JP2017072667A - Liquid crystal panel and manufacturing method of liquid crystal panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To accurately determine the amount of liquid crystal to be dropped in manufacturing a liquid crystal panel by using a drop injection system.SOLUTION: A liquid crystal panel according to the present invention comprises: a TFT array substrate 1; a CF substrate 2 that is arranged opposite to the TFT array substrate 1; a post spacer 3 that is in contact with the TFT array substrate 1 and CF substrate 2 to maintain the interval between both substrates; a seal pattern 5 that is arranged in a closed curve shape on a principal surface of the TFT array substrate 1 facing the CF substrate 2 or a principal surface of the CF substrate 2 facing the TFT array substrate 1; and a liquid crystal layer 4 that is encapsulated between the TFT array substrate 1 and CF substrate 2 with the seal pattern 5. The CF substrate 2 includes an insulating substrate 21, a plurality of color filters 23 that are arranged on a principle surface of the insulating substrate 21 on the liquid crystal layer 4 side, and an organic film 24 that covers the boundary between the adjacent color filters 23.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a color filter substrate of a liquid crystal panel manufactured by a dropping injection method.

  In general, in a liquid crystal display device, a backlight as a light source is disposed on the side opposite to the display surface side of a liquid crystal panel provided with a pair of substrates, and light emitted from the backlight passes through the liquid crystal panel, so that a desired Images and videos are displayed. The liquid crystal panel is configured by sealing liquid crystal between two substrates (a first substrate and a second substrate) bonded together with a sealing material. The first substrate is an array substrate having a display area in which a plurality of pixels are arranged in a matrix, and the second substrate is a counter substrate on which a black matrix (light shielding film), a color filter, a post spacer, and the like are formed. (Color filter substrate).

  In the liquid crystal panel having such a structure, a dropping injection method is known as one of methods for sealing liquid crystal between an array substrate and a color filter substrate. The dropping injection method is a method in which a sealing material is applied so as to surround a display area in which a plurality of pixels are formed in the array substrate, and after the liquid crystal is dropped onto the display area, the array substrate and the color filter substrate are bonded together. It is. In the dropping injection method, it is extremely important to drop the liquid crystal in the display area with an appropriate dropping amount without excess or deficiency. If the amount of liquid crystal dropped is insufficient, bubbles may be generated when the substrates are bonded together, or vacuum bubbles may be generated at low temperatures. On the other hand, if the amount of liquid crystal dropped is excessive, the liquid crystal protrudes from the sealing material when the substrates are bonded together, and the substrate is contaminated, or gravity unevenness occurs at high temperatures.

  The dropping amount of the liquid crystal can be calculated by calculating the volume of the space that fills the liquid crystal material in the liquid crystal panel (hereinafter referred to as “cell volume”). The cell volume can be calculated, for example, by the product of the area of the region surrounded by the seal of the liquid crystal panel and the height of the liquid crystal panel. Conventionally, the height of the liquid crystal panel is the height of the post spacer (PS) for maintaining the cell gap of the liquid crystal panel. That is, the dropping amount of the liquid crystal was calculated from the product of the area of the region surrounded by the seal of the liquid crystal panel and the PS height. In actual manufacturing, the liquid crystal drop amount accuracy is improved by measuring the PS height for each panel and feeding back the value when calculating the liquid crystal drop amount.

  Further, Patent Document 1 shows that the liquid crystal panel height is improved by adjusting the height of the post spacer in consideration of the step between the color filters to improve the liquid crystal dropping amount accuracy. .

JP 2007-004112 A

  The process error that may occur during the color filter layer forming process includes a gap in the distance between the color filters in addition to the step between the color filters. In the color filter layer, layers of three colors (RGB layers) of red (R), green (G), and blue (B) are repeatedly arranged, so that the RGB layers must be individually applied and patterned. During this patterning, the color filter interval may be widened or narrowed due to an error due to a mask misalignment or the like.

  As described above, when the liquid crystal dripping amount is calculated from the product of the area of the region surrounded by the seal of the liquid crystal panel and the PS height, if the color filter interval becomes wider due to an error, the calculated amount is an actually required amount. It will be less. On the contrary, when the interval between the color filters becomes narrow and overlap occurs, the overlapped portion becomes a protrusion, and the calculation amount becomes larger than the actually required amount.

  In Patent Document 1, the step between the color filters is considered as an error that occurs in the color filter layer forming process, but the deviation of the interval between the color filter layers is not taken into account. A reduction in error could not be avoided.

  In view of the above-described problems, an object of the present invention is to accurately determine a liquid crystal dropping amount when a liquid crystal panel is manufactured using a dropping injection method.

  The liquid crystal panel of the present invention includes a first substrate, a second substrate disposed opposite to the first substrate, a post spacer that contacts the first substrate and the second substrate and maintains a distance between the two substrates, A seal pattern arranged in a closed curve on a main surface of the substrate facing the second substrate or a main surface of the second substrate facing the first substrate, and between the first substrate and the second substrate by the seal pattern The second substrate is an organic substrate covering a boundary between the insulating substrate, a plurality of color filters disposed on the main surface of the insulating substrate on the liquid crystal layer side, and an adjacent color filter. A membrane.

  The liquid crystal panel of the present invention includes a first substrate, a second substrate disposed opposite to the first substrate, a post spacer that contacts the first substrate and the second substrate and maintains a distance between the two substrates, A seal pattern arranged in a closed curve on a main surface of the substrate facing the second substrate or a main surface of the second substrate facing the first substrate, and between the first substrate and the second substrate by the seal pattern The second substrate is an organic substrate covering a boundary between the insulating substrate, a plurality of color filters disposed on the main surface of the insulating substrate on the liquid crystal layer side, and an adjacent color filter. A membrane. Therefore, even if the color filter interval fluctuates due to a process error, the cell volume can be prevented from fluctuating, so that the liquid crystal dripping amount can be determined with high accuracy.

It is sectional drawing which shows the structure of the liquid crystal panel which concerns on Embodiment 1 of this invention. It is a top view which shows the structure of the liquid crystal panel which concerns on Embodiment 1 of this invention. It is a top view which shows the pixel area | region of the liquid crystal panel which concerns on Embodiment 1 of this invention. It is a flowchart which shows the manufacturing method of the liquid crystal panel which concerns on Embodiment 1 of this invention. It is sectional drawing which shows the structure of the liquid crystal panel which concerns on Embodiment 2 of this invention. It is sectional drawing which shows the structure of the liquid crystal panel which concerns on Embodiment 3 of this invention. It is sectional drawing which shows the structure of the liquid crystal panel which concerns on Embodiment 4 of this invention. It is a figure which shows the formation process of the organic film in the liquid crystal panel which concerns on Embodiment 4 of this invention.

<A. Embodiment 1>
<A-1. Configuration>
FIG. 1 is a cross-sectional view of a liquid crystal panel 101 according to Embodiment 1 of the present invention. The liquid crystal panel 101 includes a TFT array substrate 1 (first substrate), a color filter (CF) substrate 2 (second substrate), a post spacer 3, a liquid crystal layer 4, and a seal pattern 5. The TFT array substrate 1 and the CF substrate 2 are disposed to face each other, and a liquid crystal layer 4 is disposed between the two substrates. The seal pattern 5 is formed in the shape of a closed curve on the outer periphery of either the TFT array substrate 1 or the CF substrate 2, and plays a role of sealing the liquid crystal layer 4 between both substrates.

  Although not shown, a polarizing plate and a phase plate are attached to both surfaces of the liquid crystal panel 101.

  A liquid crystal display device is configured by attaching a backlight, an external circuit, a housing, and the like to the thus configured liquid crystal panel 101.

  The color filter substrate 2 includes an insulating substrate 21, a black matrix 22, a color filter 23, an organic film 24, and a transparent electrode 25. The insulating substrate 21 is made of glass or plastic. The black matrix 22 is made of a black organic resin and is formed on the insulating substrate 21. The color filter 23 includes color filters corresponding to the three primary colors of the red color filter 23R, the green color filter 23G, and the blue color filter 23B, and these color filters are formed on the insulating substrate 21 and the black matrix 22. In FIG. 1, the green color filter 23G is arranged next to the red color filter 23R, and the blue color filter 23B is arranged next to the green color filter 23G, but the adjacent color filters are arranged apart from each other. The organic film 24 is disposed so as to fill these gaps. In the above description, the three color filters 23 corresponding to the three primary colors are used. However, in order to improve color reproducibility, the color filters 23 corresponding to four or more colors may be used.

  In the liquid crystal panel 101, the color filters 23R, 23G, and 23B of the respective colors are provided apart from each other, but the intervals are widened or narrowed due to a positional deviation of the mask when the color filters 23R, 23G, and 23B are patterned. When the cell volume fluctuates due to this deviation, there is a problem that an appropriate amount of liquid crystal cannot be dropped in the liquid crystal dropping step. However, since the organic film 24 is disposed between the adjacent color filters 23 in the liquid crystal panel 101, the change in cell volume is suppressed even if the interval between the color filters 23 changes. Therefore, an appropriate amount of liquid crystal can be dropped in the liquid crystal dropping step.

  The transparent electrode 25 is made of Indium Tin Oxide (ITO) or the like, and is formed so as to cover the black matrix 22, the color filter 23, and the organic film 24. However, in the case of an IPS or FFS mode liquid crystal panel using a lateral electric field, the transparent electrode 25 is not formed.

  FIG. 2 is a plan view of the liquid crystal panel 101. As shown in FIG. 2, the seal pattern 5 is provided in a closed curve shape surrounding the display area 6 of the liquid crystal panel 101, and the TFT array substrate 1 and the color filter substrate 2 are bonded together by the seal pattern 5. Liquid crystal is injected into a region surrounded by the seal pattern 5.

  FIG. 3 is a plan view showing a state in which the pixel region of the liquid crystal panel 101 is viewed from the liquid crystal layer 4 side. Here, for the sake of explanation, a total of nine pixels of 3 rows and 3 columns are shown, but in reality, a larger number of pixels are arranged in the pixel region. In FIG. 3, a red color filter 23R is arranged in the leftmost column, a green color filter 23G is arranged in the center column, and a blue color filter 23B is arranged in the rightmost column. An organic film 24 is disposed between the red color filter 23R and the green color filter 23G and between the green color filter 23G and the blue color filter 23B so as to fill these gaps.

  The post spacer 3 is provided on the transparent electrode 25, but is provided at a position overlapping the black matrix 22 avoiding the pixel opening. The liquid crystal panel 101 may employ a dual spacer structure having two types of post spacers. In this case, the higher post spacer 3 is called a main spacer 3m, and the lower post spacer 3 is called a sub-spacer 3s. The main spacer 3m always contacts both the TFT array substrate 1 and the CF substrate 2, and keeps the distance between the substrates in a predetermined range. The sub-spacer 3s does not normally contact the TFT array substrate 1 and the CF substrate 2, but only touches both substrates to maintain the distance between the substrates when an external force or the like acts on the display surface of the liquid crystal panel 101. Such a structure having two types of post spacers is called a dual spacer structure, and can keep the distance between the TFT array substrate 1 and the CF substrate 2 following the expansion or contraction of the liquid crystal due to temperature change.

  As shown in FIG. 3, the post spacers 3 are arranged, for example, every two rows of pixels. Of the six post spacers 3, one is the main spacer 3m and the remaining five are the sub-spacers 3s. Therefore, the main spacer 3m is arranged at one place per 12 pixels and the sub-spacer 3s is arranged at 5 places per 12 pixels. In addition, what is necessary is just to adjust each arrangement | positioning ratio suitably according to the characteristic of the desired liquid crystal panel.

<A-2. Manufacturing process>
A method for manufacturing the liquid crystal panel 101 will be described with reference to the flowchart of FIG. Usually, a liquid crystal panel is manufactured by cutting out one or a plurality of liquid crystal panels from a mother substrate larger than the final shape (this is also referred to as multi-sided drawing). The processes in steps S1 to S9 in FIG. 4 are processes in the state of the mother substrate.

  First, in the substrate preparation process, wiring and the like are formed on the mother TFT substrate and the mother CF substrate which are insulating substrates. In the mother TFT substrate, a process of forming a gate wiring, a source wiring, a TFT, a pixel electrode, and the like is performed. Since these processes are the same as the manufacturing method of a TFT substrate in a general liquid crystal panel, a detailed description of the manufacturing method is omitted.

  On the other hand, in the mother CF substrate, a black matrix 22, a color filter 23, a transparent electrode 25, a post spacer 3 having a dual spacer structure, an organic film 24, and the like are formed.

  Here, the organic film 24 disposed so as to fill the gaps in the color filter 23 is a characteristic configuration of the liquid crystal panel 101 and is not provided on a general mother CF substrate. The organic film 24 is formed by using a known general post spacer forming process to determine the film thickness of the photosensitive transparent resin film to be applied and the exposure mask design during patterning (that is, the planar pattern design). It can be formed by changing as appropriate. For example, after patterning of the color filter 23, a photosensitive transparent resin film having a film thickness corresponding to the thickness of the organic film 24 is applied and formed on the entire surface of the mother CF substrate, and further, a patterning technique using exposure and development. Thus, the organic film 24 may be formed by patterning into a planar shape that fills the gap of the color filter 23.

  Since the fabrication of the mother CF substrate other than the organic film 24 is the same as the method of manufacturing a CF substrate in a general liquid crystal panel, detailed description regarding the manufacturing method thereof will be omitted.

  After preparing the mother TFT substrate and the mother CF substrate as described above, these substrates are cleaned (step S1).

  Next, an alignment film material is applied to the main surfaces of the mother TFT substrate and the mother CF substrate facing each other (step S2). The alignment film material is composed of an organic material. For example, the alignment film material is transferred and applied by a flexographic printing method, then baked by a hot plate or the like and dried. Whether the alignment film material is a general alignment film material for rubbing treatment or a photo-alignment film material for photo-alignment treatment, it depends on the alignment treatment method performed in the subsequent alignment treatment step (step S3). An appropriate alignment film material may be selected.

  Next, by performing a predetermined alignment process on the alignment film material, the alignment film material surface is subjected to an alignment process to form an alignment film (step S3). Here, according to the alignment film material selected in step S2, either the rubbing process or the photo-alignment process, whichever is appropriate, is selected. In this step, the post spacer 3, the color filter 23, and the organic film 24 formed on the mother CF substrate are covered with an alignment film. However, since the alignment film is thinner than the height of the post spacer 3, the color filter 23 and the organic film 24, the illustration thereof is omitted in FIG.

  Next, the height of the post spacer 3 is measured (step S4). Here, the initial height of the post spacer 3 is measured on the mother CF substrate. Note that the meaning of measuring the height of the post spacer 3 in this step will be described later again, but in order to determine the amount of dripping when the liquid crystal material is injected by the dropping injection (ODF) method. Therefore, the height of the main spacer 3m that determines the cell gap value related to the cell volume is measured.

  Next, the sealing material is discharged as a paste from the dispenser nozzle of the seal dispenser device, and is applied in a closed curve shape so as to surround the display region 6 of the liquid crystal panel 101 on the main surface of either the mother TFT substrate or the mother CF substrate ( Step S5). Thus, the seal pattern 5 is formed.

  Next, a liquid crystal material is dropped into a region surrounded by the seal pattern 5 on the substrate on which the seal pattern 5 is formed. The liquid crystal dripping amount here is obtained by multiplying the height of the main spacer 3m measured in step S4 by the area surrounded by the seal pattern 5, and from there the volume of the organic film 24 (the height of the organic film 24 and the top area or bottom). It is good to set it to a value excluding a constant value from the product of the area.

  Note that the optimal drop amount of the liquid crystal may not be accurately calculated, and may be finely adjusted using a correction value obtained through an experiment or the like after being estimated as a guide. In the liquid crystal panel 101, by arranging the organic film 24 so as to fill the gaps between the color filters 23, fluctuations in the optimum liquid crystal dripping amount due to fluctuations in the distance between the color filters 23 can be suppressed. Therefore, the optimum dripping amount can be obtained by fine adjustment using the correction value.

  Next, the mother TFT substrate and the mother CF substrate are bonded together in a vacuum state to form a mother cell substrate (step S7). Then, the mother cell substrate is irradiated with ultraviolet rays (UV) to temporarily cure the seal pattern 5 (step S8). Thereafter, after-curing is performed by heating to completely cure the seal pattern 5 (step S9).

  Further, the mother cell substrate is cut along the scribe lines and divided into individual liquid crystal panels (step S10). A polarizing plate is attached to each liquid crystal panel divided as described above (step S11), a control board provided with an external circuit is attached (step S12), and a series of manufacturing processes is completed. 101 is completed.

  Further, a backlight unit is disposed on the back side of the TFT array substrate 1 on the opposite side of the liquid crystal panel 101 via an optical film such as a phase difference plate, and placed in a frame (casing) made of resin or metal. Then, the liquid crystal panel 101 and these peripheral members are appropriately accommodated to complete a liquid crystal display device to which the present invention is applied.

<A-3. Effect>
The liquid crystal panel 101 according to the first embodiment of the present invention includes a TFT array substrate 1 (first substrate), a CF substrate 2 (second substrate) disposed opposite to the TFT array substrate 1, and the TFT array substrate 1 and CF A post spacer 3 that is in contact with the substrate 2 and maintains the distance between the two substrates, and a main surface of the TFT array substrate 1 that faces the CF substrate 2 or a main surface of the CF substrate 2 that faces the TFT array substrate 1, A seal pattern 5 arranged in a closed curve shape and a liquid crystal layer 4 sealed between the TFT array substrate 1 and the CF substrate 2 by the seal pattern 5 are provided. The CF substrate 2 includes an insulating substrate 21, a plurality of color filters 23 disposed on the main surface of the insulating substrate 21 on the liquid crystal layer 4 side, and an organic film 24 that covers the boundary between adjacent color filters 23. As described above, since the boundary of the color filter 23 is covered with the organic film 24, even if the interval of the color filter 23 varies due to a process error, the influence of the variation on the cell volume can be suppressed. Further, since the color filter 23 is individually patterned for each of the three color filters, for example, red, green, and blue, the interval is likely to fluctuate due to a process error. Therefore, the position variation due to the process error is small. Therefore, when the liquid crystal material is injected by the ODF method in the manufacture of the liquid crystal panel 101, the amount of dropping can be accurately determined.

  Further, since the organic film 24 extends along the boundary of the color filter 23, even if the interval of the color filter 23 varies due to a process error, the influence of the variation on the cell volume can be suppressed. In injecting the liquid crystal material by the ODF method in manufacturing, the dropping amount can be determined with high accuracy.

  In addition, by arranging the organic film 24 at all boundaries of the color filter 23, even if the interval between the color filters 23 fluctuates due to a process error, the fluctuation does not affect the cell volume. In the case of injecting the liquid crystal material by the ODF method, the dropping amount can be determined with higher accuracy.

  In addition, when the plurality of color filters 23 are arranged apart from each other, the gap may increase or decrease due to a process error, which causes the cell volume to fluctuate. By disposing the organic film 24 so as to cover it, fluctuations in the cell volume can be suppressed.

  The manufacturing method of the liquid crystal panel 101 according to the first embodiment of the present invention prepares a TFT array substrate 1 (first substrate) and a CF substrate 2 (second substrate), and either the TFT array substrate 1 or the CF substrate 2 is prepared. The seal pattern 5 is arranged in a closed curve shape on the main surface of the TFT, and liquid crystal is dropped on the TFT array substrate 1 or the CF substrate 2 on which the seal pattern 5 is arranged, so that the TFT array substrate 1 and the CF substrate 2 are Paste. In preparation of the CF substrate 2, a plurality of color filters 23, an organic film 24 that covers the boundary between adjacent color filters 23, and a post spacer 3 are formed on the main surface of the insulating substrate 21. As described above, the boundary of the color filter 23 is covered with the organic film 24, so that the influence of the change on the cell volume can be suppressed even if the interval of the color filter 23 changes due to the process error. In addition, since the color filter 23 is individually patterned for each of the three color filters of red, green, and blue, the interval is likely to fluctuate due to a process error. Since it is formed by a mask process, there is little position variation due to process errors. Therefore, the amount of liquid crystal dripped can be determined with high accuracy.

<B. Second Embodiment>
<B-1. Configuration>
FIG. 5 is a cross-sectional view showing the configuration of the liquid crystal panel 102 according to the second embodiment. The liquid crystal panel 102 is obtained by reversing the positional relationship between the organic film 24 and the transparent electrode 25 with respect to the liquid crystal panel 101 according to the first embodiment. In the liquid crystal panel 101, the black matrix 22, the color filter 23, the organic film 24, and the transparent electrode 25 are laminated in this order on the insulating substrate 21 in the CF substrate 2. That is, the organic film 24 is disposed in the gap between the color filters 23, and the transparent electrode 25 covers the organic film 24 and the color filter 23 with the transparent electrode 25.

  On the other hand, in the liquid crystal panel 102, the black matrix 22, the color filter 23, the transparent electrode 25, and the organic film 24 are laminated in this order on the insulating substrate 21. The transparent electrode 25 covers the color filter 23, but a step is generated corresponding to the gap between the color filters 23. An organic film 24 is disposed so as to fill this step.

  That is, the liquid crystal panel 102 according to the second embodiment includes the transparent electrode 25 that covers the color filter, the post spacer 3 is formed on the transparent electrode 25, and the organic film 24 is a transparent electrode generated by a gap between the color filters 23. Arranged to fill 25 steps. By providing the transparent electrode 25 under the organic film 24, the organic film 24 and the post spacer 3 can be formed in one exposure process as described later, and the organic film which is a characteristic configuration of the liquid crystal panel 102 The additional process for forming 24 becomes unnecessary, and the manufacturing cost can be reduced.

<B-2. Manufacturing process>
In the manufacturing method of the liquid crystal panel 102, the order of forming the organic film 24 and the transparent electrode 25 is opposite to that of the liquid crystal panel 101. That is, the black matrix 22, the color filter 23, and the transparent electrode 25 are laminated in this order on the insulating substrate 21, and the organic film 24 is formed so as to fill the step of the transparent electrode 25 that occurs according to the gap between the color filters 23.

  Further, not only the organic film 24 but also the post spacer 3 is formed on the transparent electrode 25. The organic film 24 and the post spacer 3 may be formed in different processes, but may be formed in a single exposure process using a photomask whose transmittance is changed in accordance with each formation region. By forming the organic film 24 and the post spacer 3 in the same process, an additional process for forming the organic film 24 which is a characteristic configuration of the liquid crystal panel 102 is not required, and the manufacturing cost can be reduced.

  When the organic film 24 and the post spacer 3 are formed in a single exposure process, the transmittance of the mask is adjusted by using a halftone method in which intermediate exposure is performed using a semi-transmissive film or a slit having a resolution lower than that of the exposure machine. It is possible to use a gray tone method in which an intermediate exposure is performed by blocking a part of light.

  When the liquid crystal panel 102 adopts a dual spacer structure, first, a photosensitive transparent resin film having a thickness corresponding to the thickness of the main spacer 3m (first post spacer) is applied and formed, and exposure processing using known intermediate exposure is performed. And the main spacer 3m is formed by the unexposed area, and the organic film 24 and the sub-spacer 3s (second post spacer) are formed by the intermediate exposed area. That is, a mask having a transmittance different from that of the organic film 24 and the sub-spacer 3s is used for forming the main spacer 3m.

  Further, the sub-spacer 3s and the organic film 24 may be formed at the same height by making the exposure amounts of the formation regions of the sub-spacer 3s and the organic film 24 the same. That is, the sub-spacer 3s and the organic film 24 use the same transmittance mask. Thus, by adjusting the exposure amount of the intermediate exposure for forming the organic film 24 and the sub-spacer 3s, the adjustment of the exposure amount of the intermediate exposure can be simplified.

<C. Embodiment 3>
<C-1. Configuration>
FIG. 6 is a cross-sectional view showing the configuration of the liquid crystal panel 103 according to the third embodiment. The liquid crystal panel 103 includes an overcoat layer 26 that covers the color filter 23 in addition to the configuration of the liquid crystal panel 101 according to the first embodiment. Since a step corresponding to the gap of the color filter 23 is generated in the overcoat layer 26, if the distance between the color filters 23 is shifted due to a process error, the step of the overcoat layer 26 is also shifted, and the cell volume is changed. Therefore, the organic film 24 is disposed so as to fill the step of the overcoat layer 26. Thus, by providing the overcoat layer 26, impurities generated from the color filter 23 can be blocked.

  Since other configurations of the liquid crystal panel 103 are the same as those of the liquid crystal panel 101 according to Embodiment 1, the description thereof is omitted.

  Note that FIG. 6 illustrates an example in which the overcoat layer 26 is applied to the liquid crystal panel 101 according to the first embodiment. However, the overcoat layer 26 may be applied to the liquid crystal panel 102 according to the second embodiment. That is, the transparent electrode 25 may be disposed not in the upper layer of the organic film 24 but in the lower layer. In this case, the transparent electrode 25 is disposed on the overcoat layer 26, and a step is generated in the transparent electrode 25 corresponding to the gap between the color filters 23. Therefore, the organic film 24 is disposed so as to fill the step.

<C-2. Manufacturing process>
A manufacturing process of the liquid crystal panel 103 will be described. In the preparation of the CF substrate 2, the process up to the step of forming the black matrix 22 and the color filter 23 on the insulating substrate 21 is the same as that of the liquid crystal panel 101. In the liquid crystal panel 103, after the color filter 23 is formed, the color filter 23 is covered with an overcoat layer 26. Thereafter, the organic film 24 is formed so as to fill in the steps generated in the overcoat layer 26 corresponding to the gaps in the color filter 23.

  Since other manufacturing processes of the liquid crystal panel 103 are the same as the manufacturing processes of the liquid crystal panel 101 according to Embodiment 1, the description thereof is omitted.

<D. Embodiment 4>
<D-1. Configuration>
FIG. 7 is a cross-sectional view showing the configuration of the liquid crystal panel 104 according to the fourth embodiment. The liquid crystal panel 104 has a configuration in which the color filter 23 is partially overlapped with the liquid crystal panel 101 of Embodiment 1, and the other configuration is the same as that of the liquid crystal panel 101.

  As shown in FIG. 7, protrusions are formed in the overlapping portion of the color filter 23. If a displacement occurs in the arrangement interval of the color filters 23 due to a process error, a displacement occurs in the overlapping state of the color filters 23. As a result, the volume of the protrusions changes, and the cell volume changes.

  Therefore, the liquid crystal panel 104 is disposed so as to cover the protrusions generated by the overlapping of the color filters. More specifically, the organic film 24 is disposed so as to cover the largest protrusion caused by an assumed process error. Thereby, even if the volume of the protrusion varies due to a process error, the cell volume does not vary, so that the liquid crystal dropping amount can be determined with high accuracy.

<D-2. Manufacturing process>
A manufacturing process of the liquid crystal panel 104 will be described. In the liquid crystal panel manufacturing process, in the preparation process of the CF substrate 2, the color filter 23 is formed so as to partially overlap the main surface of the insulating substrate 21, and the organic film is covered so as to cover the protrusion of the overlapping part of the color filter. Except forming 24, it is the same as that of Embodiment 1.

  The organic film 24 is formed by forming an organic film so as to cover the entire surface of the color filter 23 and then patterning so as to cover the protrusions of the overlapping portions of the color filter. At this time, if the photomask 7 having a certain transmittance is used in the region where the organic film 24 is left, a protrusion corresponding to the protrusion of the color filter 23 is formed on the surface of the organic film 24 as shown by a dotted line in FIG. .

  Therefore, the transmittance of the photomask 7 is changed between the protrusions of the overlapping portion of the color filter 23 and the periphery thereof. That is, in the region where the organic film 24 is not formed, the transmittance is reduced to 0%, for example, and in the region where the organic film 24 is formed and the projection of the color filter 23 is not increased, the transmittance is increased to, for example, 100%, the organic film 24 is formed. In the region where the protrusions of the color filter 23 are present, the transmittance is set to a medium with a halftone film, for example, 50%. The transmittance is adjusted by the halftone film according to the height of the protrusion. As a result, the protrusions on the surface of the organic film 24 are reduced, so that the change in cell volume due to the change in the color material interval of the color filter 23 can be further suppressed.

  To adjust the transmittance of the photomask 7, a halftone method that performs intermediate exposure using a semi-transmissive film, or a gray tone method that performs intermediate exposure by blocking a part of light by creating a slit below the resolution of the exposure machine. Use.

<D-3. Modification>
In FIG. 7, the liquid crystal panel 104 according to the fourth embodiment has been described as a configuration in which the color filter 23 is partially overlapped with the liquid crystal panel 101 of the first embodiment. However, in the liquid crystal panel 102 of the second embodiment or the liquid crystal panel 103 of the third embodiment, the color filter 23 may be partially overlapped.

  In the case where the color filter 23 is partially overlapped on the liquid crystal panel 102, the transparent electrode 25 covers the color filter 23. Due to the overlap of the color filter 23, a protrusion is generated on the transparent electrode 25. An organic film 24 is disposed so as to cover this protrusion. Thereby, even when the overlapping state of the color filter 23 is changed due to a process error and the volume of the protrusion of the transparent electrode 25 is changed, the cell volume does not change, so that the liquid crystal dropping amount can be accurately determined. .

  In the case where the color filter 23 is partially overlapped on the liquid crystal panel 103, the overcoat layer 26 covers the color filter 23. Due to the overlap of the color filters 23, protrusions are generated in the overcoat layer 26. An organic film 24 is disposed so as to cover this protrusion. As a result, even when the overlapping degree of the color filter 23 is changed due to a process error and the volume of the protrusion of the overcoat layer 26 is changed, the cell volume does not change, so that the liquid crystal dropping amount can be accurately determined. it can.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

  1 TFT array substrate, 2 color filter (CF) substrate, 3 post spacer, 3 m main spacer, 3s sub spacer, 4 liquid crystal layer, 5 seal pattern, 6 display area, 7 photomask, 21 insulating substrate, 22 black matrix, 23 Color filter, 23B Blue color filter, 23G Green color filter, 23R Red color filter, 24 Organic film, 25 Transparent electrode, 26 Overcoat layer, 101, 102, 103, 104 Liquid crystal panel.

Claims (13)

A first substrate;
A second substrate disposed opposite to the first substrate;
A post spacer that contacts the first substrate and the second substrate to maintain a distance between the two substrates;
A seal pattern arranged in a closed curve on a main surface of the first substrate facing the second substrate or a main surface of the second substrate facing the first substrate;
A liquid crystal layer sealed between the first substrate and the second substrate by the seal pattern,
The second substrate is
An insulating substrate;
A plurality of color filters disposed on a main surface of the insulating substrate on the liquid crystal layer side;
An organic film covering a boundary between the adjacent color filters,
LCD panel. The organic film extends along the boundary;
The liquid crystal panel according to claim 1. The organic film is disposed at all the boundaries,
The liquid crystal panel according to claim 2. The plurality of color filters are spaced apart from each other,
The organic film is disposed so as to cover gaps between the plurality of color filters.
The liquid crystal panel according to claim 1. A transparent electrode covering the color filter;
The post spacer is formed on the transparent electrode,
The organic film is disposed so as to fill a step of the transparent electrode caused by a gap between the color filters.
The liquid crystal panel according to claim 4. An overcoat layer covering the color filter;
The organic film is disposed so as to fill a step of the overcoat layer caused by a gap between the color filters.
The liquid crystal panel according to claim 4. The plurality of color filters are partially overlapped,
The organic film is disposed so as to cover protrusions generated by the overlap of the color filters.
The liquid crystal panel according to claim 1. A transparent electrode covering the color filter;
The post spacer is formed on the transparent electrode,
The organic film is disposed so as to cover the protrusion of the transparent electrode generated by the overlap of the color filters.
The liquid crystal panel according to claim 7. An overcoat layer covering the color filter;
The organic film is disposed so as to cover the protrusion of the overcoat layer generated by the overlap of the color filters.
The liquid crystal panel according to claim 7. Preparing a first substrate and a second substrate;
On the main surface of either the first substrate or the second substrate, a seal pattern is arranged in a closed curve,
A liquid crystal is dropped on the first substrate or the second substrate on which the seal pattern is disposed,
Bonding the first substrate and the second substrate;
A method of manufacturing a liquid crystal panel,
The preparation of the second substrate is as follows:
Forming a plurality of color filters on the main surface of the insulating substrate, an organic film covering a boundary between the adjacent color filters, and a post spacer.
A method for manufacturing a liquid crystal panel. In the preparation of the second substrate, the organic film and the post spacer are formed by the same exposure process using masks having different transmittances.
The manufacturing method of the liquid crystal panel of Claim 10. The post spacer includes a first post spacer and a second post spacer having a height lower than that of the first post spacer.
In the preparation of the second substrate, the organic film and the second post spacer use a mask with the same transmittance, and the first post spacer uses a mask with a different transmittance, and each has the same exposure process. It is formed,
The manufacturing method of the liquid crystal panel of Claim 10. In preparing the second substrate, the plurality of color filters are partially overlapped on the main surface of the insulating substrate, and masks having different transmittances are formed on the protrusions of the overlapping portions of the color filters and the periphery thereof. Forming and forming the organic film by exposure using the mask,
The manufacturing method of the liquid crystal panel of Claim 10.

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