JPH10319223A - Production of color filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process for producing color filters by forming colored pixels without using chemicals for development. SOLUTION: This method consists in laminating the colored resin surface of a transfer film 1 having a foaming layer 3 which is foamed to have its adhesive power lost when gas is generated by heating and an uncured colored resin layer 4 which is not cured by heating on this foaming layer 3 on a heat ray transmissible film 2 so as to face a color filter substrate 5. Next, the transfer film 1 is irradiated with heat rays by using mask patterns and thereafter, the transfer film 1 is peeled. The colored resin layer 4 of the parts irradiated with the heat rays is transferred to the color filter substrate 5 by the degradation in the adhesive power of the foaming layer 3 of the parts irradiated with the heat rays. Further, the transferred colored resin layer 4 is subjected to a curing treatment by UV rays.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a color filter used in a color liquid crystal display device and other color display devices.

[0002]

2. Description of the Related Art A color liquid crystal display device comprises, for example, a substrate in which an alignment film is formed on a transparent electrode of a color filter substrate in which a black matrix, colored pixels, and transparent electrodes are formed in this order on a transparent substrate such as glass; A liquid crystal is sealed in a cell in which an alignment film is formed on a substrate on which a switching element, a transparent electrode, and the like are arranged, and each alignment film surface is opposed to each other and a spacer is interposed therebetween. It has a structure in which an object is sandwiched between two polarizing plates. The color filter has, on a transparent substrate on which a black matrix is formed, red, green, and blue colored pixels arranged in a mosaic shape, a stripe shape, and the like, and has a transparent protective layer that covers the black matrix and the colored pixels. Further, a transparent conductive layer such as ITO is formed.

A method of forming a colored pixel on a transparent substrate on which a black matrix is formed includes a dyeing method,
A colored photosensitive material method of repeatedly applying, exposing and developing a photosensitive resin in which a pigment is dispersed, using a film-shaped photosensitive material having a photosensitive colored layer formed thereon, laminating a photosensitive colored layer on a substrate, and exposing and developing. Are known.

[0004] The dyeing method has a problem in light resistance and the like, and the colored light-sensitive material method can use a pigment excellent in physical properties such as light resistance as a colorant. The steps of exposure and development must be repeated, and the method of using a film-shaped photosensitive material is also a method of laminating the film-shaped photosensitive material instead of coating the colored photosensitive resin layer and treating the same. Yes, it is necessary to carry out processes such as exposure, rinsing, and drying using a large amount of chemicals such as a developer, and an alkaline aqueous solution used to avoid using an organic solvent as a chemical such as a developer. , The corrosion resistance of the colored pixels is required.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing a color filter, which comprises forming colored pixels on a filter substrate by a simple dry method without using a large amount of chemicals. It is assumed that.

[0006]

According to the present invention, there is provided a method for producing a color filter, comprising a heat-transmissive film having a foam layer which foams due to generation of gas by heating and loses adhesive strength. The transfer resin film having an uncured color resin layer that is not cured by heating is laminated with the colored resin surface facing the color filter substrate, and then the transfer film is irradiated with heat rays using a mask pattern. By peeling off and lowering the adhesive strength of the foam layer in the portion irradiated with the heat ray, the colored resin layer in the portion irradiated with the heat ray is transferred to the color filter substrate, and the transferred color resin layer is further cured. It is a manufacturing method. Further, it is the above-mentioned method for producing a color filter, wherein the colored resin layer is made of an ultraviolet curable composition.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view illustrating a method for manufacturing a color filter according to the method of the present invention. FIG. 1A shows a diagram in which the transfer film 1 is laminated on a color filter substrate 5 made of glass or the like. The transfer film 1 has, on a heat ray permeable film 2, a foam layer 3 made of a foamable substance foamed by heat and an adhesive, and contains a pigment for forming a colored pixel on the foam layer. It has an uncured colored resin layer 4.

The colored resin layer 4 of the transfer film is brought into close contact with the color image forming surface of the color filter substrate 5. For the close contact, the color filter substrate 5 and the colored resin layer surface of the transfer film are opposed to each other, and the two are overlapped, and the two are adhered through two rolls. Alternatively, heating may be performed to the extent that the foamed layer does not foam during bonding.

Next, as shown in FIG. 1B, an exposure mask 6 having a pattern of colored pixels to be formed is placed on the transfer film, and a heat ray source 7 irradiates a heat ray 8. The heat rays heat the foam layer 3 of the transfer film according to the pattern of the photomask. As a result, the adhesive strength between the heat ray irradiating portion 9 of the foam layer and the colored resin layer 4 becomes smaller than the adhesive force between the heat ray irradiating portion 9 of the foam layer and the heat ray transmitting film. Is in a state of being easily peeled.

Next, as shown in FIG. 1C, when the transfer film is peeled off from the transparent substrate, a patterned colored resin layer 10 is formed on the transparent substrate. The obtained pattern is irradiated with ultraviolet rays 11 and cured as shown in FIG. The color filter is formed by performing the above-described transfer process for each colored pixel formed on the color filter. Even if the curing step of the colored resin layer is performed every time the colored resin layer corresponding to each of the landing pixels is transferred onto the transparent substrate,
Alternatively, the curing treatment may be performed after transferring all the colored resin layers.

[0011] The heat permeable film of the transfer film used in the transfer method of the present invention includes synthetic resins such as polyethylene naphthalate, polyethylene terephthalate, polyether sulfone, polyphenylene sulfide, polyamide, polyimide, polyamide imide and aromatic polyamide. A film can be used. Further, the thickness of the heat permeable film is preferably 2 to 100 μm.

Further, the foamed layer can be formed by applying a composition in which a foaming agent is dispersed in an adhesive substance containing a block copolymer and a tackifier resin. Examples of the block copolymer include a styrene / butadiene / styrene block copolymer, a styrene / isoprene / styrene block copolymer, and a styrene / ethylene butylene / styrene block copolymer.

As the tackifier resin, rosin and its derivatives, polyterpenes, petroleum resins, cyclopentadiene petroleum resins, styrene petroleum resins, cumarone indene resins, and the like can be used. The tackifier resin is 40 per 100 parts by weight of the block copolymer.
If it is less than 40 parts by weight, the adhesive strength will be poor, and if it exceeds 200 parts by weight, releasability will not be obtained.

As the foaming agent, a substance which foams or expands by heating of an inorganic compound or an organic compound can be used. As the inorganic foaming agent, ammonium carbonate, ammonium hydrogen carbonate, sodium hydrogen carbonate, ammonium nitrite, hydrogen Examples thereof include sodium borohydride and metal azide. Examples of the organic blowing agent include azo compounds such as azobisisobutyronitrile, hydrazine compounds such as paratoluenesulfonyl hydrazide, semicarbazide compounds, triazole compounds, and N-nitroso compounds. These foaming agents may be directly dispersed or may be dispersed in microcapsules.

The amount of the foaming agent is preferably 10 to 100 parts by weight per 100 parts by weight of the block copolymer. If the compounding amount is less than 10 parts by weight, the decrease in adhesive strength due to foaming during heating is not sufficient, and the peeling property is not preferable. Also, 10
If it exceeds 0 parts by weight, the adhesive strength will be poor. Further, the intensity of the heat ray for heating the foam layer is 10 at a wavelength of 15 μm.
0 to 1000 mJ / cm ² , preferably 50
It is preferable to be 0 to 800 mJ / cm ² .

For the colored resin layer used in the present invention, it is preferable to use a photocurable resin which is not cured by heat. For example, a monofunctional or polyfunctional (meth) acrylate monomer and a (meth) acrylate ester or A photopolymerizable composition comprising a composition in which a photopolymerization initiator and the like are combined with a copolymer with (meth) acrylic acid can be used. In addition,
In the present invention, (meth) acryl means both acryl and methacryl compounds. Monofunctional and polyfunctional (meth) acrylate monomers (meth)
Methyl acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, ethylene glycol di (meth)
Acrylate, trimethylolpropane di (meth) acrylate, trimethylolpropane tri (meth) acrylate, telomerol methane tri (meth) acrylate, telomerol methane tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol Hexa (meth) acrylate, pentaerythritol tetra (meth) acrylate, trimethylolpropane triglycidyl ether triacrylate, bisphenol A diglycidyl ether di (meth) acrylate, alkyl ester of β-hydroxyethyl (meth) acrylic acid, trimethylhexamethylene Urethane obtained by reacting diisocyanate, dihydric alcohol and (meth) acrylic acid monoester of dihydric alcohol Acrylate compounds of capital. Examples of copolymers of (meth) acrylic acid ester and (meth) acrylic acid include copolymers of alkyl (meth) acrylate and copolymers of alkyl (meth) acrylate and (meth) acrylic acid. In addition to the polymer, a copolymer of (meth) acrylic acid alkyl ester, (meth) acrylic acid, and a vinyl monomer copolymerizable therewith can be used.

Examples of the alkyl (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and 2-ethylhexyl (meth) acrylate.

The vinyl monomers copolymerizable with the alkyl (meth) acrylate and the (meth) acrylic acid include benzyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, and dimethylethyl (meth) acrylate. , Diethyl (meth) acrylate glycidyl (meth) acrylate, 2,2,2-trifluoroethyl (meth) acrylate, 2,2,3,3-tetrafluoropropyl (meth) acrylate, acrylamide, diacetone acrylamide, Styrene, vinyltoluene and the like can be mentioned.

Further, copolyesters, for example, polyesters such as terephthalic acid, isophthalic acid and sebacic acid, copolymers of butadiene and acrylonitrile, cellulose acetate, cellulose acetate butyrate, methylcellulose and ethylcellulose can also be used.

Examples of the polymerization initiator include benzophenone, Michler's ketone, N, N-tetramethyl-
4,4'-diaminobenzophenone, 4-methoxy-
Aromatic ketones such as 4'-dimethylaminobenzophenone, 4,4'-diethylaminobenzophenone, 2-ethylanthraquinone and phenanthrenequinone; Benzoin, 2- (o
-Chlorophenyl) -4,5-diphenylimidazole dimer, 2- (o-chlorophenyl) -4,5-di (m
-Methoxyphenyl) imidazole dimer, 2- (o-
2,4,5-triarylimidazole dimer such as (fluorophenyl) -4,5-diphenylimidazole dimer and 2- (o-methoxyphenyl) -4,5-diphenylimidazole dimer -Benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone and 2-trichloromethyl-5-styryl-1,3,3
4-oxadiazole, 2-trichloromethyl-5-
Halomethyloxadiazole compounds such as (p-cyanostyryl) -1,3,4-oxadiazole and 2-trichloromethyl-5- (p-methoxystyryl) -1,3,4-oxadiazole; 2,4-bis (trichloromethyl) -6-p-methoxystyryl-s-triazine,
2,4-bis (trichloromethyl) -6- (1-p-dimethylaminophenyl-1,3-butanedienyl) -s
-Triazine, 2-trichloromethyl-4-amino-6
-P-methoxystyryl-s-triazine, 2- (naphth-1-yl) -4,6-bistrichloromethyl-s-
Triazine, 2- (4-ethoxy-naphth-1-yl)
-4,6-bis-trichloromethyl-s-triazine,
Examples include halomethyl-s-triazine-based compounds such as 2- (4-butoxy-naphth-1-yl) -4,6-bis-trichloromethyl-s-triazine.

As a coloring agent to be added to the resin mixed with the photopolymerizable composition, a dye or a pigment can be used. However, a pigment is preferably used in terms of light resistance and the like, and the particle size is 0.4 μm or less. It is preferable to use Preferred pigments include Victoria Pure Blue BO
(CI. 42595), auramine (CI. 410)
00), Fat Black HB (CI. 2615)
0), Monolight Yellow GT (C.I.
Yellow 12), permanent yellow GR (CI pigment yellow 17), permanent yellow HR
(CI Pigment Yellow 83), permanent
Carmine FBB (CI Pigment Red 14
6), Hoster Palm Red ESB (CI Pigment Violet 19), Permanent Ruby FBH
(CI Pigment Red 11), Fastel Pink B Supra (CI Pigment Red 81), Monastral Fast Blue (CI Pigment Red)
Blue 15), Monolight First Black B
(CI Pigment Black 1) and carbon.

Further suitable pigments include C.I. I. Pigment Red 97, C.I. I. Pigment Red 12
2, C.I. I. Pigment Red 149, C.I. I. Pigment Red 168, C.I. I. Pigment Red 1
77, C.I. I. Pigment Red 180, C.I. I. Pigment Red 192, C.I. I. Pigment Red 215, C.I. I. Pigment Green 7, C.I. I. Pigment Green 36, C.I. I. Pigment Blue 15: 1, C.I. I. Pigment Blue 15: 4, C.I.
I. Pigment Blue 15: 6, C.I. I. Pigment Blue 22, C.I. I. Pigment Blue 60, C.I.
I. Pigment Blue 64 and the like.

An additive such as a surfactant is added to the photopolymerizable composition and the colorant to prepare a photopolymerizable composition, and the foamed layer formed on the heat ray permeable film is A colored resin layer having a thickness of 0.5 to 3.0 μm made of a photosensitive resin is formed by roll coating, gravure coating, air knife coating, dip coating, or other coating methods. Further, when bonding the transparent substrate and the transfer film, a pressure-sensitive adhesive can be applied in advance to the surface of the substrate or the surface of the transfer film to form a pressure-sensitive adhesive layer. As the pressure-sensitive adhesive that can be used for such a purpose, a pressure-sensitive adhesive composition using a resin as a vehicle can be used. As the transparent substrate, a substrate made of soda lime glass, non-alkali glass, borosilicate glass, quartz glass, silicon, or the like can be used.

[0024]

Embodiments of the present invention will be described below to explain the present invention. Example 1 Hydrocarbon resin 6 having a softening point of 86 ° C. was prepared by dissolving 100 parts by weight of styrene / butadiene / styrene block copolymer in 200 parts by weight of toluene.
0 parts by weight and a solution obtained by dissolving 60 parts by weight of an alicyclic saturated hydrocarbon resin having a softening point of 115 ° C. in 100 parts by weight of toluene are mixed, and 5 parts by weight of a naphthenic softener and 2 parts by weight of an antioxidant are added thereto. And 40 parts by weight of heat-expandable fine particles (Microsphere F-301D manufactured by Matsumoto Yushi Co., Ltd.) to prepare a toluene solution of a peelable pressure-sensitive adhesive. It was applied on an axially stretched polyethylene terephthalate film so that the thickness after drying was 50 μm, and dried at 60 ° C. for 5 minutes to form a foamed layer. Next, a red photopolymerizable composition described below was applied on the foamed layer so that the film thickness after drying was 2 μm, and a colored resin layer was formed to prepare a transfer film.

(Red photopolymerizable composition) Benzyl methacrylate / methacrylic acid copolymer (molar ratio 73/27) 60 parts by weight Pentaerythritol tetraacrylate 43 parts by weight 2,4-bis (trichloromethyl) -6-p- Methoxystyryl-s-triazine 2.5 parts by weight Irukadine Red BPT 20 parts by weight Methyl cellosolve acetate 560 parts by weight Methyl ethyl ketone 280 parts by weight The obtained transfer film was formed into a black matrix having a length and width of 300 mm x 400 mm, thickness 1.1 mm The surface on which the colored resin layer was formed was intimately laminated on the glass substrate of Example 1 and pressed at room temperature with a roll having a linear pressure of 10 kg / cm. A red pattern forming photomask is placed on the heat ray transmitting film of the color filter substrate on which the obtained transfer film is laminated, and a heat ray having a wavelength of 15 μm is irradiated at an intensity of 1000 mJ / cm ² , and then the transfer film is peeled off. did.

Next, as a photopolymerizable composition, the following green photopolymerizable composition was applied in the same manner on the heat ray permeable film on which the foamed layer was formed, to produce a green transfer film. (Green photopolymerizable composition) Benzyl methacrylate / methacrylic acid copolymer (molar ratio 73/27) 60 parts by weight Pentaerythritol tetraacrylate 43 parts by weight 2,4-bis (trichloromethyl) -6-p-methoxystyryl- 2.5 parts by weight of s-triazine 20 parts by weight of copper phthalocyanine 560 parts by weight of methyl cellosolve acetate 280 parts by weight of methyl ethyl ketone The obtained green transfer film is a color filter having a red colored resin layer formed thereon in the same manner as the red transfer film. After being in close contact with the substrate, a photomask for forming a green pattern was placed on the heat ray transmitting film and irradiated with heat rays, the transfer film was peeled off.

Further, as a photopolymerizable composition, the following blue photopolymerizable composition was applied in the same manner on the heat ray permeable film on which the foamed layer was formed to prepare a green transfer film. (Blue light polymerizable composition) Benzyl methacrylate / methacrylic acid copolymer (molar ratio 73/27) 60 parts by weight Pentaerythritol tetraacrylate 43 parts by weight 2,4-bis (trichloromethyl) -6-p-methoxystyryl- 2.5 parts by weight of s-triazine 20 parts by weight of phthalocyanine blue 560 parts by weight of methyl cellosolve acetate 280 parts by weight of methyl ethyl ketone The obtained blue transfer film was formed into red and green colored resin layers in the same manner as the red transfer film. After being in close contact with the color filter substrate, a blue pattern forming photomask was placed on the heat ray transmitting film and irradiated with heat rays, the transfer film was peeled off.

The colored resin layer of the transparent substrate has a wavelength of 365 nm.
Was irradiated with ultraviolet rays of 500 mJ / cm ² to cure the colored resin layer, and a color filter having colored pixels was obtained.

The obtained color filter was free from missing or uneven pixels, and had good pixel accuracy.

[0030]

The present invention provides a photomask in which a transfer film formed on a heat-transmissive film in the order of a heat-peelable foam layer and an ultraviolet-curable colored resin layer is adhered to a transparent substrate to form a photomask. After placing and irradiating with heat rays, the transfer film is peeled to transfer the colored resin layer, and then, it is a method of irradiating with ultraviolet rays and photo-curing to form a colored pixel. And can be easily manufactured in a dry manner.

[Brief description of the drawings]

FIG. 1 is a diagram illustrating a manufacturing method of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Transfer film, 2 ... Heat ray transmissive film, 3 ... Foam layer, 4 ... Colored resin layer, 5 ... Color filter substrate, 6 ... Exposure mask, 7 ... Heat ray generation source, 8 ... Heat ray, 9 ... Heat ray irradiation part, 10: patterned colored resin layer, 11: ultraviolet rays

Claims (2)

[Claims] 1. A method for producing a color filter, comprising: a heat-transmissive film, a foamed layer which foams due to generation of gas by heating and loses adhesive strength, and is not cured by heating on the foamed layer. The colored resin surface of the transfer film having the cured colored resin layer was laminated facing the color filter substrate, and then the transfer film was irradiated with heat rays using a mask pattern, and then the transfer film was peeled off and irradiated with heat rays. A method for producing a color filter, comprising: transferring a part of a colored resin layer to a color filter substrate; and curing the transferred colored resin layer. 2. The method for producing a color filter according to claim 1, wherein the colored resin layer is made of an ultraviolet curable composition.