JPH11249155A - Method and apparatus for manufacturing flowable substance-enclosed structure - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To ensure that bubbles remain in a liquid crystal region while controlling the spread of a liquid crystal when disposing a liquid crystal between the substrates by disposing a substrate oppositely in the air. An object of the present invention is to provide a method for manufacturing a liquid crystal element and a manufacturing apparatus for the liquid crystal element, in which a large-sized liquid crystal display element can be manufactured in a short time by preventing the liquid crystal from spreading well. SOLUTION: After applying a predetermined pattern of a sealant 7 and a liquid crystal 8 to a lower base 1, when an upper base 2 is arranged to face the upper base 1, spacers 3, 4, and 5 are previously arranged between upper and lower bases 1 and 2 so as to be predetermined. The spacers 3 are held at intervals and when the upper substrate 2 is pressed,
The upper base 2 is sequentially brought into contact with the lower base 1 from the one end 2a side to the other end 2b side while sequentially removing 5, 5 from the one end 2a side.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a structure for enclosing a flowable substance (in particular, a method of manufacturing a liquid crystal element such as a liquid crystal display element) and an apparatus therefor.

[0002]

2. Description of the Related Art As a method of manufacturing a liquid crystal display element called a liquid crystal panel, for example, an empty panel is formed by adhering and fixing peripheral portions of a pair of bases opposed to each other at a predetermined interval of 1 to 10 μm with a sealant. Then, the empty panel is housed in a vacuum device, the inside of the panel is evacuated, and an injection port provided in advance in the sealant portion is immersed in the liquid crystal. An injection method of injecting liquid crystal into a panel by gradually returning the inside of a vacuum device to an atmospheric pressure and utilizing a pressure difference between the inside and outside of the panel and a capillary phenomenon is well known.

However, this injection method has a problem that it takes a long time to inject a liquid crystal having a relatively high viscosity, and in particular, a large amount of injection time is required as the size of the liquid crystal display element increases. In addition, there is a problem that it takes a long pre-treatment time to evacuate the inside of the vacuum device, and there is also a problem that an expensive vacuum device is required. That is, the conventional injection method has problems such as an increase in manufacturing time and an increase in cost.

Therefore, for example, Japanese Patent Application Laid-Open No. 60-75817 discloses a method.
JP-A-60-230636, JP-A-1-3034
No. 14, JP-A-3-25416, JP-A-4-2180
As described in each publication of No. 27, a sealing material is applied to one of a pair of bases so as to surround a display area, and liquid crystal is dropped or applied to the display area, and then the other is placed in a vacuum device. (A dropping method or a coating method) in which the base material is pressed in parallel and then the sealing material is cured. According to this method, the time required for injecting the liquid crystal is greatly reduced, but since the substrates are overlapped under vacuum, the pretreatment time for evacuating the inside of the vacuum apparatus is also long, and the cost is high. Since a special vacuum device is required, there has been a problem that the manufacturing time increases and the manufacturing cost increases.

[0005] Japanese Patent Application Laid-Open No. 2-84616,
As described in JP-A-123324 and JP-A-6-208097, in the above-described dropping method or coating method, a method of superposing substrates in the atmosphere has also been proposed. Since this method does not require a vacuum device, the manufacturing time and cost can be reduced as compared with the above-described dropping method or coating method using a vacuum device. However, in this method, since the substrates are superposed in the atmosphere,
At the time of the superposition, air bubbles remain in the liquid crystal in the display area, which causes a display defect, resulting in a problem that the yield is reduced.

Further, in order to solve the above-mentioned problem of air bubbles remaining, a liquid crystal is applied in a predetermined thin line pattern.
A method in which substrates are superposed gradually or intermittently (Japanese Patent Laid-Open No.
Or a pair of substrates facing each other in a wedge shape, or one substrate facing each other in a state of being warped in a convex shape, and gradually bringing the substrates closer together so as to be parallel to each other and crimping. (Japanese Unexamined Patent Publication No. 4-179919)
Etc. have been proposed. However, in such a method, the time required for overlaying the substrates is long, and
A special device is required to precisely stack the substrates, which also causes a problem that the manufacturing time increases and the manufacturing cost increases.

[0007]

Accordingly, the present applicant has filed a Japanese Patent Application No. 9-22 / 98.
No. 9360, for example, after dropping liquid crystal onto one end inside a seal region on one of the substrates and superimposing the two substrates from the side, at least one of a pair of substrates arranged opposite to each other While the upper portion is pressed by the pressing means from one end to the other end of the liquid crystal area, the pressing means is relatively moved to spread the liquid crystal from one end to the entire liquid crystal area, and the sealing area is pressed. A method has been proposed in which the air in the liquid crystal region is exhausted from an opening provided in advance and the sealing region is cured (hereinafter referred to as the prior invention).

According to the invention of the prior application, the liquid crystal supplied to one end of the pair of bases is spread between the bases by superimposing the two bases and then pressing the liquid crystal by pressing means such as a pressing roller. Therefore, the liquid crystal can be filled extremely easily in a short time. At this time, a predetermined gap between the substrates can be obtained by appropriately adjusting the pressing force of the pressing means and further holding this pressed state by the auxiliary roller.

Further, since the bubbles entrained in the liquid crystal are extruded as the liquid crystal spreads, fine bubbles do not remain in the liquid crystal region. Therefore, a liquid crystal element having good characteristics can be manufactured by a simple and short manufacturing process. In addition, since it is not necessary to use an expensive vacuum apparatus as in the related art, the manufacturing cost can be reduced.

Further, the prior invention is particularly effective when applied to a case where a ferroelectric liquid crystal having a high viscosity is generally filled between substrates, and by using a ferroelectric liquid crystal in a liquid crystal element, for example, In addition, an inexpensive liquid crystal element that does not use an expensive thin film transistor can be provided.

[0011]

However, it has been found that the invention of the prior application has various features as described above, but still has points to be improved.

In the case of the invention of the prior application, specifically, as shown in FIG. 28, first, a sealant 49 is applied to the periphery of one of the substrates 47, and a liquid crystal material 50 is applied to one edge 47a of the substrate.
A method of applying a linear pattern on the side is adopted. Then, as shown in FIG. 29, the other substrate 48 is superimposed on the substrate 47 on which the liquid crystal 50 is applied, and
The upper portion is pressed by the pressing roller 52 in the direction from the one edge 48a to the other edge 48b.

However, before the pressing, both substrates 47, 48
As shown in FIG. 28, the applied liquid crystal 50 spreads around the leading surface 50a while forming the leading surface 50a by the weight of the overlapping base 48, but bubbles are formed in the corners inside the sealant 49, as shown in FIG. 51 sometimes remained.

Further, the pressure can be applied by the roller 52 while discharging air from the air outlet 49a of the sealant 49. During the pressurization, the roller 52 is pressed forward (ie, on the other end 47b side) from the position of the roller 52. A part of the base 48 is easily lifted and air is easily entrained, and as shown in FIG. 29, new air bubbles 51 may remain with the progress of pressurization. In addition, a part 50a of the liquid crystal 50 may run over the sealant 49 and protrude to the outside, and as shown in FIG. In some cases, the liquid crystal 50a leaking to the outside of the sealant 49 may be formed.

Such a phenomenon is more likely to occur when the liquid crystal coating amount (that is, the coating area) is increased due to an increase in the size of the substrate or an increase in the distance between the substrates (cell gap). In other words, since the central portion of the liquid crystal application portion is more likely to have a concave portion due to insufficient interfacial tension of the liquid crystal, when the other substrate is overlapped, air bubbles enter the concave portion, and a large-sized large-sized liquid crystal device can be manufactured. Manufacture can be difficult.

In addition, in advance inside the seal area or the like,
By providing grooves for accommodating excess liquid crystal and the like in the base, as described above, leakage of liquid crystal to the outside of the sealant can be prevented, and the liquid crystal application pattern can be arbitrarily set to a certain degree (excess liquid crystal inside the seal region). However, there is an advantage that the coating pattern can be freely selected.) However, a step of forming a groove in the base in advance is required, and air or the like is formed in a region between the seal portion and the groove. Tends to remain, and if the air enters the effective screen, the screen quality may be degraded.

On the other hand, as a shape for applying a liquid crystal material, as described in Japanese Patent Application Laid-Open No. 3-89315, there is a shape in which a liquid crystal material is applied so as to form an approximate>-<shape over the entire area of one substrate. However, with this coating shape, when applied to a method of sequentially and continuously applying pressure from one end to the other end as in the prior application, an area where the liquid crystal does not spread (or overflows the liquid crystal) in the effective screen. However, there is a drawback that high-quality liquid crystal cannot be filled, for example, entrapment of air bubbles or the like occurs.

The present invention has been made in view of the above circumstances, and has a structure in which substrates are opposed to each other in the air, and a liquid material such as liquid crystal is spread between the substrates. A large liquid crystal display element that controls the spreading, reliably prevents bubbles from remaining in the sealed area, spreads the flowable substance well, and prevents the flowable substance from protruding from the sealant. However, it is an object of the present invention to provide a method and an apparatus for manufacturing a fluid-filled structure capable of manufacturing a high-quality liquid crystal element in a short time.

[0019]

The inventor of the present invention has made intensive studies to solve the above-mentioned problems, and as a result, it has been found that the contact between the substrates when the substrates are opposed to each other and pressurized is adjusted to prevent entrapment of bubbles and the like. The present invention has reached the present invention by observing that the spreadability of the flowable substance is largely affected.

That is, the present invention relates to a method of manufacturing a structure for enclosing a flowable substance such as a liquid crystal element in which a flowable substance (particularly, liquid crystal is enclosed in a liquid crystal area) is enclosed in a sealing area between a pair of substrates arranged facing each other at a predetermined interval. And a step of disposing a fixing material on at least one of the pair of substrates in the bonding region, and holding the pair of substrates in a non-contact state by the non-contact state holding means on the side of the fixing material, including the fixing material. And disposing the pair of substrates from being held by the non-contact state holding means and sequentially contacting them from one end side to the other end side to spread the flowable substance in the sealed area. And a method for producing a fluid substance enclosing structure (hereinafter, may be referred to as a first method of the present invention).

According to the first method of the present invention, a pair of substrates in which a fluid substance such as a liquid crystal is applied to one of the substrates is held in a non-contact state by means of a non-contact state and opposed to each other. The holding state is released, and the fluid substance is spread in the sealed area by sequentially contacting from one end side to the other end side, so that the base body sequentially released from the one end side is removed from the one end side. The flowable material can be spread while controlling the spread of the flowable material while sequentially making contact with the edge side. As a result, the flowable substance can be spread without leaving bubbles in the sealed area,
Leakage of a fluid substance outside the seal portion can be prevented, and even in the case of a large-sized liquid crystal display element, a high-quality liquid crystal element or the like can be manufactured in a short time and with good workability.

Further, the present invention provides a method of manufacturing a fluid substance enclosing structure such as a liquid crystal element in which a fluid substance (particularly, liquid crystal is enclosed in a liquid crystal area) is enclosed in a sealing area between a pair of substrates opposed to each other at a predetermined interval. In the step of disposing a fixing material on at least one of the pair of substrates in the bonding area, holding the pair of substrates in a non-contact state by holding means including the fixing material on the side of the fixing material, Having a step of causing the flowable material to spread in the enclosing region, wherein the step of causing the flowable substance to sequentially contact from one end side to the other end side while holding at least one of the pair of bases by the holding means while holding at least one of the pair of bases. The present invention relates to a method for producing a fluid substance enclosing structure, which is a feature (hereinafter, may be referred to as a second method of the present invention).

According to the second method of the present invention, the pair of bases are held in a non-contact state with each other by the holding means and are opposed to each other. To the other end side so as to spread the flowable material into the enclosing area, so that the base material comes into contact sequentially from the one end side and can achieve the same effect as the first method described above. A method for fabricating the structure can be provided.

Further, the present invention provides an apparatus for producing a structure for enclosing a flowable substance such as a liquid crystal element in which a flowable substance (particularly, liquid crystal is enclosed in a liquid crystal area) is enclosed in a sealing area between a pair of substrates opposed to each other at a predetermined interval. In, in a bonding region, a fixing material arranging means for arranging a fixing material on at least one of the pair of bases, and holding the pair of bases in a non-contact state with each other including the fixing material on the side of the fixing material, Non-contact state holding means to be disposed in opposition, attaching and detaching means for the non-contact state holding means to and from the pair of bases, and releasing the pair of bases from holding by the non-contact state holding means by the attaching and detaching means; A pressurizing means for sequentially contacting the base material from one end side to the other end side, and pressurizing the flowable substance in the sealing area. Manufacturing apparatus in which according to (hereinafter sometimes referred to as the first device of the present invention.).

According to the first apparatus of the present invention, since it is an apparatus based on the above-mentioned first method, there is provided an apparatus for producing a fluid substance enclosing structure capable of exhibiting the same effects as the first method. can do.

The present invention is also directed to an apparatus for manufacturing a structure for enclosing a flowable substance such as a liquid crystal element in which a flowable substance (particularly, liquid crystal is enclosed in a liquid crystal area) is enclosed in a sealing area between a pair of substrates opposed to each other at a predetermined interval. And a fixing material disposing means for disposing a fixing material on at least one of the pair of substrates in the bonding region, and the pair of substrates including the fixing material are held in a non-contact state with each other on the side of the fixing material to face each other. Holding means for disposing, and pressure means for sequentially contacting from one end side to the other end side while holding at least one of the pair of substrates by the holding means, and spreading the flowable substance in the sealing area. The present invention relates to an apparatus for producing a fluid substance-enclosed structure (hereinafter, may be referred to as a second apparatus of the present invention).

According to the second apparatus of the present invention, since it is an apparatus based on the above-mentioned second method, there is provided an apparatus for producing a fluid substance enclosing structure capable of exhibiting the same effects as the second method. can do.

[0028]

BEST MODE FOR CARRYING OUT THE INVENTION In the method and the apparatus of the present invention, in order to effectively carry out each of the above, it is desirable to specifically perform the following.

First, the fixing material is disposed on at least one of the pair of substrates along the outer peripheral portion thereof, and a liquid crystal material is applied in advance on one edge side of the substrate inside the fixing material. A spacer for holding the pair of substrates in a non-contact state, including the fixing material, is arranged at a plurality of optimum positions, and these spacers are sequentially removed from one end side, and the pair of substrates are pressed by a pressing unit. It is desirable to spread the flowable substance in the encapsulation area while making contact under pressure.

Therefore, in this case, in order to fix the pair of bases to each other in the bonding region provided along the outer peripheral portion, a curable adhesive as the fixing material is applied to the bonding region of at least one of the bases. Applying step;
Disposing a predetermined amount of a fluid substance on one end side of the enclosing region of at least one of the pair of bases; disposing a first spacer on the one end side; A step of disposing a second spacer, a step of disposing the pair of substrates facing each other with the curable adhesive and the fluid substance interposed therebetween, and selectively removing the first spacer; When pressure is applied in a direction from the one end to the other end by a pressing unit that relatively moves on at least one of the pair of bases, when the pressing unit is located at a predetermined relative movement position. Preferably, a step of selectively removing the second spacer and further applying pressure to completely contact the pair of substrates and a step of curing the curable adhesive are performed.

In addition, the first spacer (preferably 250 μm in height) and the second spacer (preferably 100 to 150 μm in height) are provided, and in the case of a large liquid crystal panel, the space between these spacers is provided. A third spacer (preferably 450 μm in height) is arranged on the side of the base, and the third spacer can also be selectively removed when the pressing means is relatively moved, by sequentially removing the base from one end side to the other end side. While controlling the spread of the liquid crystal by contact,
It is desirable to prevent entrapment of air bubbles and to prevent air bubbles from remaining.

For this purpose, the height of the first spacer is made higher than the height of the second spacer, and the height of the third spacer is made higher than the height of the first spacer. It is desirable in controlling the rolling and preventing the remaining of bubbles and the like.

The spread of the fluid material is mainly controlled by the first spacer, the curable adhesive is mainly prevented from contacting with the other substrate by the second spacer, and the third spacer is mainly controlled by the third spacer. It is desirable to control the spread of the fluid material and to prevent the fluid material from leaking out of the curable adhesive.

In this case, at least one of the plurality of spacers is disposed on the upper surface of the lower substrate of the pair of substrates in the outer peripheral portion, and the upper substrate protrudes from the lower substrate at the support position. If, the lower substrate of the pair of substrates is supported on a support surface such as a stage,
In the outer peripheral portion, it is preferable that at least one of the plurality of spacers is disposed between a lower surface of an upper substrate of the pair of substrates and the support surface.

It is more effective and desirable to extend the flowable substance while bending at least one of the pair of substrates by the pressurizing means.

Further, it is preferable that a gas discharge port is formed in the application pattern of the fixing material on the one edge side and the other edge side of the base.

Preferably, the fluid substance is applied in a predetermined pattern to the sealing area on the one edge side.

When the pressurizing means is relatively moved to perform the pressurization, the pair of substrates are fixed via the fixing material, and the gas is discharged from the gas discharge port and the gas is blocked. (Specifically, closing the gas discharge port due to deformation of the fixing material due to pressurization) desirably not only discharges bubbles but also facilitates sealing.

In the above-described manufacturing method, the fixing material is disposed on at least one of the pair of bases along the outer peripheral portion thereof, and a liquid crystal material or the like is previously provided on one end edge side of the base inside the fixing material. A fluid substance is applied, and the pair of substrates including the fixing material are disposed at predetermined positions on the substrates instead of the spacers. The flowable substance may be spread in the sealed area while the pair of substrates are brought into contact with each other under pressure by a pressing means while being held by means.

In this case, a step of holding at least one of the pair of bases in a non-contact state with each other by the suction means and disposing the pair of bases to face each other with the curable adhesive and the fluid substance interposed therebetween. And a step of contacting the pair of substrates disposed opposite to each other on one edge side,
A step of pressing in the direction from the one end edge to the other end edge by a pressurizing means that relatively moves on at least one of the pair of bases disposed opposite to each other, and bringing the pair of bases into complete contact, Releasing the substrate from the adsorption means.

Preferably, the suction means is disposed on the upper surface of the upper substrate of the pair of substrates, and the pressurizing means is disposed on the upper surface of the suction means to press the pair of substrates. .

The object to which the method and the apparatus of the present invention are applied is not limited to liquid crystal, but may be other fluid substances as long as it is required to prevent air bubbles from being mixed at the time of delay. .

Hereinafter, the present invention will be described in detail with reference to preferred embodiments.

<First Embodiment> First, FIGS.
Active matrix type TFT
A first embodiment in which the first method and apparatus of the present invention are applied to a (thin film transistor) driven 10-inch liquid crystal panel will be described.

FIG. 1A shows that the lower substrate 1 is
After being placed on the liquid crystal 4, the sealant 7 having a predetermined pattern and the liquid crystal 8 having a predetermined pattern (8 a, 8 b, 8 c) have one edge 1 a.
FIG. 1B is a plan view showing a state in which the position of the other end 1b is regulated by a U-shaped stopper 6, and FIG.
FIG. 4 is a plan view showing a state in which upper substrates 2 having substantially the same size are arranged facing each other. The liquid crystal 8 may be a known nematic liquid crystal or ferroelectric liquid crystal (the same applies to other embodiments described later).

Then, pixel electrodes, alignment films, TFTs (thin film transistors) and the like are previously formed on a pair of upper and lower substrates 1 and / or 2 constituting an active matrix type display element according to the active matrix type. The same applies to other embodiments described later), but these are not shown.

As shown in the figure, in the present embodiment, a pair of spacers 3 are arranged along both ends of one end 1a of the lower base 1 along the direction of the other end 1b. 1b
A pair of spacers 5 and a pair of spacers 4 are sequentially arranged on both sides closer to each other in the direction of the other end edge 1b.

Accordingly, as shown in FIG. 1 (b), when the upper substrate 2 is disposed on the moving stage 34 so as to face the lower substrate 1, as shown in FIG. 2 (a sectional view taken along line IIa-IIa in FIG. 1 (b)). In addition, since the upper substrate (indicated by oblique lines in FIG. 1B) 2 is supported by the spacers 3 and 5, it is held in a non-contact state with the sealant 7 applied to the lower substrate 1. Then, as described later, the spacers 3, 5, and 4 are sequentially removed from the one edge 1a side to the other edge 1b side to release the holding state, and the upper base 2 is pressed from the one edge 2a side to the other end by pressure. It is a remarkable feature that the lower substrate 1 is sequentially brought into contact with the edge 2b side.

As shown in FIG. 2A, the upper and lower substrates 1, 2
The thickness of each spacer for maintaining the interval between the spacers 3 is 25 in order from the one edge 1a side.
0 μm, and the thickness 5t of the spacer portion 5a of the spacer 5 is 45
0 μm, and the thickness 4t of the spacer portion 4a of the spacer 4 is set to 10
0 to 150 μm. As described above, the spacer 5 is formed higher than the spacer 3 and the spacer 4 is formed lower, so that the upper substrate 2 before pressing is inclined and held in a non-contact state as shown in FIG. Even if the size of the substrate changes, it is better to change the liquid crystal application pattern without changing the thickness of the spacer.

FIG. 2B is an enlarged sectional view of the vicinity of the spacer 3 in FIG.
A base 3b placed on the stage 34 with the same thickness as
Although it is constituted by the spacer portion 3a integrally joined thereon, the base portion and the spacer portion may be integrally formed as shown in FIG. 2C (this is also possible with the other spacers 4 and 5). Similar). The other spacers 4 and 5 also have the pedestals 4b and 5b and the spacers 4a and 5a, like the spacer 3.

FIGS. 3 to 8 are sectional views showing the steps from the above-described arrangement of the upper substrate 2 to the end thereof and the end of pressurization.
14 to 14 are plan views corresponding to the respective sectional views.
In each of these figures, the moving stage 34 and the stopper 6 shown in FIG. 2 are not shown.

First, FIG. 3 is similar to FIG. 2 (a), and FIG. 9 is similar to FIG. 1 (b), in which the sealant 7 and the liquid crystal 8 are coated on the lower substrate 1 When the upper substrate 2 is opposed to the first substrate 1, the upper substrate 2 is not in contact with the sealant 7 applied to the lower substrate 1 by the spacers 3 and 5 disposed on both sides near the one edge 1 a and the other edge 1 b of the lower substrate 1. Indicates a state in which it is held slightly inclined forward. However, at this time, spreading by the liquid crystal 8 starts by the weight of the upper base 2.

Next, as shown in FIGS. 4 and 10, the spacer 3 on the side of the one edge 1a is removed. The removal of the spacer 3 is performed by grasping the above-mentioned base 3b with a robot arm (not shown) or manually and pulling it out to the side (the same applies to other spacers 5 and 4). This allows
The one edge 2a side of the upper substrate 2 further descends toward the lower substrate 1 by its own weight, starts to contact the sealant 7, and further presses the liquid crystal 8 applied to the lower substrate 1. As a result, the leading end 9a in the spreading direction of the liquid crystal 8 is pushed rearward and laterally, and spreads while the liquid crystal 8 is held inside the sealing agent 7, and at the same time, the air existing in this region is removed by the sealing agent 7. Opening 11a
From the front. At this point, the sealant 7 is somewhat crushed.

Next, as shown in FIGS. 5 and 11, the pressing roller 10 is brought into contact with the upper surface of the upper substrate 2 at one edge 1a and rolled backward, so that the uppermost and lower substrates 1, 2 While the upper substrate 2 is warped upward by the pressure of the pressure roller 10 until reaching the spacer 5 having a large distance holding dimension,
The air in the liquid crystal 8 in the passage area of the pressure roller 10 is efficiently discharged to the front and to the side, and the leading edge 9b of the liquid crystal further spreads to prevent the sealant from leaking out while controlling the spread of the liquid crystal 8. While spreading, it is spread evenly in the liquid crystal region inside the sealant 7. At the same time, the sealing agent 7 is crushed, and the opening 11a is automatically closed.

Next, as shown in FIGS. 6 and 12, the intermediate spacer 5 is removed. And furthermore, the pressure roller 1
0, and the pressing is advanced, so that the upper base 2 is supported by the spacer 4 on the other end edge 2b side and slightly warped,
The liquid crystal 8 is further expanded and extended like the leading end 9c. At this time, the upper substrate 2 is not brought into contact with the sealing agent 7 of the lower substrate 1 in this region and in the vicinity thereof by the spacer 4.

Next, as shown in FIGS. 7 and 13, the last spacer 4 is removed, and the pressure roller 10 is further rolled to apply pressure, thereby discharging air from the opening 11b of the sealant 7. The leading end 9 d of the liquid crystal 8 is made to reach near the rear end of the sealant 7.

Then, as shown in FIGS. 8 and 14, the pressing by the pressing roller 10 to the other end 2b of the upper substrate 2 is completed, and the liquid crystal 8 is completely applied to the entire liquid crystal region inside the sealant 7. And the openings 11b and 11c of the sealant 7
To close automatically.

In the above-described pressurizing process, as shown in FIG. 9, the sealant 7 applied to the peripheral portion of the lower base 1 is used when the upper base 2 is arranged to face the lower base 1 as shown in FIG. One end 1a side starts to be crushed, and as shown in FIG.
It is further crushed to a predetermined thickness (to form a predetermined gap between the two substrates at the time of commercialization, that is, to form a cell gap) by pressing by the pressing roller 10, and the opening 11 a on one end edge 1 a side is formed.
Are simultaneously closed. Then, as shown in FIG. 14, when the pressurization is advanced and the pressurization is completed, the sealant 7 is all crushed to a thickness corresponding to a predetermined cell gap between the upper and lower substrates 1 and 2, and the other end edge The openings 11b and 11c on the 1b side are also closed at the same time.

As described above, in the present embodiment, one edge 1a
The upper substrate 2 is removed by removing the spacer 3 on the side of the
The lower substrate 1 (actually, the sealant 7) is brought into contact from the side, and the spacers 5 and the spacers 4 are removed in order in accordance with the development of the pressure, and the two substrates are brought into contact from the front to the rear. Therefore, the liquid crystal 8 is sufficiently spread over the entire liquid crystal region while the spread is controlled, and the liquid crystal 8 does not run over the sealant 7 and protrude outside the sealant. Further, since the upper substrate 2 pressed by the pressure roller 10 is sequentially contacted with the lower substrate 1 while being warped upward by the spacers 5 and 4, there is no air entrainment between the substrates at a constant pressing speed. In addition, air is efficiently exhausted from between the substrates, and no air bubbles remain.
This pressing can be performed by, for example, an air jet method other than the above-described roller.

FIGS. 15A and 15B are schematic diagrams showing the liquid crystal panel according to the present embodiment in the order of the manufacturing steps. FIG. 15A shows a step of applying a sealant and liquid crystal and arranging spacers, and FIG. , (C) shows a pressing step, and (d) shows a curing step of a sealant.

First, as shown in FIG. 15A and an enlarged plan view of FIG. 16, an ultraviolet-curing type Using a dispenser, a sealant 8 made of an adhesive is applied to an opening 11a on one edge 1a side as shown in the figure.
Further, openings 11b and 11c are provided on the side of the other end 1b, and are applied so as to surround the display area inside the adhesive area (the details will be described later). At this time, the above-mentioned spacers 3, 5, 4 and the stopper 6 are provided on the lower base 1, respectively.
The sealant 7 may be applied to the upper substrate 2 on the side of the opposing surface on which the alignment film is formed, or may be applied to the opposing surfaces of both substrates (see another embodiment described later). The same).

In this case, while the lower substrate 1 is heated, a liquid crystal in which spacer particles for controlling the gap between the substrates are mixed in advance is applied to the inside of the above-mentioned sealant 7 application portion on the lower substrate 1 side. Further, the spacer particles may be sprayed on one of the substrates in advance.

Next, as shown in FIG. 15B, the upper substrate 2 is disposed so as to face the application surface of the lower substrate 1 on which the sealant 7 and the liquid crystal 8 have been applied as described above. In this figure,
The upper substrate 2 shown by a virtual line and a solid line shows an initial state of the facing arrangement.
After the b side is positioned as shown by the imaginary line, the two bases 1 and 2 are brought into contact at one end 1a as shown by the solid line, and fall to the other end 1b.

Next, as shown in FIG. 15C, after lowering the pressure roller 10, the two substrates 1 and 2 are moved in the direction of the arrow while performing the above-described selective technique of the spacers 3, 5, and 4. Meanwhile, the upper and lower substrates 1 and 2 are moved downward by the pressure roller 10 from one edge 2 a to the other edge 2 b of the upper substrate 2.
2 is sequentially pressurized. Therefore, the liquid crystal 8 applied to the upper surface of the lower substrate 1 is spread over the entire display area surrounded by the sealing agent 7, and the openings 11 a, 11 b, 11 c formed in the sealing agent 7 for discharging air are also air. Is sealed at the same time after discharging. Pressing in this case may be performed by fixing both the substrates 1 and 2 and moving the pressing roller 10.

Next, as shown in FIG. 15D, after the pressing is completed, the substrates 1 and 2 cover the display area filled with the liquid crystal 8 with a stainless plate 13 having a thickness of 1 mm, for example. The entire display element is irradiated with, for example, 50 seconds by an ultraviolet lamp unit 14 that emits ultraviolet light at an intensity of, for example, 100 mJ / cm ² , and the sealant 7 is cured. Thereby, the sealant 7 is completely cured and sealed.

FIG. 16 shows a coating pattern of the sealant 7 and the liquid crystal 8 in the present embodiment (the same applies to other embodiments described later), and the liquid crystal 8 applied to the lower substrate 1 This explains a situation in which the display area extends over the entire display area in response to pressure from one end edge 1a.

First, the application pattern groups 8a and 8
b and 8c are closer to one edge (one of the base length D shown in FIG. 16).
/ 2).

[0068] Also, as shown, each interval l between the liquid crystal pattern 8a-8b-8c on the center line C ₁ is brought close to each pattern with each other, narrower than the other portions. As a result, only by arranging the upper substrate 2 facing the lower substrate 1, a part of the liquid crystal 8 in the above-mentioned adjacent portion first spreads back and forth as indicated by the thick arrow 15, and at the same time, the liquid crystal 8 in the other portions also becomes thin lines. The pattern 8a extends as shown by an arrow 15a, and the bent both end portions 8a 'of the pattern 8a extend to the sealant corner A. The liquid crystal 8 is further completely filled into the corner A by the above-described pressurization. The leading surface 9a of the liquid crystal at this time is indicated by a chain line.

[0069] Then, with this, including the area of the corner portion A, the air that existed between the two substrates is sufficiently discharged from the opening 11a in the arrow B ₁ direction. With the progress of pressurization,
The spreading front end of the liquid crystal 8 spreads in the direction of the other end edge of the base as in the preceding ends 9b, 9c, 9d in the same manner as in FIGS. And the same time, the opening 11b of the other end of the air in the display area, while discharging as indicated by the arrow B ₂ from 11c, with eventually spread throughout the entire display area, each aperture 11a , 11b, 11c are closed by pressurization.

As shown in FIG. 17, the sealing agent 7a at one end 1a and the sealing agent 7 at the other end 1b are provided so as to easily discharge the air and finally close the opening.
b is formed to have an inclination (inclination angle α = approximately 5.7 °) projecting toward each of the openings 11a and 11b. Further, the openings 11a and 11b protrude in a C-shape and reduce in diameter, and the divergent angles θ ₁ and θ ₂ are respectively set to 30 ° to 60 °, for example, 45 °.
° and then, back and forth 5mm spacing L ₂ of the opening tip, forming a gap L ₁ of the opening start point unit back and forth 20 mm.

The openings 11c at both corners on the other end side are made symmetrical as shown in the figure, and the spread angle is basically set to a combination of 60 ° to 90 ° (θ ₁ , θ ₂ ) according to FIG. The interval between the tip portions is 5 mm. After the pressure roller 10 has passed, the respective openings 11a, 11a
The spread angle of the seal pattern and the interval between the opening end portions are adjusted so that b and 11c are closed.

The opening angle θ of the opening and the inclination angle α of the sealant on the opening side are not limited to the above, and may be any suitable value. It is not restricted to. Also, a line segment (may be a curve)
The length of 7 'may also be arbitrary.

For the application of the liquid crystal 8 as shown in FIG. 16, the required amount of liquid crystal is calculated in accordance with the liquid crystal enclosing area according to the size of the upper and lower substrates 1 and 2 and the gap between the upper and lower substrates 1 and 2. The contact speed (time) and contact amount (area) of the liquid crystal sealant in consideration of the contact of the liquid crystal 8 with the sealant 7 after spreading.
Is determined, the arrangement of the application patterns 8a, 8b, and 8c and the length of each line segment are determined. That is, as shown in FIG. 16, along the one edge 1a, both ends 8a 'are curved outwardly (on the side of the one edge 1a), and the curved pattern 8a is bent in the opposite direction (the other edge 1b). It is preferable to form a basic pattern including a curved pattern 8c curved to the side (a side) and a pattern 8b extending linearly between the two patterns.

The application pattern of the liquid crystal may be variously changed. For example, if the liquid crystal region is not completely filled with liquid crystal after pressurization and the amount of liquid crystal becomes insufficient, the amount of liquid crystal to be applied may be increased or an application pattern may be added at an appropriate position. In the case of a liquid crystal panel, for example,
The intermediate pattern 8b in FIG. 16 may be omitted.

The liquid crystal display device of the present embodiment described above
It is manufactured by a manufacturing apparatus schematically shown in FIG. The same applies to other embodiments described later.

First, the lower substrate 1 is placed on the moving table 34 by the transfer robot 32 driven by the XY robot 31, and then the lower substrate 1 is moved by the dispenser robot 33.
After applying the sealing agent 7 and the liquid crystal 8 in a predetermined pattern thereon, the spacers 3, 5, and 4 are arranged by the spacer attaching / detaching robots 17, 18, and 19, and the lower substrate 1 is previously moved downward by the transport robot 32. The opposing upper substrate 2 heated to the same temperature as the substrate 1 is arranged. After the liquid crystal is spread to one edge side by the weight of the upper base 2 as shown in FIG. 16, the upper and lower bases are kept at a predetermined temperature by the heat retaining dispenser 35, and the moving table 34 is moved in the direction of the arrow (Y direction). 4k with 70mm diameter pressure roller 10
It is pressurized at a pressure of not more than g / cm ² , and is moved under a roller 10 to a predetermined position.

During the movement by the movement table 34,
The substrates 1 and 2 are pressurized at a predetermined pressure by a pressure roller 10 so that the applied liquid crystal 8 fills the entire display area and the opening of the sealant 7 is closed as shown in FIG. Then, the UV lamp unit 39 having the above-described ultraviolet lamp unit 14 moves in the direction of the arrow, and irradiates ultraviolet rays from above the base on the moving table 34 which has reached the predetermined position, thereby curing the sealant.

Thus, in the case of a liquid crystal having a high viscosity, a large amount of time was required for liquid crystal injection in a normal injection method. For example, even a ferroelectric liquid crystal can be uniformly filled in a very short time, and there is no need for an expensive vacuum device or sealing device as in the related art, so that the manufacturing cost can be reduced.

<Second Embodiment> The first embodiment described above can be variously modified based on the technical idea of the present invention. For example, the following figures shown in FIGS. 19 to 25 show other various embodiments (however, a sealant and a liquid crystal pattern are not shown).

First, FIG. 19 shows a case where the lower base 1A has a longer length L, protrudes at both end edges 1a and 1b, and has a smaller width W than the upper base 2A. Therefore, the spacers 20, 21, and 22 in this case do not sandwich the spacer between the upper and lower substrates as in the above-described first embodiment, but add a required interval t to the thickness of the lower substrate 1A. The spacers 20, 21, 22 are disposed between the upper base 2A and the stage 34 near the side surface of the lower base 1A, thereby supporting the upper base 2A at a predetermined distance from the lower base 1A.
Each spacer may be arranged in contact with the side surface of the lower base 1A.

As shown in FIG. 20 (a sectional view taken along line XX-XX in FIG. 19), the structure of the spacers 20, 21, and 22 includes a base portion 22b having the same thickness as the lower base 1A and a required portion. The spacer 20 may be integrally joined with another member 22a forming the interval t, or the spacer 20 may be formed by a single member as shown in FIG. The same applies to other embodiments).

The region of the upper substrate 2A on which the spacers are arranged and the region of the lower substrate 1A exposed from the upper substrate 2A can be used as terminal portions of electrodes such as ITO, respectively (also in other embodiments described below). Similar).

FIG. 21 shows a case in which the length L and the width W of the lower base 1B are smaller than those of the upper base 2B. Therefore, also in this case, the spacers 20, 2
What is necessary is just to arrange | position 1 and 22 similarly to the case of FIG.

FIG. 22 shows that the lower base 1C has a longer length L than the upper base 2C, protrudes at the other end 1b, and has a width W
Indicates a small case. Therefore, in this case, the spacers 20, 21, and 22 may be arranged in the same manner as in the case of FIG.

FIG. 23 shows a case where the lower base 1D has a longer length L, protrudes on the other end 1b side, and has a smaller width W than the upper base 2D. Therefore, in this case, spacers 21 and 22 similar to those in FIG. 19 are used in a portion where the upper base 2D protrudes from the lower base 1D.
In the portion where the edges of the upper and lower bases 1D and 2D coincide with each other, the spacer 3 may be used on one end 1a side and the spacers 4 and 5 may be used on the side as in the first embodiment. .

FIG. 24 shows a case where the size of the upper and lower substrates 1E and 2E is the same, but the upper substrate 2E protrudes from the one edge 1a and the upper and lower substrates 1E and 2E are displaced in the length direction. Is shown. Therefore, in this case, the spacers 20 similar to those in FIG. 19 may be used on one end edge 1a side, and the spacers 4 and 5 similar to those in the above-described first embodiment may be used on both sides.

FIG. 25 shows a case where the lower base 1F is longer than the upper base 2F, and the lower base 1F protrudes on the other end 1b side. Therefore, in this case, all the spacers 3, 4, 5 are the same as those in the first embodiment.
Should be used.

<Third Embodiment> Referring to FIG. 26, a third embodiment of the present invention will be described. In the present embodiment, the present invention is applied to a liquid crystal panel similar to that of the above-described first embodiment, and common portions are denoted by common reference numerals, and description thereof may be omitted. .

While the first embodiment uses spacers as the spacing means before the upper and lower substrates contact each other, in the present embodiment, the upper body 2 is held by the spacing device 24 by suction, and the pressing means is used. The difference is that the cam system is adopted.

That is, according to the spacing device 24, the holding means is incorporated in the main body 25 having a large number of suction holes 25a and communication holes 25b communicating with the suction holes 25a on the suction surface 25c having substantially the same dimensions as the upper base 2. Shaft 2 for manufacturing equipment (not shown)
8a, it is supported by a lever 28 attached to the shaft. The communication hole 25b leads to a connecting portion 26 projecting from the main body 25, and the upper substrate 2 is sucked to the suction surface 25c by suction of a vacuum pump (not shown) connected from the connecting portion 26 via a conduit (not shown). I do.

A driven wheel 29 is mounted on a flange 27 formed on the upper portion of the main body 25 by a shaft 29a. The driven wheel 29 is pressed down by driving a cam 30 provided above the driven wheel 29, and the main body 25 is The holding device 24 is configured to move up and down about a shaft 28a of the holding member 24.

Therefore, as shown in the figure, when the upper and lower bases 1 and 2 are overlapped, the main body 25 is pressed by the cam 30 while the upper base 2 is being sucked, and finally, the main body 25 is at a predetermined interval (product (The distance between the upper and lower substrates at the time).

The upper surface of the upper substrate 2 adsorbed on the adsorbing surface 25c at the time of pressurization is not parallel to the upper surface of the lower substrate 1. One end edge 1a is approached and comes into contact with the liquid crystal 8 and the sealant (not shown) formed on the lower substrate 1. Then, as the pressurization proceeds, the contact is made sequentially from one end edge 2a side to the other end edge 2b side.

Therefore, in the initial state in which the one edge 2a side of the upper substrate 2 starts to contact, as in the first embodiment (see FIGS. 4 and 10), the lower substrate 1 has the one edge 1a side. While spreading the liquid crystal 8 over the liquid crystal area inside the sealant,
Exhaust the air present there. Then, the liquid crystal 8 can be sequentially spread over the entire liquid crystal region without bubbles remaining with the progress of pressurization. Then, after the pressurization is completed, the suction pump is stopped, and if the communication portion 25b is returned to the atmospheric pressure, the held upper substrate 2 naturally separates from the suction surface 25c.

After the upper substrate 2 is suctioned to the suction surface 25c of the main body 25 at a place other than the above-described transfer stage 34,
The holding device 24 is moved onto the transfer stage 34 on which the lower substrate 1 is placed, and the above-described superposition and pressurization are performed. The holding device 24 is incorporated in the manufacturing apparatus shown in FIG.

In the present embodiment, the upper substrate is sucked and held when the two substrates are overlapped, and the lower substrate is successively brought into contact with the lower substrate by the cam means. Therefore, it is necessary to use the spacer as in the first embodiment. And the workability of the superposition is improved.

In the present embodiment, it is preferable to prepare the main body 25 according to the size of various liquid crystal panels. For example, the main body 25 for a large liquid crystal panel covers an extra suction hole 25a with a lid or a cover. It can be closed with a shielding plate or the like and applied to the manufacture of a small liquid crystal panel. This embodiment is particularly effective for manufacturing a large liquid crystal panel.

<Fourth Embodiment> A fourth embodiment of the present invention will be described with reference to FIG. In the present embodiment, the present invention is applied to a liquid crystal panel similar to that of the above-described first embodiment, and common portions are denoted by common reference numerals, and description thereof may be omitted. .

In this embodiment, the spacing means before and after contact with the upper and lower substrates is provided by a spacing device 41 by suction equivalent to that of the above-described third embodiment and a roller equivalent to that of the above-described first embodiment. It is characterized in that it is used in combination with the pressurizing means 10A.

That is, the main body 42 having a large number of suction holes 42a and the communication holes 42b communicating with the suction holes 42a on the suction surface 42c having substantially the same size as the upper base 2 is mounted on a manufacturing apparatus (not shown) by the shaft 44a. It is supported by a lever 44.
The communication hole 42b is provided with a connection portion 43 protruding from the main body 42.
To the upper substrate 2 by suction of a vacuum pump (not shown) connected from the connection portion 43 via a conduit (not shown).
On the suction surface 42c.

In the spacing device 41, a hook 45 is provided on the side edge of the main body 42 opposite to the connecting portion 43, and the main body 42 is suspended by the rod 46. The weight is adjusted so that the liquid crystal 8 and the sealant (not shown) are not excessively pressed, and only the pressing force of the roller 10A acts upon pressing.

The upper surface 42d of the main body 42 is formed flat, and the roller 10A is
The roller 42 is rolled in the direction from the side a to the other end 2b and pressurized. By suspending the other end 2b as described above, the main body 42
Is slightly warped upward, so that the liquid crystal 8 can be favorably spread in the same manner as in the above-described first embodiment.

Also in the case of the present embodiment, when the upper and lower substrates are overlapped, the main body 42 is suspended from the other end 2b while the weight is adjusted while the upper substrate 2 is being sucked, while the upper body 2 is being sucked. The liquid crystal 8 and the sealant are successively brought into contact with the other end 2b side, and are finally formed at a predetermined interval (interval between the upper and lower substrates at the time of commercialization) as shown by a virtual line by pressurization.

Therefore, as in the third embodiment described above, in the process until the upper and lower substrates 1 and 2 reach the final predetermined interval, the lower surface of the upper substrate 2 adsorbed on the adsorption surface 42c of the main body is moved downward. The contact is not parallel to the upper surface of the base 1 but from the one edge 2a side to the other edge 2b side sequentially, and finally becomes a parallel state.

At the initial stage when the one edge 2a side of the upper substrate 2 starts to contact, as in the above-described embodiments, the liquid crystal is applied to the liquid crystal region inside the sealant on the one edge 1a side of the lower substrate. The air in the area is discharged while spreading the liquid crystal 8, and the liquid crystal 8 is sequentially spread over the entire liquid crystal area without leaving bubbles as the pressurization proceeds.

After the pressurization is completed, the suction pump is stopped.
By returning the communication portion 42b to the atmospheric pressure, the upper substrate 2 held by the main body 42 is separated from the suction surface 42c, and the holding device 41 is pulled up by the rod 46.

In this embodiment, the same effect as in the third embodiment can be obtained by using no spacer, and the first embodiment can be used to control the contact between the two substrates during pressurization. The same effect as in the embodiment is obtained.

Also, in the present embodiment, it is preferable to provide the main body 42 of various sizes according to the size of the liquid crystal panel. Of course, by using the same device as in the second embodiment, the main body 42 for a large liquid crystal panel can be used for a small liquid crystal panel, and the same as in the second embodiment. Incorporated in the manufacturing apparatus shown in FIG. 18,
Treated in a similar manner.

In the third and fourth embodiments described above, in addition to the above-described structure, for example, a magnet may be provided on each of the main bodies 25 and 42 so that the upper Adsorption can also be performed by applying (adhering) magnetic powder. Also, the main body 25,
An adhesive tape or the like may be provided on the lower surface of the, or another appropriate method may be used.

[0110]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to embodiments.

Example 1 In accordance with the first embodiment shown in FIGS. 1 to 18, a TFT driven 10-inch liquid crystal display element was manufactured by an active matrix method.

First, according to the first embodiment, a pair of upper and lower substrates 1 and 2 constituting an active matrix type liquid crystal display element were prepared.

Next, as shown in FIG.
Using a dispenser along the outer periphery of the sealant 7
(Sealant capable of contacting liquid crystal: UV curable resin 30Y-298F manufactured by Three Bond Co.) was applied. At this time, the opening 11a was formed on one end 1a side of the base 1 and the openings 11b and 11c were formed on the other end 1b side for air discharge.

Next, a liquid crystal 8 mixed with spacer particles for controlling the gap between the substrates while heating the lower substrate 1 is coated with a predetermined pattern (8a, 8b, 8c) inside the coating portion of the sealant 7 using a dispenser. Was applied dropwise.

Next, as shown in FIG.
Thickness 250 on one end 1a side outside the sealant application portion of
A spacer 3 having a thickness of 130 μm and a spacer 450 having a thickness of 450 μm are provided on both sides of the lower substrate 1 near the other end 1b.
The μm spacers 5 were arranged facing each other.

Next, the pre-heated upper substrate 2 is
As shown in FIG. 2A, the upper and lower substrates 1 and 2 were overlapped so that their respective alignment film (polyimide, rubbed) -formed surfaces faced each other. The liquid crystal starts to spread due to the weight of the upper substrate 2 superimposed from above, and by further removing the spacer 3 on one end 1a side, the liquid crystal 8 is brought into the liquid crystal region inside the sealant 7 close to the liquid crystal region as shown in FIGS. Went around.

Next, as shown in FIGS. 5 and 11, from the outside of the seal portion on the one end edge 2a side where the liquid crystal 8 was dropped, the diameter 7
A 0 mm pressure roller 10 was pressed and rolled with a pressure of 4 kg / cm ² or less.

Next, as shown in FIGS. 6, 7, 12, and 13, the intermediate spacer 5 and the last spacer 4 were sequentially removed while the pressure roller 10 was rolling. As a result, the liquid crystal 8 uniformly spreads over the entire liquid crystal region inside the sealant 7 as shown in the figure, and the gap between the upper and lower substrates 1 and 2 at the end of pressurization as shown in FIGS. Was formed as designed.

Each opening 11 provided in the sealing agent 7
In a, 11b, and 11c, as shown in FIG. 14, the sealant 7 was crushed and closed when passing through the pressure roller 10.

Next, as shown in FIG.
Is shielded by a 1 mm thick stainless steel metal plate 13 and then the entire liquid crystal panel is covered with 100 mJ / c.
Ultraviolet rays were irradiated for 50 seconds with an ultraviolet lamp 14 at an intensity of m ² to cure the sealant 8.

As a result, an active matrix liquid crystal display device was obtained in a very short time. And sealing agent 7
In the area surrounded by the mark, no residual fine bubbles including the display area were observed, and there was no leakage of the liquid crystal 8 from the seal portion.

According to this embodiment, the state in which the spacing between the substrates is maintained by the spacers 3, 4, and 5 is such that the liquid crystal is applied to the one edge 1a by the weight of the upper substrate 2 by removing the spacer 3 on the one edge 1a side. 8 spreads. And the pressure roller 1
By removing the spacers in the order of the spacers 5 and 4 in accordance with the pressurization by the relative movement of 0, the upper base 2 comes into contact sequentially from the one end 2a side to the other end 2b side while warping,
It is possible to spread the liquid crystal 8 over the entire liquid crystal region while completely discharging the air and controlling the spread of the liquid crystal 8.
Therefore, the liquid crystal 8 is prevented from leaking out of the sealant 7, and a large liquid crystal panel can be manufactured in a short time.

Example 2 The main steps were performed in accordance with the third embodiment shown in FIG. 26, and the other steps were the same as in Example 1 to manufacture a TFT-driven 10-inch liquid crystal display element by the active matrix method. did.

First, as in Example 1, a pair of upper and lower substrates 1 and 2 constituting an active matrix type liquid crystal display element were prepared.

Next, in the same manner as in Example 1, a sealant 7 (a sealant capable of contacting with a liquid crystal: a UV curable resin 30Y-298F manufactured by Three Bond Co., Ltd.) was applied along the outer periphery of the lower substrate 1 using a dispenser. Applied. At this time, the opening 11a is provided on one end 1a side of the base 1 and the opening 11a is provided on the other end 1b side.
b and 11c were formed for air discharge.

Next, the liquid crystal 8A mixed with the spacer particles for controlling the gap between the substrates while heating the lower substrate 1 was heated in the same manner as in Example 1 by using a dispenser to form a sealant 7A.
A predetermined pattern (8a, 8b, 8c) was applied dropwise to the inside of the application section.

Next, the pre-heated surface of the non-oriented film of the upper substrate 2 is brought into contact with the suction surface 25c of the main body 25 of the holding device 24, and the vacuum pump is operated to adsorb the upper substrate 2 on the suction surface 25c. I let it.

Next, as shown in FIG. 26, the upper and lower substrates 1 and 2 face each other on the surface on which the alignment film (polyimide, rubbed) has been formed, and the cam 30 was driven to overlap. The liquid crystal starts to spread due to the pressure caused by the driving of the cam 30, and the liquid crystal 8A comes close to the sealant 7.
In the same manner as in Example 1.

Then, as the pressing force by the cam 30 further increases, the liquid crystal 8A spreads over the entire liquid crystal region inside the sealant, and after the upper substrate 2 reaches the position shown by the phantom line in FIG. The pump was stopped, the communication hole 25b was returned to the atmospheric pressure, and the upper substrate 2 was released from the suction state. As a result, the base 1,
The gap between the two was formed as designed.

Each opening 11 provided in the sealing agent 7
In a, 11b, and 11c, the sealant was crushed and closed by pressurization by the cam 30, as in the first embodiment.

Next, as in Embodiment 1, as shown in FIG. 15D, the display area filled with the liquid crystal 8A is shielded by a stainless steel plate 13 having a thickness of 1 mm. UV lamp 1 with UV intensity 1 cm ²
4 for 50 seconds to cure the sealant 7.

As a result, an active matrix liquid crystal display device was obtained at a very short time, similarly to the first embodiment.
In the area surrounded by the sealing agent 7, no fine bubbles including the display area remained, and no liquid crystal 8A leaked from the sealing portion.

According to the present embodiment, the spacing between the substrates is maintained by the holding device 24 using the vacuum suction means and the cam 30 is held.
, The upper substrate 2 adsorbed on the adsorption surface 25c is in the same manner as in the first embodiment.
The contact is made sequentially from the a side to the other end edge 2b side, and the same effect as in the first embodiment can be obtained.

Example 3 The main steps were performed in accordance with the fourth embodiment shown in FIG. 27, and the other steps were the same as in Example 1 to fabricate a 10-inch TFT-driven liquid crystal display element driven by an active matrix system. did.

First, in the same manner as in Example 1, a pair of upper and lower bases 1 and 2 constituting an active matrix type liquid crystal display element were prepared.

Next, in the same manner as in Example 1, a sealant 7 (a sealant capable of contacting with a liquid crystal: a UV curable resin 30Y-298F manufactured by Three Bond Co., Ltd.) was applied along the outer periphery of the lower substrate 1 using a dispenser. Applied. At this time, the opening 11a is provided on one end 1a side of the base 1 and the opening 11a is provided on the other end 1b side.
b and 11c were formed for air discharge.

Next, in the same manner as in Example 1, the liquid crystal 8B mixed with spacer particles for controlling the gap between the substrates was heated while heating the lower substrate 1, and the sealing agent
A predetermined pattern (8a, 8b, 8c) was applied dropwise to the inside of the application section.

Next, the pre-heated surface of the non-alignment film of the upper substrate 2 is brought into contact with the suction surface 42c of the main body 42 of the holding device 41, and the vacuum pump is operated to adsorb the upper substrate 2 on the suction surface 42c. I let it.

Next, as shown in FIG. 27, the upper and lower substrates 1 and 2 face each other on the surface on which the alignment film (polyimide, rubbed) has been formed, and were overlapped while adjusting with the rod 46. Substrate 2 superimposed from above
The liquid crystal 8B starts to spread by the adjusted weight including the liquid crystal 8B, and the liquid crystal 8B is placed in the liquid crystal region inside the sealant 7 close to the first embodiment.
And spread as well.

Next, as shown in FIG. 27, the pressure roller 10A is brought into contact with the main body 42 on the one end edge 2A side of the upper substrate 2, and the pressure roller 10A is It was rolled in the direction of the edge 2b and pressed. In this pressurizing process, the main body 42 contacts the liquid crystal 8B and the sealant 7 on the lower base 1 while gradually holding the upper base 2 from the one end 2b side to the other end 2b while exhibiting a slight warp as shown in the figure. I let it.

After the upper substrate 2 reaches the position indicated by the phantom line in FIG. 27, the vacuum pump is stopped, the communication hole 42b is returned to the atmospheric pressure, the upper substrate 2 is released from the suction state, and the rod 46 42 was lifted. As a result, the liquid crystal 8B spread over the entire liquid crystal region, and the gap between the substrates 1 and 2 was formed as designed.

Each opening 11 provided in the sealing agent 7
In a, 11b, and 11c, the sealant 7 was crushed and closed when passing through the pressure roller 10A, as in Example 1.

Next, as in Embodiment 1, as shown in FIG. 15D, the display area filled with the liquid crystal 8B is shielded by a stainless steel plate 13 having a thickness of 1 mm. UV lamp 1 with UV intensity 1 cm ²
4 for 50 seconds to cure the sealant 7.

As a result, an active matrix liquid crystal display device was obtained at a very short time, similarly to the first embodiment.
In the area surrounded by the sealing agent 7, no fine bubbles including the display area remained, and no liquid crystal 8B leaked from the sealing portion.

According to the present embodiment, the upper substrate 2 is held by the holding device 41 using the same suction means as in the second embodiment, and the pressure is adjusted by the pressure roller 10A while adjusting the contact pressure with the rod 46. As in the second embodiment, since the contact is made from the one end 2a side of the upper base 2 to the other end 2b side sequentially, as in the second embodiment,
The same effect as can be obtained.

[0146]

As described above, the present invention relates to a method for manufacturing a fluid substance enclosing structure such as a liquid crystal element in which liquid crystal is sealed in a sealing area between a pair of substrates opposed to each other at a predetermined interval. Disposing a fixing material on at least one of the pair of substrates, and disposing the pair of substrates including the fixing material on the side of the fixing material in a non-contact state by means of a non-contact state holding means so as to face each other. Process and
The pair of substrates are released from the holding by the non-contact holding means, and are sequentially contacted from one end side to the other end side,
And a step of spreading the flowable substance in the enclosing area, so that the substrate that has been sequentially released from the non-contact holding state from one end side sequentially contacts from one end side to the other end side, The flowable material can be spread while controlling the spread of the material. As a result, the flowable substance can be spread without leaving air in the sealing area, and the flowable substance can be prevented from leaking out of the seal portion. A liquid crystal element or the like can be manufactured in a short time and with good workability.

[Brief description of the drawings]

FIG. 1 is a schematic plan view showing a manufacturing step of a liquid crystal element according to a first embodiment of the present invention, wherein (a) shows a state in which a sealant and liquid crystal are applied and spacers are arranged, and (b) is a substrate. Are arranged facing each other.

FIG. 2 shows a cross-sectional view of the same, wherein (a) is IIa in FIG. 1 (b).
FIG. 1B is a cross-sectional view taken along line IIa, and FIGS.
(C) -IIb (c) It is an expanded sectional view.

FIG. 3 is a schematic cross-sectional view showing a manufacturing process.

FIG. 4 is a schematic sectional view showing another manufacturing process.

FIG. 5 is a schematic sectional view showing another manufacturing process.

FIG. 6 is a schematic cross-sectional view showing another manufacturing process.

FIG. 7 is a schematic sectional view showing another manufacturing process.

FIG. 8 is a schematic sectional view showing still another manufacturing process.

FIG. 9 is a schematic plan view showing the manufacturing process.

FIG. 10 is a schematic plan view showing another manufacturing process.

FIG. 11 is a schematic plan view showing another manufacturing process.

FIG. 12 is a schematic plan view showing another manufacturing process.

FIG. 13 is a schematic plan view showing another manufacturing process.

FIG. 14 is a schematic plan view showing still another manufacturing process.

FIG. 15 is a schematic perspective view showing the manufacturing process.
(A) is a step of applying a sealant and liquid crystal and arranging a spacer;
(B) is a step of arranging the substrates facing each other, (c) is a pressing step,
(D) is a curing step of the sealant.

FIG. 16 is a plan view showing a stepwise spreading process of the liquid crystal.

FIG. 17 is a detailed view of the sealant opening.

FIG. 18 is a schematic plan view showing an apparatus for manufacturing a liquid crystal element.

FIG. 19 is a schematic plan view showing another embodiment of the present invention.

FIG. 20 is a schematic plan view showing another embodiment of the present invention.

FIG. 21 is a schematic plan view showing another embodiment of the present invention.

FIG. 22 is a schematic plan view showing another embodiment of the present invention.

FIG. 23 is a schematic plan view showing another embodiment of the present invention.

FIG. 24 is a schematic plan view showing another embodiment of the present invention.

FIG. 25 is a schematic plan view showing still another embodiment of the present invention.

FIG. 26 is a schematic sectional view showing a holding device according to another embodiment.

FIG. 27 is a schematic sectional view showing a holding device according to still another embodiment.

FIG. 28 is a schematic plan view showing spreading of a liquid crystal in a manufacturing step of a liquid crystal element according to a conventional example.

FIG. 29 is a schematic sectional view showing the same at the time of pressurization.

FIG. 30 is a schematic plan view of the liquid crystal element showing a state after filling the liquid crystal.

[Explanation of symbols]

1, 1A-1F ... lower base, 1a, 2a ... one edge, 1b,
2b: the other edge, 2, 2A to 2F: upper substrate, 3, 4, 5,
20, 21, 22 ... spacer, 6 ... stopper, 7 ... sealant, 8, 8A, 8B ... liquid crystal, 8a, 8b, 8c ... liquid crystal application pattern, 9a, 9b, 9c, 9d ... leading edge, 1
0, 10A ... pressure roller, 11a, 11b, 11c ...
Openings (air outlets), 15, 15a ... spreading direction, 2
4, 41: holding device, 25a, 42a: suction hole, 25
b, 42b communication part, 25c, 42c suction surface, 39 ...
UV lamp unit, 42d top surface, 47, 48 base, 49 sealant, 50 liquid crystal, 51 bubbles, 52
Pressure roller, A: corner, D: substrate length, t: interval

Claims (42)

[Claims] 1. A method for producing a fluid substance enclosing structure in which a fluid substance is encapsulated in a sealing area between a pair of substrates opposed to each other at a predetermined interval, wherein a bonding material is attached to at least one of the pair of substrates in an adhesive area. Disposing; and, on the side of the fixing material, holding the pair of substrates in a non-contact state with each other by a non-contact state holding means, including the fixing material, and disposing them opposite to each other; Releasing from the holding by the non-contact state holding means, sequentially contacting from one end side to the other end side, and spreading the flowable substance in the sealing area. Method of manufacturing. 2. The method according to claim 1, wherein the liquid crystal is filled in a liquid crystal region between a pair of substrates opposed to each other at a predetermined interval, and the liquid crystal is filled in the liquid crystal region. The method for producing a flowable substance-enclosed structure according to claim 1, wherein: 3. A method for disposing the fixing material on at least one of the pair of bases along an outer peripheral portion thereof, and holding the pair of bases in a non-contact state on the outer peripheral portion including the fixing material. The spacer according to claim 1, wherein a plurality of spacers are arranged, the spacers are sequentially removed, and the flowable substance is spread in the sealing region while the pair of substrates are brought into contact with each other under pressure by a pressure unit. A method for producing a flowable substance enclosing structure. 4. A step of applying a curable adhesive as the fixing material to the sealing region of at least one of the bases so that the pair of bases are fixed to each other in a bonding region provided along an outer peripheral portion thereof. Disposing a predetermined amount of a fluid substance on one end side of the enclosing region of at least one of the pair of bases; disposing a first spacer on the one end side; A step of disposing a second spacer on a side; a step of disposing the pair of bases to face each other with the curable adhesive and the fluid substance interposed therebetween; and selectively removing the first spacer; Pressure is applied in the direction from the one edge to the other edge by a pressing unit that relatively moves on at least one of the pair of substrates arranged, and the pressing unit is located at a predetermined relative movement position. sometimes 4. The fluid substance enclosing structure according to claim 3, further comprising a step of selectively removing the second spacer and further applying pressure to completely contact the pair of substrates, and a step of curing the curable adhesive. 5. Method of manufacturing. 5. The first spacer and the second spacer are arranged, and a third spacer is arranged between the spacers on a side of the base, and the third spacer is also positioned relative to the pressing means. The method for producing a flowable substance-enclosed structure according to claim 4, wherein the structure is selectively removed at the time of movement. 6. The flowable material enclosure according to claim 5, wherein the height of the first spacer is higher than the height of the second spacer, and the height of the third spacer is higher than the height of the first spacer. How to make the structure. 7. The spreader for controlling the flowable substance is mainly controlled by the first spacer, the contact between the curable adhesive and the other base is mainly prevented by the second spacer, and the third spacer is used for controlling the spread of the flowable substance. The method for producing a fluid substance enclosing structure according to claim 6, wherein the spreading of the fluid substance is controlled and the leakage of the fluid substance from the curable adhesive is prevented. 8. The method according to claim 3, wherein at least one of the plurality of spacers is disposed on an upper surface of a lower substrate of the pair of substrates in the outer peripheral portion. 9. A lower substrate of the pair of substrates is supported on a support surface, and the plurality of the plurality of substrates are disposed between the lower surface of the upper substrate of the pair of substrates and the support surface at the outer peripheral portion. The method for producing a fluid substance enclosing structure according to claim 3, wherein at least one of the spacers is provided. 10. The method according to claim 3, wherein the fluid substance is spread while bending at least one of the pair of substrates by the pressurizing means. 11. The method according to claim 1, wherein a gas outlet is formed in the application pattern of the fixing material on the one end side and the other end side of the base. 12. The method according to claim 1, wherein the flowable substance is applied in a predetermined pattern to the sealing area on the one edge side. 13. When the pressurization is performed by relatively moving the pressurizing means, the pair of substrates are fixed via the fixing material, and gas is discharged from the gas discharge port and the gas is closed. 13. The method for producing a fluid substance enclosing structure according to claim 12, wherein 14. A manufacturing method of a fluid substance enclosing structure in which a fluid substance is sealed in a sealing area between a pair of substrates opposed to each other at a predetermined interval, wherein a bonding material is attached to at least one of the pair of substrates in an adhesion region. Arranging, and holding the pair of bases including the fixing material in a non-contact state with each other by holding means on the side of the fixing material, and arranging the pair of bases to face each other. A step of sequentially contacting from one end side to the other end side while holding by the holding means, and spreading the flowable substance in the sealing area. 15. A liquid crystal device in which a liquid crystal as a fluid substance is sealed in a liquid crystal region between a pair of substrates opposed to each other at a predetermined interval, and the liquid crystal is spread in the liquid crystal region. The method for producing a flowable substance enclosing structure according to claim 14, wherein 16. A suction means for arranging the fixing material on at least one of the pair of bases along an outer peripheral portion thereof and holding the pair of bases in a non-contact state with each other including the fixing material. 15. The fluid substance is spread in the sealed area while being arranged at a predetermined position of the base and brought into contact with the pair of bases under pressure by a pressing unit while being held by the suction unit. Method for producing a sealed flowable substance enclosed structure. 17. In order to fix the pair of bases to each other in an adhesive region provided along an outer peripheral portion thereof,
A step of applying a curable adhesive as the fixing material to the adhesive region of at least one of the substrates; and disposing a predetermined amount of a fluid substance on one edge side of the enclosing region of at least one of the pair of substrates. A step of holding at least one of the pair of substrates in a non-contact state with each other by the suction means, and disposing the pair of substrates to face each other with the curable adhesive and the fluid substance interposed therebetween; Contacting the pair of opposing bases with each other on one end side; and pressing means relatively moving on at least one of the pair of opposing bases from the one end to the other end. And a step of completely contacting the pair of substrates, a step of releasing the substrates from the suction means, and a step of curing the curable adhesive. The method for manufacturing a flowable material enclosed structure according to claim 16. 18. The structure according to claim 16, wherein the suction means is disposed on an upper surface of an upper substrate of the pair of substrates, and the pressurizing means is disposed on an upper surface of the suction means. Method of manufacturing. 19. The method according to claim 14, wherein a gas outlet is formed in the application pattern of the fixing material on the one end side and the other end side of the base. 20. The method according to claim 14, wherein the flowable substance is applied in a predetermined pattern to the sealing area on the one edge side. 21. When the pressurization is performed by relatively moving the pressurizing means, the pair of bases are fixed via the fixing material, and the gas is discharged from the gas discharge port and the gas is closed. 21. The method for producing a fluid substance enclosing structure according to claim 20, wherein 22. An apparatus for producing a fluid substance enclosing structure in which a fluid substance is enclosed in a sealing area between a pair of substrates opposed to each other at a predetermined interval, wherein a bonding material is attached to at least one of the pair of substrates in an adhesion region. Non-contact state holding means for holding the pair of bases in a non-contact state with each other on the side of the fixing material and including the fixing material, and disposing the pair of bases in opposition to each other; The detachable means of the non-contact state holding means, and after releasing the pair of bases from the holding by the non-contact state holding means by the detachable means, the pair of bases are sequentially contacted from one end side to the other end side, And a pressurizing means for spreading the flowable substance in the sealing area. 23. A liquid crystal device in which liquid crystal as the fluid substance is sealed in a liquid crystal region between a pair of substrates opposed to each other at a predetermined interval, and the liquid crystal is spread in the liquid crystal region. 23. The manufacturing apparatus of a fluid substance enclosing structure according to claim 22, further comprising a pressurizing unit for causing the fluid substance to be enclosed. 24. A plurality of locations on an outer peripheral portion of the base in order to keep the pair of substrates in a non-contact state, including the fixing material disposed on at least one of the pair of substrates along the outer peripheral portion thereof. Spacers are arranged, and these spacers are sequentially removed by the attaching / detaching means, and the fluid substance is spread in the enclosing area while the pair of substrates are brought into contact with each other under pressure by the pressing means. Configured as
An apparatus for producing a fluid substance enclosing structure according to claim 22. 25. In order to fix the pair of bases to each other in an adhesive region provided along an outer peripheral portion thereof,
Application means for applying a curable adhesive as the fixing material to the adhesive region of at least one of the substrates; and disposing a predetermined amount of a fluid substance on one edge side of the enclosing region of at least one of the pair of substrates. A fluid substance supply means, a first spacer disposed on the one end side, a second spacer disposed on a side of the base on the other end side, and the curable adhesive and the fluid substance. First spacer removing means for selectively removing the first spacer in a state where the pair of substrates are opposed to each other with the pair of substrates interposed therebetween; Pressure is applied in the direction from the one end edge to the other end edge by the moving pressing means, and the second spacer is selectively removed when the pressing means is located at a predetermined relative movement position. 25. The manufacturing apparatus of a fluid substance enclosing structure according to claim 24, further comprising: a second spacer removing unit configured to completely contact the pair of substrates by pressing, and a curing unit configured to cure the curable adhesive. And a third spacer disposed between said first spacer and said second spacer on a side of said base, said third spacer also being selectively provided when said pressing means is relatively moved. 26. The apparatus of claim 25, wherein the apparatus is removed. 27. The structure according to claim 26, wherein the height of the first spacer is higher than the height of the second spacer, and the height of the third spacer is higher than the height of the first spacer. Production equipment. 28. The spread of the flowable substance is mainly controlled by the first spacer, the contact between the curable adhesive and the other of the bases is mainly prevented by the second spacer, and the third spacer is used to prevent the spread of the flowable substance. 28. The manufacturing apparatus of a fluid substance enclosing structure according to claim 27, wherein control of spreading of the fluid substance and prevention of leakage of the fluid substance from the curable adhesive to the outside are performed. 29. The manufacturing apparatus according to claim 24, wherein at least one of the plurality of spacers is disposed on an upper surface of a lower substrate of the pair of substrates in the outer peripheral portion. . 30. The lower substrate of the pair of substrates is supported on a support surface, and the plurality of the plurality of substrates are disposed between the lower surface of the upper substrate of the pair of substrates and the support surface at the outer peripheral portion. 25. At least one of the spacers is arranged.
3. The apparatus for producing a fluid substance-enclosed structure described in 1. above. 31. The manufacturing apparatus of a fluid substance enclosing structure according to claim 24, wherein the fluid substance is spread while at least one of the pair of substrates is bent by the pressurizing means. 32. The manufacturing apparatus according to claim 22, wherein a gas discharge port is formed in the application pattern of the fixing material on the one edge side and the other edge side of the base. 33. The apparatus according to claim 22, wherein the flowable substance is applied in a predetermined pattern to the sealing area on the one edge side. 34. When the pressurization is performed by relatively moving the pressurizing means, the pair of substrates are fixed via the fixing material, and the gas is discharged from the gas discharge port and 34. The apparatus of claim 33, wherein the closing is performed. 35. A manufacturing apparatus for a fluid substance enclosing structure in which a fluid substance is sealed in a sealing area between a pair of substrates opposed to each other at a predetermined interval, wherein a bonding material is attached to at least one of the pair of substrates in an adhesion area. Fixing means for arranging the fixing material; holding means for holding the pair of bases including the fixing material in a non-contact state with each other on the side of the fixing material so as to face each other; and at least one of the pair of bases, An apparatus for producing a fluid substance enclosing structure, comprising: a pressurizing means for causing the fluid substance to spread in the enclosing area by sequentially contacting one end edge side to the other end side while being held by the holding means. 36. A liquid crystal device in which a liquid crystal as the fluid substance is sealed in a liquid crystal region between a pair of substrates opposed to each other at a predetermined interval, and the liquid crystal is spread in the liquid crystal region. 36. The manufacturing apparatus of a fluid substance enclosing structure according to claim 35, further comprising a pressurizing means for causing the fluid substance to be enclosed. 37. An adsorbing means for adsorbing and holding said pair of bases in at least one of said pair of bases in a non-contact state with each other, including said fixing material disposed along an outer peripheral portion of said bases. 36. The method according to claim 35, wherein the flowable material is arranged at a predetermined location and spreads the flowable substance in the sealed area while the pair of substrates are brought into contact with each other under pressure by a pressure unit while being held by the adsorption unit. An apparatus for producing the described fluid substance enclosing structure. 38. In order to fix the pair of bases to each other in an adhesive region provided along an outer peripheral portion thereof,
Application means for applying a curable adhesive as the fixing material to the adhesive region of at least one of the substrates; and disposing a predetermined amount of a fluid substance on one edge side of the enclosing region of at least one of the pair of substrates. A fluid substance supply means to be provided, and at least one of the pair of substrates is held in a non-contact state with each other by the adsorption means, and the pair of substrates are opposed to each other with the curable adhesive and the fluid substance interposed therebetween. A moving unit that relatively moves the suction unit to bring the pair of substrates into contact with each other on one edge side from the state where the pair of substrates are disposed, and relatively moves at least one of the pair of substrates arranged opposite to each other. Release means for applying pressure in the direction from the one edge to the other edge by the moving pressure means to bring the pair of substrates into complete contact, and then releasing the substrates from the suction means. , And a curing means for curing said curable adhesive, apparatus for producing flowable material enclosed structure according to claim 37. 39. The method of claim 37, wherein the suction means is disposed on an upper surface of an upper substrate of the pair of substrates, and the pressurizing means is disposed on an upper surface of the suction means. Structure manufacturing equipment. 40. The manufacturing apparatus according to claim 35, wherein a gas outlet is formed in the application pattern of the fixing material on the one edge side and the other edge side of the base. 41. The manufacturing apparatus of a fluid substance enclosing structure according to claim 35, wherein the fluid substance is applied in a predetermined pattern to the enclosing area on the one edge side. 42. When the pressurization is performed by relatively moving the pressurizing means, the pair of substrates are fixed via the fixing material, and the gas is discharged from the gas discharge port and the gas is discharged. 42. The manufacturing apparatus of a fluid substance enclosing structure according to claim 41, wherein the closing is performed.