JPH04369604A - Defect part correcting method for color filter - Google Patents

Abstract

PURPOSE:To correct a defect part which is generated in the manufacture process of the color filter. CONSTITUTION:After a protective layer 13 is formed of a material with good peelability and flexibility at the defect part with which foreign matter 9 is mixed, the defect part is irradiated with a laser beam to remove the peripheral part of the foreign matter 9 and then the removed part is coated with a light- shielding material 14 corresponding to the color of a color pattern layer 3; and then the protection film layer 13 is mechanically peeled to leave a light shield material 14 at the removed part. Lastly, the light shield material 14 is cured with ultraviolet rays or heat.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for correcting protrusions and white defects that occur in color filters during the process of manufacturing color filters for liquid crystal display devices.

0002

2. Description of the Related Art First, an example of a method for manufacturing a color filter will be explained with reference to FIG. For example, by screen printing on a transparent substrate 1 such as glass, a line width of 60 μm and a pitch of 2 are printed.
A black light-shielding layer 2 consisting of a striped pattern with a thickness of about 00 μm and a film thickness of about 2 μm is formed (A). This black light-shielding layer may not be provided. Next, a first color, for example, a red coloring sensitive material is applied from above the black light-shielding layer 2, a photomask is placed, exposed, and developed to form a red pattern layer 3 (B). For example, after the color,
After coating green and blue coloring sensitive materials, a photomask is placed and exposed, followed by development to form green and blue pattern layers 4 and 5 (C, D). Each color pattern layer overlaps the black light-shielding layer 2 by about 20 to 30 μm on both sides in the longitudinal direction, and has a film thickness of about 2 μm. Next, for the purpose of physicochemical protection, surface smoothing, and flattening, a photocurable resin is applied on the color pattern layer to form a protective film layer 6 with a thickness of about 2 to 3 μm (E
). Furthermore, after forming a film of indium tin oxide (ITO) on the protective film layer 6 using a vacuum film forming method, a mask vapor deposition method,
Electrode pattern processing is performed using an etching method or the like to form a transparent electrode layer 7 to manufacture a color filter (F).

0003

[Problems to be Solved by the Invention] In the manufacturing process of the above-mentioned color filter, as shown in FIG. If foreign matter 10 such as dust adheres to the surface of the color pattern layer 5, when the protective film layer 6 is formed on the color pattern layer, protrusions 11 will be formed in the portions corresponding to the foreign matter 9, 10 such as dust. Put it away. Also,
If dust adheres to the photomask, white defect portions 12 will occur in the color pattern layer 4. Such defects may disturb the alignment of liquid crystals in liquid crystal cells provided on the surface of the color filter, or cause defects in captured images or displayed images, resulting in products using the color filter being defective. Therefore, for example, it may be possible to adopt a method of forming a protective film layer and then drilling holes in the protective film with a laser and sealing the holes. However, the protective film layer flattens the unevenness of the colored layer and forms a transparent electrode. If the above-mentioned method is adopted, the problem arises that the smoothness of the protective film layer is extremely deteriorated. In addition, the protective film layer must be thermally stable because it undergoes a thermal history such as forming a transparent electrode, and corrections after the formation of the protective film layer should be avoided in case thermal distortion occurs. This may lead to the occurrence of defects such as cracks, and is also disadvantageous in terms of chemical separation of the liquid crystal layer and the colored layer.

[0004] The present invention solves the above problem, and by removing the defective parts with a laser before forming the protective film layer, it is possible to easily correct the defective parts that occur during the manufacturing process of color filters. The purpose is to provide a method that can be used.

[0005]

[Means for Solving the Problem] To this end, the method for repairing defective parts of a color filter according to claim 1 includes forming a protective film layer on the surface of the defective part of the color pattern layer, and irradiating the defective part with a laser beam. After removing the defective part, a light-shielding material corresponding to the color of the color pattern layer is applied to the removed part, and then the protective film layer is mechanically peeled off and a light-shielding material is applied to the removed part. remains, and finally, the light-shielding material is cured by ultraviolet rays or heat. After removing the defective part by irradiating the defective part with a laser beam, a light-shielding material corresponding to the color of the color pattern layer is applied to the removed part, and then the light-shielding material is exposed to ultraviolet rays or heat. and finally, the protective film layer is mechanically peeled off to leave the light-shielding material in the removed portion. After forming a temporary protective film layer on the surface of the layer, the defective part of the color pattern layer is irradiated with a laser beam to remove the defective part, then the temporary protective film layer is removed by solvent cleaning, and finally The method is characterized in that it forms a true protective film layer of the color filter.

[0006]

[Operation] In the present invention, for example, as shown in FIG.
After forming a protective film layer 13 made of a material with good removability and flexibility on the defective part where the foreign matter 9 has entered, the defective part is irradiated with a laser beam to remove the surrounding part of the foreign matter 9, and then the removed part is covered with a protective film layer 13. Light-shielding material 1 corresponding to the color of color pattern layer 3
4 is applied, and then the protective film layer 13 is mechanically peeled off, leaving the light-shielding material 14 in the removed portion. Finally, if the light-shielding material 14 is a photocurable resin colored with a pigment or the like, ultraviolet rays are irradiated from the front or back side of the transparent substrate 1 to cure the light-shielding material 14. In the case of a colored thermosetting resin, the light-shielding material 14 is cured by placing it in an oven to complete the modification. Note that the protective film layer 13 may be mechanically peeled off after a part of the light-shielding material 14 is cured by irradiating ultraviolet rays from the front side or the back side of the transparent substrate 1 by under-exposure.

[0007]

Embodiments Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1 and 2 show one embodiment of the method for correcting defective portions of a color filter according to the present invention, FIG. 1 is a diagram for explaining the repair method, and FIG. 2 is an enlarged sectional view showing the repair process.

In FIG. 2A, 1 is a transparent substrate, 2 is a black light-shielding layer, and 3 is a color pattern layer, and shows a state in which foreign matter 9 has been mixed into the color pattern layer 3. First, as shown in step 21 of FIG. 1 and FIG. 2(B), a protective film layer 13 is applied to the defective portion where the foreign matter 9 has entered using a dropper or dispenser, and then dried to form the protective film layer 13. This protective film layer 13 is made of a material with good peelability and flexibility with respect to the color pattern layer 3. In this example, a synthetic resin solution was used in which a vinyl chloride vinyl acetate copolymer was diluted in a mixed solvent of toluene and methyl ethyl ketone so that the solid content was 15% by weight.

Next, as shown in step 22 and FIG. 2(C), the defect area is irradiated with a laser beam to remove the surrounding part of the foreign object 9, and then, as shown in step 23 and FIG. 2(D), A light-shielding material 14 corresponding to the color of the color pattern layer 3 is applied to the removed portion. Note that if the defective portion is a black light-shielding layer, black is applied. This light-shielding material 1
4 is made of photocurable resin or thermosetting resin. Next, as shown in steps 24 and 25 and FIG.
remains. Finally, if the light-shielding material 14 is a photocurable resin colored with a pigment or the like, ultraviolet rays are irradiated from the front or back side of the transparent substrate 1 to harden the light-shielding material 14 and the modification is completed. If the light-shielding material 14 is a thermosetting resin colored with a pigment or the like, it is placed in an oven to harden the light-shielding material 14 and the correction is completed.

Note that steps 24 and 25 are reversed, and after curing a part of the light-shielding material 14 by irradiating ultraviolet rays from the front or back side of the transparent substrate 1 by under-exposure, the protective film layer 13 is mechanically removed. It may also be peeled off. In addition, in the above embodiment, the foreign matter 9 that causes the protrusion is
Although the removal and correction of the white defect portion 12 explained in FIG.

Next, another embodiment of the present invention will be explained with reference to FIG. This embodiment is applied to removing foreign matter. The surface on which the color pattern is formed has large irregularities that make it difficult to observe defects caused by foreign matter during color pattern formation.In order to smooth the surface and make it easier to detect foreign matter, first, in step 31, solvent cleaning is performed. A removable temporary protective film layer is formed by spin coating. For this protective film layer, a resin is selected that allows easy detection of foreign substances. In this example, the trade name Renotac was used. next,
In step 32, the foreign object that has become easier to observe is irradiated with a laser beam in a spot of about 20 μm to remove the surrounding area of the foreign object.In step 33, the temporary protective film layer is removed by solvent cleaning, and finally In step 34, a true protective film layer with good ITO resistance is formed by spin coating. In this example, the defective part is 20μ
The color pattern will not be corrected because it will be a white spot with a size of about m, but it cannot be distinguished with the naked eye. Note that if the defective portion has a size of approximately 20 μm or more, it is corrected by the method shown in FIG. 2.

0012

[Effects of the Invention] As is clear from the above description, according to the present invention, defects are removed by laser before forming a protective film layer, so that some irregularities caused by correction can be removed by forming the protective film in the next step. This has the effect of flattening the liquid crystal layer, and there is no risk of thermal distortion occurring during modification after the formation of the protective film layer. You will never be at a disadvantage. In addition, defects that occur during the color filter manufacturing process can be easily corrected.

[Brief explanation of the drawing]

[Fig. 1] A diagram for explaining one embodiment of the defect repair method of the present invention.

FIG. 2 is an enlarged sectional view showing one embodiment of the defect repair method of the present invention.

FIG. 3 is a diagram for explaining another embodiment of the defect repair method of the present invention.

[Fig. 4] Enlarged cross-sectional view for explaining the method of manufacturing a color filter

[Fig. 5] Enlarged cross-sectional view for explaining defective parts of color filters

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1... Transparent substrate, 2... Black light shielding layer, 3... Color pattern layer, 9... Foreign matter, 13... Protective film layer, 14... Light blocking material.

Claims (3)

[Claims] 1. A protective film layer is formed on the surface of the defective part of the color pattern layer, and after the defective part is removed by irradiating the defective part with a laser beam, the removed part is coated with a color corresponding to the color of the color pattern layer. A light-shielding material is applied, then the protective film layer is mechanically peeled off to leave the light-shielding material in the removed portion, and finally, the light-shielding material is cured by ultraviolet rays or heat. How to repair defects in color filters. 2. A protective film layer is formed on the surface of the defective part of the color pattern layer, and after the defective part is removed by irradiating the defective part with a laser beam, the removed part is coated with a color corresponding to the color of the color pattern layer. A light-shielding material is applied, then the light-shielding material is cured by ultraviolet rays or heat, and finally, the protective film layer is mechanically peeled off to leave the light-shielding material in the removed portion. A method for repairing defects in color filters. 3. After forming a temporary protective film layer on the surface of the color pattern layer, the defective part of the color pattern layer is irradiated with a laser beam to remove the defective part, and then the temporary protective film layer is removed. A method for correcting defects in a color filter, which comprises removing the defects by solvent cleaning and finally forming a true protective film layer of the color filter.