JP3102996B2 - Liquid crystal display device and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a liquid crystal display device used for AV (Audio Vidual) equipment and OA (Office Automation) equipment, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, home televisions used as AV equipment and display devices used for OA equipment have been reduced in weight.
There is a demand for thinner, lower power consumption, higher definition, and larger screens. For this reason, CRTs and liquid crystal displays (L
CD), plasma display (PDP), EL (electrolu
minescent) display device, LED (light emitting display)
The development and commercialization of a large-screen display device such as a display device has been promoted.

[0003] Among them, the liquid crystal display device has the advantages that the thickness (depth) can be remarkably reduced, the power consumption is small, and the full color display is easy, compared with other display devices. It is being used in various fields, and there is great expectation for larger screens.

On the other hand, when the size of the screen of the liquid crystal display device is increased, a defective rate due to disconnection of a signal line, a pixel defect, or the like in a manufacturing process sharply increases, and further, the price of the liquid crystal display device increases. Such a problem arises. In order to solve this problem, a plurality of liquid crystal display devices are connected to form a single multi-display type liquid crystal display device as a whole, and the screen size is increased.

[0005] However, in the above-mentioned multi-display type liquid crystal display device, in a display device in which liquid crystal panels are simply joined together, light from a backlight leaks from a gap formed at a connection portion of each liquid crystal panel, and a joint of the liquid crystal panels is formed. Is noticeable.

Therefore, in order to obtain a natural large-screen image, it is necessary to make joints between display screens inconspicuous. Specifically, the following multi-display method has been proposed.

(Conventional example A) Japanese Patent Application Laid-Open Nos. 1-213621 and 5-127605 disclose a direct-view large-screen liquid crystal display device. As shown in FIG.
In the liquid crystal display device 101 disclosed in Japanese Patent Laid-Open No. 127605, a transparent electrode 103 is formed on a liquid crystal layer 102 of a polymer dispersion type.
, Color filter 104 and glass substrate 105
Is provided.

On the other hand, a thin film transistor (TFT) 106
A liquid crystal display element 114 is formed by forming a matrix array including a source electrode 107, a drain electrode 108, a gate electrode 109, amorphous silicon 110, and a gate insulating film 112 and a pixel electrode portion 111 on a glass substrate 113. Is provided.

Then, a plurality of liquid crystal display elements 114.
By arranging and connecting the pixel electrode portions 111 of the liquid crystal display elements 114 and the transparent electrodes 103 forming a pair with each other on the same plane on the glass reinforcing plate 115, The screen is being enlarged.

(Conventional Example B) As shown in FIG. 27, in a liquid crystal display device 120 disclosed in Japanese Utility Model Publication No. 6-17178, a plurality of liquid crystal panels 121 are connected to a reinforcing substrate 123.
By providing blind layers 122 covering the gaps of the seams formed in the reinforcing substrate 123 when joining on the upper side, the seams between the liquid crystal panels 121 are concealed, and the screen size is increased while avoiding the deterioration of the display image quality. It is trying to make it.

(Conventional Example C) FIG. 28 shows a configuration example of a liquid crystal display device disclosed in JP-A-5-188340 and JP-A-5-341310. That is, in the liquid crystal display device 130, a plurality of transmissive liquid crystal panels 131 ...
Light sources 132 are provided as irradiation means on the back side of
Further, as an image enlarging unit or an image parallel moving unit, a refractive index distribution lens group 133.
4 and the screen 135 are the respective liquid crystal panels 131.
Are provided on the surface side which is the display surface side.

The respective refractive index distribution lens groups 133,..., Fresnel, so that the respective display images projected and formed on the screen 135 by the respective liquid crystal panels 131 are joined on the screen 135. The lenses 134 are adjusted. As a result, in each display image on the screen 135, a good display image with no noticeable seam can be obtained, and a large-screen rear-projection liquid crystal display device that avoids deterioration of display image quality is realized.

(Conventional Example D) FIG. 29 shows a configuration example of a liquid crystal display device disclosed in JP-A-5-19346 and JP-A-5-19347. That is, the liquid crystal display device 1
In 40, the projection lens 1 having the variable diaphragm 141
42, liquid crystal light valve 143, field lens 14
4, a projection type image display unit 147 composed of a concave reflecting mirror 145 and a light source lamp 146, and a screen 148 are used.

The plurality of projection image display units 147 are arranged such that projection images projected from the projection image display units 147 are arranged adjacent to each other on the screen 148 in the vertical and horizontal directions. As a result, a front-projection large-screen liquid crystal display device constituting one large screen is realized.

In the liquid crystal display device 140, the viewing angles of the upper and lower two-stage projection type image display units 147 are set to be vertically opposite to each other, and the amount of light at the seam on the large screen is reduced. , Or by adjusting the luminance unevenness of each of the projection image display units 147.

However, the system of the conventional example C has the following problems. That is, it is basically a type of rear projection type display device (rear projector) that projects an image on the back of the screen, and it is necessary to use a screen that exhibits scattering and semi-transmission. Therefore, there is a problem that a decrease in contrast in a display image cannot be denied.

In addition, since a lens optical system such as an image enlarging unit and a parallel moving unit is used, light use efficiency is reduced, and a high-luminance irradiating unit is required. Therefore, there is a problem that power consumption increases.

Further, there is a problem that the cost is increased due to the presence of the lens optical system, and the thickness (depth) of the device is increased as compared with a direct-view type liquid crystal display device.

The method of the prior art D is the same as the screen 14
8 is a type of a front projection type display device (front projector) that projects an image on the front surface of the display device 8, and it is necessary to use a screen that exhibits scattering and reflection. Therefore, similarly to the method of the above-mentioned conventional example C, there is a problem that the reduction of contrast cannot be denied and a problem that power consumption increases due to the necessity of a high-brightness projection lamp.

On the other hand, the systems of the conventional examples A and B are liquid crystal display devices of a direct-view type. That is, a backlight such as a cold-cathode tube is placed behind the liquid crystal panel. Then, the liquid crystal panel modulates the light of the backlight in accordance with the image information, so that the observer can observe the image information input to the liquid crystal panel. Therefore, unlike a rear projection type or front projection type liquid crystal display device as in the above-mentioned conventional examples C and D, it is not necessary to use a screen showing scattering, translucency or reflection. Thereby, a decrease in contrast can be prevented.

Further, since a lens optical system such as an image enlarging means and a parallel moving means is not required, the light use efficiency is not reduced and a high-luminance irradiating means is not required. Thereby, an increase in power consumption can be prevented. Further, since a lens optical system is unnecessary, the cost can be reduced, and the increase in the thickness (depth) of the device can be suppressed.

[0022]

However, the conventional large-screen liquid crystal display devices using the multi-display system as shown in the above-mentioned conventional examples A and B have the following problems, respectively.

In the method of the conventional example A, the seam of the glass substrates 113 on which the TFTs 106 are formed is affected by the warpage of the glass substrates 113 and the variation of the glass thickness.
A step of 10 μm occurs. Therefore, the thickness of the liquid crystal layer 102 sealed in the liquid crystal panel varies.

In a twisted nematic (TN) liquid crystal display mode generally used in a TFT-LCD or the like, if the liquid crystal layer thickness has such a degree of variation, display is adversely affected and display quality is lowered.

For this reason, among the systems of the conventional example A, the system disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 5-127605 employs the polymer dispersion type liquid crystal display mode as described above, and this A method to avoid the adverse effects is proposed. However, the direct-view polymer dispersed liquid crystal display mode is
In principle, the contrast is poor, that is, display is performed by switching between confusion and transmission. Therefore, there is a problem that the contrast is deteriorated. In addition, the driving voltage increases due to the presence of the polymer, and the power consumption increases. It also has problems and is not a valid solution.

In the system of the prior art B, as described above, when connecting the plurality of liquid crystal panels 121, the blindfold layers 122 are provided on the reinforcing substrate 123 in order to prevent light leaking from the gap. However, since the glass substrates constituting the liquid crystal panels 121 have a thickness of usually 1.1 mm or 0.7 mm, when observing the liquid crystal display device 120 from an oblique direction, a liquid crystal layer for displaying an image and a blindfold layer 122. Parallax occurs according to the glass thickness. For this reason, there is a problem that the blind layers 122 are conspicuous from the oblique direction, and the joints of the liquid crystal panels 121 are conspicuous.

It is an object of the present invention to provide a liquid crystal display device which solves these problems in the multi-display system and has excellent display image quality in which the display images of the liquid crystal panels are not conspicuous even on a large screen. And

[0028]

According to a first aspect of the present invention, there is provided a liquid crystal display device having a large number of pixels for displaying an image in a matrix, and driving the pixels. A first substrate and a second substrate, each having a substantially rectangular shape and having signal lines intersecting each other in a matrix, are attached to each other with a sealing material for sealing a liquid crystal between the first and second substrates. A liquid crystal panel having a first surface obtained by removing at least one side portion of the first and second substrates along the outside of the sealing material;
A composite panel composed of a plurality of liquid crystal panels is provided with the first surfaces of the liquid crystal panels facing each other so that the display surfaces of the liquid crystal panels are flush with each other, and the first substrate includes:
Terminals that can be connected to the outside are formed at both ends of each of the signal lines. In each of the liquid crystal panels, the sealing material and the first
And the second substrate is divided in the thickness direction of the first and second substrates, whereby the sealing material and the first and second substrates are formed so that the first surfaces are flush with each other. It is characterized by: Claim 3 of the present invention
The liquid crystal display device according to the above configuration, wherein the seal
The material and the first and second substrates are combined with the first and second substrates.
The sealing material can be separated by batch cutting in the thickness direction.
And the first and second substrates are flush with the first surface.
, Respectively. Ma
The liquid crystal display device according to claim 4 of the present invention has the above configuration.
Wherein the sealing material and the first and second substrates are
Dicing blade in the thickness direction of the first and second substrates
By dividing using the sealing material,
The second substrate is formed so that the first surface is flush with the first surface.
It is characterized by being made.

According to a second aspect of the present invention, there is provided a method for manufacturing a liquid crystal display device, comprising: a first substrate having a substantially rectangular shape having signal lines for driving pixels for displaying an image in a matrix shape crossing each other; Are formed so as to have terminals that can be connected to the outside at both ends of each of the signal lines, and then the first for forming the pixels in a matrix is formed.
After bonding the substrate and the second substrate with a sealing material for sealing liquid crystal between them, the sealing material and the first and second substrates are bonded in the thickness direction of the first and second substrates. Then, a plurality of liquid crystal panels in which the first surface on which the sealing material and the first and second substrates are flush with each other are formed at different positions by dividing the sealing material along the sealing material are formed. A composite panel having a large screen is manufactured by fixing the liquid crystal panels with the first surfaces of the liquid crystal panels facing each other so that the display surfaces of the liquid crystal panels are flush with each other. In addition, the present invention
The method of manufacturing a liquid crystal display device according to claim 5, wherein
In at least the step of forming the first surface,
The sealing material is separated from the first and second substrates in a lump.
It is characterized by. According to claim 6 of the present invention.
The method for manufacturing a liquid crystal display device according to
At least in the step of forming the first surface, the sealing material
Using a dicing blade to cut the first and second substrates
It is characterized by that.

[0030]

According to the first aspect of the present invention, the first and second substrates are bonded together with a sealing material, and at least one side of the first and second substrates is removed along the sealing material. Since a plurality of liquid crystal panels having the same first surface are provided and the composite panel is provided with the first surfaces facing each other, the seam of each liquid crystal panel in the composite panel can be made smaller than before. And a composite panel with less noticeable seams.

In addition, in the above configuration, terminals connectable to the outside are provided at both ends of each signal line, so that the liquid crystal panel can be driven by using either terminal at each end of each signal line. it can.

Therefore, a plurality of first and second substrates bonded by a sealing material are used, and their dividing positions are determined by removing one terminal of each first substrate and setting the removed terminal to a different position. By setting each of the first and second substrates to be bonded, for example, by using two substrates and dividing them as described above,
Each of the two divided first and second substrates can be, for example, left and right liquid crystal panels.

Thus, in the above configuration, one kind of first type
The left and right liquid crystal panels are respectively manufactured from the substrates, that is, the first substrate having one type of each signal line pattern is
A large-screen composite panel can be manufactured by using a plurality of composite panels.

According to the second aspect of the present invention, the sealing material is separated from the first and second substrates in the thickness direction of the first and second substrates along the sealing material. And a first surface, which is a cross section in which the first and second substrates are flush with each other, are formed at different positions, and a plurality of such liquid crystal panels are arranged so that the first surface faces each other. By fixing the display surfaces so as to be flush with each other and obtaining the composite panel, the joints in the composite panel can be made inconspicuous.

That is, since the sealing member and the end faces of the first and second substrates that are exposed are flush with each other, a gap is prevented between the first and second substrates in the dividing section by the sealing material. Since it is possible to provide each pixel in each of the liquid crystal panels closer to each other, it is possible to make joints generated between the liquid crystal panels less noticeable than in the related art.

In addition, in the above method, the first substrate is manufactured so that each signal line has terminals that can be connected to the outside at both ends of each signal line. Even if one of the terminals of each signal line is removed from the substrate by cutting, the first substrate can be driven by the remaining terminals.

Thus, in the above method, a plurality of first substrates having one type of each signal line pattern are used, and a plurality of first substrates each having one type of each signal line pattern are changed by changing their dividing positions. For example, left and right liquid crystal panels can be easily manufactured from the substrate.

[0038]

【Example】

[Embodiment 1] An embodiment of the present invention will be described below with reference to FIGS. In the liquid crystal display device according to the present embodiment, as shown in FIG.
A composite panel having a plurality of liquid crystal panels 2 'for displaying an image by transmitting / blocking transmitted light based on an image signal and joined to each other such that the display surfaces of the liquid crystal panels 2' are flush with each other. 1 is provided.

Thus, in the above-mentioned liquid crystal display device, it is easy to manufacture the large-screen composite panel 1 by using a plurality of small liquid crystal display elements of about 10 inches which can be manufactured with high yield as the liquid crystal panel 2 ′. , And can be stabilized.

The composite panel 1 is a direct-view type liquid crystal display device having a large screen, and is manufactured as follows.
First, the active matrix type liquid crystal panel 2 ′ is
Are arranged so that the display surfaces of the liquid crystal panels 2 'are flush with each other on the same plane of a large substrate 3 (substrate). LCD panel 2 '
Are provided with a backlight such as a cold cathode tube for supplying the transmitted light.

The driver for controlling the image signal and the above-mentioned backlight are omitted in the figure. This liquid crystal panel 2 '... Modulates the light of the backlight in accordance with the image signal, that is, connects and disconnects, thereby forming
.. Can be observed as a display image by the observer.

As shown in FIG. 3, the configuration of the liquid crystal panel 2 'has an active matrix type liquid crystal panel structure using active elements arranged in a matrix, which is generally well known.

The liquid crystal panel 2 'is provided by dividing the liquid crystal panel 2 at a side having a joint surface. The liquid crystal panel 2 includes a glass substrate 10 (panel substrate) and a glass substrate 11 as a counter substrate disposed in parallel with the glass substrate 10 at an interval for enclosing the liquid crystal 7.

On the glass substrate 10, a pixel electrode 15 is provided.
And a large number of thin film transistors (TFTs) 16 for driving the pixel electrodes 15 are formed in a matrix, and further, a scanning signal line 14 and a data signal for transmitting a control signal based on an image signal to each of the TFTs 16. A large number of lines 13 are formed like a ruled line of a go board crossing each other.

Therefore, on the glass substrate 10, the TFTs 1 are located at the intersections of the signal lines 13 and 14 so that the control signals from the signal lines 13 and 14 can be easily transmitted.
6 and each pixel electrode 15 are arranged.

Each of the TFTs 16 is a field-effect transistor using a semiconductor thin film such as amorphous silicon (a-Si: H) or polycrystalline silicon (p-Si). On the other hand, the supply of the image signal to the pixel electrode 15 is controlled by connecting the source electrode of each TFT 16 to the data signal line 13.

The pixel electrode 15 is formed of a transparent conductive film such as ITO (Indium Tin Oxide) when used as a transmissive display device and a reflective conductive film such as Al when used as a reflective display device. .

On the glass substrate 11, a common electrode 12 for forming an electric field and a black matrix 5 for separating each pixel are formed facing the whole of the pixel electrodes 15. ing. When performing color display, R (red), G (green), and B (red) correspond to each pixel electrode.
(Blue) color filters 4 are formed. The black matrix 5 is provided on the glass substrate 11 on the display surface side.
Not only on the side but also on the glass substrate 10 side which is the back side.

The black matrix 5 includes the pixel electrode 1
5 are provided to block light from entering the gaps between the TFTs and the TFT area, and block light along the signal lines 13 and 14 and from positions different from the pixel electrodes 15. It is formed in a net-like shape.

When light passes through areas other than the pixel electrodes 15, there is a problem that the quality of the black display state is reduced and the contrast is reduced. In addition, TFT16
.. Incident on the TFT channel, a leakage current occurs due to light excitation, which causes a problem of deteriorating display image quality. Therefore, the black matrix 5 is provided to avoid the above problems.

In this embodiment, the black matrix 5 is formed of a light absorbing film made of a material that absorbs light and exhibits a black color. As a material of this light absorbing film,
Organic materials in which pigments and semiconductor particles such as carbon particles and titanium oxide particles are dispersed in resin, or Group IV semiconductor materials such as silicon (Si), carbon (C), germanium (Ge), and tin (Sn) An inorganic material such as an amorphous thin film mainly composed of is used.

When the above-mentioned black organic material is used, it is not necessary to use a vacuum apparatus, and the organic material can be applied by printing or spin coating to form a light absorbing film. There is an advantage that can be formed.

In order to form an amorphous thin film using a group IV semiconductor material, a CVD (Chemical Vapor Deposi
Although it is necessary to use a vacuum device such as an option, there is an advantage that a black matrix 5 having a larger absorption coefficient than an organic material can be formed.

For example, a typical absorption coefficient of a black organic material in which fine carbon particles are dispersed in a resin is 10 ⁴ (cm).
^-1 ), whereas the absorption coefficient of an amorphous thin film (a-SiGe: H) using Si and Ge is 10 ⁵ (cm).
^-1 ). However, both are absorption coefficients for light having a wavelength of 650 nm.

The liquid crystal panel 2 is formed by bonding the glass substrates 10 and 11 via the sealing material 6 shown in FIG. 2 so that the pixel electrode 15 and the common electrode 12 face each other. This is performed by enclosing the liquid crystal 7 between 10 and 11.

Here, the sealing material 6 in the vicinity of the connection portion of the liquid crystal panel 2 must be arranged precisely in the vicinity of the pixel. However, when a thermosetting resin such as an epoxy resin is used for the sealing material 6, poor alignment of the liquid crystal occurs in a region of several hundred μm near the seal due to heat dripping of the sealing material 6 during thermosetting.

Therefore, in the liquid crystal display device according to the present embodiment, the sealing material 6 is irradiated with an ultraviolet curable resin or a thermosetting ultraviolet curable resin, for example, an acrylic or epoxy resin, or ultraviolet rays. Uses one that cures. For this reason, in the liquid crystal display device, since no heat dripping occurs in the liquid crystal of the pixel, it is possible to dispose the sealing material 6 very close to the pixel.

FIGS. 4 (a) and 4 (b) show the liquid crystal panel 2 obtained by removing the side of the liquid crystal panel 2 obtained in this manner at the position to be the bonding surface by dividing it. FIG. 2 is a layout view when each of the liquid crystal panels 2 ′ is formed and the respective liquid crystal panels 2 ′ are arranged on one large-sized substrate 3 (not shown). As shown in FIG.
Is a dividing line 17 near the edge of the image display area.
Break along 17

As shown in FIG. 5B, each liquid crystal panel 2 ′ is attached on the large-sized substrate 3 so as to join the bonding surfaces, which are the above-mentioned divided portions. At this time, the connection is made such that the width b of the gap (connection portion) generated at the time of joining is smaller than the line width a of the black matrix 5 required for one pixel.

If the width b of the gap is too large as compared with the line width a of the black matrix 5, the pixel pitch of the entire display screen is broken at the connection portion of the liquid crystal panels 2 '. On the other hand, the observer may feel uncomfortable. The pixel has an area approximately equal to that of the color filter 4.

Therefore, the division of the liquid crystal panel 2 requires a high degree of positional accuracy and finishing accuracy of the divided section. what if,
If the dividing lines 17 of the liquid crystal panel 2 are distorted or if there are irregularities of several hundred μm in the dividing plane of the liquid crystal panel 2 ′, more gaps will be generated when the liquid crystal panels 2 ′ are joined.

However, in the method of dividing the liquid crystal panel 2 by a general scribing, it is not possible to avoid the distortion of the cross section of several hundred μm. A cutting method using a dicing device is suitable for obtaining high cutting position accuracy and cutting section finishing accuracy.

Therefore, in the present embodiment, the dividing position accuracy is set to 50 μm or less by the dividing method using the dicing device.
The cross-section finishing accuracy could be suppressed to 5 μm or less, and the joint of the liquid crystal panel 2 ′ could be narrowed. Since the width b of the gap is equal to or less than the line width a of the black matrix 5, for example, 200 μm, the pixel pitch of the entire composite panel 1 can be made uniform.

As shown in FIG. 2, the liquid crystal panel 2 '
Are joined together with a refractive index adjusting material 9 at the connection portions of the liquid crystal panels 2 '. In this embodiment, the glass substrate 1
Since a glass substrate (Corning 7059) having a refractive index of 1.53 is used for 0 and the glass substrate 11, it is necessary to use a material having a refractive index of 1.53 as the refractive index adjusting material 9.

As such a material, for example, a resin having a double bond site such as an acrylic type or an ene / thiol type, and the above double bond is cleaved by irradiation with ultraviolet rays to carry out polymerization. It is preferable to use a resin whose refractive index after curing is adjusted to 1.53. The refractive index adjusting material 9 can also be used as an adhesive when the liquid crystal panel 2 ′ is bonded to the large substrate 3. In addition, a refractive index adjusting liquid such as silicone oil having a refractive index of 1.53 can be used.

The polarizing plates 8.8 are provided on substantially the entire front and back surfaces of the liquid crystal panels 2 'joined together in such a manner that the polarization axes thereof are orthogonal to each other, so that a composite structure is obtained. The panel 1 is formed.

Here, in general, in a liquid crystal display device in which an active matrix type liquid crystal panel using a TFT is simply joined as a multi-display type liquid crystal display device, a gap generated at a connection portion of each liquid crystal panel is taken into consideration. Light from the backlight leaks and the seams of the liquid crystal panel are conspicuous.

However, in the liquid crystal display device of the present embodiment, the polarizing plates 8.8 are provided on almost the entire surface of the composite panel 1 constituted by joining a plurality of liquid crystal panels 2 '. As shown in FIG. 5, light leakage 18 from the connection between the liquid crystal panels 2 ′ is caused by the polarization plates 8.
Is in a crossed Nicol state, and is therefore blocked.

As a result, when viewed from an observer A located substantially in front of the composite panel 1, the joints of the connection portions of the liquid crystal panels 2 'are completely in the crossed Nicols state of the polarizing plates 8.8. , The joints between the liquid crystal panels 2 ′... Can be made less noticeable.

When a metal light-shielding material such as chromium (Cr) or molybdenum (Mo) is used for the black matrix 5, the state of surface reflection by the black matrix 5 and the black color of the connection portions of the liquid crystal panels 2 '. State (crossed Nicol state of polarizing plates 8.8)
The effect of making the seams less noticeable is weakened.

However, in the liquid crystal display device of this embodiment, since the black matrix 5 uses a light absorbing film made of a black material and absorbs light, the reflected light 19 from the black matrix 5 is absorbed by the light. It takes on a black color.
That is, surface reflection on the black matrix 5 can be reduced.

As a result, both the leakage 18 of the backlight light from the gap generated at the connection between the liquid crystal panels 2 'and the reflected light 19 from the black matrix 5 become black and cannot be distinguished. As a result, the liquid crystal panel 2 '...
Joints can be made less noticeable.

In general, when joining a plurality of liquid crystal panels, it is very difficult to join them without a step due to the influence of variations in the glass thickness of the liquid crystal panels and warpage. Further, when processing the liquid crystal panel, scratches such as pitching are generated on the edge of the liquid crystal panel. If there is such a step at the joint portion of the liquid crystal panel or a scratch on the edge of the liquid crystal panel, light is scattered there, which causes the seam to stand out.

However, in the liquid crystal display device of this embodiment, as shown in FIG. 2, the composite panel 1 is provided by bonding a plurality of liquid crystal panels 2 ′ on one large substrate 3. When an observer observes an image from the large-sized substrate 3 side, no steps or scratches are exposed on the surface of the composite panel 1 due to the influence of the variation in the glass thickness of the liquid crystal panels 2 ′, warpage, and the like. Thereby, in the composite panel 1, it is possible to obtain a natural image in which the joints are less noticeable.

The large-sized substrate 3 also serves as a reinforcing plate when a plurality of liquid crystal panels 2 ′ are joined together to increase the area of the composite panel 1, so that the impact resistance of the composite panel 1 can be increased. Can be. Thereby, in the composite panel 1, it is possible to stably obtain a natural image with less noticeable seams over a long period of time.

Further, as described above, the liquid crystal panel 2 '
Since there is no variation in the thickness of the liquid crystal layer encapsulated therein, the display is not adversely affected even when the twisted nematic (TN) liquid crystal display mode is used. Thereby, it is possible to prevent a decrease in display quality in such a display mode.

At the same time, in the configuration of the above embodiment, it is not necessary to use the direct-view type polymer dispersion type liquid crystal display mode as in the related art, so that the contrast does not decrease.
Further, since the driving voltage can be kept low, an increase in power consumption can be suppressed.

Further, as described above, when the black matrix 5 is formed using a Group IV semiconductor material, the absorption coefficient of the black matrix 5 can be further increased as compared with the case where the black matrix 5 is formed using an organic material. , The surface reflection of the black matrix 5 can be reduced more effectively. This makes it possible to make the joints of the liquid crystal panels 2 '... Less noticeable.

Further, as described above, in the composite panel 1, since the ultraviolet curing resin or the thermosetting ultraviolet curing resin is used as the sealing material 6, no heat dripping occurs and the pixel is extremely close to the pixel. It is possible to dispose the sealing material 6 on the surface. This makes it possible to obtain a natural image in which the seams are less noticeable.

As described above, since the width b of the gap between the liquid crystal panels 2 '... Is smaller than the line width a of the black matrix 5 (see FIG. 4), the pixel pitch of the entire composite panel 1 is made uniform. can do. This makes it possible to obtain a natural image in which the joints are less noticeable.

As described above, each of the liquid crystal panels 2 '.
Are filled with a refractive index adjusting material 9 having substantially the same refractive index as the glass substrate 10 and the glass substrate 11 which are the substrates constituting the liquid crystal panel 2 '. Light is refracted due to unevenness of the end face
Scattering is prevented. This makes it possible to obtain a natural image in which the seams are less noticeable.

As described above, the refractive index adjusting material 9 is
The liquid crystal panel 2 ′ can also be used as an adhesive for bonding the liquid crystal panel 2 ′ to the large substrate 3. In this case, when light is reflected at the interface between the large substrate 3 and the glass substrate 11, the display contrast is reduced. Therefore, it is preferable to use a resin having the same refractive index as the glass substrate 11 and the large-sized substrate 3. This makes it possible to obtain a natural image in which the seams are less noticeable.

Further, as described above, in this embodiment, an active matrix type liquid crystal panel using TFTs 16 is used as the liquid crystal panel 2 ′. However, as the active matrix type liquid crystal panel, a diode ( MI
M, Metal Insulator Metal) is also effective. Further, the present invention is also effective for a liquid crystal panel of a duty drive type as a liquid crystal panel other than the active matrix type.
However, it is desirable to use an active-matrix liquid crystal panel because crosstalk between pixels is small and an image with higher display quality can be obtained.

Embodiment 2 Another embodiment of the present invention will be described below as Embodiment 2 with reference to FIGS. 2 and 6. For the sake of convenience of explanation, members having the same functions as those shown in the drawings of the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted.

As shown in FIG. 6, in the liquid crystal display device of this embodiment, two joined liquid crystal panels 2 'are composed of two large substrates, that is, a large substrate 3 (substrate) and a large substrate 21.
A composite panel 20 sandwiched between (a substrate) is provided. Each of the liquid crystal panels 2 'used has the same structure as that used in the first embodiment. Note that a driver for controlling an image signal and a backlight are omitted in the drawing.

The composite panel 20 is the composite panel 1 of the first embodiment.
The difference is that after the liquid crystal panel 2 'is pasted on the same plane of the large substrate 3, the large substrate 21 is further pasted on the liquid crystal panel 2'. In order to attach the large-sized substrate 21, it is preferable to use the refractive index adjusting material 9 used when joining the liquid crystal panels 2 '.

The composite panel 1 according to the first embodiment (FIG. 2)
), A plurality of liquid crystal panels 2 ′ are adhered on the same plane of the large substrate 3 with the resin as the refractive index adjusting material 9. Protrusion, steps and irregularities are formed.

The steps and irregularities are light scattering elements, and the light passing therethrough is scattered to change the polarization state. Therefore, the black state of the polarizing plates 8.8 due to crossed Nicols cannot be maintained. Therefore, it is necessary to remove the protruding resin.

However, in the composite panel 20 according to the present embodiment, as shown in FIG. 6, the large substrate 21 is provided on the back surface (backlight side) of the composite panel 20, that is, on the glass substrate 10 side. The resin does not protrude from the connection part of 2 ′. Therefore, light scattering elements such as steps and unevenness between the resin surface of the connection portion of the liquid crystal panel 2 ′... And the surface of the liquid crystal panel 2 ′ on the glass substrate 10 side can be eliminated.

Therefore, it is possible to suppress the scattering of the light passing through the connecting portions of the liquid crystal panels 2 '... And to prevent the change in the polarization state. The visible state can be kept good. As a result, compared to the composite panel 1 according to the first embodiment, a more natural image display with less noticeable joints can be easily obtained.

Also, the joined liquid crystal panels 2 'are
Since the composite panel 20 is sandwiched between the two large substrates 3 and the large substrate 21, the strength of the composite panel 20 can be further increased. Handling can be significantly facilitated.

Further, there are steps such as unevenness of the glass thickness of the liquid crystal panel 2 'on the back surface (backlight side) of the composite panel 20 due to the influence of warpage and the like, and scratches such as pitching of the edge of the liquid crystal panel 2'. Exposure can be prevented by the large substrate 21.

Therefore, the scattering of light passing through the connecting portions of the liquid crystal panels 2 '... Is further suppressed, and the change in the polarization state is further prevented. It can be kept better. This makes it easier to obtain a more natural image display with less noticeable joints.

Third Embodiment A third embodiment of the present invention will be described below with reference to FIGS. 7 to 10 as a third embodiment. For the sake of convenience, members having the same functions as those shown in the drawings of the above-described embodiment will be denoted by the same reference numerals, and description thereof will be omitted.

As shown in FIG. 7, in the liquid crystal display device according to the present embodiment, in addition to the composite panel 1 in the first embodiment, a black portion is formed on the connection portion (the end face of the glass substrate 11) of the liquid crystal panel 2 '. There is provided a composite panel 30 in which second light-shielding films 31, 31 extending perpendicular to the matrix 5 and extending in the surface direction of the liquid crystal panel 2 'are formed.

The second light-shielding films 31 may be made of a black resin in which a pigment or semiconductor fine particles (for example, carbon fine particles or titanium oxide fine particles) are dispersed in a resin.

As described above, in the composite panel 1 and the composite panel 20 shown in the first and second embodiments, the backlight light leaked from the gap generated at the connection portion of the liquid crystal panels 2 '. The connection portion is cut off in the direct Nicol state of 8.8, and the connection portion looks black, so that the black of the black matrix 5 and the blackness of the connection portion cannot be distinguished. As a result, the seams of the liquid crystal panels 2 'are less noticeable. Composite panel 1 and composite panel 20
Has such a feature.

The above features are the same in the composite panel 30 of the liquid crystal display device according to the third embodiment. That is, as shown in FIG. 8, when viewed from an observer A located substantially in front of the composite panel 30, the joints of the connection portions of the liquid crystal panels 2 ′... Since a black state can be realized (indicated by a circle in the figure), the seams of the liquid crystal panels 2 'are inconspicuous.

However, a polarizing plate generally has a viewing angle characteristic. In other words, the light obliquely incident on the polarizing plate cannot be completely blocked even in the crossed Nicols state, and the black state at the connection cannot be maintained. As shown in FIG. 10, in the composite panel 1 of the first embodiment, when viewed from an observer A located substantially in front of the composite panel 1, the liquid crystal panels 2 ′. A completely black state of the connection part can be realized (in the figure, ○
), And the seams of the liquid crystal panels 2 'are inconspicuous.

However, from the observer B located in the oblique direction of the composite panel 1, light leakage of the backlight occurs at the connection portion of the liquid crystal panels 2 '... Depending on the viewing angle characteristics of the polarizing plates 8 (8). In the figure, the result is indicated by x, and the seam is slightly conspicuous.

On the other hand, in the liquid crystal display device according to the present embodiment, as shown in FIG. 8, even when viewed from an observer B located in the oblique direction of the composite panel 30, the liquid crystal panel 2 '. Since the leakage light generated at the connection portion is shielded by the second light shielding film 31, it is possible to realize a state in which the connection portion looks completely black, as in the case of the observer A (in the figure, a circle). ), The joints of the liquid crystal panels 2 ′... Can be made inconspicuous.

Thus, in the liquid crystal display device according to the present embodiment, the seams of the liquid crystal panels 2 'can be made inconspicuous in a wide viewing angle range regardless of the viewing angle of the observer.

Here, as shown in FIG. 9, when the line width at the end of the glass substrate 11 of the black matrix 5 is c and the width of the second light-shielding film 31 is d, the design is such that c ≒ d. Is within ± 45 degrees, color filter 4
Is not blocked by the second light shielding film 31.

However, if c <d, the angle at which the image display light passing through the color filter 4 is shielded by the second light-shielding film 31 is increased, so that the viewing angle of the composite panel 30 is reduced. Therefore, it is necessary to satisfy c ≒ d or c> d when designing the second light shielding film 31 so as not to narrow the viewing angle of the composite panel 30.

The formation position and shape of the second light-shielding film 31 are not limited to those shown in FIGS. 6 to 8, and the observation position of the composite panel 30 in the oblique direction is not reduced without reducing the viewing angle of the composite panel 30. When viewed from the user, it is only necessary that light leaking from the connection portions of the liquid crystal panels 2 ′.

Fourth Embodiment A fourth embodiment of the present invention will be described below with reference to FIGS. 11 and 12 as a fourth embodiment. For the sake of convenience of explanation, members having the same functions as those shown in the drawings of the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted.

As described above, the liquid crystal display devices shown in Embodiments 1 to 3 use a film formed of a black organic material or an inorganic material for the black matrix 5 and reflect light from the black matrix 5. Of the liquid crystal panel 2 ′...

Here, as described above, the black matrix 5 using an organic material or an inorganic material has a lower light-shielding property than a black matrix using a metal film. Is required to be 1 μm or more. However, if the thickness is 1 μm or more, there is a possibility that the uniformity of the cell gap of the liquid crystal panel 2 ′ is adversely affected.

On the other hand, in the liquid crystal display device according to the present embodiment, as shown in FIG. 11, the light absorbing film 41 and the metal film 42 are laminated to form the black matrix 5.
(First light-shielding film). Note that chromium (Cr), aluminum (Al), or the like can be used for the metal film 42.

Due to the excellent light-shielding properties of the metal film 42,
The light shielding properties of the black matrix 5 can be improved while the thickness of the black matrix 5 is suppressed to 0.5 μm or less. Therefore, the uniformity of the cell gap of the liquid crystal panel 2 ′ can be improved.

As shown in FIG. 12, similarly to the composite panel 20 of the second embodiment, a composite panel 45 having two large substrates 3 and 21 and employing the black matrix 5 can be provided. Also in this case, the uniformity of the cell gap of the liquid crystal panel 2 'can be improved as described above.

In this embodiment, the black matrix 5 formed by the light absorbing film 41 and the metal film 42 is provided on the glass substrate 11 side, but the black matrix 5 may be provided on the glass substrate 10 side. Instead of the black matrix 5, only the metal film 42 is
A structure in which only the light absorbing film 41 is provided on the glass substrate 11 side may be provided on the 0 side.

Fifth Embodiment Still another embodiment of the present invention will be described as a fifth embodiment with reference to FIG. For the sake of convenience of explanation, members having the same functions as those shown in the drawings of the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted.

In the first to fourth embodiments, one or two substrates (large substrates 3 and 21) are used as reinforcing substrates when a plurality of liquid crystal panels 2 ′ are joined. The liquid crystal display device of the present invention is not limited to the configuration in which these are provided, and may have a configuration in which these reinforcing substrates are omitted.

That is, as shown in FIG. 13, in the liquid crystal display device of this embodiment, the liquid crystal panels 2 'are joined and joined without using a reinforcing substrate. A pair of polarizing plates 8 on both end surfaces in the thickness direction.
8 is attached so that their polarization axes are orthogonal to each other, and a composite panel 50 is provided.

When an acrylic plate having a thickness of about 1 to 2 mm is used as the polarizing plate 8.8, the polarizing plate 8.8 also functions as a reinforcing plate in the composite panel 50.
The strength of the composite panel 50 can be maintained. Thereby, the impact resistance of the composite panel 50 can be improved, and a natural image with no noticeable seams of the liquid crystal panel 2 ′ can be stably obtained over a long period of time. Although not shown, a space between each of the polarizing plates 8.8 and each of the glass substrates 10 and 11 is filled with a refractive index adjusting material 9.

Sixth Embodiment A sixth embodiment of the present invention will be described below with reference to FIGS. 14 to 19 as a sixth embodiment. For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are denoted by the same reference numerals, and description thereof will be omitted.

In the composite panel in each of the above embodiments, when a plurality of liquid crystal panels 2 'are bonded to the large-sized substrate 3 using a refractive index adjusting material (for example, an ultraviolet curable resin) 9, the glass of the liquid crystal panel 2' By setting the refractive index of the refractive index adjusting member 9 so that the refractive index of the substrate 11 and the refractive index of the refractive index adjusting member 9 become substantially equal, the joints between the liquid crystal panels 2 'are made inconspicuous. I have.

However, the composite panel has the following problems. Usually, the glass substrates 11 and 10 used for the liquid crystal panel 2 'are said to have considerable flatness, but have a thickness variation of up to about 30 μm.

Therefore, as shown in FIG. 14, when the liquid crystal panels 2 'using different glass substrates 10 and the like are joined to each other, a maximum of 30 μm is provided between the liquid crystal panels 2'.
There may be a step of about m. Also, even when the thickness of the glass substrates 10 and 11 of the liquid crystal panel 2 'is very small, if the thickness of the refractive index adjusting material 9 varies, a step is formed at the joint of the liquid crystal panels 2'. Occurs.

Even if such a step occurs, the refractive index adjusting material 9 filled between the bonding surfaces of the liquid crystal panels 2 '.
In principle, if each of the glass substrates 10 and 11 of the liquid crystal panel 2 ′ has the same spectral transmittance and the same refractive index in the entire visible light region, the above glass substrates 1 in principle can be used.
The steps 0.11 and 11 have no optical effect and should not be able to identify the seam at the junction.

However, since it is actually very difficult to find the refractive index adjusting material 9 satisfying the above-mentioned perfect condition, the following mechanism causes a problem that the joint at the joining portion is slightly noticeable. .

(1) The refraction angles of the light transmitted through the step formed at the junction are different (see FIG. 15).

(2) The transmitted light is scattered by the step formed at the junction, and the polarization of the light transmitted through the junction is eliminated.

Each liquid crystal panel 2 'shown in FIG.
Are different between the left and right liquid crystal panels 2 ', the image displayed on each of the liquid crystal panels 2' becomes unnatural, giving an uncomfortable feeling to the observer.

Therefore, in the liquid crystal display device of this embodiment, as shown in FIG. 16, the spacer 6 is used as the refractive index adjusting material 9 for the composite panel 20 of the second embodiment.
1 is mixed to provide the composite panel 60.

First, a method of manufacturing the composite panel 60 will be described. A spacer 61 made of plastic beads having a refractive index of 1.54 and a particle diameter of 10 μm is mixed between the large substrate 3 and the liquid crystal panel 2 ′. The refractive index adjusting material 9 is filled.

Next, the plurality of liquid crystal panels 2 ′ are aligned so that their display surfaces are flush with each other, and each liquid crystal panel 2 ′ is temporarily fixed to the large substrate 3. After this,
Each of the liquid crystal panels 2 ′ is pressed with a predetermined load in the direction of their thickness to push out an excess refractive index adjusting material 9 from between each of the liquid crystal panels 2 ′ and the large substrate 3. .

At this time, the used refractive index adjusting material 9 and spacer 61 are adjusted so as to have substantially the same refractive index as the glass substrate 2 used for the liquid crystal panel 2 ′. , Spacer 61 and glass substrate 2
Is 0.03 at D-line (wavelength about 590 nm).
Hereinafter, 0.03 or less is also preferable in the visible light region (400 nm to 700 nm).

As a result, the refractive index adjusting member 9 having a more uniform thickness can be obtained by the spacer 61.
The generation of steps on the glass substrate 11 in each of the liquid crystal panels 2 '... Can be prevented. Therefore, each of the liquid crystal panels 2 '...
Since all the refraction angles of the light passing through are equal, and the scattering of the light can be avoided, the liquid crystal panels 2 ′.
It is possible to obtain a liquid crystal display device having a good display image quality in which the seams are not noticeable.

Further, the reinforcing plate 21 may be used on the backlight side. In the sixth embodiment, an example is described in which an ultraviolet curable resin is used as the material of the refractive index adjusting material 9 to be filled. However, if the refractive index satisfies the above-described conditions, the thermosetting resin may be used. Also, an epoxy-based adhesive or the like can be used.

Further, although an example using plastic beads as the spacer 61 has been described, silica beads or the like can be used as long as the above conditions are satisfied. However, since the plastic beads have higher elasticity than the silica beads, the variation in the thickness of the glass substrate 11 or the large substrate 3 can be more absorbed, and the step generated between the glass substrates 11 can be reduced by the spacer 61. An excellent effect can be exhibited in that it can be suppressed.

In the sixth embodiment, the liquid crystal panel 2 '
Is eliminated on the side of the glass substrate 11 constituting the liquid crystal panel 11, there is a possibility that a step may occur on the side of each of the glass substrates 10... On the backlight side. The inventors of the present application have experimentally confirmed that even if a step is formed on the side of the 10..., It does not adversely affect the visibility of the liquid crystal panels 2 ′ at the joints. Therefore, it is not necessary to consider the steps generated on the glass substrates 10... As much as the steps generated on the glass substrates 11.

When a load is applied to each of the liquid crystal panels 2 ′ in order to extrude a surplus refractive index adjusting material 9,
When the area of each of the liquid crystal panels 2 'becomes large, it is necessary to apply a very large pressure. To perform this with a small pressure, the viscosity of the refractive index adjusting material 9 is reduced, If the diameter is increased, the refractive index adjusting member 9 can be easily extruded even with a small load.

Therefore, the viscosity of the refractive index adjusting material 9 is preferably 3000 cp or less as a result of producing the composite panel 60 using the refractive index adjusting materials adjusted to various viscosities. The larger the particle size of the spacer 61 is, the more preferable it is. However, the larger the gap 62 between the joining surfaces 2a of the respective liquid crystal panels 2 'is, the more unsuitable it is.
It is desirable to set the undulation, that is, the roughness to be less than the magnitude of the roughness.

As described above, in the sixth embodiment, the method of reducing the step when joining the plurality of liquid crystal panels 2 '... Has been described. Next, the allowable range of the step will be described. FIG. 17 is an enlarged view of a joined portion (joined portion) of each liquid crystal panel 2 ′. If the width x of the black matrix 5 shown in the figure changes by about 20% with respect to the width of the black matrix 5 in other places, even in one place,
In this regard, the present inventors have experimentally verified that the observer has a feeling of strangeness in the image displayed by each liquid crystal panel 2 ′.

Therefore, when the general viewing angle range of the composite panel 60 is ± 45 degrees, each liquid crystal panel 2 ′
It is sufficient that the visible width of the black matrix 5 at the joint portion of... Is within the range of about 20% increase and decrease when there is a step and when there is no step.

FIG. 18 (a) shows a case where there is no step in the black matrix 5 at the joint portion of each liquid crystal panel 2 ', 45 degrees with respect to the normal on the display surface of each liquid crystal panel 2'.
That is, it is a diagram geometrically showing a width x ′ of the black matrix that is actually felt by the observer viewed from the 45-degree oblique direction. It can be seen from the figure that x ′ = x / (2 ^1/2 ).

On the other hand, FIG. 18B shows each liquid crystal panel 2 ′.
... is a diagram geometrically showing a width x "of the black matrix which the observer actually feels when viewed from a 45-degree oblique direction when the black matrix at the junction of"... "Has a step y.
From the figure, it can be seen that x ″ = (x + y) / (2 ^1/2 ).

If the relationship between x ′ and x ″ increases or decreases by about 20%, the observer does not have a sense of discomfort in the image.

[0141]

(Equation 1)

Since (Equation 1), -0.2 x <
y <0.2 x (Equation 2).

By setting the displacement in the thickness direction of each of the liquid crystal panels 2 'within the range satisfying such a condition (Equation 2), it is possible to stably produce a liquid crystal display device having excellent display image quality. it can.

As described above, according to the structure and method of the sixth embodiment, the refractive index adjusting material 9 mixed with the spacer 61 is filled between the glass substrate 11 and the large substrate 3 of the liquid crystal panel 2 ', and a load is further applied. Since there is a manufacturing process for removing the extra refractive index adjusting material 9 by using the liquid crystal panel 2 ′, it is possible to prevent a step from being formed in each glass substrate 11 at a joint portion between the liquid crystal panels 2 ′.

As a result, as shown in FIG. 19, the refraction angles of the transmitted light are all equal, and the scattering of the light is prevented, so that a liquid crystal display device having good display image quality with no noticeable seams is manufactured. Can be stabilized.

Further, by setting the particle size of the spacer 61 so as to be smaller than the undulation generated on the joint surface 2a of the liquid crystal panel 2 ', that is, the maximum value of the roughness, the liquid crystal panel 2 is formed by the spacer 61. Since an increase in the interval between 2 'is avoided, the display quality of the composite panel 60 is prevented from deteriorating by adding the spacer 61.

As described above, in the configuration of the sixth embodiment, when a plurality of liquid crystal panels 2 ′ are joined to each other to form a composite panel 60, the joints of the liquid crystal panels 2 ′ are further made inconspicuous. In a direct-view type liquid crystal display device having a large screen by a multi-display method, it is possible to further improve the display image quality.

Further, according to the manufacturing method of the sixth embodiment, a direct-view type liquid crystal display device having a large screen by a multi-display system with further improved display image quality can be stably manufactured, and the size of the liquid crystal display device can be increased. Can be manufactured with higher yield.

Seventh Embodiment A seventh embodiment of the present invention will be described below with reference to FIGS. 1, 20 to 24 as a seventh embodiment. For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are denoted by the same reference numerals, and description thereof will be omitted.

First, in each of the above embodiments, for example, the composite panel 1 has a liquid crystal panel (hereinafter referred to as a right liquid crystal panel) 2 'disposed on the right side and a liquid crystal panel (hereinafter referred to as the left liquid crystal panel) disposed on the left side. 2 ′).

In such a liquid crystal panel 2 ′, for example, as shown in FIG. 20 showing the left liquid crystal panel, a gap 2 b is formed between the respective glass substrates 10 and 11 on the joint surface 2 a with the right liquid crystal panel. .

The gap 2b is of the order of a few μm. If the signal lines 13 and 14 are exposed in the gap 2b, only small foreign matters such as dust adhere to the gap 2b. Each signal line 13 of each of the glass substrates 10 and 11
An electric leak occurs between the liquid crystal panel 14 and the common electrode 12, and the display quality of each liquid crystal panel 2 'will deteriorate in the future.

Therefore, in each of the first to sixth embodiments, the TF
On the glass substrate 10 on which T16 are formed, as shown in FIG. 21A, the scanning signal lines 14 are formed so that the scanning signal lines 14 are not formed on the side facing the gap 2b. The setting prevents the occurrence of the electric leak.

For this reason, in the right liquid crystal panel 2 'and the left liquid crystal panel 2', the arrangement pattern of the scanning signal lines 14 is changed as shown in FIG.
It was necessary to design them separately so as to be symmetrical with respect to the center.

That is, in each of the first to sixth embodiments, in the right liquid crystal panel 2 ′, each signal line 13.
In the left liquid crystal panel 2 ′, on the other hand, on the left, lower, and lower sides, the signal lines 13 and 14 are provided with external terminals for extraction. I have.

As described above, the direction of the terminal for taking out each scanning signal line 14 of the glass substrate 10 in each of the first to sixth embodiments is different between the right liquid crystal panel 2 'and the left liquid crystal panel 2'. In the manufacturing process of the liquid crystal panel 2 that makes extensive use of technology, it is necessary to use two more types of photomasks, resulting in an increase in cost. Further, at present, when the right liquid crystal panel 2 'and the left liquid crystal panel 2' are individually manufactured, it is difficult to match the yield of the right liquid crystal panel 2 'and the left liquid crystal panel 2', and the production efficiency is reduced. There was also the problem of inviting

Therefore, in the liquid crystal display device of the seventh embodiment, as shown in FIG. 1, a glass substrate (first substrate) 10 is used instead of the liquid crystal panel 2 'used in each of the first to sixth embodiments. Are the same as those in the first to sixth embodiments, except that each scanning signal line 14 'is a liquid crystal panel 2 "having extraction terminals at both ends thereof. Thus, a composite panel 70 is manufactured from each of the liquid crystal panels 2 ".

When the composite panel 70 is manufactured by using two liquid crystal panels 2 ″ on the left and right sides, for example, when the dividing line 17a is selected as the dividing line, the left liquid crystal panel 2 ″ ′ is formed. When the disconnection 17b is selected, the right liquid crystal panel 2 "" is displayed.

When the liquid crystal panel 2 ″ is divided in this way, as shown in FIG. 22, between each of the liquid crystal panels 2 ″, the glass substrate 10 and the glass substrate (second substrate) 11
The sealing members 6a and 6b are formed on both sides of the dividing line 17 along the necessary dividing lines 17, respectively.

Further, as shown in FIG. 23, when cutting is performed by the dancing blade 71 along the dividing line 17, the sealing members 6a and 6b are almost equally contacted on both sides of the blade of the dicing blade 71. The distance between the sealing members 6a and 6b is set as described above.

By providing such sealing materials 6a and 6b and dividing by the dicing blade 71, the sides of the glass substrates 10 and 11 to be removed are also held by the sealing material 6b. Glass substrate 1
It is possible to suppress the abnormal vibration of 0.11
-The occurrence of cracks and the like in the section plane of 11 is prevented. This makes it possible to maintain high smoothness in the above-mentioned cross section due to the use of the dancing blade 71.

Further, by providing the above-mentioned sealing members 6a and 6b, as shown in FIG.
a is also cut together with each of the glass substrates 10 and 11, so that the space between the glass substrates 10 and 11 is filled between the bonding surfaces (first surfaces) 2a, and the sealing material 6 'is made flush with the bonding surface 2a. Is formed.

Thus, each of the above glass substrates 10 and 11
Between the glass substrate 1 between the bonding surfaces 2a,
Since the occurrence of a gap between the first and second glass substrates 10 and 11 is avoided, the occurrence of electrical leakage in each of the glass substrates 10 and 11 that may occur in the first to sixth embodiments can also be prevented.

By using the sealing materials 6a and 6b in this manner, the glass substrate 10 can be separated from the one type of the glass substrate 10 having the terminals for taking out the scanning signal lines 14 on both sides by the dividing lines 17a and 17b. By dividing, the left and right liquid crystal panels 2 ″ ′ can be obtained.

Therefore, in the configuration and method of the seventh embodiment, when fabricating each liquid crystal panel 2 ″ ′, a photomask of one type of design pattern is formed on the glass substrate 10 to form each scanning signal line 14 ′. Since only one type of liquid crystal panel 2 ″ needs to be used for each of the above embodiments,
6, cost can be reduced.

Further, since the yield of the right liquid crystal panel 2 "" and the yield of the left liquid crystal panel 2 "" can be matched, the above configuration can be manufactured efficiently. The extending direction of the scanning signal line 14 and the data signal line 13 is not limited to the direction of FIG. 1, and the same effect can be obtained by setting the scanning signal line 14 to extend in the Y direction and the data signal line 13 to extend in the X direction. Obtainable.

The above structure and method are not limited to the TFT liquid crystal panel, but can be applied to other active matrix type liquid crystal panels such as MIM and simple matrix type liquid crystal panels. However, in the manufacturing process, a photomask
In the case of using about nine TFT liquid crystals and the yield is relatively low, the above configuration and method can exert a great effect.

By using the refractive index adjusting material 9 and the spacer 61 of the sixth embodiment having electrical insulation, the scanning signals exposed on the bonding surface 2a can be further improved. The occurrence of electric leakage between the lines 14 can be prevented, and the pattern of the photomask for each scanning signal line 14 ′ on the glass substrate 10 can be reduced by one.
The effect of the seventh embodiment, which can be of different types, can be made more effective.

In the method of the seventh embodiment, the seal members 6a and 6b are individually formed. However, it is sufficient that the seal members 6a and 6b are in contact with both sides of the blade of the dancing blade 71, for example. Even if a wide sealing material is formed so as to straddle along the dividing line 17 and the sealing material and each of the glass substrates 10 and 11 are divided in the sealing material by the dancing blade 71 along the dividing line 17. Good.

[Eighth Embodiment] The following will describe another embodiment of the present invention as an eighth embodiment with reference to FIGS. For convenience of explanation, members having the same functions as the members shown in the drawings of the above-described embodiments are denoted by the same reference numerals, and description thereof will be omitted.

In the seventh embodiment, an example was described in which a composite panel 70 having a large display screen was manufactured by joining two liquid crystal panels 2 ″ ′.
An example is shown in which a composite panel 80 having a larger cover screen is produced by joining the sheets together.
0 can be similarly applied to the method of the seventh embodiment.

In the composite panel 80, the liquid crystal panel 2 "shown in FIG. 1 is divided at the dividing lines 17b and 17c to obtain the upper right liquid crystal panel 2"", and divided at the dividing lines 17b and 17d. Thus, the lower right liquid crystal panel 2 "" is obtained, and the upper left liquid crystal panel 2 "" is obtained by dividing at the dividing lines 17a and 17c.
The lower left liquid crystal panel 2 "" is obtained by dividing at 7a and 17d.

The four types of liquid crystal panels 2 "" up, down, left, and right
As shown in FIG. 25, as shown in FIG. 25, the composite panel 80 having a larger screen can be manufactured by joining the above-described cross sections in one section of the liquid crystal panel 2 ′.
Is possible.

Therefore, when the above-described liquid crystal panel 2 ″ is used, the liquid crystal panel 2 ″ having one type of signal line pattern
By changing the position of the dividing line, four types of liquid crystal panels 2 "" can be obtained, respectively, left, right, upper and lower, so that the left, right, upper, and lower liquid crystal panels are individually manufactured and their photomask patterns are different from each other. The manufacturing cost of the composite panel 80 can be reduced as compared with the case of using.

Further, the yield of each liquid crystal panel 2 "" can be matched, and the composite panel 80 can be manufactured efficiently.

[0176]

As described above, in the liquid crystal display device according to the first aspect of the present invention, each signal line is provided on one of the plurality of liquid crystal panels for producing a large-screen composite panel. However, terminals that can be connected to the outside are formed at both ends of each of the signal lines. In each of the liquid crystal panels, the first and second substrates and the sealing material that bonds the first and second substrates are formed with the first and second substrates. The sealing material and the first and second substrates are formed so as to be flush with the first surface by dividing the first and second substrates in the thickness direction. A liquid crystal display device according to claim 3 of the present invention.
In the above configuration, the first and second sealing materials are
The substrate and the first and second substrates are collectively arranged in the thickness direction.
By dividing, the sealing material and the first and second bases are separated.
Plates are formed so that the first surface is flush with the first surface.
Configuration. The liquid crystal according to claim 4 of the present invention.
In the above configuration, the display device may include the first sealing material and the first sealing material.
And the second substrate in the thickness direction of the first and second substrates.
By dividing using a dicing blade,
The sealing material and the first and second substrates are flush with the first surface.
This is a configuration in which each is formed.

[0177] Therefore, the above-described structure is such that the first and second substrates bonded by the sealing material are flush with each other by removing at least one side of the first and second substrates along the outside of the sealing material. A plurality of liquid crystal panels each having the first surface are provided, and the composite panel is provided with the first surfaces facing each other. Therefore, the seam of each liquid crystal panel in the composite panel can be made smaller than in the related art, so that the seams are conspicuous. Since there can be no composite panel, there is an effect that excellent display image quality can be realized on a large screen.

In addition, in the above configuration, the liquid crystal panel can be driven by using any one of the terminals at both ends of each signal line. Therefore, a plurality of first and second substrates are used, and the dividing positions are used. By removing one terminal of each first substrate,
In addition, by setting the terminals to be removed at different positions, for example, the first and second bonded two sheets are removed.
The substrates can be left and right liquid crystal panels.

Thus, in the above configuration, one type of first type
The left and right liquid crystal panels are respectively manufactured from the substrates, that is, the first substrate having one type of each signal line pattern is
A composite panel with a large screen can be manufactured by using a plurality of the panels, and an effect that the cost of the composite panel can be reduced as compared with the related art in which it is necessary to separately form the patterns of the signal lines is also provided. .

According to a second aspect of the present invention, in a method of manufacturing a liquid crystal display device, a substantially rectangular first substrate having each signal line in a matrix crossing each other is connected to the outside at both ends of each signal line. After the first substrate and the second substrate for forming pixels in a matrix are attached to each other with a sealing material for sealing a liquid crystal between the first substrate and the second substrate. Dividing the sealing material and the first and second substrates in the thickness direction of the first and second substrates along the sealing material so that the sealing material and the first and second substrates are flush with each other; Became the first
This is a method of producing a plurality of liquid crystal panels each having a surface formed at a different position, and producing a composite panel including the above liquid crystal panels. A liquid crystal according to claim 5 of the present invention.
The method for manufacturing a display device includes, in the above method, at least
In the step of forming the first surface, the sealing material and the first
This is a method in which the cutting of the second substrate is performed in a lump. Also,
The method for manufacturing a liquid crystal display device according to claim 6 of the present invention is characterized in that
Forming at least the first surface in the method.
Then, a die is used to separate the sealing material from the first and second substrates.
This is a method using a single blade.

Therefore, in the above method, the first surfaces of the liquid crystal panels face each other by fixing the display surfaces so as to be flush with each other to obtain the composite panel. Since the joints between them can be made inconspicuous, there is an effect that a composite panel capable of realizing excellent display image quality on a large screen can be manufactured.

Further, conventionally, when liquid crystal panels each having a plurality of signal line patterns are separately manufactured, it is difficult to arbitrarily adjust the yields, and the loss due to such a difference in the yield is difficult. As a result, the manufacturing cost of the composite panel has been increased.

However, according to the above method, each liquid crystal panel having a different pattern in each signal line can be manufactured from the first substrate having one type of each signal line pattern, and a large screen composed of each liquid crystal panel can be formed. There is also an effect that a composite panel having the same can be manufactured efficiently and at low cost.

[Brief description of the drawings]

FIGS. 1A and 1B are explanatory diagrams showing a process of manufacturing a composite panel in which liquid crystal panels are joined in Example 7 of a liquid crystal display device of the present invention, wherein FIG. 1A is a schematic configuration diagram of the liquid crystal panel; () Is a schematic configuration diagram of the composite panel.

FIG. 2 is a schematic configuration diagram of a composite panel according to a first embodiment of the liquid crystal display device of the present invention.

FIG. 3 is a perspective view showing the internal structure of the liquid crystal panel of the composite panel.

4A and 4B are explanatory views showing a process of forming the composite panel, wherein FIG. 4A is a plan view of two liquid crystal panels before bonding, and FIG. 4B is a diagram in which two liquid crystal panels are bonded. It is a top view of a compound panel after.

FIG. 5 is an explanatory diagram showing a difference in visibility between a joint and a black matrix in the composite panel.

FIG. 6 is a schematic configuration diagram of a composite panel according to a second embodiment of the liquid crystal display device of the present invention.

FIG. 7 is a schematic configuration diagram of a composite panel according to a third embodiment of the liquid crystal display device of the present invention.

FIG. 8 is an explanatory diagram showing that a difference in visibility due to parallax at a joint of the composite panel is corrected.

FIG. 9 is an enlarged sectional view of a main part of the composite panel.

FIG. 10 is an explanatory diagram showing a difference in visibility of a joint due to parallax in the composite panel of FIG. 2;

FIG. 11 is a schematic configuration diagram of a composite panel according to a fourth embodiment of the liquid crystal display device of the present invention.

FIG. 12 is a schematic configuration diagram showing a modified example of the composite panel.

FIG. 13 is a schematic configuration diagram of a composite panel in a fifth embodiment of the liquid crystal display device of the present invention.

14 is a schematic configuration diagram of a composite panel as a comparative example with respect to the composite panel in FIG.

FIG. 15 is an enlarged configuration diagram of a main part of a composite panel as a comparative example with respect to the composite panel in FIG. 6;

FIG. 16 is a schematic configuration diagram of a composite panel in Embodiment 6 of the liquid crystal display device of the present invention.

17 is a main part configuration diagram showing an allowable range of a position error of each liquid crystal panel in the composite panel in FIG. 6;

FIGS. 18A and 18B are explanatory diagrams showing an allowable range of a position error of each of the liquid crystal panels, wherein FIG. 18A shows a case where the position error does not occur, and FIG. 18B shows a case where the position error occurs. FIG.

FIG. 19 is a main part configuration diagram when no step occurs in each liquid crystal panel in the composite panel.

FIG. 20 is a schematic perspective view showing that a gap is formed at a joint portion of the liquid crystal panels in Examples 1 to 6;

FIG. 21 is a schematic configuration diagram of each liquid crystal panel and a composite panel including each of the liquid crystal panels in Examples 1 to 6;

FIG. 22 is a schematic plan view of each glass substrate showing an arrangement of each sealing material in the seventh embodiment.

FIG. 23 is a schematic configuration diagram showing a state in which each glass substrate is cut by a dancing blade.

FIG. 24 is a perspective view of an essential part of a liquid crystal panel formed by cutting each glass substrate by a dancing blade.

FIG. 25 is a configuration diagram of a main part of a composite panel according to an eighth embodiment of the present invention.

FIG. 26 is a sectional view of a main part of a conventional liquid crystal display device.

FIG. 27 is a cross-sectional view of a main part of another conventional liquid crystal display device.

FIG. 28 is a cross-sectional view of a main part of still another conventional liquid crystal display device.

FIG. 29 is a sectional view of a main part of still another conventional liquid crystal display device.

[Explanation of symbols]

 2 "'liquid crystal panel 2a bonding surface (first surface) 6 sealing material 10 glass substrate (first substrate) 11 glass substrate (second substrate) 14' scanning signal line (signal line) 70 composite panel

Continuation of the front page (56) References JP-A-63-24283 (JP, A) JP-A-6-148610 (JP, A) JP-A-63-200186 (JP, A) JP-A-5-127605 (JP) JP-A-60-67925 (JP, A) JP-A-4-292087 (JP, A) JP-A-57-136616 (JP, A) JP-A-3-276186 (JP, A) (58) Field surveyed (Int.Cl. ⁷ , DB name) G02F 1/1333 G02F 1/13

Claims (6)

(57) [Claims] 1. A substantially rectangular first and second substrate having a large number of pixels for displaying an image in a matrix and having signal lines for driving the pixels in a matrix crossing each other. Are bonded together by a sealing material for sealing liquid crystal therebetween, and the first and second substrates are removed along the sealing material by removing at least one side of the first and second substrates. A liquid crystal panel having one surface is provided; a composite panel including a plurality of liquid crystal panels is provided with the first surfaces of the liquid crystal panels facing each other so that the display surfaces of the liquid crystal panels are flush with each other; Terminals that can be connected to the outside are formed on both ends of each of the signal lines on the first substrate. In each of the liquid crystal panels, the sealing material and the first and second terminals are provided.
The substrate is divided in the thickness direction of the first and second substrates, whereby the sealing material and the first and second substrates are formed so that the first surfaces are flush with each other. Liquid crystal display device. 2. A substantially rectangular first substrate having signal lines for driving pixels for displaying an image in a matrix crossing each other can be externally connected to both ends of each of the signal lines. After manufacturing so as to have terminals, the first substrate and the second substrate for forming the pixels in a matrix are attached to each other with a sealing material for sealing liquid crystal therebetween, By dividing the sealing material and the first and second substrates along the sealing material in the thickness direction of the first and second substrates, the sealing material and the first and second substrates are flush with each other. After producing a plurality of liquid crystal panels each having the first surface formed at a different position, the first surfaces of the liquid crystal panels face each other so that the display surfaces of the liquid crystal panels are flush with each other. Fix the LCD panel Method of manufacturing a liquid crystal display device characterized by manufacturing a composite panel having a large screen by. 3. The seal material and the first and second substrates are placed on top of each other.
The first and second substrates are collectively cut in the thickness direction.
With this, the sealing material and the first and second substrates are
Being formed so that the first surface is flush with each other
The liquid crystal display device according to claim 1, wherein: 4. The sealing material and the first and second substrates are placed on top of each other.
A dicing blade in a thickness direction of the first and second substrates;
By dividing the sealing material with first and
And the second substrate so that the first surface is flush with the first surface.
The liquid crystal according to claim 1, wherein the liquid crystal is formed.
Display device. 5. The method of claim 1, wherein at least the first surface is formed.
Collectively separates the sealing material from the first and second substrates.
3. The liquid crystal display device according to claim 2, wherein
Manufacturing method. 6. The method according to claim 6, wherein at least the first surface is formed.
Is a die for separating the sealing material from the first and second substrates.
3. The method according to claim 2, wherein a cutting blade is used.
Of manufacturing a liquid crystal display device.