JP3766090B2 - Method for manufacturing liquid crystal display device - Google Patents

Description

  The invention disclosed in this specification relates to a method for manufacturing a liquid crystal display device using a flexible film substrate. The invention disclosed in this specification also relates to a liquid crystal display device using a flexible film substrate.

  A liquid crystal electro-optical device is known as a thin, light and light display device (display). The liquid crystal electro-optical device has a configuration in which a liquid crystal is sandwiched and held between a pair of substrates arranged at intervals of about several μm. As the substrate, a glass substrate is generally used because it is required to have an optical characteristic of transmitting visible light. The reason why the glass substrate is used is that it has the necessary optical characteristics and is low in cost.

As technical requirements for liquid crystal electro-optical devices,
・ Reduced size and weight ・ Reduces production costs and improves productivity.
There is something like this.

  In the above matters, the reduction in size and weight means that the thickness is reduced and the weight is reduced. As a configuration that satisfies the above requirements, a configuration using a light-transmitting resin substrate (generally also referred to as a plastic substrate) is known.

  When a resin substrate is used, the requirement for reduction in size and weight can be satisfied. In addition, since the substrate itself has flexibility, it can be used in a state where physical stress is applied or in a curved state. Use in such a state can further expand the application range of the liquid crystal electro-optical device.

  However, even when a resin substrate is used as the substrate, the requirement for reducing the production cost and improving the productivity is not satisfied.

  Accordingly, an object of the invention disclosed in this specification is to provide a technique that has a low production cost and a high productivity, in particular, in a liquid crystal electro-optical device configured using a flexible substrate. To do.

One of the inventions disclosed in this specification is:
A first roll on which a flexible first substrate is wound;
A second roll on which a flexible second substrate is wound;
Means for forming a liquid crystal layer on the surface of the first substrate;
Means for bonding the first substrate and the second substrate;
It is characterized by having.

  A specific configuration having the above configuration is shown in FIG. In FIG. 1, reference numeral 119 denotes a first roll on which a flexible first substrate 206 is wound. Reference numeral 101 denotes a second roll around which a flexible second substrate 201 is wound. Reference numeral 135 denotes a liquid crystal dropping device for forming a liquid crystal layer on the surface of the first substrate 206. A pair of rolls 137 and 138 is a means for bonding the first substrate and the second substrate together.

  As the substrate having flexibility, a substrate selected from PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PES (polyethylene sulfide), and polyimide can be used.

Other aspects of the invention are:
A liquid crystal cell having a long length is formed by sandwiching liquid crystal between a flexible first substrate wound around a roll and a second substrate.

Other aspects of the invention are:
On a flexible substrate wound around a roll,
A step of printing an alignment film;
A step of performing an orientation treatment;
Spraying spacers;
A step of printing a sealing material;
Is applied continuously.

  A specific example of the above configuration is shown in FIG. In the system shown in FIG. 1, an alignment film 209 is formed by rolls 127 and 128 on a flexible substrate 206 wound around a roll 119, spacers 211 are further dispersed, and a sealing material is further printed by a printing method. 212 is formed.

  When a flexible liquid crystal cell is manufactured, a liquid crystal cell can be continuously produced by using a flexible substrate wound around a roll.

  In this embodiment, a production system capable of continuously producing a liquid crystal electro-optical device using a flexible resin substrate is shown. FIG. 1 shows an outline of the production system shown in this embodiment. The system shown in FIG. 1 is for obtaining a substrate using a flexible resin substrate wound around rolls 101 and 119 as a substrate constituting a liquid crystal electro-optical device.

  First, the process of the resin substrate wound around the roll 119 will be described. Here, an example in which a PET (polyethylene terephthalate) film is used as a resin substrate wound around a roll 119 is shown.

  First, RGB color filters 203 are formed on the surface of the PET film 200 fed from the roll 112 by a printing method. This PET film 200 functions as a base for constituting a color filter. The color filter is formed by three sets of rolls 113. If the liquid crystal display device to be manufactured is monochrome, these three sets of rolls are not necessary.

  After the color filter is formed, the protective film 205 wound around the roll 115 is formed so as to cover the color filter 203 previously formed. Furthermore, the adhesive film 204 wound up by the roll 116 is bonded to the back side where the color filter is formed. These steps are performed by a pair of pressure rolls 117 and 118.

  Next, a PET film 206 serving as a substrate wound around the roll 119 is bonded via the previous adhesive film. This adhesion is performed by a pair of pressure rolls 120 and 121.

  Then, the protective film 205 is peeled off by the roll 123 and wound around the roll 122.

  Further, an overcoat film 207 is formed by a printing method using a pair of rolls 123 and 124. The overcoat film 207 is for flattening the surface that has become uneven due to the formation of the color filter. As a material constituting the overcoat film 207, a light-transmitting resin material may be used.

  Further, a pair of rolls 125 and 126 is used to form an electrode 208 in a required pattern by a printing method. The electrode is formed by this printing method using a conductive ink.

  Further, the alignment film 209 is formed by a printing method using a pair of rolls 127 and 128. And it is baked by passing through the heating furnace 129. By this firing, the alignment film 209 is baked and solidified to 210.

  Further, the surface of the alignment film 209 is rubbed by passing between the rolls 130 and 131. In this way, the alignment process is performed.

  Next, spacers are sprayed from the spacer sprayer 132, and the spacer 211 is disposed on the alignment film 210 that has been subjected to the alignment treatment.

  Then, a sealing material (not shown) is formed by a printing method. The sealing agent is for adhering opposing substrates and for preventing liquid crystals from leaking between a pair of substrates.

  Thereafter, liquid crystal is dropped using the liquid crystal dropping device 135 to form the liquid crystal layer 212. Thus, one substrate side is completed. The above process proceeds continuously as each roll rotates.

  A manufacturing process on the other substrate side is described below. First, an electrode 213 is formed in a predetermined pattern on the PET film 201 fed from the roll 101 by a pair of rolls 102 and 103. Further, the alignment film 214 is formed by a printing method by the pair of rolls 104 and 105. Then, by baking in the heating furnace 108, a baked and solidified alignment film 215 is formed. Thereafter, the substrate is guided to the rolls 137 and 138 for performing the cell set via a pair of rolls 109 and 110.

  Through the steps described above, a configuration for forming a liquid crystal cell is formed on a pair of PET films. Then, the pair of PET films are bonded together by passing between a pair of rolls 137 and 138. The substrates are bonded to each other with a sealing material.

  Thereafter, heating is performed in the heating furnace 139, whereby the sealing material is cured, and the bonding between the substrates is completed. Further, the liquid crystal cell is completed by cutting into a predetermined size by the cutter 150.

  The above process is continuously performed as each roll rotates. Then, by cutting with the cutter 150, liquid crystal cells are produced one after another.

  In this embodiment, an example of manufacturing a passive liquid crystal cell is shown. However, an active liquid crystal cell can be manufactured by simultaneously manufacturing a non-linear element and a thin film transistor by a printing method.

An outline of a system for manufacturing a liquid crystal electro-optical device will be described.

Explanation of symbols

DESCRIPTION OF SYMBOLS 101 Roll in which resin substrate used as color filter substrate was wound 200 Resin substrate used in color filter substrate 113 Roll for forming color filter by printing method 203 Color filter 115 Roll wound in protective film 205 Protection Film 117 Pressurizing roll 118 Pressurizing roll
119 Roll in which resin substrate is wound 206 Resin substrate 120 Roll for pressurization 121 Roll for pressurization 123 Roll for peeling protective film 122 Roll for winding protective film 123 Roll for printing overcoat agent 124 Overcoat agent 207 Overcoat film 125 Roll for forming electrode 126 Roll for forming electrode 208 Electrode 127 Roll for forming alignment film 128 Roll for forming alignment film 209 Alignment film 129 Heating furnace 210 Baked alignment film 130 Roll for performing rubbing (alignment treatment) 131 Roll for performing rubbing (alignment treatment) 132 Means for spraying spacer 133 Roll for performing seal printing 134 For performing seal printing The low 212 Sealant 135 Means for dropping liquid crystal 137 Roll for performing cell assembly 138 Roll for performing cell assembly 139 Heating furnace 150 Cutter 101 Roll in which resin substrate is wound 201 Resin substrate 102 Forming electrode by printing method Roll for forming 103 Roll for forming electrode by printing method 213 Electrode 104 Roll for forming alignment film by printing method 105 Roll for forming alignment film by printing method 214 Alignment film 108 Heating furnace 215 Baking Alignment film

Claims (13)

Forming a color filter on one surface of the first flexible substrate fed from the first roll;
A protective film is formed so as to cover the color filter at the same time as the adhesive film is adhered to the other surface of the first flexible substrate by a second set of pressure rolls,
After the third flexible substrate fed from the fourth roll and the first flexible substrate are bonded to each other by the third set of pressure rolls via the adhesive film, the protection The film is peeled off by the fifth roll,
Forming an overcoat film on the color filter from which the protective film has been peeled;
An electrode pattern is formed on the overcoat film by a printing method,
Liquid crystal is dropped on the electrode pattern to form a liquid crystal layer,
A method for manufacturing a liquid crystal display device, wherein the first flexible substrate and a third flexible substrate are bonded to each other so as to sandwich the liquid crystal layer. Forming a color filter on one surface of the first flexible substrate fed from the first roll;
A protective film is formed so as to cover the color filter at the same time as the adhesive film is adhered to the other surface of the first flexible substrate by a second set of pressure rolls,
After the third flexible substrate fed from the fourth roll and the first flexible substrate are bonded to each other by the third set of pressure rolls via the adhesive film, the protection The film is peeled off by the fifth roll,
Forming an overcoat film on the color filter from which the protective film has been peeled;
An electrode pattern is formed on the overcoat film by a printing method,
An alignment film is formed on the electrode pattern by a printing method,
Heating the alignment layer;
Rubbing the surface of the alignment layer;
A spacer is disposed on the surface of the alignment film,
After placing the spacer, forming a sealing material,
After forming the sealing material, a liquid crystal layer is formed by dropping liquid crystal on the alignment film on which the spacer is disposed,
After passing the first flexible substrate and the third flexible substrate between the sixth set of rolls, the sealing material is cured to sandwich the liquid crystal layer. Bonding the first flexible substrate and the third flexible substrate,
A method for manufacturing a liquid crystal display device, comprising cutting the bonded first flexible substrate and the third flexible substrate into a plurality of pieces. Forming a color filter on one surface of the first flexible substrate fed from the first roll;
A protective film is formed so as to cover the color filter at the same time as the adhesive film is adhered to the other surface of the first flexible substrate by a second set of pressure rolls,
After the third flexible substrate fed from the fourth roll and the first flexible substrate are bonded to each other by the third set of pressure rolls via the adhesive film, the protection The film is peeled off by the fifth roll,
Forming an overcoat film on the color filter from which the protective film has been peeled;
Forming a first electrode pattern on the overcoat film by a printing method;
By forming a liquid crystal layer by dropping liquid crystal on the first electrode pattern, one substrate is formed,
By forming the second electrode pattern on the third flexible substrate by a printing method, the other substrate is formed,
A method for manufacturing a liquid crystal display device, characterized in that the one substrate and the other substrate are bonded together so as to sandwich the liquid crystal layer. Forming a color filter on one surface of the first flexible substrate fed from the first roll;
A protective film is formed so as to cover the color filter at the same time as the adhesive film is adhered to the other surface of the first flexible substrate by a second set of pressure rolls,
After the third flexible substrate fed from the fourth roll and the first flexible substrate are bonded to each other by the third set of pressure rolls via the adhesive film, the protection The film is peeled off by the fifth roll,
Forming an overcoat film on the color filter from which the protective film has been peeled;
Forming a first electrode pattern on the overcoat film by a printing method;
Forming a first alignment film on the first electrode pattern by a printing method;
Heating the first alignment layer;
Rubbing the surface of the first alignment layer;
A spacer is disposed on the surface of the first alignment film;
After placing the spacer, forming a sealing material,
After forming the sealing material, one substrate is formed by forming a liquid crystal layer by dropping liquid crystal on the first alignment film on which the spacer is disposed,
Forming a second electrode pattern on the third flexible substrate by a printing method;
By forming the second alignment film on the second electrode pattern by a printing method, the other substrate is formed,
The one substrate and the other substrate are sandwiched between the one substrate and the other substrate through a sixth set of rolls and then the sealing material is cured to sandwich the liquid crystal layer. Pasted together,
A method for manufacturing a liquid crystal display device, wherein the bonded one substrate and the other substrate are cut into a plurality of pieces. 3. The method for manufacturing a liquid crystal display device according to claim 2 , wherein the alignment film is formed using a set of rolls. Claim 1, in any one of 2, 5, a method for manufacturing a liquid crystal display device wherein the electrode pattern, characterized in that it is formed with a pair of rolls. Claim 1, in any one of 2,5,6, the electrode pattern is a method for manufacturing a liquid crystal display device characterized by being formed using a conductive ink. 5. The method for manufacturing a liquid crystal display device according to claim 4 , wherein each of the first and second alignment films is formed using a pair of rolls. According to any one of claims 3, 4, and 8, wherein each of the first and second electrode patterns, a method for manufacturing a liquid crystal display device characterized by being formed by using a pair of rolls. According to any one of claims 3, 4, 8, 9, a method for manufacturing a liquid crystal display device, characterized in that said first electrode pattern is formed using a conductive ink. In any one of claims 1 to 10, for manufacturing a liquid crystal display device wherein the color filter is formed using three sets of rolls, the overcoat is characterized by being formed by using a pair of rolls Method. The method for manufacturing a liquid crystal display device according to claim 2 , wherein the sealant is formed using a set of rolls. In any one of claims 1 to 12, wherein the first flexible substrate, the second flexible substrate, and the third flexible substrate include polyethylene terephthalate, polyethylene naphthalate or polyimide, A method for manufacturing a liquid crystal display device, comprising:

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