HK1112063A - Liquid crystal display apparatus forming assembly, liquid crystal cell, and liquid crystal display apparatus, and manufacturing method thereof - Google Patents

Description

Liquid crystal cell, liquid crystal display device, and forming assembly and manufacturing method thereof

Cross reference to related patent applications

The present patent application is based on the earlier japanese patent application No.2006-207601 filed on 31.7.2006 and claiming priority benefits thereof, the entire contents of which are incorporated herein by reference.

Technical Field

The invention relates to a liquid crystal display device forming assembly, a liquid crystal cell, a liquid crystal display device and a manufacturing method thereof.

Background

According to a conventional method of manufacturing a liquid crystal cell and a liquid crystal display device, two large glass substrates each having an area on which a completed liquid crystal display device can be formed are adhered to each other with an approximately square seal member interposed therebetween, thereby forming a liquid crystal display device forming assembly. The liquid crystal display device forming assembly is cut along scribe lines formed on respective outer surfaces thereof in the column direction and the row direction, thereby forming a liquid crystal cell. A polarizing plate was attached to the liquid crystal cell, and a driving circuit was mounted on the liquid crystal cell, thus obtaining a liquid crystal display device. Such a method is disclosed in, for example, Japanese patent application laid-open No. 2006-143506. In this case, the surface of one of the two substrates included in each liquid crystal cell, which faces the other substrate, has scanning signal lines, data signal lines, thin film transistors, pixel electrodes, alignment films, and the like. The surface of the other substrate facing the first substrate has a color filter, an alignment film, and the like. The two substrates are adhered to each other by the sealing member. The liquid crystal is sealed between the two substrates.

In cutting the liquid crystal display device forming assembly, first, scribe lines (scribes lines) are formed on both surfaces located on the outer side among the respective surfaces of a pair of glass substrates included in the liquid crystal display device forming assembly, using a scriber. Since the liquid crystal display device forms the structure of the assembly, the scribe line cannot be formed on both inner surfaces of the pair of glass substrates. Therefore, when the liquid crystal display device forming assembly is cut, the accuracy of the shape on each surface located on the outer side may be different from the accuracy of the shape on each surface located on the inner side corresponding to the outer surface. In this case, the cut end face of the glass substrate is not perpendicular to the surface of the glass substrate and is undesirably obliquely broken. The end face of the glass substrate is relatively larger at the portion where the scribe lines in the row direction and the scribe lines in the column direction intersect than at the other portion, and is not perpendicular to the surface of the glass substrate and is easily broken obliquely. This forms a relatively large burr (burr), which causes an obstacle when the resulting liquid crystal display device is built in an electronic apparatus.

Disclosure of Invention

According to an aspect of the present invention, there is provided a method of manufacturing a liquid crystal cell, including:

preparing a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

adhering the pair of glass substrates to form a liquid crystal display device forming assembly after inserting a plurality of seals and a plurality of pillars each including ends abutting against the pair of glass substrates, respectively, between the pair of glass substrates; and

forming a plurality of scribe lines intersecting each other on surfaces of the pair of glass substrates opposite to surfaces of the pair of glass substrates opposed to each other after forming the liquid crystal display device forming assembly,

wherein at least a portion of each of the pillars is disposed to overlap one of regions between the pair of glass substrates corresponding to the scribe lines.

According to another aspect of the present invention, there is provided a method of manufacturing a liquid crystal display device, including:

preparing a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

adhering the pair of glass substrates to form a liquid crystal display device forming assembly after inserting a plurality of seals and a plurality of pillars each including ends abutting against the pair of glass substrates, respectively, between the pair of glass substrates; and

forming a plurality of scribe lines intersecting each other on surfaces of the pair of glass substrates opposite to surfaces of the pair of glass substrates opposed to each other after forming the liquid crystal display device forming assembly,

wherein at least a portion of each of the pillars is disposed to overlap one of regions between the pair of glass substrates corresponding to the scribe lines.

According to another aspect of the present invention, there is provided a liquid crystal display device forming assembly including:

a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

a plurality of sealing members interposed between the pair of glass substrates; and

a plurality of pillars each including an end abutting against the pair of glass substrates, respectively,

wherein at least a part of each of the pillars is provided so as to include one of regions between the pair of glass substrates corresponding to scribe lines that intersect with each other on surfaces of the pair of glass substrates opposite to each other.

According to another aspect of the present invention, there is provided a liquid crystal cell including:

a pair of glass substrates;

a sealing member interposed between the pair of glass substrates; and

including at least one pillar abutting against ends of the pair of glass substrates, respectively,

wherein at least one of the at least one support posts is provided on at least one of the glass substrates in at least one region corresponding to one of the ends of the glass substrate.

According to another aspect of the present invention, there is provided a liquid crystal display device including:

a pair of glass substrates;

a sealing member interposed between the pair of glass substrates; and

including at least one pillar abutting against ends of the pair of glass substrates, respectively,

wherein at least one of the at least one support is provided on at least one of the pair of glass substrates in at least one region corresponding to one of the ends of the pair of glass substrates.

According to an aspect of the present invention, a pair of glass substrates has a plurality of scribe lines intersecting each other on a surface of the pair of glass substrates opposite to the surface of the pair of glass substrates opposite to each other, wherein at least a portion of each of the pillars is provided to overlap (overlap) one of regions between the pair of glass substrates corresponding to the scribe lines; therefore, at the ends of the pair of glass substrates, it is possible to suppress the frequency at which the end faces of the glass substrates after cutting are relatively larger than the other portions and may be obliquely broken to the surfaces of the glass substrates, or relatively large burrs are formed to cause defective outer shapes.

Advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.

Fig. 1A is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a first embodiment of the present invention;

FIG. 1B is a sectional view taken along line IB-IB of FIG. 1A;

fig. 2 is a flowchart showing a process of manufacturing the liquid crystal display device shown in fig. 1A and 1B;

fig. 3 is a partially cut-away plan view partially cutting away the first and second large glass substrates to explain steps S1 through S5 in fig. 2;

fig. 4 is a plan view of the liquid crystal cell obtained by step S5 (second cutting) in fig. 2;

fig. 5 is a partially cut-away plan view showing an experimental liquid crystal display device;

fig. 6 is a partially cut-away plan view partially cutting away a pillar to explain cutting of the liquid crystal display device shown in fig. 5;

fig. 7 is a table explaining measurement results obtained at the respective measurement points shown in fig. 6;

fig. 8 is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a second embodiment of the present invention;

fig. 9 is a plan view similar to fig. 3 to explain an example of a method of manufacturing the liquid crystal display device shown in fig. 8;

fig. 10 is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a third embodiment of the present invention;

fig. 11 is a plan view similar to fig. 3 to explain an example of a method of manufacturing the liquid crystal display device shown in fig. 10;

fig. 12 is an enlarged plan view similar to fig. 3 to explain an example of a manufacturing method according to a fourth embodiment of the invention;

fig. 13A is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a fifth embodiment of the present invention;

FIG. 13B is a cross-sectional view taken along line XIIIB-XIIIB in FIG. 13A;

fig. 14 is a partially cut-away plan view partially cutting away the first and second large glass substrates to explain steps S1 through S5 in fig. 2;

fig. 15 is a plan view of the liquid crystal cell obtained by step S5 (second cutting) in fig. 2;

fig. 16 is a plan view of a liquid crystal cell according to a sixth embodiment of the present invention;

fig. 17 is a plan view similar to fig. 14 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 16;

fig. 18 is a plan view of a liquid crystal cell according to a seventh embodiment of the present invention;

fig. 19 is a plan view similar to fig. 12 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 18;

fig. 20 is a plan view of a liquid crystal cell obtained by cutting the liquid crystal display device forming assembly shown in fig. 19;

fig. 21 is a plan view of a liquid crystal cell according to an eighth embodiment of the present invention;

fig. 22 is a plan view similar to fig. 12 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 21;

fig. 23 is a plan view of a liquid crystal cell obtained by cutting the liquid crystal display device forming assembly shown in fig. 22;

fig. 24 is a plan view similar to fig. 12 to explain an example of a manufacturing method according to the ninth embodiment of the invention;

fig. 25 is a plan view similar to fig. 12 to explain an example of a manufacturing method according to a tenth embodiment of the invention; and

fig. 26 is a partially cut-away plan view partially cutting away a pillar portion to explain an example of a manufacturing method according to the eleventh embodiment of the invention.

Detailed Description

(first embodiment)

Fig. 1A is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a first embodiment of the present invention, and fig. 1B is a sectional view taken along line IB-IB in fig. 1A. In fig. 1B, the wiring 9 to be described later is not shown. In this liquid crystal display device, a first glass substrate 1 and a second glass substrate 2 disposed on the first glass substrate 1 facing it are adhered to each other by an approximately square seal member 3. Liquid crystal 4 is filled in the interior of the sealing member 3 between the two glass substrates 1 and 2 through a liquid crystal injection hole 5 formed in the sealing member 3. The sealant 6 seals the liquid crystal injection hole 5.

In this example, the lower side of the first glass substrate 1 protrudes out of the second glass substrate 2 in fig. 1A. The portion of the first glass substrate 1 protruding beyond the second glass substrate 2 is referred to as a protrusion (projection)1 a. The drive circuit 8 is mounted on the upper surface of the projection 1 a. Thin film transistors, pixel electrodes, and the like (not shown), and wirings 9 for driving the thin film transistors, the pixel electrodes, and the like such as gate lines and drain lines are formed on the upper surface of the first glass substrate 1. The wiring 9 extends to the protruding portion 1 a. One end of each wiring 9 forms a connection terminal electrically connected to the output terminal of the corresponding drive circuit 8. Respective input terminals of the drive circuit 8 are electrically connected to connection terminals of input wirings (not shown) formed on the upper surface of the first glass substrate 1. Pillars 7 (pilars) each having an approximately square shape when viewed from the top and abutting (abut against) both ends of the glass substrates 1, 2 are provided between both corners (ends) of the upper side of the first glass substrate 1 and the second glass substrate 2 in fig. 1A. Pillars 7 (each having an approximately square shape when viewed from the top) are formed on the upper surfaces of two corners (distal ends) of the lower side of the protruding portion 1a of the first glass substrate 1.

An example of a method of manufacturing such a liquid crystal display device will be described with reference to a manufacturing process flowchart shown in fig. 2. First, in step S1 (preparation of two large glass substrates) in fig. 2, two large glass substrates 11, 12 each having a region on which a completed liquid crystal display device (e.g., 3 × 3 — 9) can be formed are prepared, as shown in fig. 3. A thin film transistor, a pixel electrode, and the like (not shown) are formed on one surface of the first glass substrate 11, and a common electrode (not shown) and the like are formed on one surface of the second glass substrate 12. A region (to be described later) surrounded by one-dot dashed lines 13, 15 is a liquid crystal display device forming region 16. In the areas surrounded by the one-dot chain lines 13, 15 and the one-dot chain line 14, those where the seal member 3 is not provided are the projection (1a) forming areas 17. No additional region is formed between the liquid crystal display device formation regions 16 adjacent to each other in the row direction and the column direction.

In step S2 (seal formation) in fig. 2, an approximately square frame-shaped seal 3 made of thermosetting epoxy-based resin (thermosetting epoxy-based resin) or the like is formed by screen printing, a dropping method (dispensing method), or the like in each liquid crystal display device formation region 16 on one surface of the first large glass substrate 11 so as to surround the region other than the corresponding protrusion portion formation region 17. Meanwhile, the support posts 7 (each of which has an approximately square shape when viewed from the top and is made of a thermosetting epoxy-based resin or the like) are provided on four corners (ends) of each liquid crystal display device forming area 16 on one surface of the first glass substrate 11. A liquid crystal injection hole 5 is formed in one portion of the sealing member 3.

Subsequently, in step S3 (adhesion substrate) in fig. 2, the first and second large glass substrates 11, 12 prepared in step 1 are disposed through the seal 3 and the pillars 7 so that one surface of the first large glass substrate 11 faces one surface of the second large glass substrate 12. The sealing member 3 and the pillars 7 are heated and cured (set), so that the two large glass substrates 11, 12 are adhered to each other through them. In the following description, an assembly including two large glass substrates 11, 12 adhered together in this manner will be referred to as a liquid crystal display device forming assembly (liquid crystal display apparatus) 100.

In fig. 3, a one-dot dashed line extending in the row direction along the distal ends of the respective liquid crystal injection holes 5 of the seal 3 is a first virtual line (virtual line) 13. A one-dot dashed line extending in the row direction along the outer side of the respective lower sides of the seal members 3 is a second scribe line virtual line 14. A one-dot dashed line extending in the column direction along the respective left or right sides of the seal member 3 is a third scribe line virtual line 15. As will be described later, scribe lines are formed on the other surface of the first large glass substrate 11 and the other surface of the second large glass substrate 12 constituting the outer surfaces of the liquid crystal display device forming assembly 100, the other surfaces being opposite to the surfaces opposed to each other, each scribe line being along any one of scribe line virtual lines 13, 14, and 15.

The pillars 7 are interposed between the two large glass substrates 11, 12 at portions corresponding to intersections of first scribe line virtual lines 13 extending in the row direction and third scribe line virtual lines 15 extending in the column direction. Both ends of each pillar 7 abut (abut against) on the first and second large glass substrates 11, 12, respectively. In this example, the planar size (plaiarsize) of the pillar 7 is larger than the planar size of the area where the scribe line formed along the first scribe line virtual line 13 extending in the row direction and the scribe line formed along the third virtual line 15 extending in the column direction intersect. For example, the planar dimensions of the pillars 7 are 0.3mm × 0.3 mm. As will be described later, each of the scribe lines formed along the first and third scribe line virtual lines has a width of about 20 μm. The first and third scribe line virtual lines 13 and 15 extend through the center points of the respective pillars 7.

In step S4 (first cutting) in fig. 2, the first and third scribe lines are formed on the outer surface (located above) of the first large glass substrate 11 along the first and third scribe line virtual lines 13, 15 using a scriber while the liquid crystal display apparatus forming assembly 100 shown in fig. 3 is turned over. Then, the liquid crystal display device forming assembly 100 is turned over. An external force is applied to the first and third scribe portions of the first large glass substrate 11 via the seal 3 or the like, for example, by pressing (or applying an impact) to the upper surface of the second large glass substrate 12 located above (upper side), so as to cut the first large glass substrate 11 located below along the first and third scribe lines.

In step S5 (second cutting) in fig. 2, first, second, and third scribe lines are formed on the outer surface of the second large glass substrate 12 located above along the first, second, and third scribe line virtual lines 13, 14, and 15 using a scriber. Then, the liquid crystal display device forming assembly 100 is turned over. An external force is applied to the first, second, and third scribe line portions of the second large glass substrate 12 via the seal 3 or the like, for example, by pressing the upper surface of the first large glass substrate 12 located above, or applying an impact to the upper surface, to cut the second large glass substrate 12 located below along the first, second, and third scribe lines.

Thus, nine liquid crystal cells 18(liquid crystal cells) each shown in fig. 4 were obtained. In this state, on each of the second large glass substrates 12, a portion corresponding to the protruding portion forming region 17 (the region between the first and second scribe line virtual lines 13, 14 shown in fig. 3) is removed to expose the protruding portion 1a of the first glass substrate 1. The pillars 7 are cut together with the two large glass substrates 11, 12 so that each pillar forms a cross when viewed from the top. The pillars 7 (each having an approximately square shape when viewed from the top) remain between the two corners (ends) of the upper side of the second glass substrate 2 and the first glass substrate 1 in fig. 4. Pillars 7 (each having an approximately square shape when viewed from the top) remain on the upper surfaces of the two corners (distal ends) of the lower side of the protruding portion 1a of the first glass substrate 1. The function of the strut 7 will be described later.

In step S6 (filling liquid crystal) in fig. 2, liquid crystal (not shown) is filled between the two glass substrates 1, 2 inside the seal member 3 of the liquid crystal cell 18 through the liquid crystal injection hole 5 of the seal member 3. Subsequently, in step S7 (sealing the liquid crystal injection hole) in fig. 2, a photo-curing sealant 6 (see fig. 1A) is provided at the liquid crystal injection hole 5 of the sealing member 3 of the liquid crystal cell 18, and the sealant 6 is fixed by light, for example, ultraviolet rays, to seal the liquid crystal injection hole 5. In step S8 (mounting a driving circuit) in fig. 2, a polarizing plate is attached to the liquid crystal cell, and the driving circuit is mounted on the liquid crystal cell. Thus, the liquid crystal display device shown in fig. 1A and 1B can be obtained.

The function of the strut 7 will be described using the experimental results shown in fig. 7. First, a structure obtained by adhering two glass substrates 1, 2 through a seal member 3 and pillars-7 is prepared, as shown in fig. 5. The two glass substrates 1, 2 have the same planar size, and the pillar 7 is provided at one central portion between the two glass substrates 1, 2. The two glass substrates 1, 2 are cut along scribe lines 21 formed on the respective outer surfaces, as indicated by a one-dot dashed line extending in the row direction through the center point of the pillar 7 in fig. 5. Each of the two glass substrates 1, 2 has a thickness of 0.5 mm. The pillars 7 have a planar dimension of 0.3mm × 0.3 mm. The scribe lines 21 have a width of about 20 μm.

The cut surface of the first glass substrate 1 is inspected at a center point 21a of the pillar 7, a point 21b located on the right end face of the pillar 7, and points 21c, 21d, 21e, 21f spaced apart from the right end face of the pillar 7 by 0.3mm, 0.5mm, 0.6mm, and 1.0mm, respectively, on the scribe line 21 as indicated by the black dots in fig. 6. The results shown in fig. 7 were obtained.

In fig. 7, "outer dimension of scribe surface (scribe surface)" means a distance from the outer side of the lower side of the sealing member 3 shown in fig. 5 to the cut surface on the surface opposite to the surface of the first glass substrate 1 facing the second glass substrate 2. "the outer dimension of the opposing scribe surface" refers to the distance from the outer side of the lower side of the sealing member 3 shown in fig. 5 to the cut surface on the surface of the first glass substrate 1 facing the second glass substrate 2. "outer shape error" refers to a value obtained by subtracting the outer shape of the opposing scribing surface from the outer shape of the scribing surface described above.

As is apparent from fig. 7, the depth of the scribe line 21 reaches the deepest 110 μm at the center point 21a of the pillar 7, and gradually decreases to be smaller as farther from the center point 21a, reaches 97 μm (less than 100 μm) at a point 21d distant from the right end face of the pillar 7 by 0.5mm, reaches 90 μm at a point 21e distant by 0.6mm, reaches 72 μm at a point 21f distant by 1.0mm, and reaches 15 μm which is extremely small at a point 21g distant by 2.0 mm.

The outline dimension of the scribe surface is constant at 3.97mm regardless of the depth of the scribe line 21. This is because the cut surface on the outer surface of the first glass substrate 1 is linear so as to conform to the scribe line 21 formed on the outer surface. Instead, the physical dimensions of the opposing scribe surfaces vary, indicating that the depth of the scribe line 21 has an effect thereon.

The shape error is ± 0mm at a point 21c apart from the right end surface of the pillar 7 by 0.3mm, negative (-0.02mm, -0.018mm) on the left side of the point 21c, positive (0.02mm, 0.03mm, 0.09mm, 0.14mm) on the right side of the point 21c, and gradually becomes larger as going to the right side. If the shape error is equal to or less than 0.02mm, the resulting liquid crystal display device causes little hindrance when built in an electronic apparatus. Thus, it is considered that the frequency at which the end face of the glass substrate after cutting is not perpendicular to the surface of the glass substrate but obliquely disconnected to cause a defective appearance is suppressed. Specifically, it is considered that it is possible to suppress the frequency at which the end face of the glass substrate after cutting at the corner (end) of the glass substrate is relatively larger than the end face on the other portion and is obliquely broken to the surface of the glass substrate, or a relatively large burr is formed, thereby causing the appearance of a defect.

More specifically, regarding the shape error, it is considered that the frequency of defective shapes can be suppressed at the center point 21a (-0.02mm) of the support post 7, at the point 21b (-0.018mm) passing through the right end face of the support post 7, at the point 21c (± 0mm) away from the right end face of the support post 7 by 0.3mm, and at the point 21d (0.02mm) away from the right end face of the support post 7 by 0.5 mm. However, it is considered that the frequency of defective outer shapes cannot be suppressed at points 21e (0.03mm), 21f (0.09mm) and 21g (0.14mm) which are respectively 0.6mm, 1.0mm and 2.0mm from the right end face of the pillar 7. Thus, in order to suppress the frequency of defective outer shapes, the pillars 7 may be formed in the vicinity of the portion where defective outer shapes tend to occur (e.g., in the area of 0.05 mm).

Based on the above experimental results, in the liquid crystal display device forming assembly 100 shown in fig. 3, assuming that the support post 7 is provided at the portion corresponding to the intersection of the first and third scribe line virtual lines 13, 15, as in the liquid crystal display device according to the first embodiment described above, the frequency of defective outer shapes at the portion is generally high. Then, on the four corners (ends) of the first glass substrate 1 obtained by cutting the liquid crystal display device forming assembly 100 shown in fig. 4, it is possible to suppress the frequency of defective outer shapes. Meanwhile, on the upper two corners (ends) of the second glass substrate 2 shown in fig. 4, the same effects as those obtained on the four corners (ends) of the first glass substrate 1 described above can be obtained.

This is probably because the scribing strength is stable at the portion corresponding to the intersection of the first and third scribing virtual lines 13, 15, and because the depth of the scribe line formed at this portion may be deeper than the predetermined depth (97 μm) (110 μm at the center point 21a of the pillar 7, 105 μm at the end face of the pillar 7).

More specifically, when microscopic observation is performed, the scribe line is a step formed on the outer surface of the first and second large glass substrates 11 and 12. In a portion where the scribe lines intersect, when the second scribe line is formed to intersect the first scribe line formed for the first time, the scriber goes over (ride over) a step corresponding to the first scribe line. The pressure with which the scriber is pressed against the outer surface of the glass surface described above becomes unstable, and the pressure with which the scriber is pressed against the outer surface of the glass substrate tends to decrease. The score lines formed on this portion tend to be shallower than on other portions. Thus, the frequency of defective features may be higher at the portions where the scribe lines intersect than at other portions.

(second embodiment)

Fig. 8 is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a second embodiment of the present invention. This liquid crystal display device differs from the device shown in fig. 1A in that additional pillars 7 are continuously formed on the upper surfaces of the two corners (ends) on the lower side of the second glass substrate 2 and the first glass substrate 1 in fig. 8 and the two corners (ends) on the upper side of the protrusion 1A of the first glass substrate 1 in fig. 8.

Fig. 9 is a plan view similar to fig. 3 to explain an example of a method of manufacturing the liquid crystal display device shown in fig. 8. Fig. 9 differs from fig. 3 in that an additional pillar 7 is inserted between the two large glass substrates 11, 12 at a portion corresponding to the intersection of the second scribe line virtual line 14 and the third scribe line virtual line 15. With a manufacturing process similar to that of the first embodiment, the liquid crystal display device shown in fig. 8 can be obtained. The shape error at each of the four corners (ends) of the first and second glass substrates 1 and 2 shown in fig. 8 can be set to 0.02mm or less. Thus, the frequency of defective outer shapes can be suppressed.

(third embodiment)

Fig. 10 is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a third embodiment of the present invention. This liquid crystal display device is different from the device shown in fig. 1 in that two adjacent sides (lower and right sides) of the first glass substrate 1, which are in contact with each other, protrude outside the second glass substrate 2. In the same manner as in the first and second embodiments described above, the portion of the first glass substrate 1 that protrudes outside the second glass substrate 2 is referred to as a protruding portion 1 a. The data driving circuit 8a is mounted on a portion of the protruding portion 1a where the first glass substrate 1 protrudes downward outside the second glass substrate 2. The gate drive circuit 8b is mounted on a portion of the protruding portion 1a where the first glass substrate 1 protrudes rightward outside the second glass substrate 2. Thin film transistors, pixel electrodes, and the like (not shown), and gate lines 9b and drain lines 9a for driving the thin film transistors, the pixel electrodes, and the like are formed on the upper surface of the first glass substrate 1. One end of each gate line 9b and one end of each drain line 9a form connection terminals electrically connected to output terminals of the corresponding gate driving circuit 8b and data driving circuit 8a, respectively. The input terminals of the gate driver circuit 8b and the data driver circuit 8a are electrically connected to connection terminals of input wirings (not shown) formed on the upper surface of the first glass substrate 1.

Pillars 7a are formed between the four corners (ends) of the second glass substrate and the first glass substrate 1. On the upper surface of the protruding portion 1a of the first glass substrate 1, pillars 7b are formed in regions respectively adjoining three corners (ends), i.e., the upper right corner (end), the lower right corner (end), and the lower left corner (end), of the second glass substrate 2 in fig. 10 so as to be continuous with the respective pillars 7a formed on the above-described three corners (ends) of the second glass substrate 2. Pillars 7c are formed on the upper surface of three corners (ends), i.e., the upper right corner (end), the lower right corner (end), and the lower left corner (end) of the first glass substrate 1 in fig. 10.

Fig. 11 is a plan view similar to fig. 3 to explain an example of a method of manufacturing the liquid crystal display device shown in fig. 10. Fig. 11 is largely different from fig. 3 in that the protrusion forming region 17 has an approximately L-shaped planar surface (as shown in fig. 10) to obtain a liquid crystal display device in which two adjacent sides (lower side and right side) contacting each other protrude outside the second glass substrate 2. When both sides of the first glass substrate 1 protrude in this manner, the driving circuit can be mounted on the protruding portions of the respective sides.

The region surrounded by the scribe line virtual lines 13, 19 forms a liquid crystal display device forming region 16. In each liquid crystal display device forming region 16, a protrusion forming region 17 is formed except for a region surrounded by the scribe line virtual lines 13, 19 and the scribe line virtual lines 14, 15. The pillars 7 are interposed between the two glass substrates 11, 12 at portions corresponding to intersections of scribe line virtual lines 13, 14 extending in the row direction and scribe line virtual lines 15, 19 extending in the column direction. With a manufacturing process similar to that of the first embodiment, the liquid crystal display device shown in fig. 9 can be obtained. The shape error at each of the four corners (ends) of the first and second glass substrates 1 and 2 shown in fig. 10 can be set to 0.02mm or less. Thus, the frequency of defective outer shapes can be suppressed.

(fourth embodiment)

For example, in fig. 3, a case has been described in which the pillars 7 are inserted between the two large glass substrates 11, 12 at portions corresponding to the intersections of the first and third scribe line virtual lines 13, 15. However, the present invention is not limited thereto. For example, as in the fourth embodiment of the present invention shown in fig. 12, the pillars 7 may be formed between the two large glass substrates 11, 12 in those regions on the first, second and third scribe line virtual lines 13, 14 and 15 (excluding the intersection of the first, second scribe line virtual lines 13, 14 and third scribe line virtual line 15).

In each of the groups of four pillars 7, the spacing distance between the opposite end faces of the pair of pillars 7 formed on the same scribe line is set to 1.0mm or less. Thus, as is apparent from the above-described experimental results, in the range of 70.5 mm from the strut, the profile error can be set to 0.02mm or less, and thus the frequency of defective profiles can be suppressed. More specifically, for example, the two pillars 7 closest across the intersection of the first and third scribe line virtual lines 13, 15 on one scribe line virtual line may be formed such that the separation distance between the two pillars 7 on this scribe line virtual line is 1.0mm or less.

(fifth embodiment)

Fig. 13A is a plan view of an example of a liquid crystal display device manufactured by a manufacturing method according to a fifth embodiment of the present invention, and fig. 13B is a sectional view taken along line XIIIB-XIIIB in fig. 13A. This liquid crystal display device is greatly different from the device shown in fig. 1A in that the outer end faces of the left and right sides of the sealing member 3 are located at the same positions as the outer end faces of the left and right sides of the second glass substrate 2.

The lower side of the first glass substrate 1 in fig. 13A protrudes out of the second glass substrate 2. The portion of the first glass substrate 1 that protrudes outside the second glass substrate 2 is referred to as a protrusion 1 a. Connection terminals (not shown) and the like are formed on the upper surface of the protruding portion 1 a. As shown in fig. 13A, the width of the seal member 3 is the same throughout the entire portion thereof. The outer end faces of the upper and lower sides of the sealing member 3 (except for the liquid crystal injection hole 5 thereof) are disposed at positions further inside than the end faces of the upper and lower sides of the second glass substrate 2. The outer end faces of the left and right sides (two opposite sides) of the seal member 3 are disposed at the same positions as the end faces of the left and right sides (two opposite sides) of the second glass substrate 2.

Pillars 7 each having an approximately square shape when viewed from the top and abutting both ends of the glass substrates 1, 2 are provided between both corners (ends) of the upper side of the first glass substrate 1 and the second glass substrate 2 in fig. 13A. Pillars 7 each having an approximately square shape when viewed from the top are formed on the upper surfaces of two corners (distal ends) of the lower side of the protruding portion 1a of the first glass substrate 1.

An example of a method of manufacturing such a liquid crystal display device will be described with reference to the manufacturing process flow chart shown in fig. 2, since this is the same as the first embodiment described above. First, in step S1 (preparation of two large glass substrates) in fig. 2, two large glass substrates 11, 12 each having a region on which a completed liquid crystal display device (e.g., 3 × 3 — 9) can be formed are prepared, as shown in fig. 14. A thin film transistor, a pixel electrode, and the like (not shown) are formed on one surface of the first glass substrate 11, and a common electrode (not shown) and the like are formed on one surface of the second glass substrate 12. An area (to be described later) surrounded by one-dot dashed lines 13, 15 is a liquid crystal display device forming area 16. In the areas surrounded by the one-dot chain lines 13, 15 and the one-dot chain line 14, those where the seal member 3 is not provided are the projection (1a) forming areas 17. No additional region is formed between the liquid crystal display device formation regions 16 adjacent to each other in the row direction and the column direction. Thus, one side (e.g., the right side) of one liquid crystal display device among the liquid crystal display devices manufactured in the large glass substrates 11, 12 is shared by one side (e.g., the left side) of the other sides in another liquid crystal display device adjacent to the liquid crystal display device.

In step S2 (seal formation) in fig. 2, an approximately square frame-shaped seal 3 made of a thermosetting epoxy-based resin or the like is formed by screen printing, dropping, or the like in each of the liquid crystal display device formation regions 16 on the one surface of the first large glass substrate 11 so as to surround the region other than the corresponding protrusion formation region 17. Meanwhile, the support posts 7 (each of which has an approximately square shape when viewed from the top and is made of a thermosetting epoxy-based resin or the like) are provided on four corners (ends) of each liquid crystal display device forming area 16 on one surface of the first glass substrate 11.

Referring to fig. 14, a liquid crystal injection hole 5 is formed at one portion of the upper side of each sealing member 3. Further, the outer end faces of the upper and lower sides of the seal member 3 (except for the liquid crystal injection hole 5 thereof) are disposed at positions more inside than the end faces of the upper and lower sides of that region of the liquid crystal display device forming region 16 (except for the protrusion forming region 17). The left side (common side) 3a of the seal 3 disposed on the central portion in the row direction is shared by the right side (common side) 3a of the left adjacent seal 3. The right side (common side) 3a of the seal 3 disposed on the central portion in the row direction is shared by the left side (common side) 3a of the seal 3 adjacent on the right.

The left side of the seal member 3 disposed on the left side in the row direction forms a common side 3a which is continuously connected to the seal member disposed on the left side of the liquid crystal display device forming region 16 including the seal member 3, and is axisymmetric centering on a one-dot chain line 15. The right side of the seal member 3 disposed on the right side in the row direction forms a common side 3a which is continuously connected to the seal member disposed on the right side of the liquid crystal display device forming region 16 including the seal member 3, and is axisymmetric centering on a one-dot chain line 15. As for the width of the common side 3a of the sealing member 3, if the width of the other portion is 0.6mm to 0.8mm, the former is twice as wide as the latter, i.e., 1.2mm to 1.6 mm.

Subsequently, in step S3 (adhesion substrate) in fig. 2, the first and second large glass substrates 11, 12 prepared in step 1 are disposed through the seal 3 and the pillars 7 so that one surface of the first large glass substrate 11 faces one surface of the second large glass substrate 12. The sealing member 3 and the pillars 7 are heated and cured, so that the two large glass substrates 11, 12 are adhered to each other through them. In the following description, an assembly including two large glass substrates 11, 12 adhered together in this manner will be referred to as a liquid crystal display device forming assembly 100.

In fig. 14, a one-dot dashed line extending in the row direction along the distal ends of the respective liquid crystal injection holes 5 of the seal 3 is a first virtual line (virtual line) 13. A one-dot dashed line extending in the row direction along the outer side of the respective lower sides of the seal members 3 is a second scribe line virtual line 14. A one-dot dashed line extending in the column direction along the center in the width direction of the common side 3a of the seal 3 is a third scribe line virtual line 15. As will be described later, scribe lines are formed on the other surface of the first large glass substrate 11 and the other surface of the second large glass substrate 12 constituting the outer surfaces of the liquid crystal display device forming assembly 100, the other surfaces being opposite to the surfaces opposed to each other, each scribe line being along any one of scribe line virtual lines 13, 14, and 15.

The pillars 7 are interposed between the two large glass substrates 11, 12 at portions corresponding to intersections of first scribe line virtual lines 13 extending in the row direction and third scribe line virtual lines 15 extending in the column direction. Both ends of each pillar 7 abut (abut against) on the first and second large glass substrates 11, 12, respectively. In this example, the planar size (plaiarsize) of the pillar 7 is larger than the planar size of the area where the scribe line formed along the first scribe line virtual line 13 extending in the row direction and the scribe line formed along the third virtual line 15 extending in the column direction intersect. For example, the planar dimensions of the pillars 7 are 0.3mm × 0.3 mm. As will be described later, each scribe line formed along the first or third scribe line virtual line 13 or 15 has a width of about 20 μm. The first and third scribe line virtual lines 13 and 15 extend through the center points of the respective pillars 7.

In step S4 (first cutting) in fig. 2, the first and third scribe lines are formed on the outer surface (located above) of the first large glass substrate 11 along the first and third scribe line virtual lines 13, 15 using a scriber while the liquid crystal display apparatus forming assembly 100 shown in fig. 14 is turned over. Then, the liquid crystal display device forming assembly 100 is turned over. For example, by pressing the upper surface of the second large glass substrate 12 located above or applying an impact to the upper surface, an external force is applied to the first and third scribe portions of the first large glass substrate 11 via the seal 3 or the like to cut the first large glass substrate 11 located below along the first and third scribe lines.

In step S5 (second cutting) in fig. 2, first, second, and third scribe lines are formed on the outer surface of the second large glass substrate 12 located above along the first, second, and third scribe line virtual lines 13, 14, and 15 using a scriber. Then, the liquid crystal display device forming assembly 100 is turned over. An external force is applied to the first, second, and third scribe line portions of the second large glass substrate 12 via the seal 3 or the like, for example, by pressing the upper surface of the first large glass substrate 12 located above, or applying an impact to the upper surface, to cut the second large glass substrate 12 located below along the first, second, and third scribe lines.

Thus, nine liquid crystal cells 18 each as shown in fig. 15 were obtained. In this state, on each of the second large glass substrates 12, a portion corresponding to the protruding portion forming region 17 (the region between the first and second scribe line virtual lines 13, 14 shown in fig. 14, i.e., the region where the sealing member 3 is not formed) is removed to expose the protruding portion 1a of the first glass substrate 1. In fig. 14, the common side 3a of the sealing member 3 is cut along the third scribe line virtual line 15 at the center of the width of the common side 3a of the sealing member 3 together with the two large glass substrates 11, 12. Therefore, in fig. 15, the outer end faces of the seal 3 on the left and right sides are located at the same positions as the end faces of the second glass substrate 2 on the left and right sides. The width of the seal 3 is the same throughout its entire portion.

Further, in fig. 14, the pillars 7 are cut together with the two large glass substrates 11, 12 so that each pillar forms a cross when viewed from the top. Thus, in the state shown in fig. 15, the pillars 7 (each having an approximately square shape when viewed from the top) remain between the two corners (distal ends) of the upper side of the second glass substrate 2 and the first glass substrate 1. Pillars 7 (each having an approximately square shape when viewed from the top) remain on the upper surfaces of the two corners (distal ends) of the lower side of the protruding portion 1a of the first glass substrate 1. The function of the strut 7 is as described above.

In step S6 (filling liquid crystal) in fig. 2, liquid crystal (not shown) is filled between the two glass substrates 1, 2 inside the seal member 3 of the liquid crystal cell 18 through the liquid crystal injection hole 5 of the seal member 3. Subsequently, in step S7 (sealing the liquid crystal injection hole) in fig. 2, the light-curing sealant 6 (see fig. 1A) is provided at the liquid crystal injection hole 5 of the sealing member 3 of the liquid crystal cell 18, and the sealant 6 is fixed by light, for example, ultraviolet rays, to seal the liquid crystal injection hole 5. In step S8 (mounting a driving circuit) in fig. 2, a polarizing plate is attached to the liquid crystal cell, and the driving circuit is mounted on the liquid crystal cell. Thus, the liquid crystal display device shown in fig. 13A and 13B can be obtained.

Based on the above experimental results, in the liquid crystal display device forming assembly 100 shown in fig. 14, assuming that the support post 7 is provided at the portion corresponding to the intersection of the first and third scribe line virtual lines 13, 15, as in the liquid crystal display device according to the first embodiment described above, the frequency of defective outer shapes at the portion is generally high. Then, on the four corners (ends) of the first glass substrate 1 obtained by cutting the liquid crystal display device forming assembly 100 shown in fig. 15, it is possible to suppress the frequency of defective outer shapes. Similarly, on the upper two corners (ends) of the second glass substrate 2 shown in fig. 15, the same effects as those obtained on the four corners (ends) of the first glass substrate 1 described above can be obtained.

In the liquid crystal display device forming assembly 100 shown in fig. 14, the common side 3a of the sealing member 3 is cut along with the two large glass substrates 11, 12 at the center in the width direction thereof. Thus, the cut surface of the first glass substrate 1 at the portion corresponding to the common side 3a can be considered to be equivalent to the cut surface at the center point 21a of the pillar 7 in fig. 6. The same effect is obtained in the actual cutting.

In the liquid crystal display device shown in fig. 13, the outer end faces of the left and right sides of the seal member 3 are located at the same positions as the end faces of the left and right sides of the second glass substrate 2. When compared with the case of fig. 5 in which the outer end faces of the left and right sides of the seal member 3 are disposed at positions more inside than the end faces of the left and right sides of the second glass substrate 2, the area of the frame can be reduced.

(sixth embodiment)

Fig. 16 is a plan view of a liquid crystal cell according to a sixth embodiment of the present invention. This liquid crystal display device differs from the device shown in fig. 13A in that additional pillars 7 are continuously formed on the upper surfaces of the two corners (ends) on the lower side of the second glass substrate 2 and the first glass substrate 1 in fig. 16 and the two corners (ends) on the upper side of the protrusion 1a of the first glass substrate 1 in fig. 16.

Fig. 17 is a plan view similar to fig. 14 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 16. Fig. 17 differs from fig. 14 in that an additional support post 7 is inserted between the two large glass substrates 11, 12 at a portion corresponding to the intersection of the second scribe line virtual line 14 and the third scribe line virtual line 15. With a manufacturing process similar to that of the fifth embodiment, a liquid crystal display device shown in fig. 16 can be obtained. The shape error at each of the four corners (ends) of the first and second glass substrates 1 and 2 shown in fig. 16 can be set to 0.02mm or less. Thus, the frequency of defective outer shapes can be suppressed.

(seventh embodiment)

Fig. 18 is a plan view of a liquid crystal cell according to a seventh embodiment of the present invention. This liquid crystal display device differs from the device shown in fig. 16 in that the outer end face of the upper side of the seal member 3 is disposed at the same position as the end face of the upper side of the second glass substrate 2, and no pillars 7 are formed on the upper surfaces of the two corners (ends) of the lower side of the protruding portion 1a of the first glass substrate 1.

Fig. 19 is a plan view similar to fig. 12 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 18. Fig. 19 differs from fig. 12 in that the upper side of each seal member 3 forms a common side which is continuously connected to the seal member disposed on the upper side of the liquid crystal display device forming region 16 including the seal member 3 so as to be vertically symmetrical with respect to the first virtual scribe line 13 (as a center), and no pillar 7 is provided at a portion corresponding to the intersection of the first virtual scribe line 13 and the third virtual scribe line 15.

The liquid crystal cell 18 shown in fig. 20 can be obtained in the same manner as in the fifth embodiment described above, with the first and second cutting steps of the steps S4 and S5 shown in fig. 2. In the liquid crystal cell 18, the seal member 3b remains on the upper surface of the lower side of the projection 1a of the first glass substrate 1 in fig. 20. When the flexible circuit board is bonded to a connection terminal (not shown) formed on the upper surface of the protruding portion 1a of the first glass substrate 1, the remaining seal 3b causes an obstacle. Thus, the remaining seal member 3b is removed by a solvent or by mechanical grinding.

In step S6 (filling liquid crystal) in fig. 2, liquid crystal (not shown) is filled between the two glass substrates 1, 2 inside the seal member 3 of the liquid crystal cell 18 through the liquid crystal injection hole 5 of the seal member 3. Subsequently, in step S7 (sealing the liquid crystal injection hole) in fig. 2, a photo-curing sealant 6 (see fig. 1A) is provided at the liquid crystal injection hole 5 of the sealing member 3 of the liquid crystal cell 18, and the sealant 6 is fixed by light, for example, ultraviolet rays, to seal the liquid crystal injection hole 5. In step S8 (mounting a driving circuit) in fig. 2, a polarizing plate is attached to the liquid crystal cell, and the driving circuit is mounted on the liquid crystal cell. Thus, a liquid crystal display device shown in fig. 18 can be obtained.

The shape error at each of the four corners (ends) of the first and second glass substrates 1 and 2 shown in fig. 18 can be set to 0.02mm or less. Thus, the frequency of defective outer shapes can be suppressed. In the liquid crystal cell shown in fig. 18, the outer end face of the upper side of the seal member 3 is disposed at the same position as the end face of the upper side of the second glass substrate 2. When compared with the liquid crystal cell shown in fig. 16, the length in the vertical direction is reduced, thereby reducing the size of the liquid crystal cell.

(eighth embodiment)

Fig. 21 is a plan view of a liquid crystal cell according to an eighth embodiment of the present invention. This liquid crystal display device differs from the device shown in fig. 18 in that the outer end face of the lower side of the seal member 3 is disposed at the same position as the end face of the lower side of the second glass substrate 2, the seal member 3c is formed on the upper surface of the upper side of the protruding portion 1a of the first glass substrate 1 in fig. 21 so as to be continuous with the seal member 3 inserted between the lower sides of the two glass substrates 1, 2 in fig. 21, and the pillars 7 are formed on the upper surface of the central portions of both ends of the protruding portion 1a of the first glass substrate 1.

Fig. 22 is a plan view similar to fig. 12 to explain an example of a method of manufacturing the liquid crystal cell shown in fig. 21. Fig. 22 differs from fig. 12 in that the lower side of each seal member 3 forms a common side 3c which is continuously connected to the seal member provided on the lower side of the liquid crystal display device forming region 16 including the seal member 3 so as to be vertically symmetrical with respect to the second scribe line virtual line 14 (as a center), and the pillar 7 is not formed at a portion corresponding to the intersection of the second scribe line virtual line 14 and the third scribe line virtual line 15, while the pillar 7 is formed at a portion corresponding to the third scribe line virtual line 15 at the center portion in the width direction of the protrusion forming region 17.

The liquid crystal cell 18 shown in fig. 23 can be obtained in the same manner as in the fifth embodiment described above, with the first and second cutting steps of the steps S4 and S5 shown in fig. 2. In the liquid crystal cell 18, the seal member 3b and the seal member 3c remain on the upper surfaces of the lower side and the upper side of the projection 1a of the first glass substrate 1 in fig. 23. Among the remaining sealing members 3b and 3c, the sealing member 3c does not cause an obstacle when bonding a flexible circuit board to a connection terminal (not shown) formed on the upper surface of the protruding portion 1a of the first glass substrate 1. Thus, of the remaining seal members 3b and 3c, only the seal member 3b causing the obstacle is removed with a solvent or by mechanical grinding.

In step S6 (filling liquid crystal) in fig. 2, liquid crystal (not shown) is filled between the two glass substrates 1, 2 inside the seal member 3 of the liquid crystal cell 18 through the liquid crystal injection hole 5 of the seal member 3. Subsequently, in step S7 (sealing the liquid crystal injection hole) in fig. 2, a photo-curing sealant 6 (see fig. 1A) is provided at the liquid crystal injection hole 5 of the sealing member 3 of the liquid crystal cell 18, and the sealant 6 is fixed by light, for example, ultraviolet rays, to seal the liquid crystal injection hole 5. In step S8 (mounting a driving circuit) in fig. 2, a polarizing plate is attached to the liquid crystal cell, and the driving circuit is mounted on the liquid crystal cell. Thus, a liquid crystal display device shown in fig. 21 can be obtained.

The shape error at each of the four corners (ends) of the first and second glass substrates 1 and 2 shown in fig. 21 can be set to 0.02mm or less. Thus, the frequency of defective outer shapes can be suppressed. In the liquid crystal cell shown in fig. 21, the outer end face of the lower side of the seal member 3 is disposed at the same position as the end face of the lower side of the second glass substrate 2. When compared with the liquid crystal cell shown in fig. 18, the length in the vertical direction is reduced, thereby reducing the size of the liquid crystal cell.

(ninth embodiment)

For example, in fig. 22, a case has been described in which the pillars 7 are provided at the widthwise central portion of the protrusion forming region 17 corresponding to the third scribe line virtual line 15. However, the present invention is not limited thereto. For example, as in the ninth embodiment of the present invention shown in fig. 24, a pillar 7a may be formed between the two large glass substrates 11, 12 of the projection (1a) -forming region so as to connect the common sides 3a of the seal members 3 adjacent in the column direction extending in the column direction.

When the first and second large glass substrates 11, 12 are cut along the first to third scribe line virtual lines 13 to 15, the sealing members 3b, 3c and the pillars 7a remain at the peripheral portion of the upper surface of the protruding portion 1 a. Of the seals 3b, 3c and the pillars 7a, the seal 3b may be removed at least with a solvent or by mechanical grinding.

(tenth embodiment)

For example, in fig. 14, a case has been described in which the pillars 7 are inserted between the two large glass substrates 11, 12 at portions corresponding to the intersections of the first and third scribe line virtual lines 13, 15. However, the present invention is not limited thereto. For example, as in the tenth embodiment of the present invention shown in fig. 25, the pillars 7 may be formed between the two large glass substrates 11, 12 in those regions on the first, second and third scribe line virtual lines 13, 14 and 15 but not including the intersections of the first, second scribe line virtual lines 13, 14 and the third scribe line virtual line 15.

In each of a set of three pillars 7 and the seals in the vicinity thereof, the spacing distance between the opposite end faces of the pair of pillars 7 formed on the same scribe line, or the spacing distance between each of such pillars 7 and the seal in the vicinity thereof, is set to 1.0mm or less. Thus, as is apparent from the above-described experimental results, in the range of 70.5 mm from the strut, the profile error can be set to 0.02mm or less, and thus the frequency of defective profiles can be suppressed. More specifically, for example, the two pillars 7 closest to each other across the intersection of the first and third scribe line virtual lines 13, 15 on one scribe line virtual line 13 may be formed such that the separation distance between the two pillars 7 on this scribe line virtual line 13 is 1.0mm or less.

(eleventh embodiment)

For example, in the above-described first to tenth embodiments, the case has been described in which the plane size of the strut 7 is set larger than the plane size of the intersection of the corresponding scribe line virtual line 13 extending in the row direction and the scribe line virtual line 15 extending in the column direction. However, the present invention is not limited thereto. For example, as in the eleventh embodiment of the present invention shown in fig. 26, the planar size of each pillar 7 may be set smaller than the planar size of the intersection of the corresponding two scribe line virtual lines 13, 15. For example, when each of the scribe line virtual lines 13, 15 has a width of 50 μm, the planar size of the pillar 7 may be 30 μm × 30 μm. The planar shape of the pillar 7 is not limited to the square, but can be another shape surrounded by an arbitrary closed curve, including a rectangle, a circle, and the like.

(other embodiments)

In the above embodiment, the case has been described in which the stay 7 is made of the same material as the seal member 3 and is formed simultaneously with the seal member 3. However, the present invention is not limited thereto, and the stay 7 may be formed independently of the seal member 3 from a material different from that of the seal member 3. For example, the sealing member 3 may be formed on the upper surface of the first large glass substrate 11 from a liquid crystal low-contamination (Less-polarizing) material such as a thermosetting or ultraviolet-curable epoxy-based resin by screen printing, and then the pillars 7 may be formed from a material such as an ultraviolet-curable polyimide-based resin by a dropping method. For example, if the support post 7 including an ultraviolet light curing polyimide-based resin is used, the support post 7 can be easily cut along the scribe lines when the resulting liquid crystal display device forming assembly is cut. When the support post is not removed but left in each liquid crystal display device as a finished product, the support post can be reliably left in a divided (segmented) form on each liquid crystal display device.

The pillars 7 may be formed on the lower surface of the second large glass substrate 12. For example, a pillar type spacer made of a photosensitive resin, such as an acrylic resin, may be formed together with the pillar on the surface of the second large glass substrate 12 opposite to the first large glass substrate 11. In such a liquid crystal display device in which a photo spacer (photo spacer) is to be formed on any one of the respective opposing surfaces of the first and second large glass substrates 11, 12, when the photo spacer is formed, it is only necessary to provide the support posts at the portions described in the above-described first to eleventh embodiments at the same time. Thus, in addition to the effects described above, another advantage is obtained in that it is not necessary to increase the number of manufacturing steps of the liquid crystal display device.

In the first to eleventh embodiments described above, the first glass substrate (first large glass substrate) and the second glass substrate (second large glass substrate) may be interchanged. For example, in the liquid crystal display device manufactured in this manner, the second glass substrate includes a protruding portion protruding from the first glass substrate. When the support post 7 is formed on the first or second large glass substrate 11 or 12, after the liquid crystal display apparatus forming assembly 100 is divided into the respective devices, the support post 7 may be removed by solvent or mechanical polishing as necessary.

The support post does not have to be provided at or near the intersection of the scribe line virtual lines. In this case, it is desirable to form the pillars so as to overlap the first, second, and third scribe line virtual lines 13, 14, and 15. According to the above experimental results, it is more desirable to dispose the pillars at such positions that the minimum distance between adjacent pillars provided to overlap the corresponding scribe line virtual lines is 1.0mm or less. According to the above experimental results, it is not necessary to form the pillars to overlap the corresponding scribe line virtual lines. In this case, it is desirable to dispose the pillars at such positions that the minimum distance between each pillar and the corresponding scribe line virtual line is 0.5mm or less. In which case the posts may be formed to overlap the scribe line virtual lines, or not to overlap them.

Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made to the embodiments of the invention without departing from the spirit or scope of the general inventive concept as defined by the following claims and their equivalents.

Claims (18)

1. A method of manufacturing a liquid crystal cell, comprising:

preparing a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

adhering the pair of glass substrates to form a liquid crystal display device forming assembly after inserting a plurality of seals and a plurality of pillars each including ends abutting against the pair of glass substrates, respectively, between the pair of glass substrates; and

forming a plurality of scribe lines intersecting each other on surfaces of the pair of glass substrates opposite to surfaces of the pair of glass substrates opposed to each other after forming the liquid crystal display device forming assembly,

wherein at least a portion of each of the pillars is disposed to overlap one of regions between the pair of glass substrates corresponding to the scribe lines.

2. The method of claim 1, wherein at least a portion of each of the pillars is disposed to overlap one of regions between the pair of glass substrates corresponding to a portion where at least one of the scribe lines intersects.

3. The method of claim 1, wherein at least a portion of each of the pillars is disposed around one of regions between the pair of glass substrates corresponding to a portion where at least one of the scribe lines intersects.

4. The method of claim 1, wherein the struts are made of the same material as the seal and are formed simultaneously with the seal.

5. The method of claim 1, wherein the struts are of a material different from the seal material and are more easily cut than the material of the seal.

6. The method of claim 1, wherein the pillars are made of the same material as pillar-shaped spacers inserted between the pair of glass substrates and are formed simultaneously with the pillar-shaped spacers.

7. The method of claim 1, further comprising, after forming the scribe line, cutting the pair of glass substrates and then removing at least one of the pillars.

8. The method of claim 1, further comprising, after forming the scribe lines, cutting the pair of glass substrates and the seal along each of the scribe lines to obtain a plurality of liquid crystal cells, and wherein

One of a plurality of sides of one of the liquid crystal cells is shared by one of a plurality of sides of another one of the liquid crystal cells adjacent to the one of the liquid crystal cells,

at least a portion of each of the pillars is provided so as to overlap one of regions between the pair of glass substrates corresponding to the scribe line, and the seal is provided so as to overlap one of regions between the pair of glass substrates corresponding to the one of the side edges to be shared, and

at least one of the scribe lines is arranged to overlap an area corresponding to the one of the plurality of side edges to be shared.

9. A method of manufacturing a liquid crystal display device, comprising:

preparing a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

adhering the pair of glass substrates to form a liquid crystal display device forming assembly after inserting a plurality of seals and a plurality of pillars each including ends abutting against the pair of glass substrates, respectively, between the pair of glass substrates; and

forming a plurality of scribe lines intersecting each other on surfaces of the pair of glass substrates opposite to surfaces of the pair of glass substrates opposed to each other after forming the liquid crystal display device forming assembly,

wherein at least a portion of each of the pillars is disposed to overlap one of regions between the pair of glass substrates corresponding to the scribe lines.

10. The method of claim 9, further comprising, after forming the scribe line, cutting the pair of glass substrates and then removing at least one of the pillars.

11. The method of claim 10, further comprising, after removing the posts, mounting at least one drive circuit on one of the pair of glass substrates.

12. A liquid crystal display device forming assembly, comprising:

a pair of glass substrates, each of the glass substrates including a region configured to form a plurality of completed liquid crystal display devices thereon;

a plurality of sealing members interposed between the pair of glass substrates; and

a plurality of pillars each including an end abutting against the pair of glass substrates, respectively,

wherein at least a part of each of the pillars is provided so as to include one of regions between the pair of glass substrates corresponding to scribe lines that intersect with each other on surfaces of the pair of glass substrates opposite to each other.

13. The assembly of claim 12, wherein one of a plurality of sides of one of the liquid crystal display devices is shared by one of a plurality of sides of another one of the liquid crystal display devices that is adjacent to the one of the liquid crystal display devices,

at least one of the scribe lines is arranged to overlap at least one region corresponding to the one of the side edges to be shared, and

the sealing member is provided so as to include one of regions corresponding to the one scribe line formed to overlap at least one region corresponding to the one to be shared among the plurality of side edges between the pair of glass substrates.

14. A liquid crystal cell, comprising:

a pair of glass substrates;

a sealing member interposed between the pair of glass substrates; and

including at least one pillar abutting against ends of the pair of glass substrates, respectively,

wherein at least one of the at least one support posts is provided on at least one of the glass substrates in at least one region corresponding to one of the ends of the glass substrate.

15. A unit according to claim 14, wherein outer end faces of two opposite sides of said sealing member are disposed at the same positions as end faces of two opposite sides of each of said pair of glass substrates.

16. A liquid crystal display device, comprising:

a pair of glass substrates;

a sealing member interposed between the pair of glass substrates; and

including at least one pillar abutting against ends of the pair of glass substrates, respectively,

wherein at least one of the at least one support is provided on at least one of the pair of glass substrates in at least one region corresponding to one of the ends of the pair of glass substrates.

17. The apparatus according to claim 16, wherein outer end faces of two opposite sides of the sealing member are disposed at the same positions as end faces of two opposite sides of each of the pair of glass substrates.

18. The apparatus of claim 16, further comprising at least one drive circuit mounted on one of the pair of glass substrates.