JP2003344819A - Method for manufacturing color liquid crystal display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To make a defective pattern area easily discriminated among a plurality of pattern areas for a display device provided on a color filter substrate in manufacturing a color liquid crystal display device. <P>SOLUTION: The color liquid crystal display device is manufactured by forming markings with arbitrary shapes and sizes on at least one or more arbitrary positions on a color filter substrate comprising at least one or more kinds of color filters formed on a glass substrate. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a suitable color liquid crystal display device. In particular, it relates to a manufacturing method when a plurality of display elements are laid out on one large substrate.

[0002]

2. Description of the Related Art A color filter, which is a very expensive member, is used in a color liquid crystal display device. FIG. 8 shows a schematic sectional structure of the color liquid crystal display element. As shown, a color filter is formed on the substrate 26.
The color filter is formed of a plurality of colored portions. In this figure, the color filter is composed of three colored portions of R, G, and B and a black matrix, but various structures can be adopted according to the specifications of the color filter. A transparent resin layer 6 is provided on the color filter. Further, a transparent electrode 7 for applying a voltage to the liquid crystal 28 is formed thereon. The substrate 26 is joined to the counter substrate 36 by a seal material 27 with a certain gap. The liquid crystal 28 is enclosed in this fixed gap. A transparent electrode is also provided on the counter substrate 36.

The display elements having such a structure are not always individually formed. In particular, when manufacturing a medium- or small-sized color liquid crystal display device, more than 100 patterns (color filters, transparent electrodes) for a plurality of display devices are laid out on one large substrate. Then, a plurality of display elements are collectively assembled in the state of the large substrate, and then separated to form one display element. That is, first, a color filter substrate on which a plurality of color filters are arranged is formed. Next, a transparent resin layer is formed so as to correspond to each color filter. A transparent conductive film is provided on this transparent resin layer and patterned to form a display electrode. In this way, the color filter substrate, the color filter, the transparent resin layer, and the display electrode are laminated and laid out so as to correspond to the plurality of display elements. On the other hand, transparent electrodes are provided on the counter substrate facing the color filter substrate so as to correspond to the display electrodes of the display elements of the color filter substrate. And
The color filter substrate and the counter substrate are bonded together with a sealant at a fixed interval. After that, the display element is separated into individual display elements, and liquid crystal is injected into the gap.

Of these steps, an inspection step is added at a necessary step. For example, after forming a plurality of color filters on a substrate, it is necessary to inspect each color filter for a defect and specify the defective color filter area. This is because if the color filter substrate is not inspected to identify a defective pattern, a pattern area having some defect will flow out to a subsequent process, which requires sorting in the inspection process and the like, resulting in reduced productivity. . Further, the cost of loss is increased by assembling and mounting unnecessary circuit components on the color liquid crystal display panel manufactured using the defective pattern area. Therefore, an identification number is assigned to each pattern area, the identification number is drawn outside the pattern area of the color filter substrate on which the pattern area is provided, and when the defective pattern area is found, the defective pattern area is dealt with. A method of marking the identification number was used.

[0005]

However, in the above-mentioned method, when a plurality of patterns are separately manufactured from one color filter substrate, it is impossible to judge whether the display element is a good product or a defective product after the separation. Even if an identification number is written in the pattern area, it cannot be written large because the area is limited, and various thin films may be provided on the surface in a post process, which makes it very difficult to distinguish. Alternatively, in the case where each color filter pattern has a defect caused by the presence of a foreign substance or the like, the method of recording the identification number assigned to each pattern area and managing the quality is
This has been extremely difficult because it must be continuously dealt with through the subsequent manufacturing process of the liquid crystal display device.

Therefore, the advent of a method for technically solving the above-mentioned problems has been desired.

[0007]

A manufacturing method is used in which markings are provided at least at one or more positions in a plurality of display device pattern areas provided in a color filter substrate. By doing so, the defective pattern area of the color filter substrate can be easily recognized, and the outflow to the subsequent process can be prevented.

The marking can be formed by an ink jet method, a method using a laser device, stamping, or the like.

This marking is performed at the same time as a pattern inspection which is performed in the manufacturing process of the color filter substrate after the formation of the colored layer, the formation of the transparent resin layer, the formation of the transparent electrode, the patterning of the transparent electrode, or the patterning of the transparent electrode. ,
Can be performed at the timing of.

That is, according to the method of manufacturing a color liquid crystal display device of the present invention, the first step of forming a display element pattern including a plurality of color filter patterns on a substrate and the substrate and the counter substrate are joined to face each other. Thus, a second step of forming a plurality of color liquid crystal display elements by a pair of substrates, and a third step of separating the plurality of color liquid crystal display elements into individual color liquid crystal display elements, the first step, A step of forming a marking with an arbitrary shape and an arbitrary size was provided in the display element pattern area having a defective color filter pattern.

Further, the marking is provided in the area of the display element pattern having some defect. This marking was formed by inkjet, laser, and stamping.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The manufacturing method of the present invention will be described below.

The method for manufacturing a color liquid crystal display device according to the present invention includes the step of providing a marking on at least one position of the display device pattern area as described above.

This marking can be provided at any place on the surface of the color filter substrate by ink jet printing. In this method, since the marking is provided by the ink liquid ejected from the recording head, the marking can be performed without touching the surface of the color filter substrate. Therefore, there is no concern that a new defect will be generated by touching the non-defective pattern area around the defective pattern area.

Also, there is no restriction on the shape or size of the marking. Therefore, it is only necessary to select the size and shape that are most visible.

It is preferable that the marking is provided at a specific position of all the display device pattern areas. This makes it easy to recognize the defective pattern area.

It is preferable to use a quick-drying ink. Alternatively, it is preferable to use a method of rapidly solidifying by irradiation of ultraviolet rays or a method of drying by blowing air. By doing so, it is possible to quickly shift to a subsequent process such as cleaning, and ink does not flow to contaminate the color filter substrate.

There are various methods other than ink jet printing as methods for providing markings on the pattern area of the color filter substrate. These will be described below.

The marking can also be formed by irradiating the pattern area with a laser. Since this method also does not touch the surface of the color filter substrate directly,
There is no concern that new defects will be generated by touching the surface. Further, similarly to the inkjet printing, there is no restriction on the timing of providing the marking and the shape of the marking.

It is preferable that the marking is provided at a specific position of the display device pattern area. This makes it easier to recognize the defective surface.
Further, it is preferable to select a place where scattered matter of the color filter substrate constituent material generated when the marking is provided does not affect the adjacent pattern area. That is, it is preferable to provide the marking at a place distant from the adjacent pattern area, for example, at the center of the pattern area.

Further, in order to prevent the surface of the color filter substrate from being contaminated by scattered substances, it is advisable to install an exhaust device in the immediate vicinity of the laser irradiation portion.

The marking depth is preferably such that the glass substrate is not damaged. That is, it is advisable to adjust the output so that the black matrix portion or the colored layer portion of the color filter substrate and the metal film thereunder, even if the metal film portion is deep, are scraped off. In this way, it is possible to prevent the glass substrate from cracking and the glass substrate from breaking.

The marking can also be formed by stamping on the pattern area. Also in this case, it is preferable to use a quick-drying ink. Also in this method, there is no restriction on the timing of providing the marking or the shape of the marking.

Similar to the above method, it is preferable to determine that the marking is provided at a specific position in all the display device pattern areas. This makes it easier to recognize the defective surface.

The marking is not limited to the above method, as it may take any form as long as it can be confirmed later. Furthermore, although some of the timings for providing the markings have been described above, the markings can be formed in any process as long as the target pattern area is determined, and thus the markings are not limited to the above timings. Absent.

[0026]

Embodiments of the present invention will be described below with reference to the drawings. In addition, each figure is to the extent that the present invention can be understood,
The shapes, sizes, and arrangement relationships of the respective constituents are only schematically shown, and the present invention is not limited to the illustrated examples.

Various marking methods according to the embodiments of the present invention will be described below.

(Embodiment 1) FIG. 3 shows an outline of a marking device 11 for carrying out a method by ink jet printing. This apparatus includes a recording head 13 that ejects ink toward a color filter substrate 12, and the recording head 1.
3 and a transport mechanism that enables marking by moving the color filter substrate 12 relative to each other.

The internal structure of the marking device 11 will be described with reference to FIG. The carriage 15 is connected to the pulse motor 16 via the timing belt 14 so that the carriage 15 can reciprocate in the apparatus. Further, the drive table 17 that conveys the color filter substrate 12 is the motor 1
By utilizing the rotational driving force of 8, the carriage 15 can move in a direction perpendicular to the moving direction. With respect to the transport mechanism, the recording head 13 may be fixed and the drive table 17 may be movable to any position on the plane.

Color filter substrate 12 of carriage 15
A recording head 13 is attached to the surface opposite to, and ink is ejected from the recording head 13 to provide markings on the color filter substrate 12.

The ink to be used is prepared, for example, by dissolving or dispersing an ultraviolet curable resin, a dye or pigment, a surfactant such as ethylene glycol or the like in a solvent such as water, alcohol, toluene or methyl ethyl ketone.

The outline of the recording head 13 is shown in FIG. The recording head 13 is provided with a plurality of nozzles 19, and the openings of the nozzles 19 are all connected to the pressure generating chamber 20. An elastically deformable diaphragm 2 which is a wall surface of the pressure generating chamber 20 is generated by generating pressure in the pressure generating chamber 20.
The pressure generating chamber 20 is contracted by deforming 1 and ink is ejected from the opening of the nozzle 19. A piezoelectric vibrator PZ such as a piezo element for deforming the vibration plate 21.
T is provided.

When the piezoelectric vibrator PZT contracts, the vibrating plate 21 deforms upward, and the pressure generating chamber 20 expands, ink flows from the ink tank 22 into the pressure generating chamber 20. After that, when the piezoelectric vibrator PZT expands and the vibrating plate 21 returns to its original state and the ink in the pressure generating chamber 20 is compressed, the nozzle 19
Ink is ejected from the opening. At this time, which nozzle 19
It is possible to change the shape of the marking depending on whether or not to use.

The control system and drive system of the marking device 11 will be described with reference to FIG. First, the control system 51
Input the position coordinates of the place on the color filter substrate 12 where marking is desired. Upon receipt of this input signal, the control system 51 controls the drive table control circuit 55, the carriage drive circuit 56, and the like together with the print head drive circuit 54 including the drive voltage generation circuit 52 and the print head selection circuit 53 to carry out the marking work. To do.

The drive voltage generating circuit 52 is configured to generate a voltage necessary for ejecting ink from the opening of the nozzle 19. The recording head selection circuit 53 controls the transistor T formed in each nozzle 19 to selectively apply the drive voltage of the drive voltage generation circuit 52 to the piezoelectric vibrator corresponding to the marking shape among the plurality of piezoelectric vibrators PZT. It is supposed to do. The drive table control circuit 55 controls a motor or the like to transfer the drive table. Further, the carriage drive circuit 56 controls a drive means 58 such as a pulse motor for driving the carriage.

(Embodiment 2) FIG. 6 shows an outline of a marking device for carrying out the method by laser marking. The main configuration of the marking device 23 includes a laser head 24 that irradiates the color filter substrate 12 with a laser, and a transport mechanism that relatively moves the laser head 24 and the color filter substrate 12 to enable marking. The drive system may have the same structure as that of the inkjet printing apparatus described above. Hereinafter, a method of fixing the laser head 24 and moving the drive table 17 will be described. The types of lasers that can be used are those that can remove the black matrix, colored layer, transparent resin or metal film, such as CO ₂ laser, YAG laser, X
An e-laser, a rare gas laser, an excimer laser, etc. are suitable. The shape of the marking can be any shape such as a circle, an ellipse, various polygons such as a triangle and a quadrangle, and letters and numbers, and there is no restriction on the size.

The control system and drive system of the marking device 23 will be described. First, information about the position coordinates on the color filter substrate 12 where marking is to be provided in the control system is input. Upon receiving this information, the drive table 17
The color filter substrate 12 is moved so that the portion where the marking is to be provided comes to the laser irradiation portion, and the marking is provided by the laser irradiation.

Also, scattered matter of the color filter substrate constituent material generated by laser irradiation is the color filter substrate 1.
In order to prevent the pollutant 2 from being contaminated, it is preferable to mount the exhaust device 25 in the vicinity of the laser irradiation portion. In the case of the driving method of moving the laser head 24, the exhaust device 2
By integrating 5 with the laser head 24, it is possible to always arrange the exhaust function in the immediate vicinity of the laser irradiation portion, so that the color filter substrate 12 can be always prevented from being contaminated.

FIG. 1 shows a structural example of a color liquid crystal display device provided with markings in various steps. FIG. 1 (A) is after forming the colored layers (4R, 4G, 4B), FIG. 1 (B) is after forming the transparent resin layer 6, and FIG. 1 (C), FIG. 1 (D) and FIG.
(E) schematically shows a cross-sectional structure of the color liquid crystal display device when marking is performed after the transparent electrode 7 is formed or at the time of pattern inspection thereafter. FIG. 1 (C) and FIG.
The marking depth can be controlled by adjusting the laser output as in (D). In any case, it is desirable to adjust the laser output so that the glass substrate 26 on which the color liquid crystal display device pattern area 10 is formed is not damaged. If the glass substrate 26 is scratched, it may be damaged in a later process, which may adversely affect the surrounding good products.

FIG. 1G schematically shows a state in which the markings M are made on some pattern areas of the color filter substrate 12 provided with a plurality of pattern areas.
A color display device is formed by using such a color filter substrate, and then an external view of each color display device which is separately formed is shown in FIG. As shown in the drawing, the marking M is provided on the defective color display device.
In this way, it is possible to continuously recognize defective surfaces from the color filter substrate 12 to the color liquid crystal display device.

(Embodiment 3) In this embodiment, the construction of a stamping device for marking a color filter substrate by stamping will be described. This stamping mechanism is provided with a transport mechanism that enables marking by moving the color filter substrate relatively. Since the marking method is the same as the marking method by inkjet printing except that the marking is provided by stamping, the device configuration may be the same as that of the inkjet printing. The marking can have any shape and size by changing the stamp portion. Preferably, in this method as well, as in the case of the inkjet method, it is good to use a quick-drying ink. Alternatively, it is preferable to use a method of rapidly solidifying by irradiating with ultraviolet rays, or blowing air to dry. By doing so, it is possible to quickly shift to a subsequent process such as cleaning, and the color filter substrate is not contaminated by the flowing of the ink. Further, in this method, since the stamp directly contacts the color filter substrate, it is desirable to adjust the place where the marking is provided and the size of the marking so that the surrounding good product pattern area is not adversely affected.

A method of manufacturing a color filter substrate using the above-described marking method will be described below. An example of a method of manufacturing a color filter substrate is shown in FIG. Here, a method for manufacturing a color filter substrate containing three colors of red (R), green (G) and blue (B) will be described. Figure 2
As shown in (A), the metal film 2 is formed on the glass substrate 1 by a sputtering method or the like to a thickness of about 1000 to 1500 Å. Then, the black matrix 3 is formed by the photolithography method. First, metal chrome (Cr), which will become the black matrix 3 in a later step, is formed on the glass substrate 1 by sputtering to a film thickness of 0.1 to 0.1.
It is formed to have a thickness of about 5 μm. Other materials for the black matrix 3 include chromium oxide (CrO).
x) or resin can also be used. And exposure
After the developing process, an island-shaped black matrix 3 is formed as shown in FIG.

Next, as shown in FIG. 2C, any of the photosensitive red coloring material 4R, the green coloring material 4G, or the blue coloring material 4B is filled so as to fill the gap of the black matrix 3. 1 color (here red coloring material 4
G) is applied within a range of a film thickness of about 1 to 2 μm. Next, as shown in FIG. 2D, exposure is performed using a suitable photomask 5, and then a developing process is performed. As a result, the colored layer 4R is formed as shown in FIG.

Then, the steps of FIGS. 2C to 2E are repeated for the other two color materials (here, the green coloring material 4G and the blue coloring material 4B), and the coloring layer is formed with the three coloring materials. To form. As a result, the first structure 8 is obtained as shown in FIG.

Next, the marking for specifying the defective pattern area is formed by the above-described marking method. Subsequently, as shown in FIG. 2G, a flattening film for smoothing and resistance, that is, a so-called top coat film 6 is formed on the entire surface of the colored layer.
(Sometimes called an overcoat film) is formed. As the top coat film 6, for example, a photosensitive cured resin film is formed with a film thickness of about 2 μm to obtain the second structure 9.

Further, as shown in FIG. 2H, a transparent electrode 7 is formed on the top coat film 6. This transparent electrode 7
Indium oxide film (Indium Tin Oxide film: ITO film) mixed with tin oxide as an impurity is used as the
A pattern area 10 for a color liquid crystal display device is obtained by forming the film with a film thickness of about 1 to 0.15 μm by sputtering or the like.

Here, the description has been made assuming that the first structure 8 shown in FIG. 2F is marked.
Marking may be performed on the second structure 9 having the topcoat layer shown in (G) or the pattern area 10 for the color liquid crystal display device shown in FIG. 2 (H).

FIG. 7 is a flow chart showing an outline of a method of manufacturing a color liquid crystal display device using the color filter substrate thus formed. First, FIG. 2 (H)
There is a step of patterning the transparent electrode 7 provided in step 2, that is, the ITO film. If the marking is not performed in the manufacturing process of the color filter substrate described with reference to FIG. 2, the color filter is inspected simultaneously with the pattern inspection of the transparent electrode performed after the patterning process to provide the marking. When marking is performed in this manner, productivity is not reduced because the inspection is performed at the same time.

After the pattern inspection, an alignment film is formed, a sealant is printed, assembling / pressing and primary scribing / separating are performed to make the stacked substrates into a strip shape. After that, liquid crystal injection, secondary scribing / separation (separating individual color liquid crystal display device patterns), inspection, and removal of defective products are performed. A display device is manufactured.

In the inspection process, the following inspection is performed.

(1) A visual inspection is performed.

(2) A conductive rubber or the like is used to apply a voltage to all the lines of the transparent electrode to illuminate the entire display area, and then display characteristics such as contrast are inspected.

(3) A polarizing plate is attached, and an inspection in a form closer to the product is performed.

Conventionally, the defective pattern area was selected and removed through the various inspections described above, but by using the color filter substrate provided with the marking of the present invention,
At the time of the appearance inspection of (1), all the defective pattern areas can be removed.

It is possible to remove defective products at an earlier stage, that is, at the time when the secondary scribing / separation before the inspection is completed.

Although various steps have been described as the timing for providing the markings, the steps are not limited to the above-mentioned timings since they can be performed in any step if the pattern area 10 for the color liquid crystal display device to be provided with the markings is determined. .

[0057]

As described above, by providing markings in the defective color liquid crystal display device pattern area 10 to manufacture the color liquid crystal display device,
It has become possible to easily identify the defective pattern area.

As a result, it is possible to prevent the color liquid crystal display panel using the defective pattern area from flowing out to the subsequent steps such as the polarization plate attachment and the circuit component mounting, and accordingly, the productivity is improved and the loss cost is reduced. Reduction was realized.

[Brief description of drawings]

FIG. 1 is a schematic diagram illustrating an example of a marked color liquid crystal display element.

FIG. 2 is a schematic view showing an example of a method for manufacturing a color filter substrate.

FIG. 3 is an external view showing an outline of an inkjet printing marking device.

FIG. 4 is a schematic diagram showing an internal structure of a recording head unit.

FIG. 5 is a block diagram showing a schematic configuration of an inkjet printing marking device.

FIG. 6 is an external view showing an outline of a laser marking device.

FIG. 7 is a flowchart showing an outline of a method of manufacturing a liquid crystal display device.

FIG. 8 is a cross-sectional view showing a schematic configuration of a conventional color liquid crystal display device.

[Explanation of symbols]

1 glass substrate 2 metal film 3 Black Matrix 4R, 4G, 4B Photosensitive coloring material 5 photo mask 6 Top coat film 7 Transparent electrode 8 First structure 9 Second structure 10 Color liquid crystal display pattern area 11 Inkjet printing machine 12 Color filter substrate

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Claims (6)

[Claims] 1. A first step of forming a display element pattern including a plurality of color filter patterns on a substrate, and the substrate and a counter substrate facing each other and bonded to each other,
A second step of forming a plurality of color liquid crystal display elements by a pair of substrates, and a third step of separating the plurality of color liquid crystal display elements into individual color liquid crystal display elements, the first step, A method for manufacturing a color liquid crystal display device, comprising the step of forming a marking in an arbitrary shape and an arbitrary size in a display element pattern area having a defective color filter pattern. 2. The method for manufacturing a color liquid crystal display device according to claim 1, wherein the marking is provided in an area of the display element pattern having some defect. 3. The method for manufacturing a color liquid crystal display device according to claim 1, wherein the marking is formed by an inkjet method. 4. The method of manufacturing a color liquid crystal display device according to claim 1, wherein the marking is formed by using a laser. 5. The method of manufacturing a color liquid crystal display device according to claim 1, wherein the marking is formed by stamping. 6. The first step comprises: forming a color filter pattern on a substrate; forming a transparent resin layer on the color filter pattern; and patterning a transparent electrode on the transparent resin layer. 6. The method according to claim 1, further comprising a step and a step of performing a patterning inspection of the transparent electrode pattern, wherein the marking is formed at the same time as the patterning inspection of the transparent electrode. Of manufacturing a color liquid crystal display device of.