TWI457646B - 平面顯示裝置及製造該裝置的方法 - Google Patents
平面顯示裝置及製造該裝置的方法 Download PDFInfo
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- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
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- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
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- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133509—Filters, e.g. light shielding masks
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Description
本發明係有關於可在一分離程序中從基板將壓印模具脫膜時,於壓印模具與基板之間形成脫膜籽的薄膜製造裝置及薄膜製造方法。
近來已引進有各種平面顯示裝置,其缺點在於可容納陰極射線管(Cathode Ray Tube,CRT)的重量和體積。所述平面顯示裝置包括液晶顯示器、場發射顯示器(field emission display)、電漿顯示器面板(plasma display panel)及電致發光顯示器(electro-luminescence(EL)display)。
所述平面顯示裝置可配置多片由罩幕製程(mask process)形成的薄膜,該罩幕製程包括:沉積(塗佈)程序、曝光(exposure)程序、顯影(development)程序及蝕刻(etching)程序。然而,該罩幕製程具有因複雜製程所衍生的高製造成本問題。因此,近來業已針對「在圖案化程序中使用壓印模具來形成薄膜」進行研究。
根據所述圖案化程序,係將壓印樹脂塗佈於基板上後,使具有凹部(groove)及凸部(projection)的壓印模具接觸該壓印樹脂。將該壓印模具的凹部及凸部反轉移(轉印)於該壓印樹脂之際,於一硬化過程中,硬化該經反轉移的壓印樹脂,由此所要之薄的圖案便形成於基板上。
此處,使壓印模具接觸壓印樹脂時所施加的壓力會使壓印模具與基板之間產生狹小間隙,因此,壓印樹脂6便會如圖1所示以毛細管狀擴展至基板4的一端為止,結果只是導致其過度擴展至基板4側面的不正常狀況。此時,便無法於壓印模具2與基板4之間適當形成脫膜籽,而且會有無法於壓印模具2與基板4之間適當進行脫膜程序的問題。
因此,本發明係有關於一種平面顯示裝置。
本發明之目的在於提供一種平面顯示裝置及製造該平面顯示裝置的方法,該方法可穩定地進行一壓印模具及一基板之間所執行的脫膜程序。
本發明之其他優點、目的及特徵將描述於以下部分敘述中,且當該行
業人士檢視以下內容時該部分敘述將更趨明顯,或該部分敘述可由實施本發明來得到教示。本發明之目的及其他優點可由實施方式、其申請專利範圍及圖式中所特別指出的結構來實現及達成。
為達根據本發明之此等目的及其他優點,如此處所具體實施並廣泛敘述,一種平面顯示裝置包括:一薄膜圖案,由一壓印模具按壓一壓印樹脂於一基板上所形成;以及一外側薄膜圖案,形成於該基板的外側區域、與該薄膜圖案相鄰並在將該基板從該壓印模具脫膜時用作脫膜籽,該外側薄膜圖案被配置以限制壓印樹脂的移動。
於本發明之另一形態中,一種製造平面顯示裝置的方法包含:提供一基板及壓印樹脂,該基板包含一形成於其外側區域的外側薄膜圖案,該壓印樹脂相鄰於該外側薄膜圖案而形成;在該基板上對準一壓印模具;藉由接合該壓印模具與該壓印樹脂,形成一薄膜圖案於該基板上,並藉由使用該外側薄膜圖案,防止該壓印樹脂移動到該外側區域;以及藉由使用該外側薄膜圖案作為該基板及該壓印模具的脫膜籽,從該基板脫膜該壓印模具。
根據本發明,形成於基板外側區域的外側薄膜圖案在接合壓印模具與基板時可限制壓印樹脂的移動,由此可防止壓印樹脂擴展至基板的側面,而能夠防止基板及壓印模具的側面受污。
再者,由於外側薄膜圖案未與該壓印模具接合,故相較於習知技術可減少壓印樹脂與壓印模具間的接合度(bondage)。因此,根據本發明的外側薄膜圖案可用作基板與壓印模具之間脫膜程序的脫膜籽。
由此,藉由根據本發明的外側薄膜圖案,基板即可穩定地從壓印模具脫模。
應理解本發明的以上概略敘述及以下詳細敘述為示範性質及說明性質,並用以提供如本發明所主張的進一步解釋。
詳細參照本發明之特殊實施例,其實例已說明於附圖中。儘可能在所有圖式中使用相同的元件符號,以代表相同或相似的部件。
如下述,參照圖式來詳述本發明之示範性實施例。
圖2為說明根據本發明第一實施例之平面顯示裝置的俯視圖,圖3為圖2所示之平面顯示裝置中沿I-I’剖面線的剖面圖。
圖2及圖3所示之彩色濾光片基板100包括:黑色矩陣102,被配置以防止光線漏洩;彩色濾光片104,被配置以呈現光線;外覆層(overcoat layer)106,被配置以平坦化;柱間隔件(column spacer)108,被配置以保持單元間隙;以及外側薄膜圖案120,形成於基板101的外側區域。
黑色矩陣102界定每個次像素區域並形成於基板101上,以防止光線在次像素區域中發生干涉。又外側黑色矩陣112係形成於圍繞配置為該次像素區域之顯示區域的非顯示區域中,以防止光線漏洩到基板101外。
紅色(R)、綠色(G)與藍色(B)濾光片104係形成於基板101的顯示區域中,以分別呈現相應的之色彩。
外覆層106係補償彩色濾光片104與黑色矩陣102的高度落差(step),由此可使彩色濾光片基板100的表面平坦化。
柱間隔件108係與外覆層106一體形成,並由相同材料形成。形成該柱間隔件108以接觸薄膜電晶體基板(未圖示),並保持彩色濾光片基板100與薄膜電晶體基板之間的間隙。
形成外側薄膜圖案120以圍繞基板101之邊緣部分,並與形成在基板101之非顯示區域的外側黑色矩陣112相鄰。
所述外側薄膜圖案120由與黑色矩陣102之材料相同的材料形成,並具有如圖4A所示之單層結構。另外,外側薄膜圖案120可由與紅色(R)、綠色(G)與藍色(B)濾光片104的其中之一的材料相同的材料形成,並具有如圖4B所示之多層結構。另外,如圖4C至圖4E所示,外側薄膜圖案120包括第一外側薄膜圖案120a及第二外側薄膜圖案120b,該第一外側薄膜圖案120a由與黑色矩陣102之材料相同的材料形成,該第二外側薄膜圖案120b則由與紅色(R)、綠色(G)與藍色(B)濾光片104的其中之一的材料相同的材料形成。
再者,外側薄膜圖案120具有等同於或低於壓印樹脂高度的預定高度。在塗佈可作為黑色矩陣102之材料的壓印樹脂之前,先對彩色濾光片104、外覆層106及柱間隔件108進行塗佈,藉此外側薄膜圖案120即可在接合壓印模具與壓印樹脂時,防止壓印樹脂溢出基板101。
圖5A至圖5F為說明製造根據本發明第一實施例之液晶顯示裝置的彩色濾光片基板的方法的剖面圖,並將圖4C所示之外側薄膜圖案120應用於此實施例中。
如圖5A所示,將黑色層沉積於基板101上,之後,於一圖案化程序中使用壓印模具對該黑色層進行圖案化,其後便形成黑色矩陣102及第一外側薄膜圖案120a。形成該第一外側薄膜圖案120a以圍繞基板101的邊緣區域。
如圖5B所示,將彩色層沉積於具有黑色矩陣102及第一外側薄膜圖案120a的基板101上,之後,於一圖案化程序中使用壓印模具對該彩色層進行圖案化,此後在具有黑色矩陣102及第一外側薄膜圖案120a的基板101上便形成有紅色(R)、綠色(G)與藍色(B)濾光片104及第二外側薄膜圖案120b。該紅色(R)、綠色(G)與藍色(B)濾光片104係形成於對應基板101之次像素區域的區域上。
可根據使用壓印模具的壓印方法,同時對黑色矩陣102、彩色濾光片104、第一外側薄膜圖案120a及第二外側薄膜圖案120b進行圖案化而形成,或可於光微影(photolithography)與蝕刻程序中對其等進行圖案化而形成。
如圖5C所示,將壓印樹脂130塗佈於基板101上,該基板101具有形成於其上的黑色矩陣102及彩色濾光片104。考量到由接合壓印模具132與基板101時施加之壓力所產生的壓印樹脂的擴展性(spreadability),則該壓印樹脂130係以隔開一預定距離D(如與外側薄膜圖案120相隔數微米)的方式塗佈。又該壓印樹脂130係以等同於或高於外側薄膜圖案120高度的預定高度來塗佈,藉此即可在接合壓印模具132與基板101時,防止外側薄膜圖案120致使壓印模具變形或塑模不良(poor molding)。
由此,在壓印樹脂130上,對準將具有凹部132b與凸部132a的壓印模具132。該凸部132a係對應將形成外覆層的區域,而該凹部132b則對應將形成柱間隔件的區域。
所述壓印模具132係如圖5D所示般按壓壓印樹脂130。此後,壓印樹脂130便移動至壓印模具132的凹部132b內,此時防止壓印樹脂130由外側薄膜圖案120擴展至基板101的末端,藉此防止壓印樹脂130的擴展。
藉由光(如紅外光)或熱來硬化經按壓的壓印樹脂130,之後,便形成相對壓印模具132的凹部132b具有反轉移外形的柱間隔件108,且於對應壓印模具132的凸部132a的區域形成外覆層106。
如圖5E所示,在壓印模具132吸附於真空吸盤(vacuum pad)122的狀態下,接合基板的壓印模具132同時向上方轉移,以使其從基板101脫膜,該基板101具有形成於其上的所述柱間隔件108及外覆層106。與此同時,將如氮氣的預定氣體注入壓印模具132與基板101之間,由此壓印模具132即可順利從基板101脫膜。
如上述,具有形成於其上之柱間隔件108及外覆層106的基板101便同時從壓印模具132脫膜,藉此即如圖5F所示,完全形成彩色濾光片基板100。
圖6為說明根據本發明第二實施例之液晶顯示裝置的彩色濾光片的俯視圖,圖7為說明液晶顯示裝置的彩色濾光片基板中沿II-II’剖面線的剖面圖。
相較於圖2及圖3所示之彩色濾光片基板,圖6及圖7所示之彩色濾光片基板除外側薄膜圖案120係從外覆層106延伸,並由與外覆層106之材料相同的材料所形成之外包括同樣的組件,故省略同樣組件的詳細敘述。
外側薄膜圖案120係以遠離形成於基板101之非顯示區域的外側黑色矩陣112而形成於基板101的外側區域。具體而言,外側薄膜圖案120係形成於每個角落區域,而此區域係介於多邊形(如矩形及三角形、或於外側黑色矩陣112之相對側具有弧度(curvature)之扇形)基板的每條邊之間。此外,如圖8所示,形成外側薄膜圖案120以圍繞基板101的顯示區域。此時,形成相對於基板101之外側薄膜圖案120的相交區域大於其他區域,以使壓印模具的脫膜程序更為順利進行。
圖9A至圖9G為說明製造圖8所示之彩色濾光片基板的方法的剖面圖。如圖9A所示,將黑色層沉積於基板101上,之後,於一圖案化程序中使用壓印模具對該黑色層進行圖案化,此後,便可形成有黑色矩陣102及外側黑色矩陣112。
如圖9B所示,紅色(R)、綠色(G)與藍色(B)濾光片104係形成於將黑色矩陣102形成在其上之的基板101之區域,並對應於次像素區域。沉積相應之彩色層並於一圖案化程序中使用壓印模具對該彩色層進行圖案化,以形成紅色(R)、綠色(G)與藍色(B)濾光片104。
同時,本發明中可具體實施:在使用壓印模具的壓印方法中,對黑色矩陣102及彩色濾光片104進行圖案化而形成,亦可於光微影程序與蝕刻程序中對其等進行圖案化而形成。
如圖9C所示,將壓印樹脂130塗佈於將黑色矩陣102及彩色濾光片104形成於其上的基板101上。預先硬化塗佈於基板角落區域的壓印樹脂130後,即形成外側薄膜圖案120。具體而言,如圖10A所示,將承載於底部載臺(stage)136的基板101及承載於頂部載臺134的壓印模具132定位於腔室138中。在光源128內所產生的光經由穿通腔室138及底部載臺136而形成的開孔(open hole)124入射,藉此可背面硬化形成於基板101上的壓印樹脂130,以形成外側薄膜圖案120。另一方面,如圖10B所示,藉由形成在相對於壓印樹脂130之側面的光源128內所產生的光,側面硬化壓印樹脂130,以形成外側薄膜圖案120。此時,將由反光材料(light reflective material)構成的光源外罩(housing)126安裝於腔室138內,以防止從光源128照射的光朝壓印樹脂130的相反方向照射,由此可改善光效率。此處,壓印模具132係位於具有部分硬化部件(如圖10A及10B所示之光源128)的腔室138內,當硬化壓印樹脂130之後,即可接合壓印模具132與基板101。此外,塗佈裝置係位於具有部分硬化部件(如光源128)的腔室138內,當塗佈壓印樹脂130於基板101之後,即可部分硬化壓印樹脂130。另外,可將具有塗佈裝置位於其中的塗佈部件、具有供部分硬化壓印樹脂之腔室的硬化部件,以及具有壓印模具132位於其中的接合部件獨立對準成一條線。
由此,如圖9D所示,在壓印樹脂130上,可對準具有凹部132b與凸部132a的壓印模具132。該凸部132a係對應將形成外覆層的區域,而該凹部132b則對應將形成柱間隔件的區域。
所述壓印模具132係如圖9E所示般按壓壓印樹脂130,壓印樹脂130便流動至壓印模具132的凹部132b內。此時,由於外側薄膜圖案120既已硬化,故減少接觸壓印模具132的壓印樹脂130區域。又,防止壓印樹脂130從外側薄膜圖案120擴展至基板101的相交區域,藉此可防止其過度擴展。
使用光(如紅外光)或熱來硬化受按壓的壓印樹脂130,藉此便形成相對壓印模具132的凹部132b具有反轉移形狀的柱間隔件108,並可形成對應壓印模具132的凸部132a的外覆層106。
如圖9F所示,在壓印模具132固定於真空吸盤122的狀態下,接合基板的壓印模具132同時向基板101的相對側(即上方)移動,然後,其便從基板101脫膜,該基板101具有形成於其上的柱間隔件108及外覆層106。同時,將如氮氣的預定氣體注入壓印模具132與基板101之間,以使壓印模具順利從基板101脫膜。此處,未與壓印模具接合的外側薄膜圖案120係用作壓印模具132與基板101之間所進行之脫膜程序中的脫膜籽,藉此即可穩定進行使用真空吸盤122的脫膜程序,並可順利將如氮氣的氣體注入壓印模具132與基板101之間。
如上述,具有形成於其上之柱間隔件108及外覆層106的基板101便同時從壓印模具132脫膜,並如圖9G所示完成彩色濾光片基板。
同時,根據本發明的壓印模具132包括用以形成薄膜圖案的凹部和凸部。惟,如圖11所示,外側凸部114可形成於相鄰外側薄膜圖案120之內側區域及外側區域的至少其中之一的預定區域內。該外側凸部114在接合壓印模具132與基板時可防止樹脂擴展,並減少壓印樹脂與壓印模具132接觸的區域以順利形成脫膜籽。
而且,根據本發明的壓印模具132係同時對外覆層106及柱間隔件108進行圖案化。然而,除此之外,用作對薄膜進行圖案化之罩幕的光阻圖案可形成於使用根據本發明的壓印模具的壓印程序中,該薄膜係由非有機材料如液晶顯示器面板之薄膜電晶體、閘極線、資料線及像素電極所構成。尚且,由有機材料如液晶顯示器面板之彩色濾光片104及黑色矩陣102所形成的薄膜圖案可形成於使用根據本發明的壓印模具的壓印程序中。又,外側薄膜圖案120可與液晶顯示器面板之薄膜電晶體、閘極線、資料線及像素電極、閘極介電層(gate dielectric layer)與保護層同時形成。
再者,根據本發明的外側薄膜圖案120不僅可適用於液晶顯示器面板,亦可適用於包括電漿顯示器面板、電致發光顯示器及場發射顯示器的平面顯示裝置。
顯然在不脫離本發明之精神與範圍的情況下,該行業人士可對本發明進行各種修飾與變化,由此其意指在後述申請專利範圍及與其實質上均等的範圍內,本發明涵蓋此發明之修飾與變化。
本申請案主張韓國專利申請第10-2010-0041748號(申請日為2010年5月4日)之效益,如此處所完整闡述者,茲將其載入以供參照。
100...彩色濾光片基板
101...基板
102...黑色矩陣
104...彩色濾光片
106...外覆層
108...柱間隔件
112...外側黑色矩陣
114...外側凸部
120...外側薄膜圖案
120a...第一外側薄膜圖案
120b...第二外側薄膜圖案
122...真空吸盤
124...開孔
126...光源外罩
128...光源
130...壓印樹脂
132...壓印模具
132a...凸部
132b...凹部
134...頂部載臺
136...底部載臺
138...腔室
將所附圖式來進一步理解本發明,同時將其載入並構成本申請案之一部分。本發明所圖示說明之實施例及其敘述係用以解釋本發明之意旨,於圖中:
圖1為說明習知壓印樹脂過度擴展的剖面圖;
圖2為說明根據本發明第一實施例之平面顯示裝置的俯視圖;
圖3為圖2所示之平面顯示裝置中沿I-I’剖面線的剖面圖;
圖4A至圖4E為說明圖3所示之外側薄膜圖案的第一至第五實施例的剖面圖;
圖5A至圖5F為說明製造根據本發明第一實施例之液晶顯示裝置的彩色濾光片基板的方法的剖面圖;
圖6為說明根據本發明第二實施例之液晶顯示裝置的彩色濾光片的俯視圖;
圖7為說明液晶顯示裝置的彩色濾光片基板中沿II-II’剖面線的剖面圖;
圖8為說明根據本發明第二實施例之液晶顯示裝置的彩色濾光片的剖面圖;
圖9A至圖9G為說明製造圖8所示之彩色濾光片基板的方法的剖面圖;
圖10A及圖10B為說明用以硬化圖9C所示之壓印樹脂的硬化部件的剖面圖;以及
圖11為說明根據另一實施例的壓印模具的剖面圖,該模具係使用於根據本發明之平面顯示裝置的製造程序中。
100...彩色濾光片基板
101...基板
102...黑色矩陣
104...彩色濾光片
106...外覆層
108...柱間隔件
112...外側黑色矩陣
120...外側薄膜圖案
Claims (10)
- 一種平面顯示裝置,包含:一薄膜圖案,由一壓印模具按壓一壓印樹脂於一基板上所形成;以及一外側薄膜圖案,形成於該基板的外側區域之上且與該薄膜圖案相鄰,其中,該外側薄膜圖案在將該基板從該壓印模具脫膜時用作一脫膜籽,以及該外側薄膜圖案被配置以限制該壓印樹脂的移動,以及其中,該薄膜圖案係一液晶顯示裝置的一外覆層,或者該薄膜圖案係以相同於該外側薄膜圖案材料的預定材料所形成。
- 如申請專利範圍第1項所述之平面顯示裝置,其中,該薄膜圖案為一液晶顯示裝置之外覆層;以及該外側薄膜圖案在至少一單層結構中由一預定材料所形成,該預定材料與提供在形成於該外覆層之下的該液晶顯示裝置中的一彩色濾光片及一黑色矩陣之至少其中之一的材料相同。
- 如申請專利範圍第1項所述之平面顯示裝置,其中,該薄膜圖案係從該外側薄膜圖案延伸,並由與該外側薄膜圖案之材料相同的一預定材料形成。
- 一種製造平面顯示裝置的方法,包含:提供一基板及壓印樹脂,該基板包含一形成於其外側區域的外側薄膜圖案,該壓印樹脂相鄰該外側薄膜圖案而形成;在該基板上對準一壓印模具;藉由接合該壓印模具與該壓印樹脂,形成一薄膜圖案於該基板上,以及,藉由使用該外側薄膜圖案,防止該壓印樹脂移動到該外側區域;以及藉由使用該外側薄膜圖案作為該基板及該壓印模具的一脫膜籽,從該基板脫膜該壓印模具,其中,該薄膜圖案係一液晶顯示裝置的一外覆層,或者該薄膜圖案係以相同於該外側薄膜圖案材料的預定材料所形成。
- 如申請專利範圍第4項所述之製造平面顯示裝置的方法,其中該基板提供包含:於該基板外側區域的交點區域形成該外側薄膜圖案;以及從該外側薄膜圖案隔開數微米(μm)塗佈該壓印樹脂。
- 如申請專利範圍第5項所述之製造平面顯示裝置的方法,其中, 該薄膜圖案為一液晶顯示裝置之外覆層;以及該外側薄膜圖案在至少一單層結構中由一預定材料所形成,該預定材料與提供在形成於該外覆層之下的該液晶顯示裝置中的一彩色濾光片及一黑色矩陣之至少其中之一的材料相同。
- 如申請專利範圍第4項所述之製造平面顯示裝置的方法,其中該基板提供包含:塗佈壓印樹脂於該基板上;藉由部分硬化位於該基板外側區域的該壓印樹脂,形成該外側薄膜圖案,且形成該薄膜圖案於該基板上包括:硬化該壓印樹脂,該壓印樹脂係塗佈於除了形成有該外側薄膜圖案之預定區域以外的其他區域內。
- 如申請專利範圍第7項所述之製造平面顯示裝置的方法,其中該外側薄膜圖案形成包含:提供一腔室,該腔室包含承載有該基板的載臺,其中該基板具有塗佈於其上的該壓印樹脂;以及藉由使用形成於該載臺的一開孔及位於該基板背面的該腔室,背面硬化形成在對應該基板外側區域的區域內的該壓印樹脂。
- 如申請專利範圍第7項所述之製造平面顯示裝置的方法,其中該外側薄膜圖案形成包含:提供一腔室,該腔室包含承載有該基板的載臺,其中該基板具有塗佈於其上的該壓印樹脂;以及藉由使用形成於位在該基板外側區域之位於相對壓印樹脂之側面的區域內的一光源,側面硬化該壓印樹脂。
- 如申請專利範圍第4項所述之製造平面顯示裝置的方法,其中該壓印模具對準在該基板上包含:對準該壓印模於該基板上,其中該壓印模具包含一外側凸部,該外側凸部相鄰於形成在該基板外側區域內之該外側薄膜圖案的一外框而形成。
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CN108227283A (zh) * | 2018-01-22 | 2018-06-29 | 深圳市华星光电技术有限公司 | 彩色滤光片基板的制作方法及彩色滤光片基板 |
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