JPH04317002A - Production of color filter - Google Patents

Abstract

PURPOSE:To obtain the color filter to be used for flat displays, such as liquid crystal displays or imagers, such as CCDs, or color sensors, etc., with high accuracy and good efficiency. CONSTITUTION:A photosensitive layer formed on a base is exposed via a photomask having prescribed patterns and tacky adhesiveness is developed in the exposed parts, by which a colored powder material is stuck to these exposed parts and colored patterns are formed. The colored layers 16 consisting of plural colors of the required color patterns are formed on the base by repeating this operation, then the colored layers 16 on the base are transferred onto the tacky adhesive layer 6 on a transparent substrate, by which the color filter is obtd.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a method for manufacturing color filters, and in particular, to manufacture color filters for use in flat displays such as liquid crystal displays, imagers such as CCDs, color sensors, etc. with high precision and efficiency. The present invention relates to a method of manufacturing color filters that can be obtained easily.

0002

2. Description of the Related Art For example, the image pickup tube of a color video camera is equipped with a color filter in which fine stripes of a plurality of colors are formed on a transparent substrate. Furthermore, in liquid crystal displays (LCDs), color filters are used in both active matrix and simple matrix systems in order to meet the recent demand for colorization. For example, a thin film transistor (
In active matrix liquid crystal displays using TFT, the color filters are red (R) and green (G).
The three primary colors of , blue (B) are used, and by turning on and off the electrodes corresponding to each pixel of R, G, and B, the liquid crystal operates as a shutter and lights each pixel of R, G, and B. Transparent color display is performed. And the color mixture is 2
This is visually performed on the retina using the principle of additive color mixing, in which liquid crystal shutters corresponding to pixels of more colors are opened and the colors are mixed to appear as different colors.

[0003] Color filters used as described above have conventionally been manufactured using methods such as dyeing methods and dispersion methods. Here, the production of color filters by the dyeing method is carried out, for example, as follows. That is, a coating solution made by adding a photosensitive agent such as dichromate to a hydrophilic resin such as gelatin, casein, or polyvinyl alcohol is applied onto a transparent glass substrate by spin coating or the like, and then a mask with a predetermined pattern is applied. Exposure and development are carried out using
Thereafter, the first colored layer is formed by dyeing with a dye. Thereafter, a resisting layer is provided on the first colored layer to prevent double dyeing, and then a second colored layer and a third colored layer are formed in the same manner as the first colored layer. Thereby, a color filter including R, G, and B colored layers on a transparent glass substrate can be obtained.

[0004] Color filters are manufactured using the dispersion method, for example, as follows. That is,
A photosensitive liquid in which a coloring agent such as a dye, an organic pigment, an inorganic pigment, etc. is dispersed in a transparent photosensitive resin is applied onto a transparent glass substrate to form a photosensitive resin layer. Next, a mask having an opening pattern of a predetermined shape is placed on this photosensitive resin layer, and exposure and development are performed to form a first colored layer. Similarly, the second colored layer,
By forming a third colored layer, a color filter including R, G, and B colored layers can be obtained.

[0005]

[Problems to be Solved by the Invention] However, while the dyeing method provides a color filter with a rich variety of tones and excellent resolution, it is difficult to prevent the already colored areas from being dyed twice during dyeing. There was a problem that the process was complicated and the manufacturing cost was high due to the need to take countermeasures. Furthermore, since a water-soluble polymer material is used for the object to be dyed, there is also a problem that heat resistance, chemical resistance, light resistance, etc. are inferior.

[0006]Also, although it is possible to form fine patterns using the dispersion method, it is necessary to perform a photolithography process every time the color is changed, making the process complicated and difficult to reduce manufacturing costs. There was a problem. Against this background, a printing method has been proposed as a method of manufacturing color filters that enables cost reduction and mass production at the same time, and also allows for larger screens. Conventionally proposed printing methods include offset methods such as lithographic offset printing and intaglio offset printing, screen printing methods, and flexo printing methods.

However, the printing method has the problem that the printed shape deteriorates due to thickening or thinning of pixels, generation of pinholes, etc., and it is particularly difficult to reproduce fine patterns. In addition, since the thickness of particularly thin lines cannot be made sufficiently,
For example, it is not suitable for manufacturing a color filter having a colored pattern such as a black matrix that requires light-shielding properties. Therefore, when manufacturing a color filter with a high-quality black matrix,
It was necessary to form a black matrix by a costly chromium vapor deposition method or the like. Furthermore, in conventional printing methods, when ink is transferred from the blanket to the glass substrate, only a portion of the ink is transferred, resulting in splits within the ink layer, resulting in the ink surface not being smooth after printing. was there. Furthermore, since the process is unstable, if printing is continued continuously, there is a problem that the printed film thickness changes and the printed shape deteriorates.

The present invention has been made in view of the above-mentioned circumstances, and it is an object of the present invention to produce color filters used in flat displays such as liquid crystal displays, imagers such as CCDs, color sensors, etc. with high precision and efficiency. It is an object of the present invention to provide a method for manufacturing a color filter that can be obtained.

[0009]

[Means for Solving the Problems] In order to achieve the above object, the present invention provides a method for manufacturing a color filter having a colored layer consisting of a colored pattern of a plurality of colors. After forming a photosensitive layer by coating it on a support, the photosensitive layer is exposed to light through a photomask having a predetermined pattern, and a colored powder substance is attached to the exposed area to form a colored pattern. The colored layer was formed repeatedly for the required number of colors, and then the colored layer on the support was transferred to the adhesive layer of the transparent substrate on which the adhesive layer was previously formed.

0010

[Operation] The photosensitive layer formed on the support is exposed to light through a photomask having a predetermined pattern to develop tackiness in the exposed areas, and a colored powder substance is attached to the exposed areas to form a colored pattern. is formed, and by repeating this process, a colored layer consisting of the required colored pattern of multiple colors is formed. Next, the colored layer on the support is transferred to the adhesive layer on the transparent substrate to obtain a color filter. . As a result, the surface smoothness of the colored layer formed on the transparent substrate is good, and a transparent common electrode can be formed without forming a protective film, which simplifies the color filter process and reduces manufacturing costs. It is possible to reduce

[0011]

Embodiments Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an example of an active matrix liquid crystal display (LCD) using a color filter manufactured according to the present invention, and FIG. 2 is a schematic cross-sectional view. 1 and 2, the LCD 1 includes a color filter 10 and a transparent glass substrate 20.
A liquid crystal layer 40 made of twisted nematic (TN) liquid crystal and having a thickness of approximately 5 to 10 μm is formed between the color filter 10 and the color filter 10 .
Polarizing plates 50 and 51 are arranged on the outside of a transparent glass substrate 20.

FIG. 3 is an enlarged partial sectional view of the color filter 10. The color filter 10 includes a transparent substrate 12, a black matrix 14 formed on the transparent substrate 12 via an adhesive layer 6, a colored layer 16, It includes a protective layer 18 provided to cover the black matrix 14 and the colored layer 16, and a transparent common electrode 19. This color filter 10 is arranged so that the transparent common electrode 19 is located on the liquid crystal layer 40 side. The colored layer 16 includes a red pattern 16R, a green pattern 16G, and a blue pattern 16.
The colored patterns are arranged in a mosaic arrangement as shown in FIG. Note that the arrangement of the colored patterns is not limited to this, and may be a triangular arrangement, a striped arrangement, or the like.

Further, display electrodes 22 are provided on the transparent glass substrate 20 so as to correspond to the colored patterns 16R, 16G, and 16B, and each display electrode 22 has a thin film transistor (TFT) 24. Furthermore, scanning lines (gate electrode bus lines) 26 a and data lines 26 b are arranged between each display electrode 22 so as to correspond to the black matrix 14 .

In such an LCD 1, each of the colored patterns 16R, 16G, and 16B constitutes a pixel, and the liquid crystal is turned on and off by turning on and off the display electrode corresponding to each pixel while illumination light is irradiated from the polarizing plate 51 side. The layer 40 operates as a shutter, and light is transmitted through each pixel of the colored patterns 16R, 16G, and 16B to perform color display. As the transparent substrate 12 of the color filter 10, a rigid material without flexibility such as quartz glass, Pyrex glass, or a synthetic quartz plate, or a flexible material with flexibility such as a transparent resin film or an optical resin plate is used. be able to. Among these, Corning's 7059 glass is a material with a low coefficient of thermal expansion, and has excellent dimensional stability and workability in high-temperature heat treatment.Also, since it is an alkali-free glass that does not contain any alkali components, it is a material with a low coefficient of thermal expansion. Suitable for matrix type LCD color filters.

In the present invention, a colored layer is once formed on a support using a photosensitive substance that develops adhesiveness when exposed to light, and this colored layer is transferred onto the transparent substrate 12 via the adhesive layer to form the colored layer. 16. Here, an example of manufacturing a color filter according to the present invention will be described with reference to FIGS. 4 and 5. First, a photosensitive material is applied onto a flexible film 11 as a support to form a photosensitive layer 13 having a thickness of about 0.5 to 5 μm (FIG. 4(A)). Next, the photosensitive layer 13 is exposed to light through a photomask for a black matrix, and the exposed portion 13 is
a to develop adhesiveness (Fig. 4(B)). Then, a concealing powder substance is scattered on the photosensitive layer 13 (FIG. 4(C)), and the concealing powder substance is attached to the exposed portion 13a, and the excess concealing powder substance is blown off to form the black matrix 1.
4' (Fig. 4(D)). Next, the photosensitive layer 13 is exposed to light through a photomask for a red pattern to develop adhesiveness in the exposed portion 13b (FIG. 4(E)). and,
A red powder substance is sprinkled on the photosensitive layer 13 (FIG. 5(A)).
, a red powder material is attached to the exposed portion 13b and the excess red powder material is blown off to form a red pattern 16'.
R is formed (FIG. 5(B)). Similarly, exposure is performed through a photomask for a green pattern, a green powder substance is deposited to form a green pattern 16'G (FIG. 5(C)), and exposed through a photomask for a blue pattern. A blue powder material is deposited to form a blue pattern 16'B (FIG. 5D).

On the other hand, an adhesive layer 6 is previously formed on the transparent substrate 12 (FIG. 6(A)), and a black matrix 14' and each colored pattern 16'R, 1 are formed on this adhesive layer 6.
Flexible film 11 so that 6'G and 16'B are in close contact with each other
are superimposed on the transparent substrate 12. And flexible film 1
By rolling the roller 8 on the flexible film 11 and pressing the flexible film 11, the black matrix 14' and each colored pattern 16'R, 16'G, 16'B are adhered to the adhesive layer 6 and the flexible film 11 is pressed. The adhesive film 11 is peeled off (FIG. 6(B)). As a result, black matrix 1
4, and a colored layer 16 consisting of colored patterns 16R, 16G, and 16B is formed on the transparent substrate 12 via the adhesive layer 6.

Note that by omitting the black matrix forming step in the above manufacturing process, a color filter without a black matrix can be manufactured. Further, in the above embodiment, the colored patterns 16'R, 16'G, and 16'B are formed after forming the black matrix 14' on the flexible film 11, but the order of formation is as follows. It is not limited.

Another aspect of manufacturing a color filter according to the present invention will be explained with reference to FIG. In FIG. 7, a photosensitive material is coated on the circumferential surface of a roller-shaped support 71 to a thickness of 0.
．． A photosensitive layer 73 having a thickness of approximately 5 to 5 μm is formed, and the photosensitive layer 73 on the support 71 is exposed to light through a photomask for a black matrix in the same manner as in the above example to develop tackiness in the exposed portion. Then, a concealing powder material is spread on the photosensitive layer 73, and the concealing powder material is adhered to the exposed portion, and the excess concealing powder material is blown off to form a black matrix 74'. Next, the photosensitive layer 73 on the support body 71 is exposed to light through a photomask for a red pattern to develop adhesiveness in the exposed portion, and then the photosensitive layer 73
A red powder material is sprinkled on the exposed portion 13b, and the red powder material is blown off to form a red pattern 76'R. Similarly, a green powder material is deposited by exposure through a photomask for a green pattern to form a green pattern 76'G, and
Exposure is performed through a photomask for a blue pattern, and a blue powder material is deposited to form a blue pattern 76'B. As a result, a black matrix 74' and colored patterns 76'R, 76'G, and 76'B are formed on the photosensitive layer 73 of the roller-shaped support 71 (see FIG. 7(A).
)).

Next, this roller-shaped support 71 is rotated and moved onto the adhesive layer 78 previously provided on the transparent substrate 72 to form a black matrix 74' on the photosensitive layer 73.
Then, the colored patterns 76'R, 76'G, and 76'B are transferred onto the transparent substrate 72. As a result, the black matrix 74 and each colored pattern 76R, 76G, 7
A colored layer 76 made of 6B is formed on the transparent substrate 72 via an adhesive layer 78.

The flexible film 11 as a support is made of polyolefin, vinyl chloride, cellophane, acetate, acetal, phenol, epoxy silicone, rubber, nylon, polyester, polyamide, polycarbonate,
polyarylate, polysulfone, acrylic polyimide,
Resin films such as fluorine-based, polyether sulfone, polyether ether ketone, polyvinyl alcohol, ethylene vinyl alcohol, nitrile, urethane, polyvinyl butyral, etc., metal, ceramic films, composite films thereof, etc. can be used. The surface roughness of such flexible film 11 is ±1μ.
It is preferable that it is within m.

Methods for smoothing the flexible film include transparent layer coating, mirror drum calendaring, polishing,
Although other general methods are possible, in particular, a surface-smoothed film can be easily obtained by narrowing an ultraviolet curable resin or the like between the polished surface of the surface-polished glass and the film, stretching it, and curing it with ultraviolet rays. Furthermore, when this film is used, the smoothness of the surface of the color filter after the colored layer is transferred becomes particularly good.

Further, as the roller-shaped support 71,
Supports made of materials such as steel materials such as stainless steel, non-ferrous metal materials such as aluminum, inorganic materials such as glass, organic materials such as polyolefin, and composite materials thereof can be used. The surface of such a support on which the photosensitive layer is formed is coated with a material such as silicone resin, wax, fluorine resin, cellulose resin, or other material that has release properties from the support and/or the photosensitive layer. It is preferable to perform mold treatment.

As the photosensitive substance that develops tackiness upon exposure to light, 1,4-dihydropyridine compounds as shown below can be used. 1,4-dihydropyridine compound: 2,6-dimethyl-4-(2'-
Nitrophenyl)-1,4-dihydropyridine-3,5
-dicarboxylic acid dimethyl ester; 2,6-dimethyl-4-(2'-nitrophenyl)-1,4-dihydropyridine-3,5-dicarboxylic acid diethyl ester;
2,6-dimethyl-4-(2'-nitro-4',5'
-dimethoxyphenyl)-1,4-dihydropyridine-
3,5-dicarboxylic acid diethyl ester; 2,6-
Dimethyl-4-(2'-nitrophenyl)-1,4-dihydropyridine-3,5-dicarboxylic acid diisopropyl ester; 2,6-dimethyl-4-(2'-nitrophenyl)-1,4-dihydropyridine-3 ,5-dicarboxylic acid di(β-ethoxyethyl) ester; 2,
6-dimethyl-4-(2'-nitrophenyl)-1,4
-dihydropyridine-3,5-dicarboxylic acid 3-methyl-5-ethyl ester; 2,6-dimethyl-4-(
2'-nitrophenyl)-1,4-dihydropyridine-
3,5-dicarboxylic acid 3-isopropyl-5-methyl ester; 2,6-dimethyl-4-(2'-nitrophenyl)-3-aceto-1,4-dihydropyridine-5
-Carboxylic acid ethyl ester; 2,6-dimethyl-
4-(2'-nitrophenyl)-3,5-diaceto-1
, 4-dihydropyridine and 2,6-dimethyl-4-
(2'-nitrophenyl)-3,5-dicyano-1,4
-dihydropyridine.

Such 1,4-dihydropyridine compounds can contain, for example, 1 mol of an aliphatic or aromatic aldehyde,
It can be produced from 1 mol of ammonia and 2 mol of β-ketocarboxylic acid ester, β-ketocarboxylic acid nitrile or β-diketone according to the method of Hantzsch synthesis. In addition to the 1,4-dihydropyridine compounds shown above, various photosensitive diazonium salts such as DDMA shown by the following chemical formula can be used as the photosensitive substance.

[0025]

[Chemical formula 1]

However, when a photosensitive diazonium salt is used as the photosensitive substance, the uniform distribution of the concealing powder substance or the colored powder substance in the exposed area cannot be achieved if the exposure and powder substance scattering are carried out in the presence of a fixed amount of moisture. This is only possible if This requires expensive equipment to determine and control indoor humidity and indoor air exposure time.

The above photosensitive materials may be used alone to form the photosensitive layer 13, or may be used in combination with a binder. The mixing ratio with the binder is preferably about 0.2 to 9 parts by weight per 1 part by weight of the binder. Binders used include copolymers of polyacrylic esters and/or polymethacrylic esters, acrylic acid and/or methacrylic acid or other acrylic monomers and/or vinyl monomers;
Copolymers of maleic anhydride, maleic acid and/or its styrene, or di- or semi-esters of other vinyl monomers; polyvinyl chloride, its chlorinated products, polyvinylidene chloride, chlorinated polyethylene, etc. Chlorine-containing vinyl polymer or copolymer;
Styrene copolymers with polystyrene and maleic acid, etc., ethylene copolymers with polyethylene and maleic acid, etc.; Synthetic rubbers based on butadiene, chloroprene, etc. and their copolymers with styrene, acrylonitrile, etc.; High molecular weight polyethylene oxide Or a polyether such as polyepichlorohydrin.

[0028] Furthermore, the photosensitive substance may contain a sensitizer, a stabilizer, and the like. In order to apply the photosensitive material as described above onto the transparent substrate 12, a known method such as a spin coating method can be used. Further, examples of the light source used for exposing the photosensitive layer 13 include an ultra-high pressure mercury lamp, a xenon lamp, a fluorescent lamp, and the like. The irradiance during exposure is 50
It is preferably about 300 mJ/cm2.

The concealing powder material and the colored powder material include titanium oxide (TiO2), SiO2, glass powder, carbon black, graphite, copper-phthalocyanines,
Azo dyes, metal powders such as aluminum, copper, iron, etc. or metal oxides are mixed with a binder to an average particle size of 30 μm.
Hereinafter, preferably fine particles of 3 μm or less can be used.

As the binder, polystyrene homopolymer, hydrogenated styrene resin, styrene-isobutylene copolymer, styrene-butadiene copolymer, ABS (
Acrylonitrile-butadiene-styrene terpolymer), ASA or AAS (acrylonitrile-styrene-acrylic acid ester terpolymer), AS or SA
N (styrene/acrylonitrile copolymer), AAS (
Acrylonitrile/acrylic rubber/styrene terpolymer), ACS (acrylonitrile/chlorinated polyethylene/styrene terpolymer), AES (acrylonitrile/EVA/styrene terpolymer), styrene/P-chlorostyrene copolymer Coalescence, styrene-propylene copolymer,
Styrene/butadiene crosslinked polymer, styrene/allyl alcohol copolymer, styrene/butadiene rubber emulsion, styrene/maleic acid ester copolymer, styrene/isobutylene copolymer (self-crosslinked), styrene/maleic anhydride copolymer, Polystyrene resins such as styrene/3-N,N diethylaminopropyl acrylate copolymer; polymethyl methacrylate, ethyl methacrylate, n-butyl methacrylate, glycidyl methacrylate, fluorine-containing acrylate, methylene methacrylate/butyl methacrylate Acrylic resins such as acrylate copolymers, ethyl acrylate/acrylic acid copolymers; styrene/acrylic copolymers, styrene/diethylamino/ethyl methacrylate copolymers,
Styrene-butadiene-acrylic ester copolymer,
Styrene/butadiene copolymer, styrene/butadiene/chlorinated paraffin copolymer, styrene/methyl methacrylate copolymer, styrene/methyl methacrylate copolymer/styrene butyl methacrylate blend, styrene/n-butyl methacrylate , styrene/diethylamino/ethyl methacrylate, styrene/methyl methacrylate/n-butyl acrylate (
75:5:20), styrene/methyl methacrylate/butyl acrylate-N-(ethoxymethyl)acrylamide, styrene/glycidyl methacrylate, styrene/dimethylamino/ethyl methacrylate, styrene/butadiene/dimethyl/aminoethyl methacrylate ( 60:26:4), styrene/acrylic ester/maleic ester (terpolymer), styrene/methyl methacrylate/2-ethylhexyl acrylate copolymer, styrene/n-butyl acrylate/ethyl glycol meth Acrylate, styrene/n-butyl methacrylate/acrylic acid copolymer (59:40
:1), Styrene/n-butyl methacrylate/maleic anhydride resin, styrene/butyl acrylate/isobutyl maleic acid half ester/divinylbenzene copolymer, styrene/n-butyl acrylate-4-hexafluorobutyl methacrylate copolymer Coalescence, styrene-butadiene-acrylate copolymer (59:36:5
) can be used.

[0031]Additives such as wetting agents and antistatic agents may also be added to the binder. Incidentally, as the concealing powder substance, powder of metal, carbon black, graphite, etc. may be directly used without using a binder. In this case, the metal powder preferably has an average particle size of 1 μm or less, and the carbon black powder and graphite powder preferably have an average particle size of 3 μm or less.

[0032] The deposition of the concealing powder substance and each colored powder substance on the exposed area may be performed only once as described above, or may be repeated multiple times. In addition, the black matrix 14'(74') and each colored pattern 16'R, 16'G, 16'B (76'R, 76'
'G, 76'B) is then heat treated (100-500
C, preferably 200 to 300 C), and then transferred to a transparent substrate. In particular, from the support to the transparent substrate 1
If the photosensitive layer 13 transferred to 2 is present on the entire surface of the transparent substrate 12, the photosensitive layer 13 will also be present at the peripheral edge of the resulting color filter, and therefore there is a risk of peeling from this area. be. In such a case, it is extremely effective to sublimate and remove the photosensitive material of the photosensitive layer 13 (73) by the heat treatment as described above.

Adhesive layer 6 (78) formed on transparent substrate 12
) are transparent adhesives such as rubber-based, acrylic-based, silicone-based, vinyl ether-based, vinyl acetate-based, urethane-based, epoxy-based, nylon-based, polyester-based, phenol-based, etc.
Ionizing radiation-curable transparent resins such as unsaturated polyester/styrene, acrylic ester, polythiol/polyene, epoxy, vinyl ether, etc., and other transparent resins that are sticky during transfer but harden with subsequent heat treatment, etc. A curable transparent resin or the like can be used.

A protective layer 18 is provided to cover the black matrix 14 and colored layer 16 of the color filter 10.
smooths the surface of the color filter 10, improves reliability,
It is intended to prevent contamination of the liquid crystal layer 40, etc., and can be formed using a transparent resin for acrylic resin, epoxy resin, polyimide resin, or a transparent inorganic compound such as silicon dioxide. . The thickness of the protective layer is preferably about 0.5 to 50 μm. Here, in the present invention, as described above, a colored layer is once formed on a support using a photosensitive substance that develops adhesiveness upon exposure to light, and this colored layer is transferred onto a transparent substrate via an adhesive layer. Since it is a colored layer,
The surface smoothness of the colored layer on the transparent substrate is high, and there is no need to form a protective layer as described above.

As the transparent common electrode 19, an indium tin oxide (ITO) film can be used. The ITO film can be formed by a known method such as a vapor deposition method or a sputtering method, and the thickness is preferably about 200 to 2000 Å. Next, the present invention will be explained in more detail by showing experimental examples. (Experimental example 1) First, 500 ml of methyl ethyl ketone solvent
50 g each of DHP-E and DHP-M manufactured by DuPont were dissolved in the solution to prepare a photosensitive material that becomes sticky when exposed to light. And the thickness is 100μ as a support.
Spin coating method (rotation speed = 45
0r. p. m. ) to form a photosensitive layer (thickness = 1.5 μm).

Next, the photosensitive layer was exposed to ultraviolet light through a black matrix photomask. The light source for exposure is an ultra-high pressure mercury lamp, and the irradiation amount is 365 nm.
It was set to 200 mJ/cm2 at the wavelength of . It was confirmed that by such exposure to ultraviolet rays, adhesiveness was developed in the area of the photosensitive layer that was irradiated with ultraviolet rays. Next, black toner (manufactured by Tomoekawa Paper Manufacturing Co., Ltd., average particle size = 5 μm) was sprinkled over the entire surface of the photosensitive layer, and then the black toner was blown away with compressed air. As a result, the black toner adhered only to the area where tackiness was developed due to the above-mentioned ultraviolet exposure, and a black matrix pattern was formed. Note that the black toner blown away (removed) by compressed air in this step can be collected and used again. The resolution at this time was 10 μm for lines and spaces.

Next, the photosensitive layer to which the black toner was attached was exposed to ultraviolet light at predetermined positions through a photomask for a red pattern. The ultraviolet exposure conditions were the same as those for the above exposure. Then, as in the case of the black toner, a red pattern was formed using a red toner (manufactured by Tomoekawa Paper Manufacturing Co., Ltd., average particle size = 8 μm). Next, the photosensitive layer to which the black toner and red toner are attached is exposed to ultraviolet light at predetermined positions through a photomask for the green pattern in the same manner as the red pattern, and the green toner (Tomoekawa Paper Mills) Co., Ltd., average particle size = 5 μm) to form a green pattern.

Furthermore, the photosensitive layer to which the black toner, red toner, and green toner are attached is exposed to ultraviolet light at predetermined positions through a photomask for the blue pattern in the same manner as the red pattern, and the blue toner is (manufactured by Tomoekawa Paper Manufacturing Co., Ltd., average particle size = 5 μm) to form a blue pattern. Next, we used Corning's 7 as a transparent substrate.
Nissetsu PE- on 059 glass (thickness = 1.1mm)
115 (manufactured by Nippon Carbide Co., Ltd.) was applied by spin coating to form an adhesive layer with a thickness of 5 μm. Then, the above-mentioned PET film was layered on this adhesive layer, the black matrix and each colored pattern were brought into close contact with the adhesive layer, and only the film was peeled off while a roller (1 kg in weight) having a diameter of 10 cm was rotated over the film. As a result, a black matrix and a red (
A colored layer consisting of colored patterns of R), green (G), and blue (B) was formed.

Next, a protective layer was formed to cover the colored layer. This protective layer was formed by spin coating using Optomer SS manufactured by Nippon Synthetic Rubber Co., Ltd., and had a thickness of about 3 μm. Furthermore, a transparent common electrode (ITO film) having a thickness of about 220 Å was formed on this protective layer by sputtering to obtain a color filter. The resolution of this color filter was 10 μm in line and space. (Experimental Example 2) After forming a black matrix and colored patterns of red (R), green (G), and blue (B) on a polysulfone film in the same manner as in Experimental Example 1, heat treatment was performed at 270°C for 30 minutes. A color filter was obtained in the same manner as in Experimental Example 1, except that the protective layer was not formed. In this color filter, the photosensitive substance was removed by sublimation, and the resolution was 10 μm in line and space. (Experimental Example 3) The same photosensitive material as in Experimental Example 1 was coated on the peripheral surface of a surface-smoothed stainless steel roller (diameter 30 cm) as a support by dipping to a thickness of 1.
A 5 μm photosensitive layer was formed. Then, using a cylindrical black matrix photomask and a photomask for each colored pattern, a black matrix and each colored pattern were formed on a roller support in the same manner as in Experimental Example 1. Next, Corning 7059 glass (thickness = 1.1 m) on which an adhesive layer was formed as in Experimental Example 1 was prepared.
m) The black matrix and each colored pattern on the roller support were transferred onto the transparent substrate by rotating the roller support. As a result, a colored layer consisting of a black matrix and colored patterns of red (R), green (G), and blue (B) was formed on the adhesive layer of the transparent substrate.

A transparent common electrode (ITO film) was then formed to cover the black matrix and colored layer to obtain a color filter. The resolution of this color filter was 15 μm in line and space.

[0041]

As described in detail above, according to the present invention, the photosensitive layer formed on the support is exposed to light through a photomask having a predetermined pattern, and the exposed areas develop tackiness. A colored pattern is formed by attaching a colored powder substance to the exposed portion, and by repeating this process, a colored layer consisting of a colored pattern of a plurality of colors as required is formed,
Next, the colored layer on the support is transferred to the adhesive layer on the transparent substrate to obtain a color filter, so the colored layer formed on the transparent substrate has good surface smoothness and forms a protective film. It is possible to form a transparent common electrode without any problems, simplifying the color filter process, and reducing manufacturing costs.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing an example of an active matrix liquid crystal display using a color filter manufactured according to the present invention.

FIG. 2 is a schematic cross-sectional view of the liquid crystal display shown in FIG. 1;

3 is an enlarged partial cross-sectional view of a color filter used in the liquid crystal display shown in FIG. 1. FIG.

FIG. 4 is a process diagram for explaining a method for manufacturing a color filter according to the present invention.

FIG. 5 is a process diagram for explaining a method for manufacturing a color filter according to the present invention.

FIG. 6 is a process diagram for explaining a method of manufacturing a color filter according to the present invention.

FIG. 7 is a diagram for explaining another aspect of the method for manufacturing a color filter according to the present invention.

[Explanation of symbols]

10... Color filter 6... Adhesive layer 11... Flexible film (support) 12... Transparent substrate 13... Photosensitive layer 14... Black matrix 16... Colored layers 16R, 16G, 16B... Colored pattern 71... Roller-shaped support 73 ...Photosensitive layer 74...Black matrix 76...Colored layer

Claims (6)

[Claims] 1. A method for manufacturing a color filter having a colored layer consisting of a colored pattern of a plurality of colors, in which a photosensitive material that develops tackiness upon exposure to light is coated on a support to form a photosensitive layer, and then a predetermined layer is formed. A colored layer is formed by repeating the process of exposing the photosensitive layer to light through a photomask having a pattern and adhering a colored powder substance to the exposed portion to form a colored pattern for the required number of colors. A method for manufacturing a color filter, comprising transferring a colored layer on the support to the adhesive layer of the transparent substrate on which the color filter is formed. 2. The method for producing a color filter according to claim 1, wherein the support is a flexible film. 3. The flexible film has a surface roughness of ±
3. The method for manufacturing a color filter according to claim 2, wherein the thickness is within 0.1 μm. 4. The method for manufacturing a color filter according to claim 1, wherein the support is a roller-shaped support. 5. The method of manufacturing a color filter according to claim 1, wherein a heat treatment is performed after forming the colored layer. 6. The method of manufacturing a color filter according to claim 1, wherein the photosensitive substance is a 1,4-dihydropyridine compound.