WO2009093765A1

WO2009093765A1 - Color display pannel

Info

Publication number: WO2009093765A1
Application number: PCT/KR2008/000418
Authority: WO
Inventors: Nak Hoon Seong
Original assignee: Nak Hoon Seong
Priority date: 2008-01-22
Filing date: 2008-01-23
Publication date: 2009-07-30
Also published as: KR20090080611A

Abstract

Disclosed herein is a method of manufacturing a color display panel and a color display panel manufactured using the method. The method of manufacturing a color display panel comprises forming pixel-holding grooves in a transparent flat panel and filling the pixel-holding grooves with pixels. The method further comprises grinding the transparent panel to flatten the surface of the color display panel. The pixels have three colors, namely, red (R), green (G) and blue (B), and the R, G and B pixels are alternately and repeatedly arranged over the entire color display panel.

Description

Description COLOR DISPLAY PANNEL

Technical Field

[1] The present invention relates to a method of manufacturing a color display panel, and to a color display panel manufactured using the method. More particularly, the present invention relates to a method of manufacturing a color display panel by forming pixel-holding grooves in a transparent panel and then filling the grooves with pixels, in which the pixels have three colors of red (R), green (G) blue (B), and the R, G and B pixels are alternately and repeatedly arranged over the entire surface of the color display panel.

[2] The color display panel of the present invention can be applied to display panels for displaying all colors, for example, liquid crystal display (LCD) panels.

[3] Further, the color display panel of the present invention can also be applied to organic light emitting display (OLED) panels for emitting light by filling the pixel- holding grooves of the transparent panel with organic compounds as well as by filling the pixel-holding grooves of the transparent panel with pixels that display three colors, that is, R, G and B. Background Art

[4] Generally, a color display panel, which is used for LCDs, etc., serves to form R, G and B, which are the three primary colors of light, thereon using photosensitive materials.

[5] Here, color units are regularly and repeatedly formed over the entire color display panel.

[6] A conventional color display panel for LCDs is generally called "a color filter".

Such a color filter includes three kinds of pixels, that is, R, G and B pixels, and these R, G and B pixels are variously formed on a transparent panel through a dyeing process, an electrodeposition process, a pigment dispersion method, or a printing process.

[7] Each pixel of the completed color filter has a thickness of about 1.0 to 3.0 μm, a width of several tens to several hundreds of μm, and a length of several tens to several hundreds of μm.

[8] Most conventional color filters include black matrices for dividing the pixels, a protective film and an ITO layer. Further, glass substrates have been generally used as transparent panels.

[9] FIGS. 1 to 14 illustrate a conventional typical method of manufacturing a color display panel using a photosensitive material. [10] A color display panel includes R, G and B pixels, black matrices for partitioning the pixels, and ITO, which is a transparent conductive material, on a transparent substrate.

[11] Since these constituents are variously configured as technically necessary, they do not constitute part of the essential field of the present invention.

[12] That is, in the present invention, it is important that colors be efficiently realized on a transparent flat panel at low cost.

[13] As the most typical conventional method of manufacturing a color display panel, there is a method of manufacturing a color display panel using a photosensitive material.

[14] The conventional method of manufacturing a color display panel using a photosensitive material will be described with reference to FIGS. 1 to 15.

[15] In FIGS. 1 to 15, only one color unit is shown and described, but, in reality, the same process is concurrently conducted with respect to all color units of the color display panel.

[16] FIG. 1 is a sectional view showing a color display panel in which R, G and B pixels are alternately formed on a transparent panel. A very large number of R, G and B pixels 2, 3 and 4 are formed on a transparent flat panel 1.

[17] FIG. 2 is a sectional view showing the state in which the transparent flat panel 1 is coated with a photosensitive material 5.

[18] FIG. 3 is a sectional view illustrating a process of forming exposure portions 6 and spaces 7 by exposing and developing the photosensitive material 5 applied on the transparent flat panel 1.

[19] FIG. 4 is a sectional view illustrating a process of placing an R screen 8 having injection holes 9 on the photosensitive material 5 in order to fill the spaces of FIG. 3 with R pixels.

[20] In the present invention, the term "screen" is defined as a body which is located over a transparent panel and thus serves to introduce only desired pixels into pixel- holding grooves through injection holes.

[21] That is, in the present invention, an R screen is a body serving to inject only R pixels into pixel-holding grooves formed in the entire transparent panel, a G screen is a body serving to inject only G pixels into pixel-holding grooves formed in the entire transparent panel, and a B screen is a body serving to inject only B pixels into pixel- holding grooves formed in the entire transparent panel.

[22] FIG. 5 is a sectional view illustrating a process of injecting R pixels 10 into spaces located on the transparent panel 1 through injection holes in the R screen 8.

[23] FIG. 6 is a sectional view showing the state in which the R screen 8 is removed after the process of FIG. 5.

[24] FIG. 7 is a sectional view illustrating a process of forming only R pixels on the transparent panel 1 by melting and thus removing the exposure portions 6 after the process of FIG. 6. [25] It is shown in FIG. 7 that two R pixels are formed on the transparent panel, but, in reality, a very large number of R pixels are formed thereon. [26] FIGS. 8 to 13 are sectional views illustrating a process of forming G pixels beside the R pixels. [27] FIG. 8 is a sectional view illustrating a process of applying a photosensitive material 5 on both the transparent panel 1 and the R pixels 11. [28] FIG. 9 is a sectional view illustrating a process of forming exposure portions 12 and spaces 13 by exposing and developing the photosensitive material 5 applied on the transparent panel 1 and the R pixels 11. [29] FIG. 10 is a sectional view illustrating a process of placing a G screen 14 having injection holes 15 on the photosensitive material 5 in order to fill the spaces of FIG. 9 with G pixels. [30] FIG. 11 is a sectional view illustrating a process of injecting G pixels 16 into spaces located on the transparent panel 1 through injection holes in the G screen 14. [31] FIG. 12 is a sectional view showing the state in which the G screen 14 is removed after the process of FIG. 11. [32] FIG. 13 is a sectional view illustrating a process of forming G pixels beside the R pixels on the transparent panel 1 by melting and thus removing the exposure portions

12 after the process of FIG. 12.

[33] FIG. 14 is a sectional view illustrating a process of forming B pixels.

[34] Specifically, FIG. 14 is a sectional view illustrating a process of forming B pixels by applying a photosensitive material 5 on both the transparent panel 1 and the R pixels 11 and G pixels 17, forming exposure portions 19 and spaces by exposing and developing the photosensitive material 5 applied on the transparent panel 1 and the R pixels 11 and G pixels 17, placing a B screen 18, having injection holes therein, on the photosensitive material 5 in order to fill the spaces with B pixels 20, and then injecting

B pixels 20 into spaces located on the transparent panel 1 through injection holes in the

B screen 18. [35] FIG. 15 is a sectional view showing the state in which the B screen 18 and the exposure portions are removed after the process of FIG. 14. It is evident from FIG. 15 that R pixels 11, G pixels 17 and B pixels 21 are alternately and repeatedly formed on the transparent panel 1. [36] As described above, the conventional technologies are problematic in that, since R,

G and B pixels are alternately and repeatedly formed on a transparent flat panel using a photosensitive material, exposure and development processes are performed several times, thus increasing the processing cost. Disclosure of Invention

Technical Problem

[37] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a method of manufacturing a color display panel using a transparent panel having pixel-holding grooves without using a photosensitive material, by which a complicated and repetitive process of applying a photosensitive material on a transparent panel, forming spaces by exposing and developing the photosensitive material, and injecting pixels into the spaces each time each of the pixels is formed on the transparent panel need not be performed.

[38] That is, the object of the present invention is to provide a method of manufacturing a color display panel using an intaglio process, which can greatly simplify the working process by injecting pixels into respective pixel-holding grooves formed in a transparent panel, and can greatly decrease manufacturing costs, and a color display panel manufactured using the method. Technical Solution

[39] In order to accomplish the above object, in the present invention, a transparent panel, in which pixel-holding grooves are formed, is used so that a process of applying a photosensitive material thereon, which is required in the prior art each time pixels are applied, need not be conducted, and the methods of forming the pixel-holding grooves in the transparent panel are various.

[40] In an aspect of the method of forming pixel-holding grooves in a transparent panel, it is possible to form pixel-holding grooves by passing a transparent panel, which is previously fabricated in a flat sheet shape, through a roller having embossed portions. Further, it is possible to form pixel-holding grooves by pressing a transparent panel using a roll press or a flat press.

[41] As another aspect of the method of forming pixel-holding grooves in a transparent panel, there is a method of forming pixel-holding grooves in the surface of a melted material when the melted material is formed into a flat sheet, in a process of fabricating a transparent panel. In this method, it is also possible to easily and variously form pixel-holding grooves using a mold having embossed portions.

[42] The features and advantages of the present invention will be more clearly understood from the following detailed description, taken in conjunction with the accompanying drawings. The terms and words mentioned in the specification and claims must not be construed as general and dictionary meanings, and must be construed such that they coincide with the technical features of the present invention.

Advantageous Effects [43] According to the method of manufacturing a color display panel of the present invention, since pixel-holding grooves are directly formed in a transparent panel, a conventional complicated working process of applying a photosensitive material on the transparent panel each time pixels are injected need not be conducted. [44] Accordingly, the method of manufacturing a color display panel according to the present invention is advantageous in that processes are simplified, thus greatly decreasing manufacturing costs, and in that the production of defective products can be minimized.

Brief Description of the Drawings [45] FIG. 1 is a sectional view showing a color display panel in which R, G and B pixels are alternately formed on a transparent panel; [46] FIG. 2 is a sectional view showing the state in which the transparent flat panel is coated with a photosensitive material; [47] FIG. 3 is a sectional view illustrating a process of forming exposure portions and spaces by exposing and developing the photosensitive material applied on the transparent flat panel; [48] FIG. 4 is a sectional view illustrating a process of placing an R screen, having injection holes therein, on the photosensitive material in order to fill the spaces of FIG.

3 with R pixels; [49] FIG. 5 is a sectional view illustrating a process of injecting R pixels into spaces located on the transparent panel through injection holes in the R screen; [50] FIG. 6 is a sectional view showing the state in which the R screen is removed after the process of FIG. 5; [51] FIG. 7 is a sectional view illustrating a process of forming only R pixels on the transparent panel by melting and thus removing the exposure portions after the process of FIG. 6; [52] FIG. 8 is a sectional view illustrating a process of applying a photosensitive material 5 on both the transparent panel and the R pixels; [53] FIG. 9 is a sectional view illustrating a process of forming exposure portions and spaces by exposing and developing the photosensitive material applied on the transparent panel and the R pixels; [54] FIG. 10 is a sectional view illustrating a process of placing a G screen having injection holes on the photosensitive material in order to fill the spaces of FIG. 9 with

G pixels; [55] FIG. 11 is a sectional view illustrating a process of injecting G pixels into spaces located on the transparent panel through injection holes in the G screen; [56] FIG. 12 is a sectional view showing the state in which the G screen is removed after the process of FIG. 11; [57] FIG. 13 is a sectional view illustrating a process of forming G pixels beside the R pixels on the transparent panel by melting and thus removing the exposure portions after the process of FIG. 12;

[58] FIG. 14 is a sectional view illustrating a process of forming B pixels;

[59] FIG. 15 is a sectional view showing the state in which the B screen and the exposure portions are removed after the process of FIG. 14; [60] FIG. 16 is an enlarged sectional view showing a part of a color unit a transparent panel having pixel-holding grooves; [61] FIG. 17 is a sectional view illustrating a process of placing an R screen, having injection holes therein, on the transparent panel having pixel-holding grooves in order to fill the pixel-holding grooves with R pixels; [62] FIGS. 18 and 19 are sectional views illustrating a process of injecting R pixels into the pixel-holding grooves through the injection holes and then removing the R screen; [63] FIGS. 20 and 21 are sectional views illustrating a process of injecting G pixels into pixel-holding grooves through injection holes and then removing a G screen; [64] FIGS. 22 and 23 are sectional views illustrating a process of injecting B pixels into pixel-holding grooves through injection holes and then removing a B screen; [65] FIG. 24 is a sectional view illustrating a process of flattening the surface of a transparent panel through a grinding process; and [66] FIG. 25 is a sectional view showing a color display panel in which pixels and partitions having the same thickness are arranged. [67] <Description of the elements in the drawings>

[68] 1 : transparent panel

[69] 2: R pixel

[70] 3: G pixel

[71] 4: B pixel

[72] 5: photosensitive material

[73] 6: exposure portion

[74] 7: space

[75] 8: R screen

[76] 9: injection hole

[77] 10, 11: R pixel

[78] 12: exposure portion

[79] 13: space

[80] 14: G screen

[81] 15: injection hole

[82] 16: G pixel [83] 17: G pixel

[84] 18: G screen

[85] 19: exposure portion

[86] 20: B pixel

[87] 21: B pixel

[88] 22: transparent panel having pixel-holding groove

[89] 23,24,25: pixel-holding groove

[90] 26,27: partition

[91] 28: R screen

[92] 29: injection hole

[93] 30: R pixel

[94] 31: R pixel

[95] 32: injection hole

[96] 33: G pixel

[97] 34: G screen

[98] 35: G pixel

[99] 36: B pixel

[100] 37: B screen

[101] 38: injection hole

[102] 39: B pixel

[103] 40 : grinding wheel

[104] 41: R pixel

[105] 42: G pixel

[106] 43: B pixel

[107] 44,45: partition

Best Mode for Carrying Out the Invention [108] The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description. [109] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. [110] Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components. The detailed description of commonly-known functions and constitutions relating to the present invention will be omitted in order to clarify the essential points of the present invention. [I l l] In the present invention, a method of manufacturing a color display panel by forming pixel-holding grooves in the surface of a transparent panel and then injecting pixels into the pixel-holding grooves is defined as a method of manufacturing a color display panel using an intaglio process. [112] As shown in FIG. 16, in the method of manufacturing a color display panel according to an embodiment of the present invention, a transparent panel 22, in which pixel-holding grooves 23, 24 and 25 are formed, is used. [113] FIG. 16 is an enlarged sectional view showing a part of a color unit of a transparent panel having pixel-holding grooves. Generally, since three pixels, comprising R, G and

B pixels, constitute a color unit, the present invention will be described based on three pixel-holding grooves. However, if it is necessary to use three or more pixels to constitute a color unit, the pixel-holding groove may be variously configured depending on the kind of pixel. [114] In a color display panel, the color units are regularly and repeatedly formed over the entire panel. A conventional color display panel for LCDs is generally referred to as a color filter. [115] Such a color filter includes three pixels, that is, R, G and B pixels, and these R, G and B pixels are variously formed on a transparent panel through a dyeing process, an electrodeposition process, a pigment dispersion method, or a printing process. [116] Each pixel of the completed color filter has a thickness of about 1.0 to 3.0 μm, a width of several tens to several hundreds of μm, and a length of several tens to several hundreds of μm. [117] Most conventional color filters include black matrices for dividing the pixels, a protective film and an ITO layer. Further, glass substrates have generally been used as transparent panels. [118] Flexible transparent panels composed of various materials may be used as transparent panels of the present invention. [119] When pixel-holding grooves are formed in a flexible transparent panel, a color display panel manufactured in such a manner can be bent or folded, and thus can be applied to products having various structures. [120] That is, since a foldable color display panel can be manufactured, it can be variously used for LCD monitors, foldable electronic books, foldable and portable displays, and the like. [121] Methods of forming pixel-holding grooves in the transparent panel that is used in the present invention may be various. [122] In an aspect of the method of forming pixel-holding grooves in a transparent panel, it is possible to form pixel-holding grooves by passing a transparent panel, which is previously fabricated to have a flat sheet shape, through a roller having embossed portions. [123] In this case, it is also possible to form pixel-holding grooves by pressing a transparent panel using a roll press or a flat press. Generally, the pixel-holding grooves are formed in a state in which the transparent panel is heated and thus softened.

[124] As another aspect of the method of forming pixel-holding grooves in a transparent panel, there is a method of forming pixel-holding grooves in the surface of a melted material when the melted material is formed into a flat sheet, in a process of fabricating a transparent panel. In this method, it is also possible to easily and variously form pixel-holding grooves using a mold having embossed portions.

[125] The mold having embossed portions, used in the present invention, can be fabricated using various methods, such as laser processing, electric plating, etching, and the like.

[126] As shown in FIG. 16, pixel-holding grooves 23, 24 and 25, formed in the transparent panel 22, are defined by partitions 26 and 27.

[127] Generally, each of the pixel-holding grooves has a width of several tens to several hundreds of μm, and a length of several tens to several hundreds of μm.

[128] Each boundary located between the pixel-holding grooves is referred to as a partition. The partition of the present invention is configured to have a width of several tens to several hundreds of μm. However, the width of the partition may also be variously changed depending on the characteristics of products.

[129] As shown in FIG. 17, an R screen 28 having injection holes 29 is placed on a transparent panel 22, in which pixel-holding grooves 23, 24 and 25 are formed, in order to inject R pixels into the pixel-holding grooves.

[130] Subsequently, as shown in FIGS. 18 and 19, R pixels are injected into the pixel- holding grooves through injection holes 29, and then the R screen 28 is removed, and thus only the R pixels 31 remain in the pixel-holding grooves.

[131] Subsequently, as shown in FIGS. 20 and 21, G pixels are injected into the pixel- holding grooves through injection holes 32, and then a G screen 34 is removed, and thus only the G pixels 35 remain in the pixel-holding grooves.

[132] Subsequently, as shown in FIGS. 22 and 23, B pixels are injected into the pixel- holding grooves through injection holes 38, and then a B screen 37 is removed, and thus only the B pixels 39 remain in the pixel-holding grooves.

[133] Through the above processes, the R, G and B pixels are sequentially injected into the pixel-holding grooves.

[134] Thereafter, if necessary, as shown in FIG. 24, the surface of the transparent panel may be flattened through grinding work.

[135] The grinding work is a process of flattening the surface of a color display panel using a grinding wheel 40. In this process, partitions 26 and 27 as well as pixels 31, 35 and 39 can be flush with each other such that they have the same height.

[136] In such a flattening process, the height of all of the pixels can be constantly and precisely controlled, and the uniformity of the image can be increased.

[137] FIG. 25 shows a color display panel in which pixels 41, 42 and 43, which are injected into pixel-holding grooves in the transparent panel 22, and partitions 44 and 45 are arranged such that they have the same thickness.

[138] According to the method of manufacturing a color display panel of the present invention, since pixel-holding grooves are directly formed in a transparent panel, a conventional complicated working process of applying a photosensitive material on the transparent panel each time pixels are injected need not be conducted, and the color display panel can be rapidly manufactured at low cost.

[139] In the present invention, an R screen is used when R pixels are injected, a G screen is used when G pixels are injected, and a B screen is used when B pixels are injected. In this work, it is important to precisely set the position of each screen using a guide pin.

[140] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

[1] A method of manufacturing a color display panel using an intaglio process, comprising: forming pixel-holding grooves in a transparent flat panel; and filling the pixel-holding grooves with pixels. [2] The method of manufacturing a color display panel according to claim 1, further comprising, after the filling the pixel-holding grooves with pixels: grinding a resulting color display panel to flatten a surface thereof. [3] The method of manufacturing a color display panel according to claim 1, wherein the pixels have three colors, comprising red (R) pixels, green (G) pixels and blue (B) pixels, and the R, G and B pixels are alternately and repeatedly arranged over the entire color display panel. [4] The method of manufacturing a color display panel according to claim 1 or 2, wherein the pixels include organic compounds. [5] A color display panel manufactured using the method according to any one of claims 1 to 4.