JP2008158237A - Manufacturing method of liquid crystal display device - Google Patents

Manufacturing method of liquid crystal display device Download PDF

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JP2008158237A
JP2008158237A JP2006346784A JP2006346784A JP2008158237A JP 2008158237 A JP2008158237 A JP 2008158237A JP 2006346784 A JP2006346784 A JP 2006346784A JP 2006346784 A JP2006346784 A JP 2006346784A JP 2008158237 A JP2008158237 A JP 2008158237A
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seal
liquid crystal
product panel
substrate
substrates
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Osamu Sato
治 佐藤
Hidefumi Yamashita
英文 山下
Yoshinori Seihikari
義則 正光
Shino Lee
志瑙 李
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LG Display Co Ltd
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LG Display Co Ltd
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Priority to JP2006346784A priority Critical patent/JP2008158237A/en
Priority to KR1020070052579A priority patent/KR101296649B1/en
Publication of JP2008158237A publication Critical patent/JP2008158237A/en
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    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1341—Filling or closing of cells
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/133351—Manufacturing of individual cells out of a plurality of cells, e.g. by dicing
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1339—Gaskets; Spacers; Sealing of cells
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1341—Filling or closing of cells
    • G02F1/13415—Drop filling process

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  • Physics & Mathematics (AREA)
  • Nonlinear Science (AREA)
  • Mathematical Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Liquid Crystal (AREA)
  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To previously prevent breakage of a sealing material by expansion of a liquid crystal during main curing and to prevent liquid crystal leakage and gap unevenness by breakage of a product panel seal. <P>SOLUTION: A manufacturing method of a liquid crystal display device includes: a step S1 for forming an annular product panel seal for defining a liquid crystal packing region and an external seal for sealing a gap between two substrates along an outer peripheral part of the substrates on the surface of one substrate of the two substrates of an array substrate and a color filter substrate; a step S3 for dropping a liquid crystal material onto the liquid crystal packing region enclosed by the product panel seal; a step S4 for facing the other substrate to the one substrate on which the liquid crystal material is dropped and sticking the substrates under vacuum; a step S5 for temporarily curing the product panel seal and the external seal; a step S6 for breaking a part of the external seal to break vacuum; and a step S7 for performing main curing of the product panel seal and the external seal. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

この発明は、液晶表示装置の製造方法に関する。   The present invention relates to a method for manufacturing a liquid crystal display device.

液晶表示装置に用いられる液晶パネルは、一般的に、ＴＦＴアレイ基板と、当該ＴＦＴアレイ基板に対向して設けられたカラーフィルタ基板と、これらの２枚の基板の間に形成された液晶層とから構成されている。ＴＦＴアレイ基板は、透明基板から構成され、その表面には、ＴＦＴ（Thin Film Transistor）、データライン、ゲートライン、および、画素電極等が形成され、その上に、配向膜が形成されている。また、カラーフィルタ基板も、透明基板から構成され、その表面には、Ｒ（赤）、Ｇ（緑）、Ｂ（青）のカラーフィルタ層が形成され、その上に、透明なＩＴＯ（Indium Tin Oxide）膜からなる対向電極が設けられ、さらにその上に、配向膜が設けられている。   A liquid crystal panel used for a liquid crystal display device generally includes a TFT array substrate, a color filter substrate provided opposite to the TFT array substrate, and a liquid crystal layer formed between these two substrates. It is composed of The TFT array substrate is composed of a transparent substrate, on which a TFT (Thin Film Transistor), a data line, a gate line, a pixel electrode, and the like are formed, and an alignment film is formed thereon. The color filter substrate is also composed of a transparent substrate, on which R (red), G (green), and B (blue) color filter layers are formed, on which transparent ITO (Indium Tin) is formed. A counter electrode made of an Oxide film is provided, and an alignment film is further provided thereon.

なお、液晶層の形成方法としては、主に、２つの方法が用いられている。その１つは、真空封入法であり、これは、ＴＦＴアレイ基板とカラーフィルタ基板とを貼り合わせた後に、それらを真空に保ち、毛細管現象を利用して、液晶材を注入口から注入し、注入後に、その注入口を封止するという方法である。もう１つは、滴下注入法（ＯＤＦ）であり、これは、カラーフィルタ基板の額縁部にシール材を描画しておき、当該シール材で囲まれた領域内に液晶材を滴下し、その後に、真空下において、カラーフィルタ基板とＴＦＴアレイ基板とを貼り合わせるという方法である。   Note that two methods are mainly used for forming the liquid crystal layer. One of them is a vacuum sealing method, in which after the TFT array substrate and the color filter substrate are bonded together, they are kept in a vacuum, and a liquid crystal material is injected from the injection port by utilizing capillary action. This is a method of sealing the injection port after the injection. The other is a drop injection method (ODF), in which a sealing material is drawn on the frame portion of the color filter substrate, a liquid crystal material is dropped into a region surrounded by the sealing material, and thereafter In this method, the color filter substrate and the TFT array substrate are bonded together under vacuum.

真空封入法によれば、液晶表示パネルに液晶を封入するのにかなりの時間を要していたが、滴下注入法の開発により、液晶封入に要する時間を大幅に短縮することができ、注目される技術となっている（例えば、特許文献１参照）。   According to the vacuum encapsulation method, it took a considerable amount of time to encapsulate the liquid crystal in the liquid crystal display panel. However, the development of the drop injection method can greatly reduce the time required for encapsulating the liquid crystal, and is attracting attention. (For example, refer to Patent Document 1).

以下、図に基づいて、この種の一般的な滴下注入法について説明する。図６は、一般的な滴下注入法を実施する際の一般的なシール配置を示したものである。図６に示すように、基板１００には、液晶充填領域を定義する、略々矩形の複数の製品パネルシール１０１が縦横に配列されて形成されており、液晶層形成後に、当該製品パネルシール１０１間を切断することにより、製品パネルが形成される。また、基板１００の表面上の周辺部には、図６に示すように、切れ目のない環状の外周シール１０２が一周以上配置され、その内側に、上記の製品パネルシール１０１が配置される構成となっている。外周シール１０２は、製造工程中に２枚の基板間の密封を確保するためのものである。なお、製品パネルシール１０１も切れ目がなく、環状に繋がった形状となっている。   Hereinafter, this type of general dropping injection method will be described with reference to the drawings. FIG. 6 shows a general seal arrangement when performing a general dropping injection method. As shown in FIG. 6, a plurality of substantially rectangular product panel seals 101 that define a liquid crystal filling region are formed in the substrate 100 so as to be arranged vertically and horizontally. After the liquid crystal layer is formed, the product panel seal 101 is formed. A product panel is formed by cutting the gap. In addition, as shown in FIG. 6, at least one annular outer peripheral seal 102 is disposed around the periphery of the surface of the substrate 100, and the product panel seal 101 is disposed on the inner side. It has become. The outer peripheral seal 102 is for ensuring a seal between two substrates during the manufacturing process. In addition, the product panel seal 101 has a continuous shape and is not cut.

図７は、一般的な滴下注入法を実施する際の一般的な工程の流れを示したフローチャートである。図７に示すように、まずはじめに、２枚の基板のうちの一方の基板１００の表面に、上述した製品パネルシール１０１および外周シール１０２をそれぞれ描画する（ステップＳ１００）。ここでは、２枚の基板のうち、カラーフィルタ基板に描画することとする。次に、必要に応じて、製品パネルシール１０１および外周シール１０２の溶媒を除去したり、粘度を上昇させたりすることを目的にシールプレベーク工程を行う（ステップＳ１０１）。なお、この工程は、液晶材とシール材との反応による液晶汚染を防止する目的のものであるが、必ずしも行う必要はない。次に、製品パネルシール１０１および外周シール１０２が形成された基板１００の表面の製品パネルシール１０１で囲まれた液晶充填領域内に液晶材を滴下する（ステップＳ１０２）。次に、カラーフィルタ基板とＴＦＴアレイ基板との両方を、貼り合わせ装置（図示せず）に導入して、装置内を真空排気して、真空下でこれら２枚の基板を位置合わせして重ね合わせ、弱く加圧して貼り合わせる（ステップＳ１０３）。これにより、液晶材は、製品パネルシール１０１により、２枚の基板間に密封される。   FIG. 7 is a flowchart showing a general process flow when a general dropping injection method is performed. As shown in FIG. 7, first, the product panel seal 101 and the outer periphery seal 102 described above are respectively drawn on the surface of one of the two substrates 100 (step S100). Here, drawing is performed on the color filter substrate of the two substrates. Next, a seal pre-baking process is performed for the purpose of removing the solvent of the product panel seal 101 and the outer periphery seal 102 or increasing the viscosity as necessary (step S101). This step is for the purpose of preventing liquid crystal contamination due to the reaction between the liquid crystal material and the sealing material, but is not necessarily performed. Next, a liquid crystal material is dropped into a liquid crystal filling region surrounded by the product panel seal 101 on the surface of the substrate 100 on which the product panel seal 101 and the outer peripheral seal 102 are formed (step S102). Next, both the color filter substrate and the TFT array substrate are introduced into a bonding apparatus (not shown), the inside of the apparatus is evacuated, and the two substrates are aligned and stacked under vacuum. Bonding is performed by applying a weak pressure (step S103). As a result, the liquid crystal material is sealed between the two substrates by the product panel seal 101.

次に、貼り合わされた２枚の基板は、大気中に取り出され、その後に、加熱又は紫外線照射を行って、製品パネルシール１０１及び外周シール１０２を一定程度（ギャップ変化や位置ずれが生じない程度）に硬化させ、２枚の基板間に適正なギャップを確保する（ステップＳ１０４）。ステップＳ１０４の工程を、仮硬化と呼ぶ。なお、シール材が熱硬化タイプのものの場合には加熱により仮硬化を行うが、シール材が紫外線硬化タイプのものの場合には紫外線照射により仮硬化を行う。次に、熱硬化炉（図示せず）に、仮硬化後の２枚の貼り合わせた基板を投入し、高温加熱して、本硬化処理を行う（ステップＳ１０５）。   Next, the two bonded substrates are taken out into the atmosphere, and then heated or irradiated with ultraviolet rays, so that the product panel seal 101 and the outer peripheral seal 102 are fixed to a certain extent (no gap change or misalignment occurs). ) To secure an appropriate gap between the two substrates (step S104). The process of step S104 is called temporary curing. In addition, when the sealing material is a thermosetting type, temporary curing is performed by heating, but when the sealing material is an ultraviolet curing type, temporary curing is performed by ultraviolet irradiation. Next, the two substrates after temporary curing are put into a thermosetting furnace (not shown) and heated at a high temperature to perform the main curing process (step S105).

特開平８−１９００９９号公報JP-A-8-190099

しかしながら、この従来の方法においては、製品パネルシール１０１の外側は真空であるため、製品パネル内に充填された液晶による強い力がかかり、シールが破壊されやすいという問題点があった。   However, in this conventional method, since the outside of the product panel seal 101 is in a vacuum, there is a problem that a strong force is applied by the liquid crystal filled in the product panel and the seal is easily broken.

図に基づいてこの現象を具体的に説明する。図８は、従来の方法により製造された製品パネルの製品パネルシール１０１の内外圧差を示した図である。図８において、１０３は液晶充填領域であり、１０４は製品パネル間のパッド部、１０５は液晶が製品パネルシール１０１を押す力である。図８に示すように、製品パネルシール１０１で囲まれた領域には液晶が充填されているが、製品パネルシール１０１の外側のパッド部１０４は真空であるため、製品パネルシール１０１に対して矢印１０５で示すような強い力がかかり、製品パネルシール１０１が破壊されやすい。特に、図７のステップＳ１０５の本硬化工程において、熱硬化炉に基板が投入されると、熱により、製品パネルシール１０１のシール材が一時的に軟化するとともに、液晶が膨張するため、その際には、特に、製品パネルシール１０１が破壊されやすい状態となる。   This phenomenon will be specifically described with reference to the drawings. FIG. 8 is a view showing the internal and external pressure difference of the product panel seal 101 of the product panel manufactured by the conventional method. In FIG. 8, 103 is a liquid crystal filling region, 104 is a pad portion between product panels, and 105 is a force by which the liquid crystal pushes the product panel seal 101. As shown in FIG. 8, the region surrounded by the product panel seal 101 is filled with liquid crystal. However, since the pad portion 104 outside the product panel seal 101 is in a vacuum, an arrow is formed with respect to the product panel seal 101. A strong force as indicated by 105 is applied, and the product panel seal 101 is easily broken. In particular, in the main curing process of step S105 in FIG. 7, when the substrate is put into the thermosetting furnace, the sealing material of the product panel seal 101 is temporarily softened due to heat, and the liquid crystal expands. In particular, the product panel seal 101 is easily broken.

図９は、図８のＡ−Ａ’線による断面図である。図９において、１０８は液晶、１０９は基板間のギャップを確保するためのスペーサー材、１１０はカラーフィルタ基板に設けられたカラーフィルタ層である。このとき、製品パネルシール１０１の外側が真空状態であると、液晶充填領域１０３と段差構造が異なる部分（パッド部１０４を例に図示）は大気圧１０６により押しつぶされ、その影響で製品パネルシール１０１の内側に歪み１０７が生じ、その部分のセルギャップ（２枚の基板間の距離）が厚くなる。この状態で、シール材が熱硬化されると、ギャップムラが固定化されてしまうという問題点があった。   FIG. 9 is a cross-sectional view taken along line A-A ′ of FIG. 8. In FIG. 9, 108 is a liquid crystal, 109 is a spacer material for ensuring a gap between the substrates, and 110 is a color filter layer provided on the color filter substrate. At this time, if the outside of the product panel seal 101 is in a vacuum state, a portion having a step structure different from that of the liquid crystal filling region 103 (illustrated by taking the pad portion 104 as an example) is crushed by the atmospheric pressure 106, and the product panel seal 101 is affected by the influence. The distortion 107 is generated inside the cell, and the cell gap (distance between the two substrates) in that portion becomes thick. In this state, when the sealing material is thermally cured, there is a problem that gap unevenness is fixed.

図１０は、パッド部１０４付近にギャップムラが発生している様子を図示したものである。当該ギャップムラが発生している部分においては、色ムラが生じ、画質が劣化してしまう等の問題点があった。   FIG. 10 illustrates a state in which gap unevenness is generated near the pad portion 104. In the portion where the gap unevenness occurs, there is a problem that color unevenness occurs and the image quality deteriorates.

この発明は、かかる問題点を解決するためになされたものであり、製品パネルシールの破壊を防止するとともに、ギャップムラの発生を防止するための液晶表示装置の製造方法を得ることを目的とする。   The present invention has been made to solve such a problem, and an object of the present invention is to obtain a method of manufacturing a liquid crystal display device for preventing the breakage of a product panel seal and the occurrence of gap unevenness. .

この発明は、アレイ基板とカラーフィルタ基板の２枚の基板のうちの一方の基板の表面に、液晶充填領域を定義するための環状の製品パネルシールと、前記２枚の基板間を密封するための基板の外周に沿った外部シールとを形成するステップと、前記製品パネルシールで囲まれた前記液晶充填領域に対して液晶材を滴下するステップと、前記液晶材が滴下された一方の基板に対して、もう一方の基板を対向させて、真空下で貼り合わせるステップと、前記製品パネルシールおよび前記外部シールを仮硬化させるステップと、前記外部シールの一部を破壊して、前記外部シールの内部の真空を破るステップと、前記製品パネルシールおよび前記外部シールを本硬化させるステップとを備えた液晶表示装置の製造方法である。   The present invention provides an annular product panel seal for defining a liquid crystal filling region on the surface of one of two substrates, an array substrate and a color filter substrate, and a seal between the two substrates. Forming an external seal along the outer periphery of the substrate, dropping a liquid crystal material onto the liquid crystal filling region surrounded by the product panel seal, and applying the liquid crystal material to one of the substrates on which the liquid crystal material is dropped On the other hand, the other substrate is opposed to each other and bonded together under vacuum, the product panel seal and the external seal are temporarily cured, and a part of the external seal is broken to remove the external seal. A method of manufacturing a liquid crystal display device, comprising: breaking an internal vacuum; and finally curing the product panel seal and the external seal.

この発明は、アレイ基板とカラーフィルタ基板の２枚の基板のうちの一方の基板の表面に、液晶充填領域を定義するための環状の製品パネルシールと、前記２枚の基板間を密封するための基板の外周に沿った外部シールとを形成するステップと、前記製品パネルシールで囲まれた前記液晶充填領域に対して液晶材を滴下するステップと、前記液晶材が滴下された一方の基板に対して、もう一方の基板を対向させて、真空下で貼り合わせるステップと、前記製品パネルシールおよび前記外部シールを仮硬化させるステップと、前記外部シールの一部を破壊して、前記外部シールの内部の真空を破るステップと、前記製品パネルシールおよび前記外部シールを本硬化させるステップとを備えた液晶表示装置の製造方法であるので、本硬化時における液晶の膨張によるシール材の破壊を未然に防止でき、製品パネルシールの破壊による液晶漏れおよびギャップムラの発生を防止することができる。   The present invention provides an annular product panel seal for defining a liquid crystal filling region on the surface of one of two substrates, an array substrate and a color filter substrate, and a seal between the two substrates. Forming an external seal along the outer periphery of the substrate, dropping a liquid crystal material onto the liquid crystal filling region surrounded by the product panel seal, and applying the liquid crystal material to one of the substrates on which the liquid crystal material is dropped On the other hand, the other substrate is opposed to each other and bonded together under vacuum, the product panel seal and the external seal are temporarily cured, and a part of the external seal is broken to remove the external seal. Since it is a manufacturing method of a liquid crystal display device comprising a step of breaking an internal vacuum and a step of main-curing the product panel seal and the outer seal, Can prevent breakage of the sealing material due to expansion of the liquid crystal in advance, it is possible to prevent the occurrence of liquid crystal leakage and uneven gap by the products panel seal failure.

実施の形態１．
以下、図面に基づいて、この発明の実施の形態１に係る液晶表示装置の製造方法について説明する。図１は、本実施の形態１に係る液晶表示装置の製造方法の流れを示したフローチャートであり、図２は、本実施の形態１に係る液晶表示装置の製造方法における一工程の様子を示した説明図である。 Embodiment 1 FIG.
Hereinafter, a method for manufacturing a liquid crystal display device according to Embodiment 1 of the present invention will be described with reference to the drawings. FIG. 1 is a flowchart showing a flow of a manufacturing method of the liquid crystal display device according to the first embodiment, and FIG. 2 shows a state of one step in the manufacturing method of the liquid crystal display device according to the first embodiment. FIG.

図１および図２に示すように、本実施の形態においても、まずはじめに、ＴＦＴアレイ基板およびカラーフィルタ基板の２枚の基板のうちの一方の基板１０の表面に製品パネルシール１および外周シール２をそれぞれ描画する（ステップＳ１）。ここでは、カラーフィルタ基板にこれらシールを描画することとする。ＴＦＴアレイ基板およびカラーフィルタ基板の構成については、上述したものと同じであるため、ここでは説明を省略する。また、これらシールのシール材としては、熱硬化タイプのものでも、紫外線硬化タイプのものでも、どちらでもよい。なお、本実施の形態においても、上述の図６と同様に、基板１０には、略々矩形の複数の製品パネルシール１が縦横に配列されて形成され、本硬化工程後に、当該製品パネルシール１間を切断することにより、製品パネルが形成される。ステップＳ１により描画される外周シール２は、基板１０の表面上の周辺部に、基板１０の外周に沿って、環状に一周が切れ目無く繋がった略々矩形の形状のもので、一周以上が同心状に配置される。また、各製品パネルシール１は、外部シール２の内側に、同様に略々矩形で、環状に切れ目無く一周が繋がった形状となっている。ステップＳ１の時点で、もう一方の基板の表面に（ここでは、ＴＦＴアレイ基板の表面に）、スペーサー材９（図４参照）を散布する。これは、ＴＦＴアレイ基板とカラーフィルタ基板との間に液晶８（図４参照）を満たす隙間を確保するためである。なお、スペーサー材９を散布せずに、カラーフィルタ基板に（カラーフィルタ工程の一部として）フォトリソグラフィによりフォトスペーサーを形成する場合もあるが、その場合には、スペーサー材９を散布するこのステップは不要である。   As shown in FIGS. 1 and 2, also in this embodiment, first, the product panel seal 1 and the outer peripheral seal 2 are formed on the surface of one of the two substrates of the TFT array substrate and the color filter substrate. Are respectively drawn (step S1). Here, these seals are drawn on the color filter substrate. Since the configurations of the TFT array substrate and the color filter substrate are the same as those described above, description thereof is omitted here. The seal material for these seals may be either a thermosetting type or an ultraviolet curable type. Also in the present embodiment, similarly to FIG. 6 described above, a plurality of substantially rectangular product panel seals 1 are arranged in the vertical and horizontal directions on the substrate 10, and after the main curing step, the product panel seals are formed. A product panel is formed by cutting between one. The outer peripheral seal 2 drawn in step S1 has a substantially rectangular shape in which one round is continuously connected to the peripheral portion on the surface of the substrate 10 along the outer circumference of the substrate 10, and one or more rounds are concentric. Arranged. Further, each product panel seal 1 is also substantially rectangular inside the outer seal 2 and has a shape in which one round is connected without a break in an annular shape. At the time of step S1, spacer material 9 (see FIG. 4) is sprayed on the surface of the other substrate (here, on the surface of the TFT array substrate). This is to ensure a gap that fills the liquid crystal 8 (see FIG. 4) between the TFT array substrate and the color filter substrate. In some cases, a photo spacer may be formed by photolithography (as part of the color filter process) on the color filter substrate without spraying the spacer material 9. In this case, this step of spraying the spacer material 9 is performed. Is unnecessary.

次に、必要に応じて、製品パネルシール１および外周シール２の溶媒を除去したり、粘度を上昇させたりすることを目的としたシールプレベーク工程を行う（ステップＳ２）。なお、この工程は、液晶材とシール材との反応による液晶汚染を防止する目的のものであるが、必ずしも行う必要はない。次に、製品パネルシール１および外周シール２が形成された基板１０の表面の製品パネルシール１で囲まれた液晶充填領域内に液晶材を滴下する（ステップＳ３）。次に、カラーフィルタ基板とＴＦＴアレイ基板との両方を、貼り合わせ装置（図示せず）に導入して、装置内を真空排気して、真空下でこれら２枚の基板を位置合わせして重ね合わせ、弱く加圧して貼り合わせる（ステップＳ４）。このとき、液晶材は、製品パネルシール１０１により、２枚の基板間に密封される。   Next, if necessary, a seal pre-baking process for removing the solvent of the product panel seal 1 and the outer peripheral seal 2 and increasing the viscosity is performed (step S2). This step is for the purpose of preventing liquid crystal contamination due to the reaction between the liquid crystal material and the sealing material, but is not necessarily performed. Next, a liquid crystal material is dropped into the liquid crystal filling region surrounded by the product panel seal 1 on the surface of the substrate 10 on which the product panel seal 1 and the outer peripheral seal 2 are formed (step S3). Next, both the color filter substrate and the TFT array substrate are introduced into a bonding apparatus (not shown), the inside of the apparatus is evacuated, and the two substrates are aligned and stacked under vacuum. Bonding is performed by applying a weak pressure (step S4). At this time, the liquid crystal material is sealed between the two substrates by the product panel seal 101.

次に、貼り合わされた２枚の基板は、大気中に取り出され、この時点で、滴下された液晶材は、製品パネルシール１で囲まれた領域のほぼ全面に偏り無く行き渡ることになる。その後に、加熱又は紫外線照射を行って、製品パネルシール１および外周シール２を一定程度（ギャップ変化や位置ずれが生じない程度）に硬化させ、２枚の基板間に適正なギャップを確保する（ステップＳ５）。ステップＳ５の工程を、仮硬化と呼ぶ。なお、シール材が熱硬化タイプのものの場合には加熱により仮硬化を行うが、シール材が紫外線硬化タイプのものの場合には紫外線照射により仮硬化を行う。次に、２枚の基板間にカッター等の刃物を入れ、外周シール２の一部（符号２０のハッチングが施されている部分）を剥がすか、あるいは、外周シール２の一部に切れ込みを入れて、外周シール２の内側の真空状態を破る（ステップＳ６）。なお、このとき、単に、真空状態が破られれば良いので、外部シール２は完全に除去する必要はなく、剥がされたり、切り込みを入れられたりした状態のまま、外部シール２の残骸が残っていても全く問題はない。次に、熱硬化炉（図示せず）に、ステップＳ６により真空が破られた２枚の基板を投入し、高温加熱して、本硬化処理を行う（ステップＳ７）。   Next, the two bonded substrates are taken out into the atmosphere, and at this time, the dropped liquid crystal material spreads almost evenly over the entire area surrounded by the product panel seal 1. Thereafter, heating or ultraviolet irradiation is performed to cure the product panel seal 1 and the outer peripheral seal 2 to a certain extent (so that no gap change or misalignment occurs), thereby ensuring an appropriate gap between the two substrates ( Step S5). The process of step S5 is called temporary curing. In addition, when the sealing material is a thermosetting type, temporary curing is performed by heating, but when the sealing material is an ultraviolet curing type, temporary curing is performed by ultraviolet irradiation. Next, insert a blade such as a cutter between the two substrates, and peel off a part of the outer peripheral seal 2 (the part indicated by hatching 20), or cut a part of the outer peripheral seal 2 Thus, the vacuum state inside the outer peripheral seal 2 is broken (step S6). At this time, it is only necessary to break the vacuum state, so it is not necessary to completely remove the outer seal 2, and the remains of the outer seal 2 remain in a state of being peeled off or cut. There is no problem at all. Next, the two substrates whose vacuum has been broken in step S6 are put into a thermosetting furnace (not shown) and heated at a high temperature to perform the main curing process (step S7).

図３は、上記のステップＳ６により外部シール２の一部を剥がした場合の製品パネルのシール内外圧差を示した図であり、図４は図３のＢ−Ｂ’線による断面図である。これらの図において、３は液晶充填領域であり、４は製品パネル間のパッド部、５は液晶が製品パネルシールを押す力であり、６は大気が製品パネルシール１を押す力、７はカラーフィルタ基板に設けられたカラーフィルタ層、８は液晶、９は基板間のギャップを確保するためのスペーサー材である。なお、図３においては、図の簡略化のため、液晶が製品パネルシールを押す力５及び大気が製品パネルシール１を押す力６を１つの製品パネルの部分にのみ記載しているが、実際には、図８に示すように、各製品パネルの全てに対して同様に当該力５，６が加わっている。本実施の形態においては、上記のステップＳ６の工程により、外部シール２の一部を破壊して、真空を破るようにしたので、図３および図４に示すように、製品パネルシール１の外部が大気圧領域となり、製品パネルシール１のシール内外圧差は小さくなり、段差構造が異なる部分（パッド部４を例にして図示）も押しつぶされることは無く、製品パネルシール１の内側のギャップムラは発生しない。   FIG. 3 is a view showing a pressure difference between the inside and outside of the product panel when a part of the outer seal 2 is peeled off in the above step S6, and FIG. 4 is a cross-sectional view taken along the line B-B 'of FIG. In these drawings, 3 is a liquid crystal filling region, 4 is a pad portion between product panels, 5 is a force that the liquid crystal pushes the product panel seal, 6 is a force that pushes the product panel seal 1, and 7 is a color. A color filter layer provided on the filter substrate, 8 is a liquid crystal, and 9 is a spacer material for securing a gap between the substrates. In FIG. 3, for simplification of the drawing, the force 5 for pushing the product panel seal by the liquid crystal and the force 6 for pushing the product panel seal 1 by the atmosphere are shown only in one product panel. As shown in FIG. 8, the forces 5 and 6 are similarly applied to all the product panels. In the present embodiment, a part of the outer seal 2 is broken and the vacuum is broken by the above-described step S6, so that the exterior of the product panel seal 1 is removed as shown in FIGS. Becomes the atmospheric pressure region, the pressure difference between the inside and outside of the product panel seal 1 is reduced, and the portion having a different step structure (illustrated by taking the pad portion 4 as an example) is not crushed. Does not occur.

このように、本実施の形態においては、ステップＳ７の本硬化の工程の前の段階で、外部シール２の一部を破壊し、基板１０の外部シール２の内部の真空を破り、製品パネルシール１のシール内外の圧力差を低減させたので、製品パネルシール１にかかる力を緩和することができ、本硬化（熱硬化）時のシール材の軟化および液晶の膨張による製品パネルシール１の破壊を防止することができる。また、シール材を熱硬化する前段階で、外部シール２の一部を破壊して、製品パネルにかかる応力のムラを低減するようにしたので、図１０に示したような従来発生していたギャップムラの発生を抑えることができる。   Thus, in the present embodiment, part of the outer seal 2 is broken before the main curing process in step S7, the vacuum inside the outer seal 2 of the substrate 10 is broken, and the product panel seal Since the pressure difference between the inside and outside of the seal 1 is reduced, the force applied to the product panel seal 1 can be relaxed, and the product panel seal 1 is destroyed due to softening of the sealing material and expansion of the liquid crystal during main curing (thermosetting). Can be prevented. Further, in the previous stage of thermosetting the sealing material, a part of the external seal 2 is broken to reduce the unevenness of stress applied to the product panel, so that it has conventionally occurred as shown in FIG. The occurrence of gap unevenness can be suppressed.

なお、本硬化（熱硬化）前に外周シール２を破壊した場合と破壊しない場合の製品パネルシールの破壊による液晶漏れを比較したところ、外周シール２を破壊しなかった従来のものは、約３０％の製品において製品パネルシール破壊による液晶漏れが発生したのに対し、外周シール２を破壊した本実施の形態に係るものは、製品パネルシールの破壊は全くなく、従って、それによる液晶漏れも全く発生しなかった。尚、今回の実験における製品パネルシール１のシール幅は約０．５５ｍｍであった。   In addition, when the liquid crystal leakage due to the breakdown of the product panel seal when the outer peripheral seal 2 was broken before and after the main curing (thermosetting) was compared, the conventional one that did not destroy the outer peripheral seal 2 was about 30 % Liquid crystal leaks due to product panel seal breakage, whereas the product according to the present embodiment in which the outer peripheral seal 2 is broken does not cause any product panel seal breakage. Did not occur. Note that the seal width of the product panel seal 1 in this experiment was about 0.55 mm.

また、本硬化（熱硬化）前に外周シール２を破壊した場合と破壊しない場合の製品パネルシールのギャップムラの状態を比較したところ、外周シール２を破壊しなかった従来のものは、図１０に示したようなパッド部１０４付近にギャップムラが見られたが、これに対し、外周シール２を破壊した本実施の形態に係るものは、パッド部４付近のギャップムラは全く発生しなかった。   Further, when the state of gap unevenness of the product panel seal when the outer peripheral seal 2 was broken before and after the main curing (thermosetting) was compared, the conventional one that did not destroy the outer peripheral seal 2 was shown in FIG. Gap unevenness was observed in the vicinity of the pad portion 104 as shown in FIG. 5, but in the case of the present embodiment in which the outer peripheral seal 2 was broken, no gap unevenness in the vicinity of the pad portion 4 occurred. .

以上のように、本実施の形態においては、上下基板を貼り合わせ、本硬化（熱硬化）を実施する前の段階で、基板内部を密閉している基板外周に配置された外部シールの一部を破壊して、外部シール内部の真空を破るようにしたので、これにより、製品パネルの製品パネルシールにかかる力を緩和して、製品パネルシールの破壊を防ぎ、液晶漏れを防止することができる。また、本硬化（熱硬化）を実施する前の段階で、硬化製品パネルにかかる応力を緩和するようにしたので、ギャップムラを防止することができ、画質の劣化を未然に防ぐことができる。   As described above, in the present embodiment, a part of the external seal disposed on the outer periphery of the substrate that seals the inside of the substrate at the stage before the upper and lower substrates are bonded and the main curing (thermosetting) is performed. This breaks the vacuum inside the external seal, so it can ease the force applied to the product panel seal of the product panel, prevent the product panel seal from being broken, and prevent liquid crystal leakage . In addition, since stress applied to the cured product panel is relaxed before the main curing (thermosetting) is performed, gap unevenness can be prevented and image quality deterioration can be prevented.

このように、本発明を適用することで、シール幅が細い・シール材の粘度が低い等、シール強度が弱い場合に発生するシール材破壊による液晶漏れを防止することができる。また、製品パネルシールの本硬化前に製品パネルにかかる応力を緩和することで、ギャップムラの改善ができる。また、中小型パネルは額縁部が狭く、シール幅を細く設計せざるを得ない場合が多いので、中小型パネルへの液晶滴下注入法の適用の際に特に有効である。   In this way, by applying the present invention, it is possible to prevent liquid crystal leakage due to sealing material destruction that occurs when the sealing strength is weak, such as a narrow sealing width and a low viscosity of the sealing material. Moreover, the gap unevenness can be improved by relaxing the stress applied to the product panel before the main curing of the product panel seal. In addition, since the small and medium panel has a narrow frame portion and must be designed to have a narrow seal width, it is particularly effective when the liquid crystal dropping injection method is applied to the small and medium panel.

実施の形態２．
本実施の形態においては、外周シールの一部を破壊する他の方法について示す。なお、他の工程および基板の構成等は全て上記の実施の形態１と同じであるため、ここでは詳細な説明は省略する。本実施の形態においては、図５に示すように、図１のステップＳ６の工程において、外周シール２を含む基板１０の一部（符号３０で示した破線部分）を切り落とすことにより、外周シール２の内部の真空を破壊する。 Embodiment 2. FIG.
In the present embodiment, another method for breaking a part of the outer peripheral seal will be described. Note that the other steps, the configuration of the substrate, and the like are all the same as those in the first embodiment, and thus detailed description thereof is omitted here. In the present embodiment, as shown in FIG. 5, in the process of step S <b> 6 of FIG. Break the vacuum inside.

以上のように、本実施の形態においても、上下基板を貼り合わせ、本硬化（熱硬化）を実施する前の段階で、基板内部を密閉している基板外周に配置された外部シールの一部を基板ごと切り落として、外部シール内部の真空を破るようにしたので、上記の実施の形態１と同様の効果を得ることができる。   As described above, also in the present embodiment, a part of the external seal disposed on the outer periphery of the substrate that seals the inside of the substrate in a stage before the upper and lower substrates are bonded and main curing (thermosetting) is performed. Is cut off together with the substrate to break the vacuum inside the external seal, so that the same effect as in the first embodiment can be obtained.

なお、本発明の外部シールの破壊方法については、上記の実施の形態１および２に示した方法に限定されるものではなく、外部シール内の真空が破れる方法であれば、いずれの方法を用いてもよいものとする。   The method for breaking the outer seal of the present invention is not limited to the method shown in the first and second embodiments, and any method can be used as long as the vacuum in the outer seal is broken. It may be.

この発明の実施の形態１に係る液晶表示装置の製造方法の処理の流れを示したフローチャートである。It is the flowchart which showed the flow of the process of the manufacturing method of the liquid crystal display device which concerns on Embodiment 1 of this invention. この発明の実施の形態１に係る液晶表示装置の製造方法における一工程を説明した平面図である。It is a top view explaining 1 process in the manufacturing method of the liquid crystal display device which concerns on Embodiment 1 of this invention. この発明の実施の形態１に係る液晶表示装置の製造方法によって製造した製品パネルの状態を説明した平面図である。It is a top view explaining the state of the product panel manufactured by the manufacturing method of the liquid crystal display device which concerns on Embodiment 1 of this invention. この発明の実施の形態１に係る液晶表示装置の製造方法によって製造した製品パネルの状態を説明した断面図である。It is sectional drawing explaining the state of the product panel manufactured by the manufacturing method of the liquid crystal display device which concerns on Embodiment 1 of this invention. この発明の実施の形態２に係る液晶表示装置の製造方法における一工程を説明した平面図である。It is a top view explaining 1 process in the manufacturing method of the liquid crystal display device which concerns on Embodiment 2 of this invention. 従来の一般的な基板表面のシール配置を示した平面図である。It is the top view which showed the conventional seal arrangement | positioning of the board | substrate surface. 従来の液晶表示装置の製造方法の処理の流れを示したフローチャートである。It is the flowchart which showed the flow of the process of the manufacturing method of the conventional liquid crystal display device. 従来の液晶表示装置の製造方法によって製造した製品パネルの状態を説明した平面図である。It is the top view explaining the state of the product panel manufactured with the manufacturing method of the conventional liquid crystal display device. 従来の液晶表示装置の製造方法によって製造した製品パネルの状態を説明した断面図である。It is sectional drawing explaining the state of the product panel manufactured with the manufacturing method of the conventional liquid crystal display device. 従来の液晶表示装置の製造方法によって製造した製品パネルの状態を説明した平面図である。It is the top view explaining the state of the product panel manufactured with the manufacturing method of the conventional liquid crystal display device.

符号の説明Explanation of symbols

１ 製品パネルシール、２ 外部シール、３ 液晶充填領域、４ パッド部、７ カラーフィルタ、８ 液晶、９ スペーサー材、１０ 基板。   1 Product panel seal, 2 External seal, 3 Liquid crystal filling area, 4 Pad part, 7 Color filter, 8 Liquid crystal, 9 Spacer material, 10 Substrate.

Claims (3)

アレイ基板とカラーフィルタ基板の２枚の基板のうちの一方の基板の表面に、液晶充填領域を定義するための環状の製品パネルシールと、前記２枚の基板間を密封するための基板の外周に沿った外部シールとを形成するステップと、
前記製品パネルシールで囲まれた前記液晶充填領域に対して液晶材を滴下するステップと、
前記液晶材が滴下された一方の基板に対して、もう一方の基板を対向させて、真空下で貼り合わせるステップと、
前記製品パネルシールおよび前記外部シールを仮硬化させるステップと、
前記外部シールの一部を破壊して、前記外部シールの内部の真空を破るステップと、
前記製品パネルシールおよび前記外部シールを本硬化させるステップと
を備えたことを特徴とする液晶表示装置の製造方法。 An annular product panel seal for defining a liquid crystal filling region on the surface of one of the two substrates of the array substrate and the color filter substrate, and the outer periphery of the substrate for sealing between the two substrates Forming an external seal along
Dropping a liquid crystal material on the liquid crystal filling region surrounded by the product panel seal;
The other substrate is opposed to the one substrate on which the liquid crystal material is dropped, and bonded under vacuum,
Pre-curing the product panel seal and the external seal;
Breaking a portion of the outer seal to break a vacuum inside the outer seal;
And a step of subjecting the product panel seal and the external seal to main curing. 前記真空を破るステップは、
前記外部シールの一部分を剥離させることにより行う
ことを特徴とする請求項１に記載の液晶表示装置の製造方法。 Breaking the vacuum comprises:
The method for manufacturing a liquid crystal display device according to claim 1, wherein a part of the outer seal is peeled off. 前記真空を破るステップは、
前記外部シールの一部分を前記基板とともに切り落とすことにより行う
ことを特徴とする請求項１に記載の液晶表示装置の製造方法。 Breaking the vacuum comprises:
The method for manufacturing a liquid crystal display device according to claim 1, wherein a part of the outer seal is cut off together with the substrate.
JP2006346784A 2006-12-22 2006-12-22 Manufacturing method of liquid crystal display device Pending JP2008158237A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010197967A (en) * 2009-02-27 2010-09-09 Sony Corp Method for manufacturing liquid crystal display device and liquid crystal display device manufactured by the same
JP2010230959A (en) * 2009-03-27 2010-10-14 Casio Computer Co Ltd Method for manufacturing liquid crystal display panel

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH09138417A (en) * 1995-11-15 1997-05-27 Yazaki Corp Production of liquid crystal cell
JPH11194352A (en) * 1997-10-30 1999-07-21 Matsushita Electric Ind Co Ltd Manufacture for liquid crystal display device
JP4587242B2 (en) 2000-04-11 2010-11-24 スタンレー電気株式会社 Manufacturing method of liquid crystal device
KR100656906B1 (en) 2000-04-20 2006-12-15 삼성전자주식회사 Method for manufacturing a panel for a liquid crystal display, Manufacture devices for the same, In-line system including the same, and Methods for manufacturing a liquid crystal display using the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010197967A (en) * 2009-02-27 2010-09-09 Sony Corp Method for manufacturing liquid crystal display device and liquid crystal display device manufactured by the same
JP2010230959A (en) * 2009-03-27 2010-10-14 Casio Computer Co Ltd Method for manufacturing liquid crystal display panel

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