JPH08184849A - Liquid crystal display device and its production - Google Patents

Abstract

PURPOSE: To obtain a liquid crystal display device which has high reliability with a change with lapse of time and improved display grade by providing the part where small-sized substrates constituting a pixel substrate are connected with each other with a supporting material for holding a specified spacing between the pixel substrate and a common substrate. CONSTITUTION: A common electrode is formed on the translucent substrate (common substrate) 2 and non-translucent patterns 10 are formed in a grid form corresponding to the circumferences of the respective pixels. The end sides facing each other of four sheets of the small-sized substrates 1a to 1d are adhered by adhesives 9 for fixing to constitute one sheet of the pixel substrate 1. The supporting material 7 for holding the specified spacing between the pixel substrate 1 and the translucent substrate 2 is so disposed as to exist between the connecting parts by the adhesives 9 and the non-translucent patterns 10 facing the connecting parts. The pixel substrate 1 and the translucent substrate 2 are disposed to face each other and the outer peripheral part of the substrate 2 is provided with a sealing material 4. Liquid crystals 5 are enclosed into the spacing between the substrate 2 and the substrate 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a liquid crystal display device and a method for manufacturing the same, and more particularly to a large-sized liquid crystal display device, a liquid crystal display device having a high display quality in which an active matrix substrate is combined, and a method for manufacturing the same. .

[0002]

2. Description of the Related Art In recent years, TVs and monitors have become larger in size, including high-definition TVs (televisions) such as so-called high-definition TVs. Currently, large-sized display devices of about 40-inch are mainly CRTs (Cathode Ray Tubes), and liquid crystal projections are used in some of them. However, in the CRT or projection type display device, the larger the screen, the larger the thickness (depth), and the occupied area increases. Therefore, there is an increasing need for a large-sized flat panel display having a small thickness, particularly a liquid crystal display device having advantages such as low power consumption and easy full-color display.

However, liquid crystal display devices, especially TFT (Thin
Film Transistor), MIM (Metal-Insulator-Metal)
In the case of an active matrix type liquid crystal display device having active elements such as the above, as the size of the substrate increases, the rate of non-defective products deteriorates, and the cost of producing a large size substrate that can be used for a 40-inch TV or the like becomes very high. Also, it is not a good idea in terms of the price of the manufacturing equipment and the installation space.

Therefore, Japanese Laid-Open Patent Publication No. 5-1080 shown in FIG.
In the liquid crystal display device described in Japanese Patent No. 18, a plurality of liquid crystal display panels are connected to achieve a large screen. More specifically, as shown in FIG. 11, the first liquid crystal display panel is formed by enclosing the liquid crystal in the upper substrate 101a and the lower substrate 101b, and the second and third liquid crystal display panels are also similarly formed. Liquid crystal is filled in the upper substrate 102a and the lower substrate 102b, and the upper substrate 103a and the lower substrate 103b, respectively. In addition, common electrodes or signal electrodes are alternately formed on each of the upper substrates 101a, 102a, and 103a.
In 1b, 102b, and 103b, common electrodes or signal electrodes are alternately formed so that the common electrodes and the signal electrodes form pairs in the upper substrate and the lower substrate. Then, between the adjacent liquid crystal display panels, the common electrode terminals or the signal electrode terminals are connected by the anisotropic conductive film 106.
As a result, the first, second, and third liquid crystal display panels are electrically connected to each other.

Further, the upper substrate 101a located on the outermost side
The TAB (Tape Automated Bonding) type LSI (Large Scale Integrated Circuit) 104 supplies a power supply voltage and a signal to the independent terminals. The anisotropic conductive film 106 uses an anisotropic conductive adhesive in which conductive metal particles are mixed in the adhesive.

In addition to the above, another conventional technique for increasing the screen size of a liquid crystal display device using a plurality of substrates is disclosed in Japanese Patent Laid-Open No. 1-94381. 12
FIG. 12B is a perspective view of this liquid crystal display device.
The structure of the vertical cross section which follows the AA line shown in (a) is shown.

This liquid crystal display device comprises four small substrates 51 each having a TFT switching element, a pixel electrode and the like formed thereon.
a to 51d are opposed to a common upper transparent substrate 52, and liquid crystals 55.5 are arranged on the side opposite to the upper transparent substrate 52.
The lower translucent substrate 53 for enclosing 6 is also made to face,
It is composed of a three-layer substrate. On the lower surface of the upper light-transmissive substrate 52, a non-light-transmitting pattern 60 made of a non-light-transmitting material and having a role of a shadow mask for preventing light bleeding or color bleeding from adjacent pixels is formed between adjacent pixels. It is formed along the boundary.

Further, the liquid crystal 55 has a sealing material 54 around the gap between the upper transparent substrate 52 and the small substrates 51a to 51d.
By sealing with a, it is sealed between the upper translucent substrate 52 and the small substrates 51a to 51d. On the other hand, the liquid crystal 56 includes the small substrates 51a to 51d and the lower light-transmissive substrate 5.
By sealing the periphery of the gap between the lower transparent substrate 53 and the small substrates 51a to 51d with a sealing material 54b, the space between the lower transparent substrate 53 and the small substrates 51a to 51d is sealed. The liquid crystals 55 and 56 are in communication with each other through a gap between the small substrates 51a to 51d.
A polarizing plate 58 is provided outside each of the upper transparent substrate 52 and the lower transparent substrate 53.

Further, instead of providing the above liquid crystal 56,
As shown in FIG. 13, the small substrates 51a to 51d and the lower light-transmissive substrate 53 are attached to each other with an adhesive 59.
There is also a conventional example in which a to 51d are reinforced.

[0010]

However, in the conventional liquid crystal display device shown in FIG. 11, the upper substrate 101a is
A common electrode or a signal electrode is formed in the lateral direction on 102a and 103a, and terminals of the common electrode or the signal electrode are overlapped and connected by the anisotropic conductive film 106, so that the connection area can be reduced. Has a limit. The connection region provided with the anisotropic conductive film 106 serves as the non-display portion 105 irrelevant to image display, so that the non-display portion 105 is conspicuous around each of the plurality of liquid crystal display panels, resulting in a large screen display quality. However, there is a problem that it will drop significantly.

On the other hand, in the conventional liquid crystal display device shown in FIGS. 12 (a) and 12 (b), it is not necessary to electrically connect the small substrates 51a to 51d to each other, so that the small substrates 51a to 5d are connected.
It is not necessary to take a width between the 1d butting portions. For this reason, the abutting locations of the small substrates 51a to 51d are covered with the non-translucent pattern 60 corresponding to the periphery of each pixel, which affects the display quality of a large screen like the non-display portion 105. There is no giving.

However, since the liquid crystal 56 that does not participate in the display is enclosed between the small substrates 51a to 51d and the lower light-transmissive substrate 53, the liquid crystal material is very expensive. (B) The liquid crystal display device shown in (b) causes a significant increase in cost. Further, by enclosing the liquid crystal 56 in addition to the liquid crystal 55, the production efficiency of the liquid crystal display device is significantly deteriorated, which also leads to a significant increase in cost. In addition, the lower light-transmissive substrate 53 allows the liquid crystal 5 that does not participate in display.
Since it is provided only for the purpose of enclosing 6, the liquid crystal display device has a problem that it is difficult to reduce the thickness and the weight.

The small substrates 51a to 51d are likely to warp due to environmental changes such as temperature changes. As a result,
Since the gap between the upper light-transmissive substrate 52 and the small-sized substrates 51a to 51d becomes non-uniform, discoloration (color unevenness) of the display color occurs and the display quality deteriorates. Furthermore, the small substrates 51a to
When the warp 51d is generated, the alignment direction of the liquid crystal 55 is not uniform, which causes a problem that the display quality is deteriorated.

Further, in the above-mentioned conventional liquid crystal display device shown in FIG. 13, the small substrates 51a to 51d are replaced with the lower translucent substrate 53.
Since the lower translucent substrate 53 is provided, there is a problem that an increase in weight and an increase in cost are caused because the lower translucent substrate 53 is provided. Furthermore, since the small substrates 51a to 51d are attached to the lower translucent substrate 53, the small substrates 51a to 51d
Although the problem of warpage of 51d is somewhat alleviated, the problem of deterioration in display quality still remains, especially since the edges of the small substrates 51a to 51d near the bonding locations are easily warped.

Further, Japanese Patent Laid-Open No. 1-94381 discloses that
Although it is disclosed that the lower translucent substrate 53 may be omitted, in this configuration, the small substrates 51a to 51d and the upper translucent substrate 52 should be adhered to each other with a sealing material 54a on the outer peripheral portion.
It is unstable with respect to the stress applied from the outside toward the center of the small substrates 51a to 51d, and lacks durability and reliability.

Since there is a limit to the size of the small substrates 51a to 51d, if four or more small substrates are butted against each other to form a larger liquid crystal display device,
It becomes necessary to electrically connect small boards. However, as described above, since the electrically connecting portion between the small boards is a wide non-display portion, a technique for electrically connecting the small boards without hindering the display of a large screen has not yet been provided. Not not.

Further, conventionally, the liquid crystal 55 is the small substrate 51.
It is injected from one place between a to 51d and the translucent substrate 52 and is integrally sealed. However, if liquid crystal is injected between large substrates at one time, it takes a very long time and productivity is poor. Therefore, it is not suitable for mass production. Further, as the size of the substrate increases, it is more difficult to balance the atmospheric pressure for vacuuming when injecting liquid crystal, and the sealing material 54 peels off or a hole is opened in the sealing material 54, and sealing cannot be performed, resulting in a non-defective product rate. Deteriorate.

An object of the present invention is to provide a liquid crystal display device which has a high reliability and is improved in display quality in a liquid crystal display device in which a plurality of small substrates having pixel electrodes are combined to achieve a large screen. At the same time, it is to provide a liquid crystal display device excellent in cost performance and a manufacturing method thereof.

Another object of the present invention is to further increase the size of the liquid crystal display screen by using two or more small substrates, or to use a smaller small substrate to reduce the size of the small substrates, and thus the yield rate of the liquid crystal display device. Therefore, it is an object of the present invention to provide a liquid crystal display device and a manufacturing method thereof, which can further reduce the cost.

Still another object of the present invention is to provide a liquid crystal display device and a method of manufacturing the same which can improve mass production efficiency by significantly shortening the liquid crystal injection time.

Still another object of the present invention is a thin and lightweight large liquid crystal display device of high reliability which does not require a third substrate such as a liquid crystal encapsulating substrate or a reinforcing substrate which is not involved in display, and its large size. A manufacturing method capable of manufacturing a liquid crystal display device at low cost.

[0022]

In order to solve the above-mentioned problems, a liquid crystal display device according to the invention of claim 1 comprises a plurality of small substrates each having at least pixel electrodes corresponding to a plurality of pixels. The pixel substrate is arranged so as to form one flat plate-like pixel substrate having a uniform pixel pitch, and the common substrate on which the common electrode is formed is opposed to the pixel substrate with a width substantially corresponding to the pixel substrate. In a liquid crystal display device in which liquid crystal is held between a common substrate and a common substrate, a supporting material that holds a constant gap between the pixel substrate and the common substrate is provided at least in a joint portion that joins the small substrates together. Is characterized by.

In order to solve the above-mentioned problems, the liquid crystal display device according to the invention of claim 2 has the configuration of claim 1
It is characterized in that the support material is formed in a wall shape along the joining portion.

In order to solve the above-mentioned problems, a liquid crystal display device according to a third aspect of the present invention comprises a plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed, and a plurality of small substrates having a uniform pixel pitch are provided. Between the pixel substrate and the common substrate, the common substrate, which is arranged so as to constitute a flat plate-shaped pixel substrate and has a common electrode formed thereon, is arranged so as to face the pixel substrate with a spread substantially corresponding to the pixel substrate. In the liquid crystal display device that holds the liquid crystal in the above, by providing a conductive material in the joining portion that joins the small-sized substrates together, the small-sized substrates are electrically connected to each other so as to form the one pixel substrate. The conductive material is provided within the width of the non-display portion formed on the contour of each pixel.

In order to solve the above-mentioned problems, the liquid crystal display device according to the invention of claim 4 has the configuration of claim 3
A support member that holds a constant gap between the pixel substrate and the common substrate is provided, and the conductive material is provided on at least a part of the support member so that the one pixel substrate is formed. The feature is that a small board is electrically connected.

In order to solve the above-mentioned problems, a liquid crystal display device according to a fifth aspect of the present invention uses, in addition to the configuration of the third or fourth aspect, conductive particles having a substantially spherical shape as the conductive material. It is characterized by having been.

In order to solve the above-mentioned problems, a liquid crystal display device according to a sixth aspect of the present invention includes, in addition to the configuration of the third, fourth or fifth aspect, a connecting portion for connecting the small substrates to each other. Then, a non-translucent pattern corresponding to the non-display portion formed on the contour of each pixel is formed on either the pixel substrate or the common substrate, and the conductive pattern corresponding to the location of the conductive material is formed. Is formed into a non-translucent pattern, and the conductive material and the conductive pattern are brought into close contact with each other.

In order to solve the above-mentioned problems, a liquid crystal display device according to a seventh aspect of the present invention comprises a plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed, and a plurality of small substrates having a uniform pixel pitch. The common substrates, which are arranged so as to form a flat plate-shaped pixel substrate and on which common electrodes are formed, are arranged so as to face each other with a spread substantially corresponding to the pixel substrate, and the non-corresponding non-corresponding pixels In a liquid crystal display device in which a translucent pattern is formed on either the pixel substrate or the common substrate, and liquid crystal is held between the pixel substrate and the common substrate, the small substrate is opposed to a joint portion for joining the small substrates. The amount of protrusion of the non-translucent pattern is substantially equal to the uniform distance between the pixel substrate and the common substrate.

In order to solve the above problems, a method of manufacturing a liquid crystal display device according to an eighth aspect of the present invention is directed to a plurality of small substrates having at least pixel electrodes corresponding to a plurality of pixels, and the pixel substrate. A common substrate on which a common electrode is formed and which has a width substantially corresponding to the above, and a sealing material is used so that the plurality of small substrates form one flat pixel substrate having a uniform pixel pitch. The support member that holds the gap between the pixel substrate and the common substrate in a constant manner corresponds to the peripheral portion of the common substrate, and corresponds to the joining portion that joins the small substrates together. It is characterized in that the small substrate and the common substrate are adhered to each other at a constant interval via a sealing material and a supporting material, and liquid crystal is sealed between the pixel substrate, the common substrate, the sealing material and the supporting material.

In order to solve the above-mentioned problems, in the method for manufacturing a liquid crystal display device according to the invention of claim 9, in addition to the structure of claim 8, the supporting material is formed into a wall shape along the joining portion. It is characterized in that the space surrounded by the pixel substrate, the common substrate and the sealing material is divided into two or more small chambers, and the liquid crystal is injected into each small chamber.

[0031]

According to the structure of the first aspect, since the supporting member is provided at least in the joint portion for joining the small substrates to each other, the end portion of each small substrate in the joint portion can be reliably supported. Therefore, the stability of each small substrate is improved and the structure is strong against the load applied in the direction perpendicular to the display surface of the pixel substrate in which the small substrates are integrated. As a result, the uniform facing distance between the common substrate and the pixel substrate is reliably maintained.

Further, at each end portion of the small board in the joining portion, a warp tends to occur gradually due to an external factor such as a temperature change. However, by providing the supporting material in the joining portion, The support member has a structure of pressing each end. As a result, it is possible to prevent the end portion of each small substrate from warping with time, and it is possible to improve the reliability of the display quality of the liquid crystal display device.

Further, if the above-mentioned supporting material is provided after the small substrates are bonded together at the joining portion, the bonding portion between the small boards is further covered with the supporting material, so that the bonding property between the small boards is improved. Can also be improved. Moreover, the support material can improve the adhesion strength between each small substrate and the common substrate. As a result, the durability and reliability of the liquid crystal display device can be improved. Also, since it is not necessary to separately provide another board for reinforcing the small board,
The liquid crystal display device can be made thinner and lighter, and the cost can be reduced.

Further, since the plurality of small-sized substrates are arranged so as to form one flat plate-shaped pixel substrate having a uniform pixel pitch, the connecting portion does not disturb the uniform pixel pitch. There is no. That is, since the joining portion is one of the non-display portions that does not participate in the display in the contour portion of each pixel, it does not have any influence on the display of a large screen including a plurality of small substrates.

Therefore, the liquid crystal display device according to the first aspect of the present invention can provide a large-screen display which is thin and lightweight and has high reliability in display quality.

According to the structure of claim 2, the supporting member is
Since it is formed in a wall shape along the joining portion, it is possible to further improve the strength against a load, the bondability between small substrates, or the adhesion strength between each small substrate and the common substrate. The effect can be further enhanced.

According to the structure of claim 3, each small board is
Since it is electrically connected at the joining portion of the small substrates by the conductive material so as to form one pixel substrate,
A large-screen liquid crystal display device can be manufactured.

Further, since the plurality of small-sized substrates are arranged so as to form one flat plate-shaped pixel substrate having a uniform pixel pitch, the joining portion does not disturb the uniform pixel pitch. There is no. That is, the joining portion is one of the non-display portions that are not involved in the display in the contour portion of each pixel. Therefore, in the joining portion, since the conductive material is provided within the width range of the non-display portion,
The conductive material does not interfere with the display on a large screen.

By the way, the smaller the size of the small substrate on which the pixel electrodes are formed, the lower the yield rate and the higher the cost. Therefore, when the small substrates are not electrically connected to each other, the liquid crystal display device has a large screen. A limit is born naturally.

On the other hand, according to the third aspect of the invention, since the small boards are electrically connected to each other, it is possible to combine a plurality of smaller boards to obtain a large screen. That is, since the pixel substrate can be assembled using a substrate that is smaller in size and has a higher yield rate and is cheaper than that not electrically connected, the cost of the large-screen liquid crystal display device can be reduced.

According to the structure of claim 4, the conductive material is provided at the connecting portion between the small substrates, and the support material having the conductive material as a part is provided.
It is possible to provide a liquid crystal display device having more excellent characteristics, which also has the effects of the above configuration.

According to the fifth aspect of the invention, the conductive particles provided at the connecting portion between the small substrates not only electrically connect the small substrates, but also form a gap between the pixel substrate and the common substrate. The same function as that of the support material according to claim 1 which is held constant is fulfilled. In addition, since conductive particles having a substantially spherical shape can be easily manufactured by making their particle diameters substantially uniform, the gap between the pixel substrate and the common substrate is adjusted to be constant in the manufacturing process of the liquid crystal display device. It becomes easy to improve the production efficiency.

Further, when the conductive particles made of resin are used, the conductive particles themselves made of resin are crushed when the gap between the pixel substrate and the common substrate is adjusted to be constant, so that some variation in particle size is allowed. Be done. Therefore, it becomes easier to adjust the gap constant, and the production cost can be reduced.

According to the structure of claim 6, the non-translucent pattern generally serves as a shadow mask for preventing light bleeding and color bleeding from adjacent pixels and improving the resolution of an image. . It is easy to form a conductive pattern on such a non-translucent pattern by using a photolithography method or the like. When the conductive pattern is brought into close contact with the conductive material that electrically connects the small boards to each other, the connection resistance value between the small boards can be reduced as compared with the case where only the conductive material is used.

As a result, the scanning voltage and the signal voltage for driving each pixel are uniformly applied to each pixel without being attenuated, and a large screen and high image quality without display unevenness are realized. be able to. Therefore, the effect of high-quality display can be added to the effect of the configuration of claim 3, 4 or 5.

According to the configuration of claim 7, as described in the operation of claim 6, the protrusion amount of the non-translucent pattern is set between the pixel substrate and the common substrate at the joint portion between the small substrates. The non-translucent pattern can serve not only as a shadow mask, but also as a support material according to claim 1 since the non-translucent pattern is substantially matched with the uniform spacing.

As a result, the liquid crystal display device provided with the non-translucent pattern can be made thin and lightweight with a simple structure, and the cost can be reduced.

Further, since the non-translucent pattern is formed along the joint portion which becomes the non-display portion, the void portion between the pixel substrate and the common substrate is partitioned into some small rooms. . The liquid crystal injection time is significantly shorter in the small chamber than in the gap between the pixel substrate and the common substrate all at once. Even, the injection can be completed quickly. As a result, the production efficiency is improved and the cost can be further reduced.

According to the structure of claim 8, the supporting member is provided so as to correspond to the connecting portion for connecting the small substrates to each other, and the small substrate and the common substrate are bonded at a constant interval via the supporting member. The conventional manufacturing method can be directly applied except for the steps. Moreover, since the supporting material and the sealing material may be the same material, the step of providing the supporting material so as to correspond to the joining portion and the step of providing the sealing material so as to correspond to the peripheral portion of the common substrate are performed at the same time. You can

Therefore, it is possible to manufacture the liquid crystal display device having the excellent effect according to the structure of claim 1 only by adding simple steps.

According to the structure of claim 9, the space surrounded by the pixel substrate, the common substrate and the sealing material is partitioned into a plurality of small chambers by the supporting material. The liquid crystal injection time is significantly shorter in the small chamber than in the gap between the pixel substrate and the common substrate all at once. Even, the injection can be completed quickly. As a result, the production efficiency is improved and the cost can be further reduced. Further, if the liquid crystal is injected into each small room at the same time, the production efficiency can be further improved.

[0052]

【Example】

[Embodiment 1] FIG. 1 to FIG.
The explanation is based on the following.

The liquid crystal display device according to the present invention is shown in FIG.
As shown in FIG. 1, one translucent substrate 2 is provided, and the four small substrates 1 a to 1 d that are planarly arranged are opposed to the translucent substrate 2. A common electrode (not shown) is formed on the light-transmissive substrate 2, and as shown in FIG. 1B, a non-light-transmissive pattern 10 is formed in a grid pattern corresponding to the periphery of each pixel. . This non-translucent pattern 10 is
It is also called a black matrix (BM) and is formed of a non-translucent material, and has a role as a shadow mask that prevents light bleeding and color bleeding from adjacent pixels and improves image resolution.

On the other hand, each of the four small substrates 1a to 1d has a TFT (not shown) which controls ON / OFF of the pixel.
(Thin Film Transistor) element or MIM (Metal-Ins
The active element such as the emulator-metal element and the wiring are 1
Pixel electrodes for applying a scanning voltage or a signal voltage to each pixel are formed around each pixel. Therefore, the periphery of each pixel is a non-display portion where an image is not displayed, but the lattice-shaped non-translucent pattern 10 is provided in this non-display portion.

Further, as shown in FIG. 1B, the four edges of the four small boards 1a to 1d are adhered to each other with a fixing adhesive 9, so that the four small boards are attached. 1
The pixels a to 1d are one pixel substrate 1 having a larger area than the translucent substrate 2. The connecting portion by the fixing adhesive 9 is a non-display portion, but as shown in FIG. 1B, it has a positional relationship of being hidden under the non-translucent pattern 10 when viewed from the translucent substrate 2 side. Therefore, the pixel pitch of the adjacent small substrates does not change at any joining portion, and therefore does not affect the display quality of a large screen.

The fixing adhesive 9 may be made of the same material as the sealing material 4a, which will be described later, or a different material may be prepared. The light reflectance of the non-translucent pattern 10 is
The lower the better. The material thereof may be a metallic material such as aluminum or chromium or a resin material such as a black resin, and is not particularly limited.

Further, electrode terminals (not shown) for supplying the scanning voltage and the signal voltage to the active elements are provided along the two sides of the small substrates 1a to 1d which are not bonded, that is, along the outer periphery of the pixel substrate 1. Has been. A liquid crystal drive circuit such as TAB (Tape Au
tomated bonding (LSI) Large Scale Integrate
d Circuit) is connected.

The pixel substrate 1 and the translucent substrate 2 are opposed to each other, and the sealing material 4 is provided on the outer peripheral portion of the translucent substrate 2, so that the space between the translucent substrate 2 and the pixel substrate 1 is increased. The liquid crystal 5 is sealed in the gap. A polarizing plate 8 is arranged outside each of the pixel substrate 1 and the translucent substrate 2. The liquid crystal 5 is arranged so as to obtain a desired display mode, such as a twist nematic type.

An important feature of the present invention is that it is located between the joining portion formed by the fixing adhesive 9 and the non-translucent pattern 10 facing the joining portion.
Support material 7 is provided. In addition, the supporting member 7 is formed in a column shape or a wall shape in at least one place at each joining portion between the small substrates. The support material 7 may be made of the same material as the seal material 4 or may be prepared as a different material.

Next, a method for manufacturing the liquid crystal display device applied to the present invention will be briefly described.

[Manufacturing Example 1] (1) As shown in FIG. 2A, after forming the non-translucent pattern 10, a color filter (not shown) and the like on the translucent substrate 2, the sealing material 4 and the supporting material are formed. Form 7. FIG. 3A or FIG. 3 is a diagram showing the formation positions of the seal material 4 and the support material 7 in correspondence with the arrangement of the small substrates 1a to 1d.
(B).

Although the example of FIG. 3B will be described later, in the example of FIG. 3A, as shown in FIG. 2A, the sealing material 4 is formed in the peripheral portion of the transparent substrate 2. At the same time, the support material 7 is formed on the non-translucent pattern 10 and in a cross shape so as to press the edges of the small-sized boards 1a to 1d in correspondence with the joining portions of the small-sized boards 1a to 1d. are doing. As a result, four small chambers partitioned by the sealing material 4 and the supporting material 7 are formed, and the liquid crystal 5 is provided in each small chamber.
The sealing material 4 is formed so as to provide the injection ports 4a for injecting each one.

In this manufacturing example, the sealing material 4 and the supporting material 7 are made of the same photo-curing resin. When forming the sealing material 4 and the supporting material 7, the gap material 12 made of plastic beads is sprinkled all over the transparent substrate 2 and then the sealing material 4 and the supporting material 7 are temporarily cured. this is,
When the support material 7 is in an uncured state, the small substrate 1a is placed on the support material 7.
After placing, until the small substrate 1d is further placed,
This is because the support member 7 may not be able to maintain the predetermined shape. In this way, the gap material 12 is included as a spacer in the temporarily cured seal material 4 and the support material 7.

In this embodiment, for example, FIG.
As shown in (c), the size of the gap material 12 and the width of the non-translucent pattern 10 are shown to be substantially the same.
This is for convenience of understanding, and in practice, the grain size of the gap material 12 is considerably smaller than the width of the non-translucent pattern 10. For example, when the width of the non-translucent pattern 10 is several tens μm to several hundreds μm, the particle size of the gap material 12 is several μm.
m.

(2) Next, as shown in FIG.
The small substrates 1a to 1d are sequentially placed on the seal material 4 and the support material 7. Since the gap material 12 is contained as a spacer in the temporarily cured sealing material 4 and the support material 7, it is possible to maintain the gap between the small substrates 1a to 1d and the translucent substrate 2. It will be easier. At this time, the hardness of the temporarily cured photo-curable resin is small substrates 1a to 1
It is preferable that the lower surfaces of the small substrates 1a to 1d naturally come into contact with the gap material 12 with the weight of d. Then, in the example of FIG. 2B, the photocurable resin slightly protrudes to the joining portion between the small substrate 1a and the small substrate 1d, so that the photocurable resin can also be used as the above-mentioned adhesive 9 for fixing. The efficiency of can be improved.

When the small boards 1a to 1d are placed in order, the small boards 1a to 1d are not brought into close contact with each other, but each small board 1a is straddled over the joining portion.
It is advisable to provide a slight clearance to such an extent that the pixel pitch in 1d is kept constant and within the range hidden under the non-translucent pattern 10. This is for the following reason.

When manufacturing the small-sized substrates 1a to 1d, usually, a plurality of small-sized substrates provided with active elements and pixel electrodes are formed on a large substrate, and then the divided small-sized substrates are inspected. You have selected. Therefore, fine unevenness is formed by cutting on the divided surface of the small substrates 1a to 1d as non-defective products. Adhering the small substrates 1a to 1d to each other with a slight clearance as described above has an advantage that the irregularities formed on the divided surface can be left as they are.

The first problem is that when the unevenness is polished by a polishing machine or the like to be parallel, the mass production efficiency is lowered and the cost is increased. Also,
In particular, an active matrix liquid crystal display device including a TFT element or the like has a second problem in that since the dust and the dust are extremely disliked, the dust and the dust generated at the time of cutting lowers the non-defective rate. In addition, active elements are sensitive to static electricity,
There is a third problem that the device is destroyed by static electricity generated during polishing. Therefore, these problems can be avoided by omitting the step of polishing unevenness.

(3) Next, as shown in FIG.
All the small boards 1a to 1d are placed, and the small boards 1a to 1d
Adjustment is performed to set the facing interval between the transparent substrate 2 and the transparent substrate 2 to a uniform predetermined value. At this time, columnar or spherical glass beads may be used as the gap material 12, but when plastic beads are used, the plastic beads are crushed against the pressure, which enables highly accurate gap control. In addition, since the plastic beads are less likely to damage the terminals and wiring, the gap control process can be redone, which is advantageous. Thus, the sealing material 4 and the support material 7 are fully cured through the gap control step.

(4) After that, the liquid crystal 5 is injected from the above-mentioned injection port 4a shown in FIG. As the injection method, there are a method of simultaneously injecting from four injection ports 4a, a method of injecting the liquid crystal 5 into the injection port 4a in the lower half first, and then sealing the injection port 4a after the injection and then injecting the upper half. is there. In either method, there is no peeling of the sealing material 4, and the liquid crystal is injected in a shorter time than in the case where the liquid crystal is integrally injected from one injection port provided in the sealing material 4 without providing the support material 7. 5 could be injected. By providing the support member 7 at the joining portion, the small substrate 1 after completion is provided.
The adhesion strength between the pixel substrate 1 in which a to 1d are integrated and the translucent substrate 2 was extremely good.

[Manufacturing Example 2] (1) As another manufacturing example, first, as shown in FIG. 4A, two small substrates 1a and 1b are connected to each other without connecting wiring between the substrates. After the one sides having no electrode terminals are opposed to each other with a predetermined clearance, they are bonded with a fixing adhesive 9. As a result, the pixel substrate 1 is formed by the two small substrates 1a and 1b. After that, the sealing material 4 is formed on the peripheral portion of the pixel substrate 1, and the supporting material 7 is formed on the joint portion of the small substrates 1a and 1b. Here, a thermosetting resin is used for the seal material 4 and the support material 7.

Although not shown, a gap material is provided at a predetermined position, as in the first manufacturing example. Seal material 4
If a gap material is also put in the resin of the support material 7 in advance, parallelism can be obtained as in the case of Preparation Example 1 and a high-quality display without unevenness can be obtained. Further, at this stage, it is not necessary to cure the sealing material 4 and the supporting material 7 by semi-curing, and there is no problem even if the translucent substrate 2 is placed in the next step.

Further, if the small substrates 1a and 1b are arranged on the polarizing plate 8, there will be no positional deviation after the small substrates 1a and 1b are aligned. However, the polarizing plate 8 is added later to the small substrate 1.
It may be adhered to a and 1b.

(2) Next, as shown in FIG.
The translucent substrate 2 having the non-translucent pattern 10 formed thereon is placed on the seal material 4 and the support material 7.

(3) Through a gap control step for making the facing distance between the transparent substrate 2 and the pixel substrate 1 uniform,
The seal material 4 and the support material 7 are cured (see FIG. 4).
(C)).

(4) After that, the liquid crystal 5 is simultaneously injected from the injection ports (not shown) provided in advance in the two small chambers, respectively, and the injection ports are sealed.

(5) Then, as shown in FIG. 5, a polarizing plate 8 is provided on the translucent substrate 2, and a drive circuit composed of the TAB type LSI 11 is attached to each of the small substrates 1a and 1b, and a liquid crystal is formed. The display device is completed.

In the above structure, since the supporting member 7 is provided at least at the joint between the small substrates 1a to 1d, the end portions of the respective substrates 1a to 1d at the joint can be reliably supported. Therefore, the stability of the small substrates 1a to 1d is improved, and the small substrates 1a to 1d are
It becomes easy to position d and the small substrates 1a to 1
Even if a vertical load is applied to the display surface of the pixel substrate 1 having a large area where d is integrated, it is possible to reliably maintain a uniform facing distance between the translucent substrate 2 and the pixel substrate 1. . This facilitates gap control for uniformly maintaining the facing distance in the manufacturing process of the liquid crystal display device.

Also, the small substrate 1 in the joining portion
The edges a to 1d tend to gradually warp over time due to external factors such as temperature changes. However, since the support material 7 is provided at the joining portion, the support material 7 is provided at each end. It will hold down the edges. As a result, it is possible to prevent warpage with time on each edge of each of the substrates 1a to 1d, and to improve the reliability of the display quality of the liquid crystal display device.

These effects are further enhanced by forming the support member 7 in a continuous wall shape along the joint portion.

Furthermore, FIG. 1 (b), FIG. 2 (c), and FIG.
As shown in (c), the small substrates 1a to 1 are made of a photocurable resin or a thermosetting resin for forming the support material 7.
Since the joint between the d's is further covered, the bondability between the small substrates 1a to 1d can be improved, and the durability and reliability of the liquid crystal display device can be improved. Moreover, since a substrate for reinforcing the small substrates 1a to 1d is not particularly required, the liquid crystal display device can be made thin and lightweight, and the cost can be reduced.

Further, as shown in FIG. 3 (a), the inside of the frame-shaped sealing material 4 is partitioned by the formation of the supporting material 7, whereby the space into which the liquid crystal 5 is injected is divided into a plurality of small chambers. Can be divided. As a result, the time for injecting the liquid crystal 5 into each small chamber is significantly shortened, so that even if the liquid crystal 5 is sequentially injected in each small chamber, the entire injecting time can be shortened. Furthermore, if the liquid crystal 5 is injected into a plurality of small chambers at the same time, the entire injection time can be significantly shortened. Therefore, the productivity of the liquid crystal display device can be improved.

Although the floor areas of the small rooms can be arbitrarily set depending on the positions where the seal material 4 and the support material 7 are formed, it is better to make the floor areas of the small rooms uniform at the same time when the liquid crystal is started at the same time. Since the injection of 5 can be completed at the same time, it is convenient for improving productivity.

By the way, the connecting portions of the small substrates 1a to 1d do not affect the pixel pitch, and the non-translucent pattern 1 having the function of a shadow mask is used.
Since it is hidden under 0, the user sees it as if it were composed of one large board without any seams. Therefore, the liquid crystal display device according to the present invention can provide a thin, lightweight, high-quality and large-screen display.

[Embodiment 2] Another embodiment of the present invention will be described below with reference to FIGS. 3B and 6. For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are designated by the same reference numerals, and the description thereof will be omitted.

Regarding the location of the support member 7, in the first embodiment, the case where the support member 7 is provided at the joint portion between the small substrates 1a to 1d has been described, but as shown in FIG. The support material 7 may be provided on the non-translucent pattern 10 other than the translucent pattern 10.

In the example shown in FIG. 3 (b), each of the small rooms described with reference to FIG. 3 (a) is further divided into two,
The support material 7 is formed. The support member 7 newly provided in each small chamber is provided with the above-mentioned injection port 4 in the seal member 4.
Openings 7a are formed corresponding to the formation positions of a. As a result, even if the liquid crystal 5 is injected from the injection port 4a, the support material 7 provided in each small chamber does not hinder the injection.

In the liquid crystal display device of this embodiment, since the supporting material 7 is also provided in the non-display portion other than the connecting portion, the pixel substrate 1 in which the small substrates 1a to 1d are integrated is further reinforced by the supporting material 7. It is configured to. This makes it possible to more favorably maintain a uniform facing distance between the pixel substrate 1 and the transparent substrate 2 with respect to the stress applied to the pixel substrate 1, and at the same time, to prevent the pixel substrate 1 and the transparent substrate 2 from being damaged. The adhesion strength with is further improved. As a result, the durability of the liquid crystal display device and the reliability of the display quality can be further improved.

[Embodiment 3] The following description will discuss still another embodiment of the present invention with reference to FIGS. 7 (a) and (b) and FIGS. 8 (a) to 8 (c). For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are designated by the same reference numerals, and the description thereof will be omitted.

As shown in FIG. 7A, in this embodiment,
The pixel substrate 1 is formed using nine small substrates 1a to 1i. On the sides other than the sides to which the small-sized boards 1a to 1i are adhered, that is, on the sides that form the peripheral edge of the pixel substrate 1, mounting terminals that are connected to an external drive circuit board are formed. Therefore, the small substrate 1e located at the center of the pixel substrate 1 is
9 small boards 1a-
The smallest of 1i. 1 side for mounting terminals
The small boards 1b, 1d, 1f, 1h having only one are smaller than the other small boards 1a, 1c, 1g, 1i having two sides on which mounting terminals are formed.

Further, terminals of the scanning lines and the signal lines formed in a grid pattern on the small-sized boards 1a to 1i are drawn out to the sides to which the small-sized boards 1a to 1i are bonded.

In manufacturing the liquid crystal display device, first, the small substrates 1a to 1i are arranged so as to have a slight clearance between the sides serving as the connecting portions, and are bonded with the fixing adhesive 9. Pixel pitch is small substrate 1a-1i
The pixel substrate 1 is not affected by the joint between the pixels.
It is constant throughout.

Subsequently, a sealing material 4 is formed on the peripheral portion of the transparent substrate 2 to form the pixel substrate 1 and the transparent substrate 2.
A space for enclosing the liquid crystal 5 is formed between and, and this space is partitioned into nine small chambers by a support member 7 provided in a wall shape at a connecting portion between the small substrates 1a to 1i. After enclosing the liquid crystal 5 between the pixel substrate 1 and the translucent substrate 2 which have been subjected to the alignment treatment or the like according to the desired display mode, the polarizing plate 8 is provided outside each of the substrates 1 and 2. . In order to inject the liquid crystal 5 into the small substrate 1e located at the center of the pixel substrate 1, the support member 7 is appropriately provided with the opening 7a as described in the second embodiment. However,
The openings 7a are not provided in all the support members 7, but may be provided in the minimum places where the liquid crystal 5 is spread over the entire surface.

As described above, when the support material 7 is provided in the shape of a wall, spherical conductive particles 13 are put in the support material 7 as shown in FIG. The terminals of the scanning line or the signal line drawn out to the side to be bonded are electrically connected by the conductive particles 13. As the conductive particles 13, for example, a commercially available particle such as a metal piece or plastic beads having a metal plated surface can be used.
First, it is preferably spherical. This is because spherical particles are easy to have a uniform particle size.

Among the spherical bodies, the plastic bead type is more preferable. The reason for this is that the plastic beads type has a more uniform size of commercially available particles than the metal particles type, and the particles are crushed by placing the transparent substrate 2 on the pixel substrate 1 and pressing it. Since the contact area is widened, it is convenient for the terminals of each of the small substrates 1a to 1i to be electrically conductive, and since the particles are crushed, if they are within a certain error range, they will not depend on the variation of the particle diameter and the pixel substrate 1. It can be mentioned that the gap between the transparent substrate 2 and the transparent substrate 2 can be easily made uniform.

It is desirable that the conductive particles 13 be provided only at the connecting portions between the terminals by using a method such as photolithography, which will be described later, from the viewpoint of insulating the connecting portions located next to each other. Although an anisotropic conductive film may be used as the support material 7, a type in which insulating particles and conductive particles are mixed is preferable. This improves the insulating property for the adjacent connection point and helps prevent short circuit.

Next, one method for selectively forming the conductive particles 13 on the above-mentioned connecting portion will be described with reference to FIGS. 8 (a) to 8 (c). Note that FIG. 8C corresponds to a sectional view taken along the line DD of FIG. 7B.

(1) First, as shown in FIG.
When the photocurable resin 16 is applied onto the pixel substrate 1 provided with the polarizing plate 8 and light is irradiated from the polarizing plate 8 side using the scanning line or signal line terminal 18 as a mask, the photocurable resin 16 is selectively exposed. Then, the photo-curable resin 16 other than the connection portion of the terminal 18 is cured.

(2) Next, the conductive particles 13 are scattered on one surface of the photocurable resin 16. However, since the photo-curable resin 16 is not cured only on each terminal 18, the conductive particles 13 adhere to the uncured photo-curable resin 16. As a result, FIG.
As shown in (b), the conductive particles 13 are selectively arranged only on each terminal 18.

Subsequently, the non-translucent pattern 10 in which the conductive pattern 10a is selectively formed (to be described later) so as to face the connection portion of the terminal 18, and the non-translucent pattern 10 provided with, for example, thermosetting The light-transmissive substrate 2 provided with the supporting material 7 made of resin is placed on the pixel substrate 1.

(3) At this time, by overlapping the pixel substrate 1 and the translucent substrate 2 so that the conductive particles 13 are embedded in the supporting material 7, the conductive particles 13 are formed into the conductive pattern 1.
0a and the terminal 18 are contacted. Here, it is preferable that the conductive particles 13 have a diameter slightly larger than the distance between the substrates 1 and 2 so that the conductive particles 13 are somewhat crushed. After that, the photo-curing resin 16, the supporting material 7, and the sealing material (not shown) remaining in the uncured state are cured, and the liquid crystal 5 is injected to complete the liquid crystal display device.

In the formation of the conductive pattern 10a, when a metal-based material is used for the non-translucent pattern 10, chromium or aluminum which can be anodized is preferable. By using these, the non-translucent pattern 10 can be selectively anodized by a method such as photolithography to form the anodized insulating portion and the conductive pattern 10a having conductivity.

Also, when a resin material is used for the non-translucent pattern 10, conductive particles may be selectively embedded to form a conductive pattern 10a similar to the above.

In the above structure, each of the small boards 1a-1
The terminals of the scanning line and the signal line formed on i are connected to the small substrates 1a to 1i by the conductive particles 13 selectively arranged.
They are electrically connected at the joints between them. Moreover,
Since the terminals are connected so as to be hidden by the non-translucent pattern 10, that is, within the range of the width of the non-display portion,
A plurality of small substrates 1a to 1 while keeping the pixel pitch constant
The number of i is not limited to 9, and any number of i can be electrically connected, and a large-screen liquid crystal display device can be manufactured. In addition, since the conductive pattern 10a corresponding to the terminal connection portion is selectively formed on the non-translucent pattern 10,
The connection resistance value between the small-sized boards 1a to 1i can be kept low.

As a result, the scanning voltage and the signal voltage are uniformly applied from the drive circuit connected at the peripheral portion of the pixel substrate 1 to the pixels of the small substrates 1a to 1i without being attenuated, and the large screen is displayed. However, it is possible to realize high image quality without display unevenness,
It is possible to provide a large-screen liquid crystal display device suitable for high-definition display such as sign).

By the way, in the first embodiment, the small substrates 1a to 1a are used.
Since the pixel substrate 1 is configured without electrically connecting d, the number of small substrates that can be combined is limited to four. The smaller the size of a small board with pixels, the lower the yield rate and the higher the cost.
When a to 1d are not electrically connected, the liquid crystal display device naturally has a limit in increasing the screen size.

On the other hand, in this embodiment, the small substrate 1a is used.
Since 1 to 1i are electrically connected to each other, a large screen can be achieved by combining a plurality of smaller small substrates. That is, the pixel substrate 1 using a substrate that is small, has a good yield rate, and is low in cost as compared with the case where no electrical connection is made.
Therefore, according to the present embodiment, it is possible to improve the non-defective rate of the large-screen liquid crystal display device and to reduce the cost.

Further, as described in the first embodiment, the support member 7 is provided at the joint between the small substrates 1a to 1i, so that each substrate 1 in the joint is joined.
The end portions of a to 1i can be reliably supported. Therefore, the stability of the small substrates 1a to 1i is improved, and
Even if a vertical load is applied to the display surface of the large-area pixel substrate 1, it is possible to maintain a uniform facing distance between the translucent substrate 2 and the pixel substrate 1. This facilitates gap control for uniformly maintaining the facing distance in the manufacturing process of the liquid crystal display device.

Also, the small substrate 1 in the connecting portion
It is also possible to prevent warp over time from occurring at each end of a to 1i, and it is possible to improve the reliability of the display quality of the liquid crystal display device. In addition, these effects are
This is further enhanced by forming the support member 7 in the shape of a continuous wall along the joining portion.

Further, the small substrates 1a to 1 are made of a photo-curing resin or a thermosetting resin for forming the supporting material 7.
Since the joint portion of i is further covered, the bondability between the small substrates 1a to 1i can be improved, and the durability and reliability of the liquid crystal display device can be improved. Further, since it is not necessary to provide a substrate for reinforcing the small substrates 1a to 1i, the liquid crystal display device can be made thin and lightweight, and the cost can be reduced.

[Embodiment 4] The following description will discuss still another embodiment of the present invention with reference to FIGS. 9 (a) and 9 (b) and FIG. For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are designated by the same reference numerals, and the description thereof will be omitted.

In each of the above-mentioned embodiments, the support material 7 and the non-translucent pattern 10 are separately provided, but in this embodiment, FIG.
As shown in (a), the protrusion amount of the non-translucent pattern 10 corresponding to the joining portion of the small substrates is increased to form the support member 10b also having the function of the support member 7. The predetermined distance between the flexible substrate 2 and the pixel substrate 1 is matched.

For example, when four or less small substrates are used as in the first and second embodiments, it is not necessary to electrically connect the small substrates to each other. Form according to the space. Further, when the pixel substrate 1 is formed by electrically connecting a plurality of small substrates of four or more as in the third embodiment, the support material 10b is selectively anodized to obtain insulation not shown. And a conductive pattern are formed. In this case, the supporting material 10b is pressure-bonded to the small boards to be bonded to each other via an insulating adhesive.

That is, as shown in FIG. 9B, a layer of an insulating fixing adhesive 9 is formed on the bottom of the support material 10b and, for example, pressure-bonded to the places where the small substrates 1a and 1d are to be bonded. . Then, the insulative fixing adhesive 9 flows into the gap between the small substrates 1a and 1d, and the small substrates 1a and 1d.
At the same time as bonding the two together, the fixing adhesive 9 is pushed out to the periphery of the connection portion by pressure bonding at the connection portion between the terminals of the small-sized boards 1a and 1d, and the conductive pattern comes into close contact with the connection portion. As a result, similarly to the third embodiment, the conductive pattern can suppress the connection resistance value between the small boards to be low.

If the edges of the joint between the small boards 1a and 1d are chamfered as shown in FIG. 9B, the fixing adhesive 9 will easily flow into the gap.
convenient.

Further, as shown in FIG. 10, a conductive pattern 10a may be formed on the non-translucent pattern 10 by using an anisotropic conductive film so as to face the terminal 18 on the pixel substrate 1. By using the anisotropic conductive film, the connection resistance value between the small substrates can be further reduced.

As described above, by using the support material 10b that also serves as the support material 7 and the non-translucent pattern 10, and also by using the support material 10b for electrical connection between the small substrates, the liquid crystal display device is obtained. The manufacturing process can be simplified, and further cost reduction can be achieved.

Although the first to fourth embodiments have been described in detail with reference to the drawings, the present invention is not limited to this, and the small substrate is a non-translucent substrate such as a silicon wafer or a ceramic substrate, and a reflective display is used. It can also be configured as a device.

In the above embodiment, all TFTs and MIs are used.
Although the example of the active matrix type using the M element or the like has been described, the present invention is not limited thereto, and the present invention can be applied to various types of liquid crystal display devices such as DUTY type, polymer dispersion type liquid crystal, and polymer liquid crystal. As an example, in a DUTY color type liquid crystal display device, by forming a color filter on a smaller substrate, it is possible to reduce the cost of a color filter substrate having a poor yield rate and to increase the overall yield rate. be able to. Further, when the polymer type liquid crystal is used, a polarizing plate and an alignment film are not required, and the cost can be further reduced.

Further, in the present embodiment, the case where the number of the small substrates used is 2, 4, and 9, respectively, is explained, but the present invention is not limited to this, and it may be 12 or more.

Although the non-translucent pattern 10 is formed on the translucent substrate 2, it is not limited to this and may be formed on the pixel substrate 1 side.

Further, although the conductive particles 13 are used as the conductive material, the present invention is not limited to this, and it is clear that a plate-shaped conductive material may be used.

Further, the supporting member 7 may be formed at the intersections of the non-display portions between the respective pixels like a pillar.

Further, a reflection type liquid crystal display device may be constructed by using not only a polarizing plate but also a reflection plate, and further a wide viewing angle liquid crystal display device may be constructed by using microlenses and lenticulars. In particular, since the latter wide viewing angle type has a large screen, even if the viewing angle is widened vertically and horizontally, the image can be visually recognized without being inverted, and it is possible to provide a higher quality liquid crystal display device. .

[0125]

The liquid crystal display device according to the invention of claim 1
As described above, the support member that holds the gap between the pixel substrate and the common substrate constant is provided at least in the joint portion where the small substrates are joined together.

Therefore, the joint portion does not hinder the display of a large screen at all, the stability of each small substrate is improved, and the structure is strong against the load applied in the direction perpendicular to the display surface of the pixel substrate. Further, the support material can also improve the adhesion strength between each small substrate and the common substrate. In addition, it is possible to prevent the warp of the ends of each small substrate from occurring over time, and it is possible to improve the durability and reliability of display quality of a large-screen liquid crystal display device.

Further, since it is not necessary to provide another substrate for reinforcing the small-sized substrate, it is possible to reduce the thickness and weight of the large-screen liquid crystal display device and to reduce the cost. Play.

As described above, in the liquid crystal display device according to the invention of claim 2, in addition to the constitution of claim 1,
It is a structure formed in a wall shape along the joining portion.

Therefore, it is possible to further improve the strength against a load, the bondability between small substrates, or the adhesion strength between each small substrate and the common substrate, and it is possible to further enhance the effect of the configuration of claim 1. Produce an effect.

As described above, in the liquid crystal display device according to the third aspect of the present invention, the one pixel substrate is formed by providing a conductive material in the joint portion for joining the small substrates together. The small substrates are electrically connected to each other and the conductive material is provided within the width of the non-display portion formed in the contour of each pixel.

Therefore, the joint portion is one of the non-display portions that does not participate in the display in the contour portion of each pixel, and the conductive material is provided within the width of the non-display portion in the joint portion. Since it is provided, the conductive material does not hinder the display on a large screen. Therefore, it is possible to assemble a pixel substrate having a large area by using a substrate that is small in size and has a good yield rate and is low in cost as compared with a case where small substrates are not electrically connected to each other. There is an effect that can be achieved.

As described above, the liquid crystal display device according to the invention of claim 4 is, in addition to the structure of claim 3, provided with a supporting material for maintaining a constant gap between the pixel substrate and the common substrate,
By providing the conductive material on at least a part of the support material, each small substrate is electrically connected so as to configure the one pixel substrate.

Therefore, since the conductive material is provided at the connecting portion between the small substrates and the supporting material having the conductive material as a part is provided, it is possible to obtain the effects of the configurations of the first and third aspects. A liquid crystal display device having excellent characteristics can be provided.

As described above, the liquid crystal display device according to a fifth aspect of the present invention is, in addition to the configuration of the third or fourth aspect, a configuration in which conductive particles having a substantially spherical shape are used as the conductive material. .

Therefore, the conductive particles provided at the connecting portion between the small substrates not only electrically connect the small substrates, but also maintain a constant gap between the pixel substrate and the common substrate. The same function as the support material described in No. 1 is fulfilled. In addition, since conductive particles having a substantially spherical shape can be easily manufactured by making their particle diameters substantially uniform, the gap between the pixel substrate and the common substrate is adjusted to be constant in the manufacturing process of the liquid crystal display device. This facilitates the operation, and has the effect of improving production efficiency.

As described above, in the liquid crystal display device according to the invention of claim 6, in addition to the structure of claim 3, 4 or 5,
Including a connecting portion for connecting the small substrates, a non-translucent pattern corresponding to the non-display portion formed in the contour portion of each pixel is formed on one of the pixel substrate or the common substrate, A conductive pattern corresponding to the location of the conductive material is formed into a non-translucent pattern,
This is a configuration in which the conductive material and the conductive pattern are in close contact with each other.

Therefore, if the conductive pattern is brought into close contact with the conductive material for electrically connecting the small boards to each other, the connection resistance value between the small boards can be reduced as compared with the case where only the conductive material is used. As a result, the scanning voltage and the signal voltage for driving each pixel are uniformly applied to each pixel without being attenuated, so that it is possible to realize a large screen and high image quality without display unevenness. . Therefore, in addition to the effect of the third, fourth or fifth aspect, there is an effect that high-quality large-screen display is possible.

As described above, in the liquid crystal display device according to the invention of claim 7, the projection amount of the non-translucent pattern facing the joining portion for joining the small substrates together, the pixel substrate and the common substrate are provided. The configuration is such that the uniform spacing between the two is substantially the same.

Therefore, the non-translucent pattern can serve not only as a shadow mask for improving the resolution of the screen but also as a support material according to claim 1. As a result, the strength of the large-screen liquid crystal display device provided with the non-translucent pattern can be improved with a simple structure, so that the device can be made thin and lightweight, and the cost can be reduced.

Further, since the non-translucent pattern is formed along the joint portion which becomes the non-display portion, the void portion between the pixel substrate and the common substrate is divided into some small chambers. . The liquid crystal injection time is significantly shorter in the small chamber than in the gap between the pixel substrate and the common substrate all at once. Even, the injection can be completed quickly. As a result, the production efficiency of the large-screen liquid crystal display device provided with the non-translucent pattern is improved, and the cost can be further reduced.

As described above, the method of manufacturing a liquid crystal display device according to the invention of claim 8 corresponds to a plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed, and to the pixel substrate. A common substrate on which a common electrode is formed, which has a spread, is prepared, and the sealing material is a peripheral edge of the common substrate so that the plurality of small substrates form one flat pixel substrate having a uniform pixel pitch. The sealing material and the supporting material such that the supporting material that holds a constant gap between the pixel substrate and the common substrate corresponds to the connecting portion that connects the small substrates to each other. The small substrate and the common substrate are bonded to each other at a constant interval via a material, and liquid crystal is sealed between the pixel substrate, the common substrate, the sealing material, and the supporting material.

Therefore, the conventional manufacturing method can be applied as it is, except for the step of providing the above-mentioned supporting material and adhering the small substrate and the common substrate at a constant interval via the supporting material. Moreover, since the support material and the seal material may be the same material, the step of providing the support material and the step of providing the seal material can be performed simultaneously.

Therefore, it is possible to manufacture the liquid crystal display device having the excellent effect according to the structure of the first aspect only by adding the simple steps.

As described above, in the method for manufacturing a liquid crystal display device according to the ninth aspect of the present invention, in addition to the structure of the eighth aspect, the support material is formed in a wall shape along the joint portion. Thus, the space surrounded by the pixel substrate, the common substrate and the sealing material is divided into two or more small chambers, and liquid crystal is injected into each small chamber.

Therefore, the injection time of the liquid crystal is significantly shortened when the liquid crystal is injected into the small chambers rather than at once into the space between the pixel substrate and the common substrate. Even if they are injected separately, the injection can be completed quickly. As a result, the production efficiency is improved and the cost can be further reduced. In addition, if liquid crystal is injected into each small room at the same time, the production efficiency can be further improved.

[Brief description of drawings]

FIG. 1 relates to an embodiment of a liquid crystal display device according to the present invention,
(A) is a perspective view schematically showing the outer appearance of a liquid crystal display device,
(B) is a longitudinal sectional view taken along the line BB of (a).

2A to 2C are vertical cross-sectional views showing an example of a manufacturing process of the liquid crystal display device step by step.

FIG. 3A is an explanatory plan view showing an arrangement example of a seal material and a support material included in the liquid crystal display device, and FIG. 3B is another arrangement example of the seal material and a support material included in the liquid crystal display device. It is an explanatory view showing in plan.

4A to 4C are vertical cross-sectional views showing stepwise another example of the manufacturing process of the liquid crystal display device.

FIG. 5 is a perspective view schematically showing the outer appearance of a liquid crystal display device completed by connecting a drive circuit.

FIG. 6 is a vertical cross-sectional view schematically showing the configuration of a liquid crystal display device in another embodiment of the liquid crystal display device according to the present invention.

7A and 7B relate to still another embodiment of the liquid crystal display device according to the present invention, FIG. 7A is a perspective view schematically showing the appearance of the liquid crystal display device, and FIG. 7B is taken along line CC of FIG. FIG.

8A to 8C are vertical cross-sectional views showing stepwise an example of a manufacturing process of the liquid crystal display device shown in FIG. 7, and FIG. 8C is a sectional view taken along line DD in FIG. 7B. FIG.

9A and 9B relate to still another embodiment of the liquid crystal display device according to the present invention, FIG. 9A is a vertical cross-sectional view schematically showing the configuration of the liquid crystal display device, and FIG. 9B is a connecting portion of a supporting material and a small substrate. It is explanatory drawing which shows the adhesion process with.

FIG. 10 is a vertical cross-sectional view schematically showing a case where a conductive pattern is formed on a non-translucent pattern in another configuration example of the liquid crystal display device.

FIG. 11 is an explanatory diagram schematically showing a connection example of a plurality of liquid crystal panels in a conventional liquid crystal display device.

FIG. 12 is another perspective view of another conventional liquid crystal display device, FIG. 12A is a perspective view schematically showing the appearance of the liquid crystal display device, and FIG. 12B is a vertical cross-sectional view schematically showing the configuration of the liquid crystal display device.

FIG. 13 is a vertical cross-sectional view schematically showing the configuration of still another conventional liquid crystal display device.

[Explanation of symbols]

 1 Pixel Substrate 1a to 1i Small Substrate 2 Translucent Substrate (Common Substrate) 4 Sealing Material 5 Liquid Crystal 7 Supporting Material 10 Non-Translucent Pattern 10a Conductive Pattern 10b Non-Translucent Pattern and Supporting Material 13 Conductive Particles (Conductive Material)

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location G09F 9/30 321 7426-5H

Claims (9)

[Claims] 1. A plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed are arranged so as to form one flat plate pixel substrate having a uniform pixel pitch, and a common electrode is formed. In the liquid crystal display device, in which the common substrate is arranged so as to face the pixel substrate with a spread substantially corresponding to the pixel substrate and liquid crystal is held between the pixel substrate and the common substrate, A liquid crystal display device, wherein a supporting material for holding a constant gap is provided at least in a joint portion for joining the small substrates. 2. The liquid crystal display device according to claim 1, wherein the support member is formed in a wall shape along the joining portion. 3. A common electrode is formed by arranging a plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed so as to form one flat plate pixel substrate having a uniform pixel pitch. In the liquid crystal display device, in which the common substrate is arranged so as to face the pixel substrate with a width substantially corresponding to the pixel substrate and liquid crystal is held between the pixel substrate and the common substrate, the small substrates are joined together. By providing a conductive material in the portion, each small substrate is electrically connected so as to form the above-mentioned one pixel substrate, and within the width of the non-display portion formed in the contour portion of each pixel. A liquid crystal display device comprising the conductive material. 4. A single pixel substrate is constructed by providing a supporting material for holding a constant gap between the pixel substrate and a common substrate, and providing the conductive material on at least a part of the supporting material. 4. The liquid crystal display device according to claim 3, wherein the small substrates are electrically connected to each other. 5. The liquid crystal display device according to claim 3, wherein conductive particles having a substantially spherical shape are used as the conductive material. 6. A non-translucent pattern corresponding to a non-display portion formed in a contour portion of each pixel, including a joint portion for joining the small substrates together, to either the pixel substrate or the common substrate. 5. The conductive pattern, which is formed on one side and corresponds to the location where the conductive material is disposed, is formed as a non-translucent pattern, and the conductive material and the conductive pattern are brought into close contact with each other. The liquid crystal display device according to item 5. 7. A plurality of small substrates, on which at least pixel electrodes corresponding to a plurality of pixels are formed, are arranged so as to form one flat pixel substrate having a uniform pixel pitch, and a common electrode is formed. The common substrate is arranged so as to face the pixel substrate with a width substantially corresponding to the pixel substrate, and a non-translucent pattern corresponding to the contour of each pixel is formed on either the pixel substrate or the common substrate. In a liquid crystal display device in which liquid crystal is held between a pixel substrate and a common substrate, the projection amount of the non-translucent pattern facing the joint portion that joins the small substrates together and the pixel substrate and the common substrate A liquid crystal display device characterized in that a uniform interval between them is substantially matched. 8. A plurality of small substrates on which at least pixel electrodes corresponding to a plurality of pixels are formed, and a common substrate having a common electrode having a spread substantially corresponding to the pixel substrate are prepared. A plurality of small substrates constitutes one flat plate-shaped pixel substrate having a uniform pixel pitch, the sealing material corresponds to the peripheral portion of the common substrate, and between the pixel substrate and the common substrate. A support material that holds a constant gap, so as to correspond to a joining portion that joins the small substrates, the small substrate and the common substrate are bonded at a constant interval via the sealing material and the support material, A method for manufacturing a liquid crystal display device, characterized in that liquid crystal is sealed between the pixel substrate, the common substrate, the sealing material and the supporting material. 9. The support member is formed in a wall shape along the joining portion, so that the space surrounded by the pixel substrate, the common substrate and the sealing material is divided into two or more small chambers. The method of manufacturing a liquid crystal display device according to claim 8, wherein liquid crystal is injected into the room.