JP2000029052A - Production of liquid crystal panel - Google Patents
Production of liquid crystal panelInfo
- Publication number
- JP2000029052A JP2000029052A JP10198863A JP19886398A JP2000029052A JP 2000029052 A JP2000029052 A JP 2000029052A JP 10198863 A JP10198863 A JP 10198863A JP 19886398 A JP19886398 A JP 19886398A JP 2000029052 A JP2000029052 A JP 2000029052A
- Authority
- JP
- Japan
- Prior art keywords
- liquid crystal
- pressure
- crystal panel
- panel
- injection port
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Liquid Crystal (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は画像表示を行なう液
晶表示装置における液晶パネルの製造方法に関するもの
である。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a liquid crystal panel in a liquid crystal display device for displaying images.
【０００２】[0002]
【従来の技術】近年、液晶パネルの表示品位は日増しに
高まり、文字認識のためだけの用途から、フルカラー画
像表示に耐える品位にまで進歩してきた。さらに大型液
晶パネルの生産力が向上してきていることと相俟って、
ついにはＣＲＴの独壇場だったモニタ市場にも液晶パネ
ルが参入するに至った。この市場で液晶モニタがＣＲＴ
を凌駕するためには、さらに大画面でかつ高い品位での
表示が液晶パネルに要求されるが、高い表示品位を得る
ためには、明るくて視野角が広く、高解像度であるとい
う性能面の向上と、画面内での表示むらがなく均一な表
示ができることや、各液晶パネル間で性能がばらつかな
いという生産工程での品質向上との両面での取り組みが
重要となる。その中で画面全体で均一な表示ができるよ
うにするために、生産上もっとも重要なことは、液晶パ
ネルの基板間のギャップを均一に形成することであり、
従来より種々の改良が行われているが、以下、その一般
的な液晶パネルの製造方法の一例について説明する。2. Description of the Related Art In recent years, the display quality of liquid crystal panels has been increasing day by day, and has progressed from use only for character recognition to quality that can withstand full-color image display. In addition, the productivity of large LCD panels has been improving,
Finally, LCD panels have entered the monitor market, which was the dominant market for CRTs. LCD monitors are CRTs in this market
LCD panels require larger screens and higher quality displays in order to surpass the standard, but in order to obtain high display quality, they must be bright, have a wide viewing angle, and have high resolution. It is important to work on both improvement and quality improvement in the production process, in which uniform display can be achieved without display unevenness in the screen, and performance does not vary between liquid crystal panels. Among them, the most important thing in production is to make the gap between the substrates of the liquid crystal panel uniform so that the display can be uniform on the entire screen.
Various improvements have been made conventionally, and an example of a general method of manufacturing a liquid crystal panel will be described below.
【０００３】まず、配向処理の施された２枚の基板を所
定のギャップをもって接着させるために、シール材を一
方の基板にその外周部を囲むように枠状に形成する。こ
の時、後でシール材と基板に囲まれた領域に液晶を注入
できるように、一部シールのない部分を設け、これを注
入口としている。また、シール材には２枚の基板間にギ
ャップが形成されるように、所定の粒径のスペーサーが
一定量混入されている。次に基板の一方に所定の粒径の
スペーサーを散布する。このスペーサーも、基板間のギ
ャップを設けるためのものである。このスペーサーは、
画面の端はシールに混入されたスペーサーでギャップを
保持するのに対して、画面内全体を所定のギャップで保
持するために重要なものである。First, a sealing material is formed in a frame shape on one of the substrates so as to surround the outer periphery thereof in order to bond the two substrates subjected to the orientation treatment with a predetermined gap. At this time, a part without a seal is provided so that the liquid crystal can be injected into a region surrounded by the sealing material and the substrate later, and this is used as an injection port. Further, a certain amount of spacer having a predetermined particle size is mixed in the sealing material so that a gap is formed between the two substrates. Next, a spacer having a predetermined particle size is sprayed on one of the substrates. This spacer is also for providing a gap between the substrates. This spacer is
While the edge of the screen holds the gap with a spacer mixed in the seal, it is important to hold the entire screen with a predetermined gap.
【０００４】従来の製造工程においては、このスペーサ
ーを基板に散布する時の散布均一性が悪く、例えば、ス
ペーサー散布密度は通常１ｍｍ2あたり１５０個から２
００個程度であるが、１５０個を目標に散布しても、基
板面内では密度ばらつきが生じ、１００個／ｍｍ2から
２００個／ｍｍ2程度の分布を持っていた。このばらつ
きは、パネルのギャップばらつきに大きく影響する。[0004] In the conventional production process, poor spray uniformity at the time of spraying the spacers into the substrate, for example, the spacer dispersion density from 150 per normal 1 mm 2 2
Although the number was about 00 pieces, even if the target was sprayed with 150 pieces, density variation occurred in the substrate surface, and the distribution was about 100 pieces / mm 2 to 200 pieces / mm 2 . This variation greatly affects the panel gap variation.
【０００５】図４はスペーサー散布密度とパネルギャッ
プ値との関係を示す曲線図であり、ここで使用したスペ
ーサーは日本触媒（株）製のエポスターＧＰ−Ｈ５０で
ある。この図４に示すようにスペーサー散布密度１００
個／ｍｍ2ではパネルギャップ値４.８１μｍに対し１５
０個／ｍｍ2で４.９１μｍ，２００個／ｍｍ2では４.９
６μｍとなり、このような散布密度分布を持った基板で
パネルを試作した場合、パネル面内のギャップばらつき
は最大で０.１５μｍとなってしまうのである。しかし
ながら、現在ではスペーサー散布装置の性能が向上し、
散布密度分布も±１０％以内に収まるものになり、１５
０個／ｍｍ2散布であれば、±１５個／ｍｍ2のばらつき
で作成できるので、パネルギャップ精度も±０.０３μ
ｍ以内を実現することも可能になってきている。FIG. 4 is a curve diagram showing the relationship between the spacer spray density and the panel gap value. The spacer used here is Eposter GP-H50 manufactured by Nippon Shokubai Co., Ltd. As shown in FIG.
Pcs / mm 2 , 15 for panel gap value of 4.81 μm
4.91μm with 0 / mm 2, in 200 pieces / mm 2 4.9
When a panel is manufactured on a trial basis with a substrate having such a distribution density, the gap variation in the panel surface is 0.15 μm at the maximum. However, now the performance of the spacer sprayer has improved,
The distribution of the spray density also falls within ± 10%,
If the spraying rate is 0 pieces / mm 2 , it can be created with a variation of ± 15 pieces / mm 2 , so that the panel gap accuracy is also ± 0.03 μm.
m is also possible.
【０００６】このような工程を経た基板に、もう一方の
基板を貼りあわせ、シール材を硬化させることにより、
２枚の基板間のシールで囲まれた部分にギャップの形成
されたパネルが作られる。この状態では、基板間のギャ
ップには空気が入っており、注入口を介して外界とつな
がっているため、パネル内外ともに１気圧（１０１３０
０Ｐａ）となっている。このパネルに液晶を注入する方
法として、一般的には真空注入法がよく使われている。
この方法はパネル内の空気を真空引きにより排気したの
ち、液晶材料を毛細管現象と、パネル内外圧力差を利用
して注入する方法である。[0006] The other substrate is bonded to the substrate that has undergone such a process, and the sealing material is cured, whereby
A panel is formed in which a gap is formed in a portion surrounded by a seal between two substrates. In this state, air enters the gap between the substrates and is connected to the outside world through the injection port.
0 Pa). As a method of injecting liquid crystal into this panel, generally, a vacuum injection method is often used.
In this method, after air in a panel is evacuated by evacuation, a liquid crystal material is injected using a capillary phenomenon and a pressure difference between the inside and outside of the panel.
【０００７】すなわち、パネルと液晶材料の入った容器
を注入装置に入れ、注入装置内を真空引きして１Ｐａ以
下にする。このときパネルと液晶材料は接触させないの
で、注入口からパネル内の空気は排気され、装置内と同
じ１Ｐａ以下になる。次に注入口と液晶材料を接触させ
た後、注入装置内に窒素を導入して装置内の圧力を１気
圧にまで上げていく。この状態でパネル内外にほぼ１気
圧の圧力差が生じ、液晶材料はこの力によりパネル内へ
注入されていく。That is, a container containing a panel and a liquid crystal material is put into an injection device, and the inside of the injection device is evacuated to 1 Pa or less. At this time, since the panel and the liquid crystal material are not brought into contact with each other, the air in the panel is exhausted from the injection port, and the pressure becomes 1 Pa or less, which is the same as in the apparatus. Next, after the injection port is brought into contact with the liquid crystal material, nitrogen is introduced into the injection apparatus to increase the pressure in the apparatus to 1 atm. In this state, a pressure difference of about 1 atm is generated inside and outside the panel, and the liquid crystal material is injected into the panel by this force.
【０００８】この場合、液晶材料がパネル内全体に満た
される瞬間まではパネル内外圧力差はほぼ１気圧である
が、そのまま放置するとパネル内外圧力差がなくなるま
で液晶は注入され続ける。そしてこの内外圧力差によっ
て形成される液晶パネルのギャップは内外圧力差が高い
ほど薄く、低いほど厚くなる。通常この液晶注入工程
は、真空引きや注入に時間がかかるので、一つの大きな
注入装置に多数のパネルを入れて注入を行うが、このと
き各パネル間で、そのスペーサの量、注入口の大きさ、
液晶材料に注入口が接触する時間などに微妙な違いがあ
り、まったく同じ速度で液晶が注入されるわけではな
い。したがって、すべてのパネルが確実に注入されるよ
うに注入工程の時間は長めに設定するが、それでも各パ
ネルでの内外圧力差にばらつきが生じ、この工程だけで
は均一なギャップは形成できない。そこで、一般的には
この液晶注入工程の後、液晶パネルを加圧する工程が設
けられており、この工程では、通常１.５気圧（１５２
０００Ｐａ）程度で加圧することで過剰に入った液晶材
料を注入口から押し出す。次にこの状態で紫外線硬化型
の封止樹脂で注入口を封止するが、このときパネル内外
圧力差は０.５気圧（５０６５０Ｐａ）となる。さらに
加圧を解除して１気圧に戻すとパネル内へ封止樹脂は若
干吸い込まれ、この時点で紫外線を照射すると封止樹脂
は硬化し、一定の内外圧力差をもった液晶パネルが作成
される。In this case, the pressure difference between the inside and outside of the panel is almost 1 atm until the moment when the liquid crystal material is entirely filled in the panel, but if left as it is, the liquid crystal continues to be injected until the pressure difference between inside and outside of the panel disappears. The gap of the liquid crystal panel formed by the internal / external pressure difference becomes thinner as the internal / external pressure difference becomes higher, and becomes thicker as the internal / external pressure difference becomes lower. Usually, in this liquid crystal injection step, it takes a long time to evacuate or inject, so that many panels are put into one large injection device and injection is performed. At this time, the amount of the spacer and the size of the injection port are increased between the panels. Well,
There are subtle differences in the time that the injection port contacts the liquid crystal material, and the liquid crystal is not injected at exactly the same speed. Therefore, the time of the injection step is set to be long to ensure that all the panels are injected. Nevertheless, the pressure difference between the inside and outside of each panel varies, and a uniform gap cannot be formed only by this step. Therefore, a step of pressurizing the liquid crystal panel is generally provided after the liquid crystal injection step. In this step, a pressure of 1.5 atm (152
The excess liquid crystal material is extruded from the injection port by applying pressure at about 000 Pa). Next, in this state, the injection port is sealed with an ultraviolet-curing sealing resin. At this time, the pressure difference between the inside and outside of the panel becomes 0.5 atm (50650 Pa). Further, when the pressure is released and the pressure is returned to 1 atm, the sealing resin is slightly sucked into the panel. At this point, when the ultraviolet ray is irradiated, the sealing resin hardens, and a liquid crystal panel having a constant internal and external pressure difference is produced. You.
【０００９】[0009]
【発明が解決しようとする課題】しかしながらこのよう
な従来の製造方法では、パネル面内のギャップのばらつ
きが比較的大きいことと、同じ工程で作成した液晶パネ
ル間でのギャップ値にもばらつきが生じるという問題点
がある。このパネル面内でのギャップのばらつきは、通
常のＴＮ方式の液晶パネルを５μｍのギャップで作成し
た場合、一般的に±０.１μｍ以上である。特に薄膜ト
ランジスタ（ＴＦＴ）アレイを設けたような段差のつい
た基板においては、±０.３μｍ以上となることもあ
る。However, in such a conventional manufacturing method, the variation in the gap in the panel surface is relatively large, and the gap value between the liquid crystal panels formed in the same process also varies. There is a problem. The variation in the gap in the panel surface is generally ± 0.1 μm or more when a normal TN type liquid crystal panel is formed with a gap of 5 μm. In particular, in the case of a substrate having a step such as a thin film transistor (TFT) array, the thickness may be ± 0.3 μm or more.
【００１０】このようなギャップばらつきが発生する要
因としては、パネル内外圧力差があり、従来、この内外
圧力差は主に液晶注入後の加圧封止工程によって制御し
ていたが、前述のように、液晶注入直後の液晶パネル内
圧には、そのパネル状態によりばらつきが生じているこ
とから、加圧封止を一定条件に保っても、同一の内外圧
力差で封止できるとは限らない。さらに加圧工程は、液
晶パネルを加圧装置に挟み込み基板を押圧し、注入口か
ら液晶を押し出すものであるが、一度注入された液晶は
その粘性の大きさから、押圧されてもわずかに開口され
た注入口からはすぐには押し出されず、加圧に応じた一
定のギャップになるには多くの時間を要する。また、基
板上を均一に押圧しても、狭い注入口に集中する液晶の
流れのために、パネル内の液晶量に分布（むら）が生じ
てしまう。すなわち注入口付近に液晶が集中するために
一般に急速な加圧封止を行うと、注入口付近のギャップ
が厚くなる傾向となる。これらのことから、加圧封止工
程ではできる限りゆっくりと圧力を上げていき、一定圧
力で長時間保持しない限りギャップ精度の高い液晶パネ
ルを作成することはできない。The cause of such a gap variation is a pressure difference between the inside and outside of the panel. Conventionally, the difference between the inside and outside pressures is controlled mainly by a pressure sealing step after liquid crystal injection. In addition, since the internal pressure of the liquid crystal panel immediately after the injection of the liquid crystal varies depending on the state of the panel, it is not always possible to seal the liquid crystal panel with the same internal / external pressure difference even if the pressure sealing is maintained under a certain condition. In the pressurizing step, the liquid crystal panel is sandwiched by a pressurizing device to press the substrate and extrude the liquid crystal from the injection port. It is not immediately extruded from the injected inlet, and it takes a lot of time to reach a certain gap corresponding to the pressure. Further, even if the substrate is pressed uniformly, the liquid crystal flow in the panel is uneven (distributed) due to the flow of the liquid crystal concentrated in the narrow injection port. That is, in general, when the liquid crystal is concentrated near the injection port, when rapid pressure sealing is performed, the gap near the injection port tends to be thick. For these reasons, in the pressure sealing step, the pressure is increased as slowly as possible, and a liquid crystal panel with a high gap accuracy cannot be produced unless the pressure is maintained at a constant pressure for a long time.
【００１１】一方、表示品位の高い表示性能を得るため
には、ＴＦＴ方式の液晶パネルが必要であるが、従来の
ＴＦＴ方式の液晶パネルにおいては、電圧印加により黒
を表示するＴＮのノーマリーホワイト方式を採用してお
り、この表示方式ではパネルのギャップばらつきが表示
の均一性にあまり影響しないため、上記のギャップ精度
でも十分製品として耐えるものであったが、近年さらに
液晶パネルの最大の欠点であった視野角を拡大する取り
組みが盛んに行われるようになり、表示方式の改善がな
されると、もはや±０.１μｍのギャップばらつきも許
されなくなってきている。On the other hand, a TFT type liquid crystal panel is required to obtain high display quality display performance. However, in a conventional TFT type liquid crystal panel, TN normally white which displays black by applying a voltage is used. In this display method, since the gap variation of the panel does not affect the uniformity of the display much, the gap accuracy described above was enough to endure as a product. As the efforts to expand the viewing angle have been vigorously made and the display system has been improved, the gap variation of ± 0.1 μm is no longer allowed.
【００１２】例えば、視角拡大法の一つであるフィルム
位相補償方式では、液晶パネルのギャップｄと液晶の屈
折率異方性Δｎとの積Δｎ・ｄとフィルムの位相差との
厳密な合わせ込みが必要となることから、ギャップｄは
少なくとも±０.１μｍ以下のギャップ精度が要求され
る。また視角拡大のもう一つの方式であるＩＰＳ（In-P
lane-Switching）方式では、液晶の複屈折性を利用する
ことから、やはりΔｎ・ｄを厳密に制御しなければなら
ず、このときは±０.０５μｍ以下の精度が要求される
等、従来の製造方法では対応しきれなくなってきてい
る。For example, in the film phase compensation method, which is one of the viewing angle enlarging methods, a strict adjustment of the product Δn · d of the liquid crystal panel gap d and the refractive index anisotropy Δn of the liquid crystal and the phase difference of the film. Is required, the gap d is required to have a gap accuracy of at least ± 0.1 μm or less. In addition, IPS (In-P
In the lane-switching method, since the birefringence of liquid crystal is used, Δn · d must also be strictly controlled. In this case, accuracy of ± 0.05 μm or less is required. The manufacturing method is becoming inadequate.
【００１３】本発明は上記従来の問題点を解決するもの
であり、液晶の効果的なパネル注入により、高ギャップ
精度（±０.０５μｍ以下）を得る液晶パネルの製造方
法を提供することを目的とする。An object of the present invention is to provide a method of manufacturing a liquid crystal panel which achieves a high gap accuracy (± 0.05 μm or less) by effectively injecting the liquid crystal into the panel. And
【００１４】[0014]
【課題を解決するための手段】本発明の液晶パネルの製
造方法は、対向する２枚の基板を注入口を設けたシール
材を介して貼り合わせた液晶パネルの製造方法であっ
て、液晶パネルと液晶材料の入った容器を注入装置に入
れ、前記注入装置を大気圧から減圧して第１の圧力Ｐ１
に保持する工程と、前記シール材の注入口を前記液晶材
料と接触させてから、前記注入装置を前記第１の圧力Ｐ
１と大気圧との間の第２の圧力Ｐ２にして前記液晶パネ
ル内に液晶を充填させる工程と、前記注入口を前記容器
から離し、前記注入口を封止する紫外線硬化型の封止樹
脂を塗布する工程と、前記注入装置を前記第２の圧力Ｐ
２と大気圧との間の第３の圧力Ｐ３にした状態で紫外線
を照射して前記封止樹脂を硬化させる工程と、前記注入
装置を大気圧に戻して前記液晶パネルを取り出す工程を
備えたものである。A method of manufacturing a liquid crystal panel according to the present invention is a method of manufacturing a liquid crystal panel in which two opposing substrates are bonded together via a sealing material provided with an inlet. And a container containing a liquid crystal material into an injection device, and the injection device is depressurized from atmospheric pressure to a first pressure P1.
And contacting the injection port of the sealing material with the liquid crystal material, and then operating the injection apparatus at the first pressure P
Filling the liquid crystal into the liquid crystal panel at a second pressure P2 between 1 and the atmospheric pressure; and an ultraviolet-curing sealing resin for sealing the injection port by separating the injection port from the container. And applying the injection device to the second pressure P.
A step of irradiating ultraviolet rays at a third pressure P3 between 2 and atmospheric pressure to cure the sealing resin, and a step of removing the liquid crystal panel by returning the injection device to atmospheric pressure. Things.
【００１５】この発明によれば、液晶のパネル注入時点
でのパネル内外圧力差が精度良く一定に保たれるので、
±０.０５μｍ以下のギャップ精度が得られる。According to the present invention, the pressure difference between the inside and outside of the panel when the liquid crystal is injected into the panel is accurately and constantly maintained.
A gap accuracy of ± 0.05 μm or less can be obtained.
【００１６】[0016]
【発明の実施の形態】本発明においては、従来のような
液晶注入後の加圧工程を省き、真空注入後の圧力を１気
圧に戻すことなく所定の減圧状態で封止樹脂を塗布し、
硬化させることによってパネル内圧をこの減圧状態のま
まに保つようにしたものであり、以下、本発明の一実施
の形態について図面を参照しながら説明する。DESCRIPTION OF THE PREFERRED EMBODIMENTS In the present invention, a conventional pressurizing step after liquid crystal injection is omitted, and a sealing resin is applied under a predetermined reduced pressure without returning the pressure after vacuum injection to 1 atm.
The inside pressure of the panel is maintained at this reduced pressure by curing, and an embodiment of the present invention will be described below with reference to the drawings.
【００１７】図１は本発明の液晶パネルの製造方法の一
実施の形態における製造工程の流れ図、図２は本発明の
液晶パネルの製造方法の一実施の形態において製造対象
となる液晶パネルの平面図、図３は本発明の液晶パネル
の製造方法の一実施の形態における液晶パネル内外圧力
差とパネルギャップとの関係を示す図である。FIG. 1 is a flow chart of a manufacturing process in an embodiment of a liquid crystal panel manufacturing method of the present invention, and FIG. 2 is a plan view of a liquid crystal panel to be manufactured in an embodiment of the liquid crystal panel manufacturing method of the present invention. FIG. 3 is a diagram showing the relationship between the pressure difference between the inside and outside of the liquid crystal panel and the panel gap in one embodiment of the method for manufacturing a liquid crystal panel of the present invention.
【００１８】まず、図１に示す製造工程に入る前に、図
２に示す液晶パネルにスペーサーを散布する。即ち、こ
の液晶パネルは基板１の外部を囲むように枠状に形成し
たシール材２を有し、そのシール材２の一部に液晶注入
のための注入口３を備えたものに、これと対向するもう
一枚の基板を重ねて貼り合わせるものであるが、図２は
この貼り合わせる方の基板を取り除いた状態を示してい
る。この一方の基板１に（株）エスイー社製のセミドラ
イ方式スペーサー散布装置を用いて、日本触媒（株）製
のエポスターＧＰ−Ｈ５０（スペーサー）を平均１５０
個／ｍｍ2となるように散布した。散布後の基板面内の
スペーサー散布密度は少ないところで１３７個／ｍ
ｍ2、最も多いところで１６４個／ｍｍ2であった。この
スペーサーの散布された基板ともう一方の基板とを貼り
合わせ、前記基板間のギャップを約５μｍとした液晶パ
ネルとする。First, before starting the manufacturing process shown in FIG. 1, spacers are sprayed on the liquid crystal panel shown in FIG. That is, this liquid crystal panel has a sealing material 2 formed in a frame shape so as to surround the outside of the substrate 1, and a part of the sealing material 2 having an injection port 3 for injecting a liquid crystal. Another opposing substrate is laminated and bonded, and FIG. 2 shows a state where the substrate to be bonded is removed. Using a semi-dry type spacer spraying device manufactured by SEI Co., Ltd. on one of the substrates 1, eposter GP-H50 (spacer) manufactured by Nippon Shokubai Co., Ltd. was averaged 150 times.
Pieces / mm 2 . 137 spacers / m at a low spacer density in the substrate surface after spraying
m 2 , and 164 / mm 2 at the maximum. The substrate on which the spacers are scattered and the other substrate are bonded together to form a liquid crystal panel having a gap between the substrates of about 5 μm.
【００１９】ここで図１の工程Ｐｒ１に入り、前記液晶
パネルと液晶材料の入った容器を注入装置（真空槽）に
設置する。この注入装置内に入れた液晶パネルは画面サ
イズが１０.４型、シール材２で囲まれた内側の寸法は
２１５ｍｍ×１６２ｍｍ、注入口３は２箇所で各々幅８
ｍｍであった。この液晶パネルの注入口３の下に液晶材
料の入った容器（図示省略）を設置するが、この時、注
入口に液晶が接触しないように、注入口３と容器に入っ
た液晶面との距離を１００ｍｍ隔てて設置した。At step Pr1 in FIG. 1, the container containing the liquid crystal panel and the liquid crystal material is set in an injection device (vacuum tank). The liquid crystal panel put in this injecting apparatus has a screen size of 10.4 type, the inner size surrounded by the sealing material 2 is 215 mm × 162 mm, and the injecting port 3 has two places each having a width of 8 mm.
mm. A container (not shown) containing a liquid crystal material is installed below the inlet 3 of the liquid crystal panel. At this time, the inlet 3 and the liquid crystal surface contained in the container are connected so that the liquid crystal does not contact the inlet. They were installed at a distance of 100 mm.
【００２０】次に工程Ｐｒ２において、注入装置を外界
と遮断し、注入装置を第１の圧力の１Ｐａになるまで減
圧し、１Ｐａに到達してから９０分たった後、工程Ｐｒ
３において、液晶パネルの設置位置を下げ、注入口と液
晶を接触させた。注入口に液晶が十分接触するように１
分間待機した後、工程Ｐｒ４において、５分間で第２の
圧力の５００００Ｐａになるまで注入装置に窒素ガスを
供給した。この状態で２００分間放置したところ、液晶
パネル全体に液晶材料が充填された。この後、工程Ｐｒ
５において、液晶パネルの注入口３と液晶材料の入った
容器を離し、工程Ｐｒ６において、この圧力下で注入口
３にアクリル系の紫外線硬化型の封止樹脂を塗布した直
後、工程Ｐｒ７において、注入装置が第３の６５０００
Ｐａになるように窒素ガスを導入した。この圧力になっ
て２分後、工程Ｐｒ８において、封止樹脂に紫外線を１
５秒照射し、封止樹脂を完全に硬化させた。最後に工程
Ｐｒ９において、注入装置に窒素ガスを導入し槽内を１
０１３００Ｐａ（１気圧）に戻して、液晶パネルを取り
出した。Next, in step Pr2, the injection device is shut off from the outside world, and the pressure of the injection device is reduced to the first pressure of 1 Pa. After reaching 1 Pa, 90 minutes later, the process Pr
In 3, the installation position of the liquid crystal panel was lowered, and the injection port was brought into contact with the liquid crystal. 1 so that the liquid crystal contacts the inlet
After waiting for minutes, in step Pr4, nitrogen gas was supplied to the injector until the second pressure reached 50000 Pa in 5 minutes. When left for 200 minutes in this state, the entire liquid crystal panel was filled with the liquid crystal material. Thereafter, the process Pr
In step 5, the injection port 3 of the liquid crystal panel is separated from the container containing the liquid crystal material, and in step Pr6, immediately after the injection port 3 is coated with the acrylic ultraviolet curing type sealing resin under this pressure, in step Pr7, The injection device is the third 65000
Nitrogen gas was introduced so as to be Pa. Two minutes after this pressure is reached, in step Pr8, ultraviolet light is applied to the sealing resin for 1 minute.
Irradiation was performed for 5 seconds to completely cure the sealing resin. Finally, in the process Pr9, nitrogen gas is introduced into the injection device, and
After returning to 01300 Pa (1 atm), the liquid crystal panel was taken out.
【００２１】このようにして作成された液晶パネルの面
内のギャップ値の測定を行ったところ、最小値が４.９
９μｍで最大値が５.０３μｍであり、その差は０.０４
μｍで非常に均一性に優れたパネルを作成することがで
きた。When the in-plane gap value of the liquid crystal panel thus produced was measured, the minimum value was 4.9.
The maximum value is 5.03 μm at 9 μm, and the difference is 0.04.
It was possible to produce a panel having a very uniform thickness of μm.
【００２２】比較のために、同じサイズの液晶パネルを
従来の製造方法でも作成した。この時、注入装置は１Ｐ
ａになるまで減圧し、１Ｐａに到達してから９０分たっ
た後、液晶パネルの設置位置を下げて、注入口と液晶を
接触させた。その後注入口に液晶が十分接触するように
１分間待機した後、５分間で１０１３００Ｐａ（１気
圧）になるまで注入装置に窒素ガスを供給した。この状
態で１２０分間放置したところ、液晶パネル全体に液晶
材料が充填されていた。この液晶注入工程の後、液晶パ
ネルを加圧装置において１５２０００Ｐａに加圧し、液
晶材料を注入口から押し出した。この状態で１５分間放
置した後、紫外線硬化型の封止樹脂で注入口を封口し
た。その後加圧を１１５００Ｐａにまで落とし、２分間
放置した後紫外線を照射して封止樹脂を硬化した。この
従来の製造工程で作成された液晶パネルの面内のギャッ
プ値は、最小値で４.８７μｍで最大値が５.２２μｍと
なり、その差は０.３５μｍとギャップ値のばらつきが
大きいものとなった。このばらつきの発生要因として
は、パネル面内での内外圧力差のばらつきが考えられ
る。For comparison, a liquid crystal panel of the same size was prepared by a conventional manufacturing method. At this time, the injection device is 1P
The pressure was reduced to a, and 90 minutes after reaching 1 Pa, the installation position of the liquid crystal panel was lowered to bring the injection port into contact with the liquid crystal. Then, after waiting for 1 minute so that the liquid crystal sufficiently contacts the injection port, nitrogen gas was supplied to the injection apparatus until 101300 Pa (1 atm) was reached in 5 minutes. When left in this state for 120 minutes, the entire liquid crystal panel was filled with the liquid crystal material. After this liquid crystal injecting step, the liquid crystal panel was pressurized to 152000 Pa with a pressurizing device, and the liquid crystal material was extruded from the inlet. After standing for 15 minutes in this state, the injection port was sealed with an ultraviolet-curing sealing resin. Thereafter, the pressure was reduced to 11500 Pa, and the mixture was allowed to stand for 2 minutes, and then irradiated with ultraviolet rays to cure the sealing resin. The in-plane gap value of the liquid crystal panel produced by this conventional manufacturing process is 4.87 μm at the minimum and 5.22 μm at the maximum, and the difference is 0.35 μm, which greatly varies the gap value. Was. A possible cause of the variation is a variation in the pressure difference between the inside and outside of the panel surface.
【００２３】以上のことから、本発明の製造方法で作成
された液晶パネルは、従来の製造方法により作成された
ものと比べて、ギャップ精度の良いものができることが
確認された。From the above, it was confirmed that a liquid crystal panel manufactured by the manufacturing method of the present invention can have a better gap accuracy than a liquid crystal panel manufactured by a conventional manufacturing method.
【００２４】なお、前記の実施の形態における第２の圧
力（工程Ｐｒ４）は、第１の圧力（工程Ｐｒ３）より高
くないと液晶が注入されないことは当然であるが、これ
ら第１の圧力と第２の圧力との差圧が注入には重要であ
る。この圧力差が小さい場合、注入に要する時間が長く
なり、差が大きいと短い時間で注入できる。この時間と
圧力差の関係はほぼ反比例するので、あまり圧力差が小
さくて注入時間が長くなるのは工程上好ましくない。ま
た圧力差が小さいとスペーサーの散布密度のばらつきに
よるギャップばらつきが大きくなり、この意味でも好ま
しくない。It should be noted that the liquid crystal is not injected unless the second pressure (step Pr4) in the above embodiment is higher than the first pressure (step Pr3). The pressure difference from the second pressure is important for injection. When the pressure difference is small, the time required for injection is long, and when the difference is large, injection can be performed in a short time. Since the relationship between the time and the pressure difference is almost inversely proportional, it is not preferable in the process that the pressure difference is too small and the injection time is long. Also, if the pressure difference is small, the gap variation due to the variation in the distribution density of the spacers increases, which is not preferable in this sense.
【００２５】例えば、第２の圧力が３００００Ｐａであ
る場合、第１の圧力との差はほぼ３００００Ｐａであ
り、さらにパネル完成後はパネル内圧力がこの３０００
０Ｐａ、パネル外圧力は１気圧であるので、パネル内外
圧力差は、７００００Ｐａとなる。この場合、図３より
１５０±２０個／ｍｍ2のスペーサー散布密度分布を持
つとすると、そのギャップばらつきは０.０７６μｍと
なることがわかる。このギャップばらつきはパネル内外
圧力差が大きくなるほど増えて行き、スペーサーの硬度
や散布密度数によってもちろん変化するが、大略７００
００Ｐａ以上にすることは好ましくない。For example, when the second pressure is 30,000 Pa, the difference from the first pressure is almost 30,000 Pa, and after the panel is completed, the internal pressure of the panel becomes this 3000 Pa.
Since the pressure outside the panel is 0 atm and the pressure outside the panel is 1 atm, the pressure difference between the inside and outside of the panel is 70000 Pa. In this case, it can be seen from FIG. 3 that if the spacer scatter density distribution is 150 ± 20 / mm 2 , the gap variation is 0.076 μm. This gap variation increases as the pressure difference between the inside and outside of the panel increases, and of course varies depending on the hardness of the spacers and the number of spraying densities.
It is not preferable to set the pressure to 00 Pa or more.
【００２６】一方、パネル内外圧力差を小さくすると、
パネル完成後に、パネルを押したり吸着したりするよう
な外部からの力によるギャップばらつきが生じる傾向が
あるので、この観点からパネル内外圧力差は大略１５０
００Ｐａ程度は最低必要と考えられ、このような内外圧
力差の範囲を得るためには、第２の圧力Ｐ２は３０００
０Ｐａ以上８５０００Ｐａ以下が望ましい。On the other hand, when the pressure difference between the inside and outside of the panel is reduced,
After the panel is completed, there is a tendency that a gap variation occurs due to an external force such as pushing or sucking the panel. From this viewpoint, the pressure difference between the inside and outside of the panel is approximately 150.
It is considered that about 00 Pa is the minimum necessary, and in order to obtain such a range of the pressure difference between inside and outside, the second pressure P2 must be 3000
0 Pa or more and 85000 Pa or less are desirable.
【００２７】第３の圧力Ｐ３は、第２の圧力との差圧で
封止樹脂をパネル内に一定量吸い込ませる効果を持つ
が、樹脂の吸い込みに要する時間、吸い込み量の最適性
を考えると、その差圧は１５０００Ｐａ以下が望まし
い。The third pressure P3 has an effect of sucking a certain amount of the sealing resin into the panel at a pressure difference from the second pressure, but considering the time required for sucking the resin and the optimum suction amount. The differential pressure is desirably 15000 Pa or less.
【００２８】以上のように本実施の形態によれば、従来
のような液晶注入後の加圧工程は省き、真空注入後の圧
力を１気圧に戻すことなく所定の減圧状態で封止樹脂を
塗布し、硬化させることによってパネル内圧を一定の減
圧状態のままに保つことが可能となり、その大気中での
使用において、一定の内外圧力差を持つ均一で精度の良
いギャップを有する液晶パネルを実現することができ
る。As described above, according to the present embodiment, the conventional pressurizing step after liquid crystal injection is omitted, and the sealing resin is removed at a predetermined reduced pressure without returning the pressure after vacuum injection to 1 atm. By applying and curing, it is possible to keep the panel internal pressure at a constant decompressed state, and in use in the atmosphere, realize a liquid crystal panel with a uniform and accurate gap with a constant internal and external pressure difference can do.
【００２９】[0029]
【発明の効果】以上のように本発明によれば、液晶パネ
ルの内圧を一定の減圧状態のままに保つことが可能とな
り、均一で精度の良いギャップを有する液晶パネルを容
易に製造することができるという有利な効果が得られ
る。As described above, according to the present invention, it is possible to maintain the internal pressure of the liquid crystal panel at a constant reduced pressure, and it is possible to easily manufacture a liquid crystal panel having a uniform and accurate gap. The advantageous effect that it can be obtained is obtained.
【図１】本発明の液晶パネルの製造方法の一実施の形態
における製造工程の流れ図FIG. 1 is a flow chart of a manufacturing process in a liquid crystal panel manufacturing method according to an embodiment of the present invention.
【図２】本発明の液晶パネルの製造方法の一実施の形態
において製造対象となる液晶パネルの平面図FIG. 2 is a plan view of a liquid crystal panel to be manufactured in one embodiment of the method for manufacturing a liquid crystal panel of the present invention.
【図３】本発明の液晶パネルの製造方法の一実施の形態
における液晶パネル内外圧力差とパネルギャップとの関
係を示す図FIG. 3 is a diagram showing the relationship between the pressure difference between the inside and outside of the liquid crystal panel and the panel gap in one embodiment of the method for manufacturing a liquid crystal panel of the present invention.
【図４】スペーサー散布密度とパネルギャップ値との関
係を示す曲線図FIG. 4 is a curve diagram showing a relationship between a spacer spray density and a panel gap value.
１ 基板 ２ シール材 ３ 注入口 1 substrate 2 sealing material 3 inlet
───────────────────────────────────────────────────── フロントページの続き (72)発明者 分元 博文 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 Ｆターム(参考） 2H089 LA07 LA33 NA09 NA25 NA39 NA44 QA14 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hirofumi Motomoto 1006 Kazuma Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Industrial Co., Ltd. F-term (reference) 2H089 LA07 LA33 NA09 NA25 NA39 NA44 QA14
Claims (3)
ール材を介して貼り合わせた液晶パネルの製造方法であ
って、液晶パネルと液晶材料の入った容器を注入装置に
入れ、前記注入装置を大気圧から減圧して第１の圧力Ｐ
１に保持する工程と、前記シール材の注入口を前記液晶
材料と接触させてから、前記注入装置を前記第１の圧力
Ｐ１と大気圧との間の第２の圧力Ｐ２にして前記液晶パ
ネル内に液晶を充填させる工程と、前記注入口を前記容
器から離し、前記注入口を封止する紫外線硬化型の封止
樹脂を塗布する工程と、前記注入装置を前記第２の圧力
Ｐ２と大気圧との間の第３の圧力Ｐ３にした状態で紫外
線を照射して前記封止樹脂を硬化させる工程と、前記注
入装置を大気圧に戻して前記液晶パネルを取り出す工程
を備えたことを特徴とする液晶パネルの製造方法。1. A method of manufacturing a liquid crystal panel in which two opposing substrates are bonded together via a sealing material provided with an injection port, wherein a container containing the liquid crystal panel and a liquid crystal material is placed in an injection device, and The pressure of the injection device is reduced from atmospheric pressure to a first pressure P
1 and contacting the injection port of the sealant with the liquid crystal material, and then setting the injection apparatus to the second pressure P2 between the first pressure P1 and the atmospheric pressure, and setting the liquid crystal panel Filling the inside with liquid crystal; separating the injection port from the container; and applying an ultraviolet-curing sealing resin for sealing the injection port; and adjusting the injection apparatus to the second pressure P2. A step of irradiating ultraviolet rays with the third pressure P3 between the atmospheric pressure and the pressure to cure the sealing resin, and a step of removing the liquid crystal panel by returning the injection device to atmospheric pressure. Liquid crystal panel manufacturing method.
第２の圧力Ｐ２は３００００Ｐａ≦Ｐ２≦８５０００Ｐ
ａであることを特徴とする請求項１記載の液晶パネルの
製造方法。2. The first pressure P1 satisfies P1 ≦ 1 Pa,
The second pressure P2 is 30,000 Pa ≦ P2 ≦ 85000P
2. The method for manufacturing a liquid crystal panel according to claim 1, wherein: a.
０Ｐａであることを特徴とする請求項１記載の液晶パネ
ルの製造方法。3. The third pressure P3 is P3 ≦ P2 + 1500
2. The method according to claim 1, wherein the pressure is 0 Pa.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19886398A JP3544124B2 (en) | 1998-07-14 | 1998-07-14 | Liquid crystal panel manufacturing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19886398A JP3544124B2 (en) | 1998-07-14 | 1998-07-14 | Liquid crystal panel manufacturing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2000029052A true JP2000029052A (en) | 2000-01-28 |
| JP3544124B2 JP3544124B2 (en) | 2004-07-21 |
Family
ID=16398185
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19886398A Expired - Fee Related JP3544124B2 (en) | 1998-07-14 | 1998-07-14 | Liquid crystal panel manufacturing method |
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| Country | Link |
|---|---|
| JP (1) | JP3544124B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003015143A (en) * | 2001-07-03 | 2003-01-15 | Matsushita Electric Ind Co Ltd | Method for manufacturing liquid crystal display device |
-
1998
- 1998-07-14 JP JP19886398A patent/JP3544124B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003015143A (en) * | 2001-07-03 | 2003-01-15 | Matsushita Electric Ind Co Ltd | Method for manufacturing liquid crystal display device |
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| Publication number | Publication date |
|---|---|
| JP3544124B2 (en) | 2004-07-21 |
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