JP2001188235A - Manufacturing method of liquid crystal device, liquid crystal device and electronic equipment - Google Patents

Abstract

(57) [Problem] To provide a method of manufacturing a liquid crystal display device with excellent display quality and a liquid crystal display device by controlling the position and the number of spacers to be scattered. SOLUTION: Water, Freon, isopropyl alcohol,
A spacer dispersion solution in which the spacers 15 are uniformly dispersed at a predetermined concentration by ultrasonic waves or the like is sprayed on the substrate 11 in a single solvent selected from ethanol or the like or a mixed solvent of two or more kinds. At this time, a predetermined amount of the spacer-dispersed solution is sprayed on a predetermined position on the substrate 11 by an ink-jet method using an ink-jet nozzle 30 that can arbitrarily set a discharge position and a discharge frequency of the discharged droplet. Then, the spacers 15 are sprinkled over a predetermined area at a uniform spray density by disposing a predetermined number of spacers 15 at predetermined positions on the substrate 11 by naturally evaporating the solvent of the spacer dispersion solution.

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 liquid crystal device, a liquid crystal device manufactured by the manufacturing method, and an electronic apparatus having the liquid crystal device, and more particularly to a technique of dispersing spacers on a substrate. is there.

[0002]

2. Description of the Related Art FIG. 9 is a schematic sectional view of a general liquid crystal display device 100 for color display of a simple matrix type, and its structure will be described.

As shown in FIG. 9, a substrate 101 (lower substrate) and an opposing substrate (upper substrate) 102 are adhered at predetermined intervals at a peripheral portion of each substrate via a sealant 104. The liquid crystal layer 103 between the opposing substrates 102
Is enclosed. On the substrate 101, a color filter layer 108 composed of a red (R), green (G), and blue (B) coloring layer 108a and a light-shielding layer (black matrix) 108b and a protective layer 109 are sequentially formed. A transparent electrode 110 is formed in a stripe shape on the upper side, and a transparent electrode 111 is formed in a stripe shape on the counter substrate 102. Alignment film 11 on transparent electrodes 110 and 111
2, 113 are formed.

In the liquid crystal display device 100, the alignment film 11
A large number of spherical spacers 105 made of silicon dioxide, polystyrene or the like are arranged between the substrates 2 and 113 in order to make the distance between the substrate 101 and the counter substrate 102 (substrate distance) uniform.

Conventionally, as a method of spraying the spacer 105 on the substrate 101 on which the transparent electrode 110, the alignment film 112, etc. are formed, a spacer dispersion solution in which the spacer 105 is dispersed in a solvent such as water, chlorofluorocarbon, isopropyl alcohol and ethanol is used. And spraying by spraying with the pressure of a gas such as nitrogen or the like, and supplying the spacer 105 with a carrier gas such as air or nitrogen, and during the supply, the spacer 105 is charged naturally or artificially. A dry spraying method in which a spacer 105 is attached to the substrate 101 using electrostatic force is generally known.

FIGS. 10 (a) and 10 (b) show a spraying apparatus 200A of a wet spraying method and a spraying apparatus 200 of a dry spraying method, respectively.
B is a schematic sectional view, and the structure of these spraying devices and the method of spraying the spacers 105 will be briefly described. FIG.
10A and 10B, the same components are denoted by the same reference numerals.

A spraying stage 201 made of stainless steel or the like is installed inside the spraying devices 200A and 200B.
On the dispersion stage 201, the transparent electrode 110 and the alignment film 11
The substrate 101 on which 2 and the like are formed is installed. Spraying device 2
A spray device 202 and a nozzle 203 are installed at the top of 00A and 200B.

In the spraying apparatus 200A of the wet spraying method, a spacer supply pipe 204A and a compressed gas supply pipe 205 are connected to a spraying apparatus 202. In the spraying apparatus 200B of the dry spraying method, a spacer supply pipe 204B is connected to the spraying apparatus 202.

In the wet spraying method, as shown in FIG. 10A, the spacer 1 is supplied from the spacer supply pipe 204A.
05 is dispersed in a solvent such as water, chlorofluorocarbon, isopropyl alcohol, or ethanol.
Compressed gas such as air and nitrogen is supplied to the spraying device 202 from the compressed gas supply pipe 205. The spacer 105 supplied to the spray device 202 is the nozzle 2
03, spouted with solvent and gas, dropped freely,
Sprayed on the substrate 101.

In the dry spraying method, as shown in FIG. 10B, the spacer 105 is sprayed from the spacer supply pipe 204B by using the air or nitrogen or the like as a carrier gas.
Supplied to At this time, the spacer 105 is charged naturally or artificially. The spacer 105 supplied to the spray device 202 is ejected from the nozzle 203 together with the carrier gas, falls freely, and is sprayed on the substrate 101. At this time, since the spacer 105 is charged, it can adhere to the substrate 101 by the electrostatic force.

[0011]

SUMMARY OF THE INVENTION Conventional spacer 10
In the wet spraying method and the dry spraying method which are the spraying methods of No. 5, since the spraying is performed by freely dropping the spacer 105 on the substrate 101, there is a problem that the position where the spacer 105 is sprayed cannot be controlled. .
Therefore, the following problems occur.

In the above-mentioned general liquid crystal display device 100, there is a problem that the distribution density of the spacers 105 becomes non-uniform due to the partial aggregation of the spacers 105 and the distribution of the intervals between the substrates occurs. The problem when a distribution occurs in the substrate spacing will be described later.

In addition, since the liquid crystal layer 103 is not formed where the spacers 105 are scattered, the liquid crystal layer 103 cannot be displayed in black, and there is a problem that light leaks therefrom and the contrast is reduced. This problem is especially
Of the colored layers 108a of the color filter layer 108, this is noticeable when the spacers 105 are scattered in the range of the green (G) colored layer 108a.

Since the color filter layer 108, the transparent electrode 110, and the like are formed on the substrate 101, a step is formed on the surface of the substrate 101, and a high part and a low part are formed at the boundary of the step. is there. Spacer 105 is used for substrate 1
01, there is a problem that a distribution is generated in the substrate interval when it is sprayed on both the high part and the low part of the surface. The problem when a distribution occurs in the substrate spacing will be described later.

Here, an example will be described in which a step is formed on the surface of the lower substrate and a distribution occurs between the substrates.

FIG. 11 shows an example in which a step is formed on the surface of a substrate 101 in a simple matrix type liquid crystal display device 300 for color display. 11, the same components as those of the liquid crystal display device 100 are denoted by the same reference numerals,
Description is omitted.

In the liquid crystal display device 300, the display area is 150 and the non-display area is 151. Normally, sealing material 1
The non-display area 151 is 1 to 2 mm from the inside of the area 04, and the display area 150 is inside the area. Liquid crystal display 3
00, the color filter layer 108 and the protective layer 10
9, transparent electrodes 110 and 111, alignment films 112 and 113
Are formed only in the display area 150 and the non-display area 151
Is not formed.

In the liquid crystal display device 300, the color filter layer 108, the protective layer 109, the transparent electrodes 110,
11. Since the alignment films 112 and 113 are formed only in the display region 150 and not in the non-display region 151, a step is formed on the surface of the substrate 101 at the boundary between the display region 150 and the non-display region 151. Is done. That is, the surface of the substrate 101 in the display region 150 is formed at a position higher than the surface of the substrate 101 in the non-display region 151.

For example, the height of the step formed on the surface of the substrate 101 (from the color filter layer 108 to the alignment film 112)
The thickness (cell thickness) of the liquid crystal layer 103 in the display area 150 and the diameter of the spacer 105 are 5 [μm], and the distance between the substrate 101 and the opposing substrate 102 (substrate distance) is 7 [μm]. ８8 [μm].

At this time, since the thickness (cell thickness) of the liquid crystal layer 103 in the non-display area 151 is the same as the substrate interval, it is 7 to 8 [μm]. However, in the non-display area 151, the cell thickness is 7 to 8 [μm].
[μm] spacers 105 are scattered,
[μm] cannot be maintained, and the distance between the substrate 101 and the opposing substrate 102 (substrate distance) is reduced.
01, as a result of distortion of the opposite substrate 102, the display region 1
At a distance of 50 substrates, a distribution occurs in which the peripheral portion is narrow and the central portion is wide.

Next, a step is formed on the surface of the lower substrate,
Another example in which distribution occurs in the substrate interval will be described.

External light such as sunlight or illumination light is used without a built-in light source, and external light incident from the outside of the liquid crystal display device (observer side) is reflected by a reflective layer provided inside the liquid crystal display device. 2. Description of the Related Art A reflective liquid crystal display device that is reflected and emitted to the outside of the liquid crystal display device (to the observer) is known. In the reflection type liquid crystal display device, by forming a number of fine irregularities on the surface of the reflection layer, and reflecting and scattering light,
2. Description of the Related Art An internal scattering type reflection type liquid crystal display device capable of obtaining a bright display has been known.

FIG. 12 is a schematic sectional view of a reflection type liquid crystal display device 400 of the internal scattering system. 12, the same components as those of the liquid crystal display device 100 are denoted by the same reference numerals, and description thereof will be omitted.

Internal reflection type reflection type liquid crystal display device 400
In (2), a large number of fine irregularities are formed on the surface of a substrate (lower substrate) 401, and a metal such as aluminum is sputtered on the substrate 401 along the minute irregularities to form a reflection having a large number of minute irregularities. A layer 406 is formed.

An insulating layer 407 is formed on the reflective layer 406, and a color filter layer 108, a transparent electrode 110 and the like are formed on the insulating layer 407 as in the liquid crystal display device 100.

When the substrate 401 is a glass substrate,
Fine irregularities on the surface of the substrate 401 are formed by a frost process or the like in which the surface of the glass substrate is unevenly etched with a hydrofluoric acid solution or the like. In the case where the substrate 401 is not limited to a glass substrate but is a general substrate, fine irregularities on the surface of the substrate 401 are formed by sandblasting or the like which makes the surface uneven by spraying fine particles on the surface of the substrate.

In the liquid crystal display device 400, the substrate 401
Fine irregularities formed on the surface are formed only in the display region 150. On the other hand, the reflective layer 406, the insulating layer 407, the color filter layer 108, the protective layer 109, and the transparent electrode 11
0 and 111 and the alignment films 112 and 113 are formed not only in the display region 150 but also in the non-display region 151.

Fine irregularities on the surface of the substrate 401 are formed by frost processing or sandblasting. In any of the processing, fine irregularities are formed by shaving the original substrate 401 surface. Therefore, on the surface of the substrate 401, a boundary between a portion where fine unevenness is formed and a flat portion where no fine unevenness is formed, ie, the display region 150 and the non-display
At the boundary of No. 1, a step is formed as shown in FIG.
This step is about 1 [μm]. Also, the substrate 40
When a step is formed on one surface, a step is also formed on the reflection layer 406, the color filter layer 108, the alignment film 112, and the like formed thereon.

As a result, the substrate 4 in the display area 150
01 is formed at a position lower than the surface of the substrate 401 in the non-display area 151.

For example, the liquid crystal layer 1 in the display area 150
In the case where the thickness (cell thickness) of No. 03 is set to 5 [μm], in order to make the cell thickness uniform, a spacer 1 of 5 [μm] is used.
When 05 is scattered, the spacers 105 scattered in the non-display area 151 are scattered at a position higher than the display area 150 by about 1 [μm] of the height of the step. As a result, the thickness (cell thickness) of the liquid crystal layer 103 in the display area 150 is 6
[μm], which is larger than the set cell thickness of 5 [μm], the display as designed is not performed.

Further, in the display area 150, 6 μm
[μm] spacer 10 at a cell thickness of about [m].
5 is scattered, the cell thickness of about 6 [μm] cannot be maintained, the distance between the substrate 101 and the opposing substrate 102 (substrate distance) is reduced, and the substrate 101 and the opposing substrate 102 are distorted. Then, a distribution occurs in the substrate interval.

Here, a description will be given of a problem when distribution occurs in the substrate interval. When a distribution occurs in the substrate interval, a distribution also occurs in the thickness (cell thickness) of the liquid crystal layer sandwiched therebetween. It is known that when the cell thickness is distributed in the display area, the display performance of the liquid crystal display device is deteriorated.

In particular, in a liquid crystal display device of STN (Super Twisted Nematic) mode, the value of Δn · d (however, Δn
Is the birefringence of the liquid crystal, d is the cell thickness), and it is known that the light transmittance changes.
That is, when the distribution of the cell thickness d is large, a distribution occurs in the light transmittance, that is, the brightness, so that the contrast is reduced.
If the change in the value of Δn · d, that is, the distribution of the cell thickness d is large, in the STN mode, the phase difference plate eliminates the unique yellow or blue coloring and compensates for black and white. The characteristics are deteriorated, and the display becomes uneven in color. Also, if the cell thickness d has a distribution, the sharpness of the liquid crystal deteriorates, and the contrast decreases. When the distribution of the cell thickness d occurs as described above, the contrast deteriorates, and color unevenness occurs in the display, which causes a problem that the display quality deteriorates.

Therefore, the present invention solves the above problems,
It is an object of the present invention to provide a method of manufacturing a liquid crystal device that enables uniform spacing between substrates by controlling a position where spacers are sprayed. Another object of the present invention is to provide a method of manufacturing a liquid crystal display device in which spacers are not scattered in a region where a green (G) colored layer is formed by controlling positions where the spacers are scattered.

It is another object of the present invention to provide a liquid crystal display device having excellent display quality and an electronic device provided with the liquid crystal display device by these manufacturing methods.

[0036]

In order to solve the above-mentioned problems, the present invention has been made to solve the above-mentioned problem by providing a large number of spacers for forming a predetermined space between two substrates sandwiching a liquid crystal layer on one substrate. When spraying on, a spacer dispersion solution obtained by dispersing the spacer in a predetermined solvent, by an ink-jet method, by spraying only a predetermined area including a pixel area on the substrate, by evaporating the solvent, It is characterized in that spacers are sprayed.

According to this means, the position and the number of the spacers to be scattered on the substrate are performed by spraying the spacers by an ink-jet method using an ink-jet nozzle capable of arbitrarily setting the discharge position and the number of times of the discharged droplets. Can be provided.

Further, according to this manufacturing method, in a liquid crystal device in which a spacer for forming a predetermined interval between two substrates sandwiching a liquid crystal layer is disposed, the spacer includes a pixel region on the entire surface of the substrate. A liquid crystal device characterized by being arranged at a uniform density only in the region of. In this liquid crystal device, since the spacers are arranged in a predetermined area at a uniform density, the liquid crystal device has excellent display quality in which the distance between the substrates is uniform.

In the case where a plurality of different colored layers for color display are provided on one of the two substrates, the predetermined region is formed of a predetermined color of the colored layers. It is a region where a layer is formed. It is preferable that the colored layer of the predetermined color is a red and blue colored layer.

In this case, since no spacer is scattered in the region where the green coloring layer is formed, light leakage can be prevented, and a method of manufacturing a liquid crystal device with good contrast and excellent display quality can be provided. Can be provided.

When a recess is formed on the surface of one of the two substrates, the predetermined region is a region where the recess is formed.

In this case, the portion where the concave portion is formed on the substrate surface is located lower than the portion of the flat region where the concave portion is not formed, but the spacer is sprayed only on the portion where the concave portion is formed. By doing so, the distance between the substrates can be made uniform, and a method for manufacturing a liquid crystal device having excellent display quality and a liquid crystal device can be provided.

When a step is formed on the surface of one of the two substrates, the height is small in the high part and the large in the low part according to the height on the one substrate. The method is characterized in that the spacers having different diameters are dispersed.

In this case, according to the height of the substrate, spacers having different diameters, which are small in the high part on the substrate and large in the low part, can be used to make the distance between the substrates uniform. In addition, a method for manufacturing a liquid crystal device having excellent display quality and a liquid crystal device can be provided.

In the above means, it is preferable that the surface of the spacer is coated with a thermoplastic resin. By using a spacer coated with a thermoplastic resin as a spacer,
Warm the spacers spread on the substrate, melt the thermoplastic resin coated on the surface, lower it to room temperature again, and solidify the thermoplastic resin, fixing the spacers spread in place on the substrate can do.

Further, by providing the liquid crystal device provided by the above means, it is possible to provide an electronic device having excellent display quality.

[0047]

Next, an embodiment according to the present invention will be described in detail.

First Embodiment FIG. 1 is a process diagram showing a method of manufacturing a liquid crystal display device 1 for a simple matrix type color display according to a first embodiment of the present invention. The manufacturing method and structure of this liquid crystal display device are shown. Will be described.

As shown in FIG. 1A, a color filter layer 18 composed of a colored layer 18a and a light-shielding layer (black matrix) 18b is formed on a substrate (lower substrate) 11 made of glass or the like. A protective layer 19 to be protected is sequentially formed, a transparent electrode 20 is formed in a stripe on the protective layer 19, and an alignment film 22 is formed on the transparent electrode 20.

The coloring layer 18a is formed by a coloring material method, a dyeing method, a transfer method, a printing method, or the like. For example, three colors of red (R), green (G), and blue (B) are arranged in a predetermined pattern. are doing. The light-shielding layer (black matrix) 18b is formed at a portion where the colored layer 18a is not formed, and is made of a metal such as chromium, a color resist in which a black pigment is dispersed, or the like.

Next, as shown in FIG.
A large number of spherical spacers 15 made of silicon dioxide, polystyrene, or the like for uniforming the distance between the substrates are scattered thereon. At this time, the spacers 15 are sprayed by using an inkjet nozzle 30 as shown in FIGS. The diameter of the spacer 15 is the same as that of the liquid crystal display device 1.
The thickness is set in accordance with the thickness (cell thickness) of the liquid crystal layer 13 to be sealed, and is selected, for example, from the range of 2 to 10 [μm]. The details of the method of spraying the spacer 15 will be described later.

Next, as shown in FIG.
And an opposing substrate (upper substrate) 12 on which a transparent electrode 21 is formed in a stripe shape on the surface and an alignment film 23 is formed on the transparent electrode 21 via a sealing material 14 such that the alignment films 22 and 23 face each other. The liquid crystal layer 13 is sealed between the substrate 11 and the counter substrate 12. Finally, although omitted in the figure,
A polarizing plate, a retardation plate, and the like are attached on the outer surfaces of the substrate 11 and the counter substrate 12, and the liquid crystal display device 1 is manufactured.

Here, a method of dispersing the spacers 15 on the substrate 11 will be described. In the present embodiment,
A spacer-dispersed solution in which the spacer 15 is uniformly dispersed at a predetermined concentration by ultrasonic waves or the like in a single solvent selected from water, chlorofluorocarbon, isopropyl alcohol, ethanol, or a mixture of two or more solvents is sprayed on the substrate 11. I do. At this time, by using an ink jet nozzle 30 as shown in FIGS. 2 and 3, which can arbitrarily set the discharge position and the number of discharges of the liquid droplet to be discharged, a predetermined amount of spacer is provided at a predetermined position on the substrate 11. Spray the dispersion solution. afterwards,
By evaporating the solvent of the spacer dispersion solution naturally, a predetermined number of spacers 15 are arranged at predetermined positions on the substrate 11.

In this embodiment, it is desirable to use, as the spacer 15, an adhesive spacer whose surface is coated with a thermoplastic resin. When an adhesive spacer is used as the spacer 15, the spacer 15 is sprayed on the substrate 11 to evaporate the solvent.
The thermoplastic resin coated on the surface of the spacer 15 is melted by warming the substrate 11 on which 5 has been sprayed to about 100 ° C., and the molten resin is solidified by lowering the temperature to room temperature again. At this time, spacer 1
5 can be fixed on the substrate 11, so that the position of the spacers 15 scattered at a predetermined position does not change over time.

Next, the structure of the ink jet nozzle 30 which is an example of the ink jet nozzle used in this embodiment will be described. 2 and 3 are a perspective view and a sectional view, respectively, of the inkjet nozzle 30.

As shown in FIG. 2, the ink jet nozzle 30 includes a nozzle plate 31 made of, for example, stainless steel and a vibrating plate 32, both of which are joined via a partition member (reservoir plate) 33. Nozzle plate 31
A plurality of spaces 34 and a liquid pool 35 are formed by the partition member 33 between the diaphragm 32 and the diaphragm 32. Each space 3
The space 4 and the inside of the liquid reservoir 35 are filled with a spacer dispersion solution, and the respective spaces 34 and the liquid reservoir 35 communicate with each other through a supply port 36. Further, the nozzle plate 31 is provided with a nozzle hole 37 for spraying the spacer dispersion solution from the space 34. On the other hand, a hole 38 for supplying a spacer dispersion solution to the liquid reservoir 35 is formed in the vibration plate 32.

As shown in FIG. 3, a piezoelectric element 39 is bonded to the surface of the diaphragm 32 opposite to the surface facing the space 34. The piezoelectric element 39 is located between the pair of electrodes 40, and when energized, the piezoelectric element 39 bends so as to protrude outward, and at the same time, the diaphragm 32 to which the piezoelectric element 39 is joined is also integrally outward. Bend. Thereby, the volume of the space 34 increases. Therefore, the spacer dispersion solution corresponding to the increased volume flows into the space 34 from the liquid reservoir 35 through the supply port 36. Next, when the power supply to the piezoelectric element 39 is released, the piezoelectric element 39 and the diaphragm 3 are released.
2 both return to the original shape. Accordingly, the space 34 also returns to the original volume, so that the pressure of the spacer dispersion solution inside the space 34 increases, and the droplets 41 of the spacer dispersion solution are ejected from the nozzle holes 37 toward the substrate.

Next, FIGS. 4 and 5 show enlarged plan views of the color filter layer 18 of the liquid crystal display device 1 when viewed from above. I do. On the color filter layer 18, a transparent electrode 20, an alignment film 22, and the like are formed.
It is omitted in the figure.

In the liquid crystal display device 1, one colored layer 1
8a is formed corresponding to the region where one transparent electrode 20 and one transparent electrode 21 intersect, and the range of one colored layer 18a is called a sub-pixel. Further, one pixel is formed by three colored layers 18a including red (R), green (G), and blue (B), and one display is possible.

In general, it is required that the application density of the spacers 15 is about 70 [pieces / mm ² ]. For example,
A liquid crystal panel having a display area of 192 [mm] × 144 [mm] and a pixel pitch P of 0.3 [mm], which is an example of a liquid crystal panel mounted on a notebook computer, has a size of 640 × 3.
Since there are (R, G, B) × 480 (= 921,600) sub-pixels, it is necessary that about two spacers 15 are dispersed in one sub-pixel.

Therefore, as shown in FIG.
It is sufficient that about two spacers 15 are scattered in a sub-pixel of 3 [mm] × about 0.1 [mm] in width.

For example, a resolution of 1440 dpi (dot per dot)
inch) inkjet nozzle 30 is used.
Since a droplet 41 of about 17.6 [μm] per dot can be ejected, when the diameter of the spacer 15 is 1 to 4 [μm], two spacers 15 are dispersed in one droplet. Then, the concentration of the spacer dispersion solution may be adjusted, and one drop may be sprayed for each sub-pixel. Alternatively, the concentration of the spacer dispersion solution may be adjusted so that one spacer 15 is dispersed in one drop, and two drops may be sprayed for each sub-pixel. The spacer 15 has a diameter of 4 to 10 [μm].
In the case of (1), the concentration of the spacer dispersion solution may be adjusted so that one spacer 15 is dispersed in one drop, and two drops may be sprayed for each sub-pixel.

Here, the ink jet nozzle 30 having a resolution of 1440 dpi has been described. However, the present invention is not limited to this, and the ink jet nozzle 30 that discharges droplets of an appropriate size is selected according to the diameter of the spacer 15. About two spacers 15 may be dispersed for each sub-pixel.

In the present embodiment, an example is shown in which a predetermined number of spacers 15 are scattered for each sub-pixel. However, the present invention is not limited to this, and a predetermined number of spacers 15 are provided at predetermined positions on the substrate 11. By spraying, the spray density of the spacers 15 can be made uniform. Further, in the present embodiment, only the liquid crystal display device for color display has been described, but the present invention is not limited to this and can be applied to a liquid crystal display device for black and white display.

As described above, when the spacers 15 are scattered in the range of the green (G) colored layer 18a, light leakage occurs and the contrast is reduced. By spraying the spacers 15 by an ink-jet method using, as shown in FIG. 5, the spacers 15 are sprayed only in the range of the red (R) and blue (B) coloring layers 18a, and the green (G) is colored. It is also possible not to spray the spacers 15 in the area of the layer 18a.

As described above, according to the present embodiment, the spacers 15 are sprayed by the ink jet method using the ink jet nozzles 30 so that the spacers 1 are dispersed.
5 can be controlled, and a method of manufacturing a liquid crystal display device in which the distribution density of the spacers 15 is made uniform can be provided. Further, by this manufacturing method, it is possible to provide a liquid crystal display device having excellent display quality, in which the distribution density of the spacers 15 is made uniform, the distance between the substrates is made uniform, and light leakage due to aggregation of the spacers is suppressed. .

The spacers 15 are sprayed only in the range of the red (R) and blue (B) colored layers 18a by spraying the spacers 15 by the ink jet method, and are spread in the range of the green (G) colored layers 18a. Can provide a method of manufacturing a liquid crystal display device in which the spacers 15 are not sprayed. Further, according to this manufacturing method, a liquid crystal display device in which the spacers 15 are arranged only in the range of the red (R) and blue (B) coloring layers 18a, which prevents light leakage and has excellent contrast and excellent display quality is provided. can do.

Second Embodiment FIG. 6 is a schematic sectional view of a liquid crystal display device 2 for color display of a simple matrix type according to a second embodiment of the present invention, and the structure and manufacturing method of the liquid crystal display device will be described. . 6, the same components as those of the liquid crystal display device 1 are denoted by the same reference numerals, and description thereof will be omitted.

In the liquid crystal display device 2, the non-display area 51 is 1 to 2 mm from the inside of the sealing material 14, and the display area 50 is inside the non-display area 51.

In the liquid crystal display device 2, the color filter layer 18, the protective layer 19, the transparent electrodes 20 and 21, the alignment film 2
2 and 23 are formed only in the display area 50, and are not formed in the non-display area 51.

In the liquid crystal display device 2, the color filter layer 18, the protective layer 19, the transparent electrodes 20 and 21, and the alignment films 22 and 23 are formed only in the display area 50 and not in the non-display area 51. On the surface of the substrate 11, a step is formed at the boundary between the display area 50 and the non-display area 51. That is, the surface of the substrate 11 in the display area 50 is formed at a position higher than the surface of the substrate 11 in the non-display area 51.

In the present embodiment, the distance between the substrate 11 and the counter substrate 12 is adjusted according to the thickness of the liquid crystal layer 13 (cell thickness).
Spacers 25A and 25B having different diameters are arranged at the steps. That is, the display area 50 is displayed in the display area 50.
0, a spacer 25A having a small diameter corresponding to the thickness (cell thickness) of the liquid crystal layer 13 in the non-display area 51 is provided.
Is provided with a spacer 25B having a large diameter corresponding to the thickness (cell thickness) of the liquid crystal layer 13 in the non-display area 51.

For example, the cell thickness in the display region 50 and the diameter of the spacer 25A are 5 μm, and the height of the step formed on the surface of the substrate 11 (the thickness from the color filter layer 18 to the alignment film 22) is 2 to 2. In the case of about 3 μm,
The distance between the substrate 11 and the counter substrate 12 (substrate distance), that is, the cell thickness in the non-display area 51 is about 7 to 8 [μm]. Therefore, the non-display area 5 is included in the non-display area 51.
A spacer 25B having a diameter of about 7 to 8 [μm] corresponding to one cell thickness of 7 to 8 [μm] is arranged.

Here, two types of spacers 25A and 25
A method of spraying B on the substrate 11 will be described. water,
A spacer dispersion solution A is prepared by uniformly dispersing the spacer 25A at a predetermined concentration in a single solvent selected from chlorofluorocarbon, isopropyl alcohol, ethanol, or the like, or in a mixture of two or more solvents by ultrasonic waves or the like. Spacer 25B
Similarly, a spacer dispersion solution B is prepared.

As described in the first embodiment, the dispersion solution A of the spacer 25A is uniformly sprayed on the display area 50 on the substrate 11, as described in the first embodiment.
Further, the dispersion solution B of the spacer 25B is uniformly sprayed on the non-display area 51 on the substrate 11 by using another inkjet nozzle 30.

In this embodiment, the spacer 25A,
As 25B, it is desirable to use an adhesive spacer whose surface is coated with a thermoplastic resin. As described in the first embodiment, the dispersed spacers 25A and 25B can be fixed on the substrate 11 by using the adhesive spacers as the spacers 25A and 25B.

According to the present embodiment, the position at which the spacers are scattered can be controlled by spraying the spacers by the ink-jet method using the ink-jet nozzles 30. In this case, a spacer 25A having a small diameter can be sprayed on the high portion and a spacer 25B having a large diameter can be sprayed on the low portion in accordance with the thickness (cell thickness) of the liquid crystal layer 13, so that the distance between the substrates can be reduced. It is possible to provide a uniform manufacturing method of a liquid crystal display device. Further, according to this manufacturing method, even when the height of the substrate 11 is formed, a liquid crystal display device having uniform display intervals and excellent display quality can be provided.

In the present embodiment, only the liquid crystal display device for color display has been described, but the present invention is not limited to this, and can be applied to a liquid crystal display device for black and white display.

Third Embodiment FIG. 7 is a schematic sectional view of a reflection type liquid crystal display device 3 of the internal scattering system, and a structure and a manufacturing method of the liquid crystal display device will be described. 7, the same components as those of the liquid crystal display devices 1 and 2 are denoted by the same reference numerals, and description thereof will be omitted.

In the liquid crystal display device 3, a large number of fine irregularities are formed on the surface of the substrate (lower substrate) 61,
A reflective layer 66 having a large number of fine irregularities is formed thereon by sputtering a metal such as aluminum along the fine irregularities. The reflection layer 66 is formed on the reflection layer 66.
An insulating layer 67 made of silicon dioxide or the like for protecting the semiconductor device is formed. On the insulating layer 67, a color filter layer 18, a transparent electrode 20, and the like are formed as in the liquid crystal display devices 1 and 2.

When the substrate 61 is a glass substrate, fine irregularities on the surface of the substrate 61 are formed by a frost process or the like in which the surface of the glass substrate is unevenly etched with a hydrofluoric acid solution or the like. In the case where the substrate 61 is not limited to a glass substrate but is a general substrate, fine irregularities on the surface of the substrate 61 are formed by sandblasting or the like which makes the surface uneven by spraying fine particles on the surface of the substrate 61.

The height of the projections of the fine unevenness is, for example, about 0.5 to 0.8 [μm]. Also, the substrate 6
On one surface, fine irregularities are formed only in the display region 50. On the other hand, the reflective layer 66, the insulating layer 67, the color filter layer 18, the protective layer 19, the transparent electrodes 20, 21, and the alignment films 22, 23 are formed not only in the display region 50 but also in the non-display region 51.

The fine irregularities on the surface of the substrate 61 are formed by a frost process, a sandblasting process, or the like. In any of the processes, the fine irregularities are formed by shaving the original substrate 61 surface. Therefore, as shown in FIG. 7, a step is formed on the surface of the substrate 61 between a portion where fine unevenness is formed and a flat portion where no fine unevenness is formed, and this step is about 1 [μm]. That is, the display area 5
0 is formed at a position lower than the surface of the substrate 61 in the non-display area 51. As a result of the steps formed on the surface of the substrate 61, as shown in FIG. 7, steps are also formed on the reflective layer 66, the color filter layer 18, the alignment film 22, and the like formed thereon.

In the present embodiment, spacers 65A and 65B having different diameters are arranged on the substrate 61 in accordance with the thickness of the liquid crystal layer 13 (cell thickness).
That is, on the substrate 61, spacers 65A according to the cell thickness in the display area are scattered, and the non-display area 51 is adjusted to the cell thickness in the non-display area 51.
A spacer 65B smaller in diameter by about 1 [μm] than the spacer 65A is arranged.

Here, two types of spacers 65A, 65
A method of dispersing B on the substrate 61 will be described. water,
A spacer dispersion solution C is prepared by uniformly dispersing the spacer 65A at a predetermined concentration in a single solvent selected from Freon, isopropyl alcohol, ethanol, or the like, or in a mixture of two or more solvents by ultrasonic waves or the like. Spacer 65B
Similarly, a spacer dispersion solution D is prepared.

As described in the first embodiment, the dispersion solution C of the spacer 65A is uniformly sprayed on the display area 50 on the substrate 61, as described in the first embodiment.
Further, the dispersion solution D of the spacer 65B is evenly sprayed on the non-display area 51 on the substrate 61 by using another inkjet nozzle 30.

In this embodiment, the spacer 6
As 5A and 65B, it is desirable to use an adhesive spacer whose surface is coated with a thermoplastic resin. First
As described in the embodiment, the spacers 65A, 65B
By using an adhesive spacer, the spacers 65A and 65B can be fixed on the substrate 61.

According to the present embodiment, since the spacers are scattered by the ink jet method using the ink jet nozzle 30, the position at which the spacers are scattered can be controlled, so that the height is formed on the surface of the substrate. In this case, according to the thickness of the liquid crystal layer (cell thickness),
A spacer 65A having a small diameter can be sprayed on the high portion, and a spacer 65B having a large diameter can be sprayed on the low portion, so that a method of manufacturing a liquid crystal display device having uniform substrate spacing can be provided. In addition, this manufacturing method can provide a liquid crystal display device with excellent display quality, in which even if the height is formed on the substrate, the distance between the substrates is uniform.

In this embodiment, the spacers 65B having a small diameter are scattered in the non-display area 51. However, the spacers 65A are scattered only in the display area 50, and the non-display area 51 is scattered.
It is also possible to make the substrate spacing uniform by not spraying spacers on the substrate. However, it is desirable to disperse the spacer 65B having a small diameter in the non-display area 51 from the viewpoint that the substrate interval can be made uniform.

Further, in this embodiment, only the liquid crystal display device for color display has been described, but the present invention is not limited to this, and can be applied to a liquid crystal display device for black and white display.

In the first to third embodiments, a simple matrix type liquid crystal display device has been described, but the present invention is not limited to this.
For example, the present invention can be applied to an active matrix type liquid crystal display device using a two-terminal element represented by MIM (Metal-Insulator-Metal) or a three-terminal element represented by TFT (Thin-Film Transistor). The present invention can be applied to any liquid crystal display device.

Further, by providing the liquid crystal display device provided by the present invention, it is possible to provide an electronic device having excellent display quality.

Next, a specific example of an electronic apparatus including any of the liquid crystal display devices 1, 2, and 3 manufactured according to the first to third embodiments will be described.

FIG. 8A is a perspective view showing an example of a portable telephone. In FIG. 8A, reference numeral 70 denotes a mobile phone main body, and reference numeral 71 denotes a liquid crystal display unit including any one of the liquid crystal display devices 1, 2, and 3 described above.

FIG. 8B is a perspective view showing an example of a portable information processing device such as a word processor or a personal computer. Fig. 8 (b)
In the figure, reference numeral 80 denotes an information processing device, 81 denotes an input unit such as a keyboard, 83 denotes an information processing main body, and 82 denotes a liquid crystal display unit provided with any one of the liquid crystal display devices 1, 2, and 3.

FIG. 8C is a perspective view showing an example of a wristwatch-type electronic device. In FIG. 8C, reference numeral 90 denotes a timepiece main body, and reference numeral 91 denotes a liquid crystal display unit including any one of the liquid crystal display devices 1, 2, and 3 described above.

Each of the electronic devices shown in FIGS. 8A to 8C is provided with any one of the liquid crystal display devices 1, 2, and 3, and thus has excellent display quality.

[0098]

As described above, according to the present invention, the spacers are scattered by the ink jet method using an ink jet nozzle which can arbitrarily set the discharge position and the number of discharges of the discharged droplets. In addition, it is possible to provide a method of manufacturing a liquid crystal display device having excellent display quality, in which the number of sprays can be controlled, so that the spray density of the spacers can be made uniform, and the substrate spacing is made uniform, and the display quality is excellent. Can be.

Further, a method of manufacturing a liquid crystal display device with good contrast, in which the spacers are scattered only in the range of the red and blue coloring layers by spraying the spacers by the ink jet method, and are not scattered in the range of the green coloring layers. And a liquid crystal device.

Further, by dispersing the spacers by the ink jet method, even when the substrate has a height, the height is small in the high part, and the diameter is large in the low part according to the thickness (cell thickness) of the liquid crystal layer. The present invention can provide a method of manufacturing a liquid crystal display device having excellent display quality and a liquid crystal display device in which spacers having different sizes can be scattered and the substrate spacing is uniform.

Further, by providing the liquid crystal display device provided by the present invention, it is possible to provide an electronic device having excellent display quality.

[Brief description of the drawings]

FIG. 1 is a process chart showing a method for manufacturing a simple matrix type liquid crystal display device according to a first embodiment of the present invention.

FIG. 2 is a schematic perspective view showing an example of an ink jet nozzle.

FIG. 3 is a schematic sectional view showing an example of an ink jet nozzle.

FIG. 4 is an enlarged schematic plan view showing one pixel of a simple matrix type liquid crystal display device according to the first embodiment of the present invention.

FIG. 5 is an enlarged schematic plan view showing one pixel of a simple matrix type liquid crystal display device according to the first embodiment of the present invention.

FIG. 6 is a schematic sectional view showing a simple matrix type liquid crystal display device according to a second embodiment of the present invention.

FIG. 7 is a schematic sectional view showing a simple matrix type liquid crystal display device according to a third embodiment of the present invention.

8A is a diagram illustrating an example of a mobile phone including the liquid crystal display device according to the embodiment, and FIG. 8B is a diagram illustrating a portable information processing device including the liquid crystal display device according to the embodiment. FIG. 8C is a diagram illustrating an example of a wristwatch-type electronic device including the liquid crystal display device according to the embodiment.

FIG. 9 is a schematic sectional view showing a general simple matrix type liquid crystal display device.

10 (a) and 10 (b) are schematic cross-sectional views showing a conventional spacer spraying device.

FIG. 11 is a schematic sectional view showing a conventional simple matrix type liquid crystal display device.

FIG. 12 is a schematic sectional view showing a conventional reflection type liquid crystal display device of an internal scattering system.

[Explanation of symbols]

1, 2, 3 Liquid crystal display device 11, 61 Substrate (lower substrate) 12 Counter substrate (upper substrate) 13 Liquid crystal layer 14 Sealing material 15, 25A, 25B, 65A, 65B Spacer 18 Color filter layer 18a Color layer 18b Light shielding layer (Black matrix) 19 Protective layer 20, 21 Transparent electrode 22, 23 Alignment film 30 Ink jet nozzle 41 Droplet of spacer dispersion solution 50 Display area 51 Non-display area 66 Reflective layer 67 Insulating layer P Pixel pitch

Claims (13)

[Claims] 1. A spacer dispersion solution in which a large number of spacers for forming a predetermined space between two substrates sandwiching a liquid crystal layer are dispersed on one substrate, and the spacers are dispersed in a predetermined solvent. Is sprayed only to a predetermined area including a pixel area on the substrate by an ink jet method, and the spacer is sprayed by evaporating the solvent. 2. The method for manufacturing a liquid crystal device according to claim 1, wherein a plurality of coloring layers of different colors for color display are provided on one of the two substrates,
The method for manufacturing a liquid crystal device, wherein the predetermined region is a region where a colored layer of a predetermined color is formed in the colored layer. 3. The method for manufacturing a liquid crystal device according to claim 2, wherein the colored layer of the predetermined color is a red and blue colored layer. 4. The method of manufacturing a liquid crystal device according to claim 1, wherein a concave portion is formed on a surface of one of the two substrates, and the predetermined region is a region where the concave portion is formed. A method for manufacturing a liquid crystal device, comprising: 5. The method for manufacturing a liquid crystal device according to claim 1, wherein a step is formed on a surface of one of the two substrates, and a step is formed on a high portion according to the height of the one substrate. A method of spraying the spacers having different diameters which are small and large in a lower part. 6. Any one of claims 1 to 5
3. The method for manufacturing a liquid crystal device according to claim 1, wherein the spacer has a surface coated with a thermoplastic resin. 7. A liquid crystal device in which a spacer for forming a predetermined space between two substrates sandwiching a liquid crystal layer is disposed only in a predetermined region including a pixel region on the entire surface of the substrate. A liquid crystal device characterized by being arranged at a uniform density. 8. The liquid crystal device according to claim 7, wherein a plurality of coloring layers of different colors for color display are provided on one of the two substrates, and the predetermined region is: A liquid crystal device, wherein the colored layer is a region where a colored layer of a predetermined color is formed. 9. The liquid crystal device according to claim 8, wherein the colored layer of the predetermined color is a red and blue colored layer. 10. The liquid crystal device according to claim 7, wherein a concave portion is formed on a surface of one of the two substrates, and the predetermined region is a region where the concave portion is formed. Characteristic manufacturing method of a liquid crystal device. 11. The liquid crystal device according to claim 7, wherein a step is formed on a surface of one of the two substrates, and a small portion is formed in a high portion according to a height on the one substrate, A liquid crystal device, wherein the spacers having different diameters are arranged at a lower portion. 12. The liquid crystal device according to claim 7, wherein the spacer has a surface coated with a thermoplastic resin. 13. An electronic apparatus comprising the liquid crystal device according to claim 7. Description: