WO2007066682A1

WO2007066682A1 - Method for disposing spacer and liquid crystal display device

Info

Publication number: WO2007066682A1
Application number: PCT/JP2006/324340
Authority: WO
Inventors: Ryusuke Hayashi; Yoshihiko Yamakado
Original assignee: Nagase & Co., Ltd.
Priority date: 2005-12-06
Filing date: 2006-12-06
Publication date: 2007-06-14
Also published as: CN101288021A; CN101288021B; TW200745702A; JP2007156182A; KR20080077232A

Abstract

This invention provides a method for disposing a spacer, which can dispose a plurality of predetermined single spacers on respective sites of a substrate, and a liquid crystal display device using the method. The method comprises a deposition step of depositing a spacer-containing liquid (200) including a combined spacer (230) comprising a plurality of single spacers (220) previously linked to each other onto a substrate and a fixation step of fixing the combined spacer (230) in the deposited spacer-containing liquid onto the substrate (100).

Description

Specification

Spacer arrangement method and liquid crystal display device

Technical field

[0001] The present invention relates to a spacer arrangement method and a liquid crystal display device.

Background technology

[0002] In the manufacture of liquid crystal displays, etc., a spacer arrangement method is known in which a liquid containing a spacer in a head container is ejected as a droplet due to the opening force of the head container and is deposited at a desired location on a substrate. It is being By drying the droplet after it is attached, the spacer in the droplet is fixed onto the substrate.

[0003] When spacers are arranged on a substrate in this way, the number of spacers in the ejected droplet is set to a predetermined number, such as one, and It is desirable to arrange a certain number of spacers at desired locations on the substrate.

[0004] Conventionally, by uniformly dispersing a single spacer in a spacer-containing liquid and appropriately adjusting the concentration of the single spacer in the spacer-containing liquid, the head container is The opening force was also adjusted so that the number of single spacers in the ejected droplet was approximately one. Patent document 1: Japanese Patent Application Publication No. 2004-145101

Disclosure of invention

Problems that the invention seeks to solve

[0005] Nowadays, for example, a plurality of predetermined single spacers, such as 2, 3, 4, 5, or 6, are placed at one location on the board. may be required. In this case, it is necessary to include a plurality of predetermined single spacers in one ejected droplet.

[0006] It has been difficult to include a plurality of predetermined single spacers in a droplet with high precision. For example, even if the spacer concentration in a spacer-containing liquid in which single spacers are dispersed is adjusted to a concentration such that an average of four single spacers are contained in one droplet, , droplets that do not contain four single spacers, such as droplets that contain one or zero single spacers, are generated with a high probability. Therefore, given one location on the board It was difficult to arrange multiple single spacers.

[0007] The present invention has been made in view of the above problems, and provides a spacer arrangement method that allows a plurality of predetermined single spacers to be arranged at each location on a substrate, and a liquid solution obtained thereby. The purpose of the present invention is to provide a crystal display device.

Means to solve problems

[0008] A method for arranging spacers according to the present invention includes a bonding step in which a plurality of single spacers are bonded in advance, and a spacer-containing liquid containing bonded spacers is bonded onto a substrate; and a fixing step of fixing the bonded spacers in the attached spacer-containing liquid to the substrate.

[0009] According to the present invention, the spacer-containing liquid contains a bonded spacer formed by bonding a plurality of single spacers in advance, so that the bonded spacer is directly attached to the substrate through the fixing process. It will become stuck. Therefore, by appropriately adjusting the number of single spacers in the combined spacer, a predetermined plurality of single spacers can be easily placed at each location on the substrate.

[0010] Here, in the adhesion step, it is preferable to form droplets of the spacer-containing liquid and to adhere the droplets onto the substrate.

[0011] In a spacer-containing liquid, each bonded spacer behaves as a single particle. Therefore, by appropriately adjusting the concentration of the bonded spacer in the spacer-containing liquid, it is possible to include one bonded spacer in the formed droplet, resulting in a single dispersed without bonding. This is much easier than including a predetermined number of spacers in a droplet.

[0012] Particularly, in the adhesion step, it is preferable that the droplet be ejected toward the substrate using an opening force of a head container that is movable relative to the substrate.

[0013] According to this, droplets of the spacer-containing liquid can be easily placed at desired locations on the substrate.

[0014] On the other hand, in the adhesion step, droplets of the spacer-containing liquid may be sprayed onto the substrate!

Further, in the adhesion step, a liquid film of the spacer-containing liquid may be formed on the substrate.

[0015] According to these, a liquid film or droplet of the spacer-containing liquid can be easily deposited on the substrate. [0016] Furthermore, in the fixing step, it is preferable to dry the spacer-containing liquid.

[0017] When the spacer-containing liquid is dried, the bonded spacers in the spacer-containing liquid can be easily fixed to the substrate.

[0018] In particular, if the surface of the bonding spacer is made of resin, or if a functional group capable of bonding to the substrate is bonded to the surface of the bonding spacer, the liquid around the spacer may By drying the spacer, the spacer can be firmly fixed to the substrate.

[0019] On the other hand, if the surface of the bonding spacer is made of resin that hardens upon irradiation with light, the bonding spacer in the spacer-containing liquid is bonded to the surface of the substrate in the fixing process. It is also preferable to irradiate the coupling spacer with light while in contact with it.

[0020] According to this, the surface of the bonded spacer that is placed in the spacer-containing liquid and comes into contact with the substrate is cured by light, so the spacer-containing liquid does not dry. The bonding spacer can be fixed to the substrate.

[0021] In addition, in the fixing step, the bonded spacers in the spacer-containing liquid present on a portion of the substrate are fixed to the substrate by irradiating light through a mask to only a portion of the substrate. To make Chidezaru.

[0022] According to this, it is preferable that the bonded spacer in the spacer-containing liquid present on a part of the substrate, that is, a desired location, can be selectively fixed to the substrate. In this case, the droplets may be dried using infrared light, or the bonding spacer may be cured and fixed using light for curing the bonding spacer.

[0023] In addition, the bonding spacer force may be such that single spacers are bonded in advance with a thermoplastic binder, or the surface of each single spacer is formed of thermoplastic resin. The bonding spacer is preferably a single spacer whose surfaces are directly bonded to each other by heating in advance. Such a coupling spacer is easy to manufacture.

[0024] In addition, when such a bonding spacer is used, after the fixing step, a stacking step is further provided in which another substrate is stacked on the substrate via the bonding spacer, and the bonding step is performed in the stacking step. The joint spacer can be heated.

[0025] In this case, heating of the bonding spacers allows rearrangement of the single spacer in each bonding spacer, so it is particularly useful for bonding four or more single spacers. three-dimensional Even if the bonding spacer is fixed to the substrate, each single spacer of the bonding spacer will be repositioned between a pair of substrates to a thickness of one layer, and the space between the substrates, e.g. color filters and drive The distance between the substrate and the substrate can be easily made uniform.

[0026] A liquid crystal display device according to the present invention includes a liquid crystal drive substrate having a pixel electrode, a color filter disposed facing the liquid crystal drive substrate, and a space disposed between the liquid crystal drive substrate and the color filter. The spacer is a combined spacer formed by combining a plurality of single spacers.

[0027] Since such a liquid crystal display device has a coupling spacer, the spacer is less likely to move, and furthermore, the spacer is less likely to collapse due to local pressure.

Effect of the invention

[0028] According to the present invention, a plurality of predetermined single spacers can be placed at each location on a substrate, and an excellent liquid crystal display device can be realized.

Brief description of the drawing

[0029] FIG. 1 is a schematic diagram illustrating a single spacer and a combined spacer formed by combining single spacers.

[Figure 2] Figure 2 is a schematic configuration diagram of an example of a spacer dispersion device used in this embodiment.

[FIG. 3] FIG. 3 is a cross-sectional view of an example of a color filter used in this embodiment.

[FIG. 4] FIG. 4 is a top view showing a state in which droplets are scattered on a color filter.

[Figure 5] Figure 5 is a view taken along the V--V arrow in Figure 4.

[Figure 6] Figure 6 shows that the concentration of single spacers or combined spacers in the spacer-containing liquid is A: about 1 spacer per droplet volume, and B: about 3 spacers per droplet volume. This is a graph showing the frequency distribution of the number of single spacers or combined spacers actually contained in one droplet.

[FIG. 7] FIG. 7 is a cross-sectional view showing a state in which the droplets of the color filter of FIG. 4 are dried.

[FIG. 8] FIG. 8 is a top view showing a mask M having an opening OP.

[Figure 9] Figure 9 is a view showing the state after drying the color filter in Figure 4 by irradiating light through the mask M, and the location is VIII--VIII in Figure 4. corresponds to the surface Ru.

[FIG. 10] FIG. 10 is a sectional view showing a state in which the force on the color filter in the state shown in FIG. 9 is removed to remove the unfixed bonding spacer.

[Figure 11] Figure 11 is a cross-sectional view showing the state in which the liquid crystal drive board is placed on the color filter.

[Figure 12] Figure 12 is a cross-sectional view showing a state in which a combined spacer made of four single spacers is fixed on a color filter.

[Fig. 13] Fig. 13 is a conceptual diagram showing a spacer-containing droplet dispersion method according to a third embodiment.

[FIG. 14] FIG. 14 is a plan view showing a state in which droplets are attached to a color filter.

[Fig. 15] Fig. 15 is a plan view showing a state in which bonding spacers are selectively fixed on a black matrix.

[FIG. 16] FIG. 16 is a conceptual cross-sectional view showing a method for forming a spacer-containing liquid film according to a fourth embodiment.

[Fig. 17] Fig. 17 is a plan view showing a state in which a liquid film is attached to a color filter.

Explanation of symbols

[0030] 12... Spacer-containing liquid, 37... Opening, 42... Head container, 100... Color filter (substrate), 200... Droplet (Spacer-containing liquid), 202... ···Pixel electrode, 210···Liquid film (liquid containing spacer), 220···Single spacer, 230···Combined spacer, 300···Liquid crystal display device, 400····Liquid crystal drive board (other board) ).

BEST MODE FOR CARRYING OUT THE INVENTION

[0031] Hereinafter, preferred embodiments of a spacer arrangement method and a liquid crystal display device according to the present invention will be described with reference to the drawings. In addition, in the explanation of the drawings, the same elements are given the same reference numerals, and duplicate explanations will be omitted. In addition, the dimensional ratios in the drawings do not necessarily match those in the description.

[0032] (First embodiment)

In the present invention, a combined spacer is created by combining a plurality of single spacers, and a spacer-containing liquid containing the combined spacers is ejected as droplets using the opening force of the head. Tekara The droplets are allowed to dry, and then the TFT substrate is placed on the color filter. This will be explained in detail below.

[0033] (Coupling spacer creation process)

First, a single spacer 220 is prepared as shown in Figure 1(a). The material of the single spacer 220 is not particularly limited, but for example, silicon oxide particles such as silica, plastic particles such as silicon modified polymer, etc. can be used. Furthermore, the particle size of the single spacer 220 is not particularly limited, and may be, for example, about 1 to 7 m.

[0034] Note that the surface of the single spacer 220 is formed of resin such as a polymer, or the surface of the single spacer is coated with an alignment film that is formed on the surface of the TFT substrate and that aligns the liquid crystal. A functional group that can be bonded to the color filter (particularly the alignment film), such as an epoxy group, glycidyl group, oxetane group, acid anhydride group, ratatone group, amide group, carboxyl group, etc., is bonded. It is preferable because it has a strong adhesion to the color filter.

[0035] For example, if the surface of the single spacer 220 is made of resin, the adhesion of the single spacer to the color filter or the alignment film on the TFT substrate surface may be reduced due to the heat during drying, which will be described later. can be further enhanced. Examples of the bamboo resin include thermoplastic resin, thermosetting resin, and resin that hardens by irradiation with light, such as visible light-curing resin, ultraviolet-curing resin, and infrared-curing resin. It will be done. Here, the entire single spacer may be made of bamboo resin, or only the surface layer may be made of resin. In addition, even if the above-mentioned functional group is present on the surface of a single spacer, chemical bonding between the functional group and the color filter or the alignment film on the surface of the TFT substrate will cause the single spacer 220 and the color to form. Improves adhesion to filters and alignment films on the surface of TFT substrates. Furthermore, in the case of resin that hardens when irradiated with light, it is also possible to fix it to the color filter or the alignment film on the surface of the TFT substrate by irradiating the light.

[0036] Next, a plurality of single spacers 220 are combined to create a combined spacer 230 as shown in (b) to (f) of FIG. The number of single spacers 220 included in the coupling spacer 230 may be a plurality, for example, 2, 3, 4, 6, etc.

[0037] The method for manufacturing the bonding spacer 230 is not particularly limited, but a known granulation method can be used. Specifically, for example, a dish-type granulator, a fluidized bed granulation coating device, a granulation device using a spray dryer, etc. can be used. In addition, the dispersant is dissolved in the liquid. Then, the resin for fixation (even if it is dissolved, it should be dispersed smaller than the spacer) and the spacer (the spacer may be chemically treated with a fixing agent) are dispersed. After that, granulation may be performed by changing the solubility parameter of the solution. Alternatively, the solution may be dried (freeze-drying may also be used), and then pulverized and classified to have a uniform size.

[0038] In particular, by using a binder, the combined spacer 230 can be suitably formed regardless of the material of the single spacer 220. Although the binder is not particularly limited, it is particularly preferable to use a thermoplastic binder. Examples of thermoplastic binders include Ataryl resin, polyester resin, polyether resin, polyolefin wax, polyvinolepyrrolidone, vinyl acetate resin, polybutyl ether resin, etc., which are suitable for spacer-containing liquids. Some examples include resin that dissolves little (to the extent that it does not affect the reliability of the LCD) or does not dissolve at all! Furthermore, such resin may be provided with a functional group that reacts with particles by applying heat, or may be provided with a functional group that prevents disordered alignment of liquid crystals. An example of a combined spacer 230 in which three single spacers 220 are combined using a node 235 is shown in Figure 1 (b).

[0039] Furthermore, the coupling spacer 230 can also be formed without using a binder. For example, if the surfaces of the single spacers 220 are made of thermoplastic resin, the surfaces of the single spacers 220 may be bonded together by heating and stirring the single spacers 220. They can be directly bonded, and the bonding spacer 230 can be produced without using a binder.

[0040] Examples of a combined spacer 230 formed by combining single spacers 220 without using a binder 235 are shown in FIGS. 1(c) to (f). Figure 1 (b) and (d) show a combined spacer 230 that combines three single spacers 220, and Figure 1 (c) shows a combined spacer 230 that combines two single spacers 220. Spacer 230, (e) in Figure 1 is a combined spacer 230 that combines four single spacers 220, and (f) in Figure 1 shows a combined spacer 230 that combines six single spacers 220. This is an example of Pesa 230.

[0041] Here, in the aggregate of bonded spacers 230 formed by the above-described granulation method, the number of single spacers 220 in each bonded spacer 230 is not very uniform; Preferably, the aggregate of post-grain bonding spacers 230 is classified. The classification method is not particularly limited, but for example, by using a multi-cyclone in a liquid or by leaving it still. Classification methods that utilize sedimentation of granulated particles, classification methods that utilize hide-mouth dynamic chromatography, and classification methods that utilize meshes, sieves, membranes, etc., are available. A collection of bonded spacers 230 containing a high proportion of bonded spacers 230 formed by bonding spacers 220 can be obtained.

[0042] Specifically, for example, in terms of the number of pieces, 90% of the combined spacers 230 are formed by combining a predetermined plurality of single spacers 220 among all the combined spacers 230. In view of the above, it is preferable to create a collection of bonding spacers 230 showing a sharp distribution, preferably containing 95% or more.

[0043] Then, the thus obtained aggregate of bonded spacers 230 is dispersed in a spacer carrier liquid to obtain a spacer-containing liquid in which bonded spacers 230 are dispersed. Here, the bonding spacer 230 is dispersed in the liquid as a single particle. Note that the concentration of the bonding spacer 230 in the spacer-containing liquid is such that approximately one bonding spacer 230 is contained in the volume V of the droplet discharged from the opening of the head container (described in detail later). Adjust to a suitable concentration. In this embodiment, a case will be explained in which a spacer-containing liquid including a combined spacer in which three spacers are combined as shown in FIG. 1(d) is used.

[0044] As the spacer carrier liquid 11 in which the bonding spacers 230 are dispersed, for example, a mixed liquid of water and IPA can be used. Moreover, a dispersant can also be used if necessary.

[0045] (Placement process)

Next, using a spacer arrangement device 1 as shown in FIG. 2, droplets 200 are formed from the spacer-containing liquid 12, and these droplets are attached to the surface of the color filter 100.

[0046] First, examples of the spacer arrangement device 1 and the color filter 100 will be described.

[0047] (Spacer arrangement device)

This spacer arrangement device 1 is a device that sprays a spacer-containing liquid from a head device 41 to each of the color filters 100 above, and deposits droplets of the spacer-containing liquid on the lower surface of the color filter 100. It is.

[0048] The spacer arrangement device 1 mainly includes a stirring tank 20 that stirs a spacer-containing liquid 12, and a stirring tank 20 that directs the spacer-containing liquid 12, which is also supplied with an internal force, toward the color filter 100 above. A head device 41 that ejects liquid droplets 200 and a color filter 100 are placed above the head device 41. It mainly includes a substrate moving unit 80 that moves the substrate, and a controller 90 that controls the head device 41, the substrate moving unit 80, and the like.

[0049] The head device 41 has a box-shaped head container 42 extending in the width direction of the color filter 100. A large number of openings 37 are formed in the upper surface of the head container 42 in a line at a predetermined pitch 37P. The arrangement direction of the openings 37 is parallel to the width direction of the color filter and perpendicular to the moving direction of the color filter.

[0050] Here, the diameter of the opening 37 can be, for example, about 10-50 μm. Further, the pitch 37P of the openings 37 can be, for example, about 100 m.

[0051] Inside the head container 42, a hammer 52 and a piezo element 54 are provided in order for the upper force.

The bottom of the piezo element 54 is fixed to the bottom of the head container 42. Furthermore, the piezo element 54 is connected to a controller 90, and expands and contracts up and down in response to signals from the controller 90. Hammer 52 is fixed on piezo element 54. The upper surface of the hammer 52 faces each opening 37 with a lower force and is spaced apart from each opening 37 by a predetermined distance.

[0052] Then, when the piezo element 54 extends upward in response to a signal from the controller 90, the hammer 52 moves upward. Therefore, the spacer-containing liquid 12 near the opening 37 is pushed out from the opening 37 by the upper end surface 52d of the hammer 52, and droplets 200 of the spacer-containing liquid 12 are sprayed upward.

[0053] The stirring tank 20 is equipped with a stirring blade 17 rotated by a motor 17a, which stirs the spacer-containing liquid 12 in which the above-mentioned bonded spacers 230 are dispersed, and transfers the bonded spacers 230 to the spacer carrier. Disperse in liquid 11. Note that the stirring strength is set to such a strength that the bond of the bonding spacer 230 is not destroyed.

[0054] One end of the head container 42 is connected to the stirring tank 20 by a line L1. Further, the other end of the head container 42 is connected to the stirring tank 20 by a line L2 equipped with a circulation pump 70. The circulation pump 70 sucks the spacer-containing liquid in the head container 42 and discharges it into the stirring tank 20. Correspondingly, the spacer-containing liquid 12 in the stirring tank 20 is supplied into the head container 42 via the line L1.

[0055] The substrate moving unit 80 includes a substrate suction section 82 and a substrate moving section 84. The substrate suction unit 82 suctions the color filter 100 above the head device 41 using static electricity, reduced pressure, etc. and support Color Filter 100. Here, the substrate suction section 82 supports the color filter 100 so that the recess 160a of the upper film 160 (described in detail later) of the color filter 100 faces downward and parallel to the arrangement direction of the openings 37.

[0056] Further, the substrate moving section 84 horizontally moves the substrate suction section 82, which has sucked the color filter 100, in the color filter moving direction, that is, in the direction orthogonal to the width direction of the color filter. That is, the color filter 100 and the opening 37 of the head device 41 move relatively along the surface of the color filter 100. Further, the substrate moving section 84 is configured to move the color filter 100 a predetermined distance in the width direction of the color filter, thereby making it possible to align the color filter 100. The substrate moving unit 84 is preferably a linear motor type that can move the color filter 100 with high precision.

[0057] The controller 90 is a computer device that performs processing based on a predetermined program, and is connected to the substrate moving unit 80, the piezo element 54, the circulation pump 70, and the motor 17a, and controls the driving of these. do.

[0058] (Color filter)

Next, an example of a color filter as a substrate to which droplets are attached will be described with reference to FIG. 3. The color filter 100 on which the droplets 200 are to be placed includes a transparent substrate 110, a black matrix 120, a red colored part 130R, a green colored part 130G, a blue colored part 130B, and an upper film 160.

[0059] The transparent substrate 110 is a transparent flat plate made of glass or the like.

[0060] The black matrix 120 is a film that also functions as a material that blocks visible light. Examples of the material of the black matrix 120 include metal materials such as chromium, chromium Z chromium oxide, and resin materials. This black matrix 120 has a lattice shape or a stripe shape, and forms a large number of openings 120p. The width of the black matrix 120W can be, for example, about 5 to 30 m. Further, the height 120H of the black matrix can be, for example, about 0.1 to 2 μm.

[0061] The red colored part 130R, the green colored part 130G, and the blue colored part 130B are arranged in order within each opening 120p of the black matrix 120, respectively. Red colored part 130R, green colored part 130G, and blue colored part 130B can selectively transmit visible light of each color. Transparent colored materials are also available; for example, transparent colored resin can be used. The width of each colored part 130R, 130G, 130B 130W can be set to 5~: LOO /zm. The height 130H of each colored plate 130R, 130G, 130B can be, for example, 1 to 2 m.

[0062] Here, the height 130H of each coloring plate 130R, 130G, and 130B is sufficiently higher than the height 120H of the black matrix 120.

[0063] Then, an upper film 160 is formed over each of these colored parts 130R, 130G, 130B and the black matrix 120. The upper film 160 is a laminate including a transparent flattening film (not shown), a transparent electrode film 140, an alignment film 150, etc., which are provided as necessary on the side of the transparent substrate 110, in this order.

[0064] The transparent electrode film 140 is a common electrode that is to be disposed opposite to the pixel electrode (details will be described later) of the liquid crystal drive substrate for driving the liquid crystal display, and is formed of a transparent conductive material such as ITO. The thickness of the transparent electrode film 140 is, for example, about 0.1 μm.

[0065] The alignment film 150 aligns the liquid crystal in a desired direction, and can be formed of, for example, a resin material such as polyimide. The thickness of the alignment film 150 is, for example, about 0.1 μm.

[0066] Then, on the surface of the color filter 100, that is, the surface of the upper film 160, the black matrix 120 A recessed portion 160a is formed on the top. The black matrix 120 has a lattice or stripe shape, and the recesses 160a have a groove shape along the black matrix 120. Further, the ends of the colored portions 130R, 130G, and 130B on the black matrix 120 side are respectively raised.

[0067] Such a color filter 100 is manufactured by, for example, forming a black matrix 120 on a transparent substrate 110 by a photolithography method, etc., and then sequentially applying each color to the opening 120p of the black matrix 120 by a photolithography method or the like. The parts 130R, 130G, and 130B are formed to be higher than the black matrix 120, and then a transparent electrode of a predetermined thickness is formed on the black matrix 120 and each colored part 130R, 130G, and 130B by sputtering, vapor deposition, or the like. A film 140 is formed, and an alignment film material such as polyimide resin is further applied to a predetermined thickness on the transparent electrode film 140 and solidified, and the surface is rubbed to form an alignment film 150. more easily obtained.

[0068] (Droplet discharge and adhesion)

Next, the process of discharging and adhering droplets will be explained. In this embodiment, as shown in FIG. 2, droplets 200 are repeatedly ejected from each opening 37 of the head container 42 while moving the color filter 100 in the color filter movement direction, forming a row of a plurality of droplets 200. (line) is repeatedly deposited on the substrate surface (see FIG. 3), a plurality of droplets 200 are deposited in a matrix on the surface of the color filter 100, as shown in FIGS. 4 and 5.

[0069] Here, by controlling the substrate moving unit 80 and the piezo element 54, the movement of the color filter 100 is controlled so that the droplet 200 adheres to the recess 160a on the surface of the upper film 160. . The pitch 37P of the droplets 200 on each recess 160a corresponds to the pitch 37P of the openings 37 of the head container 42.

[0070] The diameter of the droplet 200 on the color filter 100 can be, for example, about 50 to L00 μm. Therefore, the volume V of the droplet 200 is, for example, approximately 10 to LOOpL. Here, as described above, the concentration of the bonding spacer 230 in the spacer-containing liquid 12 in the head container 42 is such that there is approximately one bonding spacer 230 in the volume V of the droplet 200, for example, The concentration is said to be approximately 0.9 to 1.1. Therefore, most of the droplets 200 discharged from the opening 37 of the head container 42 contain only one coupling spacer 230, as shown in FIGS. 3-5.

[0071] Since each combined spacer 230 is a combination of a desired plurality of single spacers 220, a predetermined plurality of single spacers 220 can be combined with a desired plurality of single spacers 220 on the color filter. He will be placed in the same place.

[0072] Here, the fact that approximately one bonding spacer is included in the droplet 200 will be explained in detail with reference to FIG. 6. In Figure 6, the bonded spacer 230 is dispersed as a single particle in the spacer-containing liquid 12, and the concentration of the bonded spacer 230 is determined as follows: A: approximately 1 particle in the droplet volume V; , B: shows the frequency distribution of the number of bonding spacers 230 included in one droplet 200 actually ejected when the droplet volume V is set to have approximately 3 pieces. This is an example of a graph. This graph also shows that a single spacer 220 is dispersed as a single particle in the spacer-containing liquid 12, and the concentration of this single spacer 220 is approximately 1 in A: the volume of the droplet V. individual, and , B: Frequency distribution of the number of single spacers 220 included in one droplet 200 actually ejected when the droplet volume V is set to have approximately 3 spacers. It is also a graph to show.

[0073] When the single spacer 220 is dispersed as a single particle in the spacer-containing liquid 12 as in the conventional case, as shown in B in Fig. 6, the single spacer 220 in the spacer-containing liquid 12 is dispersed as a single particle. Even if the concentration of one spacer 220 is set to a concentration such that three single spacers 220 are included in the droplet volume V, the frequency of the number of single spacers 220 in a droplet 200 is The distribution becomes broad, and the number of single spacers 220 in the droplet 200 tends to vary widely.

[0074] However, as in the present embodiment, the combined spacer 230 formed by combining a plurality of predetermined single spacers 220 is dispersed as a single particle in the spacer-containing liquid 12. In this case, the bonding spacer 230 behaves as a single particle. Then, if the concentration of the bonding spacer 230 in the spacer-containing liquid 12 is set to a concentration such that approximately one bonding spacer 230 is included in the volume V of the droplet, as shown in A of Figure 6, , it is possible to contain only one bonding spacer 230 in the ejected droplet 200 with a high probability. This involves dispersing the single spacer 220 as a single particle in the spacer-containing liquid 12, and increasing the concentration of the single spacer 220 to 1 in the droplet volume V. If the concentration is set to include one single spacer 220, one single spacer 220 will be included in the droplet 200 with relatively high accuracy.

[0075] Therefore, according to the present embodiment, droplets 200 containing a predetermined plurality of single spacers 220 can be placed at each location on the color filter 100.

[0076] (Fixing process)

Subsequently, the coupling spacer 230 in the droplet 200 is fixed to the color filter 100. The fixing method is not particularly limited, and includes, for example, heating with an infrared lamp or the like, or drying with air blowing or the like. When the droplet 200 is dried, the bonding spacer 230 in the droplet 200 is fixed on the color filter 100, as shown in FIG. At this time, the bond between each single spacer 220 of the bonding spacer 230 is usually hardly destroyed.

[0077] As shown by the dotted line in Figure 4, if the droplet 200A attaches to an unintended location, this prevents the coupling spacer 230A from sticking to an unintended location. Subeg diagram 8 It is preferable to irradiate the color filter 100 with infrared rays through a mask M in which portions corresponding to the recesses 160a and the black matrix 120 are openings OP, as shown in FIG. Then, as shown in Figure 9, the liquid on the part corresponding to the opening OP dries and the bonding spacer 230 selectively sticks to that part, while the droplet 200A that is not irradiated with infrared rays dries. Therefore, it is possible to extremely efficiently prevent the coupling spacer 2 30A from sticking to a location other than the intended location on the color filter 100. In this case, after fixing the desired bonding spacer 230, as shown in FIG. Only the flexible coupling spacer 2 30A can be removed from above the color filter. Note that unfixed joint spacer 230A may be removed by blowing it out with gas or by immersing it in liquid.

[0078] In the process of fixing by drying, whether the droplets 200 are oriented upward or downward, each single spacer 220 of the bonding spacers 230 is eventually It comes into contact with 100 color filters. In this embodiment, a combined spacer 230 in which three single spacers are combined is used, and usually, after drying, any single spacer 220 of the combined spacer 230 is coated with a color filter. 100 surfaces, ie, when bonded, the height of the bonding spacer 230 is the same as the height of the single spacer 220.

[0079] Furthermore, the bonding spacer can also be fixed by a method other than drying. For example, if the surface of the bonding spacer 230 is made of resin that hardens upon irradiation with light, such as visible light-curing resin, ultraviolet-curing resin, infrared-curing resin, etc., the bond in the droplet 200 By irradiating the spacer 230 with light that hardens the resin while the spacer 230 is in contact with the surface of the color filter 100, the bonding spacer 230 can be fixed onto the color filter 10. In this case, drying is not necessarily necessary. Furthermore, it is preferable to irradiate the light through a mask M that prevents the coupling spacer 230A from sticking to an unintended location. Also, the unfixed coupling spacer 230A can be removed as described above.

[0080] At the same time as or after the fixation by curing, the color filter 100 is irradiated with infrared rays through the mask M to dry the liquid around the bonding spacer 230G and bonding spacer 230G is dried. It is also possible to increase the adhesion force between Pesa 230G and Color Filter 100. [0081] (Drive board stacking process)

Subsequently, as shown in FIG. 11, a liquid crystal drive substrate 400 having a pixel electrode 402 (for example, a TFT element, etc.) is placed on the color filter 100 via a coupling spacer 230. The liquid crystal driving substrate 400 has a pixel electrode 402, an alignment film 403, etc. provided on a glass substrate 401.

[0082] And the force between the color filter 100 and the liquid crystal drive board 400 is not one single spacer 220 as in the conventional case, but a plurality of single spacers 220 whose number is controlled more precisely. Since each panel is supported by a joint spacer 230 which is a collection of panels, the panel gap becomes uniform and the display becomes clear. In addition, since it is an aggregate, the spacer is difficult to move, and the spacer is less likely to be crushed by local pressure.

[0083] After this, liquid crystal is filled between the liquid crystal drive substrate 400 and the color filter 100, and the liquid crystal display device 300 is completed. Note that liquid crystal may be dropped onto the color filter 100 before placing the liquid crystal drive substrate 400 on the color filter 100.

[0084] As described above, according to the present embodiment, since the spacer-containing liquid 12 containing the combined spacer 230 formed by combining a plurality of single spacers 220 is used, the spacer-containing liquid 12 is In the containing liquid 12, each bonding spacer 230 acts as a single particle. By adjusting the concentration of the bonding spacer 230 in the spacer-containing liquid 12, approximately one bonding spacer 230 can be easily included in the ejected droplet 200. Therefore, a plurality of predetermined single spacers 220 can be placed at desired locations on the color filter with higher precision than in the past.

[0085] (Second embodiment)

Next, a second embodiment will be described. In this embodiment, a bonding spacer 230 in which four bonding spacers are sterically bonded as shown in (e) in FIG. 1 is used. In this case, after the droplets are attached and dried as described above, a state as shown in FIG. 12 is obtained. Then, the color filter 100 is stacked on top of the color filter 100, and a predetermined stress is applied to the coupling spacer 230 by sandwiching the coupling spacer 230 between the color filter 100 and the liquid crystal drive board 400. The bond between each single spacer 220 of the bonding spacer 230 is broken to form a bond. A combined spacer 230 is configured to rearrange each single spacer 220 into a layer. As a result, as shown in FIG. 11, the distance between the color filter 100 and the liquid crystal driving substrate 400 is determined by the height of the single spacer 220.

[0086] Here, the combined spacer 230 may be a combination of single spacers 220 bonded together via a thermoplastic binder 235, or the surface of each single spacer 220 may be a thermoplastic binder. If the bonding spacer 230 is formed by directly bonding the surfaces of a single spacer 220 to each other by heating, the bonding spacer 230 is formed by heating and bonding the surfaces of the bonding spacer 220 directly. By heating 230, the single spacer 220 can be easily rearranged with relatively low stress, and in the rearranged state, the single spacer 220 can be re-aligned with thermoplastic resin. It can be a combined spacer that is combined and rearranged.

[0087] (Third embodiment)

Next, a third embodiment of the present invention will be described. In the third embodiment, as shown in FIG. 13, a spacer arrangement device 1 like the first and second embodiments is used to spray a droplet onto a color filter 100 using a spray device 2 having a droplet spray nozzle 202. A large number of 200 droplets are applied to the surface by spraying.

[0088] As the droplet spray nozzle 202, for example, a two-fluid nozzle or the like can be used. A blower 204 is connected to this droplet spray nozzle 202 via a line L20, and a pump 206 and a stirring tank 20 similar to the first embodiment are also connected via a line L22. Then, the spacer-containing liquid 12 is supplied to the droplet spray nozzle 202 by the pump 206, and air is supplied to the droplet spray nozzle 202 by the blower 204, and the spacer-containing liquid is supplied from the droplet spray nozzle 202. A large number of droplets 200 are formed. This large number of droplets 200 adheres to the surface of the color filter 100, which is placed opposite the droplet spray nozzle 202. Note that the spray conditions such as the orifice diameter of the droplet spray nozzle 202 and the pressure of the spacer-containing liquid and air are set so that the diameter of the droplets becomes a desired size. Note that each droplet 200 preferably includes one coupling spacer 230.

[0089] In such a spraying method, it is difficult to control the adhesion position of the droplets 200 on the color filter 100 as in the first embodiment, and as shown in FIG. The containing droplets 200 are arranged almost randomly on the color filter 100. stop The bonding spacer 230 in the droplet 200 is connected to the bonding spacer 230G placed on the black matrix 120 and the bonding spacer 230H placed on the portion other than the black matrix 120. IJ is done.

[0090] Next, a mask M as shown in FIG. 8 is made, that is, a striped mask in which the part corresponding to the black matrix 120 of the color filter 100 is the opening OP, and the other part is the light shielding part. A black matrix 120 of a color filter 100 is irradiated with light through a mask M. Then, while the coupling spacer 230G on the black matrix 120 is fixed on the black matrix 120, the light is not irradiated on the part other than the black matrix 120, so the spacer 230G on the black matrix 120 is fixed on the black matrix 120. Coupling spacer 230H does not stick to color filter 100.

[0091] Examples of the fixing method include a method of drying the liquid with infrared rays, as in the first embodiment, and a method of irradiating light to harden the bonding spacer.

[0092] After the bonding spacer 230G on the black matrix 120 is fixed to the color filter, the unfixed bonding spacer 230H is removed from the surface of the color filter using running water, etc., as in the first embodiment. For example, as shown in FIG. 15, bonding spacers 230G can be selectively placed on the black matrix 120.

[0093] After that, the stacking step may be performed in the same manner as in the first embodiment or the second embodiment.

[0094] (Fourth embodiment)

In this embodiment, as shown in FIGS. 16 and 17, a liquid film 210 of the spacer-containing liquid 12 is deposited on the color filter 100 by the droplets 200. Specifically, the liquid film 210 of the spacer-containing liquid 12 can be formed on the color filter 100 using various known coating devices. For example, the liquid film 210 can be formed using a die coater 3 shown in FIG. 16 or the like. The liquid film 210 can also be formed by spraying droplets for a sufficiently long time using a spray nozzle as in the third embodiment.

[0095] When such a liquid film 210 is formed, the bonding spacers 230 are arranged almost randomly on the color filter 100 in the liquid film 210, as shown in FIGS. 16 and 17. Here, it is assumed that the bonding spacer placed on the black matrix 120 is 230G, and the bonding spacer placed on the portion other than the black matrix 120 is 230H. [0096] Thereafter, light may be irradiated through the mask M as in the third embodiment. The bonding spacer 230G may be fixed to the color filter 100 by drying the liquid around the bonding spacer 230G on the black matrix 120 using infrared rays, or the surface of the bonding spacer 230G may be hardened by light. Alternatively, the coupling spacer 230G and color filter 100 may be fixed together. After fixing, the unfixed bonding spacer 230H may be removed by cleaning or the like. As a result, the bonding spacers 230 are selectively arranged on the black matrix 120 as shown in FIG. 15. After that, the stacking process may be performed in the same manner as in the first embodiment or the second embodiment.

[0097] Note that the present invention is not limited to the above embodiments, and various modifications are possible. For example, the number of single spacers 220 included in each joint spacer 230 is not particularly limited as long as it is plural; it may be two, or it may be several dozen as long as there is no problem with discharge from the opening 37. But that's fine.

[0098] Further, in the above embodiment, the droplets 200 are ejected upward from the opening 37 of the head container 42, but they may be ejected downward or sideways.

[0099] In addition, if the relationship between the width of the opening OP of the mask M and the width of the location where the coupling spacer 230 is desired to be placed (for example, the black matrix) is approximately the same, the type of light that will be transmitted ( Ultraviolet rays Z Visible light Z Infrared rays (linearity varies depending on the type), distance between the mask and color filter, degree of unevenness of the color filter, light source strength, and power of light reaching the color filter (parallel light or convergence) The relationship between the width of the opening OP (see Figure 8) and the width of the spacer (for example, 120W in Figure 3) where you want to place the spacer can be set as desired depending on the properties of the light power, etc. can. Normally, (width of the opening) ≤ (width of the place where you want to place the spacer).

[0100] In addition, when manufacturing things other than color filters, for example, TFT substrates, liquid crystal display elements that require a cell gap using a spherical spacer, and multimode optical waveguides that require gap control, etc. Of course, it is also possible to use the methods of each of the above embodiments to arrange spacers on a substrate etc. when manufacturing optical devices such as connectors.

Industrial applicability

[0101] As described above, according to the present invention, a desired plurality of single spacers can be arranged on a substrate. Therefore, it becomes possible to manufacture liquid crystal displays with higher functionality.

Claims

The scope of the claims

[I] An attachment step of attaching a spacer-containing liquid containing a bonded spacer formed by bonding a plurality of single spacers in advance onto the substrate;

A method for arranging spacers, comprising: a fixing step of fixing the bonded spacer in the adhered spacer-containing liquid to the substrate.

[2] The spacer arrangement method according to claim 1, wherein in the attaching step, droplets of the spacer-containing liquid are formed and the droplets are attached onto the substrate.

[3] The spacer arrangement method according to claim 2, wherein in the adhering step, the droplets are discharged toward the substrate from an opening of a head container that is movable relative to the substrate.

[4] The spacer arrangement method according to claim 2, wherein in the adhering step, droplets of the spacer-containing liquid are sprayed onto the substrate.

[5] A liquid film of the spacer-containing liquid is formed on the substrate in the adhesion step.

Spacer arrangement method described in 1.

[6] The spacer arrangement method according to any one of claims 1 to 5, wherein the spacer-containing liquid is dried in the fixing step.

[7] The spacer according to claim 6, wherein the surface of the bonding spacer is formed of resin, or a functional group capable of bonding to a substrate is bonded to the surface of the bonding spacer. Placement method.

[8] The surface of the bonding spacer is formed of resin that hardens upon irradiation with light, and in the fixing step, the bonding spacer in the spacer-containing liquid is brought into contact with the surface of the substrate. The spacer arrangement method according to any one of claims 1 to 5, wherein the light is irradiated onto the coupling spacer in a state where the coupling spacer is in a state where the coupling spacer is

[9] In the fixing step, the bonded spacers in the spacer-containing liquid present on the part of the substrate are bonded to the substrate by irradiating light through a mask to only a part of the substrate. 9. The spacer arrangement method according to claim 1, wherein the spacer is fixed.

[10] The method for arranging spacers according to any one of claims 1 to 9, wherein the combined spacer is formed by bonding the single spacers to each other in advance using a thermoplastic binder.

[II] The surface of each single spacer is made of thermoplastic resin, and the surface of each single spacer is made of thermoplastic resin. 11. The method for arranging a spacer according to claim 1, wherein the single spacer has surfaces directly bonded to each other by heating in advance.

[12] Further comprising a stacking step of stacking another substrate on the substrate via the bonding spacer after the fixing step,

12. The spacer arrangement method according to claim 10, wherein the combined spacer is heated in the stacking step.

[13] A liquid crystal drive substrate having a pixel electrode, a color filter disposed opposite to the liquid crystal drive substrate, and a spacer disposed between the liquid crystal drive substrate and the color filter,

In the liquid crystal display device, the spacer is a combined spacer formed by combining a plurality of single spacers.