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CN101317205B - 显示装置的制造方法以及粘合方法 - Google Patents

显示装置的制造方法以及粘合方法 Download PDF

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Publication number
CN101317205B
CN101317205B CN2006800447485A CN200680044748A CN101317205B CN 101317205 B CN101317205 B CN 101317205B CN 2006800447485 A CN2006800447485 A CN 2006800447485A CN 200680044748 A CN200680044748 A CN 200680044748A CN 101317205 B CN101317205 B CN 101317205B
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CN
China
Prior art keywords
liquid
containing binder
coating
adhesive
cementing agent
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Application number
CN2006800447485A
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CN101317205A (zh
Inventor
松平努
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Kyoritsu Chemical and Co Ltd
Original Assignee
Seiko Instruments Inc
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • 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
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1435—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. transmission welding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

本发明提供一种在将透明板或触摸面板与平板显示器粘结的情况下以不使气泡进入的方式进行粘附的方法。在粘结面上将液体粘结剂点状地一定量地涂敷到各角附近和中心部，以线状地连结呈点状涂敷了的粘结剂的方式涂敷粘结剂。反转该粘结面在粘结剂上形成滴液，使该滴液接触对置的被粘结体并填充粘结剂，从透明板一侧照射光使粘结剂固化。即，在以点接触使粘结剂实现接触后，在使粘结剂流动为粘结剂气泡不能进入的形状之后，填充粘结剂。

Description

显示装置的制造方法以及粘合方法
技术领域
本发明涉及一种以液状粘结剂全面粘结透明基板和基板的方法。例如涉及便携式电话等设备的透明盖板(cover plate)与液晶显示装置、等离子体显示器、有机EL、无机EL或FED等平板显示器的粘合，或者触摸面板与平板显示器的粘合。
背景技术
作为在显示面板上配置透明触摸面板的方法，公知有在显示面板的外周以0.3～0.5～1mm以上厚度的两面粘着剂粘着固定透明触摸面板的方法。或者，公知还有以光学粘结剂将显示面板和触摸面板全面粘附的方法(例如，参照日本专利申请公开平09-274536号公报，以下称为专利文献1)。
此外，便携式电话的显示画面上的透明盖板和液晶面板是，在液晶面板的显示区域的外周和透明盖板的显示区域外以印刷物等形成的不透明区域中，在其间夹有0.3～0.5橡胶(ラバ一)等的弹性体而配置。
特别是在便携式电话中，透明盖板和显示面板之间的空间(space)为0.2mm以下的薄型化的需求在增加。
对于透明盖板使用丙烯酸(acrylic)或聚碳酸酯等的透明塑料、或玻璃等。在透明盖板的表面上多是设置使折射率阶段地变化的原材料层叠而形成的低反射膜、具有铜或铝等构成的格子状的蚀刻图案的电磁屏蔽、用于防止伤痕的硬质涂层。进而，在是玻璃的情况下，有在表面粘附用于防止破裂的膜片的盖板，或者有粘附用于防止单向反射的防眩光处理后的膜片等的盖板。透明盖板和显示元件的形状几乎全是四角形。此外，触摸面板有模拟电阻膜方式、数字电阻膜方式或静电电容、超声波方式等。
发明内容
平板显示器的外周与透明盖板的间隙，由于耐冲击性和薄型化导致的牛顿环的发生等原因，0.1mm以下的薄型化是困难的。在将触摸面板或透明盖板和平板显示器以光学粘结片全面粘附的情况下，会有气泡的混入。成为问题的气泡的大小是以目视可见的气泡，大约100μm以上的气泡成为问题。特别是触摸面板或透明盖板越是厚的刚体，以层合(laminate)法无气泡地粘附就越困难。此外，在光学粘结片中，在显示器或透明盖板本身有翘曲的情况下，根据可靠性试验条件或使用环境，会产生剥离现象并发生气泡。
特别是，在将驱动器IC以各向异性导电膜直接安装到玻璃基板上的玻璃覆晶(chip on glass)方式中，因安装时的热而导致IC和玻璃之间发生翘曲。在将厚度0.5mm、尺寸2×20mm的驱动器IC安装到0.5mm厚的无碱玻璃上的情况下，翘曲的量变为大约20～15μm。因此，以光学粘结片粘合时多会发生来自IC安装部附近的剥落。在使用通过UV或可见光等光来固化的液状光学透明粘结剂进行全面粘合的情况下，即使显示器或透明盖板有翘曲，在可靠性试验或使用环境中剥离现象也减轻，但在通过专利文献1中的方法进行粘合的情况下，如图16那样粘结剂的滴液只在中央部均匀地填充粘结剂很困难。如图17所示那样发生了在角部的粘结剂填充不足。为了解决角部的粘结剂填充不足，在如图18那样形成多个滴液的情况下，在填充工序中如图19、20所示那样粘结剂渐渐地填充，但涂敷部和涂敷部之间空气被封闭而发生气泡11的情况很多。
此外，即使在粘合时卷入的气泡的直径是100μm以下时，平板显示器在作为反射型时被照射强外部光的情况下、或点亮背光灯等情况下，变为亮点，看上去比气泡的直径要大而非常醒目。
因此，本发明的显示装置的制造方法是多角形的透明体和显示元件以透明粘结剂进行粘结的显示装置的制造方法，具备：在透明体的粘结面或显示元件的粘结面上将液体粘结剂以一定量呈点状地涂敷到多处的工序；以连结呈点状涂敷的多个液体粘结剂的方式将粘结剂涂敷为线状的工序；将涂敷了液体粘结剂的透明体或显示元件反转的工序；在呈点状涂敷的液体粘结剂上形成滴液的工序；以不对滴液施加冲击的方式使液体粘结剂接触被粘结体，进而填充液体粘结剂的工序；以及使液体粘结剂固化的工序。这里，对液体粘结剂使用UV固化型粘结剂或可见光固化型粘结剂，该粘结剂的固化收缩率为1～6％。此外，作为透明体，可以例示出触摸面板、塑料板或玻璃板。进而，作为液体粘结剂使用UV或可见光等的光固化型粘结剂，在使液体粘结剂固化的工序中，利用通过透明体将光照射到粘结剂的第一固化方式(means)和从透明体的侧面方向直接照射光的第二固化方式的两个固化方式，使液体粘结剂固化。
此外，本发明的粘合方法是以透明粘结剂粘结多角形的透明板和板状的被粘结体的粘合方法，具备：在透明板的粘结面的粘结面上将液体粘结剂以一定量呈点状地涂敷到多处的工序；以连结呈点状涂敷的液体粘结剂的方式将液体粘结剂涂敷为线状的工序；将涂敷了液体粘结剂的透明板反转的工序；在呈点状涂敷的液体粘结剂上形成滴液的工序；以不对滴液施加冲击的方式使液体粘结剂接触被粘结体，进而填充液体粘结剂的工序；以及使液体粘结剂固化的工序。进而，液体粘结剂是UV或可见光等的光固化型粘结剂，在使液体粘结剂固化的工序中，利用通过透明体将光照射到粘结剂的第一固化方式和从透明体的侧面方向直接照射光的第二固化方式的两个固化方式，使液体粘结剂固化。
附图说明
图1是透明基板的俯视图。
图2是本发明的对透明基板的粘结剂进行点涂敷后的状态的俯视图。
图3是本发明的将透明基板的粘结剂赋予成线的俯视图。
图4是表示本发明的将透明基板和平板显示器定位后的状态的侧视图。
图5是表示本发明的粘结剂的滴液的侧视图。
图6是表示本发明的粘结剂接触到平板显示器的状态的侧视图。
图7是表示本发明的粘结剂接触到平板显示器的状态的俯视图。
图8是表示本发明的在平板显示器上粘结剂浸润为粘结剂的涂敷形状的状态的俯视图。
图9是表示本发明的粘结剂的初期填充状态的俯视图。
图10是表示本发明的粘结剂的中期填充状态的俯视图。
图11是表示本发明的粘结剂的后期填充状态的俯视图。
图12是本发明的粘合结束状态的侧视图。
图13是表示本发明的其他的粘结剂涂敷形状的示意图。
图14是表示本发明的其他的粘结剂涂敷形状的示意图。
图15是表示本发明的粘结剂中包含的气泡的固化前和固化后的直径的图。
图16是表示现有方式的在透明板上涂敷接触剂的状态的俯视图。
图17是表示现有方式的透明板和平板显示器的粘结剂填充后的状态的俯视图。
图18是表示现有方式的其他的在透明板上涂敷粘结剂的状态的俯视图。
图19是表示现有方式的其他的透明板和平板显示器的填充初期状态的俯视图。
图20是表示现有方式的其他的透明板和平板显示器的填充中期状态的俯视图。
附图标记说明
1透明板
2粘结剂
3平板显示器
4形成了TFT阵列的透明基板
5形成了滤色片(color filter)的透明基板
6显示面一侧的偏光板
7背面一侧的偏光板
8驱动器IC
9FPC
10浸润于平板显示器表面上的粘结剂
具体实施方式
本发明在以透明粘结剂粘结多角形(polygon)的透明板和板状体的方法中，具有：在透明板的粘结面或板状体的粘结面上将液体粘结剂以一定量至少涂敷到多处的工序；涂敷将所述涂敷的多个粘结剂连结为线状的粘结剂的工序；或者是，在使粘结剂连续的线和与该线重叠的位置上将比以线涂敷的量更多的粘结剂呈点状涂敷一处以上的工序；将涂敷了粘结剂的透明板或板状体反转的工序；在粘结剂上形成滴液(spillage，液体下垂部)，使粘结剂接触所面对的被粘结体，进而填充粘结剂的工序；以及从透明板一侧照射光，使粘结剂固化(hardening)的工序。
特别是通过在各角附近涂敷一定量，从而在各部分的粘结剂的量能够平衡，粘结剂的厚度变得均匀。此外通过使涂敷的粘结剂和中心部为线状地涂敷粘结剂，从而解决了填充时空气的卷入导致的气泡。粘结剂的涂敷是一定量涂敷并线状地涂敷、进而一定量涂敷、进而线状地涂敷的工序的反复，一笔书写式(one stroke writing)涂敷粘结剂也可。在是一笔书写式的情况下，线状涂敷的地点两次写过也可。在粘结剂涂敷后将涂敷了粘结剂一侧的基板反转，形成滴液，将该滴液与对置一侧的基板慢慢地接触。在各角附近和中央涂敷的粘结剂的滴液接触时，提高涂敷了粘结剂的基板的下降速度也可。
透明触摸面板、透明盖板均同样地能够无气泡地、此外以均匀的粘结剂层地粘结到平板显示器。此外，通过粘结剂是UV固化型粘结剂或可见光固化型粘结剂，固化收缩率是1～6％，从而对固化收缩导致的色斑没有影响，粘结剂固化前包含的气泡的大小通过粘结剂固化收缩而变小，能够削减100μm以下的气泡。
此外，在透明板有不透明区域的情况下，从透明板正面通过透明板将光照射到粘结剂以实现固化的方法中，由于不透明区域，光照射不到与不透明区域重合的部分。因此，通过从透明板的侧方照射光，能够使与不透明区域重合的部分的粘结剂固化。
适于粘合长方形的透明盖板或触摸面板与平板显示器的方法如下所述。粘结剂的粘度是3000～2000cP比较适合。在粘结剂的粘结层为大约100μm的情况下，涂敷量以粘结面积换算是0.0135g/cm2±10％。在透明盖板的粘结面一侧在与粘结部的中央粘结的各角的附近，点涂敷形成滴液的粘结剂。一点的涂敷量是将其全部涂敷量的50～80％的量大致均等分开后的量。利用剩下的粘结剂以连接在各角点涂敷的粘结剂和中央部的方式进行线涂敷。这时以使气泡不进入的方式进行涂敷。将涂敷结束的透明盖板反转，在点涂敷的粘结剂上形成滴液。使前后横向的位置与平面显示器相匹配，以大约20μm/sec的速度以不施加冲击的方式使平板显示器和所述滴液接触。进而以大致同样速度减小平板显示器和透明盖板的间隔。在线涂敷的粘结剂的区域中粘结剂浸润于平板显示器和透明盖板之间的时刻，以使透明盖板不偏离前后左右的位置的方式，以利用自重填充的状态，放置大约30～120sec，全面地实现填充。在填充结束的时刻从透明盖板正面和其侧方同时照射用于固化粘结剂的UV，完成粘附。粘结剂是UV固化型，固化收缩率约为2％。
(实施例1)
以下基于附图对本发明的实施例进行说明。图1是配置在平板显示器整个面上的透明板1，材料是丙烯酸。厚度是1.5mm。大小是40×40mm。显示器的外形尺寸是45×32mm、厚度是1.3mm。显示画面的面积是36×28.5mm。显示器在比液晶显示器3的显示画面的面积大的范围上形成有框缘形状的黑色印刷物。印刷物形成在显示器一侧的面上。在印刷之外也有通过溅射等方法形成金属膜进而层叠印刷物的情况。图2是在透明板的粘结面上，以点涂敷在各角和中央五点涂敷粘结剂2的俯视图。粘结剂2对粘结面积涂敷大约0.01318g/cm2。在该情况下作为总量涂敷0.1687g。点涂敷的粘结剂2的量是每一点大约涂敷0.028g。此外，该粘结剂是紫外线固化型粘结剂，作为固化后的特性为弹性率是1.6×106Pa、折射率是1.52。进而如图3所示使涂敷到各角的粘结剂2和涂敷到中央的粘结剂2为线状地涂敷粘结剂2。线状地涂敷的粘结剂除了在点涂敷的粘结剂之间涂敷之外，在点涂敷的粘结剂的更外周侧涂敷也可。
接着如图4所示将涂敷了粘结剂2的透明板1反转，保持与粘结剂2不接触的高度与显示器3进行定位。显示器3是在形成了TFT阵列的玻璃基板4和形成了滤色片的玻璃基板5之间封入有液晶。在其表面配置有显示面一侧的偏光板6和背面一侧的偏光板7。安装有与驱动显示器的驱动器IC6和控制器连接的接口FPC。
这时如图5所示在点涂敷的粘结剂2上产生滴液。使透明板1以大约20μm/sec的速度下降，如图6所示粘结剂2点状地接触显示器3的表面。下降速度慢比较好。下降速度快时由于粘结剂与显示器的表面接触的冲击，在粘结剂2的表面产生波纹，进而透明板下降推进，因此有发生多个气泡混入的情况。
点涂敷的粘结剂2与显示器3接触开始浸润。这时从透明板的上表面观察的状态如图7所示。与显示器浸润的粘结剂10成为点状。进而下降推进，粘结剂如图8那样浸润为所涂敷的形状。浸润为所涂敷的形状之前，当使透明板1自由时有气泡混入的情况。
在该状态下，使透明板1为自由状态，以自重填充粘结剂。粘结剂如图9、图10、图11所示那样填充粘结剂10。填充时间约为60秒。能够实现不发生气泡的混入和空气的封闭的填充。在加压的情况下粘结剂的填充能产生不均匀，而且粘结剂层的厚度变得不均匀，这会对液晶的间隙带来影响，有时成为显示不均匀。
如图12所示对透明板1和显示器3之间的填充结束，对粘结剂照射2000mJ的紫外线以实现固化并结束。粘结剂2对透明板1的涂敷形状不仅是图3所示的形状，是图13或图14这样的形状也可。对于点涂敷的粘结剂，中央比各角多也可，相反中央少也可。
此外，通过使粘结剂2为紫外线以及可见光固化型、固化收缩率为1～6％，从而使粘结剂中包含的固化前的大约100μm以下的气泡，通过固化而能够消失。如果大约100μm以上的气泡在粘合时不发生，则就能够实现无气泡的粘合。图15是固化收缩率4％的粘结剂的气泡尺寸。
透明基板是模拟方式或静电电容方式或超声波等的触摸面板均可。或者，是蓝宝石玻璃、碱性玻璃、钠玻璃、以及其强化玻璃、PMMA、PC等、还有它们的层叠体也可。平板显示器不仅是TFT液晶方式，是STN液晶或其他的液晶显示器、有机EL或无机EL、等离子体显示器等的平板显示器也可。粘结剂不仅是UV固化型，是可见光固化型是UV、可见光并用的固化型也可。
产业上的可利用性
通过上述的粘合方法，解决了由气泡的混入以及被粘结体的翘曲导致的随时间经过的剥离的发生。此外，能够得到无气泡混入且均匀的粘结剂层。因此，能够使透明盖面板和平板显示器的间隔为大约200～30μm。

Claims (4)

1.一种显示装置的制造方法，多角形的透明体和显示元件以透明粘结剂进行粘结，该制造方法其特征在于，具备：
在所述透明体的粘结面或所述显示元件的粘结面上将液体粘结剂呈点状地涂敷到各角的附近和中央部的工序；
以连结所述呈点状涂敷的多个液体粘结剂的方式将液体粘结剂涂敷为线状的工序；
将涂敷了所述液体粘结剂的透明体或显示元件反转的工序；
在所述呈点状涂敷的液体粘结剂上形成滴液的工序；
以不对所述滴液施加冲击的速度使所述液体粘结剂接触与涂敷了所述液体粘结剂的透明体或显示元件相面对的被粘结体，进而将所述液体粘结剂填充到所述透明体与所述显示元件之间；以及
使所述液体粘结剂固化的工序，
其中，液体粘结剂呈点状涂覆的一点的涂敷量是将其全部涂敷量的50～80％的量大致均等分开后的量，
剩下的液体粘结剂以连接在各角点状涂敷的液体粘结剂和所述中央部的方式进行线状涂敷。
2.根据权利要求1所述的显示装置的制造方法，其特征在于，所述透明体是触摸面板、塑料板、或玻璃板。
3.根据权利要求1所述的显示装置的制造方法，其特征在于，所述液体粘结剂是利用紫外光或可见光固化的光固化型的液体粘结剂，在使所述液体粘结剂固化的工序中，利用通过所述透明体将光照射到所述液体粘结剂的第一固化方式和从所述透明体的侧面方向直接照射光的第二固化方式，使所述液体粘结剂固化。
4.一种粘合方法，以透明粘结剂粘结多角形的透明板和板状的被粘结体，该粘合方法其特征在于，具备：
在所述透明板的粘结面或所述被粘结体的粘结面上将液体粘结剂呈点状地涂敷到各角的附近和中央部的工序；
以连结所述呈点状涂敷的液体粘结剂的方式将液体粘结剂涂敷为线状的工序；
将涂敷了所述液体粘结剂的透明板或被粘结体反转的工序；
在所述呈点状涂敷的液体粘结剂上形成滴液的工序；
以不对所述滴液施加冲击的速度使所述液体粘结剂接触与涂敷了所述液体粘结剂的透明体或显示元件相面对的被粘结体，进而将所述液体粘结剂填充到所述透明体和所述被粘结体之间；以及
使所述液体粘结剂固化的工序，
其中，液体粘结剂呈点状涂覆的一点的涂敷量是将其全部涂敷量的50～80％的量大致均等分开后的量，
剩下的液体粘结剂以连接在各角点状涂敷的液体粘结剂和所述中央部的方式进行线状涂敷。
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