Color filter substrate, method for manufacturing color filter substrate, device for manufacturing color filter substrate, liquid crystal device and method for manufacturing liquid crystal device

The present invention relates to a color filter substrate in which an alignment film is formed on a color filter by dividing it into a plurality of alignment film rows, a method for manufacturing a color filter substrate, a device for manufacturing a color filter substrate, a liquid crystal device, and a method for manufacturing a liquid crystal device. Regarding.

In recent years, liquid crystal devices have been widely used in the display units of electronic devices such as mobile phones, portable computers, video cameras, and projectors. In this type of liquid crystal device, a liquid crystal is sealed between a pair of substrates, and an image is displayed by controlling the orientation state of the liquid crystal by an electric field applied to the liquid crystal. Therefore, in the liquid crystal apparatus, an alignment film is formed on each of the surfaces facing each other on the pair of substrates, and the alignment state of the liquid crystal in a state where an electric field is not applied is controlled by the orientation regulating force of the alignment film. Further, when color display is performed in a liquid crystal device, a color filter layer is formed on the lower layer side of the alignment film with respect to one substrate.

The flexographic printing method is widely known as a method for forming an alignment film on each substrate, but recently, as a method capable of obtaining relatively stable quality as compared with flexographic printing, a droplet ejection head A so-called droplet ejection method has been proposed in which an alignment film is formed on a substrate.

For example, Japanese Patent Application Laid-Open No. 2001-51269 discloses a technique for forming a pattern by ejecting a fine viscous material onto a substrate using a head for an inkjet printer.<patcit num="1"><text>Japanese Unexamined Patent Publication No. 2001-51269</text></patcit>

<p> By the way, when the width direction of the alignment film coating region on the substrate is larger than the width of the droplet ejection head, the droplet ejection head is reciprocated to reciprocate, and a plurality of alignment film materials are applied to the alignment film coating region of the substrate. It is necessary to apply in divided doses.</p><p> At that time, when the alignment film material in the next row is applied following the alignment film material applied in the previous row, the alignment film material in the previous row has already dried or solidified, or is in the process of drying and solidifying. In the next row, the edges of the alignment film material are superposed and applied to the alignment film formed by the application of the alignment film material in the previous row, thereby eliminating the boundary of the alignment film.</p><p> However, the overlapping portion of the alignment film has a different film thickness than the other portions, resulting in uneven film thickness. The uneven film thickness of the alignment film tends to affect the blur tilt angle of the liquid crystal, and may be visually recognized as streak-like uneven alignment.</p><p> In view of the above circumstances, the present invention improves the quality of the product by making it difficult to visually recognize the streak-like alignment unevenness appearing at the boundary even when the alignment film material is applied in a plurality of times. It is an object of the present invention to provide a color filter substrate, a method for manufacturing a color filter substrate, a device for manufacturing a color filter substrate, a liquid crystal device, and a method for manufacturing a liquid crystal device.</p>

<p> In order to achieve the above object, the first invention is a color filter substrate in which alignment films are formed on a plurality of color filters, and the alignment films are formed on the plurality of color filters by dividing the alignment films into a plurality of alignment film rows. The superimposing portion is formed by superimposing the end portions of the alignment film rows adjacent to each other, and the superimposing portion is formed at a position corresponding to the color filter displaying a specific color. ..</p><p> In such a configuration, since the superimposing portion of the alignment film row is formed at a position corresponding to the color filter displaying a specific color, the orientation unevenness generated by the superimposing portion becomes difficult to be visually recognized from the outside.</p><p> The second invention is characterized in that, in the first invention, the superimposing width of the superimposing portion is accommodated in the color filter displaying a specific color.</p><p> In such a configuration, since the overlapping width of the overlapping portion is accommodated in the color filter that displays a specific color, the uneven orientation becomes more difficult to see.</p><p> The third invention is characterized in that, in the first or second invention, the specific color is blue.</p><p> In such a configuration, by setting the specific color to blue, which has relatively low visibility, the visibility of uneven orientation can be further reduced.</p><p> The fourth invention is a method for manufacturing a color filter substrate in which an alignment film material is applied onto a plurality of color filters to form an alignment film, and the alignment film is formed along a preset alignment film coating row on the plurality of color filters. The step of applying the material and the front end in the width direction at the position corresponding to the color filter displaying a specific color, and the alignment film material being applied along the next alignment film application row and in the width direction. A step of superimposing the rear end portion on the front end portion of the alignment film applied to the front alignment film coating row and applying the front end portion in the width direction to a position corresponding to the color filter displaying a specific color. It is characterized by having and.</p><p> In such a configuration, since the overlapping portion of the alignment film is set at a position corresponding to the color filter displaying a specific color in the manufacturing process of the color filter substrate, the manufacturing is easy and automation can be promoted.</p><p> The fifth invention is characterized in that, in the fourth invention, the superimposition width of the superimposing portion is accommodated in the color filter displaying a specific color.</p><p> In such a configuration, since the overlapping width of the overlapping portion is accommodated in the color filter that displays a specific color, the uneven orientation becomes more difficult to see.</p><p> The sixth invention is characterized in that, in the fourth or fifth invention, the alignment film material is applied onto the color filter by a droplet ejection head.</p><p> In such a configuration, since the alignment film material is applied using the droplet ejection head, the alignment film thickness becomes constant and stable quality can be obtained.</p><p> The seventh invention is characterized in that, in the fourth or fifth invention, the alignment film material is applied on the color filter by flexographic printing.</p><p> In such a configuration, since the alignment film material is applied by using flexographic printing, the production time can be shortened.</p><p> The eighth invention is characterized in that, in the fourth to seventh inventions, the specific color is blue.</p><p> In such a configuration, by setting the specific color to blue, which has relatively low visibility, the visibility of uneven orientation can be further reduced.</p><p> The ninth invention includes a table on which a substrate on which a plurality of color filters are arranged is set, a droplet ejection head that faces the substrate and is relatively movable in a two-dimensional direction along the substrate, and the table. It is provided with a controller that controls the relative movement of the droplet ejection head in a two-dimensional direction, and is ejected from a nozzle provided in the droplet ejection head by the relative movement of the substrate and the droplet ejection head. The alignment film material to be applied is applied along the preset alignment film application row of the substrate, and the front end portion in the width direction is applied at a position corresponding to the color filter displaying a specific color, and the next alignment film is applied. The alignment film material is applied along the coating row, the rear end portion in the width direction is superimposed on the front end portion of the alignment film applied to the front alignment film coating row, and the front end portion in the width direction is formed. It is characterized in that it is applied to a position corresponding to the color filter that displays a specific color.</p><p> In such a configuration, since the overlapping portion of the alignment film is set at a position corresponding to the color filter displaying a specific color at the time of manufacturing the color filter substrate, the manufacturing is facilitated and automation can be promoted.</p><p> The tenth invention is characterized in that, in the ninth invention, the specific color is blue.</p><p> In such a configuration, by setting the specific color to blue, which has relatively low visibility, the visibility of uneven orientation can be further reduced.</p><p> The liquid crystal apparatus according to the eleventh invention is characterized by comprising the color filter substrate according to any one of the first to third inventions.</p><p> In such a configuration, the color filter substrate provided in the liquid crystal apparatus is the color filter substrate according to any one of the first to third inventions, so that the alignment unevenness generated by the overlapping portion of the alignment film row is generated. Is difficult to see from the outside.</p><p> The twelfth invention is a method for manufacturing a liquid crystal apparatus including a color filter substrate, wherein the color filter substrate is formed by the method for manufacturing a color filter substrate according to any one of the fourth to eighth inventions. It is a feature.</p><p> In such a configuration, the color filter substrate provided in the liquid crystal apparatus is formed by the method for manufacturing the color filter substrate according to any one of the fourth to eighth inventions, whereby the overlapping portion of the alignment film row is formed. It is possible to make it difficult to see the generated uneven orientation from the outside.</p>

<p> According to the present invention, even when the alignment film material is applied in a plurality of times, the streak-like alignment unevenness appearing at the boundary becomes difficult to see from the outside, and the quality of the product is improved.</p>

Hereinafter, one embodiment of the present invention will be described with reference to the drawings. 1 to 7 show one embodiment of the present invention. FIG. 1 shows a front view of the color filter substrate, and FIG. 2 shows a sectional view taken along line II-II of FIG.

Reference numeral 1 in the figure is a color filter substrate. The color filter substrate 1 is provided on, for example, an opposing substrate provided in a liquid crystal device. A plurality of color filters R, B, and G colored in red (R), blue (B), and green (G), which are the three primary colors of light, are arranged on the color filter substrate 1 according to a predetermined pattern. At the same time, the alignment film coating region 2 is set on the color filter substrate 1.

The alignment film material is applied to the alignment film coating region 2 using the droplet ejection head 3, and the alignment film 4 is formed. Since the alignment film material applied on the color filter substrate 1 and the alignment film formed by drying and solidifying the alignment film material are represented by the same shape in the drawings, they are oriented for convenience in the following. The reference numerals attached to the membrane materials are omitted.

As shown in FIG. 3, the droplet ejection head 3 for applying the alignment film material to the surface of the color filter substrate 1 has a plurality of nozzles 3a in one row or a plurality of rows, and ink is applied to each nozzle 3a. The alignment film material stored in the tank (not shown) is supplied through the supply port 3b. As the alignment film material, a material equivalent to the alignment film material used in the usual flexographic printing method such as polyimide is used, and the viscosity and the discharge amount of one drop are applied to the color filter substrate 1. It is decided in consideration of the spread of the edge. That is, as shown in FIG. 4A, the viscosity of the alignment film material and the discharge amount of one drop of the nozzle 3a diffuse on the color filter substrate 1 when the alignment film material is applied on the color filter substrate 1. It is obtained from an experiment or the like in advance and set so that it is not dried and solidified while maintaining the set film thickness.

Further, the table (not shown) on which the color filter substrate 1 is set and the droplet ejection head 3 are relatively movable in the two-dimensional (X, Y) direction via a controller (not shown), and the table and the table. The alignment film material discharged from the nozzle 3a provided in the droplet ejection head 3 is applied to the entire alignment film coating region 2 of the color filter substrate 1 by the relative movement with the droplet ejection head 3.

In this case, as shown in FIG. 1, when the effective discharge width W1 of the nozzle 3a provided on the droplet discharge head 3 is narrower than the effective width W2 in the X direction of the alignment film coating region 2 of the color filter substrate 1, the liquid is liquid. The droplet ejection head 3 is reciprocally scanned and moved along a plurality of rows of alignment film coating rows set in advance to coat the alignment film material over the entire alignment film coating region 2.

That is, one of the table and the droplet ejection head 3 which is opposed to each other with a predetermined gap above the color filter substrate 1 set on the table is moved with respect to the color filter substrate 1 in the direction of the arrow Y to liquid. The drop ejection head 3 scans the alignment film coating row of the first row of the color filter substrate 1. Next, the droplet ejection head 3 is moved by a predetermined pitch in the arrow X direction with respect to the color filter substrate 1 by the relative movement between the table and the droplet ejection head 3, and then the droplet ejection head 3 is moved in the Y direction. The second row of the alignment film coating row is scanned and moved.

Then, by repeating this, the entire alignment film coating region 2 on the color filter substrate 1 is scanned and moved, and during that time, the alignment film material discharged from each nozzle 3a provided on the droplet ejection head 3 is transferred to the color filter substrate. 1 is applied onto the alignment film, and the alignment film 4 is formed over the entire alignment film coating area 2 as shown in FIG.

By the way, when the alignment film material is applied to the next alignment film coating row following the previous alignment film coating row by using the droplet ejection head 3, the alignment film material applied to the previous alignment film coating row is It is in a state where the alignment film row 4a is formed by drying and solidifying, or is in the process of forming the alignment film row 4a. Therefore, when the alignment film material is applied to the next alignment film coating row, the front end portion of the alignment film row 4a formed in the previous alignment film coating row in the traveling direction in the X direction (hereinafter, "width direction front end portion"). To eliminate the boundary with L1 (referred to as ")", as shown in FIG. 4, the rear end of the alignment film material to be applied to the alignment film coating row in the next row in the X direction is the rear end (hereinafter referred to as "width direction"). L2 (referred to as "rear end portion") is superposed on the widthwise front end portion L1 of the alignment film row 4a applied to the front alignment film coating row to form a superimposition portion 4c having a superposition width W3.

As a result, the overlapping portion between the widthwise front end L1 of the alignment film row 4a formed in the previous alignment film coating row and the widthwise rear end L2 of the alignment film material formed in the next alignment film coating row. 4c (see Figure 4 (b)) is formed. Since the film thickness of this superposed portion 4c is different from that of the alignment film of other parts, it tends to affect the blur tilt angle of the liquid crystal, and there is a possibility that it is visually recognized as a streak-like alignment unevenness from the outside.

Therefore, in this embodiment, when the alignment film material is applied onto the color filter substrate 1 by the droplet ejection head 3, among the three primary colors (R, B, G) constituting the color filter used in the color liquid crystal display. Therefore, the relative movement between the table and the droplet ejection head 3 is set so that the overlapping portion 4c is formed at the portion corresponding to the arrangement of the specific colors. This particular color is preferably blue (B). In general, blue (B) has lower visibility than the other two colors (red and green), and even if streaky alignment unevenness occurs due to a change in the film thickness of the alignment film 4, it is visually recognized as a difference in brightness. It is known to be difficult.

Therefore, for example, when the arrangement of the color filters R, B, G is arranged in the column direction and the color filters R, B, G of the same display color are arranged in the column direction, the overlapping portion shown in FIG. Set the relative movement of the table and the droplet ejection head 3 in the two-dimensional (X, Y) direction so that 4c is formed at the portion corresponding to the row of the color filter B. In this case, as shown in FIG. 6, when the array of a plurality of color filters R, B, and G is staggered by one in each row, the superimposition portion 4c is a color filter with respect to the table. Set the color filter substrate 1 diagonally so that it is formed along B.

As described above, in this embodiment, when the table and the droplet ejection head 3 are reciprocally scanned and moved with respect to the color filter substrate 1, the alignment film row 4a formed in the previous alignment film coating row and the next alignment film coating row are formed. The superposed portion 4c (see FIG. 4) formed by the alignment film row 4b formed in is the color filter B which displays blue, which has the lowest visibility among the color filters R, B, and G, and the difference in brightness is inconspicuous. Since it is set to pass through the portion corresponding to the above, the streak-like orientation unevenness is less likely to be visually recognized from the outside, and the quality of the product can be improved.

Next, the operation of this embodiment will be described. First, the color filter substrate 1 is set with the alignment aligned with respect to the table. Then, the color filters R, B, and G provided on the color filter substrate 1 are in a state in which the same display colors are arranged along the Y direction, which is the reciprocating scanning movement direction of the droplet ejection head 3. (See Figures 6 and 7).

Next, the droplet ejection head 3 is relatively scanned and moved in the Y direction along a preset coordinate axis, and the alignment film material ejected from the nozzle 3a of the droplet ejection head 3 is arranged in one row of the color filter substrate 1. Apply to the alignment film coating row of the eye. At that time, the front end portion L1 in the width direction of the alignment film material is set to be the position of the color filter B as shown in FIGS. 4 and 5.

Then, after the application of the alignment film material to the first row of the alignment film coating row to the color filter substrate 1 is completed, the droplet ejection head 3 is moved in the X direction to orient the next alignment film coating row. Apply the membrane material. The amount of movement of the droplet ejection head 3 in the X direction with respect to the second and subsequent alignment film coating rows is the alignment film formed by the widthwise rear end L2 of the alignment film material discharged from the nozzle 3a by the previous coating. Set the position so that it overlaps or contacts the front end L1 in the width direction of row 4a. Further, the effective discharge width W1 of the nozzles 3a in the second and subsequent rows is set so that the front end portion L1 in the width direction becomes the position of the color filter B by controlling the number of discharges of the nozzles 3a.

Therefore, as shown in FIG. 4 (b), the effective discharge width W1 when both ends L2 and L1 of the alignment film material are set to form the overlapping portion 4c is the color filters R, B, and G. Set the value by adding the superimposition width W3 of the superimposition part 4c to approximately an integral multiple of the pixel spacing with the array as one unit.

The superimposition width W3 of the superimposition portion 4c fluctuates due to the relative blurring of the table and the droplet ejection head 3 during reciprocating scanning, or the accuracy error of the effective ejection width W1 of the nozzle 3a, and is constant. Absent. Therefore, when setting the effective discharge width W1, in consideration of these fluctuation factors, the superimposition width W3 of the superimposing portion 4c is always in contact with the superimposition width W3 at the maximum within the width of the color filter B and at the minimum end L1 and L2. As described above, it is obtained and set in advance from an experiment or the like.

As a result, the droplet ejection head 3 is reciprocally scanned and moved in the Y direction while moving the droplet ejection head 3 in the X direction with respect to the color filter substrate 1, so that the alignment film covers the entire alignment film coating region 2 of the color filter substrate 1. The material can be applied. Then, as shown in FIGS. 5 and 6, a color filter that displays a color having the lowest visibility among the color filters R, B, and G arranged on the color filter substrate 1 and in which the brightness difference is inconspicuous. An overlapping portion 4c (see FIG. 4) of the alignment film 4 is formed at a position corresponding to B.

As a result, the streak-like alignment unevenness caused by the overlapping portion 4c of the alignment film 4 is less likely to be visually recognized from the outside, and the quality of the product is improved.

The present invention is not limited to the above-described form, and the alignment film rows 4a and 4b are formed on the color filter substrate 1 by the flexographic printing method, and the alignment film rows 4a and 4b are repeated to form the alignment film of the color filter substrate 1. The alignment film 4 may be formed over the entire coating area 2.

Next, an example of the liquid crystal apparatus 11 that employs the color filter substrate 1 according to the present embodiment will be described. In the liquid crystal device 11 according to the present embodiment, the facing substrate 10 and the element substrate 20 are opposed to each other. Both substrates 10 and 20 are bonded to each other via a sealing material 30, and a liquid crystal encapsulation region 35 is formed inside. Then, a liquid crystal (not shown) is sealed in the liquid crystal sealing region 35. A light source device (not shown) is arranged on the outer surface of the facing substrate 10.

The facing substrate 10 has red (R), blue (B), and green (G) in the region corresponding to the intersection of the first electrode pattern 40 and the second electrode pattern 50 on the transparent substrate 101 such as a glass substrate. ) Are provided with a plurality of colored color filters 55 (R, G, and B). In this embodiment, the opposed substrate 10 corresponds to the color filter substrate 1 of the present embodiment.

On the transparent substrate 101, each color filter 55 (R, B, and G) is arranged according to a predetermined pattern (see FIG. 5 or FIG. 6). Then, the first electrode pattern 40 and the alignment film 4 are sequentially formed on the surface of each of these color filters 55 (R, B, and G). Both the first electrode pattern 40 and the second electrode pattern 50 are formed of a transparent conductive film typified by an ITO (Indium Tin Oxide) film. Further, a light-shielding film 16 is formed at the boundary portion of each color filter 55 (R, B, and G).

On the other hand, a second electrode pattern 50, an overcoat film 29, and an alignment film 4 are sequentially formed on a transparent substrate 201 such as a glass substrate constituting the element substrate 20.

Each of the alignment films 4 is formed on the color filters 55 (R, B, and G) and the overcoat film 29 by using the droplet ejection method according to this embodiment.

The alignment film 4 formed by using the droplet ejection method according to this embodiment is superposed on the positions corresponding to the color filter 55 (B) by superimposing the ends L1 and L2 of the adjacent alignment film rows 4a and 4b. Part 4c is formed.

The blue color displayed by the color filter 55 (B) is less visible than the color (R or G) displayed by the other color filters 55 (R or G), and the brightness difference is less noticeable. By arranging the superimposing portion 4c at the position corresponding to the filter 55 (B), the streak-like orientation unevenness caused by the superimposing portion 4c is less likely to be visually recognized from the outside, and the quality of the product can be improved.

Next, the manufacturing method of the liquid crystal apparatus 11 according to the present embodiment will be described with reference to the process diagram shown in FIG. First, in manufacturing the liquid crystal apparatus 11, the opposing substrate 10 and the element substrate 20 both use a semiconductor process in a state of a large substrate (not shown) capable of taking a large number of these substrates 10 and 20, respectively. The process of forming the electrode patterns 40, 50, etc. is performed.

That is, in the state of a large substrate (not shown) capable of taking a large number of transparent substrates 101, a light-shielding film 16 forming step ST11, a color filter 55 forming step ST12, an electrode pattern 40 forming step ST13, and an alignment film are formed on the large substrate. The forming step ST14, the rubbing step ST15, and the sealing material 30 coating step ST16 of 4 are performed.

Further, in the state of a large substrate (not shown) capable of taking a large number of transparent substrates 201, the electrode pattern 50 forming step ST21, the overcoat film 29 forming step ST22, the alignment film 4 forming step ST23, and rubbing on the large substrate. The process ST24 and the gap material spraying process ST25 are performed.

Then, in the bonding step ST31, the two large substrates (not shown) before being divided into a large number of the opposing substrate 10 and the element substrate 20 are bonded to each other to form a large panel structure, and then the primary In the break step ST32, the large panel structure is cut into strip-shaped panel structures.

Next, in the liquid crystal encapsulation / sealing step ST33, after injecting liquid crystal into the liquid crystal encapsulation region 35 (see FIG. 7) formed inside the strip-shaped panel structure, the liquid crystal encapsulation region 35 is sealed. Next, in the secondary break step ST34, the strip-shaped panel structure is cut for each single liquid crystal device 11, and then, in the mounting step ST35, a flexible substrate or the like is mounted on the single liquid crystal device 11. ..

In the step of forming the alignment film 4, in ST14, the alignment film rows 4a and 4b are formed for each row using the droplet ejection method, so that the alignment film 4 is finally formed in the entire alignment film coating region 2. Since the superimposing portion 4c formed on the adjacent ends L1 and L2 at that time is formed on the color filter 55 (B), the streak-like orientation unevenness caused by the superimposing portion 4c becomes difficult to be visually recognized from the outside. The quality of the product can be improved.

Further, in this embodiment, the alignment film 4 formed on the facing substrate 10 side has been described, but the alignment film 4 formed on the element substrate 20 side also has the same configuration. That is, in the step ST23 for forming the alignment film 4 on the transparent substrate 201 on the element substrate 20 side, the portion corresponding to the color filter 55 (B) is the same as in the step ST14 for forming the alignment film 4 on the opposite substrate 10 side (FIG. 7). The overlapping portion 4c of the alignment film rows 4a and 4b is formed in the direction directly below the color filter 55 (B) shown in the above. By forming the superimposing portions 4c of the alignment film rows 4a and 4b in the direction directly below the color filter 55 (B), it becomes difficult for the streak-like alignment unevenness caused by the superimposing portions 4c to be visually recognized from the outside.

<figref num="1">Front view of the color filter substrate according to this embodiment</figref><figref num="2">Same as above, II-II cross-sectional view of Fig. 1.</figref><figref num="3">The perspective view showing the state of applying the alignment film material on the color filter using the droplet ejection head.</figref><figref num="4">Similarly, an enlarged cross-sectional view of a main part in a state where the alignment film material is applied on the color filter.</figref><figref num="5">The same is a plan view showing the arrangement of the color filters provided on the color filter substrate.</figref><figref num="6">The plan view which shows the arrangement of the color filter provided on the color filter substrate by the same other aspect.</figref><figref num="7">Cross-sectional view of the liquid crystal device according to this embodiment</figref><figref num="8">The process chart showing the manufacturing method of the liquid crystal device.</figref>

Code description

1 color filter substrate, 2 alignment film coating area, 3 droplet ejection head, 3a nozzle, 3b supply port, 4 alignment film, 4a, 4b alignment film row, 4c superimposition part, 10 facing substrate, 11 liquid crystal device, 16 shading Membrane, 20 element substrate, 29 overcoat film, 30 sealant, 35 liquid crystal encapsulation area, 40,50 electrode pattern, 55 color filter, 101,201 transparent substrate, L1 width direction rear end, L2 width direction front end, W1 effective discharge Width, effective width in W2 X direction, W3 superimposition width