JPH06265712A - Production of color filter and toner used for the same and its production and developer - Google Patents

Abstract

PURPOSE:To provide the process for production of the high-performance color filter by subjecting for materials forming the colored layers contg. inorg. matter to baking in final, thereby suppressing the waste of a material for forming the color filter as far as possible and assuring the colored layer having high positional accuracy. CONSTITUTION:This process for production of the color filter having the colored layers consisting of the inorg. material has (a) a stage for electrostatically charging a photosensitive body supported on a substrate, (b) a stage for forming electrostatic latent image patterns on the surface of the photosensitive body by selectively exposing the surface, (c) a stage for sticking toners for forming the colored layers according to the electrostatic latent image patterns, (d) a stage for transferring the toners for forming the colored layers from the surface of the photosensitive body to a transparent substrate side and (e) a stage for baking the toners for forming the colored layers transferred onto the transparent substrate. The substrate is patterned and formed with the colored layers by selective exposing in such a manner and, therefore, the higher positional accuracy of the colored layers than by a printing method is assured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is provided in various display devices such as a plasma display (PDP) and a liquid crystal display (LCD) and a solid-state image pickup device, and is used for reducing reflectance, color synthesis or color separation. In particular, the present invention relates to a method for manufacturing a color filter having excellent heat resistance, a coloring material used therefor, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in order to obtain a color filter which requires high heat resistance (for example, when it is used for reducing the reflectance of the PDP), a coloring layer is generally formed by using an inorganic material. ing. When the colored layer is manufactured by a printing method using a color filter made of an inorganic material, the inorganic material forming the colored layer and a binder component mainly made of an organic material are mixed to form a paste, which is then subjected to a predetermined amount. A colored layer is formed by printing on a glass substrate and firing it. A color filter is manufactured by repeating this process for the required number of colors.

The paste used here will be described below. For example, in the case of a red color, copper oxide, tin oxide, or the like, which is a coloring component, is mixed with low-melting glass, and ethyl cellulose or acrylic resin or the like is dispersed in an organic binder dissolved in an organic solvent such as ethyl carbitol to paste. Those that have been converted are generally used.

For green color, copper oxide, chromic acid or the like as a coloring component is mixed with low melting point glass, and ethyl cellulose or acrylic resin is mixed with an organic solvent such as ethyl carbitol like the red paste. A paste prepared by dispersing in a dissolved organic binder is generally used.

For blue color, cobalt oxide, which is a coloring component, is mixed with low melting glass, and ethyl cellulose or acrylic resin is dissolved in an organic solvent such as ethyl carbitol as in the case of red color and green color. Those dispersed in an organic binder are generally used.

These pastes are printed on a predetermined glass substrate. Various printing methods can be used, for example, a screen printing method and a lithographic offset printing method are generally applied.

When the screen printing method is used, the paste may be printed on a glass substrate by using a screen printing plate of, for example, about 250 to 400 mesh.

The substrate on which the paste is printed is baked at about 500 to 600 ° C. for several minutes to form colored layers of each color. Here, the low melting point glass contained in the paste of each color has a role of melting by firing and adhering the colored layer component onto the substrate.

Further, since the organic binder and the organic solvent contained in the paste are burned and removed at such a high temperature, finally only the inorganic substance remains on the glass substrate. That is, a color filter whose colored layer is made of an inorganic material is manufactured.

By the way, the color filters used in the display device are generally arranged in a matrix of three colors of red, green and blue according to the purpose. Therefore, also in the present invention, a color filter used for a general display device can be obtained by repeating the manufacturing method characterized by passing through the printing step and the firing step for these three colors.

However, when a pattern is formed by such a printing method, the printed pattern gets wet and spreads due to factors such as the leveling of the paste during printing.
In particular, it is difficult to form a fine pattern.

In addition, for example, in screen printing,
It is difficult to obtain high positional accuracy because a printing position shift that occurs due to the distortion of the screen plate during printing occurs.

For the above-mentioned reasons, it is difficult for the manufactured color filter to maintain a high positional accuracy and a predetermined shape of the colored layer, and further, it causes a decrease in contrast.

In addition, regarding other situations, as a method of forming a pattern with higher accuracy, a pattern forming material containing a photosensitive resin is applied to the entire surface of the substrate by a spin coating method, a roll coating method or the like, and this is applied. It is common to use a so-called photolithography method in which a pattern is formed by exposing through a photomask having a predetermined mask pattern and then developing.

However, in the photolithography method, a pattern forming material (the most widely used one is photoresist) is applied to the entire surface of a substrate to form a film, and only a necessary portion of the film is left and other than that. The technique is to discard the part.

Furthermore, particularly when the entire surface of the substrate is applied by the spin coating method, most of the pattern forming material dropped on the substrate is spread over the entire surface of the substrate to form a coating film. By then, most of it has already been discarded.

That is, when the photolithography method is used, although the accuracy of pattern formation is high, on the other hand, a large amount of material is wasted, and there is a problem regarding the processing of the material which is discarded along with it. Was there.

[0018]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to finally subject a material containing an inorganic material for forming a colored layer to firing. With respect to a method for manufacturing a color filter by which a colored layer can be obtained, waste of materials forming the color filter is suppressed as much as possible, and a colored layer with high positional accuracy is secured,
Another object of the present invention is to provide a method for producing a high-performance color filter in which each colored layer maintains a good shape.

[0019]

Means provided by the present invention for solving the above-mentioned problems are as follows: In the method for producing a color filter in which the coloring layer is made of an inorganic material, the following steps, namely, (a) Depending on the electrostatic latent image pattern, a step of charging the photosensitive element by being supported by a support, (b) a step of selectively exposing the photosensitive element to form an electrostatic latent image pattern on the surface, and (c) an electrostatic latent image pattern. A step of adhering the color layer forming toner, (d) a step of transferring the color layer forming toner from the photosensitive member to the transparent substrate side, and (e) a color layer forming toner transferred onto the transparent substrate. And a step of firing at least the steps (a) to (e) as described above.

A toner used in a method of manufacturing a color filter by an electrophotographic method includes a binder resin, an inorganic color pigment made of a metal oxide, and a low melting point glass, and a method of manufacturing a color filter. It is a toner used for.

Furthermore, in the method for producing a toner used in the method for producing a color filter, the following steps are carried out: (f) a step of mixing and melting metal oxide particles and low melting point glass, and (g) crushing thereafter. After that, the step of classifying, (h) the step of heating and kneading this with a binder resin, (ri) the step of crushing this into fine powder and classifying the above, at least from (h) to (h) A method for producing a toner used in a method for producing a color filter, which comprises each step.

A developing solution for use in a color filter manufacturing method, characterized in that the toner is dispersed in a non-polar solvent.

When the above-mentioned developing solution is used, it corresponds to so-called wet development, but in order to disperse well at this time, it is preferable that the toner is as small as possible. Although there is no clear upper limit, it is experimentally preferable that the toner particle size is about 1.2 μm or less.

[0024]

According to the present invention, the accuracy of pattern formation (arrangement and dimensional shape) is largely controlled by an optical method through a photomask, as in the so-called photolithography method. Then, the toner used as the material for forming the colored layer is provided only in a necessary portion as in the so-called printing method, and then transferred onto a predetermined substrate. Therefore, similarly to the photolithography method, it is possible to secure high accuracy of the arrangement of the pattern of the colored layer and the dimensional shape. Since the colored layer forming material is provided only in the portion where the pattern is to be formed as in the printing method, the waste of the material can be reduced as much as possible.

Here, the colored layer pattern formed on the original substrate having the photoconductor is transferred to another glass substrate, but this has high heat resistance (at least to the extent that it can handle temperatures of 300 ° C. or higher). When obtaining a color filter, it is usually effective that the photoconductor does not have very high heat resistance. If the photoreceptor has the required heat resistance, it is not always necessary to transfer it to another glass substrate. In the case of transfer, at least one substrate having a photoconductor can be repeatedly used a plurality of times, whereby a large number of color filters can be manufactured.

[0026]

EXAMPLE (FIG. 1) is a flow chart showing an outline of steps in an example of a method of manufacturing a color filter according to the present invention. And (FIG. 2) thru | or (FIG. 7) is the figure which showed each process of the manufacturing method of the color filter by this invention.

The color filter in this embodiment has a structure in which a set of three colors consisting of a red coloring layer, a green coloring layer and a blue coloring layer is arranged.

The color filter having the above structure is manufactured by the following steps.

As shown in FIG. 2, the selenium photoconductor 11 covering the surface of the support 10 is charged by applying a voltage of about 5 kV.

On the charged selenium photoreceptor 11 (FIG. 3)
Exposure was performed using the photomask 12 as shown in FIG. By such exposure, charges other than the portion where the red colored layer is formed are removed, and an electrostatic latent image 13 having the same pattern as the predetermined pattern of the photomask 12 is formed.

A predetermined pattern is developed by adhering the toner 14 for forming the red color layer to the electrostatic latent image 13 as shown in FIG.

The red colored layer forming toner 14 used here was obtained by adding 5 parts by weight of chromium oxide and 5 parts by weight of copper oxide to a glass frit (manufactured by Nippon Electric Glass Co., Ltd., trade name: LS010).
0) Mix with 115 parts by weight, melt at 1200 ° C., cool to room temperature, and then use a ball mill to obtain an average particle size of 5
The weight ratio of the colored glass component produced by pulverizing to less than or equal to μm to that of a styrene-n-butylmethacrylate copolymer (manufactured by Sanyo Kasei Co., Ltd., trade name: Hymer SBM-73) was 1: 9. Fluorinated acrylate polymer (trade name: polytrifluoro, manufactured by Toray Co., Ltd.) was added to colored particles having an average particle size of 10 μm obtained by kneading, cooling, coarsely crushing with a hammer mill, crushing with a jet mill, and subsequent classification. It is prepared by spray-drying (ethyl α-chloroacrylate) to make it adhere and subjecting it to hot air treatment by a spheronizer for thermoplastic particles. The hot air at this time had a temperature of 400 ° C., a hot air flow rate of 1 m ³ / min, a particle-dispersed air flow pressure of 0.1 kgf / cm ² , and an air flow rate of 0.3 m.
³ / min, and the particle dispersion density is 10g / m
^{It was 3} .

FIG. 5 shows a predetermined pattern developed with a toner for forming a red colored layer. As shown in FIG. 6, the selenium photoconductor 11 is brought into contact with the glass substrate 15 and then about 10
The toner 14 for forming the red color layer is transferred to the glass substrate 15 by heating at 0 ° C.

This step was similarly performed for the green color layer forming toner and the blue color layer forming toner, and images of these three color toners were formed on the glass substrate.

The green colored layer forming toner used here was a glass frit (Nippon Electric Glass, trade name: LS0100) containing 10 parts by weight of copper oxide and 2 parts by weight of chromic acid.
The mixture was mixed with 15 parts by weight, melted at 1200 ° C., cooled to room temperature, and then pulverized with a ball mill until the average particle size became 5 μm or less, and the colored glass component was prepared with styrene-n-butyl methacrylate. 1 by weight ratio with copolymer (manufactured by Sanyo Kasei, trade name: Hymer SBM-73)
Fluorine-containing acrylate polymer was added to colored particles having an average particle size of 10 μm obtained by kneading in a ratio of 9 and cooling, roughly crushing with a hammer mill, crushing with a jet mill, and then classification. Name: Polytrifluoroethyl α
-Chloroacrylate) is spray-dried and adhered, and this is blown with hot air (temperature 4
00 ° C.), the hot air flow rate was 1 m ³ / min, the pressure of the particle dispersion airflow was 0.1 kgf / cm ² , and the air flow rate was 0.3 m ³ / min, and the particle dispersion density was 10 g / m ³ .

The toner for forming the blue color layer is cobalt oxide.
5 parts by weight of glass frit (Nippon Electric Glass, trade name:
LS0100) 115 parts by weight and mixed with 1,20
Use a ball mill after melting at 0 ° C and cooling to room temperature
Was prepared by crushing to an average particle size of 5 μm or less.
Colored glass component is styrene-n-butyl meta acrylate
Copolymer (manufactured by Sanyo Chemical Co., Ltd., trade name: Hymer SBM-7
3) and knead in a weight ratio of 1: 9, and after cooling, hang
Only coarsely crushed with a mar mill and then crushed with a jet mill.
The colored particles with an average particle size of 10 μm obtained by classifying
Fluorine acrylic ester polymer (product name Toray, trade name Polit
Lifluoroethyl α-chloroacrylate) spray
Dry it and attach it to a spheronizer for thermoplastic particles.
From, hot air (temperature 400 ℃), hot air volume 1m³/ Min,
Particle dispersed air pressure 0.1kgf / cm², Air volume 0.3
m³/ Min, and the particle dispersion density is 10 g /
m ³And

In this way, the toner for forming the red colored layer,
By baking the glass substrate 15 on which an image is formed with the blue color layer forming toner and the green color layer forming toner at 580 ° C. for 10 minutes, the glass substrate 15 is colored red as shown in FIG. Layer 16, green colored layer 17 and blue colored layer 18 were formed.

As a result, a color filter having excellent shape and positional accuracy of each colored layer was obtained.

[0039]

According to the present invention, the electrophotographic method is applied to form the pattern of the colored layer by selective exposure, so that a higher positional accuracy of the colored layer can be ensured as compared with the printing method, and individual coloring can be performed. The layer can maintain a good arrangement and dimensional shape, and since the material is attached only to the portion where the pattern is to be formed, the waste of the material used for the pattern formation can be suppressed as much as possible as compared with the photolithography method.

That is, the present invention relates to a method of manufacturing a color filter in which a colored layer is obtained by finally firing a material for forming a colored layer containing an inorganic substance, and the waste of the material forming the color filter is suppressed as much as possible. And a high-performance color filter in which a colored layer with high positional accuracy is secured and each colored layer maintains a good shape, a toner used therefor, a method for manufacturing the same, and a developing method. I was able to provide the liquid.

[Brief description of drawings]

FIG. 1 is a flow chart showing an outline of steps in an example relating to a method for manufacturing a color filter of the present invention.

FIG. 2 is an explanatory view showing an outline of a step of charging a selenium photoconductor using a cross-sectional view, as to one embodiment of the method for manufacturing a color filter of the present invention.

FIG. 3 is an explanatory view showing an outline of a step of forming an electrostatic latent image pattern on a surface of a photoconductor by exposure through a photomask, with reference to cross-sectional views, in one embodiment relating to a method for manufacturing a color filter of the present invention. Is.

FIG. 4 is an explanatory view showing, using a cross-sectional view, an outline of a step of adhering a toner, which is a coloring layer forming material, to a selenium photoconductor in one embodiment of the method for manufacturing a color filter of the present invention.

FIG. 5 is an explanatory view showing, using a cross-sectional view, an outline of a process of developing with a toner that is a coloring layer forming material in one example relating to the method for manufacturing a color filter of the present invention.

FIG. 6 is an explanatory diagram showing, in a cross-sectional view, an outline of a step of transferring a toner formed in a predetermined pattern from a selenium photoconductor to a glass substrate in one example of the method for manufacturing a color filter of the present invention.

FIG. 7 is an explanatory view schematically showing, in a cross-sectional view, a step of firing a toner, which is a coloring layer forming material on a glass substrate, to form a coloring layer in one embodiment of the method for manufacturing a color filter of the present invention. is there.

[Explanation of symbols]

 10 ... Support 11 ... Selenium photoconductor 12 ... Photomask 13 ... Electrostatic latent image 14 ... Red colored layer forming toner 15 ... Glass substrate 16 ... Red colored layer 17 ... Green colored layer 18 ... Blue colored layer

Claims (4)

[Claims] 1. A method of manufacturing a color filter in which a colored layer is made of an inorganic material, including the following steps: (a)
Depending on the electrostatic latent image pattern, a step of charging the photosensitive element by being supported by a support, (b) a step of selectively exposing the photosensitive element to form an electrostatic latent image pattern on the surface, and (c) an electrostatic latent image pattern. A step of adhering the color layer forming toner, (d) a step of transferring the color layer forming toner from the photosensitive member to the transparent substrate side,
(E) A step of baking the toner for forming the colored layer transferred onto the transparent substrate, and at least each of the steps (a) to (e) above. 2. A method for producing a color filter, comprising a binder resin, an inorganic coloring pigment made of a metal oxide, and a low melting point glass in a toner used in the method for producing a color filter by electrophotography. Toner used for. 3. A method for producing a toner used in a method for producing a color filter, comprising the steps of:
(F) a step of mixing and melting the metal oxide particles and the low-melting glass, (g) a step of pulverizing and then classifying,
(H) Next, a step of heating and kneading this with a binder resin, (ri) a step of crushing this and then finely pulverizing and classifying it, at least each step of (e) to (i) A method for producing a toner used in a method for producing a characteristic color filter. 4. A developer used in a method for producing a color filter, comprising the toner according to claim 2 dispersed in a non-polar solvent.