Abstract:
An object of the present invention is to provide a liquid crystal panel wherein provisions are made to effectively prevent the infiltration of gas from an end portion of a liquid crystal cell or from areas near cut portions of the liquid crystal cell, and a method for fabricating such a liquid crystal panel. More particularly, the present invention provides a liquid crystal panel includes a liquid crystal cell which includes a first substrate, a second substrate, a sealing member, and a liquid crystal layer provided between the first and second transparent substrates and sealed by the sealing member, a planarizing layer formed so as to cover an end portion of the liquid crystal cell, and a gas barrier layer formed on the planarizing layer. The invention also provides a method for producing such a liquid crystal panel.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a liquid crystal panel and a liquid crystal panel production method, and more particularly to a liquid crystal panel having a gas barrier layer on an end portion thereof and a method for producing such a liquid crystal panel. 
     BACKGROUND OF THE INVENTION 
     In a liquid crystal cell produced by sealing a liquid crystal between film substrates, there can occur cases where gas infiltrates into the sealed liquid crystal, forming gas bubbles therein. 
     To address this, it is known to apply an epoxy adhesive as a gas barrier layer around an end portion of the liquid crystal cell, thereby preventing gas from infiltrating into the liquid crystal cell from the end portion thereof (for example, patent document 1). However, with an organic material such as an epoxy adhesive, it is not possible to completely prevent the infiltration of gas, and there can still occur cases where gas bubbles are formed in the liquid crystal cell due to the infiltration of gas. 
     On the other hand, in a device constructed by sandwiching between two substrates a thin film formed from a light-emitting material that exhibits electroluminescence (EL), it is known to form a DLC (diamond-like carbon) film as a gas barrier layer around an end face of the device in order to prevent the infiltration of vapor (for example, patent document 2). 
     Further, as one example of a conventional method for forming a thin film on a substrate, it is known to provide a method that performs film deposition, for example, by stacking a plurality of substrates vertically one above another on a substrate holder (for example, patent document 3). 
     Patent document 1: Japanese Unexamined Patent Publication No. 2001-221998 (FIG. 2) 
     Patent document 2: Japanese Unexamined Patent Publication No. 2002-151253 (FIG. 1) 
     Patent document 2: Japanese Unexamined Patent Publication No. H09-167763 
     SUMMARY OF THE INVENTION 
       FIG. 15  is a diagram explaining a part of a liquid crystal cell production process. 
     As shown in  FIG. 15(   a ), a plurality of liquid crystal cells  110 , each includes a first transparent substrate  111 , a first transparent electrode pattern  112 , a first alignment layer  113 , a liquid crystal layer  114 , a second alignment layer  115 , a second transparent electrode pattern  116 , a second transparent substrate  117 , a plurality of spacers  118 , and a sealing member  119 , are simultaneously formed, and a second gas barrier layer  121  and third gas barrier layer  122  for preventing the infiltration of gas are formed by plasma coating on the outside surfaces of the first transparent substrate  111  and second transparent substrate  117 , respectively. 
     Subsequently, the completed structure is cut by a cutter (not shown) at the portions indicated by arrows “a” and “b” in  FIG. 15(   a ) to separate each individual liquid crystal cell  110 . 
       FIG. 15(   b ) is an enlarged view showing a portion of the end face of the liquid crystal cell  110  cut by the cutter; as illustrated, numerous fine grooves “g” with a depth of about 1 μm are formed in the cut face. These grooves “g” are formed presumably because, when viewed microscopically, the substrates having some degree of elasticity are cut in such a manner as to be torn off by the rounded edge of the cutter. 
     As a result, if an inorganic gas barrier layer is applied as a coating directly on the end face of the liquid crystal cell  110 , the coating cannot be formed so as to fill the grooves “g”, and it is therefore not possible to completely prevent the infiltration of gas through the portions of the grooves “g”. 
     In view of this deficiency, it is an object of the present invention to provide a liquid crystal panel wherein provisions are made to effectively prevent the infiltration of gas from the end portion of the liquid crystal cell, and a method for producing such a liquid crystal panel. 
     Further, since cracks occur in the second and third gas barrier layers  121  and  122  near the cut portions (indicated by dashed circles “c” to “f” in  FIG. 1 ) of the first and second substrates  111  and  117 , if the gas barrier layer is applied only on the end portion of the liquid crystal cell  110 , there is the possibility that gas may infiltrate through the cracks. Further, polarizers are placed on the second and third gas barrier layers  121  and  122  by interposing adhesive layers therebetween and there also is the possibility that the gas generated in the adhesive layers may infiltrate into the liquid crystal cell through the cracks formed in the second and third gas barrier layers  121  and  122 . 
     Accordingly, it is an object of the present invention to provide a liquid crystal panel wherein provisions are made to effectively prevent the infiltration of gas from the areas near the cut portions as well as from the end portion of the liquid crystal cell, and a method for producing such a liquid crystal panel. 
       FIG. 16  is a diagram showing an example of film deposition. 
       FIG. 16(   a ) is a cross-sectional view showing the condition in which wafers (substrates)  159  are mounted on a substrate supporting jig  150  installed inside a reaction tube  152 .  FIG. 16(   b ) is a diagram showing the setup of  FIG. 16(   a ) as viewed from the top. As shown in  FIG. 16 , each substrate  159  is supported on a frame  151  of the substrate supporting jig  150 . The method shown in  FIG. 16  is intended to deposit a film on the upper surface of the substrate  159 , but is not intended to deposit a film around the periphery of the substrate. As a result, no film is deposited on the peripheral portions of the substrate  159  that are located close to the substrate supporting jig  150 , and the method cannot be used for the purpose of depositing film around the periphery of the substrate. Furthermore, if dirt has collected on the frame  151  where the substrate  159  contacts, scratches may occur on the reverse side of the substrate  159 . A substrate supporting jig such as shown in  FIG. 16  can be used in applications where scratches on the reverse side of the substrate do not present a serious problem, as in the case of a silicon wafer; however, in applications where scratches on the reverse side affect the external appearance, as in the case of a liquid crystal panel, the substrate supporting jig such as shown in  FIG. 16  cannot be used because such scratches can degrade the quality. 
     Accordingly, it is also an object of the present invention to provide a liquid crystal panel production method that can deposit film around the end portion of the liquid crystal panel while preventing the occurrence of scratches on the substrates of the liquid crystal panel. 
     A liquid crystal panel according to the present invention includes a liquid crystal cell which includes a first substrate, a second substrate, a sealing member, and a liquid crystal layer provided between the first and second transparent substrates and sealed by the sealing member, a planarizing layer formed so as to cover an end portion of the liquid crystal cell, and a gas barrier layer formed on the planarizing layer. 
     A liquid crystal panel production method according to the present invention includes the steps of forming a liquid crystal cell which includes a first substrate, a second substrate, a sealing member, and a liquid crystal layer provided between the first and second transparent substrates and sealed by the sealing member, applying a planarizing layer so as to cover an end portion of the liquid crystal cell, and forming a gas barrier layer on the planarizing layer. 
     According to the liquid crystal panel of the invention thus produced in accordance with the method of the invention, it is possible to prevent the infiltration of gas from the end portion of the liquid crystal panel, thereby preventing the generation of gas bubbles in the liquid crystal layer. 
     A liquid crystal panel according to the present invention includes a liquid crystal cell which includes a first substrate, a second substrate, a sealing member, and a liquid crystal layer provided between the first and second transparent substrates and sealed by the sealing member, the liquid crystal cell further including an end portion, an upper surface, and a lower surface, a planarizing layer formed so as to cover designated portions of the upper and lower surfaces, as well as the end portion of the liquid crystal cell, and a gas barrier layer formed on the planarizing layer. 
     A liquid crystal panel production method according to the present invention includes steps of forming a plurality of liquid crystal cells, each including a first substrate, a second substrate, a sealing member, and a liquid crystal layer provided between the first and second transparent substrates and sealed by the sealing member, each liquid crystal cell further including an end portion, an upper surface, and a lower surface, separating each individual liquid crystal cell by cutting along the end portion of the liquid crystal cell; applying a planarizing layer so as to cover designated portions of the upper and lower surfaces, as well as the end portion of the liquid crystal cell, and forming a gas barrier layer on the planarizing layer. 
     According to the liquid crystal panel of the invention thus produced in accordance with the method of the invention, it is possible to prevent the infiltration of gas from the areas near the cut portions along which each liquid crystal cell is separated, as well as from the end portion of the liquid crystal panel, thereby preventing the generation of gas bubbles in the liquid crystal layer. 
     The method for producing a liquid crystal panel according to the present invention includes steps of setting up a panel holder having a panel supporting member for supporting the liquid crystal panel, mounting the liquid crystal panel onto the panel holder so that the panel supporting member supports the liquid crystal panel by contacting part of an end portion of the liquid crystal panel, and depositing a film material onto the end portion of the liquid crystal panel to form a film thereon. 
     Preferably, in the liquid crystal panel production method according to the present invention, the liquid crystal panel is supported at a plurality of places along the end portion of the liquid crystal panel by a plurality of panel supporting members. 
     Preferably, in the liquid crystal panel production method according to the present invention, the end portion of the liquid crystal panel contacts the panel supporting member along a line or at a single point. 
     Preferably, in the liquid crystal panel production method according to the present invention, the film material is deposited by sputtering onto the end portion of the liquid crystal panel. In this case, it is preferable to place the liquid crystal panel with the end portion thereof facing toward the film material to be sputtered, and to conduct the sputtering while rotating the liquid crystal panel along an outer circumferential direction. 
     According to the liquid crystal panel production method of the invention, film can be deposited on the upper and lower surfaces of the liquid crystal panel as well as on the end portion of the liquid crystal panel without causing scratches on the upper and lower surfaces of the liquid crystal panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic cross-sectional view of a liquid crystal penal according to the present invention. 
         FIG. 2(   a ) is a diagram showing the condition in which one liquid crystal cell  110  is separated,  FIG. 2(   b ) is a diagram showing the condition in which a planarizing layer  141  is formed in such a manner so as to cover the end portion of the liquid crystal cell  110 ,  FIG. 2(   c ) is a diagram showing the condition in which an inorganic gas barrier layer  142  is deposited on the planarizing layer  141 , and  FIG. 2(   d ) is a diagram showing the condition in which an organic protective layer  143  is formed over the inorganic gas barrier layer  142 . 
         FIG. 3  is a diagram showing a jig used when forming the planarizing layer. 
         FIG. 4(   a ) is a diagram explaining a method for depositing the inorganic gas barrier layer, and  FIG. 4(   b ) is a diagram for explaining a stack  330  comprising a large number of liquid crystal cells  110  stacked one on top of another. 
         FIG. 5  is a schematic cross-sectional view of another liquid crystal penal according to the present invention. 
         FIG. 6(   a ) is a diagram showing the condition in which one liquid crystal cell  110  is separated,  FIG. 6(   b ) is a diagram showing the condition in which a planarizing layer  241  is formed in such a manner as to cover the end portion of the liquid crystal cell  110 ,  FIG. 6(   c ) is a diagram showing the condition in which an inorganic gas barrier layer  242  is deposited on the planarizing layer  241 , and  FIG. 6(   d ) is a diagram showing the condition in which an organic protective layer  243  is formed over the inorganic gas barrier layer  242 . 
         FIG. 7  is a schematic diagram showing sputtering equipment. 
         FIG. 8  is a perspective view of a panel holder  403  to be used in the sputtering equipment shown in  FIG. 7 . 
         FIG. 9(   a ) is an overhead view showing the panel holder  403  before liquid crystal cells  110  are mounted, and  FIG. 9(   b ) is an overhead view showing the panel holder  403  when the liquid crystal cells  110  are mounted. 
         FIG. 10(   a ) is a front view of the panel holder  403  before the liquid crystal cells  110  are mounted, and  FIG. 10(   b ) is a front view of the panel holder  403  when the liquid crystal cells  110  are mounted. 
         FIG. 11(   a ) is a side view of the panel holder  403  before the liquid crystal cells  110  are mounted, and  FIG. 11(   b ) is a side view of the panel holder  403  when the liquid crystal cells  110  are mounted. 
         FIG. 12(   a ) is a diagram (part  1 ) illustrating how the liquid crystal cells  110  are mounted onto the panel holder  403 , and  FIG. 12(   b ) is a diagram (part  2 ) illustrating how the liquid crystal cells  110  are mounted onto the panel holder  403 . 
         FIG. 13(   a ) is a diagram (part  3 ) illustrating how the liquid crystal cells  110  are mounted onto the panel holder  403 , and  FIG. 13(   b ) is a diagram (part  4 ) illustrating how the liquid crystal cells  110  are mounted onto the panel holder  403 . 
         FIG. 14  is a perspective view of an alternative panel holder  503  to be used in the sputtering equipment shown in  FIG. 7 . 
         FIG. 15(   a ) is a diagram explaining a part of a liquid crystal cell fabrication process, and  FIG. 15(   b ) is an enlarged view showing a portion of an end face of the liquid crystal cell  110  cut by a cutter. 
         FIG. 16(   a ) is a cross-sectional view showing the condition in which wafers (substrates)  159  are mounted on a substrate supporting jig  150  installed inside a reaction tube  152 , and  FIG. 16(   b ) is a diagram showing the setup of  FIG. 16(   a ) as viewed from the top. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A liquid crystal panel and a production method thereof according to the present invention will be described below with reference to the drawings. 
       FIG. 1  is a schematic cross-sectional view of a liquid crystal penal according to the present invention. 
     The liquid crystal penal  100  shown in  FIG. 1  includes a liquid crystal cell  110 , a first polarizer  130  disposed on the upper surface of the liquid crystal cell  110 , a first adhesive layer  132  for fixing the first polarizer  130 , a second polarizer  131  disposed on the lower surface of the liquid crystal cell  110 , a second adhesive layer  133  for fixing the second polarizer  131 , and a first gas barrier layer  140  formed so as to cover an end portion (which forms a cut face) of the liquid crystal cell  110 . 
     The liquid crystal cell  110  includes a first transparent substrate  111 , a second transparent substrate  117 , a sealing member  119 , a plurality of spacers  118  arranged so as to maintain a constant gap between the first and second transparent substrates  111  and  117 , a liquid crystal layer  114  provided between the first and second transparent substrates  111  and  117  and sealed by the sealing member  119 , a second gas barrier layer  121  formed so as to cover the first transparent substrate  111 , and a third gas barrier layer  122  formed so as to cover the second transparent substrate  117 . Further, a first transparent electrode pattern  112  and a first alignment film  113  are formed on the first transparent substrate  111 , and a second transparent electrode pattern  116  opposing the first transparent electrode pattern  112  and a second alignment film  115  are formed on the second transparent substrate  117 . It is to be noted that, for illustrative purposes, the scale in  FIG. 1  may not reflect the actual scale. 
     The liquid crystal layer  114  is formed from a commonly used liquid crystal material such as a TN (Twisted Nematic) liquid crystal. 
     The first and second transparent substrates  111  and  117  are each formed from a flexible polycarbonate resin with a thickness of 100 μm. However, the first and second transparent substrates  111  and  117  are not limited to this specific material, but use may be made of a modified acrylic resin, a polymethyl methacrylate resin, a polyether sulfone resin, a polyethylene terephthalate resin, a norbornene resin, glass, or the like, and the thickness can be chosen within the range of 50 μm to 250 μm. 
     The first and second transparent electrode patterns  112  and  115  are each formed by sputtering a transparent conductive film of ITO to a thickness of about 0.03 μm over the first or second transparent substrate  111  or  117 , respectively, and then patterning the film by etching away unwanted portions. Wiring lines are provided to the first and second transparent electrode patterns so that a prescribed AC voltage can be applied from a display drive controller (not shown) of the liquid crystal panel  100 . The display drive controller of the liquid crystal panel  100  is constructed to be able to switch the liquid crystal layer  114  between transmissive mode and non-transmissive mode by applying the prescribed AC voltage between the first and second transparent electrode patterns  112  and  115 . 
     The second and third gas barrier layers  121  and  122  are formed by sputtering silicon dioxide on the first and second transparent substrates  111  and  117  during the fabrication of the liquid crystal cell. 
     The first gas barrier layer  140  includes a planarizing layer  141 , an inorganic gas barrier layer  142 , and an organic gas barrier layer  143 . The cross-sectional view of  FIG. 2  shows only a portion of the liquid crystal panel  100 , but it is to be understood that the gas barrier layer  140  is formed around substantially the entire periphery of the liquid crystal cell  110 . 
     The planarizing layer  141  is formed by depositing “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, to a thickness corresponding to a dry thickness of about 5 to 10 μm. As previously described, fine grooves are formed in the end face of the liquid crystal cell  110  when cut (see  FIG. 15(   b )), and if the inorganic gas barrier layer is formed by sputtering, etc., directly on the end face, the infiltration of gas cannot be prevented because the grooves cannot be covered in a reliable manner by the inorganic gas barrier layer. In view of this, to fill the grooves, the planarizing layer  141  as an underlying layer is formed in such a manner so as to cover the end face of the liquid crystal cell  110 . In the present embodiment, since the planarizing layer  141  is formed from a resin composed principally of epoxy having gas barrier capability, the gas barrier performance can be further enhanced. 
     Then, the inorganic gas barrier layer  142  is formed by sputtering silicon dioxide to a thickness of 100 nm. The material for the inorganic gas barrier layer is not limited to silicon dioxide, but use may be made, for example, of silicon nitride, DLC, aluminum foil, copper foil, etc. It will also be noted that the desired gas barrier capability can be obtained as long as the thickness is 10 nm or greater. Since the inorganic gas barrier layer  142  is deposited on the surface planarized by the planarizing layer  141 , the end portion of the liquid crystal cell  110  can be covered in a reliable manner. 
     The organic protective layer  143  is formed by depositing “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, to a thickness corresponding to a dry thickness of about 5 to 10 μm. Since sufficient gas barrier performance can be achieved with the planarizing layer  141  and inorganic gas barrier layer  142  having gas barrier capability, the organic protective layer  143  need not necessarily be provided. However, since the inorganic gas barrier layer  142  is hard, there can occur scratches, cracks, etc., as well as pinholes during the deposition, and the organic protective layer  143  is provided to make up for the gas barrier deficiencies that can occur due to such pinholes, scratches, cracks, etc. Accordingly, the provision of the organic protective layer  143  serves to reliably confer the gas barrier capability to the end portion of the liquid crystal cell  110 . 
       FIG. 2  is a diagram for explaining the fabrication process of the liquid crystal panel  100 . 
       FIG. 2(   a ) shows the condition in which one liquid crystal cell  110  is separated by cutting a plurality of simultaneously formed liquid crystal cells  110  by a cutter (i.e., the condition after the step of  FIG. 15(   a )). 
     In the condition shown in  FIG. 2(   a ), the liquid crystal cell  110  includes the first transparent substrate  111 , first transparent electrode pattern  112 , first alignment film  113 , liquid crystal layer  114 , second alignment film  115 , second transparent electrode pattern  116 , second transparent substrate  117 , spacers  118 , sealing member  119 , second gas barrier layer  121 , and third gas barrier layer  122 . Further, as previously described, fined grooves are formed in the end face of the liquid crystal cell  110  when cut (see  FIG. 15(   b )). 
       FIG. 2(   b ) shows the condition in which the planarizing layer  141  is formed in such a manner as to cover the end portion of the liquid crystal cell  110 . 
     A jig such as shown in  FIG. 3  is used when forming the planarizing layer  141 . That is, the liquid crystal cell  110  shown in  FIG. 2(   a ) is clamped between a metal plate  301  and a magnet  302  arranged on a base  300 , and is held fixed so that the end portion around the periphery of the liquid crystal cell  110  can be easily coated. Since the liquid crystal cell  110  is held fixed by the magnetic force working between the magnet  302  and the metal plate  301 , the planarizing layer  141  can be easily applied without scratching the liquid crystal cell  110  and without using a special adhesive, etc. 
     After fixing the liquid crystal cell  110  in position, a solution  312 , prepared by dissolving “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, into a solvent, is applied to an end of a melamine resin sponge  310  which is then brought into contact with the designated portion of the liquid crystal cell  110  to apply a coating thereon. Instead of the melamine resin sponge  310 , a high-density sponge or a cloth of finely woven fiber or the like may be used to apply the planarizing layer  141 . After forming the coating of the solution  312 , the liquid crystal cell  110  is heated at 60° to 80° for about one hour to evaporate the solvent, completing the formation of the planarizing layer  141 . The planarizing layer  141  may be formed by applying the solution a plurality of times. 
       FIG. 2(   c ) is a diagram showing the condition in which the inorganic gas barrier layer  142  is deposited on the planarizing layer  141 . 
     The inorganic gas barrier layer  142  is deposited under an argon-oxygen atmosphere by causing silicon dislodged from a target  321  to react with the oxygen while rotating the liquid crystal cell  110 . As shown in  FIG. 4(   a ), a stack  330  comprising a large number of liquid crystal cells  110  stacked one on top of another is placed on a small turntable  323  rotating in a k direction on its axis, the small turntable  323  being mounted on a large turntable  322  revolving in a j direction. As shown in  FIG. 4(   b ), the stack  330  contains about 30 liquid crystal cells  100  stacked one on top of another by alternately sandwiching therebetween spacers whose size is a little smaller than the liquid crystal cells  110 , and the liquid crystal cells  110  are arranged with their end portions exposed. Since silicon dioxide molecules  341  randomly move by colliding with argon molecules  340 , the inorganic gas barrier layer  142  can be deposited to a prescribed thickness (for example, 100 nm) evenly on the end portion of each liquid crystal cell  110 . Since each liquid crystal cell  110  is mounted with its end portion exposed, if the liquid crystal cell  110  has an opening  150  as shown in  FIG. 4(   b ), for example, the inorganic gas barrier layer can be deposited in a good condition even on the portion of the opening  150 . 
       FIG. 2(   d ) is a diagram showing the condition in which the organic protective layer  143  is formed over the inorganic gas barrier layer  142 . 
     When forming the organic protective layer  143 , a jig such as shown in  FIG. 3  is used in a manner similar to the formation of the planarizing layer  141 ; that is, a solution  312 , prepared by dissolving “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, into a solvent, is applied to an end of a melamine resin sponge  310  which is then brought into contact with the designated portion of the liquid crystal cell  110  to apply a coating thereon. After forming the coating of the solution  312 , the liquid crystal cell  110  is heated at 60° to 80° for about one hour to evaporate the solvent, completing the formation of the organic protective layer  143 . 
     By performing the fabrication steps illustrated in  FIGS. 2(   a ) to  2 ( d ), as described above, the first gas barrier layer  140  is formed on the end portion of the liquid crystal cell  110 . 
     After forming the first gas barrier layer  140 , the first adhesive layer  132  and the first polarizer are disposed on the upper surface of the liquid crystal cell  110 , and the second adhesive layer  133  and the second polarizer are disposed in like manner on the lower surface of the liquid crystal cell  110 , thereby completing the fabrication of the liquid crystal panel  100 . 
     When using an aluminum foil as the inorganic gas barrier layer  142 , the aluminum foil is bonded to the planarizing layer  141  so as to cover the coating surface thereof, and then subjected to pressure in an autoclave to purge gas bubbles; after that, an adhesive is applied around the edge of the aluminum foil to complete the placement of the aluminum foil. As the adhesive for the aluminum foil, it is preferable to use the same resin as that used to form the planarizing layer  141 . 
       FIG. 5  is a schematic cross-sectional view of another liquid crystal penal according to the present invention. 
     The liquid crystal penal  200  shown in  FIG. 5  comprises a liquid crystal cell  110 , a first polarizer  230  disposed on the upper surface “x” of the liquid crystal cell  110 , a first adhesive layer  232  for fixing the first polarizer  230 , a second polarizer  231  disposed on the lower surface “y” of the liquid crystal cell  110 , a second adhesive layer  233  for fixing the second polarizer  231 , and a first gas barrier layer  240  formed so as to cover an end portion “z” (cut face), a portion of the upper surface “x” (near the cut face), and a portion of the lower surface “y” (near the cut face) of the liquid crystal cell  110 . The liquid crystal cell  110  is the same as that used in the liquid crystal panel  100  shown in  FIG. 1 , and will not be further described herein. 
     The first gas barrier layer  240  includes a planarizing layer  241 , an inorganic gas barrier layer  242 , and an organic gas barrier layer  243 . The cross-sectional view of  FIG. 5  shows only a portion of the liquid crystal panel  200 , but it is to be understood that the gas barrier layer  240  is formed around substantially the entire periphery of the liquid crystal cell  110 . 
     The planarizing layer  241  is formed by depositing “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, to a thickness corresponding to a dry thickness of about 5 to 10 μm. As previously described, the upper and lower surfaces “x” and “y” of the liquid crystal cell  110  contain cracks in the portions thereof near the cut face, and if the cracks are left uncovered, gas may infiltrate through the cracks. Further, if the inorganic gas barrier is formed by sputtering, etc., so as to cover the cracks, the infiltration of gas cannot be prevented because the cracks cannot be covered in a reliable manner by the inorganic gas barrier layer. Likewise, fine grooves are formed in the end portion “z” of the liquid crystal cell  110  when cut (see  FIG. 15(   b )), and if the inorganic gas barrier layer is formed by sputtering, etc., directly on the end face, the infiltration of gas cannot be prevented because the grooves cannot be covered in a reliable manner by the inorganic gas barrier layer. In view of this, in order to fill the cracks and grooves, the planarizing layer  241  as an underlying layer is formed in such a manner as to cover not only the end portion “z” of the liquid crystal cell  110  but also the portions of the upper and lower surfaces “x” and “y” near the cut face. In the present embodiment, since the planarizing layer  241  is formed from a resin composed principally of epoxy having gas barrier capability, the gas barrier performance can be further enhanced. 
     Then, the inorganic gas barrier layer  242  is formed by sputtering silicon dioxide to a thickness of 100 nm. The material for the inorganic gas barrier layer is not limited to silicon dioxide, but use may be made, for example, of silicon nitride, DLC, aluminum foil, copper foil, etc. It will also be noted that the desired gas barrier capability can be obtained as long as the thickness is 10 nm or greater. Since the inorganic gas barrier layer  242  is deposited on the surface planarized by the planarizing layer  241 , the end portion “z” of the liquid crystal cell  110  and the portions of the upper and lower surfaces “x” and “y” near the cut face can be covered in a reliable manner. 
     The organic protective layer  243  is formed by depositing “MAXIVE” (registered trademark), a gas barrier resin composed principally of epoxy, to a thickness corresponding to a dry thickness of about 5 to 10 μm. Since sufficient gas barrier performance can be achieved with the planarizing layer  241  and inorganic gas barrier layer  242  having gas barrier capability, the organic protective layer  243  need not necessarily be provided. However, since the inorganic gas barrier layer  242  is hard, there can occur scratches, cracks, etc., as well as pinholes during the deposition, and the organic protective layer  243  is provided to make up for the gas barrier deficiencies that can occur due to such pinholes, scratches, cracks, etc. Accordingly, the provision of the organic protective layer  243  serves to reliably confer the gas barrier capability to the end portion “z” of the liquid crystal cell  110  and the portions of the upper and lower surfaces “x” and “y” near the cut face. 
       FIG. 6  is a diagram explaining the production process of the liquid crystal panel  200 . 
       FIG. 6(   a ) shows the condition in which one liquid crystal cell  110  is separated by cutting a plurality of simultaneously formed liquid crystal cells  110  by a cutter (i.e., the condition after the step of  FIG. 15) . In the condition shown in  FIG. 6(   a ), the liquid crystal cell  110  is identical in structure to that shown in  FIG. 2(   a ). 
       FIG. 6(   b ) shows the condition in which the planarizing layer  241  is formed in such a manner as to cover the end portion “z” of the liquid crystal cell  110  and the portions “c” and “e” of the upper and lower surfaces “x” and “y” near the cut face. 
     A jig such as shown in  FIG. 3  is used when forming the planarizing layer  241 . The detailed procedure for forming the planarizing layer  241  is the same as that described using  FIG. 3  in conjunction with  FIG. 2(   b ), and therefore, the description will not be repeated here. 
       FIG. 6(   c ) is a diagram showing the condition in which the inorganic gas barrier layer  242  is deposited on the planarizing layer  241 . 
     The inorganic gas barrier layer  242  is deposited under an argon-oxygen atmosphere by causing silicon dislodged from a target  321  to react with the oxygen while rotating the liquid crystal cell  110 . The detailed procedure for depositing the inorganic gas barrier layer  242  is the same as that described using  FIG. 4  in conjunction with  FIG. 2(   c ), and therefore, the description will not be repeated here. 
       FIG. 6(   d ) is a diagram showing the condition in which the organic protective layer  243  is formed over the inorganic gas barrier layer  242 . 
     When forming the organic protective layer  243 , a jig such as shown in  FIG. 3  is used in a manner similar to the formation of the planarizing layer  241 . The detailed procedure for forming the organic protective layer  243  is the same as that described using  FIG. 3  in conjunction with  FIG. 2(   d ), and therefore, the description will not be repeated here. 
     By performing the production steps illustrated in  FIGS. 6(   a ) to  6 ( d ), as described above, the first gas barrier layer  240  is formed on the end portion “z” of the liquid crystal cell  110  and its neighboring portions. It is desirable that the first gas barrier layer  240  be formed over the end portion of the liquid crystal cell  110  in such a manner as to extend over a distance “w” from the cut face of the liquid crystal cell  110 , as shown in  FIG. 6(   d ). In the present embodiment, the distance “w” is chosen to be 0.5 mm. 
     After forming the first gas barrier layer  240 , the first adhesive layer  232  and the first polarizer  230  are disposed on the upper surface “x” of the liquid crystal cell  110  in such a manner as to avoid the first gas barrier layer  240 , and the second adhesive layer  233  and the second polarizer  231  are disposed in like manner on the lower surface of the liquid crystal cell  110 , thereby completing the fabrication of the liquid crystal panel  200 . It is preferable to form the first and second adhesive layers  232  and  233  so as not to contact the gas barrier layer  240 , because gas may be emitted from the first and second adhesive layers  232  and  233 . 
     When using an aluminum foil as the inorganic gas barrier layer  242 , the aluminum foil is bonded to the planarizing layer  241  so as to cover the coating surface thereof, and then subjected to pressure in an autoclave to purge gas bubbles; after that, an adhesive is applied around the edge of the aluminum foil to complete the placement of the aluminum foil. As the adhesive for the aluminum foil, it is preferable to use the same resin as that used to form the planarizing layer  241 . 
     Evaluation results of the liquid crystal panels  100  and  200  produced in the above manner will be described below. 
     Liquid crystal panels were stored in an environment held at a temperature of 70° C. and a pressure of 2.2 atmospheres, and after a prescribed time elapsed, the liquid crystal panels were taken out and placed in a normal temperature, normal pressure environment; then, a pressure test was conducted using an iron ball by applying a pressure of 20 N/cm 2  for 10 seconds to each liquid crystal panel. At this time, the presence or absence of gas bubbles in the liquid crystal panel and the time required for the gas bubbles, if present, to disappear were observed. The results showed that, in the case of a liquid crystal panel provided with neither the gas barrier layer  140  nor the gas barrier layer  240  on its end portion, gas bubbles began to be observed in the liquid crystal panel when the pressure test was conducted after 300 to 400 hours had elapsed. On the other hand, in the case of the liquid crystal panel  100  provided with the gas barrier layer  140  only on its end face, gas bubbles began to be observed in the liquid crystal panel when the pressure test was conducted after about 700 hours had elapsed. In the case of the liquid crystal panel  200  provided with the gas barrier layer  240  so as to cover its end portion, gas bubbles began to be observed in the liquid crystal panel when the pressure test was conducted after about 1000 hours had elapsed. 
     When the acceleration factors for the above measurement results were estimated from the above results and the results of other reliability tests, and were applied to the respective cases, the conclusion was reached that the useful life of the liquid crystal panel provided with neither the gas barrier layer  140  nor the gas barrier layer  240  on its end portion is considered to be about two years because of the generation of gas bubbles. On the other hand, it has been found that, in the case of the liquid crystal panel  100  provided with the gas barrier layer  140  only on its end face, the useful life is four to five years and, in the case of the liquid crystal panel  200  provided with the gas barrier layer  240  so as to cover its end portion, the useful life can be greatly extended to five to six years. 
     As described above, in the liquid crystal panels  100  and  200 , the inorganic gas barrier layers  142  and  242  have been deposited using the equipment shown in  FIG. 4 . However, it is also possible to deposit such films using the equipment hereinafter described. 
       FIG. 7  is a schematic diagram showing sputtering equipment. 
     A rotary table  402  is placed inside a vacuum chamber  401 , and a panel holder  403  in which liquid crystal cells are held in a horizontal position is mounted on the table  402 . The table  402  rotates in an R direction, while a table supporting stage  404  on which the table  402  is placed rotates in a T direction inside the chamber  401 . Further, a target  405  formed from Si is disposed so that the deposition material is sputtered in a direction lateral to the panel holder  403 , and an SiO 2  film is deposited by sputtering in an oxygen atmosphere by bombarding the target  405  with an activated argon gas. The film can thus be deposited on the end portion of each liquid crystal panel. 
       FIG. 8  is a perspective view of the panel holder  403  to be used in the sputtering equipment shown in  FIG. 7 . 
     The panel holder  403  is constructed by arranging, on a rectangular supporting base  406 , a detachable post  407  near one of the shorter sides of the liquid crystal cell  110  and five other posts, i.e., the first to fifth fixed posts  481  to  485 , around the liquid crystal cell  110 . The detachable post  407  can be detached when mounting the liquid crystal cell  110 , as will be described later, and the first to fifth fixed posts  481  to  485  are fixed to the supporting base  406 . The panel holder  403  further includes panel supporting members  409  that are fixed to the first to fifth fixed posts  481  to  485  and that match the number of liquid crystal cells  110  to be mounted. None of the panel supporting members  409  are fixed to the detachable post  407 . While the present embodiment shows an example in which five liquid crystal cells  110  are mounted, the number of panel supporting members  409  need not be limited to this particular number, nor need all the panel supporting members  409  be loaded with liquid crystal cells  110 . 
       FIG. 9  is an overhead view of the panel holder  403 . 
       FIG. 9(   a ) shows the panel holder  403  before the liquid crystal cells  110  are mounted, and  FIG. 9(   b ) shows the panel holder  403  when the liquid crystal cells  110  are mounted. As shown in  FIG. 9(   a ), the detachable post  407  and the first to fifth fixed posts  481  to  485  are installed on the supporting base  406 . A bent plate-like first panel supporting portion  491  is fixed between the first fixed post  481  and the second fixed post  482 , and likewise, a bent plate-like second panel supporting portion  492  is fixed between the third fixed post  483  and the fourth fixed post  484 . Further, a bent plate-like third panel supporting portion  493 , one end of which is fixed to the fifth fixed post  485 , is provided in such a manner as to cross the first and second panel supporting portions  491  to  492  by riding upon them. As earlier described, the third panel supporting portion  493  is not fixed to the detachable post  407 . The first and second panel supporting portions  491  and  492  each have two bent portions  411 , and the third panel supporting portion  493  also has two bent portions  413 . The first to third panel supporting portions  491  to  493  together constitute one panel supporting member  409 , and one liquid crystal panel  110  is mounted on each panel supporting member  409 . While only one panel supporting member  409  is shown in  FIG. 9(   a ), a plurality of panel supporting member  409  can be arranged in a direction perpendicular to the plane of the figure. 
     The distance between the two bent portions  411  of the first panel supporting portions  491  is smaller than the lateral width of the liquid crystal cell  110 . Likewise, the distance between the two bent portions  411  of the second panel supporting portions  492  is also smaller than the lateral width of the liquid crystal cell  110 . 
       FIG. 9(   b ) shows the condition in which the liquid crystal cell  110  is mounted on the panel holder  403 . The liquid crystal cell  110  is mounted by being spaced a predetermined distance away from each post. For example, denoting the distance between the detachable post  407  and the first shorter side  1001  of the liquid crystal cell  110  by d 1 , and the distance between the fifth fixed post  485  and the second shorter side  1003  of the liquid crystal cell  110  by d 4 , it is preferable to set the distances d 1  and d 4  so that film is uniformly deposited on each end face of the liquid crystal cell  110 . Further, it is preferable to set the distances d 1  and d 4  approximately equal to each other. Likewise, denoting the distance between the second fixed post  482  and the first longer side  1002  of the liquid crystal cell  110  by d 2 , the distance between the fourth fixed post  484  and the first longer side  1002  of the liquid crystal cell  110  by d 3 , the distance between the third fixed post  483  and the second longer side  1004  of the liquid crystal cell  110  by d 5 , and the distance between the first fixed post  481  and the second longer side  1004  of the liquid crystal cell  110  by d 6 , it is preferable to set the distances d 2 , d 3 , d 5 , and d 6  so that film is uniformly deposited on each end face of the liquid crystal cell  110 . Further, it is preferable to set the distances d 2 , d 3 , d 5 , and d 6  approximately equal to each other. 
     Preferably, the liquid crystal cell  110  is supported at a total of four places on the first and second panel supporting portions  491  and  492 . Further preferably, the liquid crystal cell  110  is also supported at at least one place on the third panel supporting portion  493  and is thus supported at a total of five or six places. 
       FIG. 10  is a diagram showing the panel holder  403  as viewed from the front side of  FIG. 8 . 
       FIG. 10(   a ) shows the panel holder  403  before the liquid crystal cells  110  are mounted. For illustrative purposes, the detachable post  407  is removed. The first and second fixed posts  481  and  482  are installed on the supporting base  406 , and the plurality of first panel supporting portions  491  are fixed between the two posts. Though not shown here, the third and fourth fixed posts  483  and  484  are likewise installed on the supporting base  406 , and the plurality of second panel supporting portions  492  are fixed between the two posts. The first panel supporting portions  491  are each bent at two places  411  and formed in a bathtub shape. The second panel supporting portions  492  not shown are also formed in like manner. The plurality of third panel supporting portions  493 , each fixed at one end to the fifth fixed post  485 , are provided in such a manner as to ride upon the respective first and second panel supporting portions  491  and  492 ; as will be described later, each third panel supporting portion  493  is also bent at two places and formed in a bathtub shape. The first panel supporting portion  491 , the second panel supporting portion  492 , and the third panel supporting portion  493  are combined to form one panel supporting member  409 . 
       FIG. 10(   b ) shows the condition in which the liquid crystal cells  110  are mounted on the respective panel supporting members  409  of the panel holder  403  shown in  FIG. 10(   a ). Each liquid crystal cell  110  is held on one first panel supporting portion  491 ; in this condition, the first panel supporting portion  491  contacts only the edges  412  of the liquid crystal cell  110 . Since the first panel supporting portion  491  has a plate-like shape, when the straight line sections forming the respective edges  412  of the liquid crystal cell  110  are parallel to the first panel supporting portion  491 , the first panel supporting portion  491  contacts each edge  412  of the liquid crystal cell  110  only along a line. The phrase “only along a line” here refers to the condition in which the longitudinal length of the portion where the liquid crystal cell  110  contacts the panel supporting portion is very large compared with the width thereof. On the other hand, when the straight line sections forming the edges  412  of the liquid crystal cell  110  are not parallel to the first panel supporting portion  491 , the first panel supporting portion  491  contacts each edge  412  of the liquid crystal cell  110  at a single point. The phrase “at a single point” here refers to the condition in which the area of the portion where the liquid crystal cell  110  contacts the panel supporting portion is very small compared with the size of the liquid crystal cell  110 . 
     In this way, since the area of the portion where the liquid crystal cell  110  contacts the first panel supporting portion  491  is very small, and since neither the end faces nor the upper and lower surfaces of the liquid crystal cell  101  are in contact with the first panel supporting portion  491 , thin films of adequate thickness can be deposited on the end faces and the upper and lower surfaces of the liquid crystal cell  110  by sputtering the deposition material in a direction lateral to the panel holder  403  while rotating the panel holder  403 . Though not shown here, each edge of the liquid crystal cell  110  also contacts the second panel supporting portion  492  only along a line or at a single point. 
       FIG. 11  is a side view of the panel holder  403  shown in  FIG. 8 . 
       FIG. 11(   a ) shows the panel holder  403  before the liquid crystal cells  110  are mounted. Unlike  FIG. 10 ,  FIG. 11  shows the condition in which the detachable post  407  is installed. The first fixed post  481  (not shown) and the second fixed post  482  are installed on the supporting base  406 , and the plurality of first panel supporting portions  491  (not shown) are fixed between the two posts. Further, the third fixed post  483  (not shown) and the fourth fixed post  484  are installed on the supporting base  406 , and the plurality of second panel supporting portions  492  (not shown) are fixed between the two posts. The plurality of third panel supporting portions  493 , each fixed at one end to the fifth fixed post  485 , are provided in such a manner as to ride upon the respective first and second panel supporting portions  491  and  492 ; each third panel supporting portion  493  is bent at two places  413  and formed in a bathtub shape. The first panel supporting portion  491 , the second panel supporting portion  492 , and the third panel supporting portion  493  are combined to form one panel supporting member  409 . 
       FIG. 11(   b ) is a diagram showing the condition in which the liquid crystal cells  110  are mounted on the respective panel supporting members  409  of the panel holder  403  shown in  FIG. 11(   a ). Each liquid crystal cell  110  may be mounted in such a manner as to contact the third panel supporting portion  493 ; in that case, the third panel supporting portion  493  contacts only the edges  414  of the liquid crystal cell  110 . Since the third panel supporting portion  493  has a plate-like shape, when the straight line sections forming the edges  414  of the liquid crystal cell  110  are parallel to the third panel supporting portion  493 , the third panel supporting portion  493  contacts each edge  414  of the liquid crystal cell  110  only along a line. On the other hand, when the straight line sections forming the edges  414  of the liquid crystal cell  110  are not parallel to the third panel supporting portion  493 , the third panel supporting portion  493  contacts each edge  414  of the liquid crystal cell  110  at a single point. In this way, since the area of the portion where the liquid crystal cell  110  contacts the third panel supporting portion  493  is very small, and since neither the end faces nor the upper and lower surfaces of the liquid crystal cell  101  are in contact with the third panel supporting portion  493 , thin films of adequate thickness can be deposited on the end faces and the upper and lower surfaces of the liquid crystal cell  110  by sputtering the deposition material in a direction lateral to the panel holder  403  while rotating the panel holder  403 . 
     Next, a description will be given of how the liquid crystal cells  110  are mounted onto the panel holder  403 . 
     First, as shown in  FIG. 12(   a ), the detachable post is removed from a connecting portion  415  formed in the supporting base  406  of the panel holder  403 . Next, the liquid crystal cells  110  are mounted onto the respective panel supporting members  409 .  FIG. 12(   b ) is a diagram showing the condition in which one liquid crystal cell  110  is mounted on the uppermost panel supporting member  409 . The second and subsequent liquid crystal cells  110  are mounted onto the panel supporting members  409  in the same manner;  FIG. 13(   a ) shows the condition in which all the liquid crystal cells  110  are mounted on the respective panel supporting members  409 . Finally, the detachable post  407  is installed into the connecting portion  415  of the supporting base  406 . The detachable post  407  thus installed serves to prevent the liquid crystal cells  110  from working out of the supporting members during the film deposition process; the provision of the detachable post  407  facilitates the mounting of the liquid crystal cells  110  on the panel holder  403 . 
     The panel holder  403  is advantageously formed, for example, from stainless steel. However, other material may be chosen for use, provided that the material has the required rigidity and does not generate gases or particles. 
     The first to third panel supporting portions  491  to  493  have been described above as being formed from straight line sections having bent portions, but they may be formed in a curved shape. 
       FIG. 14  is a perspective view of an alternative panel holder  503  to be used in the sputtering equipment shown in  FIG. 7 . 
     The panel holder  503  differs from the above-described panel holder  403  in that the panel supporting members are formed from fine lines. The term “fine lines” here refers to the structure whose cross section is very small compared with its longitudinal length. These panel supporting members can be formed, for example, from wires or the like. 
     Since each panel supporting member  509  of the panel holder  503  is formed from fine lines, the panel supporting member  509  contacts the respective edges of the liquid crystal cell  110  at single points. The phrase “at single points” here refers to the condition in which the area of each portion where the liquid crystal cell  110  contacts the panel supporting member  509  is very small compared with the size of the liquid crystal cell  110 . In this way, since the area of each portion where the liquid crystal cell  110  contacts the panel supporting member  509  is very small, and since neither the end faces nor the upper and lower surfaces of the liquid crystal cell  101  are in contact with the panel supporting member  509 , thin films of adequate thickness can be deposited on the end faces and the upper and lower surfaces of the liquid crystal cell  110  by sputtering the deposition material in a direction lateral to the panel holder  503  while rotating the panel holder  503 . Other than the above difference, the structure of the panel holder  503  is identical to that of the panel holder  403 , and therefore, will not be further described here. 
     In the above embodiment, the first to third panel supporting portions  491  to  493  have been described as being formed from straight line sections having bent portions, but they may be formed in a curved shape, provided that they contact the liquid crystal cell  110  at single points. 
     The panel holder  503  is advantageously formed, for example, from stainless steel. However, other material may be chosen for use, provided that the material has the required rigidity and does not generate gases or particles.