Patent ID: 8767324

Claim:
A method for manufacturing a color filter by using a plurality of photomasks smaller than the color filter, the color filter including: a substrate; a lattice-shaped black matrix formed on the substrate; a plurality of colored pixels arranged on the substrate in a row direction and a column direction perpendicular to the row direction, wherein colored pixels of the same color are arranged in the column direction, and each of the colored pixels includes a colored layer overlapping with an area defined by the black matrix and with a portion of the black matrix around the area, the method comprising: performing, for each color, the processes of: applying a resist to the substrate; locating a first photomask so as to be opposed to a first area where a plurality of consecutive columns of the colored pixels are formed; locating a second photomask so as to be opposed to a second area where a plurality of other consecutive columns of the colored pixels are formed and that does not overlap with the first area; and exposing the substrate to which the resist has been applied by causing a light source to intermittently emit light while transporting the substrate toward the first photomask and the second photomask, thereby sequentially forming colored layers on the substrate to form the colored pixels; and performing at least one of the processes of: (a) adjusting exposure illuminances of an exposure head to which the first photomask is mounted and an exposure head to which the second photomask is mounted, such that a difference between the exposure illuminances is not higher than 1%; and (b) adjusting tilts of the first photomask and the second photomask such that a difference in distance from the substrate between the first photomask and the second photomask is not greater than 10 μm, wherein in the exposing process, exposure is performed such that the amounts of misalignment in the row direction between colored layers of the same color and the black matrix are constant in the first area, the amounts of misalignment in the row direction between colored layers of the same color and the black matrix are constant in the second area, a maximum value of differences between overlap widths in the row direction between the colored pixels of the same color and the black matrix in the first area, and overlap widths in the row direction between the colored pixels of the same color and the black matrix in the second area, is not greater than 4 μm, and a maximum value of overlap widths in the row direction between all of the colored pixels and the black matrix is not greater than 8 μm.