JPH10319224A - Manufacturing method of color filter - Google Patents

Abstract

(57) [Summary] (with correction) [PROBLEMS] An R.S.R. formed between light-shielding layers on a transparent substrate. G. FIG.
It is possible to prevent swelling occurring at each boundary portion of the B transparent colored layer. SOLUTION: A transparent colored layer 3 having optical characteristics and a pattern shape necessary as a color filter is formed on a transparent film 8, and a transparent substrate 1 on which a light shielding layer 2 pattern is formed is superposed and integrated on the transparent film 8. After that, the transparent film 8 is peeled off.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a color filter used for a flat panel display such as a color liquid crystal display.

[0002]

2. Description of the Related Art A light-shielding layer between pixels is formed on a transparent substrate made of glass, plastic, or the like. G. FIG. A method of forming each colored layer of B in a required pattern and, if necessary, forming a smooth layer of a transparent resin thereon is generally used.

As a method for forming the colored layer, a pigment dispersion method,
Dye dispersion method, electrodeposition method, printing method, etc. are used, and as the light shielding layer forming method, a thin film layer formed by sputtering mainly using chromium or chromium oxide or a thick film layer formed by spin coating of a black resin is used. Have been.

[0004]

As shown in FIG. 3A, a chromium thin film layer is conventionally used as a light shielding layer 2 formed on a transparent substrate 1 such as glass. A black resin thick film layer in which a black pigment is uniformly dispersed in a resin is used. In order to obtain sufficient optical characteristics with such a resin light-shielding layer, a film thickness of about 1 μm is required, and the thickness of the resin light-shielding layer is about ten times as large as that of a conventional thin film light-shielding layer. As shown in FIG. 3B, an R.D. G. FIG. When the B transparent colored layer 3 is formed, a bulge 4 occurs as shown in FIG. 3C due to the thickness of the light-shielding layer 2, and in the extreme case, the tendency to become a projection cannot be avoided. Therefore, the surface is polished, and
Means such as forming a smooth layer 5 of a transparent resin layer as shown in (d) are used. However, there is a problem that the degree of the bulge 4 is greatly reduced, but the tendency cannot be completely removed.

[0005] This tendency is based on the R.D.R. developed by the present inventors for the purpose of improving the productivity of color filters and reducing costs.
G. FIG. It is unavoidable in a method of printing and pressing B3 colors simultaneously. That is, on the transparent substrate 1 on which the black resin light shielding film 2 is formed, the R.R. G. FIG. In the method of simultaneously printing three colors of the B transparent colored layer 3 and pressing it uniformly as shown in FIGS. 3B and 3C to fill the gap and flatten the surface, the black resin light-shielding method is used. The effect of the thickness of layer 2 is even more pronounced. As a result, the raised portion 4 became large, and even if the smooth layer 5 was formed as shown in FIG.

According to the present invention, even when such a thick black resin light-shielding layer is used, the occurrence of swelling at the upper part, that is, at the boundary between the colored layers, is avoided, and complicated steps such as polishing and formation of a smooth layer are performed. An object of the present invention is to provide a method for efficiently manufacturing a color filter which is not required.

[0007]

According to the present invention, there is provided a method for producing a color filter, comprising the steps of: forming a transparent colored layer having necessary optical properties and a pattern shape as a color filter on a transparent film; A transparent substrate on which a light-shielding layer pattern is formed is superposed on and integrated with the transparent film, and then the transparent film is peeled off.

The manufacturing process includes a step of forming a transparent colored layer of a required pattern on a transparent film having a transparent resin layer on the surface, a step of forming a light shielding layer pattern on a transparent substrate,
A step of superimposing the transparent substrate on the transparent film, and a step of heat press-curing the two to integrate them,
It is characterized by comprising a step of peeling the transparent film.

More specifically, in the case of a flat table or a rotary offset multicolor printing method, the R.D. G. FIG. B. The method is characterized in that each colored layer is simultaneously printed on a transparent film, a transparent substrate with a light-shielding layer is superimposed thereon, and heated and pressed to fill and integrate the gap between the light-shielding layer and the colored layer. Further, a transparent film is used in which a portion having a resin characteristic that does not adhere to the resin is formed in a predetermined position in advance.

[0010]

Embodiments of the present invention will be described below. FIG.
1 shows a basic method for manufacturing a color filter of the present invention. As shown in FIG.
Is coated on a photosensitive resin film sheet 9 having a UV curable transparent resin layer 7 of 0.6 μm applied over the entire surface of a transparent film 8 by a flat-bed offset multicolor printing machine. G. FIG. B. Each of the printing inks 3 'for forming a colored layer is 80 μm in width and 1.3 μm in thickness.
m, and three colors are printed simultaneously in a stripe pattern with an interval of 30 μm. In this case, either a photo-curing type or a thermosetting type is used as the printing ink, but a UV / heat curable type is effective in terms of stability of performance and productivity.

On the other hand, a film thickness of 1.0 μm is formed by photolithography.
A transparent substrate 1 having a thickness of 0.7 mm and a thickness of 300 × 400 mm on which a black resin light-shielding layer pattern 2 having a width of 20 μm and a width of 90 μm is formed is prepared. Next, as shown in FIG. 1B, the centers of the gaps of the light shielding layer 2 and the centers of the respective colored layers 3 are made to coincide with each other, and the two are superposed. When this is uniformly pressed from the upper surface of the transparent substrate 1 by a hot press at 60 ° C., R.P. G. FIG. B: A state in which each of the colored inks 3 'is uniformly filled. After this is cured from both sides by UV irradiation of about 50 mj / cm ² , as shown in FIG. 1C, the transparent film 8 is peeled off and fully cured at 160 ° C. for 60 minutes to obtain a color having a transparent resin smooth layer on the surface. A filter is obtained.

The case where the transparent film on which the colored layers are printed is placed on the platen and the transparent substrate with the light-shielding layer is superposed from above and uniformly pressed is described above. Figure 1
As shown in (d), a method in which each colored layer is printed on a transparent substrate with a light-shielding layer and a preliminarily dried film sheet is overlapped.

FIG. 2 shows an embodiment in the case where continuous production is performed by using this production method. First, a UV curable transparent resin layer (0.6 μm thick) 7 is coated with a 20 μm thick transparent film 8.
The photosensitive resin film sheet 11 provided with a protective film (16 μm thick) 10 thereon is pulled out from a roll, and the protective film 10 is wound around a roll 10 ′ while being wound.
Transparent film 8 with V-curable transparent resin layer 7 exposed on the surface
2A to 2F by a feed roll 12 and a take-up roll 13.
Is transported as shown in FIG.

In the process, R. G. FIG. Using a flat-bed offset three-color simultaneous printing machine mainly composed of a roll plate 14 for each color for three-color printing ink and a transfer roll plate 15 for three-color simultaneous printing, the R.B. G. FIG. B
Each color ink 3 'is printed as shown in FIG. 2B. Next, the transparent substrate 1 on which the black resin light-shielding layer 2 is formed (same as in Example 1) is placed with the light-shielding layer 2 and the colored layer 3 ′ facing each other so that the center of the gap between the light-shielded layers and the center of the colored layer are as shown in FIG. 2C. Align to match. This is heated to about 60 ° C., and the glass substrate is press-pressed with a roll 16 or a flat plate as shown in FIG. 2D. 2E and 2F, the colored ink 3 'and the UV-curable transparent resin layer 7 are cured by a UV irradiation device 17 of about 100 mj / cm ² from both sides, and the transparent film 8 is peeled off. As shown in F, it is cut to the size of a glass substrate.

Next, as shown in FIG. 2G, this is fully cured at 200 ° C. for 60 minutes using a vacuum pressurizing device 18 or the like to complete a color filter. These printing, alignment, bonding, thermocompression bonding and other processes combine known means for obtaining productivity, reproducibility, stability, etc., such as processing on a platen by intermittent conveyance to improve accuracy. In this case, the process may be optimized.

[0016]

As described above, according to the present invention, R.V. is applied on a film or a transparent film having a UV-curable transparent resin layer. G. FIG. B Since only the respective colored layer patterns are formed, only the black resin light-shielding layer pattern is separately provided on the transparent substrate, and the two are pressure-bonded and integrated. Since there is no need to form each colored layer on the resin light-shielding layer, the ridges and protrusions inevitable at the boundary, that is, the portion above the light-shielding layer, are eliminated, and the color filter has excellent surface smoothness. Can be easily obtained. Therefore, complicated steps such as polishing and formation of a smooth layer, which are necessary for smoothing, are not required.

Further, since pressure is applied from above the transparent substrate itself, the entire surface is uniformly pressed under the same conditions. Therefore, if the optimum amount of printing ink for the light-shielding layer film thickness is selected, the amount of printing ink to be extruded into the gap is minimized. And homogenization improves uniformity and reproducibility. In addition, in order to print each colored layer pattern on a film or on a transparent film provided with a transparent resin layer, there are fewer restrictions on printability and workability than when printing on a conventional hard glass substrate, and the pattern is reduced. It is easy to improve accuracy, linearity, and optical characteristics.

In the conventional method, the colored layer is simultaneously printed on the glass substrate on which the light-shielding layer is formed, so that the gap between the three layers is increased in order to avoid printing restrictions and color mixing. And the fluctuation was large, so that the obtained smoothness was limited. On the other hand, in the present invention, since both are separated on separate substrates, printing can be performed at an interval similar to the width of the light-shielding layer, so that the amount of extrusion movement is reduced and the variable element is reduced, so that reproducibility and homogeneity are improved. Also contributes.

The printed color inks are pressed and cured in a state of reduced viscosity by heating, so that they are easily and uniformly filled in the gaps, so that a color filter having excellent homogeneity can be obtained, and at the same time, a base for forming a colored layer is formed. UV that is
The curable transparent resin layer plays the role of a conventional smooth layer as it is. That is, R.I. G. FIG. B. The surface condition obtained by absorbing the difference in the resistance of each pigment to the liquid crystal cell assembly process conditions and separating the film after curing is determined by the surface properties of the transparent film used. Even if a material is not applied and a smooth layer is separately formed, the same or more smoothness can be automatically obtained. In addition, a predetermined position on the transparent film has a resin characteristic, so that no resin is attached to this portion. Therefore, by bringing this portion to the pixel boundary portion, higher edge linearity is obtained. Film can be made. When a color filter is formed on a TFT array, it can be used as a method for forming a current-carrying hole.

As described above, according to the present invention, R.V. G. FIG. B. Restriction in forming each colored layer pattern is reduced, and even when a black resin light-shielding layer having a large film thickness is used, no swelling or protrusion occurs at the portion. In addition, this is an efficient color filter manufacturing method suitable for stable production in which a smooth layer is formed simultaneously with the formation of a colored layer. In addition, since the wet process is reduced and the dry process is mainly used, the continuous production process can be configured relatively easily compared to the conventional method, so that it is possible to improve productivity and yield, thereby contributing to a significant cost reduction. Things.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing method of the present invention.

FIG. 2 is an explanatory view showing one embodiment of the production method of the present invention.

FIG. 3 is a cross-sectional view showing a conventional manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Transparent substrate 2 Light-shielding layer 3 Transparent coloring layer 7 Transparent resin layer 8 Transparent film 9 Photosensitive resin film sheet 14, 15 Roll of 3 color simultaneous printing machine 16 Press roll 17 UV irradiation device

Claims (4)

[Claims] 1. A transparent colored layer having an optical property and a pattern shape required as a color filter is formed on a transparent film, and a transparent substrate on which a light-shielding layer pattern is formed is overlaid on the transparent film and integrated. And a method for producing a color filter. 2. A step of forming a transparent colored layer of a required pattern on a transparent film having a transparent resin layer on the surface, a step of forming a light-shielding layer pattern on a transparent substrate, and laminating the transparent substrate on the transparent film. 2. The method for producing a color filter according to claim 1, comprising: a step of heating, pressing and curing the two to integrate them, and a step of peeling off the transparent film. 3. An R.F.R. of a pattern smaller than a gap portion of a light-shielding layer pattern in a flatbed or rotary offset multicolor printing method.
G. FIG. B. The simultaneous printing of each colored layer on a transparent film, a transparent substrate with a light-shielding layer superimposed thereon, and heating and pressing to fill and integrate a gap between the light-shielding layer and the colored layer. 3. The method for producing a color filter according to 2. 4. The method for producing a color filter according to claim 1, wherein a portion of the transparent film, which has a resin characteristic that does not adhere to the resin, is formed in a predetermined position in advance.