JP2008203518A - Method for manufacturing display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a display device, in which gap unevenness between large-sized glass substrates on the periphery of the display area is suppressed. <P>SOLUTION: A gap between the large-sized glass substrates 3 and 4 on the outer ends of a liquid crystal panel is made larger than that on the periphery of the display area 6 by increasing an amount of coating of a seal S per unit length of a dummy seal section 12 outside a real seal section 11 located on the periphery of the display area 6 than that of the real seal section 11. The gap unevenness between the large-sized glass substrates 3 and 4 on the periphery of the display area 6 of the liquid crystal panel is suppressed, by suppressing a gap change between the large-sized glass substrates 3 and 4 on the periphery of the display area 6. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a display element having an adhesive layer formed of an adhesive that adheres edges of a pair of substrates to each other.

  Conventionally, when manufacturing a plurality of liquid crystal panels, an adhesive, that is, a seal is applied on one large glass substrate at a position corresponding to each liquid crystal panel and bonded to another large glass substrate. A liquid crystal layer, which is a light modulation layer that forms a display region by sealing a liquid crystal material inward, is formed.

  In such a substrate device, a fiber as a gap holding member may be mixed into the seal so that the height of the seal portion is not pressed below a certain value during bonding. This is because if the seal is extremely pressed, the gap at the end of the display area becomes thin and the peripheral gap becomes uneven in the liquid crystal panel. This prevents the fiber from being pressed extremely.

In addition to the sealing agent, a dummy seal may be drawn in a blank portion for the purpose of enhancing the adhesion of the large-sized glass substrate and securing an air escape path during sealing (for example, patents). Reference 1).
JP 2004-29552 A

  However, the above-described substrate device has a problem that, particularly when the margin portion is small, undulation is generated at the substrate end, and this undulation may cause the gap at the display region end to be thick and uneven the peripheral gap. ing.

  When such a peripheral thickness gap occurs, it can be considered to increase the number of dummy seals and support the undulating recesses, but this method has a problem that the tact time of the seal is extended.

  In particular, in the OCB mode liquid crystal panel, since a small change in the cell gap also appears as display unevenness, the allowable limit of the peripheral gap change amount is smaller than that in the twisted nematic (TN) mode. Therefore, it is necessary to make the peripheral part flat or change as much as possible, and at the same time, it is important to prevent side effects from occurring.

  SUMMARY An advantage of some aspects of the invention is that it provides a method for manufacturing a display element in which gap unevenness between substrates around a display region is suppressed.

  The present invention includes a pair of substrates, a light modulation layer interposed between the pair of substrates and forming a display region at a position corresponding to the display element, and at least a part of the periphery of the light modulation layer. And a bonding layer for holding a gap between the pair of substrates, wherein the bonding layer is disposed on the light modulation layer side. It is formed so that the height on the outside becomes higher.

  Then, an adhesive layer located at least at a part of the periphery of the light modulation layer forming the display region is formed so that the height on the outer side is higher than the light modulation layer side.

  ADVANTAGE OF THE INVENTION According to this invention, the change of the gap between a pair of board | substrates around a display area can be suppressed, and the gap nonuniformity between the boards in the periphery of a display area can be suppressed.

  Hereinafter, an embodiment of the present invention will be described with reference to FIG. 1 and FIG.

  1 and 2, reference numeral 1 denotes a substrate device as a display device substrate device. The substrate device 1 includes a plurality of, for example, rectangular liquid crystal panels (liquid crystal cells) which are liquid crystal display elements as two display elements. 2 is cut out along the cut line L.

  And this board | substrate apparatus 1 has the contact bonding layer 5 which formed the large format glass board | substrates 3 and 4 as a pair of board | substrate at the position corresponding to each liquid crystal panel 2 by the seal | stickers S, such as UV curable resin, as an adhesive agent. A liquid crystal layer 7 as a light modulation layer for forming a display region 6 of the liquid crystal panel 2 is interposed between the large-sized glass substrates 3 and 4 inside the adhesive layer 5.

  The large-sized glass substrate 3 is a transparent substrate as an insulating substrate, and when the liquid crystal panel 2 is cut out, it becomes an array substrate of the liquid crystal panel 2 and is scanned at a position corresponding to each liquid crystal panel 2 (not shown). Various circuit patterns such as lines, signal lines, TFTs as switching elements, pixel electrodes, and alignment films are formed.

  The large-sized glass substrate 4 is a transparent substrate as an insulating substrate, and when the liquid crystal panel 2 is cut out, it becomes a counter substrate which is a color filter (CF) substrate of the liquid crystal panel 2. A color filter, a counter electrode, an alignment film, and the like (not shown) are formed at positions corresponding to.

  The adhesive layer 5 includes a main seal portion 11 which is a main adhesive portion as a first adhesive portion located around the display area 6, and a second adhesive portion which is spaced apart from the main seal portion 11. And a dummy seal portion 12 which is an auxiliary bonding portion. A space 13 in which the cut line L is located is formed between the main seal 11 and the dummy seal 12.

  The seal portion 11 is formed so as to surround substantially the entire circumference of the display area 6 inside the cut line L, intersects the cut line L on one long side of the display area 6, and the liquid crystal A liquid crystal injection port 15 for injecting liquid crystal is partitioned. The liquid crystal injection port 15 is closed by a UV curable resin (not shown) after injecting a liquid crystal material. The seal portion 11 includes a first fiber 16 as a first gap holding member. The diameter of the first fiber 16 is set such that the height from the main surface of the large-sized glass substrate 3 is, for example, about 9 to 17 μm.

  For example, the dummy seal portion 12 is linearly parallel to the main seal portion 11 along the marginal portion on the side of the main seal portion 11 on both short sides of the display area 6. They are arranged with substantially equal width dimensions.

  The dummy seal portion 12 includes a second fiber 18 as a second gap holding member. The diameter of the second fiber 18 is set such that the height from the main surface of the large-sized glass substrate 3 is higher than that of the first fiber 16 of the main seal portion 11, for example, about 20 to 25 μm.

  Further, the dummy seal portion 12 has a width dimension substantially equal to that of the main seal portion 11 and has a larger application amount of the seal S per unit length than the main seal portion 11, and finally the dummy seal portion 12 is provided so that the height dimension is larger than that of the main seal portion 11.

  That is, the adhesive layer 5 is formed so that the height of the outer side of the liquid crystal layer 7 is higher than the display region 6 side.

  The dummy seal portion 12 is located outside the cut line L of each liquid crystal panel 2. Therefore, when the liquid crystal panel 2 is cut out by the cutting line L, the dummy seal portion 12 is configured to remain in the remaining portion of the substrate device 1 where the liquid crystal panel 2 is cut out.

  Next, a method for manufacturing the liquid crystal panel 2 according to the embodiment will be described.

  First, a circuit pattern is formed at a predetermined position on the large-sized glass substrate 3 (circuit pattern forming process), and a seal S is applied corresponding to the position of the circuit pattern (adhesive application process).

  Thereafter, the large-sized glass substrate 4 on which a predetermined pattern is formed is opposed to the large-sized glass substrate 3 coated with the seal S, and is bonded to each other through the seal S and pressed with a predetermined pressure (bonding step).

  At this time, the height dimension (diameter) of the second fiber 18 on the dummy seal portion 12 side is made larger than that of the first fiber 16 on the main seal portion 11 side, that is, outside the liquid crystal layer 7 side of the adhesive layer 5. The gap between the large glass substrates 3 and 4 bonded via the main seal portion 11 and the dummy seal portion 12 (cell gap) is increased from the end portion of the large glass substrates 3 and 4. Since the dummy seal portion 12, the main seal portion 11, and the display region 6 are formed so as to monotonously decrease, the large-size glass substrate 4 is distorted so that there is no sharp change, and the display of the liquid crystal panel 2 is eliminated. The peripheral gap unevenness in the region 6 is improved.

  In particular, when the large glass substrates 3 and 4 have a small margin, the height dimension between the first fiber and the second fiber is substantially reduced because the distance between the main seal portion 11 and the dummy seal portion 12 is short. In the same conventional configuration, the large-sized glass substrate that is curved so that the gap is narrowed toward the large-sized glass substrate between the main seal portion and the dummy seal portion is lifted again by the main seal portion, and the edge of the display area is Therefore, the margin of the large-sized glass substrate 4 is increased by making the height dimension of the dummy seal part 12 larger than the height dimension of the main seal part 11. It is possible to reliably prevent bending at the part.

  In addition, when the liquid crystal layer 7 of the liquid crystal panel 2 is in the OCB mode, a small change in the gap also appears as display unevenness. Therefore, the permissible limit of the peripheral gap change amount is smaller than that in the twisted nematic (TN) mode. Since the peripheral gap unevenness can be suppressed as described above, the substrate device 1 can also be applied to the manufacture of the OCB mode liquid crystal panel 2.

  Furthermore, since the heights of the fibers 16 and 18 included in the adhesive seal S are only changed, they can be manufactured without adding new processes or adding new configurations to the normal LCD panel manufacturing process. And no side effects such as an increase in the manufacturing tact of the liquid crystal panel 2 occur.

  Next, the gap between the large-sized glass substrates 3 and 4 in the example of the substrate device 1 and the comparative example is measured.

  As an example, the height dimension of the second fiber 18 of the dummy seal portion 12 formed in the blank portion in the substrate device 1 that cuts out the 32-inch OCB mode liquid crystal panel 2 is, for example, relative to the first fiber 16. It is assumed that the height is 1.2 to 2.8 times, and as a comparative example, the height dimension of each fiber is substantially equal.

  As a result, as shown in FIG. 3, in the comparative example, the gap value is substantially constant on the center side (point A side in the figure) of the display region 6, and the gap value is near the end (near point B in the figure). On the other hand, in the example, the gap value was substantially constant from the A point side to the B point in the example, and the peripheral gap unevenness did not occur.

  That is, in the example, it is considered that the profile from the end portions of the large-sized glass substrates 3 and 4 to the display region 6 is monotonously decreased, and the peripheral gap unevenness can be improved.

  In the above-described embodiment, any other configuration can be used as long as the height of the dummy seal portion 12 can be larger than the height of the main seal portion 11.

  Further, the adhesive layer 5 is formed by integrally or integrally forming the main seal portion 11 and the dummy seal portion 12 without forming the space portion 13 between the main seal portion 11 and the dummy seal portion 12. It is good.

  Further, the light modulation layer is not limited to the liquid crystal layer 7 and can be applied to various other layers.

It is a longitudinal cross-sectional view which shows the board | substrate apparatus for display elements in one embodiment of this invention. It is an explanatory top view which shows the board | substrate apparatus for display elements same as the above. It is a graph which shows the relationship between the measurement position in the display area periphery of an Example and a comparative example, and a gap.

Explanation of symbols

2 Liquid Crystal Panel as Display Device 3 Large Format Glass Substrate as Substrate 4 Large Format Glass Substrate as Substrate 5 Adhesive Layer 6 Display Area 7 Liquid Crystal Layer as Light Modulation Layer
11 Main seal as first adhesive
12 Dummy seal as second adhesive
16 First fiber as first gap retaining member
18 Second fiber as second gap retaining member S Seal as adhesive

Claims (3)

A pair of substrates, a light modulation layer interposed between the pair of substrates and forming a display region at a position corresponding to the display element, and an edge of the pair of substrates at at least a part of the periphery of the light modulation layer A method of manufacturing a display element, comprising an adhesive layer formed by an adhesive that adheres the parts to each other and holding a gap between the pair of substrates,
The method for manufacturing a display element, wherein the adhesive layer is formed so that the height on the outer side is higher than the light modulation layer side. By forming a first adhesive portion located around the display area, and forming a second adhesive portion having a height higher than the first adhesive portion outside the first adhesive portion, the adhesion The method for manufacturing a display element according to claim 1, wherein a layer is formed. A first gap holding member included in the first adhesive portion;
The method for manufacturing a display element according to claim 2, wherein a second gap holding member having a height dimension larger than that of the first gap holding member is included in the second adhesive portion.

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