射により修正部を整形する工程と、
を含むことを特徴とする請求項１に記載の印刷物の製造方法である。
請求項３に記載の発明は、
（Ｉ）インキ層の異物、欠陥を修正する工程、を含むことを特徴とする請求項１又は請求項２に記載の印刷物の製造方法である。
請求項４に記載の発明は、前記（ｈ）この隔壁の欠陥部分を修正する工程と前記（Ｉ）インキ層の異物、欠陥を修正する工程を、基板をワークに固定したまま順次行なうことを特徴とする請求項２又は３に記載の印刷物の製造方法である。
請求項５に記載の発明は、前記（ｈ）この隔壁の欠陥部分を修正する工程の修正方法が、針方式、ディスペンス方式から選択され、
かつ（Ｉ）インキ層の異物、欠陥を修正する工程の修正方法が、インキ吐出印刷方式、針方式、ディスペンス方式、熱転写方式から選択されることを特徴とする請求項２〜４のいずれかに記載の印刷物の製造方法である。
請求項６に記載の発明は、前記隔壁が黒色であることを特徴とする請求項１〜５のいずれかに記載の印刷物の製造方法である。
請求項７に記載の発明は、インキ層が着色インキ層であり、印刷物がカラーフィルタであることを特徴とする請求項１〜６のいずれかに記載の印刷物の製造方法である。
請求項８に記載の発明は、（Ｉ）インキ層の異物、欠陥を修正する工程が、
（Ｉ１）着色インキ層の欠陥部の面積によって、インキジェット方式、針方式、ディスペンス方式、若しくは熱転写方式を単独、若しくは組み合わせて使用し、着色インキ層の周辺部との膜厚差が０．１μｍ以下で、色差がΔＥａｂ＜５以下となるように、着色インキ層と同色の着色材料を欠陥部に被覆形成し、その後、熱硬化、若しくは光硬化させる事を特徴とする請求項７に記載の印刷物の製造方法である。
請求項９に記載の発明は、インキ層が有機発光層であり、印刷物が有機エレクトロルミネッセンス素子であることを特徴とする請求項１〜６のいずれかに記載の印刷物の製造方法である。
請求項１０に記載の発明は、インキ層が正孔輸送層であり、印刷物が有機エレクトロルミネッセンス素子であることを特徴とする請求項１〜６のいずれかに記載の印刷物の製造方法である。
By the way, the present inventors provided partition walls on the substrate, and then formed a colored ink layer by an ink ejection printing device in the openings partitioned by the partition walls without inspecting and correcting defects in the partition walls. Then, the defect of the partition wall is determined from the white spot defect of the colored ink layer formed after the partition wall is formed, and further corrected by a correction device having a plurality of correction means, the white ink defect of the color ink on the substrate and the defect of the partition wall are detected. It was found that it can be corrected in one step on the same workpiece. The present invention has been made based on such knowledge. The invention according to claim 1 is provided in a substrate, a partition wall provided in a pattern on the substrate, and an opening section partitioned by the partition wall. In the manufacturing method of the printed matter containing the formed ink layer, at least,
(A) applying a partition resin on the substrate;
(B) a step of exposing the surface of the substrate on which the partition wall resin is applied to a partition pattern;
(C) developing the substrate to form partition walls;
(D) heating the substrate and thermosetting the partition;
(E) forming a layer of ink by discharging ink using an ink discharge printing device to a region formed in the opening of the partition wall of the substrate;
(F) detecting a defect consisting of foreign matter and pinholes in the ink layer ;
(G) A step of classifying defects consisting of foreign matter and pinholes from this detection result and recording defect position information that is NG standard ,
And (h) a step of correcting a defective portion of the partition wall.
The invention described in claim 2
(H) The step of correcting the defective part of the partition wall includes:
(H1) A step of coating the same material as the partition wall on the defect portion of the partition wall;
(H2) a step of thermosetting or photocuring the partition;
(H3) shaping the correction portion by irradiation with ultraviolet to infrared laser light ;
The method for producing a printed matter according to claim 1, comprising:
The invention according to claim 3
(I) The method for producing a printed matter according to claim 1, comprising a step of correcting foreign matter and defects in the ink layer.
In the invention according to claim 4, the step (h) correcting the defective portion of the partition and the step (I) correcting the foreign matter and defect of the ink layer are sequentially performed while the substrate is fixed to the work. It is the manufacturing method of the printed matter of Claim 2 or 3 characterized by the above-mentioned.
In the invention according to claim 5, the correction method in the step (h) of correcting the defective portion of the partition wall is selected from a needle method and a dispense method,
And (I) the correction method of the process which corrects the foreign material of an ink layer, and a defect is selected from an ink discharge printing system, a needle system, a dispense system, and a thermal transfer system. It is a manufacturing method of printed matter of description.
Invention of Claim 6 is a manufacturing method of the printed matter in any one of Claims 1-5 characterized by the said partition being black.
The invention according to claim 7 is the method for producing a printed matter according to any one of claims 1 to 6, wherein the ink layer is a colored ink layer and the printed matter is a color filter.
In the invention according to claim 8, (I) the step of correcting foreign matter and defects in the ink layer comprises:
(I1) Depending on the area of the defective portion of the colored ink layer, an ink jet method, a needle method, a dispensing method, or a thermal transfer method is used alone or in combination, and the film thickness difference from the peripheral portion of the colored ink layer is 0.1 μm. The coloring material having the same color as that of the colored ink layer is formed on the defective portion so that the color difference is equal to or less than ΔEab <5, and then thermally cured or photocured. It is a manufacturing method of printed matter.
The invention according to claim 9 is the method for producing a printed material according to any one of claims 1 to 6, wherein the ink layer is an organic light emitting layer, and the printed material is an organic electroluminescence element.
The invention according to claim 10 is the method for producing a printed material according to any one of claims 1 to 6, wherein the ink layer is a hole transport layer, and the printed material is an organic electroluminescence element.
本発明によると、従来複数の工程に分かれていた印刷物の隔壁及びインキ層の修正を一度の工程で行なうことができた。また、従来欠陥の検査の難しかった隔壁の検査を精度よく行なうことが可能となった。このため、印刷物の製造の時間、コスト、歩留りを向上させることができた。
また、本発明によると、一台の装置で隔壁とインキ層の検査・修正が可能となった。そのため、隔壁およびインキ層の欠陥の情報を一度に扱えることから、修正後の形状、膜厚、濃度を最適に調整できた。特に、隔壁欠陥由来のインキ層の欠陥修正において、修正後の隔壁及びインキ層の形状変化を、周辺の正常部と比べて小さくすることできた。このため、印刷物の製造品質を向上させることができた。
さらに、本発明によれば、一台の装置で隔壁とインキ層の修正を行なうことができるので、修正にかかるコスト低減と、設置面積の節減が可能になった。
According to the present invention, the partition of the printed matter and the ink layer which have been conventionally divided into a plurality of steps can be corrected in one step. In addition, it has become possible to accurately inspect the partition wall, which has conventionally been difficult to inspect for defects. For this reason, it was possible to improve the time, cost, and yield of the printed material.
In addition, according to the present invention, it is possible to inspect and correct the partition wall and the ink layer with a single apparatus. For this reason, since the defect information of the partition walls and the ink layer can be handled at a time, the corrected shape, film thickness and density can be optimally adjusted. In particular, in the defect correction of the ink layer derived from the barrier rib defect, the shape change of the barrier rib and the ink layer after the correction can be made smaller than that of the surrounding normal part. For this reason, it was possible to improve the production quality of the printed matter.
Furthermore, according to the present invention, since the partition and the ink layer can be corrected with a single device, it is possible to reduce the cost for the correction and to reduce the installation area.
本発明の印刷物とは、例えばインキ層として着色インキ層を備えたカラーフィルタを挙げることができる。また、印刷物として、例えばインキ層として有機発光層又は／及び正孔輸送層を備えた有機エレクトロルミネッセンス素子を挙げることができる。その他、印刷物として回路基板、薄膜トランジスタ、マイクロレンズ、バイオチップ等を挙げることができる。
以下、本発明による印刷物の製造方法を、カラーフィルタを例に、その実施形態に基づいて詳細に説明する。
Examples of the printed matter of the present invention include a color filter provided with a colored ink layer as an ink layer. Moreover, as a printed matter, for example, an organic electroluminescence device including an organic light emitting layer and / or a hole transport layer as an ink layer can be exemplified. In addition, examples of the printed material include a circuit board, a thin film transistor, a microlens, and a biochip.
Hereinafter, a method for producing a printed material according to the present invention will be described in detail based on an embodiment of a color filter as an example.
図１は、カラーフィルタ１の基本構造を示す縦断面図である。ガラスなどの基板１０の表面上に、金属膜あるいは黒色顔料（カーボン等）を含む隔壁樹脂組成物からなる隔壁１１が形成され、隔壁パターンの開口部内に赤色（Ｒ）、緑色（Ｇ）及び青（Ｂ）顔料、若しくは、同色の染料を含有する着色インキ組成物がインキ吐出印刷装置により吐出され、着色インキ層１２が形成されている。この着色インキ層１２の表面上には、必要に応じて透明樹脂からなる保護膜１３が被覆され、その上にＩＴＯ（Ｉｎｄｉｕｍ Ｔｉｎ Ｏｘｉｄｅ）からなる透明電極１４が形成される。ＩＴＯのパターン形状による液晶配向が必要となる場合には、フォトリソ法やレーザ光加工によって、透明電極１４にパターニングを施す。 FIG. 1 is a longitudinal sectional view showing the basic structure of the color filter 1. A partition wall 11 made of a partition wall resin composition containing a metal film or a black pigment (carbon or the like) is formed on the surface of a substrate 10 such as glass, and red (R), green (G), and blue are formed in the openings of the partition wall pattern. (B) A colored ink composition containing a pigment or a dye of the same color is ejected by an ink ejection printing apparatus, and the colored ink layer 12 is formed. A protective film 13 made of a transparent resin is coated on the surface of the colored ink layer 12 as necessary, and a transparent electrode 14 made of ITO (Indium Tin Oxide) is formed thereon. When the liquid crystal alignment by the ITO pattern shape is required, the transparent electrode 14 is patterned by photolithography or laser beam processing.
また、最近は、ＬＣＤの性能向上要求に伴い、透明電極１４上に、液晶配向を制御するＭＶＡ（Ｍｕｌｔｉ Ｖｅｒｔｉｃａｌ Ａｌｉｇｎｍｅｎｔ）層１５や、カラーフィルタ基板とＴＦＴ（Ｔｈｉｎ Ｆｉｌｍ Ｔｒａｎｓｉｓｔｏｒ）基板間距離を、適正な値に規制するためのＰＳ（Ｐｈｏｔｏ Ｓｐａｃｅｒ）層１６を、別途、ＩＴＯ上設ける事がある。 Recently, in accordance with demands for improving LCD performance, the MVA (Multi Vertical Alignment) layer 15 for controlling the liquid crystal alignment and the distance between the color filter substrate and the TFT (Thin Film Transistor) substrate are appropriately set on the transparent electrode 14. A PS (Photo Spacer) layer 16 may be separately provided on the ITO so as to regulate to a certain value.
図２は、カラーフィルタでストライプ配列とした平面図である。モザイク配列や、デルタ配列にする場合もある。 FIG. 2 is a plan view showing a stripe arrangement with color filters. In some cases, a mosaic arrangement or a delta arrangement is used.
カラーフィルタの製造方法、ここでは着色インキ層を顔料分散法で製造されたカラーフィルタについて説明する。カラーフィルタの着色インキ層の製造方式にあわせ、下記とは異なる修正方法の組合せ等を変更することも可能である。 A color filter manufacturing method, here, a color filter in which a colored ink layer is manufactured by a pigment dispersion method will be described. A combination of correction methods different from the following can be changed in accordance with the manufacturing method of the color ink layer of the color filter.
まず、基板上に隔壁樹脂組成物を基板上に塗布し、これを隔壁パターン状に露光し、現像し、加熱して隔壁１１をパターン形成する。その後、この隔壁に区切られた開口部内に、インキ吐出印刷装置で着色インキ組成物を吐出し、着色インキ層１２をパターン状に形成する。その後、光学的な検査機（図示せず）を用いて、着色インキ層内の異物とピンホールを検出し、これにより隔壁の異物、ピンホール等の欠陥を判別し、欠陥種類、位置、大きさで分類、ＮＧ規格となる欠陥位置情報を記録した後、レーザリペア機構及び、針方式、若しくはディスペンス方式の修正ヘッドを使用して実施する。光学的な検査機による欠陥の検出は、基板上面から検査光を照射し、反射光及び透過光をＣＣＤカメラで受光し、カラーフィルタ全体を走査しながら、ＣＣＤカメラからの信号強度を、パターン毎に比較解析することで実施する。 First, a partition wall resin composition is applied onto a substrate, exposed to a partition pattern, developed, and heated to pattern the partition 11. Thereafter, the colored ink composition is discharged into the opening section partitioned by the partition walls by an ink discharge printing apparatus to form the colored ink layer 12 in a pattern. Then, using an optical inspection machine (not shown), foreign matter and pinholes in the colored ink layer are detected, thereby detecting defects such as foreign matter and pinholes in the partition wall, and the type, position and size of the defect. After classifying and recording defect position information to be NG standard, a laser repair mechanism and a needle type or dispense type correction head are used. Defect detection by an optical inspection machine is performed by irradiating inspection light from the top surface of the substrate, receiving reflected light and transmitted light with a CCD camera, and scanning the entire color filter while measuring the signal intensity from the CCD camera for each pattern. This is done by comparative analysis.
図３及び図５に、隔壁１１の修正の様子を示した。隔壁１１の外に有るＮＧ規格の異物欠陥は、隔壁用レジストに内在する異物や、製造装置による発塵、異物の付着などに起因するもので、前記、光学的な検査機から欠陥位置情報を修正機構２に取得し、レーザリペア機構２１を必要位置に移動させた後、紫外〜赤外レーザ光による異物欠陥除去で、良品化できる。 3 and 5 show how the partition wall 11 is corrected. The NG standard foreign material defect outside the partition wall 11 is caused by the foreign material present in the partition wall resist, dust generation by the manufacturing apparatus, adhesion of the foreign material, etc. The defect position information is obtained from the optical inspection machine. After obtaining the correction mechanism 2 and moving the laser repair mechanism 21 to a required position, it can be made non-defective by removing foreign substance defects with ultraviolet to infrared laser light.
次に、隔壁１１内に有るＮＧ規格の異物欠陥の場合は、前記と同様に欠陥位置情報を修正機構２に取得後、紫外〜赤外レーザ光によるレーザリペア機構２１によって、異物欠陥を除去する。異物欠陥の除去後に、黒色顔料若しくは染料を含有する黒色の着色材を、針方式、若しくは、ディスペンス方式の修正ヘッド２３から吐出、被覆する。
黒色着色材の光学濃度が低く、修正部の規格光学濃度に不足する場合は、針方式では黒色着色材の塗布回数増加で、ディスペンス方式では吐出量の調整で対応可能である。
また、インキ塗布毎にレーザリペア機構２１の赤外レーザ光による熱硬化を行い、被覆インキ径の増加を抑制する事も、修正部の光学濃度向上に有効である。
Next, in the case of the NG standard foreign substance defect in the partition wall 11, the defect position information is acquired by the correction mechanism 2 in the same manner as described above, and then the foreign substance defect is removed by the laser repair mechanism 21 using ultraviolet to infrared laser light. . After removing the foreign substance defect, a black coloring material containing a black pigment or dye is discharged and coated from the correction head 23 of the needle type or the dispense type.
When the optical density of the black coloring material is low and the standard optical density of the correction portion is insufficient, the number of times of application of the black coloring material can be increased by the needle method, and the discharge amount can be adjusted by the dispensing method.
In addition, it is also effective for improving the optical density of the correction portion by performing thermal curing with the infrared laser beam of the laser repair mechanism 21 for each ink application to suppress the increase in the diameter of the coating ink.
隔壁１１のピンホール欠陥は、前記、光学的な検査機から位置情報を修正機構２に取得、針方式、若しくは、ディスペンス方式の修正ヘッド２３をピンホール欠陥部に移動させ、黒色着色材を塗布、若しくは吐出、被覆して修正を行う。
また、インキジェット方式のカラーフィルタ等では、隔壁にインキジェットインキへの撥インキ性が付与させている事があるため、必要に応じて、撥インキ性の黒色着色材を用いて修正するか、隔壁の修正後に、別途、撥インキ性の部材を被覆形成して行う。
For pinhole defects in the partition wall 11, the positional information is obtained from the optical inspection machine by the correction mechanism 2, the needle type or dispense type correction head 23 is moved to the pinhole defect part, and the black colorant is applied. Or, correct by discharging or covering.
In addition, in an ink jet type color filter or the like, the partition may have been given ink repellency to the ink jet ink. After the partition is corrected, an ink-repellent member is separately formed.
着色インキ層１２の修正は、前記、隔壁の欠陥検査の際に記録した欠陥種類、位置、大きさで分類、ＮＧ規格となる欠陥位置情報を基に、レーザリペア機構での異物除去やピンホール形状の整形、及び、インキジェット方式、針方式、ディスペンス方式、及び、熱転写方式のいずれか、または、組み合わせてなる修正ヘッド２４による塗布／吐出／転写によって実施する。通常は、ＲＧＢ各色の着色インキ層、場合によっては、反射表示用ＲＧＢを含めた各色の着色インキ層が形成された後、透明電極１４が形成される前に、修正が行われる。 The correction of the colored ink layer 12 is classified according to the defect type, position, and size recorded at the time of the defect inspection of the partition wall, and the removal of foreign matters and pinholes by the laser repair mechanism based on the defect position information that becomes the NG standard. It is carried out by shape shaping and application / discharge / transfer by a correction head 24 that is one of, or a combination of, an ink jet method, a needle method, a dispense method, and a thermal transfer method. Usually, correction is performed after the color ink layers for each color of RGB, and in some cases, the color ink layers for each color including RGB for reflection display, and before the transparent electrode 14 is formed.
図４及び図５に、着色インキ層１２の修正の様子を示した。着色インキ層１２にあるＮＧ規格の異物欠陥は、着色インキ層用レジストに内在する異物や、製造装置による発塵、各工程で付着するレジスト滓や異物などに起因するもので、前記、光学的な検査機から欠陥位置情報を修正機構２に取得、必要な修正機構を必要位置に移動させた後、紫外〜赤外レーザ光によるレーザリペア機構２１によって、異物欠陥を除去する。次に、ＲＧＢ各色顔料若しくは染料を含有するＲＧＢの各色着色材の内、必要な色のインキジェットヘッド、針方式ヘッド、ディスペンス方式ヘッド、熱転写方式ヘッドのいずれか、または組み合わせてなる修正ヘッド２４を、修正位置に移動させ、異物除去部分に吐出、塗布、被覆する。
また、この時、ＲＧＢ各色の着色材の光学濃度が低く、修正部の規格濃度に不足する場合には、針方式では各色着色材の塗布回数増加で、ディスペンス方式及び、インキジェット方式では吐出量の増加で対応可能である。
ここでも、隔壁と同様に、インキ塗布／吐出毎にレーザリペア機構２１の赤外レーザ光によって熱硬化を行っても良い。
4 and 5 show how the colored ink layer 12 is corrected. The NG standard foreign matter defect in the colored ink layer 12 is caused by foreign matter present in the resist for the colored ink layer, dust generation by the manufacturing apparatus, resist wrinkles and foreign matter attached in each process, etc. After acquiring defect position information from the correct inspection machine to the correction mechanism 2 and moving the necessary correction mechanism to the required position, the foreign substance defect is removed by the laser repair mechanism 21 using ultraviolet to infrared laser light. Next, among the RGB colorants containing RGB color pigments or dyes, the correction head 24 is formed of any necessary ink jet head, needle type head, dispense type head, thermal transfer type head, or a combination thereof. Then, it is moved to the correction position and discharged, applied, and coated on the foreign matter removal portion.
At this time, if the optical density of each color material of RGB is low and the standard density of the correction portion is insufficient, the number of times of application of each color material is increased in the needle method, and the discharge amount in the dispense method and the ink jet method. It is possible to cope with the increase.
Here, similarly to the partition, thermal curing may be performed by the infrared laser beam of the laser repair mechanism 21 for each ink application / discharge.
着色インキ層内のピンホール欠陥は、前記、光学的な検査機から位置情報を修正機構２に取得、インキジェットヘッド、針方式ヘッド、ディスペンス方式ヘッド、熱転写方式ヘッドのいずれか、組み合わせてなる修正ヘッド２４をピンホール欠陥部に移動させ、ＲＧＢの着色材の内、修正に必要な色の着色材を、ピンホール欠陥部に吐出、被覆、転写して、修正を行う。この時、レーザリペア機構２１と２２のレーザが、紫外レーザである場合、Ｈｅ−ＣｄレーザやＹＡＧレーザの３倍以上の高調波レーザなどが使用される。 The pinhole defect in the colored ink layer is corrected by combining the position information from the optical inspection machine to the correction mechanism 2 and combining any one of the ink jet head, the needle method head, the dispense method head, and the thermal transfer method head. The head 24 is moved to the pinhole defect portion, and among the RGB colorants, a colorant having a color necessary for correction is discharged, covered, and transferred to the pinhole defect portion to perform correction. At this time, when the lasers of the laser repair mechanisms 21 and 22 are ultraviolet lasers, a harmonic laser that is three times or more of a He-Cd laser or a YAG laser is used.
着色インキ層の修正に使用する着色材が、着色インキ層と同じ顔料や染料であれば、修正部と周囲との濃度差、色差を抑えられて望ましいが、周囲との色差がΔＥａｂ＜５であれば、判別が困難となるので、修正ヘッドからの塗布／吐出、被覆量を調整すれば、着色材に使用する顔料や染料が着色インキ層と異なっても良い。 If the colorant used for correcting the colored ink layer is the same pigment or dye as the colored ink layer, it is desirable to suppress the density difference and color difference between the corrected portion and the surrounding area, but the color difference between the surrounding area is ΔEab <5. If it exists, it becomes difficult to discriminate. Therefore, the pigment or dye used for the colorant may be different from the colored ink layer by adjusting the coating / discharge from the correction head and the coating amount.
上記では、基板上に隔壁および着色インキ層を順次形成した後に、隔壁と着色インキ層の修正を一度に行なう場合を例に説明したが、基板上に隔壁を形成直後で、着色インキ層の形成前に、隔壁の欠陥検査及び修正を行なうと、隔壁の欠陥を低減させる上でさらに効果的である。
また、修正後のカラーフィルタを、次工程処理、例えば、隔壁の修正後の着色インキ層形成工程や、着色インキ層形成後の透明電極形成工程の前に、修正部の局所的な、若しくはカラーフィルタ全体の熱処理で、熱硬化させると、次工程での修正部の膨潤や剥離が防止できて望ましい。必要に応じて、光硬化剤を混合した着色材を使用し、光硬化を併用する事も可能である。
In the above description, the partition and the colored ink layer are sequentially formed on the substrate, and then the partition and the colored ink layer are corrected at once. However, immediately after the partition is formed on the substrate, the colored ink layer is formed. If the defect inspection and correction of the partition walls are performed before, it is more effective in reducing the defects of the partition walls.
In addition, the color filter after correction is subjected to subsequent processing, for example, a colored ink layer forming step after correcting the partition wall, or a transparent electrode forming step after forming the colored ink layer. It is desirable to heat-cure the entire filter by heat treatment because it prevents swelling and peeling of the corrected portion in the next step. If necessary, it is possible to use a colorant mixed with a photocuring agent and use photocuring in combination.
カラーフィルタに用いる基板として、硝子基板を好適に用いることができる。また、目的に応じて、樹脂基板等を用いることもできる。 As the substrate used for the color filter, a glass substrate can be suitably used. Moreover, a resin substrate etc. can also be used according to the objective.
隔壁樹脂組成物および着色インキ樹脂組成物は、バインダー樹脂、感光性樹脂、熱硬化性樹脂、光重合開始剤、顔料、有機溶媒、架橋剤、分散剤等を含む。
カラーフィルタにおいては、コントラスト向上のため、隔壁樹脂組成物に黒色顔料を分散させる。混色顔料としてカーボンブラックを挙げることができる。
また、着色インキ層には各色着色顔料を分散させる。例えば、Ｐｉｇｍｅｎｔ Ｒｅｄ９、１９、３８、４３、９７、１２２、１２３、１４４、１４９、１６６、１６８、１７７、１７９、１８０、１９２、２１５、２１６、２０８、２１６、２１７、２２０、２２３、２２４、２２６、２２７、２２８、２４０、 Ｐｉｇｍｅｎｔ Ｂｌｕｅ １５、１５：６、１６、２２、２９、６０、６４、 Ｐｉｇｍｅｎｔ Ｇｒｅｅｎ７、３６、 Ｐｉｇｍｅｎｔ Ｒｅｄ ２０、２４、８６、８１、８３、９３、１０８、１０９、１１０、１１７、１２５、１３７、１３８、１３９、１４７、１４８、１５３、１５４、１６６、１６８、１８５、 Ｐｉｇｍｅｎｔ Ｏｒａｎｇｅ３６、 Ｐｉｇｍｅｎｔ Ｖｉｏｌｅｔ２３などがあり、要求の色相を得るために２種類以上が混合されることもある。また、これらの顔料に限定されるものではない。
The partition resin composition and the colored ink resin composition include a binder resin, a photosensitive resin, a thermosetting resin, a photopolymerization initiator, a pigment, an organic solvent, a crosslinking agent, a dispersant, and the like.
In the color filter, a black pigment is dispersed in the partition wall resin composition in order to improve contrast. Carbon black can be mentioned as a mixed color pigment.
Further, colored pigments are dispersed in the colored ink layer. For example, Pigment Red 9, 19, 38, 43, 97, 122, 123, 144, 149, 166, 168, 177, 179, 180, 192, 215, 216, 208, 216, 217, 220, 223, 224, 226 227, 228, 240, Pigment Blue 15, 15: 6, 16, 22, 29, 60, 64, Pigment Green 7, 36, Pigment Red 20, 24, 86, 81, 83, 93, 108, 109, 110, 117, 125, 137, 138, 139, 147, 148, 153, 154, 166, 168, 185, Pigment Orange 36, Pigment Violet 23, etc. Two or more types may be mixed to obtain the required hue . Moreover, it is not limited to these pigments.
着色インキ層および隔壁の形成に熱可塑性樹脂または熱硬化性樹脂を用いることができる。熱可塑性樹脂として、例えば、ブチラール樹脂、スチレンーマレイン酸共重合体、塩素化ポリエチレン、塩素化ポリプロピレン、ポリ塩化ビニル、塩化ビニル−酢酸ビニル共重合体、ポリ酢酸ビニル、ポリウレタン系樹脂、ポリエステル樹脂、アクリル系樹脂、アルキッド樹脂、ポリスチレン樹脂、ポリアミド樹脂、ゴム系樹脂、環化ゴム系樹脂、セルロース類、ポリブタジエン、ポリエチレン、ポリプロピレン、ポリイミド樹脂等を挙げることができる。
また、熱硬化性樹脂として、例えば、エポキシ樹脂、ベンゾグアナミン樹脂、ロジン変性マレイン酸樹脂、ロジン変性フマル酸樹脂、メラミン樹脂、尿素樹脂、フェノール樹脂等を用いる事が可能であり、顔料分散性との関係や、修正後の硬化方法などから、適宜選択して使用される。耐熱性や耐光性などを考慮すると、アクリル樹脂が好ましい。
A thermoplastic resin or a thermosetting resin can be used to form the colored ink layer and the partition wall. Examples of the thermoplastic resin include butyral resin, styrene-maleic acid copolymer, chlorinated polyethylene, chlorinated polypropylene, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, polyvinyl acetate, polyurethane resin, polyester resin, Examples thereof include acrylic resins, alkyd resins, polystyrene resins, polyamide resins, rubber resins, cyclized rubber resins, celluloses, polybutadiene, polyethylene, polypropylene, and polyimide resins.
In addition, as the thermosetting resin, for example, an epoxy resin, a benzoguanamine resin, a rosin-modified maleic acid resin, a rosin-modified fumaric acid resin, a melamine resin, a urea resin, a phenol resin, or the like can be used. It is appropriately selected and used from the relationship and the corrected curing method. In view of heat resistance and light resistance, an acrylic resin is preferable.
有機溶剤としては、顔料分散用樹脂の溶解力と共に、着色顔料への分散安定性が必須であり、さらに、各修正方式に適合する適性な表面張力や沸点などの特性が要求される。
インキジェット方式では、吐出時の安定性や、ノズル詰まり耐性から、表面張力範囲３５ｍＮ／ｍ以下で、且つ、沸点が１３０℃以上のものが好ましく、具体的には、２−メトキシエタノール、２−エトキシエタノール、２−ブトキシエタノール、２−エトキシエチルアセテート、２−ブトキシエチルアセテート、２−メトキシエチルアセテート、２−エトキシエチルエーテル、２−（２−エトキシエトキシ）エタノール、２−（２−ブトキシエトキシ）エタノール、２−（２−エトキシエトキシ）エチルアセテート、２−（２−ブトキシエトキシ）エチルアセテート、２−フェノキシエタノール、ジエチレングリコールジメチルエーテル、ジエチレングリコールモノエチルエーテルアセテート、２−（２−ｎ−ブトキシエトキシ）エチルアセテート などを挙げることができる。
針方式、ディスペンス方式でも、針先に転写した着色材の過度の乾燥による転写不良や、ノズル先端での着色材乾燥による詰まりなどの防止に、上記、インキジェット方式に用いる溶剤と、ほぼ同等の沸点を有する溶剤の使用が望ましい。
また、使用する有機溶剤は、上記の例に限定されるものではなく、前記要件を満たす溶剤の使用が可能である。必要に応じて２種類以上の溶剤を混合して用いる事も差し支えない。
As an organic solvent, in addition to the dissolving power of the pigment-dispersing resin, dispersion stability in the colored pigment is essential, and characteristics such as surface tension and boiling point suitable for each correction method are required.
In the ink jet system, those having a surface tension range of 35 mN / m or less and a boiling point of 130 ° C. or more are preferable from the viewpoint of stability during ejection and nozzle clogging resistance. Ethoxyethanol, 2-butoxyethanol, 2-ethoxyethyl acetate, 2-butoxyethyl acetate, 2-methoxyethyl acetate, 2-ethoxyethyl ether, 2- (2-ethoxyethoxy) ethanol, 2- (2-butoxyethoxy) Ethanol, 2- (2-ethoxyethoxy) ethyl acetate, 2- (2-butoxyethoxy) ethyl acetate, 2-phenoxyethanol, diethylene glycol dimethyl ether, diethylene glycol monoethyl ether acetate, 2- (2-n-butoxyethoxy) ethyl acetate , And the like Tate.
The needle method and the dispense method are almost the same as the solvents used in the ink jet method described above to prevent transfer failure due to excessive drying of the coloring material transferred to the tip of the needle and clogging due to drying of the coloring material at the nozzle tip. It is desirable to use a solvent having a boiling point.
Moreover, the organic solvent to be used is not limited to said example, The use of the solvent which satisfy | fills the said requirements is possible. If necessary, two or more kinds of solvents may be mixed and used.
隔壁樹脂組成物および着色インキ樹脂組成物に用いる感光性樹脂として、水酸基、カルボキシル基、アミノ基等の反応性の置換基を有する線状高分子にイソシアネート基、アルデヒド基、エポキシ基等の反応性置換基を有する（メタ）アクリル化合物やケイヒ酸を反応させた、（メタ）アクリロイル基、スチリル基等の光架橋性基を該線状高分子に導入した樹脂が用いることができる。また、スチレン−無水マレイン酸共重合物やα−オレフィン−無水マレイン酸共重合物等の酸無水物を含む線状高分子をヒドロキシアルキル（メタ）アクリレート等の水酸基を有する（メタ）アクリル化合物によりハーフエステル化したものも用いられる。
また、透明樹脂の前駆体であるモノマーおよびオリゴマーの使用も可能であり、２−ヒドロキシエチル（メタ）アクリレート、２−ヒドロキシプロピル（メタ）アクリレート、シクロヘキシル（メタ）アクリレート、ポリエチレングリコールジ（メタ）アクリレート、ペンタエリスリトールトリ（メタ）アクリレート、トリメチロールプロパントリ（メタ）アクリレート、ジペンタエリスリトールヘキサ（メタ）アクリレート、トリシクロデカニル（メタ）アクリレート、メラミン（メタ）アクリレート、エポキシ（メタ）アクリレート等の各種アクリル酸エステルおよびメタクリル酸エステル、（メタ）アクリル酸、スチレン、酢酸ビニル、（メタ）アクリルアミド、Ｎ−ヒドロキシメチル（メタ）アクリルアミド、アクリロニトリル等が挙げられる。
The photosensitive resin used in the partition wall resin composition and the colored ink resin composition is a linear polymer having a reactive substituent such as a hydroxyl group, a carboxyl group, or an amino group, and a reactivity such as an isocyanate group, an aldehyde group, or an epoxy group. A resin in which a photo-crosslinkable group such as a (meth) acryloyl group or a styryl group obtained by reacting a (meth) acrylic compound having a substituent or cinnamic acid is introduced into the linear polymer can be used. Further, a linear polymer containing an acid anhydride such as a styrene-maleic anhydride copolymer or an α-olefin-maleic anhydride copolymer is converted into a (meth) acrylic compound having a hydroxyl group such as hydroxyalkyl (meth) acrylate. Half-esterified products are also used.
It is also possible to use monomers and oligomers that are precursors of transparent resins, such as 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, cyclohexyl (meth) acrylate, and polyethylene glycol di (meth) acrylate. , Pentaerythritol tri (meth) acrylate, trimethylolpropane tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, tricyclodecanyl (meth) acrylate, melamine (meth) acrylate, epoxy (meth) acrylate, etc. Acrylic acid esters and methacrylic acid esters, (meth) acrylic acid, styrene, vinyl acetate, (meth) acrylamide, N-hydroxymethyl (meth) acrylamide, acrylonitrile, etc. It is below.
さらに、紫外線硬化用光重合開始剤を添加させても良く、光重合開始剤として、４−フェノキシジクロロアセトフェノン、４−ｔ−ブチル−ジクロロアセトフェノン、ジエトキシアセトフェノン、１−（４−イソプロピルフェニル）−２−ヒドロキシ−２−メチルプロパン−１−オン、１−ヒドロキシシクロヘキシルフェニルケトン、２−メチル−１［４−（メチルチオ）フェニル］−２−モルフォリノプロパン−１−オン、２−ベンジル−２−ジメチルアミノ−１−（４−モルフォリノフェニル）−ブタン−１−オン等のアセトフェノン系光重合開始剤、ベンゾイン、ベンゾインメチルエーテル、ベンゾインエチルエーテル、ベンゾインイソプロピルエーテル、ベンジルジメチルケタール等のベンゾイン系光重合開始剤、ベンゾフェノン、ベンゾイル安息香酸、ベンゾイル安息香酸メチル、４−フェニルベンゾフェノン、ヒドロキシベンゾフェノン、アクリル化ベンゾフェノン、４−ベンゾイル−４’−メチルジフェニルサルファイド等のベンゾフェノン系光重合開始剤、チオキサントン、２−クロロチオキサントン、２−メチルチオキサントン、イソプロピルチオキサントン、２、４−ジイソプロピルチオキサントン等のチオキサントン系光重合開始剤、２、４、６−トリクロロ−ｓ−トリアジン、２−フェニル−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２−（ｐ−メトキシフェニル）−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２−（ｐ−トリル）−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２−ピペロニル−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２、４−ビス（トリクロロメチル）−６−スチリル−ｓ−トリアジン、２−（ナフト−１−イル）−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２−（４−メトキシ−ナフト−１−イル）−４、６−ビス（トリクロロメチル）−ｓ−トリアジン、２、４−トリクロロメチル−（ピペロニル）−６−トリアジン、２、４−トリクロロメチル（４’−メトキシスチリル）−６−トリアジン等のトリアジン系光重合開始剤、ボレート系光重合開始剤、カルバゾール系光重合開始剤、イミダゾール系光重合開始剤等が挙げられる。 Further, a photopolymerization initiator for ultraviolet curing may be added. As the photopolymerization initiator, 4-phenoxydichloroacetophenone, 4-t-butyl-dichloroacetophenone, diethoxyacetophenone, 1- (4-isopropylphenyl)- 2-hydroxy-2-methylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1 [4- (methylthio) phenyl] -2-morpholinopropan-1-one, 2-benzyl-2- Acetophenone photopolymerization initiators such as dimethylamino-1- (4-morpholinophenyl) -butan-1-one, benzoin photopolymerization such as benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, and benzyldimethyl ketal Initiator, benzophenone, Benzophenone photopolymerization initiators such as benzoylbenzoic acid, methyl benzoylbenzoate, 4-phenylbenzophenone, hydroxybenzophenone, acrylated benzophenone, 4-benzoyl-4'-methyldiphenyl sulfide, thioxanthone, 2-chlorothioxanthone, 2-methyl Thioxanthone photopolymerization initiators such as thioxanthone, isopropylthioxanthone, 2,4-diisopropylthioxanthone, 2,4,6-trichloro-s-triazine, 2-phenyl-4,6-bis (trichloromethyl) -s-triazine, 2- (p-methoxyphenyl) -4,6-bis (trichloromethyl) -s-triazine, 2- (p-tolyl) -4,6-bis (trichloromethyl) -s-triazine, 2-piperonyl-4 , 6-bis (trick (Romethyl) -s-triazine, 2,4-bis (trichloromethyl) -6-styryl-s-triazine, 2- (naphth-1-yl) -4,6-bis (trichloromethyl) -s-triazine, 2, -(4-Methoxy-naphth-1-yl) -4,6-bis (trichloromethyl) -s-triazine, 2,4-trichloromethyl- (piperonyl) -6-triazine, 2,4-trichloromethyl (4 Examples include triazine photopolymerization initiators such as' -methoxystyryl) -6-triazine, borate photopolymerization initiators, carbazole photopolymerization initiators, and imidazole photopolymerization initiators.
上記、光重合開始剤は、単独でまたは２種以上混合して用いることもできるが、増感剤として、α−アシロキシエステル、アシルフォスフィンオキサイド、メチルフェニルグリオキシレート、ベンジル、９、１０−フェナンスレンキノン、カンファーキノン、エチルアンスラキノン、４、４’−ジエチルイソフタロフェノン、３、３’、４、４’−テトラ（ｔ−ブチルパーオキシカルボニル）ベンゾフェノン、４、４’−ジエチルアミノベンゾフェノン等の化合物の併用も差し支えない。 The above photopolymerization initiators can be used alone or in admixture of two or more. As sensitizers, α-acyloxy ester, acylphosphine oxide, methylphenylglyoxylate, benzyl, 9, 10 -Phenanthrenequinone, camphorquinone, ethylanthraquinone, 4,4'-diethylisophthalophenone, 3,3 ', 4,4'-tetra (t-butylperoxycarbonyl) benzophenone, 4,4'-diethylamino A compound such as benzophenone may be used in combination.
着色インキ層の顔料分散性向上には、分散剤の使用が可能であり、非イオン性界面活性剤として、例えば、ポリオキシエチレンアルキルエーテルなどが、また、イオン性界面活性剤として、例えば、アルキルベンゼンスルホン酸ナトリウム、ポリ脂肪酸塩、脂肪酸塩アルキルリン酸塩、テトラアルキルアンモニウム塩などが、その他、有機顔料誘導体、樹脂型顔料分散剤などがあげられる。一種類の分散剤を単独で、また、二種類以上を混合してもよい。 In order to improve the pigment dispersibility of the colored ink layer, it is possible to use a dispersant. Examples of the nonionic surfactant include polyoxyethylene alkyl ether, and examples of the ionic surfactant include alkylbenzene. Examples thereof include sodium sulfonate, poly fatty acid salt, fatty acid salt alkyl phosphate, tetraalkyl ammonium salt, and other organic pigment derivatives and resin-type pigment dispersants. One type of dispersant may be used alone, or two or more types may be mixed.
樹脂型顔料分散剤としては、顔料に吸着する性質を有する顔料親和性部位と、色素担体と相溶性のある部位とを有し、顔料に吸着して顔料の色素担体への分散を安定化する働きをするものである。具体的には、ポリウレタン、ポリアクリレートなどのポリカルボン酸エステル、不飽和ポリアミド、ポリカルボン酸、ポリカルボン酸（部分）アミン塩、ポリカルボン酸アンモニウム塩、ポリカルボン酸アルキルアミン塩、ポリシロキサン、長鎖ポリアミノアマイドリン酸塩、水酸基含有ポリカルボン酸エステルや、これらの変性物、ポリ（低級アルキレンイミン）と遊離のカルボキシル基を有するポリエステルとの反応により形成されたアミドやその塩などの油性分散剤、（メタ）アクリル酸−スチレン共重合体、（メタ）アクリル酸−（メタ）アクリル酸エステル共重合体、スチレン−マレイン酸共重合体、ポリエステル系、変性ポリアクリレート系、エチレンオキサイド／プロピレンオキサイド付加化合物、燐酸エステル系等が挙げられ、これらは単独でまたは２種以上を混合して用いることができる。 The resin-type pigment dispersant has a pigment-affinity part that has the property of adsorbing to the pigment and a part that is compatible with the dye carrier, and adsorbs to the pigment to stabilize the dispersion of the pigment on the dye carrier. It works. Specifically, polycarboxylic acid esters such as polyurethane and polyacrylate, unsaturated polyamide, polycarboxylic acid, polycarboxylic acid (partial) amine salt, polycarboxylic acid ammonium salt, polycarboxylic acid alkylamine salt, polysiloxane, long Oil-based dispersants such as chain polyaminoamide phosphates, hydroxyl group-containing polycarboxylic acid esters, their modified products, amides formed by the reaction of poly (lower alkyleneimines) and polyesters having free carboxyl groups, and salts thereof , (Meth) acrylic acid-styrene copolymer, (meth) acrylic acid- (meth) acrylic acid ester copolymer, styrene-maleic acid copolymer, polyester-based, modified polyacrylate-based, ethylene oxide / propylene oxide addition Compounds, phosphate esters, etc. These may be used alone or in admixture of two or more thereof.
ＲＧＢ各色着色材の粘度が低く、修正時の流動が大きいと、隔壁を越えて他色の着色インキ層上に積層される恐れがあるため、隔壁修正用の黒色着色材に撥インキ性を付与することが望ましい。撥インキ性付与の成分としては、前記、樹脂材料との相溶性が良好で、着色材との接触角が６０°以上となるものが望ましく、主鎖または側鎖に有機シリコーンを有するシロキサン成分を含有するシリコーン樹脂やシリコーンゴムなどのシリコン系化合物や、フッ化ビニリデン、フッ化ビニル、三フッ化エレレンなどのフッ素系化合物などを用いることができる。 If the viscosity of each color material of RGB is low and the flow at the time of correction is large, there is a risk that it will be laminated on the colored ink layer of other colors beyond the partition wall, so ink repellency is imparted to the black color material for partition wall correction It is desirable to do. As the component for imparting ink repellency, those having good compatibility with the resin material and having a contact angle with the colorant of 60 ° or more are desirable, and a siloxane component having an organic silicone in the main chain or side chain is used. Silicon compounds such as silicone resin and silicone rubber, fluorine compounds such as vinylidene fluoride, vinyl fluoride, and erylene trifluoride can be used.
着色インキ層及び隔壁の欠陥修正手段として、インキ吐出印刷方式、針方式、ディスペンス方式、熱転写方式を用いることができる。インキ吐出印刷方式のヘッドは、ピエゾ方式とサーマルヘッド方式に大別され、ピエゾ方式の場合、粒子化周波数が５〜１００ＫＨｚ程度、ノズル径は５〜８０μｍ程度であり、ＲＧＢ各色の着色材の詰まりなどを考慮して、各色毎のヘッドにノズルを１０以上組み込んだ装置が好適である。
針方式では、先端の針径が３０〜１００μｍ程度であり、隔壁用着色材とＲＧＢ各色着色材とを、適度に付着可能な先端形状、表面性を有する針を、塗布位置へと適切に制御可能な装置が好適である。
ディスペンス方式では、吐出口先端の口径が１０〜１００μｍ程度であり、隔壁用着色材とＲＧＢ各色着色材とを、精密に吐出制御し、吐出位置への適切な制御可能な装置が好適である、
熱転写方式では、ＲＧＢ各色の熱転写着色材を、適切な長さで、精密に転写制御可能な感熱ヘッドを有する装置が好適である。
修正の要求に応じて、隔壁修正用と、着色インキ層修正用ヘッドの方式を選定して用いる。
As the defect correcting means for the colored ink layer and the partition wall, an ink discharge printing method, a needle method, a dispensing method, and a thermal transfer method can be used. Ink ejection printing heads are broadly divided into piezo and thermal heads. In the case of the piezo, the particle frequency is about 5 to 100 KHz, the nozzle diameter is about 5 to 80 μm, and clogging of colorants for each color of RGB. In consideration of the above, an apparatus in which 10 or more nozzles are incorporated in the head for each color is suitable.
In the needle method, the needle diameter at the tip is about 30 to 100 μm, and the needle having the tip shape and surface property capable of adhering the partitioning colorant and RGB colorant appropriately can be appropriately controlled to the application position. Possible devices are preferred.
In the dispensing method, the diameter of the tip of the discharge port is about 10 to 100 μm, and it is preferable to accurately control the partition wall colorant and each of the RGB colorants and appropriately control the discharge position.
In the thermal transfer system, an apparatus having a thermal head capable of accurately controlling the transfer of the thermal transfer coloring materials for each color of RGB with an appropriate length is suitable.
According to the request for correction, a head for correcting the partition wall and a head for correcting the colored ink layer is selected and used.
以下に本発明の実施例を具体的に説明する。
＜実施例１＞
［着色インキ樹脂組成物及び隔壁樹脂組成物の調製］
メタクリル酸２０部、メチルメタクリレート１０部、ブチルメタクリレート５５部、ヒドロキシエチルメタクリレート１５部を、乳酸ブチル３００ｇに溶解し、窒素雰囲気下でアゾビスイソブチルニトリル０．７５部を加え７０℃にて５時間の反応によりアクリル共重合樹脂を得た。アクリル共重合樹脂を樹脂濃度が１０％になるようにプロピレングリコールモノメチルエーテルアセテートで希釈し、アクリル共重合樹脂の希釈液とした。希釈液８０．１ｇに対し、ＲＧＢ用顔料各１９．０ｇ、分散剤０．９ｇを添加し、３本ロールにて混練し、Ｒ、Ｇ、Ｂの各着色ワニスを得た。各色の着色ワニスに、プロピレングリコールモノメチルエーテルアセテートを添加して顔料濃度が１２〜１５％、粘度が１５ｃｐｓとなるよう調整し、Ｒ、Ｇ、Ｂ各色の着色インキ樹脂組成物を製作した。
Examples of the present invention will be specifically described below.
<Example 1>
[Preparation of colored ink resin composition and partition resin composition]
20 parts of methacrylic acid, 10 parts of methyl methacrylate, 55 parts of butyl methacrylate and 15 parts of hydroxyethyl methacrylate are dissolved in 300 g of butyl lactate, and 0.75 part of azobisisobutylnitrile is added under a nitrogen atmosphere at 70 ° C. for 5 hours. An acrylic copolymer resin was obtained by the reaction. The acrylic copolymer resin was diluted with propylene glycol monomethyl ether acetate so as to have a resin concentration of 10% to obtain a diluted solution of the acrylic copolymer resin. 19.0 g of RGB pigments and 0.9 g of dispersant were added to 80.1 g of the diluent, and kneaded with three rolls to obtain R, G, and B colored varnishes. Propylene glycol monomethyl ether acetate was added to the colored varnish of each color to adjust the pigment concentration to 12 to 15% and the viscosity to 15 cps, thereby producing colored ink resin compositions of R, G, and B colors.
［カラーフィルタ着色インキ層、隔壁の形成］
基板上に隔壁樹脂組成物を塗布し、これをパターン露光した後、現像し、熱硬化し、隔壁を得た。この基板上に設けられた隔壁の開口部にインキ吐出印刷方式により、着色インキ層を形成した。
[Formation of color filter coloring ink layer and partition wall]
A partition wall resin composition was applied on the substrate, and this was pattern-exposed, developed, and thermally cured to obtain partition walls. A colored ink layer was formed by an ink discharge printing method at an opening of a partition wall provided on the substrate.
［カラーフィルタ隔壁の修正］
前記、調整した着色インキ樹脂組成物と同等の顔料を使用し、着色ワニスの希釈溶剤を、シクロヘキサノンにして、顔料濃度が２０〜２５％、粘度が４０ｃｐｓとなるよう調整した隔壁用修正材で、顔料分散方式で製造されたカラーフィルタのブラックマトリックス部の修正を行った。
まず、製造ラインの光学検査装置で着色インキ層の欠陥を検査し、この情報から、隔壁欠陥を判別し、隔壁欠陥の位置データを取得した隔壁のピンホール欠陥周辺に、第三高調波ＹＡＧレーザ光（３５５ｎｍ、２ｍＪ／パルス、ＨＯＹＡ社製）を照射して、ピンホール欠陥を整形して、３０μｍ□のピンホールとした。
次に、先端径５０μｍの修正針を搭載した針方式修正ヘッドで、形成されたピンホール欠陥に、隔壁用修正剤を塗布、被覆した。この時、十分な光学濃度で修正できるように、５回の重ね塗りを行った。
修正後のカラーフィルタを、オーブンによる２００℃１５分の乾燥で、各色着色材の熱硬化を行った後、ＩＴＯ工程以降の後工程を実施し、修正部と周囲との色差が５以下であり、目視では修正部を認識し得ず、修正部周辺の平坦性が良好なカラーフィルタを得ることができた。
［カラーフィルタ着色インキ層の修正］
前記、調整した着色インキ樹脂組成物と同等の顔料を使用して、インキ吐出印刷方式で設けられた着色インキ層の修正を行った。
前記の隔壁の修正の際に得た着色インキ層の欠陥の位置データを用いて、着色インキ層の異物欠陥周辺に、第三高調波ＹＡＧレーザ光（３５５ｎｍ、２ｍＪ／パルス、ＨＯＹＡ社製）を照射して、異物欠陥を除去して、５０μｍ□のピンホールを形成した。
次に、１２ｐｌ、１８０ｄｐｉヘッド（セイコーインスツルメンツ社製）を搭載したインキジェット修正ヘッドから、形成された各色のピンホールに、必要なＲ、Ｇ、Ｂ各色の着色インキ樹脂組成物を吐出し、ピンホールを被覆した。この時、着色インキ樹脂組成物量は、欠陥部周辺のカラーフィルタ光学濃度と適合するよう、３６ｐｌ〜４８ｐｌで重ね打ちを行った。
修正後のカラーフィルタを、オーブンによる２００℃１５分の乾燥で、各色着色インキ樹脂組成物の熱硬化を行った後、ＩＴＯ工程以降の後工程を実施し、修正部と周囲との色差が５以下であり、目視では修正部を認識し得ず、修正部周辺の平坦性が良好なカラーフィルタを得ることができた。
[Correction of color filter partition]
Using the same pigment as the adjusted colored ink resin composition, the diluted solvent for the colored varnish is cyclohexanone, and the correction material for the partition wall is adjusted so that the pigment concentration is 20 to 25% and the viscosity is 40 cps, The black matrix part of the color filter manufactured by the pigment dispersion method was corrected.
First, a defect in the colored ink layer is inspected by an optical inspection device on the production line, and from this information, the partition defect is determined, and the position data of the partition defect is obtained. Irradiated with light (355 nm, 2 mJ / pulse, manufactured by HOYA), the pinhole defect was shaped to form a 30 μm □ pinhole.
Next, with a needle type correction head equipped with a correction needle having a tip diameter of 50 μm, a partition correction agent was applied to and coated on the formed pinhole defect. At this time, five times of overcoating were performed so that correction was possible with sufficient optical density.
The color filter after correction is dried in an oven at 200 ° C. for 15 minutes to thermally cure each color material, and then the ITO process and subsequent steps are performed. The color difference between the corrected portion and the surrounding area is 5 or less. The correction part could not be recognized visually, and a color filter with good flatness around the correction part could be obtained.
[Correction of color filter coloring ink layer]
Using the same pigment as the adjusted colored ink resin composition, the colored ink layer provided by the ink ejection printing method was corrected.
A third harmonic YAG laser beam (355 nm, 2 mJ / pulse, manufactured by HOYA Co., Ltd.) is used around the foreign matter defect of the colored ink layer using the position data of the defect of the colored ink layer obtained at the time of correcting the partition wall. Irradiation was performed to remove foreign matter defects, and 50 μm □ pinholes were formed.
Next, from the ink jet correction head equipped with a 12 pl, 180 dpi head (manufactured by Seiko Instruments Inc.), the required colored ink resin composition of each R, G, B color is discharged into the pinhole of each color formed, and the pin The hole was covered. At this time, overprinting was performed at 36 pl to 48 pl so that the amount of the colored ink resin composition matched the optical density of the color filter around the defect.
The color filter after correction is dried in an oven at 200 ° C. for 15 minutes to thermally cure each colored ink resin composition, and then the post-process after the ITO process is performed. The color difference between the corrected portion and the surrounding area is 5 The correction part was not recognized visually, and a color filter with good flatness around the correction part could be obtained.
＜実施例２＞ <Example 2>
実施例１の隔壁樹脂組成物に、大日本インキ化学工業（株）製フッ素系界面活性剤メガファック３５０Ｃを、固形分に対して０。５％添加した隔壁用樹脂組成物を使用し、第三高調波ＹＡＧレーザ光でのピンホール欠陥を整形を、１００μｍ□とした他は、実施例１と同様の方法で、カラーフィルタの隔壁部のピンホール欠陥修正を行った。この時、ピンホール欠陥部の大きさに対して、針方式修正ヘッドで塗布可能な直径は、約６０μｍと小さいため、数回の塗布修正を、修正位置を移動させながら行い、ブラックマトリックスのピンホール部を覆うような楕円形の修正痕を形成した。ここで、再度、第三高調波ＹＡＧレーザ光で、修正部形状を直線に整形することによって、良好な形状にブラックマトリックスを再建できた。
第三高調波ＹＡＧレーザ光の照射時に、ブラックマトリックス周辺のカラーフィルタ着色インキ層にも、ピンホールが形成されたため、実施例１と同様のインキジェット修正ヘッドから、インキを吐出して修正した所、インキがブラックマトリックス修正部に乗り上げたり、他色の画素へと流動することなく、良好な形状と濃度で修正が可能であった。
A partition wall resin composition obtained by adding 0.5% of the fluorosurfactant Megafac 350C manufactured by Dainippon Ink & Chemicals, Inc. to the solid content to the partition wall resin composition of Example 1 was used. A pinhole defect in the partition wall of the color filter was corrected in the same manner as in Example 1 except that the pinhole defect in the third harmonic YAG laser beam was shaped to 100 μm □. At this time, since the diameter that can be applied by the needle type correction head is as small as about 60 μm with respect to the size of the pinhole defect portion, the application correction is performed several times while moving the correction position, and the pin of the black matrix An elliptical correction mark covering the hole portion was formed. Here, the black matrix could be reconstructed into a good shape by shaping the corrected portion shape into a straight line again with the third harmonic YAG laser light.
Since pinholes were also formed in the color filter colored ink layer around the black matrix when the third harmonic YAG laser light was irradiated, the ink was corrected by ejecting ink from the same ink jet correction head as in Example 1. The ink could be corrected with a good shape and density without running over the black matrix correction portion or flowing to other color pixels.
なお、実施例において、カラーＬＣＤ用カラーフィルタで説明したが、これに限定されるものではなく、色を分離して表示させるで用途あれば、どのようなカラーフィルタで実施してもよい。例えば、ＣＣＤ用カラーフィルや、投影装置用カラーフィルタに、本発明を適用してもよい。 In the embodiment, the color filter for color LCD has been described. However, the present invention is not limited to this, and any color filter may be used as long as the color is separated and displayed. For example, the present invention may be applied to a color filter for a CCD or a color filter for a projection apparatus.
以上説明した様に、本発明によれば、カラーフィルタの隔壁の欠陥修正と、着色インキ層の欠陥修正とを、各々に発生する欠陥状況や、修正後の要求特性に合わせられるように、異なる方式の修正方法を、一台の修正装置で適切に使用する事で、隔壁欠陥に被覆形成する修正部の形状、膜厚、光学濃度と、着色インキ層欠陥に被覆形成する修正部の形状、膜厚、色濃度とを、最適に修正できる。そのため、正常部と、欠陥修正部周辺の膜厚差が少なく、ＬＣＤパネルでの液晶配向を乱す事の少ない、良好なカラーフィルタ修正方法の提供が可能となる。
また、隔壁の欠陥を、黒色の撥インキ性を有する隔壁樹脂組成物で修正する事で、インキジェットヘッドなどから吐出、塗布されるインキが、過剰に流動することが無く、修正部と周辺部の色差が少なく、修正部が目立たないカラーフィルタの欠陥修正が可能である。
加えて、本発明によれば、一台の修正装置で、隔壁と着色インキ層修正を、適正な方式で行えるので、修正コストの低減と、設置面積の節減と共に、高い修正能力を持つため、基板大板化などによる欠陥数増加に対しても、少ない台数の修正装置での対応が可能となる。
As described above, according to the present invention, the defect correction of the partition wall of the color filter and the defect correction of the colored ink layer are different from each other so as to match the defect situation occurring in each and the required characteristics after the correction. By properly using the correction method of the method with a single correction device, the shape of the correction part, the film thickness, the optical density, and the correction part shape to cover the colored ink layer defect, Film thickness and color density can be optimally corrected. Therefore, it is possible to provide an excellent color filter correction method in which the difference in film thickness between the normal part and the defect correction part is small and the liquid crystal alignment on the LCD panel is not disturbed.
In addition, by correcting the defect of the partition wall with a black partition wall resin composition having ink repellency, the ink ejected and applied from an ink jet head or the like does not flow excessively, and the corrected section and the peripheral section Therefore, it is possible to correct the defect of the color filter in which the color difference is small and the correction part is not noticeable.
In addition, according to the present invention, since the partition and the colored ink layer can be corrected with a single correction device in an appropriate manner, the correction cost can be reduced, and the installation area can be reduced, so that it has a high correction capability. Even if the number of defects is increased due to an increase in the size of the substrate, it is possible to cope with a small number of correction devices.
１ カラーフィルタ
２ 修正装置
１０ 基板
１１ 隔壁
１２ 着色インキ層
１３ 表面張力調整層
１４ 透明電極
１５ ＭＶＡ層
１６ ＰＳ層
２０ 移動ステージ
２１ レーザリペア機構（紫外〜赤外レーザ）
２２ レーザリペア機構（紫外レーザ）
２３ インキジェット方式修正ヘッド
２４ 針方式修正ヘッド
２５ ディスペンス方式修正ヘッド
３１ ピンホール欠陥（隔壁内）
３２ 異物欠陥（隔壁内）
３３ 異物欠陥（隔壁外）
３４ 修正部（隔壁内）
４１ ピンホール欠陥（着色インキ層内）
４２ 異物欠陥（着色インキ層内）
４３ 修正部（着色インキ層内）
DESCRIPTION OF SYMBOLS 1 Color filter 2 Correction apparatus 10 Board | substrate 11 Partition 12 Colored ink layer 13 Surface tension adjustment layer 14 Transparent electrode 15 MVA layer 16 PS layer 20 Moving stage 21 Laser repair mechanism (ultraviolet to infrared laser)
22 Laser repair mechanism (ultraviolet laser)
23 Ink jet method correction head 24 Needle method correction head 25 Dispense method correction head 31 Pinhole defect (inside partition wall)
32 Foreign object defect (in the partition)
33 Foreign object defect (outside partition wall)
34 Correction (in the partition)
41 Pinhole defect (in the colored ink layer)
42 Foreign matter defects (in the colored ink layer)
43 Correction (in the colored ink layer)
Claims (10)
（ａ）基板上に隔壁樹脂を塗布する工程と、
（ｂ）この基板の隔壁樹脂が塗布された面を、隔壁パターン状に露光する工程と、
（ｃ）この基板を現像し、隔壁を形成する工程と、
（ｄ）この基板を加熱し、隔壁を熱硬化させる工程と、
（ｅ）この基板の隔壁の開口部に形成された領域に、インキ吐出印刷装置を用いてインキを吐出しインキ層を形成する工程と、
（ｆ）このインキ層の異物、ピンホールからなる欠陥を検出する工程と、
（ｇ）この検出結果から異物、ピンホールからなる欠陥を分類してＮＧ規格となる欠陥位置情報を記録する工程と、
（ｈ）この隔壁の欠陥部分を修正する工程と、を行うことを特徴とする印刷物の製造方法。
In a method for producing a printed matter comprising a substrate, a partition wall provided in a pattern on the substrate, and an ink layer provided in an opening section partitioned by the partition wall, at least,
(A) applying a partition resin on the substrate;
(B) a step of exposing the surface of the substrate on which the partition wall resin is applied to a partition pattern;
(C) developing the substrate to form partition walls;
(D) heating the substrate and thermosetting the partition;
(E) forming a layer of ink by discharging ink using an ink discharge printing device to a region formed in the opening of the partition wall of the substrate;
(F) detecting a defect consisting of foreign matter and pinholes in the ink layer ;
(G) A step of classifying defects consisting of foreign matter and pinholes from this detection result and recording defect position information that is NG standard ,
And (h) a step of correcting a defective portion of the partition wall.
（ｈ１）この隔壁の欠陥部に隔壁と同じ材料を被覆形成する工程と、
（ｈ２）この隔壁を熱硬化若しくは光硬化させる工程と、
（ｈ３）紫外〜赤外レーザ光の照射により修正部を整形する工程と、
を含むことを特徴とする請求項１に記載の印刷物の製造方法。
(H) The step of correcting the defective part of the partition wall includes:
(H1) A step of coating the same material as the partition wall on the defect portion of the partition wall;
(H2) a step of thermosetting or photocuring the partition;
(H3) shaping the correction portion by irradiation with ultraviolet to infrared laser light ;
The method for producing a printed matter according to claim 1, comprising:
前記（Ｉ）インキ層の異物、欠陥を修正する工程を、
前記基板をワークに固定したまま順次行なうことを特徴とする請求項２又は３に記載の印刷物の製造方法。 (H) a step of correcting a defective portion of the partition wall, and (I) a step of correcting foreign matter and defects of the ink layer,
The method for producing a printed matter according to claim 2, wherein the substrate is sequentially fixed while being fixed to a workpiece.
かつ（Ｉ）インキ層の異物、欠陥を修正する工程の修正方法が、インキ吐出印刷方式、針方式、ディスペンス方式、熱転写方式から選択されることを特徴とする請求項２〜４のいずれかに記載の印刷物の製造方法。 (H) The correction method of the step of correcting the defective portion of the partition wall is selected from a needle method and a dispense method,
And (I) the correction method of the process which corrects the foreign material of an ink layer, and a defect is selected from an ink discharge printing system, a needle system, a dispense system, and a thermal transfer system. The manufacturing method of printed matter of description.
（Ｉ１）着色インキ層の欠陥部の面積によって、インキジェット方式、針方式、ディスペンス方式、若しくは熱転写方式を単独、若しくは組み合わせて使用し、着色インキ層の周辺部との膜厚差が０．１μｍ以下で、色差がΔＥａｂ＜５以下となるように、着色インキ層と同色の着色材料を欠陥部に被覆形成し、その後、熱硬化、若しくは光硬化させる事を特徴とする請求項７に記載の印刷物の製造方法。 (I) The process of correcting foreign matter and defects in the ink layer includes:
(I1) Depending on the area of the defective portion of the colored ink layer, an ink jet method, a needle method, a dispensing method, or a thermal transfer method is used alone or in combination, and the film thickness difference from the peripheral portion of the colored ink layer is 0.1 μm. The coloring material having the same color as that of the colored ink layer is formed on the defective portion so that the color difference is equal to or less than ΔEab <5, and then thermally cured or photocured. Manufacturing method of printed matter.
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| JP2003066218A (en) * | 2001-08-28 | 2003-03-05 | Canon Inc | Method for repairing defect in color filter |
| JP2004119243A (en) * | 2002-09-27 | 2004-04-15 | Dainippon Printing Co Ltd | Method of removing defect in organic electro-luminescent device |
| JP4552390B2 (en) * | 2003-06-17 | 2010-09-29 | セイコーエプソン株式会社 | Manufacturing method of organic EL device |
| JP4676141B2 (en) * | 2003-09-30 | 2011-04-27 | 大日本印刷株式会社 | Color filter manufacturing method and manufacturing apparatus thereof |
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