KR101192762B1 - Method for Manufacturing Liquid Crystal Display Device - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a liquid crystal display device that can repair point defects found after a polarizer is attached to a liquid crystal panel, and includes a gate line crossing each other on a first substrate to define a pixel region; Forming a thin film transistor array comprising data lines; Forming a color filter array on a second substrate facing the first substrate, the color filter array including a black matrix layer formed corresponding to a region excluding the pixel region and a color filter layer formed corresponding to a region including the pixel region; Forming a liquid crystal panel by forming a liquid crystal layer between the first and second substrates; Forming a first polarizing plate and a second polarizing plate on the rear surfaces of the first substrate and the second substrate, respectively; Detecting a bright spot generating region of the liquid crystal panel; Cutting and separating portions of any one of the first polarizing plate and the second polarizing plate corresponding to the bright spot generating region to expose one of the first substrate and the second substrate; Forming micro holes of a predetermined depth in the exposed substrate; Forming and repairing a light shielding layer covering the bright point in the micro holes; And attaching the cut polarizing plate on the repaired substrate, wherein when the light blocking layer is formed on the first substrate, the light blocking layer is a black pigment, and the light blocking layer is formed on the second substrate. In one embodiment, the light blocking layer is a color filter pattern material having the same color as the color of the color filter layer corresponding to the black pigment or the bright spot generating region.

Point defects, repairs, coloring, micro holes

Description

Method for manufacturing liquid crystal display device

1 is an exploded perspective view showing a general liquid crystal display device

FIG. 2 is a plan view illustrating a bright point defect generated when a foreign material is generated when a foreign material is generated in a black state.

FIG. 3 is a cross-sectional view illustrating a bright spot failing part of FIG. 2 and an adjacent pixel thereof; FIG.

Figure 4 is a photograph showing the weak point light leakage type

5A and 5B are process perspective views illustrating a repair method in the method of manufacturing a liquid crystal display of the present invention.

6A to 6E are cross-sectional views illustrating a method of manufacturing the liquid crystal display of the present invention.

7 is a cross-sectional view illustrating a repairing method of a liquid crystal display according to another exemplary embodiment of the present invention.

8 is a plan view illustrating a region to which a repair method of the liquid crystal display of the present invention is applied.

Description of the Related Art [0002]

100: first substrate 101: TFT array layer

102 first alignment layer 110 first polarizing plate

115: foreign material 120: second polarizing plate

140: polarizing plate cut portion 150: seal pattern

160: liquid crystal layer 200: second substrate

201: black matrix layer 202: color filter layer

203: common electrode 204: second alignment layer

250: micro hole 251: light shielding layer

252: transparent organic film 300: liquid crystal panel

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a liquid crystal display device, and more particularly, to a manufacturing method of a liquid crystal display device capable of repairing point defects found after a polarizing plate is attached to a liquid crystal panel.

(PDP), Electro Luminescent Display (ELD), Vacuum Fluorescent (VFD), and the like have been developed in recent years in response to the demand for display devices. Display) have been studied, and some of them have already been used as display devices in various devices.

Among them, LCD is currently being used most frequently as a substitute for CRT (Cathode Ray Tube) for mobile image display devices because of its excellent image quality, light weight, thinness, and low power consumption. In addition to the mobile use, various developments have been made for televisions and monitors for receiving and displaying broadcast signals.

In order to use such a liquid crystal display as a general screen display device in various parts, it is a matter of how high quality images such as high definition, high brightness and large area can be realized while maintaining the characteristics of light weight, thinness and low power consumption. Can be.

Hereinafter, a liquid crystal display according to the related art will be described with reference to the accompanying drawings.

1 is an exploded perspective view showing a general liquid crystal display.

As shown in FIG. 1, a liquid crystal display device includes a liquid crystal injected between a first substrate 1 and a second substrate 2 bonded to each other with a predetermined space, and between the first substrate 1 and the second substrate 2. It consists of layer (3).

In more detail, the first substrate 1 may have a plurality of gate lines 4 in one direction and constant in a direction perpendicular to the gate lines 4 at regular intervals to define the pixel region P. FIG. A plurality of data lines 5 are arranged at intervals. In addition, a pixel electrode 6 is formed in each pixel region P, and a thin film transistor T is formed at a portion where the gate line 4 and the data line 5 cross each other to form the gate line 4. The data signal of the data line 5 is applied to each pixel electrode 6 according to the signal applied to the?

In addition, a black matrix layer 7 is formed on the second substrate 2 to block light in portions other than the pixel region P, and portions R corresponding to the respective pixel regions are formed to express colors. , G, B color filter layers 8 are formed, and a common electrode 9 for realizing an image is formed on the color filter layers 8.

In the liquid crystal display device as described above, the liquid crystal of the liquid crystal layer 3 formed between the first and second substrates 1 and 2 is aligned by an electric field between the pixel electrode 6 and the common electrode 9, The amount of light passing through the liquid crystal layer 3 may be adjusted according to the degree of alignment of the liquid crystal layer 3 to express an image.

Such a liquid crystal display is called a twisted nematic mode liquid crystal display, and in addition to the TN mode liquid crystal display, an in-plane switching (IPS) liquid crystal display using a horizontal electric field has been developed. In the transverse electric field (IPS) mode liquid crystal display, a pixel electrode and a common electrode are formed parallel to each other at a predetermined distance in a pixel area of the first substrate so that a transverse electric field (horizontal electric field) is generated between the pixel electrode and the common electrode. The liquid crystal layer is aligned by the lateral electric field.

Hereinafter, the causes of bright spots observed in a general liquid crystal display will be described.

FIG. 2 is a plan view illustrating bright spot defects generated when a foreign material is generated when a foreign substance is generated in a black state, and FIG. 3 is a cross-sectional view showing bright spot defects and adjacent pixels of FIG. 2.

As shown in FIG. 2 and FIG. 3, the liquid crystal display device implemented in the TN mode includes the first and second substrates 1 and 2 facing each other and the first substrate 1 as described with reference to FIG. 1. And a common electrode 9 formed on the entire surface of the second substrate 2. In addition, the black matrix layer 7 corresponds to the non-pixel region on the second substrate 2, and the color filter layer 8 corresponds to the pixel region.

When the conductive foreign material 21 remains on a predetermined portion of the pixel electrode 6 of the liquid crystal display of the TN mode formed as described above, the conductive foreign material 21 is formed of the common electrode 9 of the second substrate 2. As a result, the pixel electrode 6 and the common electrode 9 on the first and second substrates 1 and 2 of the corresponding portions are in contact with each other. The conductive foreign material 21 may be particles remaining on the first substrate 1 or the second substrate 2 because residues remaining in the chamber after the process of etching the metal or the transparent electrode may not be removed even after cleaning. Or particles falling into the first substrate 1 or the second substrate 2 during the process, and when the conductive foreign material 21 remains in a portion where the pixel electrode 6 is formed, in particular, the upper and lower portions of the conductive material 21 The conduction of the electrode 9 and the pixel electrode 6 causes a problem that the pixel electrode 6 and the common electrode 9 in which the conductive foreign material 21 remains remain in a short state at all times.

In this case, in the liquid crystal display of the TN mode, which is generally driven in a normally white mode, regardless of whether or not a voltage is applied to the pixel electrode 6, a portion of the pixel electrode 6 is always white. The state is shown, and in particular, the bright point is observed under the condition of the black state to which voltage is applied. In addition, bright spots may occur due to electric short circuits or disconnections.

On the other hand, even when the foreign material 21 is not conductive or the liquid crystal display is not in the TN mode, an alignment layer is formed on the uppermost layer of the first and second substrates 1 and 2 facing each other. Unlike the other parts, the remaining portion of the foreign material 21 during rubbing does not perform an alignment process smoothly, and the foreign material 21 is observed as a light leakage area. In the liquid crystal display, light leakage is generated by such non-uniform alignment regions, and the light leakage appears as bright spots by disturbing the light transmittance of the liquid crystal 3.

In general, when a high gray (white state) is implemented, the dark point is that one region is dark due to light leakage, and when a low gray (black state) is implemented, the bright point is shown by the light leakage. In this case, the human eye is sensitive to bright spots in a relatively dark state rather than dark spots in a bright state, thereby imparting stricter criteria to bright spot defects than dark spots when determining whether the liquid crystal panel is poor. Accordingly, a method for minimizing the defective rate of the panel due to bright spots is required.

If a defect occurs in each of the thin films of the first substrate 1 and the second substrate 2 of the conventional liquid crystal display device, the rework process is performed and the deposition process of the thin film is performed again, or using a laser or the like. Proceed to repair the site.

However, even when the above-described rework process or the repair process is performed, foreign materials 21 may be seated and remain between the first and second substrates 1 and 2, as shown in FIGS. 2 and 3. As described above, in the state in which the first and second substrates are bonded while the foreign material 21 remains, rework is not possible and repair is not easy. For example, even in the case of short circuit or disconnection on a circuit, repair often fails during repair using a laser.

Figure 4 is a photograph showing the weak point light leakage type.

4 is divided into four and four photographs are shown. The left two photographs show the color applied, the right two photographs show the white state, and the enlarged lower photograph on the left and right sides is the upper photograph. Each of these photographs shows a bright point defect caused by the alignment of the liquid crystal in the corresponding region due to the foreign material remaining in the pixel region.

The conventional liquid crystal display as described above has the following problems.

When foreign matter remains between the upper and lower substrates in the liquid crystal panel, the degree of brightness varies due to the foreign matter, depending on the mode. If the foreign material remains on the thin film during the array process of each substrate before the upper and lower substrates are bonded during the manufacturing of the liquid crystal panel, the foreign material may be removed by reworking the thin film or repairing the portion thereof. Can be removed However, when the upper and lower substrates of the liquid crystal panel are bonded while they cannot be removed through such a process or the foreign substances that fall to the substrate side are left in the cleaning process or the process after deposition, there is no solution to the bright spot defect.

The present invention has been made to solve the above problems and to provide a method for manufacturing a liquid crystal display device capable of repairing the point defects found after the polarizer is attached to the liquid crystal panel, an object thereof is have.

According to an aspect of the present invention, there is provided a method of manufacturing a liquid crystal display device, the method including: forming a thin film transistor array including a gate line and a data line intersecting each other on a first substrate to define a pixel area; Forming a color filter array including a black matrix layer formed corresponding to an area excluding the pixel area and a formed color filter layer corresponding to an area including the pixel area, on a second substrate facing the substrate; Forming a liquid crystal panel by forming a liquid crystal layer between the second substrate, forming a first polarizing plate and a second polarizing plate on the back surface of the first substrate and the second substrate, respectively, and detecting a bright spot generating region of the liquid crystal panel. And cutting a portion of one of the first and second polarizing plates corresponding to the bright spot generating region. Separating and exposing any one of the first substrate and the second substrate, forming micro holes having a predetermined depth in the exposed substrate, and forming a light shielding layer covering the bright point in the micro holes to repair And attaching the cut polarizing plate on the repaired substrate, wherein when the light blocking layer is formed on the first substrate, the light blocking layer is a black pigment, and the light blocking layer is formed on the second substrate. When formed in the light blocking layer is a color filter pattern material of the same color as the color of the color filter layer corresponding to the black pigment or the bright spot generation region.

The repairing step may further include forming a transparent organic film on the light blocking layer in the micro holes after the formation of the light blocking layer.

The light blocking layer has a thickness smaller than that of the micro holes.

A cut portion of the polarizing plate passes on the black matrix layer.

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Cutting of the polarizing plate is made using a laser.

The micro holes are formed by removing a predetermined thickness of the substrate under the polarizer cut using one of a micro drill, a milling machine, an ultrasonic machine, and a laser. do.

The forming of the light blocking layer in the micro holes uses a nozzle having a long pipe that enters the bottom of the micro holes.

Hereinafter, a manufacturing method of the liquid crystal display of the present invention will be described in detail with reference to the accompanying drawings.

5A and 5B are process perspective views showing a repair method in the method of manufacturing a liquid crystal display of the present invention.

The liquid crystal display device to which the repair method of the present invention is applied is made as follows.

As shown in FIG. 5A, the liquid crystal display device to which the repair method of the present invention is applied includes a first substrate 100 and a second substrate 200 on which the thin film transistor array and the color filter array are formed to face each other, and the first substrate ( The liquid crystal layer 160 filled between the substrate 100 and the second substrate 200, and the first polarizing plate 110 and the second polarizing plate 120 formed on the back surface of the first substrate 100 and the second substrate 200, respectively. ) Here, the components except for the first and second polarizers 110 and 120 are referred to as the liquid crystal panel 300.

At this time, when the foreign material 115 remains inside the liquid crystal panel 300, particularly when the region where the foreign material remains is a pixel region, the spot where the foreign material 115 is generated is observed as a bright spot in a black state. The defect which becomes is caused.

The repair process performed in the manufacturing method of the liquid crystal display device of the present invention is such that the foreign material 115 is found after attaching the first and second polarizing plates 110 and 120 to the liquid crystal panel 300. This has the advantage of repairing it.

As shown in FIG. 5B, in the repair process performed in the method of manufacturing the liquid crystal display device of the present invention, a portion of the second polarizing plate 120 corresponding to a portion including the foreign material 115 is irradiated with a laser to emit the second polarizing plate ( A predetermined size of 120 is cut and separated from the second substrate 200. In this case, the cut portion 140 of the second polarizing plate 120 is a boundary line of the separated second polarizing plate and passes over the black matrix layer 201 formed inside the second substrate 200. As such, the reason for placing the cut portion 140 of the second polarizing plate 120 on the black matrix layer 201 is that, when the cut polarizing plate is subsequently attached to the upper portion of the substrate after the repair process, This is to prevent the cutting site from being visually observed.

The illustrated figure shows an example of performing a repair process on the second substrate 200. In some cases, the first polarizing plate 110 formed on the rear surface of the first substrate 100 is cut after foreign objects are found. In some embodiments, a micro hole for repair may be formed on the first substrate 100 (see FIG. 7).

Reference numeral 202 not described in FIG. 5 denotes a color filter layer 202 formed on the pixel region.

6A to 6E are cross-sectional views illustrating a method of manufacturing the liquid crystal display of the present invention.

First, as shown in FIG. 6A, the first substrate 100 (first substrate) on which the thin film transistor array is formed, the second substrate 110 (second substrate) on which the color filter array is formed, and the first substrate, respectively, are formed. The liquid crystal panel including the liquid crystal layer 130 filled between the second substrates 100 and 110 is prepared. Here, the components constituting the thin film transistor array and the color filter array in the liquid crystal panel may vary depending on whether an implementation mode of the liquid crystal display device is a TN mode or an IPS mode, and the drawings will be described based on the TN mode. .

The liquid crystal panel of the present invention includes a first substrate 100 and a second substrate 200 opposed to each other, a TFT array layer 101 defining pixel regions at predetermined portions on the first substrate 100, and A black matrix layer 201 formed in a region other than the pixel region on the second substrate 200, a color filter layer 202 having a color filter representing a predetermined color corresponding to the pixel region, and the black matrix layer ( 201) and a common electrode 203 formed on the front surface including the color filter layer 202, and the liquid crystal layer 160 filled between the first substrate 100 and the second substrate 200. Here, the first alignment layer 102 and the second alignment layer 204 are formed on the innermost uppermost surface of the first substrate 100 on which the thin film transistor array is formed and the second substrate 200 on which the color filter array is formed. In addition, a seal pattern 150 is formed in an outer region of the first and second substrates 100 and 200 to support and protect the liquid crystal layer between the first and second substrates 100 and 200 so as to protect the first and second liquid crystal layers. The second substrates 100 and 200 are bonded to each other.

Here, the TFT array layer 101 formed on the first substrate 100 crosses each other and defines a gate line (not shown) and a data line (not shown) that define a pixel region, and the gate line and the data line. A thin film transistor formed at an intersection and a pixel electrode (not shown) formed in the pixel area.

In this case, since the color filter layer 202 is formed to correspond to at least a pixel region (a region defined as an intersection of the gate line and the data line), the color filter layer 202 may be partially overlapped with the black matrix layer 201 in some cases. It may be formed by completely overlapping the black matrix layer 201.

Subsequently, a first polarizing plate 110 and a second polarizing plate 120 are formed on the rear surfaces of the first and second substrates 100 and 200, respectively.

Subsequently, a voltage signal is applied to the pixel electrode (not shown) and the common electrode 203 of the liquid crystal panel 300, respectively, so that the black state (in this case, the liquid crystal panel is in a normally white mode and a black state when voltage is applied). ), The site where the bright spots caused by the foreign matter 115 in the liquid crystal panel 300 is inspected.

At this time, when the bright spot is observed, the predetermined region on the second polarizing plate 120 is irradiated with a laser on the polarizing plate of the portion including the region where the bright spot is generated, and the predetermined portion is cut. Here, as shown in FIG. 6A, after the second polarizing plate is cut by the laser, the second polarizing plate is cut and divided into the separated polarizing plate 120b and the remaining polarizing plate 120a. Here, the first and second polarizing plates 110 and 120 have a structure in which the vertical cross-sectional structure of the transparent film is protected above and below an optical layer having an optical function, and an adhesive layer is further formed on the surface on which the substrate is bonded. It is. Therefore, when the polarizing plate is cut and separated by the laser, the separation is performed with the adhesive layer as a boundary.

In the repairing method of the liquid crystal display of the present invention, first, as shown in FIG. 5B, a portion of the second polarizing plate 120 in the region including the foreign material 115 is defined as a separation site, and then separated on the second polarizing plate 120. A laser is applied so that the boundary of the portion becomes the cut portion 140, and a portion of the second polarizing plate 120b in the region including the foreign material 115 is separated from the upper portion of the second substrate 200. Here, the size of the separated second polarizing plate 120b is equal to or larger than the size of at least one pixel area and may correspond to one or more pixel areas. That is, since the cut portion 140 of the second polarizing plate 120b passes over an upper portion of the black matrix layer 201 formed on the second substrate 200, a region defined between the black matrix layers 201 is defined. The pixel region may have a size greater than or equal to an integer multiple of the pixel region.

As shown in FIG. 6B, the micro hole having a predetermined depth has a horizontal cross section of a size sufficient to cover the foreign material 115 from the back surface of the second substrate 200 where the second polarizing plate 120b is removed and exposed. 250).

The micro holes 250 may be formed to have a size corresponding to a predetermined pixel area in which the foreign material 115 remains, or may be formed to be a partial size of the pixel area corresponding to only a portion where the foreign material 115 is generated. Could be. In this case, the micro holes 250 may be located inside the cut portion 140 of the second polarizing plate 120.

The site where the foreign material 115 is generated is a site observed as a bright spot in the inspection process of inspecting the bright spot of the liquid crystal panel by applying a voltage to a black state, and the following repair process is performed on the foreign spot 115 generating site. Proceeds.

The micro holes 250 generate a bright spot caused by the foreign material 115 by using a micro drill 350 at a portion corresponding to the foreign material 115 from the back side of the second substrate 200. It is formed by drilling a width and a predetermined depth to include the site.

Such a micro hole 250 uses the above-described micro drill 350 or, in addition, a milling machine (not shown), or a laser (not shown) or an ultrasonic machine (not shown). It can be formed by drilling a predetermined depth from the back surface of the second substrate 200 using a si). In this case, the shape of the micro holes 250 is a micro-drilling, the direction of movement of the micro drill in the vertical direction, after the micro drilling (micro drilling), the cross-sectional shape of the micro holes is When the milling machine is used, the direction of movement of the milling can be up, down, left and right, and the cross-sectional shape of the hole can be arbitrarily designated. In addition, in the case of using a laser or an ultrasonic device, the thickness and shape will be determined according to the irradiation or projection area and intensity. When the thickness of the first substrate 100 and the second substrate 200 is 0.5 to 0.7mm, the thickness of the micro holes 250 is about half or about the thickness of the second substrate 200. For example, the thickness of the second substrate 200 remaining at the side of the micro hole 250 may be about 0.05 mm to 0.2 mm. In this case, when the backlight unit (not shown) is positioned at the lower side of the first substrate 100, the micro holes 250 may adjust the thickness and width in consideration of the amount of light that is emitted to the side of the first substrate 100. Form.

As illustrated in FIG. 6C, a foreign object (not shown) inside the micro hole 250 is used in the micro hole 250 by using a first nozzle (not shown) in which a tube descends into the micro hole 250. The foreign material 115 fills the generated black pigment to a thickness sufficient to cover the bright spot generated by the 115. In this case, the black pigment is a liquid, and cured through a predetermined curing process to form the light shielding layer 251. At this time, the curing proceeds differently depending on the nature of the black pigment component. For example, when the black pigment is a photocurable material, the black pigment forming part is irradiated and cured by using a UV (Ultra Violet) lamp, and when the black pigment is a thermosetting material, the black pigment The site is heated to cure. This curing process is to prevent the fall of the appropriate bright point blocking efficiency when the black pigment remains in the liquid phase, the material filled in the micro-holes 250, such as inversion or movement, fall out, or mixed with the transparent organic material formed subsequently For sake.

Here, when the black pigment is filled in the micro holes 250, bubbles or cavities are generated from the bottom of the micro holes 250 by using a first nozzle that descends to the micro holes 250. Without the bright point formed by the foreign material 115 is formed to a thickness enough to be shielded.

As such, when the tube of the first nozzle comes near the bottom of the micro hole 250, in particular, when the transparent organic material is filled on the light blocking layer 251 where the black pigment in the micro hole 250 is cured. (See FIG. 6D), the black pigment does not remain on the wall inside the micro hole 250 in which the transparent organic material layer is filled, so that transmitted light passing through the transparent material layer and passing through the side surface is transmitted to the upper part without loss. Could be.

On the other hand, the formation of the light blocking layer 251 on the bottom of the micro hole 250, replacing the first nozzle, dotting directly into the micro hole 250 using an ink-jet equipment It can also be shaped in the way that it is. Alternatively, the light blocking layer 251 may be formed by filling a black pigment in the bottom of the micro hole 250 using a spray, or spraying the black pigment at the inlet of the micro hole 250 using a spray or a nozzle. Cover the periphery of the substrate including the micro holes 250 with a vacuum cap (not shown) to cause the black pigment to descend to the bottom of the micro holes 250 due to the pressure difference generated in the micro holes 250. Can be.

As shown in FIG. 6D, the light blocking layer inside the micro holes 250 may be formed by using a second nozzle (not shown) that enters a tube into the micro holes 250. The transparent organic material is filled in the remaining area where the 251 is not formed, and then cured to form the transparent organic film 252. In this case, the transparent organic material is a liquid material, a material having photocurability or a material having thermal curability. In this case, the tube of the second nozzle does not need to enter the bottom of the micro hole 250 as compared with the first nozzle, and as long as it corresponds to the inside of the micro hole 250, the tube of the second nozzle may be closed. Ride appropriately transparent organic material will flow to fill the interior of the micro holes 250. In this case, when filling the transparent organic material, the speed and amount are appropriately adjusted so that the transparent organic material may fill the remaining portions except for the light blocking layer 251 without generation of bubbles or cavities.

Subsequently, after the injection of the transparent organic material is completed in the micro holes 250, the tube of the second nozzle is removed from the micro holes 250.

Meanwhile, as described above, the formation of the transparent organic material in the micro holes 250 replaces the second nozzle 180 and directly in the micro holes 250 using ink-jet equipment. It may also be formed in a dotting manner.

As such, after the transparent organic material is filled in the micro holes 250, the transparent organic material is formed into the transparent organic layer 252 through a curing process. As described above, the curing process may be thermally cured or photocured according to the properties of the transparent organic material.

The thickness of the transparent organic film 252 is different depending on how thick the light blocking layer 251 is formed in the micro hole 250. That is, since the transparent organic film 252 is formed to fill a portion where the light blocking layer 251 is not formed in the thickness of the micro hole 250, all of the light blocking layers 251 in the micro holes 250 are formed. If filled, it may not be formed.

As shown in FIG. 6E, the second polarizing plate 120b separated on the micro holes 250, in which the light blocking layer 251 and the transparent organic layer 252 are sequentially formed, is attached again. In this case, since the cut portion of the polarizing plate passes along the line of the black matrix 201, even if the cut polarizing plate 120b is attached again, the cut and attach portions are not visually observed.

The manufacturing method of the liquid crystal display device of this invention mentioned above demonstrated the repair process performed on a 2nd board | substrate.

7 is a cross-sectional view illustrating a repairing method of a liquid crystal display according to another exemplary embodiment of the present invention.

As illustrated in FIG. 7, the manufacturing method of the liquid crystal display according to the exemplary embodiment of the present invention shows a process in which the repair process is performed on the first substrate 100 and the first polarizing plate 210 which are lower substrates. Except for this point, other points are the same as the repair method of the liquid crystal display device described on the basis of Figs. 5A to 6E.

That is, the manufacturing method of the liquid crystal display according to another exemplary embodiment of the present invention corresponds to a region where the foreign material 115 is generated, and cuts a predetermined portion 210b of the first polarizing plate 210 including the foreign material 115. Thereafter, the exposed first substrate 100 forms the micro holes 250 on the back thereof to perform repair. In this case, the repair is performed by inverting the liquid crystal panel so that the first substrate 100 is positioned above, and the light blocking layer 251 of the black pigment component is formed on the bottom of the micro hole 250. The transparent organic film 252 is formed thereon.

Reference numeral 210a, which is not described herein, refers to a first polarizing plate that remains uncut.

8 is a plan view illustrating a region to which a repair method of the liquid crystal display of the present invention is applied.

As illustrated in FIG. 8, in the manufacturing method of the liquid crystal display of the present invention, when the repaired portion is examined in the region on the second substrate 200, a predetermined foreign material may be generated in the pixel region where the color filter layer 202 is formed. At this time, the cutting of the polarizing plate using a laser is made on the black matrix layer 201 including the predetermined pixel region where the foreign matter is generated, which is impossible to observe with the naked eye even after laser irradiation, so that the repair can proceed without deterioration of vision. .

Meanwhile, a color filter having the same color as that of the color filter layer 202 formed in the pixel area of the portion where the foreign matter 115 is generated is replaced with the light blocking layer 251 inside the micro hole 250. A pattern layer can also be formed. In this case, when the low gray (black state) is realized, the light transmitted from the lower portion is blocked by the thickness of the color filter pattern layer, and the portion corresponding to the foreign material 115 is dark, and the high gray (white state) is realized. In this case, it is observed by the color of the color filter layer of the corresponding pixel region, and compared with the method of simply repairing the corresponding portion of the foreign material 115 by using a black pigment, the perception of visibility of the water portion may be reduced. For example, if only the black pigment is filled into the micro holes 250, the bright spots of foreign matters may be blocked in the black state, but in the white state, the micro holes 250 may be blocked due to the black pigment therein. It may be observed as a black dot, the liquid crystal display device of the present invention including a color filter pattern layer can be expected to have an effect of obtaining a significant improvement in contrast.

As such, when the liquid crystal display device of the present invention fills the bottom of the microhole with the color of the color filter layer of the pixel in which the foreign matter is generated, the pixel region normally blocks light in the black state and normal driving in the white state. A similar effect can be obtained, and the bright point defect caused by foreign matter can be eliminated.

The manufacturing method of the liquid crystal display of the present invention described above will be applicable not only to the twisted nematic (TN) mode but also to the in-plane switching (IPS) mode. In this case, the common electrode and the pixel electrode are alternately formed in the pixel region of the TFT array layer on the first substrate 100, and the overcoat layer is replaced with the common electrode 203 on the second substrate 200. Will be formed.

The manufacturing method of the liquid crystal display device of the present invention described above is capable of repairing a bright spot defect found after attaching a polarizing plate to a liquid crystal panel, so that the bright spot defect can be repaired in a module state, and thus the yield of liquid crystal display device production is improved. To improve.

The manufacturing method of the liquid crystal display device of the present invention as described above has the following effects.

In the repair of the liquid crystal display device, even if a bright spot due to a foreign material is found after the polarizing plate is attached on the liquid crystal panel, the repair is possible. The polarizing plate on the upper side of the foreign material generating portion is cut by a laser. The micro hole is formed in the substrate under the cut polarizing plate, and a light shielding layer is formed in the micro hole to prevent bright spots.

After such repair, attaching the cut polarizer to the upper part of the micro-hole again, so that the laser cut portion at the time of repair is limited to the upper part of the black matrix layer. It is possible to repair without damaging the display to an unrecognizable degree.

Therefore, it is possible to improve the yield of the product by improving the bright point defects.

Claims (12)

Forming a thin film transistor array on the first substrate, the thin film transistor array including a gate line and a data line crossing each other to define a pixel region; Forming a color filter array on a second substrate facing the first substrate, the color filter array including a black matrix layer formed corresponding to a region excluding the pixel region and a color filter layer formed corresponding to a region including the pixel region; Forming a liquid crystal panel by forming a liquid crystal layer between the first and second substrates; Forming a first polarizing plate and a second polarizing plate on the rear surfaces of the first substrate and the second substrate, respectively; Detecting a bright spot generating region of the liquid crystal panel; Cutting and separating portions of any one of the first polarizing plate and the second polarizing plate corresponding to the bright spot generating region to expose one of the first substrate and the second substrate; Forming micro holes of a predetermined depth in the exposed substrate; Forming and repairing a light shielding layer covering the bright point in the micro holes; And Attaching the cut polarizer to the repaired substrate, When the light shielding layer is formed on the first substrate, the light shielding layer is a black pigment, and when the light shielding layer is formed on the second substrate, the light shielding layer is the black pigment or the color corresponding to the bright spot generation region. It is a color filter pattern material of the same color as the color of a filter layer, The manufacturing method of the liquid crystal display device characterized by the above-mentioned. The method of claim 1, The repairing method may further include forming a transparent organic layer on the light blocking layer in the micro holes after the formation of the light blocking layer. 3. The method of claim 2, The light shielding layer is a thickness smaller than the thickness of the micro holes, the manufacturing method of the liquid crystal display device. delete delete delete delete The method of claim 1, A cut portion of the polarizing plate passes on the black matrix layer. delete The method of claim 1, The said polarizing plate is cut | disconnected using a laser, The manufacturing method of the liquid crystal display device characterized by the above-mentioned. The method of claim 1, The micro holes are formed by removing a predetermined thickness of the substrate under the polarizer cut using one of a micro drill, a milling machine, an ultrasonic machine, and a laser. The manufacturing method of the liquid crystal display device characterized by the above-mentioned. The method of claim 1, The forming of the light blocking layer in the micro holes may include a nozzle having an elongated tube entering the bottom of the micro hole.

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