Liquid crystal panel, manufacturing method of liquid crystal panel, and applicator

A liquid crystal panel 10 includes a pair of substantially rectangular substrates 17, 18 attached to each other, a liquid crystal layer 19 provided between the substrates 17, 18, and a sealant portion 20 having a substantially frame-like shape surrounding and sealing the liquid crystal layer 19. The sealant portion 20 includes an oblique portion 34 arranged oblique to the sides of the substrate 17, 18, at each of the four corners thereof. The liquid crystal panel 10 further includes a reinforcing portion 35 fixed to both substrates 17, 18. The reinforcing portion 35 is arranged along a planar direction of the substrate 17, 18 so as to be located between the oblique portion 34 and a corner point of the substrate 17, 18.

This application is the U.S. national phase of international Application No. PCT/JP2008/066167, filed 8 Sep. 2008, which designated the U.S. and claims priority to Japanese Application No. 2007-322445 filed 13 Dec. 2007, the entire contents of each of which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a liquid crystal panel, a manufacturing method of a liquid crystal panel, and an applicator.

BACKGROUND ART

A liquid crystal panel as a major component of a liquid crystal display device is conventionally constructed as follows: A liquid crystal layer of the liquid crystal panel is provided between a pair of glass substrates, and a frame-like sealant portion for sealing the liquid crystal layer is formed to surround the liquid crystal layer.

A vacuum injection method is known as a conventional method for forming the liquid crystal layer between the substrates. According to the vacuum injection method, the substrates are attached to each other so that a sealant portion is provided therebetween. Thereafter, the sealant portion is hardened, and an inlet provided on the sealant portion is dipped in a liquid crystal material under the vacuum environment. Then, the environment is returned to the air pressure, and thereby the liquid crystal material intrudes between the substrates.

On the other hand, a one-drop-fill method described in Patent Document 1 below has recently been drawing attention as a technique adapted for the growing size of liquid crystal panels. According to the one-drop-fill method, a frame-like sealant portion is applied on one of the substrates. Thereafter, under the vacuum environment, a liquid crystal material is dropped on the substrate, and then the other substrate is attached thereto. The environment is thereafter returned to the air pressure. Thus, a liquid crystal layer is formed between the substrates. Compared to the vacuum injection method, the one-drop-fill method has the advantage of large reduction in consumption of the liquid crystal material, and further has the advantage of reduction in processing time.Patent Document 1: JP-A-2005-173067

DISCLOSURE OF THE INVENTION

Problem to be Solved by the Invention

However, the one-drop-fill method may cause a problem as follows: During the dropping of the liquid crystal material, a number of droplets of the liquid crystal material with a predetermined distance therebetween are dropped from the nozzles of a dispensing apparatus, and are applied on one of the substrates. Thereafter, the other substrate is attached thereon, and then the applied droplets of the liquid crystal material are spread by the pressure. When the droplets of the liquid crystal material are thus spread by the pressure, the droplets in the vicinities of the corner sections of the sealant portion may fail to spread deep into the corner areas, resulting in production of vacuum bubbles, because the corner sections are formed as slightly rounded but substantially right-angled sections.

To address this problem, the inventor of the present application proposes a construction in which oblique portions, i.e., portions oblique to the sides of the substrate, are provided at the four corner sections of the sealant portion. However, the oblique portions are inevitably displaced to the inner side from the locations of the corner sections of the conventional sealant portion. That is, the oblique portions are located at a larger distance from the corner points of the substrate, compared to the conventional construction. This construction is prone to detachment or peeling of substrates, which can be caused by an impact force applied to a corner point of the substrate, for example. There is also another problem that the oblique portions are difficult to form in the case of using a conventional sealant applicator.

The present invention was made in view of the foregoing circumstances, and a primary object thereof is to provide a liquid crystal panel in which vacuum bubbles are prevented while the peel strength is improved. A secondary object is to provide an applicator adapted for application of a sealant portion having an oblique portion.

Means for Solving the Problem

A liquid crystal panel according to the present invention includes a pair of substantially rectangular substrates attached to each other, a liquid crystal layer provided between the pair of substrates, and a sealant portion having a substantially frame-like shape surrounding and sealing the liquid crystal layer. The sealant portion includes an oblique portion arranged oblique to a side of the substrate, at each of the four corners thereof. The liquid crystal panel further includes a reinforcing portion fixed to the pair of substrates. The reinforcing portion is arranged along a planar direction of the substrate so as to be located between the oblique portion and a corner point of the substrate.

According to the construction, during the formation of the liquid crystal layer between the substrates, a liquid crystal material for forming the liquid crystal layer can be spread evenly across the area within the sealant portion, because the sealant portion includes the oblique portion at each of the four corners. Consequently, vacuum bubbles can be prevented from being produced in the liquid crystal layer. Further, the substrates are resistant to detachment or peeling even when an impact force is applied to the corner point of the substrate, because the reinforcing portion is fixed to the substrates so as to be arranged along a planar direction of the substrate and be located between the oblique portion and the corner point of the substrate.

BEST MODE FOR CARRYING OUT THE INVENTION

An embodiment 1 according to the present invention will be explained with reference toFIGS. 1 to 14. In the present embodiment, a liquid crystal panel11included in a liquid crystal display device10, and a sealant applicator40to be used by a manufacturing process thereof will be illustrated. The description of the vertical direction will be made with reference toFIGS. 2,9and10.

Referring toFIG. 2, the liquid crystal display device D forms a horizontally-long rectangular shape as a whole, which includes the liquid crystal panel10as a display panel capable of image display and further includes a backlight11that is disposed on the rear side (or back-surface side) of the liquid crystal panel10as an external light source (or a lighting device) capable of illuminating the liquid crystal panel10. The liquid crystal display device D can be applied to a television receiver TV. As shown inFIG. 1, the television receiver TV includes the liquid crystal display device D, and front and back cabinets Ca and Cb capable of holding the liquid crystal display device D therebetween. Further included are a power source2, a tuner T for broadcast reception such as TV reception, and a stand S.

The backlight11will be briefly explained first. Referring toFIG. 2, the backlight11includes a casing12having a substantially box-like shape with a front-side (i.e., liquid crystal panel10side) opening, a plurality of linear light sources13(e.g., cold cathode tubes) arranged parallel to one another in the casing12, a plurality of optical members14arranged in a stack (e.g., a diffuser plate, a diffusing sheet, a lens sheet and a brightness enhancement sheet, arranged in this order from the back side) in the opening of the casing12, and a rectangular-shaped frame15for holding the optical members14together with the casing12and therebetween. The optical members14have functions such as a function for converting light from each linear light source13into flat light. The frame15can function also as a support member for supporting the liquid crystal panel10from the back side. A frame-like bezel16(or a holding member) is mounted on the front side of the liquid crystal panel10, so as to bear down on the liquid crystal panel10. The liquid crystal panel10is thus held between the support member and the holding member.

Next, the liquid crystal panel10will be explained in detail. The liquid crystal panel10includes a pair of transparent (or light transmissive) glass substrates17,18having a horizontally-long rectangular shape, and further includes a liquid crystal layer19disposed between the substrates17,18. The liquid crystal layer19includes liquid crystal molecules as a material with an optical property that changes with applied voltage. The liquid crystal panel10further includes a substantially frame-like sealant portion20that is disposed between the substrates17,18so as to surround and seal the liquid crystal layer19. The substrates17,18are attached to each other so as to face each other, while a gap (or interval) of a predetermined size is kept therebetween. A number of spacers21are provided to scatter in the liquid crystal layer19, so that the gap between the substrates17,18is maintained (SeeFIG. 4). The spacers21are located on the array substrate18so as to be above the gate wiring lines24and therefore at the light blocking areas. During a manufacturing process, substrates are cut out from large-size parent materials17M,18M called Mother Glass Substrates, and are used as the substrates17,18of the liquid crystal panel10.

The front-side one (or obverse-side one) of the substrates17,18is provided as a CF substrate17, while the back-side one (or reverse-side one) is provided as an array substrate18. On the inner surface side (i.e., liquid crystal layer19side or CF substrate17facing surface side) of the array substrate18, as shown inFIG. 3, a number of TFTs22(Thin Film Transistors) as switching elements and pixel electrodes23are arranged, and further gate wiring lines24and source wiring lines25are arranged in a grid pattern so as to surround the TFTs22and the pixel electrodes23. The pixel electrode23is connected to the drain electrode of the TFT22. The source wiring line25is connected to the source electrode of the TFT22, while the gate wiring line24is connected to the gate electrode of the TFT22. Each pixel electrode23is formed of a transparent electrode, e.g., made of ITO (Indium Tin Oxide) or ZnO (Zinc Oxide). As shown inFIG. 4, an insulating layer26is provided on the surfaces of the array substrate18and the gate wiring lines24. The pixel electrodes23are provided on the surface of the insulating layer26. Further, an alignment film27for orientational alignment of the liquid crystal molecules included in the liquid crystal layer19is provided on the surfaces of the pixel electrodes23and the insulating layer26.

On the other hand, as shown inFIG. 4, a number of colored films28constituting a color filter are arranged on the CF substrate17so as to correspond to the respective pixels. The color filter includes colored films28of three colors, i.e., R, G and B films, which are arranged in cyclic order. A light blocking layer29(black matrix) for preventing color mixture is provided between the colored films28of the color filter. A counter electrode30is provided on the surfaces of the colored films28and the light blocking layer29, so as to be opposite to the pixel electrodes23provided on the array substrate18side. An alignment film31for orientational alignment of the liquid crystal molecules included in the liquid crystal layer19is provided on the surface of the counter electrode30. Referring toFIG. 5, the CF substrate17is slightly smaller than the array substrate18. Therefore, the peripheral edge of the CF substrate17is located to recede to the inner side from the peripheral edge of the array substrate18. As shown inFIG. 2, a pair of front and back polarizing plates32are attached on the outer surface sides of the respective substrates17,18.

Next, the sealant portion20will be explained in detail. The sealant portion20is formed of a resin material, such as an ultraviolet curable resin material that can be hardened by ultraviolet irradiation, or a UV/heat dual-curable resin material that can be hardened by ultraviolet irradiation and thereafter can improve in cure degree or adhesion strength when the heat is applied thereto. Referring toFIGS. 5 and 6, the sealant portion20has a substantially quadrangular frame-like shape when viewed planarly, which is arranged to surround the inner space to be filled with the liquid crystal layer19. The sealant portion20includes four straight portions33extending substantially straightforward along the respective sides of the substrates17,18, and further includes four oblique portions34at the four corner sections. The oblique portions34are arranged oblique to the sides of the substrates17,18, so as to be connected between the straight portions33.

The straight portions33are located to be displaced to the inner side from the peripheral edge of the CF substrate17, so that a marginal area having a constant width and extending substantially straightforward is provided between the outer edge of each straight portion33and the peripheral edge of the CF substrate17. The straight portions33include two straight portions along the long sides of the rectangular substrates17,18, and further includes two straight portions along the short sides. On the other hand, each oblique portion34is connected between the end of the straight portion33along the long side and the end of the straight portion33along the short side. The oblique portion34is arranged oblique to the both straight portions33, and extends straightforward. The distance between the oblique portion34and the peripheral edge of the CF substrate17gradually increases toward the corner point (i.e., the vertex “C”). The inclination of the oblique portion34from the straight portions33is set to 45 degrees. That is, the inner surface of the oblique portion34, facing the liquid crystal layer19, forms an angle of approximately 135 degrees (i.e., an obtuse angle) with the inner surface of each straight portion33. Accordingly, the area between the oblique portion34and the corner point of the OF substrate17(i.e., the corner area of the CF substrate17bounded by its peripheral edge) has a substantially isosceles triangular shape, when viewed planarly. The straight portions33and the oblique portions34have a substantially constant width along the entire length.

Referring toFIGS. 5 and 7, reinforcing portions35are provided to be fixed to the both substrates17,18. Each reinforcing portion35is arranged along a planar direction of the substrate17,18so as to be located between a corner point of the substrates17,18and the oblique portion34of the sealant portion20described above. The reinforcing portions35are formed of the same resin material as the sealant portions20, by the same process of the manufacturing process as the sealant portion20, as described below. Each reinforcing portion35substantially linearly extends from the middle section of the length of the oblique portion34toward the corner point C of the CF substrate17, so as to form a substantially straight line connected to the oblique portion34. The reinforcing portion35forms substantially a right angle with the oblique portion34, and has a constant with along the entire length. The distance between the distal end of the reinforcing portion35and the corner point C of the CF substrate17is set to be substantially equal to the width of the marginal area between the outer edge of the straight portion33and the peripheral edge of the CF substrate17. According to the construction, the peel strength, i.e., the strength against a force to detach the substrates17,18, is uniformly provided over the entire circumference of the liquid crystal panel10, so that the liquid crystal panel10is prevented from locally including a low-strength area on the circumference. Thus, due to the reinforcing portions35provided on the corner areas of the substrates17,18, the corner areas can have the same level of peel strength as the other areas, although the distance between the oblique portions34and the corner points of the substrates17,18is larger than the distance between the straight portions33and the substrates17,18.

<Overview of Manufacturing Method of Liquid Crystal Panel>

The liquid crystal panel10having the above construction can be manufactured from large-size parent materials17M,18M called Mother Glass Substrate (SeeFIG. 8), as described above. A brief explanation is as follows: The manufacture of the liquid crystal panel10includes a CF substrate treatment process for forming components of CF substrates17on a surface of the parent material17M for the CF substrates, and an array substrate treatment process for forming components of array substrates18on a surface of the parent material18M for the array substrates. Further included are a panel assembly process for attaching the completed parent materials17M,18M to each other while providing a liquid crystal layer19between the parent materials17M,18M, and a cutting process for cutting out liquid crystal panels10from the parent materials17M,18M. The parent materials17M,18M can include a plurality of liquid crystal panels10arranged in an array of rows and columns with a predetermined distance therebetween (e.g., a total of nine panels arranged in an array of three rows and three columns, as inFIG. 8).

The panel assembly process includes processes to be sequentially performed, which include a sealant portion application process for applying a resin material to one of the parent materials17M,18M (e.g., the CF substrates' parent material17M, in the present embodiment) so as to form sealant portions20at the areas saved for the sealant portions, and a reinforcing portion application process for applying the resin material to the CF substrates' parent material17M, i.e., to the parent material to be subjected to the application of the sealant portion20, so as to form reinforcing portions35at the areas saved for the reinforcing portions. Further included are a liquid crystal dropping process for dropping a liquid crystal material on the area provided on the inner side of each sealant portion20on the CF substrates' parent material17M, and an attachment process for attaching the parent materials17M,18M to each other while hardening and fixing the sealant portions20and the reinforcing portions35by the light irradiation using an exposure device (not shown) and/or by the application of heat. The applicator40to be used by the sealant application process and the reinforcing portion application process will be explained in detail, next.

Referring toFIGS. 8 to 10, the applicator40includes nozzles41capable of ejecting a resin material in softened state, and dispenser bodies42for supporting the nozzles41to be movable in the vertical direction (i.e., the direction approaching to and receding from the CF substrates' parent material17M, or the direction Z shown inFIGS. 9 and 10). Further included are a guide43for supporting the dispenser bodies42to be linearly slidable in the horizontal direction (i.e., along a planar direction of the CF substrates' parent material17M), and a stage44capable of horizontal rotation and movement in a direction perpendicular to the sliding direction of the dispenser bodies42on the guide43. The stage44is provided as a rest on which the CF substrates' parent material17M (i.e., the substrate to be subjected to the application) is placed.

Each nozzle41has a tapered shape, and an ejection aperture for ejecting a resin material is formed on the end portion thereof. The dispenser body42is connected with the nozzle41and also with a tank containing the resin material. The resin material can be supplied from the tank by a pump (although both of the tank and the pump are not shown). The guide43has a linear shape, and the length thereof is set to be slightly larger than the diagonal dimension of the CF substrates' parent material17M. A slide groove43ais provided on the side surface of the guide43so as to be along the length direction of the guide43(i.e., the direction X shown inFIGS. 8 and 9). The dispenser bodies42are mounted to the slide groove43aso as to be slidable (or movable) along the slide groove43a. In the present embodiment, three dispenser bodies42having respective nozzles41are mounted on the guide43. The stage44includes a substrate rest44a, a support base44bfor supporting the substrate rest44a, and a rotating shaft44carranged between the substrate rest44aand the support base44b. The CF substrates' parent material17M is directly placed on the substrate rest44a. On the support base44b, the substrate rest44acan rotate around the rotating shaft44cand in the direction R shown inFIG. 8. The support base44b, together with the rotating shaft44cand the substrate rest44a, can move in a direction perpendicular to the extending direction of the guide43(i.e., the direction Y shown inFIGS. 8 and 10). The substrate rest44ahas a substantially rectangular shape when viewed planarly, so as to fit with the CF substrates' parent material17M.

<Sealant Application Process and Reinforcing Portion Application Process>

In the present embodiment, the sealant application process and the reinforcing portion application process are consecutively performed using the same applicator40. The detailed operating procedure is as follows: The CF substrates' parent material17N is set on the substrate rest44aof the stage44, while the substrate rest44ais maintained on the stage44so that the long side thereof is parallel to the length direction of the guide43. Then, in order to horizontally position the nozzles41at the initial positions relative to the CR substrates' parent material17M, the support base44bis moved in the direction Y shown inFIG. 11while the dispenser bodies42are moved on the guide43in the direction X shown inFIG. 11. Thereafter, the nozzles41are moved down so as to approach the surface of the CF substrates' parent material17M, and the resin material is ejected from the ejection apertures while the dispenser bodies42are moved on the guide43in the direction X. Thereby, the straight portions33of sealant portions20along the long side are applied. After the application, the nozzles41are once moved up, and the stage44is moved so that the nozzles41are positioned at the next application positions. Then, the nozzles41are again moved down, and the resin material is ejected while the dispenser bodies42are moved. Thereby, the straight portions33along the long side are applied in the next row. In this way, the sealant portions20of three CF substrates17arranged along the long side of the CF substrates' parent material17M can be treated parallel and simultaneously by the simultaneous operations of the three nozzles41. The above operations are repeated, and consequently the straight portions33of sealant portions20along the long sides of the CF substrates17are applied as shown inFIG. 11.

When the application of all straight portions33along the long sides is completed, referring toFIG. 12, the substrate rest44aon the stage44is rotated substantially 90 degrees with respect to the support base44band in the direction R shown in the figure. Thereby, the short side of the substrate rest44a(or the CF substrates' parent material17M) on the stage44is arranged parallel to the length direction of the guide43. Then, the nozzles41are positioned by the individual movement of the stage44and the dispenser bodies42. Thereafter, the resin material is ejected from the nozzles41while the dispenser bodies42are moved along the guide43, in a similar manner to the above operation. Thereby, the straight portions33of the sealant portions20along the short side are applied. The operations are repeated as in the case of those along the long sides, and consequently the straight portions33of the sealant portions20along the short sides of the CF substrates17are applied.

When the application of all straight potions33along the short sides is completed, the substrate rest44aon the stage44is rotated substantially 45 degrees with respect to the support base44b, as shown inFIG. 13. The nozzles41are positioned by the movement of the stage44and the dispenser bodies42, and then the resin material is ejected from the nozzles41while the dispenser bodies42are moved along the guide43, in a similar manner to the above operation. Thereby, two oblique portions34of the sealant portion20, parallel to the length direction of the guide43, are sequentially applied on each CF substrate17so as to be located at corners opposed to each other. Specifically, the oblique portions34are first applied on the CF substrate17located at the corner area of the CF substrates' parent material17M closest to the guide43, by use of the middle nozzle41of the three nozzles41, for example. Next, by use of two nozzles41, the oblique portions34are simultaneously applied on two CF substrates17, which are arranged adjacent to the corner CF substrate17described above along the direction parallel to the length direction of the guide43. Thereafter, by use of the three nozzles41, the oblique portions34are simultaneously applied on three CF substrates17, which are arranged adjacent to the two CF substrates17described above along the direction parallel to the length direction of the guide43. In this way, the application of the oblique portions34on CF substrates17arranged in the direction parallel to the length direction of the guide43is sequentially performed. Next, the substrate rest44aon the stage44is rotated substantially 90 degrees with respect to the support base44b, as shown inFIG. 14. Then, the other oblique portions34, parallel to the length direction of the guide43, are sequentially applied in a similar manner to the above operations.

In the above application process, the application of the reinforcing portions35is performed simultaneously with the application of the oblique portions34. Specifically, during the application of each oblique portion34, the dispenser body42sliding along the guide43is stopped when the nozzle41has reached the middle point on the length of the oblique portion34. Then, the stage44is moved in the direction Y shown inFIGS. 13 and 14while the resin material is ejected from the nozzle41. Thereby, the reinforcing portion35is applied so as to form a linear shape extending in the direction perpendicular to the extending direction of the oblique portion34. At the time, the resin material is continuously ejected during the movement of the nozzle41from the oblique portion34to the reinforcing portion35, and thereby the reinforcing portion35can be formed to be connected to the oblique portion34. Alternatively, the nozzle41may be once moved up after the application of the entire length of the oblique portion34, and then the reinforcing portion35can be applied anew.

<Liquid Crystal Dropping Process and Attachment Process>

In the liquid crystal dropping process, a number of droplets of a liquid crystal material with a predetermined distance therebetween are dropped on the CF substrates' parent material17M that has undergone the sealant application process and the reinforcing portion application process as described above. Thereafter, the array substrates' parent material18M is attached thereto. At the time, the droplets of the liquid crystal material are spread by the pressure from the parent materials17M,18M, so as to permeate the entire area that is provided between the parent materials17M,18M and is surrounded by the sealant portion20. Note that the sealant portion20includes the oblique portions34at the four corner sections. In contrast to the conventional right-angled corner sections of a sealant portion, the oblique portions34of the present embodiment are located on the substrates17,18so as to recede to the inner side, i.e., be closer to the periphery of the applied droplet of the liquid crystal material. Therefore, the droplets of the liquid crystal material can be evenly spread by the pressure, so as to reach into the corner area provided on the inner side of each oblique portion34. Consequently, the production of vacuum bubbles can be prevented. After the above attachment, the light from an exposure device and/or the heat is applied to the sealant portions20and the reinforcing portions35, so that they are hardened and fixed to the parent materials17M,18M. Thereafter, liquid crystal panels10are cut out from the parent materials17M,18M, by the cutting process.

As explained above, the liquid crystal panel10according to the present embodiment includes a pair of substantially rectangular substrates17,18attached to each other, a liquid crystal layer19provided between the substrates17,18, a sealant portion20having a substantially frame-like shape surrounding and sealing the liquid crystal layer19, and a reinforcing portion35fixed to the substrates17,18. The sealant portion20includes an oblique portion34arranged oblique to the sides of the substrate17,18, at each of the four corners thereof. The reinforcing portion35is arranged along a planar direction of the substrate17,18so as to be located between the oblique portion34and a corner point of the substrate17,18.

According to the construction, during the formation of the liquid crystal layer19between the substrates17,18, a liquid crystal material for forming the liquid crystal layer19can be spread evenly across the area within the sealant portion20, because the sealant portion20includes the oblique portion34at each of the four corners. Consequently, vacuum bubbles can be prevented from being produced in the liquid crystal layer19. Further, the substrates17,18are resistant to detachment even when an impact force is applied to the corner point of the substrate17,18, because the reinforcing portion35is fixed to the substrates17,18so as to be arranged along a planar direction of the substrate17,18and be located between the oblique portion34and the corner point of the substrate17,18. Thus, the vacuum bubbles are prevented while the peel strength is improved.

Further, the reinforcing portion35is connected to the sealant portion20. Thereby, the peel strength of the substrates17,18can be further improved. Moreover, the reinforcing portion35has a linear shape extending in the direction intersecting with the oblique portion34. Accordingly, the peel strength of the substrates17,18can be further improved.

According to the present embodiment, the manufacturing method of a liquid crystal panel10includes a sealant portion application process for applying a sealant portion20having a substantially frame-like shape to the CF substrate17, i.e., one of the pair of substantially rectangular substrates17,18. The sealant portion20includes an oblique portion34arranged oblique to the sides of the substrate17,18, at each of the four corners thereof. The manufacturing method further includes a reinforcing portion application process for applying a reinforcing portion35to the CF substrate17, i.e., one of the substrates17,18. The reinforcing portion35is arranged along a planar direction of the CF substrate17so as to be located between the oblique portion34and a corner point of the substrate17,18. The manufacturing method further includes a liquid crystal dropping process for dropping a liquid crystal material on the CF substrate17having the sealant portion20applied thereon, and an attachment process for attaching the substrates17,18to each other and fixing the sealant portion and the reinforcing portion35to the substrates17,18. According to the method, the operational effects similar to those of the liquid crystal panel10described above can be achieved.

In the sealant portion application process and the reinforcing portion application process, the application of the sealant portion20and the application of the reinforcing portion35are consecutively performed for the same CF substrate17using the same applicator40. According to the method, the applicator cost can be reduced, compared to a case where the application of a sealant portion and the application of a reinforcing portion are performed for different substrates using different applicators. Further, the processing time can be shortened due to the consecutive application of the sealant portion20and the reinforcing portion35.

The present embodiment further provides the applicator40to be used for the application of the sealant portion20on the CF substrate17, i.e., one of the pair of substantially rectangular substrates17,18. The sealant portion20has a substantially frame-like shape, and includes an oblique portion34arranged oblique to the sides of the substrate17,18, at each of the four corners thereof. The applicator40includes a nozzle41capable of ejecting a sealant material onto the CF substrate17, a dispenser body42arranged to support the nozzle41to be movable in the direction approaching to and receding from the CF substrate17, a guide43arranged to support the dispenser body42to be linearly slidable along a planar direction of the CF substrate17, and a stage44provided as a rest for the CF substrate17. The stage44is rotatable in a planar direction of the CF substrate17, and is movable in a direction perpendicular to the sliding direction of the dispenser body42on the guide43.

According to the construction, the nozzle41can be positioned with respect to the CF substrate17by the movement of the stage44in the direction perpendicular to the sliding direction of the dispenser body42on the guide43and by the rotation of the stage44in the planar direction of the CF substrate17. Thereafter, the sealant material is ejected from the nozzle41while the dispenser body42is slid on the guide43. Thereby, the sealant portion20can be applied to the CF substrate17. At the time, the formation of the oblique portion34oblique to the sides of the substrate17,18can be readily achieved if the angle of the above rotation of the stage44is adjusted therefor.

An embodiment 2 of the present invention will be explained with reference toFIGS. 15 to 22. The present embodiment 2 shows a modification that includes an applicator40A dedicated for the application of the sealant portion20. In the present embodiment 2, the parts called by the same names as those of the above embodiment 1 are designated by the same symbols, even if they differ in construction. However, the suffix “A” is attached to the symbols. The redundant explanations for the constructions and operational effects will be omitted.

Referring toFIG. 15, the present applicator40A includes a guide43A formed of separate parts, i.e., a guide body43aand a pair of inclined guides43b. Specifically, the guide body43ahas a linear shape, and the length thereof is set to be slightly larger than the length of the long side of a CF substrates' parent material17M. On the other hand, each inclined guide43bis arranged oblique to the length direction of the guide body43a, and has a linear shape along the oblique direction. The inclination of the inclined guide43bfrom the guide body43ais set to conform to the inclination of the oblique portion34A of the sealant portion20from the straight portion33A (or, from the side of the CF substrate17). Specifically, it is set to 45 degrees. The two inclined guides43b, i.e., right and left inclined guides shown inFIG. 15, are reversely inclined from the guide body43a, and therefore the length directions thereof intersect each other. The angle therebetween is set to substantially 90 degrees. The two inclined guides43bare arranged symmetrically to each other. Specifically, the inclined guides43bare located to be displaced from the guide body43ain the direction Y shown inFIG. 15. Further, they are arranged in the direction X so that the whole lengths thereof are within the length of the guide body43a.

Slide grooves (not shown) are formed on the side surface of the guide body43aand the side surface of each inclined guide43bso as to be along their length directions. Dispenser bodies42A are mounted to the slide grooves so as to be slidable along the slide grooves. Three dispenser bodies42A are attached to the guide body43a, while one dispenser body42A is attached to each inclined guide43b. The nozzles41A of the dispenser bodies42A attached to the guide body43aare used for the application of straight portions33A of the sealant portion20, while the nozzles41A of the dispenser bodies42A attached to the inclined guides43bare used for the application of oblique portions34A.

In the applicator40A, a stage44A is provided to be movable in two directions, i.e., the length direction of the guide body43aand a direction perpendicular thereto (the directions X and Y shown inFIG. 15).

<Sealant Application Process and Reinforcing Portion Application Process>

In the present embodiment, sealant portions20are applied to the CF substrates' parent material17M, i.e., one of two parent materials17M,18M, by a sealant application process using the above applicator40A. In contrast, reinforcing portions35A are applied to the array substrates' parent material18M, i.e., the other of the two parent materials17M,18M (or the parent material18M other than the parent material17M to be subjected to the application of the sealant portions20), by a reinforcing portion application process using an applicator (not shown) other than the above applicator. Each reinforcing portion35A is arranged between the oblique portion34of the sealant portion20and a corner point of the substrates17,18. The reinforcing portion35A is provided as a point-like portion that is unconnected with the sealant portion20(SeeFIG. 21) as described below.

First, the reinforcing portion application process will be explained. The reinforcing portions35A are applied on the array substrates' parent material18M, i.e., one of the parent materials17M,18M, by using an applicator not shown. The applicator to be used by the present process has a construction nearly identical to the applicator40shown in the embodiment 1, except that the stage44thereof lacks rotation capability. Therefore, the detailed explanation thereof will be omitted. On the array substrates' parent material18M placed on the stage, the nozzles are positioned at the application positions of the reinforcing portions, and the point-like reinforcing portions35A are sequentially applied as shown inFIG. 16.

Next, the sealant application process will be explained. Referring toFIG. 15, the CF substrates' parent material17M is placed on the substrate rest43aA, while the substrate rest44aA is maintained on the stage44A so that the long side thereof is parallel to the length direction of the guide body43a. The nozzles41A are positioned at the application positions of straight portions33of the sealant portions20along the long side, by the movement of the stage44A and the movement of the dispenser bodies42A on the guide body43a. Then, a resin material is ejected from the nozzles41A while the dispenser bodies42A are slid on the guide body43a. Thereby, the straight portions33of the sealant portions20along the long side are applied as shown inFIG. 17. When the application of the straight portions33along the long sides of the CF substrates17is completed, the nozzles41A are positioned at the application positions of two oblique portions34of the sealant portion20, or specifically, the oblique portions34to be formed parallel to the respective inclined guides43b, by the movement of the stage44and the movement of the dispenser bodies42A on the inclined guides43b. The resin material is ejected from the nozzles41A while the dispenser bodies42A are slid on the inclined guides43b. Thereby, two oblique portions34of each sealant portion20are applied so as to be located on the same side thereof, as shown inFIG. 18.

Thereafter, the substrate rest44aA on the stage44A is rotated 180 degrees with respect to the support base44bA. Then, by the movement of the stage44and the movement of the dispenser bodies42A on the inclined guides43b, the nozzles41A are positioned at the application positions of oblique portions34to be formed parallel to the respective inclined guides43b. Thereafter, the other oblique portions34are applied in a similar manner to the above application of the two oblique portions34(SeeFIG. 19). When the application of all oblique portions34is completed, the substrate rest44aA is rotated 90 degrees so that the short side of the substrate rest44aA is arranged parallel to the guide body43a. Then, the nozzles41A are positioned at the application positions of straight portions33along the short side, by the movement of the stage44A and the movement of the dispenser bodies42A on the guide body43a. Thereafter, referring toFIG. 20, the straight portions33along the short side are applied in a similar manner to the above application of the straight portions33along the long side.

<Liquid Crystal Dropping Process and Attachment Process>

A liquid crystal material is dropped on the CF substrates' parent material17M that has undergone the application of the sealant portions20as described above. Then, the array substrates' parent material18M having undergone the application of the reinforcing portions35A is attached thereto. Thereafter, the light from an exposure device and/or the heat is applied to the sealant portions20and the reinforcing portions35, so that they are hardened and fixed to the parent materials17M,18M. In the resultant structure, referring toFIGS. 21 and 22, each reinforcing portion35A is located at the outer side of the oblique portion34of the sealant portion20but at the inner side of the corner point of the substrate17,18. The reinforcing portion34has a substantially circular horizontal section, and is arranged to be unconnected with or separated from the sealant portion20.

As explained above, in the reinforcing portion application process of the manufacturing method for a liquid crystal panel10according to the present embodiment, the reinforcing portions35A are applied on the array substrate18, i.e., one of the substrates17,18, or specifically, the other substrate than the CF substrate17to be subjected to the application of the sealant portion20. The present method is suitable for shortening the processing time, because the process for the application of the sealant portion20and the process for the application of the reinforcing portions35A can be performed parallel and simultaneously. Further, the operation of the applicator40A can be simplified, compared to a case where the application of a sealant portion and the application of reinforcing portions are consecutively performed for the same substrate by using the same applicator.

Further, according to the present embodiment, the guide43A of the applicator40A includes a guide body43ahaving a linear shape and inclined guides43barranged oblique to the guide body43a. The inclination of the inclined guide43bfrom the guide body43ais set to conform to the inclination of the oblique portion34from the sides of the substrate17,18. According to the construction, the sealant portion20except for the oblique portions34can be applied while the dispenser bodies42A are slid on the guide body43a. Thereafter, without rotating the stage44A, the oblique portions34of the sealant portion20can be applied while the dispenser bodies42A are slid on the inclined guides43b. Thus, the frequency of rotation of the stage44A can be reduced, resulting in reduction of the processing time.

Moreover, the inclined guides43bare provided as parts separated from the guide body43a, and are arranged so that the whole lengths thereof are within the length of the guide body43a. According to the construction, the applicator can be provided with a reduced size.

An embodiment 3 of the present invention will be explained with reference toFIGS. 23 to 26. The present embodiment 3 shows a modification that includes an applicator40B differing in construction from that of the embodiment 2. In the present embodiment 3, the parts called by the same names as those of the above embodiment 2 are designated by the same symbols, even if they differ in construction. However, the suffix “B” is attached to the symbols. The redundant explanations for the constructions and operational effects will be omitted.

Referring toFIG. 23, the present applicator40B includes a guide43B formed of a guide body43aB and an inclined guide43bB, which are connected to each other. Specifically, the guide body43aB has a linear shape, and the length thereof is set to be slightly larger than the length of the long side of the CF substrates' parent material17M. On the other hand, the inclined guide43bB is arranged oblique to the length direction of the guide body43aB, and has a linear shape along the oblique direction. The inclination of the inclined guide43bB from the guide body43aB is set to conform to the inclination of the oblique portion34of the sealant portion20from the straight portion33(or, from the side of the substrates17,18). Specifically, it is set to 45 degrees. The inclined guide43bB is connected to an end portion of the guide body43aB. Slide grooves (not shown) are formed on the side surface of the guide body43aB and the side surface of the inclined guide43bB, so as to be along the length directions thereof and communicate with each other. A total of three dispenser bodies42B are mounted to the slide grooves. The dispenser bodies42B can slide along the slide grooves while moving freely between the guide body43a2and the inclined guide43bB.

<Sealant Application Process and Reinforcing Portion Application Process>

In the present embodiment, sealant portions20and reinforcing portions are applied on different parent materials by using different applicators, as in the above embodiment 2. The reinforcing portion application process can be performed in a similar manner to that of the embodiment 2, and therefore the explanation thereof will be omitted.

The sealant application process will be explained. Referring toFIG. 23, the CF substrates' parent material17M is placed on the substrate rest44aB, while the substrate rest44aB is maintained on the stage44B so that the long side thereof is parallel to the length direction of the guide body43aB. The nozzles41B are positioned at the application positions of straight portions33of the sealant portions20along the long side, by the movement of the stage44B and the movement of the dispenser bodies42B on the guide body43aB. Then, a resin material is ejected from the nozzles41B while the dispenser bodies42B are slid on the guide body43aB. Thereby, the straight portions33of the sealant portions20along the long side are applied as shown inFIG. 24. When the application of the straight portions33along the long sides of the CF substrates17is completed, the nozzle41B is positioned at the application position of the oblique portion34of the sealant portion20, or specifically, the oblique portion34to be formed parallel to the inclined guide43bB, by the movement of the stage44B and the movement of the dispenser body42B on the inclined guide43bB. The resin material is ejected from the nozzle41B while the dispenser body42B is slid on the inclined guide43bB. In this way, two oblique portions34of each sealant portion20are applied so as to be located at its corners opposed to each other, as shown inFIG. 25.

Thereafter, the substrate rest44a2on the stage44B is rotated 90 degrees with respect to the support base44b2, as shown inFIG. 26. Thereby, the short side of the substrate rest44aB is arranged parallel to the guide body43aB. Then, the nozzles41B are positioned at the application positions of straight portions33along the short side, by the movement of the stage44B and the movement of the dispenser bodies42B on the guide body43aB. Thereafter, the straight portions33along the short sides are applied in a similar manner to the above application of the straight portions33along the long sides. When the application of the straight portions33along the short sides of the CF substrates17is completed, the dispenser body42B is moved on the inclined guide43bB concurrently with the movement of the stage44B, so as to be positioned at the application position of the oblique portion34to be formed parallel to the inclined guide43b2. Then, the other oblique portions34are applied in a similar manner to the above application of the two oblique portions34.

As explained above, in the applicator40B according to the present embodiment, the inclined guide43bB is connected to the guide body43aB, so that the dispenser body42B is movable between the inclined guide43bB and the guide body43aB. According to the construction, the dispenser body42B can be shared by the inclined guide43bB and the guide body43aB, and therefore the number of dispenser bodies42B can be reduced, resulting in cost reduction.

An embodiment 4 of the present invention will be explained with reference toFIGS. 27 to 29. The present embodiment 4 shows a modification in which the material and the application process of reinforcing portions35C are changed. In the present embodiment 4, the parts called by the same names as those of the above embodiment 1 are designated by the same symbols, even if they differ in construction. However, the suffix “C” is attached to the symbols. The redundant explanations for the constructions and operational effects will be omitted.

On the array substrate18, a number of gate wiring lines24and source wiring lines25are arranged in a grid pattern (SeeFIG. 3), as described in the above embodiment 1. In the end areas of the array substrate18, referring toFIG. 27, terminal sections36are provided as end portions of the gate wiring lines24and source wiring lines25. Flexible boards not shown, which are connected to an external circuit, are connected to the terminal sections36via ACFs (Anisotropic Conductive Films as anisotropic conductive adhesives), by pressure bonding. Each flexible board is formed of a flexible thin film on which a driver e.g., as an LSI chip, is mounted. Specifically, the flexible board can be provided as a so-called TCP (Tape Carrier Package) or SOF (System On Film).

In addition to the wiring lines24,25described above, conductive pads37are provided on the array substrate18, through which a voltage is applied to the counter electrode30provided on the CF substrate17side. Referring toFIGS. 28 and 29, a connecting portion38formed of a conductive resin material is fixed to each conductive pad37. The connecting portion38is arranged to penetrate the liquid crystal layer19, and is fixed to the counter electrode30on the CF substrate17. The connecting portion38has a substantially column-like shape and a circular horizontal section. The conductive resin material of the connecting portions38is formed of the same resin material as the sealant portion20(e.g., ultraviolet curable resin material or UV/heat dual-curable resin material), but has conductivity due to including a predetermined density of conductive particles, e.g., resin particles such as PBs (Plastic Balls) coated with a conductive material such as gold. Via the connecting portions38thus formed of the conductive resin material, the conductive pads37on the array substrate18can be electrically connected the counter electrode30on the CF substrate17.

As shown inFIG. 27, the plurality of conductive pads37are located in the vicinities of the terminal sections36of the source wiring lines25. A wire lead37aextends from each conductive pad37and along the source wiring line25. The terminal portion of the wire lead37ais arranged in alignment with the terminal section36of the source wiring lines25. The terminal portions of the wire leads37a, together with the terminal section36of the source wiring lines25, are electrically connected to the flexible board described above. Note thatFIG. 27provides a schematic illustration showing solely the characteristic parts of the wiring components24,25,36,37.

The reinforcing portions35C have the same shapes as those of the embodiments 2 and 3, and are arranged on the liquid crystal panel10in a similar manner to the embodiments 2 and 3. However, they differ in being formed of the same conductive resin material as the connecting portions38. The reinforcing portions35C are formed by the same process of the manufacturing process as the connecting portions38, as described below.

In a manufacturing process of the liquid crystal panel10, the array substrate treatment process for forming components of array substrates18on a surface of an array substrates' parent material18M includes a wiring process for forming gate wiring lines24and source wiring lines25. The conductive pads37(including wire leads37a) are formed in the wiring process.

The panel assembly process after the array substrate treatment process includes a connecting portion application process for applying connecting portions38on the array substrates' parent material18M, i.e., one of the two parent materials17M,18M. The connecting portion application process is performed using an applicator (not shown) capable of ejecting a conductive resin material. Thereafter, a reinforcing portion application process for applying reinforcing portions35C is consecutively performed using the applicator that has been used by the connecting portion application process. That is, the connecting portion application process and the reinforcing portion application process are performed substantially as the single process. The detailed explanation of the applicator to be used by the process will be omitted, because it has a construction nearly identical to the applicator40shown in the embodiment 1, except that the stage44thereof lacks rotation capability. The detailed explanation of the process is as follows: On the array substrates' parent material18M placed on the stage, the nozzles are positioned at the application positions of the connecting portions, and then the conductive resin material is ejected from the nozzles for application of the connecting portions38. On the other hand, in order for application of the reinforcing portions35C on the array substrates' parent material18M, the nozzles are positioned thereon at the application positions of the reinforcing portions, and then the conductive resin material is ejected from the nozzles.

In the present embodiment, the sealant portions20and the reinforcing portions35C are applied on different parent materials by using different applicators, as in the above embodiments 2 and 3. In the sealant portion application process, the application of the sealant portions20can be performed using any one of the applicators described in the above embodiments 1 to 3, and similarly. The details of the process are similar to those of the embodiments 1 to 3, and therefore the explanation thereof will be omitted. However, in the case that the applicator described in the embodiment 1 is used for the present process, the operations for application of the reinforcing portions35should be skipped.

As explained above, according to the present embodiment, the manufacturing method of a liquid crystal panel10includes a wiring process for forming wiring components24,25,36,37on the array substrate18, i.e., one of the substrates17,18, or specifically, the substrate to be subjected to the application of the reinforcing portions35C. The wiring components24,25,36,37are arranged to be connected to the TFTs22connected to the pixel electrodes23or to be connected to the counter electrode30provided on the CF substrate17, i.e., on the other substrate. The wiring components24,25,36,37include conductive pads37to be connected to the counter electrode30. The manufacturing method further includes a connecting portion application process for applying connecting portions38formed of a conductive resin material to the conductive pads37. In the reinforcing portion application process, the reinforcing portions35C formed of the same conductive resin material as the connecting portions38are applied using the applicator that is used by the connecting portion application process for the application of the connecting portions38.

According to the method, the applicator cost can be reduced and further the processing time can be shortened, because the application of the connecting portions38and the application of the reinforcing portions35C are performed using the same conductive resin material and the same applicator.

Other Embodiments

The present invention is not limited to the embodiments explained in the above description made with reference to the drawings. The following embodiments may be included in the technical scope of the present invention, for example.

(1) The shapes and/or the arrangement positions of the reinforcing portions are not limited to those of the above embodiments, but rather may be suitably changed. For example, the reinforcing portions may be provided as point-like portions having a polygonal or elliptical section. The present invention can further include linear reinforcing portions extending parallel to the oblique portions.

(2) In the above embodiments, the reinforcing portions are provided at all the corner sections of the liquid crystal panel. However, the reinforcing portions need riot necessarily be provided at all the corner sections. The present invention can include a construction having a corner section without a reinforcing portion.

(3) In the above embodiments, the reinforcing portions are provided so that one reinforcing portion is arranged at each corner section of the liquid crystal panel. However, the present invention can include a construction in which a plurality of reinforcing portions are arranged at one corner section, for example.

(4) On the sealant portion of the above embodiments, the angle between the oblique portion and the straight portion along the long side and the angle between the oblique portion and the straight portion along the short side are set to the same angle, i.e., 45 degrees. However, the present invention can include a construction in which the angle between the oblique portion and the straight portion along the long side differs from the angle between the oblique portion and the straight portion along the short side. Further, the length of the oblique portion may be suitably changed.

(5) In the above embodiments, the application of the straight portions is first performed during the application of the sealant portion by the sealant application process. However, the application of the oblique portions may be performed first. Further, the application priorities among the straight portions or the application priorities among the oblique portions may be suitably altered.

(6) In the above embodiment 1, the application priorities between the reinforcing portion and the oblique portion may be arbitrarily determined.

(7) In the above embodiments, the sealant portions are applied to the CF substrates' parent material. However, sealant portions may be applied to the array substrates' parent material. In this case, the above embodiments 2 and 3 should be modified so that reinforcing portions are applied to the CF substrates' parent material.

(8) In the above embodiment 1, the linear reinforcing portions are provided to be connected to the sealant portion. However, the present invention can include a construction in which linear reinforcing portions are provided to be separated from the sealant portion.

(9) In the applicator of the above embodiment 2, the inclined guides are arranged so that the whole lengths thereof are within the length of the guide body. However, the present invention can include a construction in which the inclined guides are partly arranged within the length of the guide body so as to partly project to the lateral side of the guide body. Further, the present invention can include a construction that includes a single inclined guide or three or more inclined guides.

(10) In the above embodiment 3, the applicator includes a single inclined guide. However, the present invention can include a construction that includes two inclined guides connected to the respective ends of the guide body.

(11) In the above embodiments, the sealant portions and/or the reinforcing portions are applied to the parent material for a plurality of liquid crystal panels. However, the present invention can include a construction in which a sealant portion and/or reinforcing portions are applied to a separate substrate that can be cut out from a parent material, for example. Further, the present invention can include a construction, in which a parent material is divided into smaller parent materials by primary cutting, and sealant portions and/or reinforcing portions are applied to each smaller parent material for a plurality of substrates. These procedures can be also applied to the application of the connecting portions shown in the embodiment 4.

(12) In the above embodiments, an ultraviolet curable material is used for the sealant portions and the reinforcing portions. However, the present invention can include a construction in which another light curable resin material to be hardened by the irradiation of light of a wavelength other than ultraviolet wavelengths or another light/heat dual-curable resin material to be hardened by the irradiation of light of a wavelength other than ultraviolet wavelengths and by the application of heat is used instead. These materials can be also used for application of the connecting portions shown in the embodiment 4.

(13). In the above embodiments, the manufacture of a liquid crystal panel by use of “a one-drop-fill method” is shown, in which a liquid crystal material is dropped on one of the two substrates and thereafter the substrates are attached to each other. However, “a vacuum injection method” may be used instead. That is, after the substrates are attached to each other, a liquid crystal material may be injected between the substrates by vacuum injection.

(14) In the above embodiments, the liquid crystal panel has a rectangular shape (or specifically, an oblong rectangular shape). However, the liquid crystal panel may have any other quadrangular shape. For example, it may have a square shape.

(15) In the above embodiments, the TFTs are used as switching elements. However, the present invention can include a construction that uses another type of switching elements than TFTs.

(16) In the above embodiments, the cold cathode tubes are shown as the light sources of the backlight. However, the present invention can include a construction that uses another type of linear light sources than cold cathode tubes (such as hot cathode tubes), and also include a construction that uses LEDs.

(17) In the above embodiments, a television receiver as a device having a tuner is shown for illustrative purposes. However, the present invention can be applied to a display device that does not have a tuner.