JPH11101908A - Manufacture of color filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a color filter, which is excellent in color characteristic and is high in precision, while maintaining good flatness by the laser beam processing. SOLUTION: A material 10 for transferring, in which a colored resin layer 12 contg. a dye on a temporary supporting body 11 is provided, is prepared and then, the material 10 for transferring is heated and press-fixed on a transparent substrate 13 at a surface of the colored resin layer 12. Thereafter, the temporary supporting body 11 is peeled off and the transparent substrate 13, to which the colored resin film layer 12 is transferred, is obtained. Next, the colored resin film layer 12 is hardened, and thereafter, an area other than a region of colored picture element is irradiated with a laser beam from above the colored resin layer 12 to transpire the colored resin layer 12 at the area to be irradiated, whereby a stage for forming the colored element consisting of the pattern-like colored resin layer is included.

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 for a liquid crystal display or the like.

[0002]

2. Description of the Related Art A color filter in which a plurality of colored pixels having different hues are formed in a pattern on a transparent substrate is mounted on a color liquid crystal display or the like. Generally, three primary colors of red, blue, and green are used as the hues of the colored pixels. If desired, colored pixels or black matrices of the fourth and subsequent hues may be formed.

Conventionally, as a method for producing a color filter, for example, a method using an ultraviolet-curable resin containing an organic dye has been proposed (Japanese Patent Application Laid-Open No. 58-7608).
issue). In this method, a step of applying a positive resist on a substrate, a step of exposing the positive resist through a mask pattern and forming a predetermined pattern by development, and a step of forming an organic dye on the substrate on which the positive resist pattern is formed are performed. Applying the UV curable resin to the entire surface, exposing the entire surface to UV light to cure the UV curable resin and exposing the positive resist pattern, and peeling off the exposed positive resist pattern together with the UV curable resin thereon The colored pixels of each color are formed by repeating each step of the step of forming a filter pattern made of the remaining ultraviolet curable resin. A method of producing a color filter in the same process as described above by using a pigment instead of an organic dye has also been proposed (JP-A-60-129).
707).

Further, in order to increase the transparency of a colored image in which a pigment is dispersed, particles having a particle size of 1 μm or more constitute one of all particles.
Using a resin composition in which a pigment having a particle size distribution of not more than 0% by weight is dispersed in a transparent photosensitive resin, a color filter for forming a patterned transparent colored image of a plurality of colors on a support is used. A manufacturing method has been proposed (Japanese Patent Publication 4-
No. 39041). In this method, a coating film of a photosensitive resin composition in which a pigment of a first hue is dispersed is formed on a substrate, the coating film is exposed to light through a mask pattern, and developed to form a first coating. Is formed, and the same steps are repeated thereon to form colored pixels of the second and third hues.

[0005] These conventional methods are photolithographic methods, and in each case, after exposure, development is performed using a developing solution such as water or an organic solvent to remove exposed or unexposed portions that are dissolved in the developing solution. Thus, a colored pixel is obtained. In such a method, waste liquid treatment of the developing solution is necessary, and furthermore, undissolved substances, dust, and the like from the developing solution are mixed in the colored pixels, which causes pixel defects.

In the method using a colored photosensitive resin,
Depending on the performance of the photosensitive component or the resin component, or the light absorption characteristics of the colorant (dye or pigment), a difference occurs in sensitivity and resolution. Therefore, to obtain the desired sensitivity and resolution,
It is necessary to select each component of the colored photosensitive resin composition.
Therefore, the colored photosensitive resin composition had to be expensive. In addition, in this method, the number of steps for obtaining a colored pixel is large, causing a decrease in yield and an increase in manufacturing cost.

When the sensitivity and the resolution are adjusted by adjusting the contents of the photosensitive component and the resin component, the thickness of the colored pixel of each hue is different, and a step is generated. If a step occurs between the colored pixels, the flatness of the color filter is impaired. If a voltage is applied between the electrodes during mounting, a difference occurs in the voltage, causing display failure. In a liquid crystal display, a voltage is applied to the liquid crystal to align the liquid crystal molecules, but the voltage that maximizes the contrast changes depending on the cell gap. If the thickness of each colored pixel of the color filter is different, the cell gap changes, and the optimal voltage changes for each color. Therefore, there arises a problem that the contrast is lowered and the color balance at the time of off is lost. If there is a step between the colored pixels of the color filter, during the rubbing process in which the surface of the alignment film is rubbed in a certain direction and the liquid crystal molecules are arranged in the rubbing direction, the pixel boundaries are not rubbed, resulting in poor alignment of the liquid crystal. , The contrast is reduced.

Recently, the present inventors have conceived of a method of manufacturing a color filter by removing a colored coating film formed on a substrate by irradiating it with laser light while leaving a portion serving as a pixel. did. In this method, a colored coating film of a first color is formed on a substrate, and a portion other than a region serving as a pixel of the first color is irradiated with a laser beam to evaporate only a portion to be irradiated. A colored pixel is formed, and then a colored coating film of the second color is formed on the entire surface of the substrate from above the colored pixel of the first color, and a laser beam is applied to a portion other than a region to be the colored pixel of the second color. Evaporating the coating film on the irradiated portion, and controlling the output of the laser light (the amount of irradiation energy) (including the control of the number of shots of the pulsed light) to leave the colored pixel of the first color. The second color pixel is formed by evaporating the second color coating film coated thereon, and the third color and subsequent pixels are formed in the same manner.

By employing this laser processing method, the above-mentioned problems associated with the use of a photosensitive resin can be solved, and a high-definition color filter can be manufactured. However, this laser processing method has the following problems. That is, in the laser processing method, a colored coating film and a colored pixel are usually formed using a colored composition containing an organic pigment, a binder resin, and a solvent as essential components. However, when an organic pigment is used as a coloring agent, spectral characteristics and contrast are inferior to those when a dye is used.

When the coloring composition is applied by a spin coating method to form a colored coating, for example, when a second colored coating is formed, the colored composition is formed on a transparent substrate and on a first colored pixel. , The thickness of the colored coating film is different, and the thickness of the colored coating film of the second color on the colored pixel of the first color is relatively thin. Therefore, by irradiating the laser light to a portion other than the region serving as the colored pixel of the second color to evaporate the coating film of the irradiated portion, even if the output of the laser light is controlled, There has been a problem that not only the second color coating film coated thereon but also the upper portion of the first color pixel is shaved and thinned.

[0011]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing a high-definition color filter having excellent color characteristics and high flatness by a laser beam processing method. The present inventors have conducted intensive studies in order to solve the above-described problems, and as a result, transferred a colored resin layer containing a dye onto a transparent substrate (including a transparent substrate on which colored pixels of other hues are already formed) by a transfer method. It has been found that by forming the color filter, the above-mentioned problems caused by the conventional coating method can be overcome and a color filter having excellent display quality can be obtained. The present invention has been completed based on these findings.

[0012]

According to the present invention, (1)
A transfer material in which a coloring resin layer containing a dye is provided on a temporary support is prepared, and (2) the transfer material is heated and pressed on a transparent substrate on the surface of the coloring resin layer. The body is peeled off to obtain a transparent substrate to which the colored resin layer has been transferred. (4) Next, after the colored resin layer is cured, (5) a laser light is applied from above the colored resin layer to a region to be a colored pixel. A method for manufacturing a color filter including a step of forming a colored pixel made of a patterned colored resin layer by irradiating a portion other than the above and evaporating the colored resin layer of the irradiated portion is provided.

According to the present invention, (I) a colored resin layer of the first color is formed on a transparent substrate, and then a laser beam is irradiated to a portion other than a region to be a colored pixel of the first color, A step of forming a colored pixel of the first color composed of a patterned colored resin layer by evaporating the colored resin layer of the irradiated portion; (II) covering the entire surface of the transparent substrate including the colored pixel of the first color; Forming a colored resin layer of the second color, and then irradiating the laser light to a portion other than the region to be the colored pixel of the second color to evaporate the colored resin layer of the irradiated portion, thereby forming a colored pattern. Forming a second colored pixel made of a resin layer, in which case controlling the output of laser light,
The second colored pixel formed on the first colored pixel is left
Production of a color filter including the step of evaporating the colored resin layer of the color and (III) the step of forming the required number of colored pixels of the third and subsequent colors by the same step as the above (II), if necessary. In the method, at least step (I)
I) In forming the colored resin layers of each color on the transparent substrate in each of the subsequent steps, (1) preparing a transfer material provided with a dye-containing colored resin layer on a temporary support; After the transfer material is heated and pressed on the transparent substrate on the colored resin layer surface, (3) the temporary support is peeled off to obtain a transparent substrate on which the colored resin layer has been transferred. (4) Next, the colored resin There is provided a method for producing a color filter, comprising curing the layer.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail. <Transfer Material> In the present invention, a transfer material in which a colored resin layer containing a dye is provided on a temporary support is prepared. The colored resin layer is formed using a colored resin composition containing a dye, a binder resin, a heat or light curing agent, and a solvent.
The dye used in the present invention is not particularly limited, but an oil-soluble dye and an acid dye are preferable. Multiple dyes may be blended to achieve the desired color. Thereby, three primary colors of red, green and blue are obtained. Hereinafter, dyes having high weather resistance will be exemplified as color filter applications. The display is performed using a color index (Color Index).

Examples of the acid dye include C.I. I. AC
ID RED 18, C.I. I. ACID RED 15
1, C.I. I. ACID YELLOW 38, C.I. I.
ACID GREEN 25, C.I. I. ACID BL
UE 9, C.I. I. ACIDBLUE 40, C.I. I.
ACID BLUE 129, C.I. I. ACIDVIO
LET 17, C.I. I. ACID VIOLET 49
And the like.

Examples of oil-soluble dyes include C.I. I. S
OLVENT RED 7, C.I. I. SOLVENT
RED 8, C.I. I. SOLVENT RED 35,
C. I. SOLVENT RED 46, C.I. I. SO
LVENT RED 68, C.I. I. SOLVENT
RED 83, C.I. I. SOLVENT RED 8
9, C.I. I. SOLVENT RED 90, C.I. I.
SOLVENT RED91, C.I. I. SOLVENT
RED 92, C.I. I. SOLVENT RED 1
09, C.I. I. SOLVENT RED 111, C.I.
I. SOLVENT RED 118, C.I. I. SOL
VENT RED 119, C.I. I. SOLVENT
RED 122, C.I. I. SOLVENT RED 1
25, C.I. I. SOLVENT RED 127, C.I.
I. SOLVENT RED 130, C.I. I. SOL
VENT RED 132, C.I. I. SOLVENT
RED 138, C.I. I. SOLVENT RED 1
60, C.I. I. SOLVENT RED 207, C.I.
I. SOLVENT RED 218, C.I. I. SOL
VENT RED 230; I. SOLVENT
ORANGE 11, C.I. I. SOLvent ora
NGE 23, C.I. I. SOLVENT ORANGE
37, C.I. I. SOLVENT ORANGE 5
9, C.I. I. SOLVENT ORANGE 62,
C. I. C. SOLVENT ORANGE 99; I.
SOLVENT YELLOW 19, C.I. I. SOL
VENTYELLOW 21, C.I. I. SOLVENT
YELLOW 25, C.I. I. SOLVENT YE
LLOW 33, C.I. I. SOLVENT YELLO
W42, C.I. I. SOLVENT YELLOW 5
6, C.I. I. SOLVENT YELLOW 62,
C. I. SOLVENT YELLOW 63, C.I.
I. SOLVENT YELLOW 77, C.I. I. S
OLVENT YELLOW 79, C.I. I. SOLV
ENT YELLOW 82, C.I. I. SOLVENT
YELLOW 83, C.I. I. SOLVENT YE
LLOW 89, C.I. I. SOLVENT YELLO
W 93, C.I. I. SOLVENT YELLOW 1
04, C.I. I. SOLVENT YELLOW 10
5, C.I. I. SOLVENT YELLOW 114,
C. I. SOLVENT YELLOW 129, C.I.
I. SOLVENT YELLOW 130, C.I. I.
SOLVENT YELLOW 138, C.I. I. SO
LVENT YELLOW 146, C.I. I. SOLVE
NT YELLOW 162, C.I. I. SOLVENT
YELLOW 163; I. GREEN 3,
C. I. GREEN 25; I. SOLVENT B
LUE 4, C.I. I. SOLVENT BLUE 5,
C. I. SOLvent BLUE 14, C.I. I. S
OLVENTBLUE 25, C.I. I. SOLVENT
BLUE 35, C.I. I. SOLVENT BLUE
37, C.I. I. SOLVENT BLUE 38,
C. I. SOLvent BLUE 44, C.I. I. S
OLVENT BLUE 45, C.I. I. SOLVEN
T BLUE 48, C.I. I. SOLVENT BLU
E 49, C.I. I. SOLVENT BLUE 67,
C. I. SOLVENTBLUE 68, C.I. I. SO
LVENT BLUE 70, C.I. I. SOLVENT
BLUE 78, C.I. I. SOLVENT BLUE
94; I. SOLVENT VIOLET 1
3, C.I. I. SOLVENT VIOLET 14,
C. I. SOLVENT VIOLET 23, C.I.
I. SOLVENT VIOLET 24, C.I. I. S
OLVENT VIOLET 33, C.I. I. SOLV
ENT VIOLET 45, C.I. I. SOLVENT
VIOLET 46 and the like. The amount of the dye in the present invention is usually 0.1 to 5 in the colored resin composition.
0% by weight. Preferably it is 1 to 20% by weight.

The resin used as the binder is not particularly limited, but is preferably a resin having good heat resistance, light resistance, and good adhesion to a substrate.
An acrylic resin, an epoxy resin, a polyamide resin, a polyurethane resin, a polyester resin, an alkyd resin, a silicone resin, a melamine resin, and the like can be given. The amount of the binder resin in the present invention is preferably 1 to 80% by weight in the colored resin composition.

Examples of the photocuring agent (photosensitive resin) include a negative diazo resin, a photopolymerizable resin (a combination of a photopolymerization initiator, a photopolymerizable monomer, and a binder resin). Examples of the thermosetting agent include a polymethylol compound, a polyisocyanate compound, and a polyepoxy compound. The amount of the photosensitive resin or thermosetting agent in the present invention is preferably 0.01 to 20% by weight and 1 to 30% by weight, respectively, in the colored resin composition.

The colored resin composition of the present invention is prepared by dissolving or mixing the above components in a solvent capable of dissolving the above components to form a uniform solution. Examples of the solvent that dissolves each component include, for example, toluene, acetone, methyl ethyl ketone, methyl isobutyl ketone, methyl cellosolve, ethyl cellosolve, chloroform, methylene chloride, methyl alcohol,
Ethyl alcohol, N, N'-dimethylformamide,
N-methyl-2-pyrrolidone, cyclohexanone, 2-
Examples include methoxyethanol, methoxypropyl acetate, isobutyl acetate, 2-butoxyethanol and the like. These solvents are used alone or in combination of two or more. The compounding amount of the solvent to be used is an amount sufficient to uniformly dissolve the components. The amount of the solvent is preferably about 2 to 8 times the total amount of each component other than the solvent. In addition, the coloring resin composition of the present invention, in addition to the above, a color former, a plasticizer, a flame retardant, a stabilizer, a thermal polymerization inhibitor, a coating property modifier, and the like may be added as necessary. it can.

The transfer material of the present invention can be produced by applying a colored resin composition on a temporary support and drying it. As the temporary support of the transfer material of the present invention, a thin sheet of Teflon, polyethylene terephthalate, polycarbonate, polyethylene, polypropylene or the like, or a laminate thereof is preferable. The thickness of the temporary support is usually 5 to 3
00 μm is appropriate, and preferably 20 to 150 μm.

It is preferable to provide a thin cover sheet on the colored resin layer for protecting the storage layer from contamination and damage during storage. The cover sheet may be made of the same or similar material as the temporary support, but is preferably one that easily separates from the colored resin layer. As the material of the covering sheet, for example, silicone paper, polyolefin or polytetrafluoroethylene sheet is suitable. The thickness of the covering sheet is preferably 5 to 100 μm. Particularly preferred is a polyethylene or polypropylene film having a thickness of 10 to 30 μm.

<Transfer Method> The transfer method of the transfer material of the present invention will be described. First, the covering sheet on the colored resin layer is removed from the transfer material. Next, as shown in FIG. 1A, the transfer material 10 having a structure in which the temporary support 11 and the colored resin layer 12 are laminated is opposed to the transparent substrate 13. FIG.
As shown in (b), the transfer material 10 is transferred to the colored resin layer 12.
The surface is heated and pressed on the transparent substrate 13. A conventionally known laminator, vacuum laminator, or the like can be used for lamination, and an auto-cut laminator can be used to further increase productivity. Next, FIG.
As shown in (5), the temporary support 11 is peeled off. Thereafter, in order to prevent the dye from seeping out, light or heat is applied to cure the colored resin layer. As a light source at the time of photocuring, a known active light source, for example, light generated from a carbon arc, a mercury vapor arc, a xenon arc, a flood lamp for photography, or the like can be used. In the case of heat curing, it is usually cured at 130 to 250 ° C.

As described above, the colored resin layer 12 is transferred onto the transparent substrate 13 (see FIG. 1D). The colored resin layer 12 is processed with a laser beam as described below to obtain a colored pattern. In the case of the present invention, this coloring pattern becomes a pixel of the color filter.

<Manufacturing Method of Color Filter> In the present invention, the steps (I) and (II) and (I)
II) A color filter is manufactured by the following steps.
In this manufacturing method, the transfer method is applied when forming a colored resin layer of each color on the transparent substrate at least in each step after the step (II). Of course, this transfer method can also be applied to the case where a colored resin layer is formed on a transparent substrate in the step (I). However, in the step (I), since a colored pixel is not formed below the colored resin layer, a colored resin layer having a uniform thickness can be formed by a coating method without necessarily using a transfer method.

A typical example of the method for manufacturing a color filter of the present invention will be described with reference to FIG. A transfer material (not shown) in which a first color resin layer is formed on a temporary support is prepared, and the first color is formed using the transfer material as shown in FIG. The resin layer 2 is transferred onto the transparent substrate 1. The first color is usually one of the three primary colors required for the color filter, and the second color, the third color,
The tint is each of the remaining colors. Usually, as three primary colors,
Red, green, and blue (R, G, B) are used.

As the transparent substrate 1, soda glass, non-alkali glass, transparent plastic plate or the like is used. A substrate in which a black matrix is formed in advance on a substrate can also be used. When a substrate without a black matrix is used, it is preferable to form the black matrix after forming the colored pixels. Here, the black matrix fills or covers the gaps between the colored pixels with a light-shielding substance to improve the contrast of the color filter. As a material of the black matrix, for example, chromium, chromium oxide, carbon black, graphite,
There is a resin composition mixed with a light-shielding substance. The black matrix may be formed by overlapping two or more colored resin layers. Next, as shown in FIG. 2B, the laser light 3 is irradiated to a portion other than the region serving as the pixel of the first color to evaporate the colored resin layer 2 at the irradiated portion, thereby forming the first color. Is formed (see FIG. 2C).

The laser beam used here must have a sufficiently short wavelength so that the colored resin layer evaporates without causing heat sag. In this regard, an excimer laser having a wavelength in the ultraviolet region is preferable. Excimer lasers include XeCl, KrF and ArF.
However, even if the wavelength is infrared light, such as a CO ₂ or YAG laser, it is possible to obtain the wavelength by using a second or third harmonic using a nonlinear optical material. However, in this case, the laser beam must have a sufficient energy density. The energy density of the laser beam is preferably 0.1 to ³ J / cm ² , and 0.2 to ² J / cm ^2.
/ Cm ² is particularly preferred. If the energy density of the laser beam is too high, not only the colored resin layer but also the underlying transparent substrate and black matrix evaporate. If the energy density of the laser beam is too low, the colored resin layer does not evaporate. It is necessary to control the output of the laser light in order to form colored pixels of the second and subsequent colors. From this point, it is desirable that the laser light is pulsed light. This is because the processing control in the depth direction of the colored resin layer can be performed by the number of shots of the pulsed light. The size of the formed colored pixel is usually about 100 × 30
0 μm and the pixel spacing is about 30 μm,
In a high-definition type used for a viewfinder or the like, a dimension of about one tenth is required.

There are two methods for irradiating the laser beam 3 to obtain a colored pixel. One is to irradiate a certain area with laser light by surface exposure through the photomask 4 to collectively form pixels, move the substrate by an XY stage or the like, and irradiate the laser light again to form pixels. . By repeating this process, colored pixels are obtained on the entire surface of the substrate. In this case, the processing time is advantageously shortened as much as possible with a large area, but if the area is enlarged too much, the irradiation energy density becomes small, and the irradiated part does not evaporate. It is preferable to widen the area of the laser beam with an energy density at which transpiration is minimal. In this method, since the area where the colored pixel is formed at one time is large, the entire processing time is shortened.

As another method, there is a method of forming a colored pixel by narrowing down the laser beam 3 and scanning it. It is necessary that the size of the spot of the laser beam is such that either the length or width of the spot is at least 30 μm or less. As a method of scanning with a laser beam, it is possible to move the substrate itself using an XY stage or the like, or to scan with a laser beam using an optical system. This method does not require a photomask, and is advantageous for fine processing. When an excimer laser is used as a light source, a method using a photomask is more advantageous in order to make use of its surface light source characteristics. As described above, the first colored pixel 5 is obtained.

Next, using the transfer material (not shown) on which the second colored resin layer is formed, the second colored resin layer 6 is converted into a transparent material on which the first colored pixels 5 are formed. The image is transferred onto the substrate 1 (see FIG. 2D). At this time, since the colored resin layer 6 is formed by the transfer method, the second
The thickness of the color resin layer 62 and the color pixel 5 of the first color
The thickness of the upper colored resin layer 61 of the second color becomes equal.

Next, in the same manner as when the first colored pixel 5 is formed, the laser light 3 is irradiated to a portion other than the region where the second colored pixel is formed, and the second colored pixel 7 is formed. (See FIGS. 2E to 2F). Here, since there is an area where the first color pixel 5 exists below the second color resin layer 61, the number of laser light pulse shots is controlled to thereby control the second color resin layer 61. Is evaporated, leaving the first colored pixel 5 underneath. For this purpose, the depth and the etch rate of the vaporization per one shot of the laser beam are measured in advance, and the thickness of the colored resin layer of the second color is separately measured to evaporate only the second color. The number of shots necessary for this is determined, and pulses are radiated by the number of shots to evaporate only the second color resin layer on the first color pixels. In this manner, the second color pixel 7 is formed on the transparent substrate 1 on which the first color pixel 5 is formed (see FIGS. 2D to 2F).

By using a transfer material on which a colored resin layer having a hue different from the first color and the second color is formed, the same steps as those described above are repeated, thereby forming a third color pixel 9. That is, using the transfer material (not shown) on which the third color resin layer is formed, the third color resin layer 8 is converted to the first color pixel 5 and the second color pixel (7). Is transferred onto the transparent substrate 1 on which is formed [see FIG. 2 (G)]. Since the colored resin layer 8 is formed by the transfer method, the thickness of the third colored resin layer 82 on the substrate and the third colored pixel 5 on the first colored pixel 5 and the second colored pixel 7 on the second colored pixel 7 are determined. The thickness of the colored resin layer 81 becomes equal.

Next, in the same manner as when the first colored pixel 5 is formed, the laser light 3 is applied to a portion other than the region where the third colored pixel is formed, and the third colored pixel 9 is formed. It is formed (see FIGS. 2H to 2I). Here, since the area where the first color pixel 5 and the second color pixel 7 exist under the third color resin layer 81, by controlling the number of shots of the laser light pulse, Only the third color resin layer 81 is evaporated, leaving the first color pixels 5 and the second color pixels 7 thereunder. For this purpose, the depth and etch rate of the laser beam per one shot of the laser beam are measured in advance, and the thickness of the colored resin layer of the third color is separately measured to evaporate only the third color. The number of shots required for this is determined, and pulses are irradiated by the number of shots, and only the third color resin layer on the first color pixels and the second color pixels is evaporated.

In this manner, on the transparent substrate 1 on which the first color pixel 5 and the second color pixel 7 are formed,
Form a third colored pixel 7 [FIGS. 2 (G) to 2 (I)].
reference〕. In this manner, a color filter in which colored pixels of three hues are formed in a pattern can be obtained (see FIG. 2I).

(Function) According to the present invention, since the colored resin layer is formed on the substrate by the transfer method, when forming the second and subsequent colors, the colored resin layer is formed on the substrate and on the colored pixels of the previous color. When the thickness becomes equal and processing by laser light is performed,
A color filter having excellent flatness can be obtained without the colored pixels of the previous color being shaved and becoming thin. Further, since the colored resin layer is cured by light or heat, there is no problem such as seepage of dye.

[0036]

The present invention will be described more specifically below with reference to examples and comparative examples. Parts and percentages are by weight unless otherwise specified.

Example 1 (Preparation of Transfer Material and Transfer Method) First, an acrylic resin solution was prepared. Acrylic acid 288 parts Styrene 300 parts n-butyl acrylate 255 parts 2-hydroxyethyl acrylate 157 parts t-butylperoxybenzoate 100 parts A mixture of the above monomer and polymerization initiator was heated to 110 ° C. in a flask. Ethanol 100
After dropping into 0 parts under stirring over 2 hours, the mixture was kept at the same temperature for 2 hours to prepare an acrylic resin solution having a solid content of 50%.

Next, a colored resin composition was prepared according to the following composition. <Red> Dye: C.I. I. SOLVENT RED 125 ... 2.02% C.I. I. SOLVENT YELLOW 62: 2.27% Binder: 50% acrylic resin solution: 10.00% Thermosetting agent: hexamethylol melamine ··· 4.64% Solvent: isobutyl acetate ······ 81.07%

<Green> Dye: C.I. I. SOLVENT YELLOW 82: 2.64% C.I. I. SOLVENT BLUE 44 1.32% C.I. I. SOLVENT BLUE 38 1.29% Binder: 50% acrylic resin solution 12.25% Thermosetting agent: hexamethylolmelamine * 5.68% Solvent: isobutyl acetate ... 76.82%

<Blue> Dye: C.I. I. SOLVENT BLUE 45... 2.61% C.I. I. SOLVENT BLUE 44 0.44% Binder: 50% acrylic resin solution 7.11% Thermosetting agent: hexamethylolmelamine ··· 3.30% Solvent: isobutyl acetate ········ 86.54%

Each of the above components was stirred with a stirrer for 2 hours to prepare each colored resin composition. Each colored resin composition was applied on a 100 μm-thick polyethylene terephthalate (PET) film using a film coater,
After drying, a colored resin layer having a thickness of 1 μm was formed. further,
A polypropylene coated sheet having a thickness of 12 μm was pressed on the colored resin layer to prepare a transfer material. Using each transfer material, it was transferred to a substrate by the following method. The coated sheet was peeled off from the transfer material, and then the colored resin layer surface was pressed (0.8 k) using a laminator (VP-II, manufactured by Taisei Laminator Co., Ltd.) on a transparent glass substrate (1.1 mm thick).
g / cm) and heated (130 ° C). After peeling off and removing the temporary support (PET film), 200
The colored resin layer was cured by heating at 10 ° C. for 10 minutes.

Example 2 (Preparation of Transfer Material and Transfer Method) A colored resin composition was prepared according to the following composition. <Red> Dye: C.I. I. SOLVENT RED 125 ... 2.02% C.I. I. SOLVENT YELLOW 62: 2.27% Photopolymerizable resin: benzyl methacrylate / methacrylic acid copolymer (molar ratio = 72/28, molecular weight 30,000): 3.46% pentaerythritol hexa Acrylate 3.28% 2,4-bis (trichloromethyl) -6- [4- (N, N-diethoxycarbonylmethyl) -3-bromophenyl] -S-triazine 0.15% Solvent: methoxypropyl acetate 35.76% Methyl ethyl ketone・ 53.06%

<Green> Dye: C.I. I. SOLVENT YELLOW 82: 2.64% C.I. I. SOLVENT BLUE 44 1.32% C.I. I. SOLVENT BLUE 38 1.29% Photopolymerizable resin: benzyl methacrylate / methacrylic acid copolymer (molar ratio = 72/28, molecular weight 30,000) ... 3.82% pentane Erythritol hexaacrylate 2.88% 2-Trichloromethyl-5- (p-styrylstyryl) -1,3,4, -oxadiazole 0.14% Solvent : Methoxypropyl acetate 35.39% Methyl ethyl ketone 52.52%

<Blue> Dye: C.I. I. SOLVENT BLUE 45... 2.61% C.I. I. SOLVENT BLUE 44 0.44% Photopolymerizable resin: benzyl methacrylate / methacrylic acid copolymer (molar ratio = 72/28, molecular weight 30,000) 3.95% pentane Erythritol hexaacrylate 3.74% 2,4-bis (trichloromethyl) -6- [4- (N, N-diethoxycarbonylmethyl) -3-bromophenyl] -S-triazine 0.18% Solvent: methoxypropyl acetate 35.87% Methyl ethyl ketone 53.21%

Each of the above components was stirred with a stirrer for 2 hours to prepare each colored resin composition. This colored resin composition was applied on a 100 μm-thick polyethylene terephthalate (PET) film using a film coater,
After drying, a colored resin layer having a thickness of 1 μm was formed. further,
A polypropylene coated sheet having a thickness of 12 μm was pressed on the colored resin layer to prepare a transfer material. Using each transfer material, the colored resin layer was transferred to the substrate by the following method. The coated sheet was peeled off from the transfer material, and then the colored resin layer surface was pressed (0.8 kg / cm) on a transparent glass substrate (1.1 mm thick) using a laminator (VP-II manufactured by Taisei Laminator Co., Ltd.). ) And heating (130 ° C.) for bonding. Next, after the temporary support was peeled off and removed, the entire surface was irradiated with light using an ultra-high pressure mercury lamp (3 kW) to cure the colored resin layer.

Example 3 (Preparation of Color Filter) Using a red transfer material, a 10 cm square non-alkali glass substrate 1 on which a black matrix of a Cr thin film having a width of 30 μm was formed according to Example 1. The transfer was performed to obtain a red colored resin layer 2. The thickness of the colored resin layer 2 measured by a contact surface roughness meter DEKTAKIIA (manufactured by Sloan) was 1.0 μm. This colored resin layer 2
In order to process with a laser beam 3, the same film as the above-mentioned colored resin layer was previously processed with a laser, and conditions were determined. The laser processing conditions are as follows.・ Laser processing machine (Lumonics Corporation PM-848) ・ Wavelength: 248 nm (KrF excimer laser) ・ Pulse energy: 300 mJ / cm ²・ Repetition: 10 Hz

Under the above processing conditions, when the colored resin layer was processed, it was found that a thickness of 0.2 μm was evaporated by one pulse. Therefore, in order to evaporate the red colored resin layer by 1.0 μm, it was found that the same region should be irradiated with 5 shots. Therefore, the same area was irradiated with five shots of laser light 3 through the photomask 4 on the colored resin layer 2 under the above processing conditions, thereby forming a colored pixel 5 having a 100 × 300 μm red stripe.

Next, using a green transfer material, the transfer was performed on the substrate 1 on which the red colored pixels 5 were formed, thereby forming a green colored resin layer 6. When the film thickness was measured,
It was 1.0 μm. The vaporized film thickness per pulse of the green colored resin layer was measured in advance, and it was 0.2 μm / pulse under the same irradiation conditions as when the red colored resin layer was processed. Therefore, in order to process the green colored resin layer on this substrate and on the red colored pixels, 5
It is sufficient to irradiate the laser light 3 through the photomask 4 for 5 shots.
, A green colored pixel 7 of the same size as red was formed.

Finally, using a blue transfer material,
Transferred onto the substrate 1 on which the red and green colored pixels are formed,
A blue colored resin layer 8 was formed. When the film thickness was measured, it was 1.0 μm. When the evaporation film thickness per pulse of the blue colored resin layer was measured in advance, it was found to be 0.2 μm / mm under the same irradiation conditions as when the red and blue colored resin layers were processed.
It was a pulse. Therefore, in order to process the blue colored resin layer on this substrate and on the red and green colored pixels, the same region may be irradiated with five shots, and the laser light 3 is actually applied through the photomask 4. By irradiating 5 shots, a blue colored pixel 9 having the same size as red and green was formed next to the red and green colored pixels.

The contrast of the color filter obtained as described above was evaluated as follows. That is, the color filter is sandwiched between two polarizing plates and placed on a light box. When the front luminance is measured by a luminance meter (LS-110, manufactured by Minolta Co., Ltd.), if the value of luminance (parallel to the polarizing axis of the polarizing plate) / luminance (perpendicular to the polarizing axis of the polarizing plate) is defined as contrast, the present invention The contrast of the color filter was 2430, indicating a sufficient contrast.

[Comparative Example 1] A color resist [RW-301 (R, G, B) manufactured by Sekisui Fine Chemical Co., Ltd.] was used as a coloring resin by a conventional pigment dispersion method. RW-301R, which is a red colored resin as the first color, was applied to the same glass substrate as in Example 3 by a spin coater, and this was placed on a hot plate at 80 ° C. for 1 minute, dried, and then placed in an oven. The coating was cured by baking at 150 ° C. for 30 minutes. At this time,
The thickness of the coating film was 1.0 μm. The obtained red colored resin layer was evaporated by a KrF excimer laser in the same manner as in Example 3 to form red colored pixels. At this time, the number of pulses required to evaporate the entire colored resin layer was 1
There were 5 shots per location. In this way, red colored pixels of 100 × 300 μm were formed on the entire substrate.

Next, RW-301R is used as a green colored resin.
Is applied under the same application conditions from above the substrate on which the red pixels are formed, and is applied on a hot plate at 100 ° C.
And dried to obtain a green coating. At this time, the thickness of the green coating film was 1.0 μm on the substrate and 0.6 μm on the red pixels. That is, 1.6 in two layers of red and green
μm. When the evaporation depth per unit pulse of the red and green coatings, that is, the etch rate, under the same laser irradiation conditions as in the example was measured in advance, it was 0.2 μm / pulse for both red and green. Therefore, in order to evaporate the green coating film on the substrate, it was found that five pulses of laser light should be irradiated. Therefore, the same region was irradiated with laser light for 5 shots via a photomask, and a green colored pixel having the same size as red was formed next to the red colored pixel. At this time, the thickness of the pixel was 1.0 μm for green and 0.6 μm for red.

Finally, RW-301R is used as a blue colored resin.
Was used to form a blue coating film under the same conditions as in the previous two colors.
At this time, the thickness of the blue coating film was 1.0 μm on the substrate, and 0.6 μm on both the R and B coating films. Since the etch rate of blue was 0.2 μm / pulse as in the previous two colors, it was found that in order to evaporate an unnecessary blue coating film on the pixel, it was sufficient to irradiate three pulses of laser light. Was. Therefore, the same region was irradiated with three shots of laser light via a photomask, and a green colored pixel having the same size as red was formed next to the red colored pixel. The thickness of each pixel of the color filter thus manufactured is 0.6 μm for red and 1.0 μm for green and blue. The step by red was remarkable. The contrast of this color filter was measured to be 450, which was insufficient.

[0054]

According to the present invention, the following remarkable effects can be obtained. Since the colored pixels are formed by a dry process by laser ablation, there is no problem such as waste liquid treatment unique to the wet process and mixing of dust from the developer, and the yield is improved. The coloring layer does not need to be photosensitive, and a wide range of materials having excellent heat resistance and solvent resistance can be used. Since a dye is used as a coloring agent, the spectral characteristics and contrast are excellent. In order to form a colored resin layer on a substrate by a transfer method,
When forming the second and subsequent colors, the thickness of the colored resin layer is equal on the substrate and on the colored pixel of the previous color, and when the laser processing is performed, the colored pixel of the previous color is not shaved and thinned. A color filter having excellent flatness can be obtained.

[Brief description of the drawings]

FIG. 1 is a diagram schematically illustrating a step of transferring a transfer material onto a transparent substrate.

FIG. 2 is a diagram schematically illustrating a color filter manufacturing process by a laser processing method.

[Explanation of symbols]

 10: Transfer material 11: Temporary support 12: Colored resin layer 13: Transparent substrate 1: Transparent substrate 2: First colored resin layer 3: Laser light 4: Photomask 5: First colored pixel 6: Second colored resin layer 61: Second colored resin layer (on the pixel) 62: Second colored resin layer (on the substrate) 7: Second colored pixel 8: Third colored resin layer 81: Third colored resin layer (on the pixel) 82: Third colored resin layer (on the substrate) 9: Third colored pixel

Claims (2)

[Claims] (1) A transfer material in which a colored resin layer containing a dye is provided on a temporary support is prepared, and (2) the transfer material is heated and pressed on a transparent substrate on the surface of the colored resin layer. After
(3) The temporary support is peeled off to obtain a transparent substrate to which the colored resin layer has been transferred. (4) Then, after the colored resin layer is cured, (5) laser light is applied from above the colored resin layer. A method for manufacturing a color filter, comprising a step of irradiating a portion other than a region to be a colored pixel to evaporate a colored resin layer in an irradiated portion to form a colored pixel formed of a patterned colored resin layer. 2. (I) A first colored resin layer is formed on a transparent substrate, and then a laser beam is irradiated to a portion other than a region to be a first colored pixel to form a first colored resin layer. A step of forming a colored pixel of the first color composed of a patterned colored resin layer by evaporating the colored resin layer, (I
I) Forming a second colored resin layer on the entire surface of the transparent substrate including the first colored pixels, and then irradiating a portion other than the region to be the second colored pixels with a laser beam, By evaporating the colored resin layer in the irradiated portion, a second colored pixel composed of a patterned colored resin layer is formed. At this time, the output of the laser beam is controlled to form the first colored pixel. The step of evaporating the second color resin layer formed thereon, and (III) if necessary, the same number of steps as in the above (II) to color the required number of the third and subsequent colors. In a method for manufacturing a color filter including a step of forming a pixel, in forming a colored resin layer of each color on a transparent substrate at least in each step after the step (II), (1) dye is added on the temporary support. Transfer material provided with a colored resin layer containing (2) The transfer material is heated and pressed on a transparent substrate on the surface of the colored resin layer, and (3) the temporary support is peeled off to obtain a transparent substrate on which the colored resin layer has been transferred. Next, a method for producing a color filter, comprising curing the colored resin layer.