WO2013172040A1 - 表示パネルと表示パネルの製造方法 - Google Patents
表示パネルと表示パネルの製造方法 Download PDFInfo
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- WO2013172040A1 WO2013172040A1 PCT/JP2013/003156 JP2013003156W WO2013172040A1 WO 2013172040 A1 WO2013172040 A1 WO 2013172040A1 JP 2013003156 W JP2013003156 W JP 2013003156W WO 2013172040 A1 WO2013172040 A1 WO 2013172040A1
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- display panel
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Images
Classifications
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
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- H10K59/8722—Peripheral sealing arrangements, e.g. adhesives, sealants
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/02—Details
- H05B33/04—Sealing arrangements, e.g. against humidity
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/842—Containers
- H10K50/8426—Peripheral sealing arrangements, e.g. adhesives, sealants
Definitions
- the present invention relates to a display panel in which a display area provided between two substrates arranged opposite to each other is sealed by a sealing material that surrounds the display area and is arranged between the substrates, and a method for manufacturing the same. Is.
- An organic electroluminescence (EL) element is a self-luminous element, and therefore has an advantage that a backlight is not required, a viewing angle is wide, a reduction in thickness and power consumption is easy, and a response speed is high. .
- An organic EL display panel in which such EL elements are arranged has attracted much attention as a next-generation display that replaces a liquid crystal display device.
- an organic EL element includes an organic EL laminated body having a lower electrode, an organic material layer including a light emitting layer, and an upper electrode in this order on a substrate.
- the materials constituting the organic EL laminate are generally highly active and unstable, and easily react with moisture and oxygen in the air. Since such a reaction with moisture or oxygen causes the characteristics of the organic EL element to be remarkably deteriorated, it is indispensable to seal the organic EL element from outside air in the organic EL display panel.
- the sealing member is provided in order to prevent deterioration due to intrusion of moisture or oxygen from the outside to a light emitting element such as an organic EL element constituting the display region.
- the display region is sealed with a paste (for example, glass paste) containing a sealing material (for example, frit glass) so as to surround the display region (element formation scheduled region) with respect to any one of the substrates. .) Is applied and dried, the other substrate is overlaid, and the sealing material is melted (fired). What baked this sealing material is called sealing member.
- a paste for example, glass paste
- a sealing material for example, frit glass
- the display panel is obtained by cutting the peripheral edge of an intermediate panel in which two substrates are bonded (sealed by a sealing member).
- the present invention has been made in view of the above problems, and provides a display panel capable of achieving both narrowing and production efficiency and a method for manufacturing the same.
- a display panel includes a first substrate, a second substrate disposed to face the first substrate, the first substrate, and the two substrates.
- a plurality of EL elements disposed therebetween, and a sealing member that is provided between the first substrate and the second substrate and seals the plurality of EL elements.
- a rectangular frame portion formed along the periphery of the EL element; and a reinforcing portion protruding outward at a corner portion of the rectangular frame portion, the reinforcing portion being at least one side surface of the corner portion of the first substrate.
- a second side surface cut in a state of being flush with a side surface on the side where the at least one side surface of the corner portion of the second substrate is present. The first side surface and the second side surface are included in the same surface.
- a method for manufacturing a display panel includes a first step of forming a plurality of EL elements in a central region on a first substrate, and sealing on the first substrate or the second substrate.
- the reinforcing portion is cut in a state where it overlaps with each of the corner portion of the first substrate and the corner portion of the second substrate when viewed from the bonding direction of the substrates.
- the display panel since the display panel includes a reinforcing portion that protrudes outward from the corner portion of the rectangular frame portion, the residual strain generated by heat during the manufacturing process of the display panel is mainly the reinforcing portion. Occurs in the outer area of the. And since the reinforcement part has the side surface cut
- the reinforcing portion protrudes outward from the corner portion of the rectangular frame portion.
- the reinforcing portion is at least one of the side surface in the corner portion of the first substrate and the side surface in the corner portion of the second substrate. Because it has a side surface that is cut in a flush state, it will be cut so that it crosses the reinforcement part, and as a result, the amount of protrusion from the corner of the rectangular frame part can be reduced, and a request for narrowing the edge Can respond.
- the reinforcing portion protrudes outward from the corner portion of the rectangular frame portion, as described above, it is possible to prevent the first substrate and the second substrate from cracking at the time of cutting due to residual strain, and the inside of the corner portion of the rectangular frame portion. Can be made smaller (closer to a right angle), and the demand for narrowing can be met.
- FIG. 3 is a view of a cross section taken along line A1-A2 of FIG.
- FIG. 3 is a cross-sectional view taken along the line B1-B2 of FIG.
- substrate is a top view of CF board
- FIG. 6 is a cross-sectional view taken along the line C1-C2 in FIG.
- FIG. 6 is a cross-sectional view taken along the line D1-D2 of FIG.
- (a) is a figure which shows the glass substrate of the state before apply
- (b) is a figure which shows the glass substrate after apply
- (c) is a figure which shows the baking state of a frit paste
- (d) is a figure which shows the glass substrate after baking.
- It is a figure explaining a joining process (a) is a figure which shows the state before bonding CF substrate and EL substrate, (b) is a figure which shows the state which bonded CF substrate and EL substrate.
- (C) is a figure which shows a resin hardening process, (d) is a figure which shows an EL integration process.
- FIG. 1 It is a figure explaining a dispenser device, (a) is a schematic diagram, (b) is a perspective view showing frit paste after application when a dispenser device moves straightly, and (c) is a dispenser device rotating. It is a perspective view which shows the frit paste after application
- FIG. 1 It is a figure which shows the example of the display panel from which the dimension of the board
- FIG. 7 is an enlarged view of a cross section of X1-X2 as viewed from the direction of the arrow, (c) is a case where a display panel according to the prior art is used, and (d) is a cross section of X3-X4 of (c) in the direction of the arrow. It is the cross-sectional enlarged view seen from. (A), (b) is a figure which shows the modification based on 2nd Embodiment. It is explanatory drawing of the large-size intermediate
- FIG. 7 is a diagram showing other examples 1 to 3 of the reinforcing portion, (a) is a diagram showing the reinforcing portion according to example 1, (b) is a diagram showing the reinforcing portion according to example 2, and (c) FIG. 4 is a diagram showing a reinforcing portion according to Example 3.
- the display panel according to the embodiment includes a first substrate, a second substrate disposed to face the first substrate, a plurality of EL elements disposed between the first substrate and the two substrates, A sealing member provided between the first substrate and the second substrate for sealing the plurality of EL elements, wherein the sealing member is formed along the periphery of the plurality of EL elements.
- a rectangular frame portion and a reinforcing portion protruding outward at a corner portion of the rectangular frame portion, and the reinforcing portion is cut in a state of being flush with at least one side surface of the corner portion of the first substrate.
- a first side surface and a second side surface cut in a state of being flush with a side surface on the side where the at least one side surface is present in a corner portion of the second substrate, and the first side surface and the second side surface The side surface is included in the same surface.
- first side surface and the second side surface coincide with each other.
- substrate can be cut
- the plurality of EL elements are provided on the first substrate, and the second substrate is located at a center of the second substrate rather than an extension line of a side surface at a corner portion of the second substrate. It has a side surface located on the side.
- the reinforcement part of a sealing member can be left between a 1st board
- the side surface of the second substrate located on the center side of the second substrate is located on the center side of the second substrate with respect to the side surface of the first substrate.
- auxiliary wiring or the like can be arranged in a region of the first substrate that does not face the second substrate.
- the sealing member is frit glass.
- the material of the sealing member is frit glass
- the difference in the elastic modulus of the substrate is large, and the stress applied between the substrate and the frit glass when the frit glass is cured and contracted causes the resin material on the sealing member. It becomes larger than the case of using.
- frit glass can be used for a sealing member.
- the sealing member further includes an intermediate reinforcing portion that protrudes outward between the corner portions of the rectangular frame portion.
- a first step of forming a plurality of EL elements in a central region on a first substrate, and a sealing material is used on the first substrate or the second substrate.
- a second step of providing a rectangular frame portion surrounding the region corresponding to the central region and a reinforcing portion protruding outward from a corner portion of the rectangular frame portion; and the first substrate and the first step through the sealing material A third step of bonding two substrates together to seal the plurality of EL elements, and a fourth step of cutting the first substrate and the second substrate, respectively, in the fourth step, When viewed from the bonding direction of the substrate, the portion is cut in a state of overlapping with each of the corner portion of the first substrate and the corner portion of the second substrate. Thereby, it is possible to achieve both the production efficiency and narrowing of the display panel.
- the reinforcing portion overlaps both a corner portion of the first substrate and a corner portion of the second substrate when viewed from the bonding direction of the substrates. And it cut
- the second substrate is cut such that the second substrate has a side surface arranged closer to the center side of the second substrate than an extension line of the cut surface at a corner portion of the second substrate. Is done. Thereby, the reinforcement part of a sealing member can be left between a 1st board
- FIG. 1 is a partial cross-sectional view schematically showing a main part of the display panel 10 of the first embodiment.
- the display panel 10 includes an EL substrate 11 and a CF substrate 12, and a sealing resin layer 13 is interposed between the EL substrate 11 and the CF substrate 12.
- the sealing resin layer 13 is obtained by curing a resin body supplied and applied in a liquid state. In addition to the purpose of bonding the EL substrate 11 and the CF substrate 12, moisture and gas are emitted from the outside of the display panel 10. The purpose is to prevent entry into the substrate 11. However, the sealing resin layer 13 is not an essential component and may not have the sealing resin layer.
- the light extraction port side of the display panel 10 is the upper side or the front side, and the light extraction port side is the lower side in FIG. (2) EL substrate
- the EL substrate 11 includes a substrate, an interlayer insulating film, an anode, a bank, a light emitting layer, and the like.
- FIG. 2 is a plan view of the EL substrate
- FIG. 3 is a view of the cross section of A1-A2 in FIG. 2 seen from the arrow direction
- FIG. 4 is a view of the cross section of B1-B2 in FIG. It is.
- a side bonded to the CF substrate 12 is an upper side or a front side (a lower side in FIG. 1).
- the EL substrate 11 has a plurality of pixels 30 arranged in a matrix direction on a substrate (111).
- one pixel 30 includes three (three colors (R, G, B)) light emitting elements 31 (R), 31 (G), and 31 (B).
- R, G, B three colors
- the symbol “31” is simply used, and the area where the plurality of pixels 30 are arranged in a matrix is the display area 131.
- the substrate (111) corresponds to the first substrate according to the embodiment
- the light emitting element 31 corresponds to the EL element according to the embodiment.
- the display region 131 is a region in which the EL substrate 11 and the CF substrate 12 are bonded to each other and is composed of the plurality of pixels 30 and the CF 122 and can display an image.
- the display region 131 is formed with the plurality of pixels 30 on the EL substrate (TFT substrate). This refers to a planned region or a region where a plurality of CFs 122 are to be formed on a CF substrate (glass substrate).
- one light emitting element 31 has a long shape, and the three light emitting elements 31 (R), 31 (G), and 31 (B) are arranged adjacent to each other in the short direction of the light emitting element 31.
- a substantially square pixel 30 is obtained in plan view (see FIG. 2).
- a pixel in which a plurality of pixels 30 are formed is referred to as EL30a.
- the TFT substrate 111 is used as the substrate.
- An interlayer insulating film 112 is formed on the upper surface of the TFT substrate 111.
- an anode 113a is disposed in units of light emitting elements 31.
- the anode 113 a has the same long shape as the plan view of the light emitting element 31.
- an auxiliary electrode 113 b is formed between the pixels 30 in addition to the anode 113 a on the upper surface of the interlayer insulating film 112.
- Banks 114 are formed between the anodes 113a and between the anode 113a and the auxiliary electrode 113b.
- the bank 114 protrudes upward from a region on the interlayer insulating film 112 where the anode 113a and the auxiliary electrode 113b are not formed and between the anode 113a and the auxiliary electrode 113b.
- a light emitting layer (in this case, an organic light emitting layer) 115 having a predetermined emission color is laminated.
- the predetermined emission colors are three colors of “blue”, “green”, and “red”, but other colors such as yellow may be included in addition to the three colors.
- the blue light-emitting layer is represented by “115 (B)”
- the green light-emitting layer is represented by “115 (G)”
- the red light-emitting layer is represented by “115 (R)”.
- the symbol “115” is simply used.
- FIG. 5 is a plan view of the CF substrate
- FIG. 6 is a cross-sectional view taken along the line C1-C2 of FIG. 5
- FIG. 7 is a cross-sectional view taken along the line D1-D2 of FIG. It is the figure seen from the direction.
- the side bonded to the EL substrate 11 is defined as the upper side or the front side (the upper side in FIG. 1).
- the CF substrate 12 includes a substrate 121, a color filter 122, and the like.
- the substrate 121 corresponds to the second substrate according to the embodiment.
- the color filter 122 has a long shape similar to the planar view shape of the light emitting element 31 shown in FIG.
- the substrate 121 is a front substrate in the display panel 10 and is made of a light transmissive material.
- Color filters 122 (B), 122 (G), and 122 (R) are provided on the upper surface of the substrate 121 corresponding to the organic light emitting layers 115 (B), 115 (G), and 115 (R) of the EL substrate 11. Is formed. It should be noted that the symbol “122” is simply used when referring to all color filters regardless of the light color.
- a so-called black matrix (hereinafter simply referred to as “BM”) 123 is formed between the color filters 122 on the upper surface of the substrate 121. As shown in FIGS. 6 and 7, each color filter 122 is formed in a state where a part of the color filter 122 rides on the peripheral edge of the upper surface of the BM 123 on both sides adjacent to each other.
- BM black matrix
- BM123 is a black layer provided for the purpose of preventing reflection of external light on the display surface of the display panel 10 and incidence of external light and improving display contrast. As shown in FIG. 1, the BM 123 is formed so as to correspond (oppose) to the bank 114 of the EL substrate 11.
- the display panel 10 is provided with a sealing material 134 and a sealing member 133 at the peripheral part thereof. Specifically, the sealing material 134 and the sealing member 133 are provided so as to surround the outer periphery of the display region 131, and the sealing member 133 is located outside the sealing material 134.
- the sealing material 134 is for sealing the inside of the bonded EL substrate 11 and CF substrate 12.
- the sealing member is a member in which the sealing material is melted and integrated with the EL substrate 11 or the CF substrate 12 to seal the display region 131, and has the same reference numerals as the sealing material. “133” is used.
- An example of the manufacturing method of the display panel 10 was prepared: an EL preparation step (1) for preparing an EL substrate 11a; a CF preparation step (2) for preparing a CF substrate 12a coated with a sealing material; The EL substrate 11a and the CF substrate 12a are manufactured through a bonding step (3) for bonding and bonding, and a cutting step (4) for cutting the periphery of the bonded intermediate panel 138.
- a paste containing a sealing material is used.
- frit glass is used as the sealing material, and the paste is a frit paste.
- the EL preparation step the EL substrate 11a is prepared. Specifically, the light-emitting element 31 (EL 30a) is formed on the substrate. In this step, a light emitting element can be formed by the same known technique as in the prior art, and thus description thereof is omitted here.
- the EL substrate 11 of the display panel 10 is obtained by cutting off the peripheral portion (unnecessary portion) of the EL substrate 11a.
- (2) CF process In the CF preparation process, the application process for applying the frit paste to the substrate, the applied frit paste (more precisely, the frit glass contained in the frit paste) and the substrate are integrated.
- the CF substrate 12a is formed by forming the CF 122a on the substrate.
- the CF substrate 12 of the display panel 10 is obtained by cutting off the peripheral portion (unnecessary portion) of the CF substrate 12a.
- FIG. 8A and 8B are diagrams for explaining the CF process, in which FIG. 8A shows a glass substrate in a state before applying the frit paste, and FIG. 8B shows a glass substrate after applying the frit paste.
- C is a figure which shows the baking state of a frit paste
- d is a figure which shows the glass substrate after baking.
- FIG. 8 two views are shown on the left and right in the same process, the left figure is a perspective view of each process, and the right figure is a sectional view in the right process.
- A) Application Step In the application step, a glass substrate 121 as shown in FIG. 8A is prepared, and a frit paste 130 is applied on the upper surface of the glass substrate 121 as shown in FIG. 8B.
- the frit paste 130 is applied by a dispenser method so as to surround the display area 131 (the area where the CF 122a is to be formed) 131.
- (B) CF integration step In the CF integration step, a drying step for eliminating the solvent contained in the frit paste 145 and a firing step for eliminating the binder and the like contained in the frit paste 145 are performed in this order.
- the firing process is performed using a laser 132, and with the disappearance of the binder or the like, the frit glass (glass powder) contained in the frit paste 145 is melted. As shown in (d), it is integrated with the glass substrate 121. Note that a material obtained by baking frit glass and integrated with the glass substrate 121 is used as a sealing material 133.
- (C) CF forming step In the CF forming step, the CF 122a is formed on the display region 131 of the glass substrate 121 on which the sealing material 133 is formed. Since this process uses the same known technique as in the past, the description here is omitted. Thereby, the CF substrate 12a is completed.
- a sealing material application step for applying a sealing material to the CF substrate 12a a resin material application step for applying a sealing resin material to the CF 122a of the CF substrate 12a, A bonding step of bonding the CF substrate 12a coated with a sealing material and a sealing resin material and the EL substrate 11a, a pressure reducing step of reducing the pressure of the bonded EL substrate 11a and the CF substrate 12a, and a resin;
- FIG. 9A and 9B are diagrams illustrating the bonding process, in which FIG. 9A illustrates a state before the CF substrate and the EL substrate are bonded together, and FIG. 9B illustrates a state where the CF substrate and the EL substrate are bonded together.
- C is a figure which shows a resin hardening process
- d is a figure which shows an EL integration process.
- the sealing materials 135a and 135b are applied to the inside and the outside of the sealing material 133 along the sealing material 133 formed in a rectangular ring shape in plan view.
- the outer sealing material 135a has a function of preventing moisture, oxygen, and the like from entering the display region from the outside mainly during the resin curing process and the EL integration process.
- the inner sealing material 135b mainly has a function of preventing the sealing resin material 136 from entering between the sealing material 133 before firing and the EL substrate 11 to cause poor adhesion.
- sealing material for example, a sealing material, an epoxy resin, an acrylic resin, a silicone resin, a phenol resin, a melamine resin, or the like can be used.
- the resin material 136 is dropped on the display area.
- the dropping of the resin material is performed so as to obtain a uniform distribution state.
- the substrate in the state where the sealing material application step and the resin material application step are finished is a CF substrate 12a in FIG.
- (B) Bonding step In the bonding step, as shown in FIGS. 9A and 9B, the CF substrate 12a that has finished the coating step and the EL substrate 11a prepared in the EL preparation step, The EL substrate 11a and the CF substrate 12a are bonded together so that the EL 30a and the CF substrate 12a face each other.
- C) Depressurization step In the depressurization step, the pressure is reduced in the bonded state. By this decompression, air (air) in the resin material, air present on the contact surface between the sealing material 135 and the CF substrate 12a, gas generated when the frit paste 130 is fired, etc. are extracted (defoamed). . In order to enhance the defoaming effect, only the CF substrate 12a may be placed under a reduced pressure before the EL substrate 11a and the CF substrate 12a are bonded together.
- the decompression step is performed after the pasting step, but the EL substrate 11a and the CF substrate 12a may be pasted together under a decompressed state, or a resin material is applied to the CF substrate 12a under the decompressed state. May be.
- Resin curing step In the resin curing step, the resin material 136 interposed between the EL substrate 11a and the CF substrate 12a is cured. The curing method here is performed using heat and ultraviolet rays as shown in FIG. Note that the resin material cured is the sealing resin 139.
- E EL integration step In the EL integration step, the sealing material 133 is melted, and the molten sealing material 133 and the EL substrate 11a are integrated. Specifically, the sealing material 133 is fired, and the firing is performed using a laser 137 as shown in FIG.
- the display region 131 is sealed with the sealing material 133, and the sealing material in this state is used as the sealing member (133).
- a substrate in which the EL substrate 11a and the CF substrate 12a are bonded together through a sealing member 133 or the like is referred to as an intermediate panel 138.
- (4) Cutting process The cutting process cuts the periphery of the intermediate panel 138.
- the cut panel is the display panel 10.
- the cutting is performed along the rectangular frame 151 of the sealing member 133 in the intermediate panel 138.
- a cutting means such as a diamond cutter or a laser scriber can be used for cutting, and the reference line at the time of cutting is also called a scribe line.
- FIG. 10 is a view for explaining a dispenser device, (a) is a schematic view, and (b) is a perspective view showing a frit paste after application when the dispenser device moves straight forward. (C) is a perspective view which shows the frit paste after application
- the dispenser device 140 includes a discharge unit 141 that accumulates and discharges the frit paste 130, a measurement unit 142 that measures a distance between the glass substrate 121, and a distance between the discharge unit 141 and the glass substrate 121 based on a measurement result of the measurement unit 142.
- a control unit (not shown) that controls and adjusts the discharge amount of the frit paste 130 from the discharge unit 141.
- the code of the frit paste before application is “130” and the code of the frit paste after application is “145”.
- the discharge unit 141 includes a cylinder 146 that accumulates the frit paste 130 and a nozzle 147 that is provided at the lower end of the cylinder 146 and discharges the frit paste 130.
- the nozzle 147 and the cylinder chamber in the cylinder 146 communicate with each other, and the frit paste 130 is discharged by pressurizing the frit paste 130 in the cylinder chamber.
- the measuring unit 142 measures the distance from the glass substrate 121 located on the front side in the traveling direction of the nozzle 147.
- a laser displacement meter is used for the measurement.
- the measurement result is output to the control unit.
- the control unit controls the height position of the nozzle 147 based on the pressure in the cylinder 146, the moving speed of the discharge unit 141, and the measurement result from the measurement unit 142.
- the height and width of the frit paste 145 applied on the glass substrate 121 are determined by pressure, moving speed, and nozzle height position.
- the controller keeps the distance between the bottom surface 147a of the nozzle 147 and the glass substrate 121 close to a certain extent and keeps it constant, and the cylinder 146
- the internal pressure (which is also the discharge amount of the frit paste 130) is kept constant.
- the height of the applied frit paste 145 is determined by the gap between the nozzle 147 and the glass substrate 121.
- the frit paste 145 applied on the glass substrate 121 becomes a flat shape having a straight shape and a constant height and width. .
- FIG. 11 is a schematic view of the applied frit paste, (a) is a perspective view, and (b) is an enlarged perspective view around a corner portion of a rectangular frame portion.
- the frit paste 130 includes a rectangular frame portion 151 and a plurality of (here, four) reinforcing portions 152, 153, 154, and 155 (hereinafter referred to as “reinforcing portions 152 to 155”). It is applied to have. That is, the applied frit paste 145 has a rectangular frame portion 151 and reinforcing portions 152 to 155. (2-1) Rectangular frame portion
- the rectangular frame portion 151 surrounds a rectangular display region (corresponding to the CF 122) 131 formed with a plurality of light emitting elements, and has a rectangular shape in plan view. .
- the rectangular frame portion 151 is composed of four side portions, and a pair of long side portions 156 and 158 extending along the longitudinal direction in the display region 131 and a pair of short sides extending along the short side direction. Portions 157 and 159. Note that it is not necessary to distinguish between the long side and the short side, and when the long side / short side portions 156, 157, 158, and 159 are represented, they are simply referred to as the side portions 156 to 159. (2-2) Reinforcement portions The reinforcement portions 152 to 155 are provided outside the corner portions 160 to 163 of the rectangular frame portion 151 and continuous with the corner portions 160 to 163.
- the reinforcing portions 152 to 155 protrude outward from the corner portions 160 to 163 of the rectangular frame portion 151.
- the reinforcing portions 152 to 155 have a circular shape such that a part of the reinforcing portions 152 to 155 overlaps corner portions 160 to 163 of the rectangular frame portion 151 (a portion on the base side).
- the reinforcing portions 152 to 155 exist on the extension line E of the bisector of the inner corner of the corner portion of the rectangular frame portion 151.
- the centers of the reinforcing portions 152 to 155 exist on the extended line E of the bisector.
- FIG. 12 is a diagram showing a frit paste coating method, (a) is a diagram showing a state where coating is started, and (b) is a diagram showing a state where one reinforcing portion is formed. (C) is a diagram showing a state where the application of the frit paste is completed.
- the application method here is an example, and the application method of the frit paste 145 having the rectangular frame portion 151 and the reinforcing portions 152 to 155 is not limited to this example.
- the position F at which application is started is the intersection (corner portion 163) of the portion where the long side portion 156 is to be formed and the portion where the short side portion 159 is to be formed.
- Application is started from the position F, and the frit paste 130 is applied linearly on the boundary line 131a of the display area 131 along the boundary line 131a to form (place) the long side portion 156.
- the moving direction is changed by 90 degrees, and the stretched portion is stretched as it is, and finally the reinforcing portion 152 is formed (arranged). To do.
- FIG. 12B shows a state in which the reinforcing portion 153 is formed at the corner portion 161.
- each of the reinforcing portions 152 to 155 moves the dispenser device 140 to the position where the reinforcing portion is to be formed, and rotates and moves the frit paste 130 (or rotates and moves the frit paste 130). It is formed by discharging.
- the dispenser device 140 is moved to the next reinforcing portion forming scheduled position, and the other reinforcing portions 152 to 154 are formed. As shown in c), the application of the frit paste 145 to the glass substrate 121 is completed.
- FIG. 13 is a diagram illustrating the cutting process.
- the peripheral portion of the intermediate panel 138 is cut as shown in FIG.
- FIG. 13 a plan view of the intermediate panel 138 is shown, and the sealing member 133 is originally not visible, but is shown by a solid thick line for convenience of explanation.
- the same reference numerals as the rectangular frame portion 151 and the reinforcing portions 152 to 155 of the frit paste 145 are used for the rectangular frame portion and the reinforcing portion of the sealing member 133 after the frit paste 145 is fired.
- the peripheral portions 138a to 138d of the intermediate panel 138 are cut off.
- the size after the peripheral portions 138a to 138d are cut off is the same as the size of the display panel 10.
- the cutting is performed by scribe lines G1, G2, G3 extending parallel to the side portions 156 to 159 constituting the rectangular frame portion 151 of the sealing member 133 in parallel at a predetermined interval. This is performed along G4 (hereinafter represented by scribe lines G1 to G4).
- the interval between the scribe lines G1 to G4 and the side portion is an interval where a part of the reinforcing portions 152 to 155 remains. That is, the scribe lines G1 to G4 pass over the reinforcing portions 152 to 155, and a diamond cutter, a laser scraper, or the like crosses the reinforcing portions 152 to 155.
- the size of the reinforcing portion and the positions of the scribe lines G1 to G4 are determined so that the intersections of the scribe lines G1 to G4 are formed inside the reinforcing portions 152 to 155. Note that the order of cutting along the scribe lines G1 to G4 is not particularly limited. 5. About strain distribution The strain in a sealing member is demonstrated using FIG.
- FIG. 22 is a plan view of an intermediate panel before cutting according to the prior art, (a) is a view when the radius of a corner portion of a sealing member arranged in a rectangular shape is increased, and (b) is a sealed view. It is a figure at the time of making the radius of the corner
- Sealing members 905 and 911 in the figure are arranged between the EL substrate and the CF substrate and should be indicated by broken lines, but stress and residual strain generated in the sealing members 905 and 911 and their surroundings.
- the sealing members 905 and 911 are indicated by solid lines in order to explain the generation region of the above.
- the arrows pointing inward and outward of the sealing members 905 and 911 arranged in a rectangular shape in the figure indicate the residual stress generated in the substrate when the sealing members 905 and 911 are fired.
- the residual stress shown in the figure is a tensile stress that is pulled in the direction of the arrow.
- regions 909 and 915 surrounded by ellipses and circles indicate regions where residual strain is generated.
- the display area 903 has a rectangular shape.
- the sealing member 905 is disposed in a rectangular shape along the display region 903, and the corner portion has an arc shape with a large radius as shown in FIG.
- portions corresponding to corner portions of the display region 903 are corner portions 907 and 913.
- the corner portion 907 is formed in an arc shape and the radius of curvature is increased because the substrate is cracked when the peripheral portions of the two bonded substrates are cut by the residual stress when the sealing member 905 is fired (production efficiency is increased). This is to prevent (decrease).
- ⁇ ⁇ ⁇ Glass breaks when a force greater than the bonding force between the atoms constituting the glass material is applied.
- glass materials are resistant to compressive stress and weak against tensile stress.
- a physical external force is applied to the substrate surface with a tensile stress applied to the glass substrate, a moment of force is generated centering on the crack, the external force is concentrated on the crack and the crack is spread, and the crack expands. And the crack of a glass substrate is confirmed on a visual level.
- the tensile stress indicated by the arrow in the figure acts as a residual stress on the glass substrate.
- the tensile stress acts in one direction perpendicular to the side portion 908 as shown in FIG.
- the technique for disposing the sealing member 905 in an arc shape having a large radius with respect to the corner portion of the display area 903 described above cannot meet the demand for narrowing. That is, in the prior art, when the radius of the corner portion (913) of the sealing member (911) is reduced as shown in FIG. 22 (b) in order to meet the demand for narrowing, residual strain is generated.
- the scribe lines F1 to F4 cross the region 915, and there is a possibility that the region 915 may be broken when the peripheral portion of the intermediate panel 910 is cut.
- FIG. 14 shows the relationship between the distortion occurrence position and the scribe line
- (a) is the intermediate panel according to the present embodiment
- (b) is the intermediate panel according to the prior art
- (c ) Is an enlarged view of the common side of (a) and (b)
- (d) is an enlarged view of the corner of (a)
- (e) is an enlarged view of the corner of (b). It is a figure to do.
- FIG. 14 shows a plan view of the intermediate panels 138 and 910, and the sealing members 133 and 911 are originally not visible, but are shown by solid lines for convenience of explanation.
- the arrow in a figure has shown the direction of the residual stress similarly to the arrow shown by FIG.
- the tensile stress acting perpendicular to the side portion 914 intersects. Therefore, torsional stress is easily generated by tensile stress in two directions, and stress is likely to be concentrated. Thereby, a larger tensile stress is generated in the region 915 outside the corner portion 913. In addition, since the stress collects inward at the corner portion 913, it becomes a compressive stress and a torsional stress is hardly generated.
- the reinforcing portions 152 to 155 having a circular shape in plan view are formed into corner portions 160 to 163 where residual stress tends to concentrate. Therefore, stress (strain) is generated in the regions 164 to 167 outside the reinforcing portions 152 to 155.
- These reinforcing portions 152 to 155 are formed so as to protrude outside the corner portions 160 to 163 of the rectangular frame portion 151, and the shape in plan view has a circular shape with a certain degree of curvature. Therefore, in the regions 164 to 167 around the reinforcing portions 152 to 155, as shown in FIG. 14D, the residual stress is dispersed, and the magnitude of the stress per unit area is reduced.
- the sealing member 911 has a rectangular shape and has a corner portion 913 close to a right angle. Therefore, the shape change at the corner portion 913 is abrupt, and the region 164 outside the reinforcing portions 152 to 155 in this embodiment is formed in the region 915 outside the corner portion 913 as shown in FIG. A residual strain larger than the strain generated in 167 will be generated.
- (2) Scribe lines The scribe lines G1 to G4 in the intermediate panel 138 according to the embodiment cross the reinforcing portions 152 to 155 as shown in FIG. In this case, as shown in FIG. 14D, the scribe lines G1 to G4 pass through the regions 164 to 167 outside the reinforcing portions 152 to 155 where the residual strain is generated, and the residual strain is passed. The crack of the intermediate panel 138 can be eliminated.
- the intermediate panel 138 since the residual strain itself is smaller than the residual strain generated in the corner portion 913 in the intermediate panel 910 of the prior art, the intermediate panel can be further prevented from cracking.
- the scribe lines H1 to H4 in the intermediate panel 910 cross the region 915 that is outside the corner portion 913 and in which residual strain is generated, as shown in FIG. . For this reason, the intermediate panel 910 is easily cracked due to residual strain.
- the residual strain itself is larger than the residual strain generated by being dispersed in the region 164 outside the reinforcing portion 152 in the intermediate panel 138 of the present embodiment, and thus is more easily broken. . 6).
- the case where one display panel 10 is manufactured from one intermediate panel 138 has been described.
- a plurality of display panels 10 are manufactured from a large intermediate panel having a plurality of intermediate panels (so-called multiple panels).
- the above example can also be applied to chamfering).
- multi-chamfering is described.
- FIG. 15 is a diagram illustrating the application of frit paste when the display panel is multi-faceted.
- the large plate 171 is a glass substrate having four display areas 173, 174, 175, and 176, as shown in FIG. Note that the four display areas are arranged in a matrix (here, 2 rows and 2 columns), and when there is no need to distinguish each display area, the display areas are represented as display areas 173 to 176.
- frit pastes 177 to 180 are applied to the display areas 173 to 176.
- the frit pastes 177 to 180 are applied so as to form a rectangular frame portion that surrounds the display regions 173 to 176 and a reinforcing portion that is disposed outside the corner portion of the rectangular frame portion.
- the cutting step of cutting four intermediate panels from a large intermediate plate formed by bonding CF to the large plate 171 and bonding a large EL substrate having pixels formed in the four display areas is the above-mentioned one step. Similar to chamfering, it is performed by cutting through each reinforcing part of each intermediate panel.
- both the EL substrate and the CF substrate are cut with the same dimensions. That is, the EL substrate is cut so that the cut surface (side surface) of the EL substrate and the cut surface (side surface) of the CF substrate coincide with each other in plan view.
- FIG. 16 is a diagram illustrating an example of a display panel having different substrate dimensions according to the second embodiment, (a) a plan view of the display panel, and (b) an enlarged perspective view of a corner of the intermediate panel.
- FIG. (1) Overall In the display panel 300, the display region 302 is sealed with a sealing member 305 in a state where the EL substrate 301 and the CF substrate 303 are bonded together.
- the sealing member 305 includes a rectangular frame portion 307 and four reinforcing portions 309 as indicated by broken lines in the drawing. The reinforcing portion 309 protrudes from the corner portion of the rectangular frame portion 307 to the outside of the rectangular frame portion 307.
- the EL substrate 301 and the CF substrate 303 have a rectangular shape in plan view, and at each corner, as shown in FIG. 16B, the side surface 309a of the reinforcing portion 309, the side surface 301a of the EL substrate 301, and the CF
- the substrate 303 is cut so that the side surface 303a is flush with the surface. That is, the reinforcing portion 309 has a side surface 309 a that is cut so as to be flush with both the side surfaces 301 a and 303 a of the side surface 301 a at the corner of the EL substrate 301 and the side surface 303 a at the corner of the CF substrate 303.
- the term “equal” refers to a state in which at least two surfaces are included in the same virtual surface.
- the reinforcing portion 309 has not only the side surface 309a but also side surfaces that coincide with the side surfaces of the corners of the EL substrate 310 and the side surfaces 303b to 303h of the corners of the CF substrate 303 as shown in FIG. Yes.
- the EL substrate 301 has a rectangular shape composed of four side surfaces J1 to J4 in plan view.
- the overall shape of the CF substrate 303 in a plan view is a rectangular shape, and the side surfaces I1 to I4 of at least a part of the side surface of the CF substrate 303 (a portion between two corners adjacent to the outer periphery of the rectangular shape) In plan view, it is located on the inner side (in other words, on the center side of the CF substrate 303) than the extension lines of the side surfaces 303a to 303h at the corners of the CF substrate 303.
- the side surfaces I1 to I4 sandwiched between the corners are recessed closer to the center of the CF substrate 303 than the side surfaces of the EL substrate 301 and the side surfaces 303a to 303h of the CF substrate 303 in the reinforcing portion 309.
- the side surfaces I1 to I4 of at least a part of the CF substrate 303 are more than the side surfaces J1 to J4 of the EL substrate 301 in plan view. Located on the center side of the CF substrate 303 and the EL substrate 301.
- An electrode 311 for electrical connection with the outside is formed on the surface of the EL substrate 301 facing the CF substrate 303 and outside the rectangular frame portion 307 of the sealing member 305. Since the two corners adjacent to each other in the circumferential direction are recessed on the center side of the CF substrate 303, the electrode 311 is exposed.
- (2) Shape of CF Substrate As shown in FIG. 16, the CF substrate 303 has side surfaces 303 i to 303 p that extend toward the display region 302 outside the rectangular frame portion 307 of the sealing member 305 at the corners. Have.
- a scribe line toward the display area of the display panel is not formed, and the CF substrate or the EL substrate is not cut along the scribe line.
- a crack along the direction in which the scribe flaw is drawn is likely to occur in the substrate.
- the CF substrate 303 is cut by using a diamond cutter, a laser scriber, or the like without using a conventional diamond scriber, so that a crack is generated in the substrate when a scribe flaw is formed. That is restrained.
- the CF substrate 303 having the side surfaces 303i to 303p facing the display region 302 in the second embodiment can be cut, and a thin substrate can be dealt with.
- Fixing member In order to bond the EL substrate 301 and the CF substrate 303 more stably, a fixing member for fixing the EL substrate 301 and the CF substrate 303 may be used.
- the fixing member is used in a manufacturing process such as when the resin material 136 disposed between the EL substrate 301 and the CF substrate 303 is cured, or is attached to the display panel 300 together with the display panel 300. It is housed in the housing of the display device.
- FIG. 17 is a view showing a state where an EL substrate and a CF substrate are bonded together using a fixing member
- FIG. 17A is a case where the display panel according to the second embodiment is used
- FIG. ) Is an enlarged view of the X1-X2 cross section of (a) as viewed from the direction of the arrow
- (c) is a case where a display panel according to the prior art is used
- (d) is X3-X4 of (c). It is the cross-sectional enlarged view which looked at the cross section of this from the arrow direction.
- FIGS. 17A and 17C are front views of each display panel, and a part of the fixing member is cut away.
- a frame-shaped frame body 315 is used as the fixing member in this example.
- the frame body 315 is composed of two members obtained by dividing the frame shape into at least two parts in plan view so that the frame body 315 can be mounted on the four sides of the rectangular display panel 300.
- the frame 315 includes a pair of plate portions 315a extending along the front and back surfaces of the display panel 300 with an interval corresponding to the thickness of the display panel. 315b and a connecting portion 315c that connects the ends of one end side (outside of the display panel 300) of the pair of plate portions 315a and 315b.
- the cross-sectional shape of the frame body 315 has a “U” shape in which an opening portion is present on the display panel 300 side.
- the pair of plate portions 315a and 315b is made of an elastically deformable material. Further, the distance between the pair of plate portions 315a and 315b becomes narrower as it moves to the other end side (the center side of the display panel 300). Thus, when the peripheral portion of the display panel 300 fits between the pair of plate portions 315a and 315b, a load in the thickness direction acts on the EL substrate 301 and the CF substrate 303, and the bonded state of both is maintained.
- FIG. 17C when the state in which the CF substrate 921 is positioned above the EL substrate 923 is viewed in plan, the CF substrate 921 is smaller than the EL substrate 923. .
- the plate portion 315b on the substrate 923 side is positioned on a straight line.
- the peripheral edge portion of the EL substrate 923 projects outward from the sealing member 913.
- the peripheral portion of the EL substrate 923 is curved. Due to this deformation, the CF substrate 921 and the sealing member 913 or the EL substrate 923 and the sealing member 913 may be peeled off.
- the frame body 315 is attached to the display panel 300 according to the second embodiment.
- the CF substrate 303 and the EL substrate 301 are cut in the same size and shape at the corners, and the reinforcing portion 309 of the sealing member 305 exists between the CF substrate 303 and the EL substrate 301. ing.
- the plate portion 315a on the CF substrate 303 side, the CF substrate 303, the reinforcing portion 309, the EL substrate 301, and the plate portion 315b on the EL substrate 301 side are positioned on a straight line. For this reason, even if the display panel 300 is held between the pair of plate portions 315a and 315b with a strong force, the load is applied to the corner portions, so that the EL substrate 301 is located at the center of each side of the EL substrate 301 or the CF substrate 303. In addition, the bending of the CF substrate 303 can be reduced. Therefore, the bending and deformation of the CF substrate 303 and the EL substrate 301 can be suppressed, and as a result, peeling between the CF substrate 303 and the EL substrate 301 can be prevented.
- the reinforcing portion 309 fixes the CF substrate 303, and the CF substrate 303 is further difficult to deform, so that the spread of the crack can be suppressed.
- the reinforcing portion 309 of the sealing member 305 exists in a wide area of the EL substrate 301 and the CF substrate 303, and a bending load is hardly applied to the peripheral portion of the EL substrate 301 or the CF substrate 303. . Therefore, there is little possibility that the CF substrate 303 and the reinforcing portion 309 or the EL substrate 301 and the reinforcing portion 309 are peeled off.
- the reinforcing portions 309 are formed only at the corners of the display panel 300, but may be formed at other portions. An example in which reinforcing portions are formed in other parts will be described below as a modification of the second embodiment.
- FIG. 18 is a figure which shows the modification concerning 2nd Embodiment.
- the sealing member 324 includes a rectangular frame portion 325 provided along the central display region 326, a corner reinforcing portion 327a provided at a corner portion of the display panel 320, and an intermediate portion provided in an intermediate region between the corner portions. And a reinforcing portion 327b.
- the corner reinforcing part 327a has the same configuration as the reinforcing part 309 in the second embodiment.
- the intermediate reinforcing portion 327b can be implemented by applying the sealing material so as to protrude outside the display region 326 at the center of the side portion corresponding to the rectangular frame portion 325 in the application step of the sealing material (frit paste).
- the intermediate reinforcing portion 327b may be positioned outside the display area 326 and outside the rectangular frame portion 325, and the shape thereof is not particularly limited.
- an elliptical shape is used, but a polygonal shape such as a circular shape, an oval shape, or a rectangular shape may be used.
- the CF substrate 323 has a rectangular shape as a whole, and has recessed portions 322a to 322h and 322i to 322p on each side.
- the CF substrate 323 has a shape along the sealing member 324. That is, the corner portions 324a to 324d corresponding to the corner reinforcing portion 327a and the intermediate portions 324e to 324h corresponding to the intermediate reinforcing portion 327b protrude outward from the portion corresponding to the rectangular frame portion 325.
- the recessed portions on each side may have a shape in which the side surfaces are linearly recessed, such as recessed portions 322a to 322h shown in FIG. 18 (a), or the recessed portions shown in FIG. 18 (b). It may have a shape in which the side surface is curvedly recessed as in the insertion portions 322i to 322p.
- the EL substrate 321 has an electrode 329 on the surface facing the CF substrate 323 and corresponding to the recessed portions 322a to 322h and 322i to 322p of the CF substrate 323.
- the intermediate portions 324e to 324h of the CF substrate 323 are joined to the EL substrate 321 via the intermediate reinforcing portion 327b. Accordingly, the EL substrate 321 and the CF substrate 323 can be fixed by the fixing member (for example, the frame body 315) not only in the corner portion of the display panel 320 but also in an intermediate region between the corner portions. At this time, by providing the intermediate reinforcing portion 327b, for example, the deformation of the substrate between the corner portions of the EL substrate 321 and the CF substrate 323 can be reduced.
- the intermediate portions 324e to 324h are located at the approximate center between the corners of the CF substrate 321, but may be located at other positions, or may be provided in a plurality instead of one on each side.
- the installation location may be determined as appropriate depending on the design of the display panel 320 or the arrangement of wirings or electrodes drawn from the display area (display portion) 326. 2. Multi-chamfering A case where the above-described display panel is multi-chasped from the large intermediate panel 339 will be described.
- FIG. 19 is an explanatory diagram of a large intermediate panel when the display panel is multi-faceted.
- FIG. 19 although it is the figure which planarly viewed the large sized intermediate
- the large-size intermediate panel 331 includes a large-size EL substrate and a large-size CF substrate bonded together, and a plurality (four in this case) of display areas are provided between the substrates. 331, 333, 335, and 337 (represented as display areas 331 to 337 when there is no need to distinguish each display area).
- the display areas 331 to 337 are sealed by sealing members 341, 343, 345, and 347 arranged around the display regions 331 (represented as sealing members 341 to 347 when there is no need to distinguish each sealing member). It has been stopped. Note that the four display areas are arranged in a matrix (here, 2 rows and 2 columns).
- the sealing members 341 to 347 include a rectangular frame portion that surrounds the display areas 331 to 337 and a reinforcing portion that is disposed outside the corner portion of the rectangular frame portion.
- FIGS. 20A and 20B are diagrams for explaining the cut-off of the display panel from the large-size intermediate panel.
- FIGS. 20A and 20B are views of the large-size intermediate panel viewed from the CF substrate side, and FIG. It is the figure which looked at the intermediate panel from the EL substrate side.
- FIG. 20 is a plan view of the large intermediate panel, it is shown by a solid line without using wavy lines so that the internal display region, sealing member, electrode position, and the like can be understood.
- a laser is used for cutting the display panel. That is, the large intermediate panel is cut with a laser scriber while adjusting the power.
- the cutting step here includes an EL outer periphery cutting step of cutting the EL substrate 351 along the outer periphery of each of the sealing members 341 to 347 formed in a rectangular shape in plan view and passing through the reinforcing portion, and a rectangular shape in plan view
- a CF corner cutting step of cutting the CF substrate 353 in a recessed manner between the portions
- the order of said each process is not specifically limited, Said order may be sufficient and the following order may be sufficient.
- (1) CF outer periphery scribing step In the CF outer periphery scribing step, as shown in FIG. 20A, sealing is performed so as to pass through the reinforcing portions of the sealing members 341 to 347 arranged around the display regions 331 to 337.
- the periphery of the rectangular frame portions of the stop members 341 to 347 is cut (the cut surface of the reinforcing portion corresponds to the “second side surface” of the present invention).
- the CF substrate 353 is scribed with scribe lines (for example, K1 to K6) extending linearly in the left-right (row direction) and vertical direction (column direction) along the display areas adjacent in a matrix. Scribe flaws are formed on the surface.
- CF corner scribing step In the CF corner cutting step, as shown in FIG. 20B, the CF substrate 353 is moved along the sides of the sealing members 341 to 347 arranged in the rectangular shape on the CF substrate 353. Disconnect.
- scribe scratches are formed on the surface of the CF substrate 353 with the elliptical scribe lines L1 to L4 so as to straddle two display panels adjacent in the row direction and the column direction.
- scribe scratches are formed on the surface of the CF substrate with the scribe lines L5 to L8 having an oval half shape.
- the CF outer periphery scribing step is performed so as to pass through the reinforcing portions of the sealing members 341 to 347 arranged around the display regions 331 to 337 as shown in FIG.
- the periphery of the rectangular frame portions of the stop members 341 to 347 is cut (the cut surface of the reinforcing portion corresponds to the “first side surface” of the present invention).
- the EL substrate 351 is scribed with scribe lines (for example, M1 to M6) extending linearly in the left and right (row direction) and up and down directions (column direction) along the display areas adjacent in a matrix. Scribe flaws are formed on the surface.
- the reinforcing part is easily cleaved on the same line.
- Manufacturing Method (1) Paste-Applied Substrate the frit paste 130 is applied to the glass substrate 121 for the CF substrate, but the frit paste 130 may be applied to the substrate for the EL substrate. good. In this case, an EL (light emitting element) may be formed after the frit integration step.
- a dispenser method using a nozzle is used as a method for applying the frit paste 130.
- a screen printing method using a screen mask may be used.
- Frit integration step In the frit integration step, the frit glass and the glass substrate 121 in the frit paste 145 are welded using the laser 132, but may be welded by other methods.
- the sealing material and the substrate can be integrated by placing a glass substrate with frit paste in a heating furnace and heating it to a temperature at which the frit glass (sealing material) melts. it can.
- CF formation process The CF formation process is performed after the frit integration process.
- the heating in the frit integration step is performed by the laser 132, the portion to be heated in the glass substrate is small, and the influence of heat on the CF 122a can be reduced.
- the CF forming step can be performed before the frit integration step performed using a laser, or can be performed before the frit paste 145 application step.
- the CF process may be performed in the order of a CF forming process, a frit paste application process, and a frit integration process, or a frit paste application process and a CF formation process. You may perform in order of a process and a frit integration process.
- the reinforcing parts 152 to 155 and 309 are formed outside the rectangular frame parts 151 and 307 in a state where the reinforcing parts 152 to 155 and 309 are connected to the corners of the rectangular frame parts 151 and 307.
- the plan view shapes of 155 and 309 are circular, but may be other shapes.
- the reinforcing portions 152 to 155 and 309 have a circular shape and the inside thereof is filled with frit paste.
- the reinforcing portion is continuous with the corner portion of the rectangular frame portion, and the rectangular frame portion It suffices if the frit paste is filled inside the reinforcing portion, and there is no particular relationship.
- FIG. 21 is a diagram showing other examples 1 to 3 of the reinforcing portion, (a) is a diagram showing the reinforcing portion according to example 1, and (b) is a diagram showing the reinforcing portion according to example 2. (C) is a figure which shows the reinforcement part which concerns on Example 3.
- the reinforcing part 501 is formed so as to straddle the side part 507 and the side part 509 constituting the corner part 505 of the rectangular frame part 503. In other words, it is formed so as to be curved in an annular shape from one side portion (for example, the side portion 507) constituting the corner portion 505 and connected to the other side portion (for example, the side portion 509). Has been.
- Example 2 The reinforcing portion 501 in Example 1 extends in an annular shape from the two side portions (507, 509) constituting the corner portion (505), but may extend in another shape, for example, a polygonal shape. A case where the rectangular shape is extended will be described as Example 2.
- the reinforcing portion 511 according to the second example is connected to two side portions 517 and 519 which are outside the corner portion 515 of the rectangular frame portion 513 and constitute the corner portion 515. It is formed in a state.
- the reinforcing portion 511 has a square shape in plan view, and after extending so as to form a square shape by extending from one side portion 517 of the two side portions constituting the corner portion (515), Connect to the other side portion 519.
- the square shape here has rounded corners.
- Example 3 As shown in FIG. 21C, the reinforcing portion 521 according to the example 3 is formed outside the corner portion 525 of the rectangular frame portion 523 and continuously to the corner portion 525.
- the reinforcing portion 521 is formed in an angle shape in plan view.
- the reinforcing portion 521 includes connection portions 521a and 521b connected to two side portions (527 and 529) constituting the corner portion 525 of the rectangular frame portion 523, and a curved portion 521c that is curved in an arc shape along the corner portion 525. have.
- the frit paste of the reinforcing portion 521 is once turned from the end of the side portion 527 constituting the corner portion 525 to the center side of the side portion 527 and to the outside of the side portion 527, and then , Linearly extending along the rectangular frame portion 523, and when reaching the corner portion 525 of the rectangular frame portion 523, it curves in an arc along the corner portion 525 and extends along the other side portion 529. It is applied by stretching (moving) so as to turn back toward the end of the side portion 529.
- the ends of the two side portions 517 and 519 constituting the corner portion 515 may be connected to each other, or as shown in FIG. 21C. May be.
- Position The center (for example, 152a) of the reinforcing portions 152 to 155 in the embodiment is a bisector of the inner angle of the corner portion of the rectangular frame portion 151 as shown in FIG. Exists on the extension line E. This is because, when the center of the reinforcing portion is arranged on a bisector, the largest region (“164” to “167” in FIG. 14) of the residual strain generated outside the reinforcing portion is the scribe line. (It is “G1” to “G4” in FIG. 14A). This is because they are off the top, and damage to the intermediate panel 138 in the cutting process can be prevented.
- the position of the reinforcing portion may be in a state where the region of the maximum residual strain generated outside the reinforcing portion does not exist on the scribe line, and the central position of the reinforcing portion may not exist on the bisector. .
- the four reinforcing portions 152 to 155 have the same shape, size, and the like, but they may not all have the same shape and size.
- the reinforcing portions on the diagonal line of the rectangular frame portion have the same shape and size, and the shape and size may be changed in units of diagonal lines.
- the shape and size of the reinforcing part may be all different. However, it is necessary to have such a size that the reinforcing portion exists on the scribe line. 3.
- Rectangular frame portion In the rectangular frame portion 151 in the embodiment, the inside of the corner portion is formed on the circular arc, but the inside of the corner portion may be formed at a substantially right angle as in Example 2 above, or the above example As shown in FIG. 3, the two side portions constituting the corner portion may not be connected.
- the present invention can be widely used to apply a paste to the first substrate.
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Abstract
Description
実施形態に係る表示パネルは、第1基板と、前記第1基板と対向して配置された第2基板と、前記第1基板と前記2基板との間に配された複数のEL素子と、前記第1基板と前記第2基板との間に設けられ前記複数のEL素子を封止する封止部材とを有し、前記封止部材は、前記複数のEL素子の周囲に沿って形成された矩形枠部と前記矩形枠部の角部分において外側に突出した補強部とを有し、当該補強部は、前記第1基板の角部における少なくとも一方の側面と面一となる状態で切断された第1側面と、前記第2基板の角部における前記少なくとも一方の側面が存在する側の側面と面一となる状態で切断された第2側面を有し、前記第1側面と前記第2側面とが同一面に含まれる。
[実施形態]
以下、本発明の実施形態に係る表示パネル及びその製造方法について図面を参照しながら説明する。なお、実施形態では、本発明で使用している、材料、数値は好ましい例を例示しているだけであり、この形態に限定されることはない。また、本発明の技術的思想の範囲を逸脱しない範囲で、適宜変更は可能である。また、他の実施形態との組み合わせは、矛盾が生じない範囲で可能である。
[第1の実施形態]
1.構成
(1)全体構成
図1は、第1の実施形態の表示パネル10の要部を模式的に示す部分断面図である。
(2)EL基板
EL基板11は、基板、層間絶縁膜、陽極、バンク、発光層等からなる。
(3)CF基板
図5はCF基板の平面図であり、図6は図5のC1-C2の断面を矢印方向から見た図であり、図7は図5のD1-D2の断面を矢印方向から見た図である。
(4)外周部
表示パネル10は、その周辺部にシール材134と封止部材133とが設けられている。具体的には、シール材134及び封止部材133は、表示領域131の外周を囲繞するように設けられ、シール材134の外側に封止部材133が位置する。シール材134は、貼り合わせたEL基板11とCF基板12との内部を封止するためのものである。
2.製造方法
表示パネル10の製造方法に一例は、EL基板11aを準備するEL準備工程(1)と、封止材料が塗布されたCF基板12aを準備するCF準備工程(2)と、準備されたEL基板11aとCF基板12aとを貼り合せて接合する接合工程(3)と、接合された中間パネル138の周囲を切断する切断工程(4)とを経て製造される。なお、ここでは、封止材料を含有するペーストを利用する。具体的には、封止材料としてフリットガラスであり、ペーストはフリットペーストである。
(1)EL準備工程
EL準備工程では、EL基板11aを準備する。具体的には、基板に発光素子31(EL30aである。)を形成する工程である。この工程は、従来と同じ公知技術で発光素子を形成できるため、ここでの説明は割愛する。なお、表示パネル10のEL基板11は、EL基板11aの周辺部(不要部)を切り落としたものである。
(2)CF工程
CF準備工程では、基板にフリットペーストを塗布する塗布工程と、塗布されたフリットペースト(正確にはフリットペーストに含有されているフリットガラスである。)と基板とを一体化させる一体化工程と、基板にCF122aを形成するCF形成工程とを含む。ここでの基板にCF122aが形成されたものがCF基板12aである。表示パネル10のCF基板12は、CF基板12aの周辺部(不要部)を切り落としたものである。
(a)塗布工程
塗布工程では、図8の(a)で示すようなガラス基板121を準備し、図8の(b)に示すように当該ガラス基板121の上面にフリットペースト130を塗布する。
(b)CF一体化工程
CF一体化工程は、フリットペースト145に含まれる溶媒を消失させる乾燥工程と、フリットペースト145に含まれるバインダ等を消失させる焼成工程とをこの順で行う。
(c)CF形成工程
CF形成工程は、封止材料133が形成されたガラス基板121の表示領域131に対してCF122aを形成する。この工程は、従来と同じ公知技術を利用しているため、ここでの説明は割愛する。これによりCF基板12aが完成する。
(3)接合工程
接合工程では、CF基板12aに対してシール材を塗布とするシール材塗布工程と、CF基板12aのCF122aに対して封止用の樹脂材料を塗布する樹脂材料塗布工程と、シール材及び封止用の樹脂材料が塗布されたCF基板12aとEL基板11aとを貼り合わせる貼合工程と、貼り合わされたEL基板11aとCF基板12aとを減圧状態にする減圧工程と、樹脂材料を硬化させる樹脂硬化工程と、EL基板11aと封止材料133とを一体化するEL一体化工程とを含む。
(a)塗布工程
シール材塗布工程では、平面視において長方形の環状に形成された封止材料133に沿って、封止材料133の内側と外側とにシール材135a,135bを塗布する。ここで、外側のシール材135aは、主に樹脂硬化工程やEL一体化工程中に外部から表示領域に水分や酸素等の侵入を防止する機能を有している。内側のシール材135bは、主に封止用の樹脂材料136が焼成前の封止材料133とEL基板11との間に侵入して密着不良を起こすのを防止する機能を有する。
(b)貼合工程
貼合工程では、図9の(a)、(b)に示すように、上記塗布工程を終えたCF基板12aと、EL準備工程で準備されたEL基板11aとを、EL基板11aのEL30aとCF基板12aのCF122aとが対向するように、貼り合わせる。
(c)減圧工程
減圧工程では、貼り合わせ状態で減圧する。この減圧により、樹脂材料中のエア(空気)、シール材135とCF基板12aとの接触面に介在しているエア、フリットペースト130を焼成した際に発生したガス等を抜き取る(脱泡する)。なお、脱泡効果を高めるために、EL基板11aとCF基板12aとを貼り合わせる前に、CF基板12aのみを減圧状態下に置いても良い。
(d)樹脂硬化工程
樹脂硬化工程では、EL基板11aとCF基板12aとの間に介在する樹脂材料136を硬化させる。ここでの硬化方法は、図9の(c)に示すように、熱と紫外線とを利用して行う。なお、樹脂材料が硬化したものが封止樹脂139である。
(e)EL一体化工程
EL一体工程は、封止材料133を溶融させて、溶融した封止材料133とEL基板11aとを一体化させる。具体的には、封止材料133を焼成することで行われ、焼成は、図9の(d)に示すように、レーザ137を用いて行われる。
(4)切断工程
切断工程は、中間パネル138の周辺部を切断する。なお、切断後のものが表示パネル10である。切断は、中間パネル138における封止部材133の矩形枠部151に沿って切断する。なお、切断には、ダイヤモンドカッタやレーザスクライバ等の切断手段を利用することができ、切断時の基準線をスクライブ線ともいう。
3.塗布工程
塗布工程について詳細に説明する。
(1)ディスペンサ装置
図10は、ディスペンサ装置を説明する図であり、(a)は概略図であり、(b)はディスペンサ装置が直進移動した場合の塗布後のフリットペーストを示す斜視図であり、(c)はディスペンサ装置が回転移動した場合の塗布後のフリットペーストを示す斜視図である。
(2)フリットペーストの塗布形状
図11は、塗布されたフリットペーストの概略図であり、(a)は斜視図であり、(b)は矩形枠部の角部分周辺の拡大斜視図である。
(2-1)矩形枠部
矩形枠部151は、複数の発光素子が形成されてなる矩形状の表示領域(CF122に対応している。)131を囲繞し、平面視矩形状をしている。矩形枠部151は、構成としては、4つの辺部分からなり、表示領域131に長手方向に沿って延伸する一対の長辺部分156,158と、短手方向に沿って延伸する一対の短辺部分157,159とを有する。なお、長辺・短辺を区別する必要がなく長辺・短辺部分156,157,158,159を表す際には、単に、辺部分156~159とする。
(2-2)補強部
補強部152~155は、矩形枠部151の角部分160~163の外側であって角部分160~163に連続する状態で設けられている。換言すると、補強部152~155は、矩形枠部151の角部分160~163から外側へと突出する。補強部152~155は、平面視形状は、一部(付け根側部分である。)が矩形枠部151の角部分160~163が重なるような円形状をしている。
(3)塗布方法
図12は、フリットペーストの塗布方法を示す図であり、(a)は塗布を開始した状態を示す図であり、(b)は1つの補強部を形成した状態を示す図であり、(c)はフリットペーストの塗布を完了した状態を示す図である。
4.切断工程
図13は、切断工程を説明する図である。
5.ひずみ分布について
封止部材中のひずみについて、図22を用いて説明する。
(1)残留ひずみ
図14の(b)に示すように、封止部材911の矩形枠部を構成する辺部分914では、図14の(c)に示すように、辺部分914を挟んで当該辺部分914に向かって応力が発生している。このため、互いの応力が打ち消し合うことになり、大きな残留応力が発生するような領域は存在せず、残留ひずみは発生し難い。
(2)スクライブ線
実施形態に係る中間パネル138におけるスクライブ線G1~G4は、図14の(a)に示すように、補強部152~155を横断する。この場合、図14の(d)に示すように、補強部152~155の外側であって残留ひずみが発生している領域164~167を避けてスクライブ線G1~G4が通ることとなり、残留ひずみによる中間パネル138の割れをなくすることができる。
6.多面取り
上記の例では、1つの中間パネル138から1つの表示パネル10を製造する場合を説明したが、中間パネルを複数有する大版中間パネルから複数の表示パネル10を製造する場合(所謂、多面取りである。)にも上記の例を適用できる。以下、多面取りの例について説明する。
<第2の実施形態>
第1の実施形態では、図13に示すように、EL基板及びCF基板とも同じ寸法で切断されている。つまり、EL基板の切断面(側面)とCF基板の切断面(側面)とが平面視において全周に亘って一致するように切断されている。
1.一面取り
図16は、第2の実施形態に係る基板の寸法の異なる表示パネルの例を示す図であり、(a)表示パネルの平面図であり、(b)は中間パネルの角の拡大斜視図である。
(1)全体
表示パネル300は、EL基板301とCF基板303とが貼り合わせられた状態で、表示領域302が封止部材305により封止されている。封止部材305は、図中の破線で示すように、矩形枠部307と4つの補強部309とを有する。補強部309は、矩形枠部307の角部分から矩形枠部307の外側に張り出している。
(2)CF基板の形状
CF基板303は、図16に示すように、角部において、封止部材305の矩形枠部307の外側であって表示領域302に向かって延伸する側面303i~303pを有する。
(3)固定部材
EL基板301とCF基板303とをより安定して貼り合わせておくために、EL基板301とCF基板303とを固定する固定部材を用いることがある。この固定部材は、例えば、EL基板301とCF基板303の間に配された樹脂材料136を硬化する際等の製造過程で使用されたり、表示パネル300に装着された状態で、表示パネル300と共に表示装置の筐体内に収容されたりする。
(4)その他
第2の実施形態では、補強部309は表示パネル300の角部にのみ形成されていたが、他の部位に形成されていても良い。他の部位に補強部が形成されている例を第2の実施形態の変形例として、以下説明する。
2.多面取り
上記の表示パネルを大版中間パネル339から多面取りする場合について説明する。
ここでは、表示パネルの切断にはレーザを用いている。つまり、レーザスクライバで、パワーを調整しながら大版中間パネルを切断する。
ここでの切断工程は、平面視矩形状に形成された各封止部材341~347の外周に沿って且つ補強部を通るようにEL基板351を切断するEL外周切断工程と、平面視矩形状に形成された各封止部材341~347の外周に沿って且つ補強部を通るようにCF基板353を切断するCF外周切断工程と、矩形状の各封止部材の周方向隣接する2つの角部の間を凹入状にCF基板353を切断するCF角間切断工程とを含む。なお、上記の各工程の順番は、特に限定するものでなく、上記の順番であっても良いし、下記順番であっても良い。
(1)CF外周スクライブ工程
CF外周切断工程は、図20の(a)に示すように、各表示領域331~337の周囲に配された封止部材341~347の補強部を通るように封止部材341~347の矩形枠部の廻りを切断する(補強部の切断面が本発明の「第2側面」に相当する。)。ここでは、まず、行列状に隣接する表示領域に沿って、左右(行方向)・上下方向(列方向)に直線状に延伸するスクライブ線(例えば、K1~K6である。)でCF基板353の表面にスクライブ傷を形成する。
CF角間切断工程は、図20の(b)に示すように、CF基板353における各矩形状に配された封止部材341~347の辺に沿ってCF基板353を切断する。ここでは、まず、行方向及び列方向に隣接する2つの表示パネルに跨るように、長円状のスクライブ線L1~L4でCF基板353の表面にスクライブ傷を形成する。
なお、行方向及び列方向において端に相当する部分では、長円状の半分の形状のスクライブ線L5~L8でCF基板の表面にスクライブ傷を形成する。
(3)EL外周スクライブ工程
CF外周切断工程は、図20の(c)に示すように、各表示領域331~337の周囲に配された封止部材341~347の補強部を通るように封止部材341~347の矩形枠部の廻りを切断する(補強部の切断面が本発明の「第1側面」に相当する。)。ここでは、まず、行列状に隣接する表示領域に沿って、左右(行方向)・上下方向(列方向)に直線状に延伸するスクライブ線(例えば、M1~M6である。)でEL基板351の表面にスクライブ傷を形成する。
(1)~(3)で加えたスクライブ傷の周辺に機械的な力を加え、CF基板353やEL基板351を歪ませることにより、CF基板353、および、EL基板351がスクライブ線で割断される。また、封止部材341~347の補強部においても、CF基板353のスクライブ線(例えば、K1~K6)および、EL基板351のスクライブ線(例えば、M1~M6)が同一平面上にあること、さらに、補強部の膜厚(例えば0.01[mm])がガラス基板の膜厚(例えば0.7[mm])に比べて十分薄いことにより、同一ライン上で容易に割断される。
<変形例>
1.製造方法
(1)ペーストの塗布基板
実施形態等では、CF基板用のガラス基板121にフリットペースト130を塗布していたが、フリットペースト130の塗布工程をEL基板用の基板に対して行っても良い。この場合は、フリット一体化工程の後に、EL(発光素子)を形成すれば良い。
(2)塗布工程
実施形態では、フリットペースト130の塗布方法として、ノズルを利用したディスペンサ法を利用したが、例えば、スクリーンマスクを利用したスクリーン印刷法を利用しても良い。
フリット一体化工程は、レーザ132を用いてフリットペースト145中のフリットガラスとガラス基板121とを溶着していたが、他の方法により溶着しても良い。他の方法としては、フリットペースト付きのガラス基板を加熱炉内に設置し、フリットガラス(封止材料)が溶融する温度にまで加熱することで、封止材料と基板とを一体化することができる。
(4)CF形成工程
CF形成工程は、フリット一体化工程の後に行われている。しかしながら、フリット一体化工程における加熱をレーザ132により実施する場合、ガラス基板において加熱される部分が小さく、CF122aに与える熱の影響を少なくできる。このため、CF形成工程は、レーザを利用して行うフリット一体化工程の前に行うことも可能であるし、フリットペースト145の塗布工程の前に行うことも可能である。
2.補強部
(1)平面視形状
実施形態では、補強部152~155,309を矩形枠部151,307の各角部分に繋がる状態で矩形枠部151,307の外側に形成し、補強部152~155,309の平面視形状が円形状をしていたが、他の形状であっても良い。
(2)構造
実施形態では、補強部152~155,309は円形状をし、その内部がフリットペーストで充満していたが、補強部は、矩形枠部の角部分に連続し、矩形枠部の外側にあれば良く、補強部の内部にフリットペーストが充満しているか否かは特に関係ない。
(a)例1
例1に係る補強部501は、図21の(a)に示すように、矩形枠部503の角部分505の外側であって当該角部分505に連続して形成されている。補強部501は、平面視形状が円環状に形成され、その内部にはフリットガラスは充填されていない。
(b)例2
例1での補強部501は、角部分(505)を構成する2辺部分(507,509)から円環状に延出していたが、他の形状、例えば多角状に延出しても良い。4角形状に延出した場合を例2として説明する。
(c)例3
例3に係る補強部521は、図21の(c)に示すように、矩形枠部523の角部分525の外側であって当該角部分525に連続して形成されている。補強部521は、平面視形状がアングル状に形成されている。補強部521は、矩形枠部523の角部分525を構成する2つの辺部分(527,529)に接続する接続部分521a,521bと、角部分525に沿って円弧状に湾曲する湾曲部分521cとを有している。
(3)位置
実施形態での補強部152~155の中心(例えば、152aである。)は、図11の(b)に示すように、矩形枠部151の角部分の内角の2等分線の延長線E上に存在している。これは、補強部の中心を2等分線上に配置すると、補強部の外側に発生する残留ひずみのうち、最大となる領域(図14における「164」~「167」である。)がスクライブ線(図14の(a)における「G1」~「G4」である。)上から外れることとなり、切断工程での中間パネル138の破損を防止できるからである。
(4)その他
実施形態では、4つの補強部152~155の形状・大きさ等が同じであったが、すべて同じ形状・大きさでなくても良い。例えば、矩形枠部の対角線上にある補強部は同じ形状・大きさであり、対角線単位で形状・大きさを変えても良い。また、補強部の形状・大きさをすべて異なるようにしても良い。ただし、スクライブ線上に補強部が存する程度の大きさが必要である。
3.矩形枠部
実施形態における矩形枠部151は、角部分の内側を円弧上に形成していたが、角部分の内側を上記の例2のように略直角に形成しても良いし、上記例3のように角部分を構成する2辺部分を接続しなくても良い。
11 EL基板
12 CF基板
13 封止樹脂層
145 フリットペースト
151 矩形枠部
152~155 補強部
Claims (8)
- 第1基板と、
前記第1基板と対向して配置された第2基板と、
前記第1基板と前記2基板との間に配された複数のEL素子と、
前記第1基板と前記第2基板との間に設けられ前記複数のEL素子を封止する封止部材と
を有し、
前記封止部材は、前記複数のEL素子の周囲に沿って形成された矩形枠部と前記矩形枠部の角部分において外側に突出した補強部とを有し、当該補強部は、前記第1基板の角部における少なくとも一方の側面と面一となる状態で切断された第1側面と、前記第2基板の角部における前記少なくとも一方の側面が存在する側の側面と面一となる状態で切断された第2側面を有し、
前記第1側面と前記第2側面とが同一面に含まれる
ことを特徴とする表示パネル。
- 前記複数のEL素子は前記第1基板に設けられ、
前記第2基板は、当該第2基板の角部における側面の延長線よりも前記第2基板の中心側に位置する側面を有する
ことを特徴とする請求項1に記載の表示パネル。
- 前記第2基板における前記第2基板の中心側に位置する側面は、前記第1基板の側面よりも前記第2基板の中心側に位置する
ことを特徴とする請求項2に記載の表示パネル。
- 前記封止部材は、フリットガラスである
ことを特徴とする請求項1~3の何れか1項に記載の表示パネル。
- 前記封止部材は、さらに、前記矩形枠部の角部分間において外側に突出した中間補強部を有している
ことを特徴とする請求項1~4の何れか1項に記載の表示パネル。
- 第1基板上に複数のEL素子を中央領域内に形成する第1工程と、
前記第1基板又は第2基板上に、封止材料を用いて、前記中央領域に対応する領域を囲む矩形枠部と当該矩形枠部の角部分から外側に突出する補強部とを設ける第2工程と、
前記封止材料を介して前記第1基板と第2基板とを貼り合せ前記複数のEL素子を封止する第3工程と、
前記第1基板と前記第2基板とをそれぞれ切断する第4工程と
を有し、
前記第4工程において、前記補強部は、前記基板の貼り合せ方向から見た場合に、前記第1基板の角部及び前記第2基板の角部のそれぞれと重複する状態で切断される
ことを特徴とする表示パネルの製造方法。
- 前記補強部は、前記基板の貼り合せ方向から見た場合に、前記第1基板の角部と前記第2基板の角部との両方に重複し、重複した部分で面一状に切断される
ことを特徴とする請求項6に記載の表示パネルの製造方法。
- 前記第2基板は、前記第2基板の角部における切断面の延長線よりも前記第2基板の中心側に配置する側面を有するように切断される
ことを特徴とする請求項6又は7に記載の表示パネルの製造方法。
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