JPH0527113A - Production of color filter array element - Google Patents

Abstract

PURPOSE:To improve thermal stability and color purity by superposing a dye- contg. layer and an image receiving layer contg. a mordant on a transparent base on each other and heating these layers, thereby forming repetitive mosaic patterns in the image receiving layer. CONSTITUTION:The dye-contg. layer 7 of a heat sensitive transfer material 8 and the image receiving layer 9 contg. the mordant on the transparent base 10 are superposed on each other to form the repetitive mosaic patterns of the images formed by the reaction of the dyes and the mordant in the image receiving layer 9. The thermally transferred images having the mosaic patterns are formed by successively transferring three kinds of the heat sensitive transfer materials 8 which yield blue, green and red dye images 14, 16, 12 in arbitrary order to form the blue, green and red mosaic patterns or by successively transferring three kinds of the heat sensitive transfer materials which yield yellow, magenta and cyan dye images in arbitrary order to form the blue, green and red dye images 14, 16, 12 in the image receiving layer 9. The heat sensitive transfer materials to yield the blue, green and red dye images 14, 16, 12 are preferably used in order to facilitate the alignment.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a color filter array element used in a liquid crystal display or the like, and more particularly to a method for manufacturing a color filter array element using thermal transfer.

[0002]

2. Description of the Related Art Attempts have been made to incorporate a color filter array element into a device for colorizing a liquid crystal display. This color filter array element is generally manufactured by a photolithographic method. In this method, exposure and development are repeated three times to manufacture a blue, green and red mosaic pattern. It has the drawbacks of being complicated, requiring a long time, and being expensive.

As a method for avoiding this drawback, JP-A-2-
No. 295790, No. 3-101995, U.S. Patent No. 4,962,081, etc.,
A method of obtaining a color filter array element using thermal transfer is disclosed. However, the manufacturing process of the display device using the color filter array element includes a severe heat treatment step, and the color filter array element formed by thermal transfer has a defect that color bleeding occurs in the heat treatment step. It was

[0004]

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a method of manufacturing a color filter array element which is easier to manufacture than conventional products and can be manufactured at low cost.

Another object of the present invention is to provide a method for producing a color filter array element having good thermal stability, sharpness and good color purity.

[0006]

The above object is to react the dye with a mordant by superposing a dye-containing layer of a heat-sensitive transfer material comprising a dye and a binder on an image-receiving layer containing a mordant on a transparent support and heating them. This is achieved by a method for producing a color filter array element, which comprises forming a repeating mosaic pattern in the image receiving layer by the image formed by.

The present invention will be described in more detail below.

In the thermal transfer image having the mosaic pattern of the present invention, the three types of thermal transfer materials provided by the blue, green and red dye images are sequentially transferred in an arbitrary order to form a blue, green and red mosaic pattern. Alternatively, it is preferable to sequentially transfer the three types of heat-sensitive transfer materials provided by the dye images of yellow, magenta, and cyan in an arbitrary order to form the dye images of blue, green, and red in the image receiving layer. To facilitate
It is particularly preferred to use a thermal transfer material that provides a blue, green or red dye image. The blue, green, and red dye images are usually formed from at least two dyes each of which is magenta and cyan for blue, cyan and yellow for green, and magenta and yellow for red.

In the mosaic pattern of the color filter of the present invention, additive primary color patterns of blue, green and red are repeated vertically and horizontally, but each mosaic pattern is used for the purpose of improving color reproduction on the display. It is preferably separated by black stripes. This black stripe may also be formed by mixing dyes by the thermal transfer used in the present invention.

The size of the mosaic of the present invention is not limited because it depends on the size of the display used.
The size of each pixel is preferably 30 to 300 μm.

The image receiving layer on which the mosaic pattern is formed is composed of at least a binder and a mordant.

As the binder, polyvinyl chloride resin,
It is selected from polymers such as polyester resin, polycarbonate resin, polyurethane resin, polyamide resin, polystyrene resin, copolymer resin of vinyl chloride and vinyl acetate, and mixtures thereof. The mordant may also serve as the binder.

As the mordant, a compound having an amino group, for example, alkylamine (decanoylamine, octylamine, dioctylamine, trioctylamine, etc.), arylamine (aniline derivative), nitrogen-containing heterocyclic group (eg, pyridine ring, Examples thereof include compounds having an imidazole ring) and quaternary ammonium salt compounds thereof. The mordant is preferably immobilized, and a polymer mordant is particularly preferable.

As a polymer mordant, Japanese Patent Laid-Open No. 48-28325 is available.
No. 54, No. 54-74430, No. 54-124726, No. 55-22766, No. 5
5-142339, 55-23850, 60-23851, 60-23852
No. 60, No. 60-23853, No. 60-57836, No. 60-60643, 60-1
18834, 60-60643, 60-118834, 60-122940
No. 60, No. 60-122941, No. 60-122942, No. 60-235134,
U.S. Patents 2,484,430, 2,548,564, 3,148,061
Issue 3,148,161, Issue 3,309,690, Issue 3,756,814,
3,898,088, 3,958,995, 4,115,124, 4,1
24,386, 4,193,800, 4,273,853, 4,282,30
5, 4,450,224, British Patents 1,594,961, 2,056,1
Those described in No. 01, No. 2,093, 041, etc. can be used.

As the transparent support carrying the image receiving layer,
Polymers such as polyethylene terephthalate, polysulfone, polycarbonate and polyimide having excellent heat resistance, glass, quartz and sapphire can be used. The thickness of the support is usually preferably 1 μm to 10 mm, especially 0.2 to 2 m.
A thickness of m is preferred.

The dye contained in the heat-sensitive transfer material is not particularly limited, and dyes used in ordinary heat-sensitive transfer materials such as anthraquinone type, azo type, azomethine type and quinophthalone type can be used, but are preferable. Is a dye having a phenolic hydroxyl group described in JP-A-3-836825, particularly JP-A-3-83687, 3-83688, 3-9368.
No. 9, No. 3-90387, No. 3-92385, No. 3-92386, No. 3-11
The azomethine dyes described in 4890 are preferred. The content of the dye is preferably 0.05 to 10 g per 1 m ² of the support. The thickness of the color material layer is preferably 0.1 to 10 μm as a dry film thickness.

The binder for the dye-containing layer is preferably a solvent-soluble polymer such as acrylic resin, methacrylic resin, polystyrene, polycarbonate, polysulfone, polyether sulfone, polyvinyl butyral, polyvinyl acetal, nitrocellulose or ethyl cellulose. The amount of binder used is 1 m ² of the support.
0.1 to 20 g is preferable.

The support for the dye-containing layer may be any as long as it has good dimensional stability and can withstand heating during recording, but it is preferably made of thin paper such as condenser paper or glassine paper, polyethylene terephthalate, polyamide or polycarbonate. Such a heat resistant plastic film is preferably used. The thickness of the support depends on the recording method,
3 to 200 μm is preferable.

Further, it is preferable that the support has an undercoat layer made of a polymer selected for the purpose of improving the adhesiveness with the binder and preventing the transfer and dyeing of the dye to the support. Further, the back surface of the support (on the side opposite to the heat-sensitive transfer layer) may have a slipping layer for the purpose of preventing the head from sticking to the support.

A basic compound is preferably added to the above-mentioned image-receiving layer or dye-containing layer for the purpose of improving the reaction between the dye and the mordant.

Examples of the basic compound include organic amines. When light energy of a laser or the like is used as a heat mode as a recording method, an infrared light absorbing substance is added to a part of the heat-sensitive transfer material, for example, a support or a coloring material layer or an undercoat layer or the back surface of the support. It is preferable to add it to the color material layer, particularly from the viewpoint of sensitivity.

Examples of the infrared light absorbing substance include carbon black, infrared dyes or pigments. As a method for producing the color filter array element of the present invention, the heat-sensitive transfer material (hereinafter referred to as a transfer material) and the material having the image receiving layer (hereinafter referred to as an image receiving material) are superposed and heated to form an image receiving layer. An image pattern of any one color (for example, blue) is formed, and then an image receiving material on which a blue pattern is formed and a transfer material capable of forming an image of a color other than blue (for example, green) are superimposed, A method of forming a green pattern image by shifting from the pattern and similarly forming a red pattern image is used. Alternatively, using a transfer material that forms a yellow, magenta, and cyan dye image,
The mosaic pattern may be formed by a combination of yellow and magenta, yellow and cyan, and magenta and cyan.

As a heating method, a method of heating with a thermal head or a method of heating with a laser can be used, but heating with a laser is preferable in order to improve the accuracy of the pattern.

[0024]

EXAMPLES Next, the present invention will be described in more detail by way of examples, but the present invention is not limited thereto.

Example 1 (Preparation of heat-sensitive transfer material) The following raw materials were mixed to obtain Ink-1 as a uniform solution containing a heat diffusible dye.

Thermal diffusible dye (M-1) 4 g Thermal diffusible dye (Y-1) 4 g Infrared dye (IR-1) 1 g Polyvinyl butyral resin (BL-1: Sekisui Chemical Co., Ltd.) 8 g Methyl ethyl ketone 250 ml Above The amount of ink applied on a polyethylene terephthalate base with a thickness of 150 μm using a wire bar is 1.
A transfer material-1 for forming a color material layer and forming a red dye image was prepared by coating and drying so that the amount was 5 g / m ² .

A transfer material-2 for forming a blue dye image having the same constitution as the transfer material-1 except that the heat diffusible dye Y-1 of the transfer material-1 is replaced with the heat diffusible dye C-1. , And a heat-sensitive transfer material for forming a green dye image having the same structure as the heat-sensitive transfer material-1, except that the heat-diffusible dye M-1 of the heat-sensitive transfer material-1 is replaced with the heat-diffusible dye C-1. Created 3.

[0028]

[Chemical 1]

(Preparation of Filter Array) On a 1.1 mm-thick transparent borosilicate glass provided with an undercoat layer, a polycarbonate layer having a thickness of 4 μm and containing a mordant (trioctylamine, coating amount 0.7 g / m ² ). Was coated with an image receiving layer.

The transfer material-1 and the image receiving layer coated surface are overlapped with each other.
Irradiate the color layer of the ink sheet with He-Ne gas laser,
A red stripe was formed on the borosilicate glass.

Next, the transfer material-2 is used to form a blue stripe by the same operation, and the transfer material-3 is used to form a green stripe by the same operation to form a color filter array-1. did.

Comparative Example-1 Example-1 except that the mordant was removed from the image-receiving layer of Example-1.
An image receiving material having the same constitution as in No. 1 was prepared, and a color filter array-2 was prepared in the same manner as in Example-1. In addition, a color filter array was similarly prepared by using transfer materials in which the thermal diffusible dyes Y-1, M-1, and C-1 of Example-1 were changed to Y-2, M-2, and C-2, respectively. Created 3.
The image receiving layer contains no mordant.

[0033]

[Chemical 2]

Example-2 As described in Example-1, except that the dyes Y-1, M-1, and C-1 of Example-1 were replaced with Y-3, M-3, and C-3, respectively. Transfer Materials-4, 5 and 6 were prepared by the method. A color filter array-4 was prepared using the transfer materials-4, 5 and 6 in the same manner as in Example-1.

[0035]

[Chemical 3]

Example 3 Color was obtained by using the same image-receiving layer as in Example-1 except that the mordant (trioctylamine) used in the image-receiving layer of Example-1 was replaced by polymer mordants P-1 to P-5. Filter arrays-5-5 were made.

[0037]

[Chemical 4]

(Evaluation of Materials) The color filter arrays-1 to 5 obtained in Examples and Comparative Examples were heated at 130 ° C. for 20 minutes and then stored at 200 ° C. for 2 hours. Color filter arrays-2 and 3 were obtained. Bleeding of the color due to diffusion of the dye was observed and color mixing occurred due to the bleeding, but almost no bleeding was observed in the color filter arrays 1 and 4.

No bleeding was observed in the color filter arrays-5 to 9.

Further, no decrease in concentration was observed in Filter Array-1, 4-9.

On the other hand, in the filter array-2, blue, green,
It was also not good for red color reproduction.

That is, according to the present invention, a color filter array which is excellent in heat resistance, has no color bleeding, and is preferable in color reproduction can be obtained by a simple method.

Example-4 Transfer material-1 prepared in Example-1 and polymer mordant P
1 is a structure in which image receiving layers containing -1 are overlapped and a light non-transmissive portion and a transparent portion for producing a color filter are repeated.
The filters shown in (1) were stacked and exposed using a flash lamp (a).

This operation was performed in the same manner using the heat-sensitive transfer materials-2 and 3 (b) and (c) to prepare a color filter array.

The blue, red, and green image units are each Y-
The periphery is surrounded by black stripes consisting of 1, M-1, and C-1, and these black stripes were also formed at the time of exposing three times.

[0046]

According to the present invention, it is possible to easily and inexpensively manufacture a color filter array element by using the thermal transfer method, and it is clear and has high color purity.
In addition, a color filter array element without bleeding can be obtained.

[Brief description of drawings]

FIG. 1A, FIG. 1B and FIG. 1C are explanatory views showing an example of a method for manufacturing a color filter array element of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 exposure lamp 2 light transmitting part 3 light non-transmitting part 4 heat insulating layer 5 filter 6 support 7a color material layer (for red image formation) 7b color material layer (for blue image formation) 7c color material layer (green image formation) 8) Thermal transfer material 9 Image receiving layer 10 Glass substrate 11 Color filter array 12 Red image 13 Red-blue mixed color 14 Blue image 15 Red-blue-green mixed color (black) 16 Green image

Claims (1)

Claim: What is claimed is: 1. A dye-containing layer of a heat-sensitive transfer material comprising a dye and a binder and an image-receiving layer containing a mordant on a transparent support are superposed and heated to give the dye and the mordant. A method for producing a color filter array element, wherein a repeating mosaic pattern formed by an image formed by the reaction of 1) is formed in the image receiving layer.