Source: http://www.google.com/patents/US7277144?ie=ISO-8859-1
Timestamp: 2014-03-15 06:04:28
Document Index: 22858049

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Patent US7277144 - Color filter substrate, method of manufacturing the same, display device ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAspects of the invention can provide a color filter substrate that is suitable for being appropriately applied with a liquid color filter material, a manufacturing method thereof, a display device, a liquid crystal display device and electronic equipment. The color filter substrate can include a first...http://www.google.com/patents/US7277144?utm_source=gb-gplus-sharePatent US7277144 - Color filter substrate, method of manufacturing the same, display device, liquid crystal display device and electronic equipmentAdvanced Patent SearchPublication numberUS7277144 B2Publication typeGrantApplication numberUS 10/898,983Publication dateOct 2, 2007Filing dateJul 27, 2004Priority dateAug 7, 2003Fee statusPaidAlso published asCN1310076C, CN1624499A, US7295267, US20050062911, US20060274240Publication number10898983, 898983, US 7277144 B2, US 7277144B2, US-B2-7277144, US7277144 B2, US7277144B2InventorsToshihiro Ushiyama, Hisashi ArugaOriginal AssigneeSeiko Epson CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (17), Referenced by (2), Classifications (19), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetColor filter substrate, method of manufacturing the same, display device, liquid crystal display device and electronic equipmentUS 7277144 B2Abstract Aspects of the invention can provide a color filter substrate that is suitable for being appropriately applied with a liquid color filter material, a manufacturing method thereof, a display device, a liquid crystal display device and electronic equipment. The color filter substrate can include a first layer having an opening, a reflective part, a transmissive part and a filter layer that is placed on the opening and formed to cover the reflective part and the transmissive part. The transmissive part can be an opening of the reflective part and can have a generally elliptical shape.
a transmissive part that is an opening of the reflective part and has a generally elliptical shape;
a first layer having a first pattern with a shape defining a gap, the first layer being a black matrix layer formed over a reflecting surface of the reflective part;
a second layer disposed on the first layer, the second layer being a bank layer having a second pattern, the second pattern being substantially the same as the first pattern;
a filter layer that is disposed in the opening and that is formed to cover the reflective part and the transmissive part, the reflective part reflecting light through the filter layer, and the transmissive part transmitting light through the filter layer;
a light transmittable substrate formed below the reflective part; and
a resin scattering layer formed between the light transmittable substrate and the reflective part,
irregular concavities and convexities being formed on the resin scattering layer in a first area that corresponds to the reflective part and in a second area that corresponds to the transmissive part, the irregular concavities and convexities affecting light that is transmitted through the transmissive part and the filter layer, and a reflecting surface of the reflective part also having the irregular concavities and convexities.
2. The color filter substrate according to claim 1, a surface of the reflective part being a light scattering surface.
3. The color filter substrate according to claim 1, a water-shedding quality of the second layer against a liquid color filter material of the filter layer being higher than that of the first layer.
4. The color filter substrate according to claim 3, the first layer showing a lyophilic quality to the liquid color filter material.
5. The color filter substrate according to claim 1, the second layer being a resist to pattern the first layer.
6. The color filter substrate according to claim 5, the resist including a fluorinated polymer.
7. The color filter substrate according to claim 1, further comprising:
8. A display device, comprising the color filter substrate according to claim 1.
9. Electronic equipment, comprising the display device according to claim 8.
10. The color filter substrate according to claim 1, a water-shedding quality of the bank layer is higher than that of the black matrix layer.
a color filter substrate that is disposed between the light source member and the liquid crystal layer, the color filter substrate including:
a transmissive part that is an opening of the reflective part and having a generally elliptical shape;
12. Electronic equipment, comprising the liquid crystal display device according to claim 11.
13. The liquid crystal display device according to claim 11, a water-shedding quality of the bank layer is higher than that of the black matrix layer.
14. The liquid crystal display device according to claim 11, a water-shedding quality of the bank layer is higher than that of the black matrix layer.
SUMMARY OF THE INVENTION Aspects of the invention has been developed in consideration of the above-mentioned problem, and can provide a color filter substrate that is suitable for being appropriately applied with a liquid color filter material, a manufacturing method thereof, a display device, a liquid crystal display device and electronic equipment.
FIGS. 1( a) and (b) show a frame format of a liquid crystal display device of a first exemplary embodiment;
FIGS. 6( a) and (b) show a frame format of a discharging member in the head of the FIG. 5;
FIGS. 8( a) through (d) show a frame format of a manufacturing method for a base substrate of the first exemplary embodiment;
FIGS. 12( a) through (d) shows a frame format of the discharging method of the first exemplary embodiment;
FIGS. 14( a) through (d) shows a frame format of a manufacturing method of the first exemplary embodiment;
FIGS. 16( a) through (e) show a frame format of a manufacturing method for a base substrate of the second exemplary embodiment;
FIGS. 17( a) through (d) shows a frame format of a discharging method of the second exemplary embodiment;
FIGS. 21( a) and (b) show a frame format of a shape of a transmissive part.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Taking a case in which the invention is applied to a liquid crystal display device for example, the invention is described below with reference to figures. Exemplary embodiments described below shall not limit an invention which is described in claims. Also, all of components described in the embodiments below are not always essential as a solution for the invention described in claims.
The planarizing layer 34 is located to cover the filter layers 111FR, 111FG and 111FB and the bank 30. To be more specific, the planarizing layer 34 covers a step formed by the filter layers 111FR, 111FG and 111FB and the bank 30 so as to obtain a substantially flat surface. A plurality of electrodes 36 can be located on the planarizing layer 34. Each electrode 36 has a stripe shape that extends in a Y-axis direction (direction perpendicular to the page of FIG. 1( a)) and the electrode runs parallel each other. The alignment film 38A is placed to cover the plurality of electrodes 36 and the planarizing layer 34, and a rubbing treatment in a certain direction is performed.
As shown in FIG. 6( a) and FIG. 6( b), each head 114 is an ink-jet head. More particularly, each head 114 has a vibrating board 126 and a nozzle plate 128. A store 129 is provided between the vibrating board 126 and the nozzle plate 128. The store 129 is always filled with the color filter material 111R that is provided from the tank 101R through an opening 131. A dividing wall 122 is located between the vibrating board 126 and the nozzle plate 128. The dividing wall 122 is provided in a plural number. And a part that is surrounded by the vibrating board 126, the nozzle plate 128 and a pair of the dividing walls 122 is a cavity 120. The number of the cavity 120 and the number of the nozzle 118 are same because the cavity 120 is provided corresponding to the nozzle 118. The color filter material 111R is provided into the cavity 120 from the store 129 through a feed opening 130 that is located between the pair of the dividing walls 122.
Firstly, the reflective part 26 and the transmissive part 28 which is the opening in the reflective part 26 are formed on a surface of a light transmittable material. More particularly, as shown in FIG. 8( a), an aluminum (Al) film is formed on the light transmittable substrate 32 such as a glass substrate so as to almost cover the whole surface of the substrate by sputtering and the like. Here, the substrate 32 corresponds to the light transmittable member. Then, as shown in FIG. 8( b), the Al film is patterned so as to form the reflective part 26 and the transmissive part 28 in each pixel region G. To be more specific, the Al film is patterned in such a way that a shape of the transmissive part 28 becomes approximately an elliptical shape. A remaining Al film on the substrate 32 is the reflective part 26 and an area where the Al film is removed is the transmissive part 28 after the patterning. In this way, the reflective part 26 and the transmissive part 28 which is the opening in the reflective part 26 are formed on the surface of the light transmittable material.
In this exemplary embodiment, as shown in detail in FIG. 21( b), a plane view shape of the transmissive part 28 is approximately the elliptical shape when the transmissive part 28 is located on a virtual plane that is parallel to the X-axis direction and the Y-axis direction. More particularly, the transmissive part 28 is made to be approximately the elliptical shape (a track shape) which is consisted of a pair of straight lines and a pair of semicircles by patterning the Al film. The elliptical shape in this specification includes not only ellipse but also the track shape and an oval shape. As mentioned before, the X-axis direction and the Y-axis direction are the direction in which the nozzle 118 moves relatively to the discharged portion.
Next, a first material layer is formed so as to cover the reflective part 26 and the transmissive part 28. To be more specific, as shown in FIG. 8( c), a thermosetting acrylic resin in which black pigments are diffused (resin black) is applied in 3 μm thick to cover the reflective part 26 and the substrate 32. As a result, a resin black layer 17′ is obtained. Here, the resin black layer 17′ is an example of the above-mentioned first material layer.
Then, a second material layer is formed by applying resist on the first material layer. More particularly, as shown in FIG. 8( c), a negative acrylic chemical amplification type photosensitive resist in which a fluorinated polymer is blended is applied to cover the whole surface of the resin black layer 17′.
Consequently, a resist layer 30′ is obtained on the resin black layer 17′. Here, the resist layer 30′ is an example of the above-mentioned �second material layer.�
Next, the resist layer 30′ and the resin black layer 17′ are patterned. To be more specific, the resist layer 30′ is exposed to a light hv through a photomask that has a light shielding part corresponding to where the pixel region G is. Then, unexposed parts to the light hv, in other words, many parts of the resist layer 30′ and the resin black layer 17′ corresponding to where a plurality of the pixel regions G are, are removed by etching with a certain etchant. In this way, the bank 30 and the black matrix 17 that have a shape surrounding the filter layer which should be formed later are obtained at the same time as shown in FIG. 8( d). Stated another way, the opening 17A corresponding to the reflective part 26 and the transmissive part 28 is obtained.
In this exemplary embodiment, in the discharged portion 18R, the transmissive part 28 is dented compared with the reflective part 26 and which forms the step in the discharged portion 18R (FIG. 8( d)). More particularly, the step is located at the border between the reflective part 26 and the transmissive part 28. This is because the transmissive part 28 is the opening of the reflective part 26 and formed by removing the part of the reflective part 26. Therefore, a size of the step is relevant to a thickness of the reflective part 26. In the discharged portions 18G and 18B, the transmissive part 28 is similarly dented compared with the reflective part 26.
FIG. 12 is a Y-Z cross-section view of the discharged portion 18R. A horizontal direction of the page of FIG. 12 is a long side of the discharged portion 18R. As shown in FIG. 12( a), the color filter material 111R is discharged to the transmissive part 28 during the first scanning period. As shown in FIG. 12( b), when the color filter material 111R arrives at the transmissive part 28, the color filter material 111R spreads to cover not only the transmissive part 28 but also the step locating at the border between the reflective part 26 and the transmissive part 28. During the second scanning period, the color filter material 111R is discharged to the area that approximately corresponds to the reflective part 26 as shown in FIG. 12( c). In this case, some droplet of the color filter material 111R may arrive to overlap the transmissive part 28. Then, as shown in FIG. 12( d), a solvent is evaporated from the color filter material 111R that is discharged during the first scanning period and the second scanning period, and a layer of the color filter material 111R is formed in the discharged portion 18R. The layer shown in FIG. 12( d) is further dried, and then the filter layer 111FR is obtained.
The base substrate 10A on which the discharged portions 18R, 18G and 18B are formed is carried by the carrier device 170 to the stage 106 of the discharging device 100R. Then, as shown in FIG. 14( a), the discharging device 100R discharges the color filter material 111R from the discharging member 127 in the head 114 so as to form the layer of the color filter material 111R on all the discharged portions 18R. A method in which the discharging device 100R discharges the color filter material 111R is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 111R is formed on all the discharged portions 18R of the base substrate 10A, the carrier device 170 puts the base substrate 10A within the drying device 150R. Then, the filter layer 111FR is obtained on the discharged portions 18R by completely drying the color filter material 111R on the discharged portions 18R.
Next, the carrier device 170 puts the base substrate 10A on the stage 106 of the discharging device 100G. Then, as shown in FIG. 14( b), the discharging device 100G discharges the color filter material 111G from the discharging member 127 in the head 114 so as to form the layer of the color filter material 111G on all the discharged portions 18G. A method in which the discharging device 100G discharges the color filter material 111G is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 111G is formed on all the discharged portions 18G of the base substrate 10A, the carrier device 170 puts the base substrate 10A within the drying device 150G. Then, the filter layer 111FG is obtained on the discharged portions 18G by completely drying the color filter material 111G on the discharged portions 18G.
Next, the carrier device 170 puts the base substrate 10A on the stage 106 of the discharging device 100B. Then, as shown in FIG. 14( b), the discharging device 100B discharges the color filter material 111B from the discharging member 127 in the head 114 so as to form the layer of the color filter material 111B on all the discharged portions 18B. A method in which the discharging device 100B discharges the color filter material 111B is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 111B is formed on all the discharged portions 18B of the base substrate 10A, the carrier device 170 puts the base substrate 10A within the drying device 150B. Then, the filter layer 111FB is obtained on the discharged portions 18B by completely drying the color filter material 111B on the discharged portions 18B.
As mentioned above, the transmissive part 28 is approximately the elliptical shape as shown in detail in FIG. 21( b). More particularly, the transmissive part 28 is approximately the elliptical shape (a track shape) which is consisted of a pair of straight lines and a pair of semicircles. Because the transmissive part 28 does not have any corners which it is difficult to be filled with the color filter materials 111R, 111G and 111B, the whole surface of the transmissive part 28 can be filled with the color filter materials 111R, 111G and 111B without leaving any unfilled parts. Therefore, when the color filter materials 111R, 111G and 111B are dried, the transmissive parts 28 are covered with the filter layers 111FR, 111FG and 111FB without leaving any space between.
Then, the plurality of electrodes 36 are formed on the planarizing layer 34 and the alignment film 38A is formed to cover the plurality of electrodes 36 and the planarizing layer 34. Accordingly, the base substrate 10A becomes the color filter substrate 10 as shown in FIG. 14( d).
A plane view shape of the transmissive part 68 is formed to be approximately the elliptical shape as shown in FIG. 21( b). More particularly, the transmissive part 68 is approximately the elliptical shape (the track shape) which is consisted of a pair of straight lines and a pair of semicircles. The track shape can be any shape as long as it is suitable to a plane view shape of an opening 57A that is defined by a shape of the black matrix 57. For example, it can be a circular form in which the pair of straight lines is omitted or a track shape that is consisted of two pairs of straight lines and two pairs of circular arc as long as the plane view shape of the opening 57A is close to square.
The planarizing layer 74 is located to cover the filter layers 211FR, 211FG and 211FB and the bank 70. To be more specific, the planarizing layer 74 covers a step formed by the filter layers 211FR, 211FG and 211FB and the bank 70 so as to obtain a substantially flat surface. The plurality of electrodes 36 is located on the planarizing layer 74. Each electrode 36 has the stripe shape that extends in the Y-axis direction (direction perpendicular to the page of FIG. 15( a)) and the electrode runs parallel each other. The alignment film 38A is placed to cover the plurality of electrodes 36 and the planarizing layer 74, and the rubbing treatment in a certain direction is performed.
Firstly, the reflective part 66 and the transmissive part 68 which is the opening in the reflective part 66 are formed on a surface of a light transmittable material. More particularly, as shown in FIG. 16( a), a resin layer that is transmissible and made of polyimide and the like is formed on the light transmittable substrate 72 such as the glass substrate so as to almost cover the whole surface of the substrate by sputtering and the like. And then, a random concavity and convexity is given to a surface of the resin layer by a blast method. Consequently the resin scattering layer 71 is obtained. Here, the resin scattering layer 71 corresponds to the light transmittable member. Then, an aluminum (Al) film is formed on the resin scattering layer 71 by sputtering and the like. After that, as shown in FIG. 16( b), the Al film is patterned so as to form the reflective part 66 and the transmissive part 68 in each pixel region G. A remaining Al film on the resin scattering layer 71 is the reflective part 66 and an area where the Al film is removed is the transmissive part 68 after the patterning. In this way, the reflective part 66 and the transmissive part 68 are formed on the surface of the light transmittable material.
In this exemplary embodiment, as shown in detail in FIG. 21( b), a plane view shape of the transmissive part 68 is approximately the elliptical shape when the transmissive part 68 is located on a virtual plane that is parallel to the X-axis direction and the Y-axis direction. More particularly, the transmissive part 68 is made to be approximately the elliptical shape (the track shape) which is consisted of the pair of straight lines and the pair of semicircles by patterning the Al film. The elliptical shape in this specification includes not only ellipse but also the track shape and the oval shape. As mentioned before, the X-axis direction and the Y-axis direction are the direction in which the nozzle 118 moves relatively to the discharged portion.
Next, as shown in FIG. 16( b), the over coat layer can be applied so as to cover the reflective part 66 and the resin scattering layer 71 and patterned to be the same shape as that of the reflective part 66. As a result, the over coat layer 65 is obtained on the reflective part 66.
Next, a first material layer is formed so as to cover the reflective part 66 and the transmissive part 68. To be more specific, as shown in FIG. 16( d), the thermosetting acrylic resin in which black pigments are diffused (resin black) is applied in 3 μm thick to cover the overcoat layer 65 and the substrate 72 that is exposed between two overcoat layers 65 (in other words, between two reflective parts 66). As a result, a resin black layer 57′ is formed. Here, the resin black layer 57′ is an example of the above-mentioned first material layer.
Then, as shown in FIG. 16( b), a negative acrylic chemical amplification type photosensitive resist in which a fluorinated polymer is blended is applied to cover the whole surface of the resin black layer 57′.
Next, the resist layer 70′ and the resin black layer 57′ are patterned. To be more specific, the resist layer 70′ is exposed to the light hv through a photomask that has the light shielding part corresponding to where the pixel region G is. Then, unexposed parts to the light hv, in other words, many parts of the resist layer 70′ and the resin black layer 57′ corresponding to where the plurality of the pixel regions G are, are removed by etching with a certain etchant. In this way, the black matrix 57 and the bank 70 and that have a shape surrounding the filter layer which should be formed later are obtained at the same time as shown in FIG. 16( e). Stated another way, the opening 57A corresponding to the reflective part 66 and the transmissive part 68 is obtained.
The base substrate 50A on which the discharged portions 58R, 58G and 58B are formed is carried by the carrier device 170 (FIG. 1) to the stage 106 of the discharging device 100R. Then, as shown in FIG. 17( a), the discharging device 100R discharges the color filter material 211R from the head 114 so as to form the layer of the color filter material 211R on all the discharged portions 58R. A method in which the discharging device 100R discharges the color filter material 211R is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 211R is formed on all the discharged portions 58R of the base substrate 50A, the carrier device 170 puts the base substrate 50A within the drying device 150R. Then, the filter layer 211FR is obtained on the discharged portions 58R by completely drying the color filter material 211R on the discharged portions 58R.
Next, the carrier device 170 puts the base substrate 50A on the stage 106 of the discharging device 100G. Then, as shown in FIG. 17( b), the discharging device 100G discharges the color filter material 211G from the head 114 so as to form the layer of the color filter material 211G on all the discharged portions 58G. A method in which the discharging device 100G discharges the color filter material 211G is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 211G is formed on all the discharged portions 58G of the base substrate 50A, the carrier device 170 puts the base substrate 50A within the drying device 150G. Then, the filter layer 211FG is obtained on the discharged portions 58G by completely drying the color filter material 211G on the discharged portions 18G.
Next, the carrier device 170 puts the base substrate 50A on the stage 106 of the discharging device 100B. Then, as shown in FIG. 17( c), the discharging device 100B discharges the color filter material 211B from the head 114 so as to form the layer of the color filter material 211B on all the discharged portions 58B. A method in which the discharging device 100B discharges the color filter material 211B is the same as the way described above with reference to FIGS. 10, 11 and 12. After the layer of the color filter material 211B is formed on all the discharged portions 58B of the base substrate 10A, the carrier device 170 puts the base substrate 50A within the drying device 150B. Then, the filter layer 211FB is obtained on the discharged portions 58B by completely drying the color filter material 211B on the discharged portions 58B.
As mentioned above, the transmissive part 68 is approximately the elliptical shape as shown in detail in FIG. 21( b). More particularly, the transmissive part 68 is approximately the elliptical shape (the track shape) which is consisted of the pair of straight lines and the pair of semicircles. Because the transmissive part 68 does not have any corners which it is difficult to be filled with the color filter materials 211R, 211G and 211B, the whole surface of the transmissive part 68 can be filled with the color filter materials 211R, 211G and 211B without leaving any unfilled parts. Therefore, when the color filter materials 211R, 211G and 211B are dried, the transmissive parts 68 are covered with the filter layers 211FR, 211FG and 211FB without leaving any space between.
Then, the plurality of electrodes 36 are formed on the planarizing layer 74 and the alignment film 38A is formed to cover the plurality of electrodes 36 and the planarizing layer 74. Accordingly, the base substrate 50A becomes the color filter substrate 50 as shown in FIG. 17( d).
In the first through third exemplary embodiments, the shape of the transmissive part 28 and the shape of the transmissive part 68 are approximately the elliptical shape. However, it should be understood that the shape of the transmissive part 28 and the shape of the transmissive part 68 may be a rectangle as shown in FIG. 21( a). Even if the shape of the transmissive part 28 and the transmissive part 68 is rectangular, the step locating at the border between the reflective part and the transmissive part can be adequately covered with discharged droplets as long as the discharging the material to the transmissive part 28 or 68 and the discharging the material to the reflective part 26 or 66 are conducted in this order. However, when the approximately elliptical shape transmissive part and the discharging method to the transmissive part are combined, certainty of covering the step will rise.
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