JP5083695B2 - Display device manufacturing method, display device manufacturing apparatus, and electronic apparatus - Google Patents

Description

The present invention relates to a manufacturing method of a display device used for display of a personal computer, a mobile phone, etc., a manufacturing device of the display device, and an electronic apparatus.

  As such a display device, for example, there is a display device in which liquid crystal is formed on a flexible substrate and bonded to a counter substrate via a seal frame provided on the outer periphery of the liquid crystal. In the manufacture of this display device, a seal frame having an opening in a part is formed on one substrate and bonded to an opposing substrate without interposing a liquid crystal, and a bonded product of upper and lower substrates without liquid crystal is used. Liquid crystal is injected into the seal frame by capillary action by creating an empty cell and removing the air inside the empty cell under vacuum, then touching the liquid crystal and the opening of the seal frame and releasing to atmospheric pressure An injection method is widely known (Patent Document 1).

In addition, as a means of improving productivity as the display device is enlarged, it is formed on the substrate without providing an opening in the seal frame, and an appropriate amount of liquid crystal that fits in the seal frame is dropped by a precision dispenser or the like. A liquid crystal dropping method in which the substrate is bonded to an opposing substrate under vacuum has also been used (Patent Document 1).
Japanese Patent No. 3084975

  By the way, such a manufacturing method of a display device is considered to have a problem from the viewpoint of productivity. For example, the former liquid crystal injection method uses a gap and an opening to make the display device have a predetermined thickness after the injection. It is necessary to seal the part. In particular, when the display device is enlarged, it takes a lot of time. Further, in the latter liquid crystal dropping method, if the amount of liquid crystal is not controlled fairly accurately, unevenness occurs in the gap that makes the display device have a predetermined thickness, causing display defects.

The present invention has been made in view of the above points, and provides a display device manufacturing method, a display device manufacturing apparatus, and an electronic apparatus that can prevent display unevenness with a simple configuration and can improve production efficiency. The purpose is that.

In order to solve the above problems and achieve the object, the present invention is configured as follows.
According to the first aspect of the present invention, at least one of the opposing substrates has a plurality of pixels, at least the other substrate has a drive circuit, one of the substrates is plastic and roll-shaped, and the other The substrate is a plate-like, and is a method for manufacturing a display device for manufacturing a display device by bonding the opposing substrates,
A seal frame forming step of forming a seal frame on the plate-like substrate with a sealant;
Forming a liquid crystal within the seal frame of the plate-like substrate;
A substrate laminating step for laminating the plate substrate and the roll substrate facing each other;
Having at least
In the seal frame forming step, a first seal frame that stores a predetermined amount of liquid crystal, and a second seal frame outside at least one side of the first seal frame,
In the liquid crystal forming step, a liquid crystal larger than a predetermined amount is formed in the first seal frame,
In the substrate bonding step,
Unwinding the rolled substrate by an unwinding section,
The roll substrate is overlaid on the plate substrate,
Pressure is applied while the roll-shaped substrate is bent from the side of the first seal frame, the center of the first seal frame, or the corner of the first seal frame by a flexible pressing member. Gradually added air to push out excess liquid crystal in the first seal frame in the second seal frame and paste the roll substrate and the plate substrate facing each other,
A manufacturing method of a display device, wherein the roll-shaped substrate is punched and a display device in which opposing substrates are bonded is manufactured, and a punching remaining portion of the roll-shaped substrate is wound around a winding shaft.

According to a second aspect of the present invention, at least one of the opposing substrates has a plurality of pixels, at least the other substrate has a drive circuit, one substrate is plastic and roll-shaped, and the other substrate The substrate is a plate, and is a display device manufacturing apparatus that manufactures a display device by bonding the opposing substrates.
An unwinding section for unwinding the roll-shaped substrate;
A winding unit for winding the roll-shaped substrate;
Seal frame forming means for forming a seal frame on the plate-like substrate with a sealant;
Liquid crystal forming means for forming liquid crystal in a seal frame of the plate-like substrate;
Substrate laminating means for laminating the plate substrate and the roll substrate facing each other;
Comprising at least
Forming a first seal frame for storing a predetermined amount of liquid crystal and a second seal frame outside at least one side of the first seal frame on the plate-like substrate by the seal frame forming means;
By the liquid crystal forming means, a liquid crystal larger than a predetermined amount is formed in the first seal frame,
The substrate bonding means is
Unwinding the rolled substrate by the unwinding part,
The roll substrate is overlaid on the plate substrate,
Pressure is applied while the roll-shaped substrate is bent from the side of the first seal frame, the center of the first seal frame, or the corner of the first seal frame by a flexible pressing member. Gradually added air to push out excess liquid crystal in the first seal frame in the second seal frame and paste the roll substrate and the plate substrate facing each other,
While manufacturing the display apparatus which stamped the said roll-shaped board | substrate and bonded the board | substrate which opposes, the punching remainder of the said roll-shaped board | substrate is wound up to a winding shaft, It is a manufacturing apparatus of the display apparatus characterized by the above-mentioned.

According to a third aspect of the present invention, there is provided an electronic apparatus comprising the display device manufactured by the display device manufacturing method according to the first aspect.

  With the above configuration, the present invention has the following effects.

  In the invention described in claim 1 and claim 2, at least one of the substrates is plastic and roll-shaped, and when the sealing agent is formed on one of the substrates, the second outside of the desired first seal frame is provided. By providing the seal frame, a slightly larger amount of liquid crystal than the predetermined amount is formed in the first seal frame, and the excess liquid crystal in the first seal frame is removed from the first seal by pasting the opposing substrates. Since the liquid is contained in the second seal frame beyond the frame, the liquid crystal in the first seal frame becomes uniform, the display device can have a predetermined thickness, and display unevenness can be prevented with a simple configuration. Further, since the excess liquid crystal leaking from the first seal frame is stored in the second seal frame, the excess liquid crystal does not leak and contaminates the apparatus, and the production efficiency can be improved with a simple configuration. .

  The invention described in claim 3 includes the display device manufactured by the joining method in the display device described in claim 1, and the display device is thin and lightly difficult to break, and it is possible to prevent the occurrence of display unevenness. is there.

Hereinafter, embodiments of a display device manufacturing method, a display device manufacturing apparatus, and an electronic apparatus according to the present invention will be described. However, the embodiment of the present invention shows the most preferable embodiment of the present invention. It is not limited to this. 1 is a cross-sectional view of a display device, FIG. 2 is a schematic view of a manufacturing process of the display device, FIG. 3 is a side view showing a seal frame forming step, FIG. 4 is a plan view showing the seal frame forming step, and FIG. FIG. 6 is a plan view showing a seal frame forming process of another embodiment, FIG. 7 is a side view showing a liquid crystal forming process, and FIG. 8 shows a liquid crystal forming process. FIG. 9 is a side view before transfer showing a liquid crystal forming process of another embodiment, FIG. 10 is a side view after transfer showing a liquid crystal forming process of another embodiment, and FIG. 11 is a substrate bonding process. 12 is a plan view showing the liquid crystal before bonding in the substrate bonding step, FIG. 13 is a plan view showing the liquid crystal after bonding in the substrate bonding step, and FIG. 14 is a bonding in the substrate bonding step. The top view which shows the liquid crystal of other embodiment after combining, FIG. 15 is a side view which shows the board | substrate bonding process of other embodiment, FIG. The top view which shows the liquid crystal before the bonding of the board | substrate bonding process of embodiment, FIG. 17 is the top view which shows the liquid crystal after the bonding of the board | substrate bonding process of other embodiment, FIG. 18 is a perspective view of a personal computer. 19 and 19 are perspective views of the mobile phone.

  First, the configuration of a display device according to the present invention will be described with reference to FIG. The display device 101 according to this embodiment includes a first substrate 110, a second substrate 120, a liquid crystal 130 interposed between the first substrate 110 and the second substrate 120, and a first substrate. 110 and a seal frame 140 formed by applying a sealant that bonds the second substrate 120 together.

  The first substrate 110 is an array substrate having a plurality of pixels, and has a structure in which a thin film switching element 112 is formed on a glass 111. Examples of the thin film switching element 112 include a thin film diode, an amorphous silicon thin film transistor, and a polysilicon thin film transistor. Of the above, it is preferable to use a polysilicon thin film transistor because the mobility is high and the switching element can be formed in a small area and the drive circuit can be formed.

  The second substrate 120 is plastic and roll-shaped, and is made of, for example, a plastic film 121. Examples of the plastic film 121 include polyethylene naphthalate, aromatic polyamide, polyimide, polybenzothiazole, and polybenzoxazole.

  The second substrate 120 includes a driving circuit 122 and drives the liquid crystal 130. The drive circuit 122 is configured by a transparent electrode. The second substrate 120 may or may not have the driving circuit 122 depending on the driving mode of the liquid crystal 130. When the driving mode of the liquid crystal 130 is twisted nematic (TN), vertical alignment, polymer dispersion, or the like, the driving circuit 122 is included. In the case of in-plane switching (IPS), the driving circuit 122 is included. Absent. The drive circuit 122 may be a color filter substrate or a transparent substrate, but it is preferable to use a color filter substrate because colorization can be easily performed. As a method of colorizing the second substrate 20 without using a color filter substrate, a method of converting the first substrate 110 into a color filter (color filter-on-array method), a method of switching the color of the backlight ( Field sequential method).

  For example, the seal frame 140 is formed in a substantially rectangular shape by applying a sealant that undergoes a curing reaction at 30 ° C. or lower, and the first substrate 110 and the second substrate 120 are bonded together via the seal frame 140. The seal frame 140 seals the liquid crystal 130 interposed between the first substrate 110 and the second substrate 120. The seal frame 140 includes a first seal frame 140a that stores a predetermined amount of liquid crystal, and a second seal frame 140b outside at least one side of the first seal frame 140a. The liquid crystal slightly larger than the predetermined amount. 130 is formed in the first seal frame 140a, and the first substrate 110 and the second substrate 120 facing each other are bonded together, so that the excess liquid crystal 130 in the first seal frame 140a is removed from the first seal frame 140a. Since the liquid crystal 130 in the first seal frame 140a is made uniform, the display device 101 can have a predetermined thickness, and the display unevenness can be displayed with a simple configuration. Can be prevented. Further, since the extra liquid crystal 130 leaking from the first seal frame 140a is stored in the second seal frame 140b, the extra liquid crystal 130 does not leak and contaminates the apparatus, and the production efficiency is improved with a simple configuration. Is possible. As this sealing agent, a two-component mixed curable resin in which the curing reaction proceeds by mixing the main agent and the curing agent, an ultraviolet curable resin in which the curing reaction proceeds by irradiating ultraviolet rays, or the like can be used. . Since the curing time is short, it is preferable to use an ultraviolet curable resin, and it is possible to cure in a room temperature environment by irradiating ultraviolet rays.

  In this way, the first substrate 110 and the second substrate 120 are provided with the seal frame 140 in which the spacer beads 131 are dispersed on the inner periphery between the two substrates in a substantially rectangular shape. The gap is sealed with a so-called cell gap. As the spacer beads 131, plastic particles such as silica particles and polystyrene particles, particles obtained by coating a thermoplastic resin around the silica particles, and the like can be used. The seal frame 140 defines a liquid crystal region between the first substrate 110 and the second substrate 120.

  Of the first substrate 110 and the second substrate 120 that face each other as described above, at least one second substrate 120 is in a plastic and roll shape, and at least one first substrate 110 has a plurality of pixels. At least the other second substrate 120 has a drive circuit 122, and the display device 101 is manufactured by bonding the first substrate 110 and the second substrate 120 facing each other.

  Hereinafter, the manufacturing process of the display device according to this embodiment will be described with reference to FIG.

  As shown in FIG. 2, the manufacturing method of the display device according to this embodiment includes a seal frame forming process A in which a seal agent is applied to the first substrate 110 to form the seal frame 140, and the liquid crystal 130 is first used. A liquid crystal forming process B applied and formed in the seal frame 140 of the substrate 110, and a substrate bonding process C for bonding the first substrate 110 and the second substrate 120 facing each other.

  In the sealing agent application step A, the first substrate 110 is placed on the support base 150 by the sealing agent application means A1, and the sealing agent 140 is applied on the first substrate 110 to form the seal frame 140. However, the seal frame 140 may be formed on the second substrate 120. The seal frame 140 includes a first seal frame 140a that stores a predetermined amount of liquid crystal, and a second seal frame 140b formed outside at least one side of the first seal frame 140a. As the seal frame forming means A1, as shown in FIGS. 3 and 4, a dispenser 1 is used, and a sealant is supplied from the storage tank 2 to the dispenser 1 and applied. The seal frame forming means A1 is not limited to the dispenser 1, and can be formed by a method such as screen printing or ink jet printing. Further, the shape of the seal frame 140 is not particularly limited. For example, as shown in FIG. 4, the first seal frame 140a has a quadrangular shape in plan view, and the outside of one side of the first seal frame 140a. However, as shown in FIG. 5, the second seal frame 140b may be formed outside the three sides of the first seal frame 140a as shown in FIG. As described above, the second seal frame 140b may be formed outside the four sides of the first seal frame 140a.

As the sealant, an ultraviolet curable resin, a thermosetting adhesive, or a photocurable adhesive can be used. For example, acryloyl bisphenol A oligomer at both ends as a curable resin component, isocyanuric acid triacrylate, tetraethylene glycol diacrylate, and 1-hydroxy-cyclohexyl-phenyl-ketone (Irgacure 184 manufactured by Ciba Specialty Chemical Co.) as an initiator An ultraviolet curable resin comprising aluminum oxide having a maximum particle size of 2 μm or less and silicon oxide having a maximum particle size of 0.5 μm or less was used as a sealant. This sealant can be cured in a temperature environment of 25 ° C. by irradiating ultraviolet rays of 2000 mJ / cm ^{2 with} a high-pressure mercury lamp.

  In the liquid crystal forming step B, as shown in FIGS. 7 and 8, the liquid crystal 130 is applied and formed in the first seal frame 140a of the seal frame 140 formed on the first substrate 110 by the liquid crystal forming means B1. Alternatively, it may be formed by transfer or the like. The liquid crystal 130 is applied in a larger amount than the volume surrounded by the first seal frame 140a. As the liquid crystal forming means B1, the droplet discharge head 3 is used, the liquid crystal 130 is supplied from the storage tank 4 to the droplet discharge head 3, and the portion surrounded by the seal frame 140 formed on the first substrate 110 is A predetermined amount of liquid crystal 130 is applied in a planar shape by the droplet discharge head 3. As a method of the droplet discharge head 3, for example, a piezo jet type using a piezoelectric element can be used. However, a method other than this piezo jet type may be used, and vibration is applied by an ultrasonic motor, a linear motor, or the like. Alternatively, the liquid crystal may be emitted by applying pressure in the storage tank 4. Here, it is desirable that the liquid crystal in the storage tank 4 has been defoamed in advance. The droplet discharge head 3 may be configured as a system in which the liquid crystal in the storage tank 4 or a mixture of the liquid crystal and the low-viscosity volatile liquid is heated and the liquid crystal is ejected by expansion and foaming of the substance. Good. When the liquid crystal 130 is transferred and formed in the first seal frame 140a, as shown in FIG. 9, a slightly larger number of liquid crystals 130 placed on the plate 200 of the film sheet are overlapped in the first seal frame 140a. As shown in FIG. 10, the liquid crystal 130 is transferred and formed in the first seal frame 140a.

  As described above, the liquid crystal 130 is formed in a solid shape so as to be sufficiently close to the inside of the seal frame 140 formed on the first substrate 110, but the same applies when the seal frame is formed on the second substrate 120. It is preferable that the liquid crystal 130 is formed in a solid shape so as to be sufficiently close to the inside of the seal frame because the liquid crystal 130 can be flattened in a short time. Many may be applied.

  In the substrate bonding step C, as shown in FIGS. 11 to 14, a large amount of liquid crystal 130 is applied in the first seal frame 140 a formed on the first substrate 110, and the first substrate 110 is covered with the liquid crystal 130. The second substrate 120 is stacked. This 2nd board | substrate 120 is unwound from the unwinding axis | shaft 170, the 1st board | substrate 110 and the board | substrate 120 which oppose by the board | substrate bonding means C1 are bonded, the 2nd board | substrate 120 is punched out, and it shows in FIG. A display device 101 as shown is manufactured, and the remaining second substrate 120 punched out is taken up on a take-up shaft 171.

  Substrate pasting means C1 has pressing member 160 which has flexibility, and extruding means 161 which extrudes air in the 1st seal frame 140a by applying pressure gradually, making a substrate fold. The pressing member 160 has a configuration in which a fluid 160b is injected and expanded into a hollow member 160a having flexibility. The hollow member 160a is formed of rubber, resin, or the like, and air, liquid, or the like is used as the fluid 160b. The extruding means 161 has a plate-like member 161a larger than the first substrate 110, applies pressure to the plate-like member 161a, and presses the second substrate 120 with a flexible pressing member 160. Is gradually added to push out the air in the seal frame 140, and the first substrate 110 and the second substrate 120 facing each other are bonded together. In this embodiment, the pressing member 160 has a configuration in which a fluid 160b is injected and expanded into a hollow member 160a having flexibility, and pressure is applied while the second substrate 120 is bent with a simple structure. Slowly add and reliably push out the air for pasting.

  In this embodiment, as shown in FIGS. 11 and 12, by gradually applying pressure while pushing the second substrate 120 from one side 140a1 of the first seal frame 140a, the air is pushed out. The liquid crystal 130 is sufficiently filled in the liquid crystal region so that no space is generated, and the display device 101 can be manufactured that is thin and lightly difficult to break and can prevent display unevenness. Further, as shown in FIG. 13, when the seal frame 140 is in the embodiment shown in FIG. 4, the extra liquid crystal 130 is stored in the second seal frame 140b over the other side 140a2. The liquid crystal 130 in the seal frame 140a becomes uniform, and the display device 101 can have a predetermined thickness, and display unevenness can be prevented with a simple configuration. In addition, since the excess liquid crystal 130 leaking from the first seal frame 140a is stored in the second seal frame 140b, the excess liquid crystal 130 will not leak and contaminate the device, improving the production efficiency with a simple configuration. Is possible. Further, as shown in FIG. 14, when the seal frame 140 is the embodiment shown in FIG. 5, the seal frame 140 is stored in the second seal frame 140b over the side portion 140a3 and the other side portion 140a2 in the left and right width direction. The

  Further, in the substrate bonding step C, as shown in FIGS. 15 to 17, when the liquid crystal 130 is applied to the center portion of the first seal frame 140a, the second portion is started from the center portion of the first seal frame 140a. The pressure is gradually applied while the substrate 120 is plied, and the air is pushed out and bonded. In this case, as shown in FIG. 17, the excess liquid crystal 130 passes over a part of the peripheral portion of the first seal frame 140a and is stored in the second seal frame 140b, and is stored in the first seal frame 140a. The liquid crystal 130 becomes uniform, the display device 101 can have a predetermined thickness, and display unevenness can be prevented with a simple configuration.

  Next, specific examples of electronic devices to which the display device according to the present invention can be applied will be described with reference to FIGS.

  First, an example in which the display device 101 according to the present invention is applied to a display unit of a portable personal computer (so-called notebook personal computer) will be described. FIG. 18 is a perspective view showing the configuration of this personal computer. The personal computer 191 includes a main body 193 having a keyboard 192 and a display 194 to which the display device 101 according to the present invention is applied.

  Next, an example in which the display device according to the present invention is applied to a display unit of a mobile phone will be described. FIG. 19 is a perspective view showing the configuration of this mobile phone. The mobile phone 292 includes a display unit 296 to which the display device 101 according to the present invention is applied, in addition to the plurality of operation buttons 293, as well as the earpiece 294 and the mouthpiece 295.

  Electronic devices to which the display device according to the present invention can be applied include, in addition to the personal computer shown in FIG. 18 and the mobile phone shown in FIG. 19, a liquid crystal television, a viewfinder type / monitor direct view type video tape. A recorder, a car navigation device, a pager, an electronic notebook, a calculator, a word processor, a workstation, a video phone, a POS terminal, a digital still camera, and the like are exemplified, but the invention is not particularly limited.

  The present invention can be applied to a manufacturing method of a display device used for display of a personal computer, a mobile phone, etc., a display device manufacturing device, and an electronic apparatus, and can prevent display unevenness with a simple configuration and can improve production efficiency. It is.

It is sectional drawing of a display apparatus. It is the schematic of the manufacturing process of a display apparatus. It is a side view which shows a seal frame formation process. It is a top view which shows a seal frame formation process. It is a top view which shows the seal frame formation process of other embodiment. It is a top view which shows the seal frame formation process of other embodiment. It is a side view which shows a liquid crystal formation process. It is a top view which shows a liquid crystal formation process. It is a side view before the transfer which shows the liquid-crystal formation process of other embodiment. It is the side view after transfer which shows the liquid-crystal formation process of other embodiment. It is a side view which shows a board | substrate bonding process. It is a top view which shows the liquid crystal before bonding of a board | substrate bonding process. It is a top view which shows the liquid crystal after the bonding of a board | substrate bonding process. It is a top view which shows the liquid crystal of other embodiment after the bonding of a board | substrate bonding process. It is a side view which shows the board | substrate bonding process of other embodiment. It is a top view which shows the liquid crystal before the bonding of the board | substrate bonding process of other embodiment. It is a top view which shows the liquid crystal after the bonding of the board | substrate bonding process of other embodiment. It is a perspective view of a personal computer. It is a perspective view of a mobile phone.

Explanation of symbols

DESCRIPTION OF SYMBOLS 101 Display apparatus 110 1st board | substrate 120 2nd board | substrate 130 Liquid crystal 140 Seal frame 140a 1st seal frame 140b 2nd seal frame A A seal frame formation process A1 seal frame formation means B Liquid crystal formation process B1 Liquid crystal formation means C Substrate Bonding process C1 substrate bonding means

Claims (3)

Among the opposing substrates, at least one substrate has a plurality of pixels, at least the other substrate has a drive circuit, one substrate is plastic and roll-shaped, and the other substrate is plate-shaped, facing each other A display device manufacturing method for manufacturing a display device by bonding the substrates to be performed,
A seal frame forming step of forming a seal frame on the plate-like substrate with a sealant;
Forming a liquid crystal within the seal frame of the plate-like substrate;
A substrate laminating step for laminating the plate substrate and the roll substrate facing each other;
Having at least
In the seal frame forming step, a first seal frame that stores a predetermined amount of liquid crystal, and a second seal frame outside at least one side of the first seal frame,
In the liquid crystal forming step, a liquid crystal larger than a predetermined amount is formed in the first seal frame,
In the substrate bonding step,
Unwinding the rolled substrate by an unwinding section,
The roll substrate is overlaid on the plate substrate,
Pressure is applied while the roll-shaped substrate is bent from the side of the first seal frame, the center of the first seal frame, or the corner of the first seal frame by a flexible pressing member. Gradually added air to push out excess liquid crystal in the first seal frame in the second seal frame and paste the roll substrate and the plate substrate facing each other,
A manufacturing method of a display device, comprising manufacturing a display device by punching the roll-shaped substrate and bonding substrates facing each other, and winding the remaining punched portion of the roll-shaped substrate around a winding shaft. Among the opposing substrates, at least one substrate has a plurality of pixels, at least the other substrate has a drive circuit, one substrate is plastic and roll-shaped, and the other substrate is plate-shaped, facing each other A display device manufacturing apparatus for manufacturing a display device by bonding the substrate to be
An unwinding section for unwinding the roll-shaped substrate;
A winding unit for winding the roll-shaped substrate;
Seal frame forming means for forming a seal frame on the plate-like substrate with a sealant;
Liquid crystal forming means for forming liquid crystal in a seal frame of the plate-like substrate;
Substrate laminating means for laminating the plate substrate and the roll substrate facing each other;
Comprising at least
Forming a first seal frame for storing a predetermined amount of liquid crystal and a second seal frame outside at least one side of the first seal frame on the plate-like substrate by the seal frame forming means;
By the liquid crystal forming means, a liquid crystal larger than a predetermined amount is formed in the first seal frame,
The substrate bonding means is
Unwinding the rolled substrate by the unwinding part,
The roll substrate is overlaid on the plate substrate,
Pressure is applied while the roll-shaped substrate is bent from the side of the first seal frame, the center of the first seal frame, or the corner of the first seal frame by a flexible pressing member. Gradually added air to push out excess liquid crystal in the first seal frame in the second seal frame and paste the roll substrate and the plate substrate facing each other,
A manufacturing apparatus of a display device, wherein the display device is manufactured by punching the roll-shaped substrate and bonding substrates facing each other, and winding the remaining punched portion of the roll-shaped substrate around a winding shaft.   An electronic apparatus comprising a display device manufactured by the method for manufacturing a display device according to claim 1.