JP2002122873A - Liquid crystal device manufacturing method - Google Patents

Abstract

(57) [Problem] To provide a method for manufacturing a liquid crystal device, which can be manufactured in a short time with a small number of steps and in which the surface of a glass substrate is less damaged. SOLUTION: A projection 11 surrounding the outer periphery of the pixel region is formed on the surface of at least one of the pair of glass substrates 10 and 14 for defining at least one pixel region. One glass substrate 10
Alternatively, the ridge 11 is provided on the surface of the other glass substrate 14.
After a seal pattern 12 is formed so as to extend along the outside of the glass substrate 10, a liquid crystal 13 is dropped into a space defined inside the ridge portion 11, and the pair of glass substrates 10 and 14 is formed.
With the ridges and the seal pattern inside, by overlapping with each other at a predetermined interval determined by the height of the ridges, by curing the seal pattern 12,
The liquid crystal device 15 is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a liquid crystal device, and more particularly to a method for manufacturing a small liquid crystal device.

[0002]

2. Description of the Related Art Conventionally, a liquid crystal device is shown in FIGS.
2 is manufactured. First, two glass substrates 101 and 131 are prepared, and a gap control agent having a predetermined particle size is formed on the first glass substrate 101 by using, for example, a dispenser D, as shown in FIG. (Hereinafter referred to as GC agent) 101a. still,
At least one pixel electrode 103 is formed in a pixel region (also referred to as a display unit or a light control unit) indicated by a dotted line on the glass substrate 101.

On the other hand, as shown in FIG.
A common electrode 133 corresponding to the pixel region of the first glass substrate 101 is formed on the second glass substrate 131, and has a predetermined particle size so as to surround the outer periphery of the common electrode 133. A sealant to which the GC agent 135a is added is applied to form a seal pattern 135.
Here, the seal pattern 135 has an opening 135b as a liquid crystal injection port.

Then, as shown in FIG. 8A, the first glass substrate 101 and the second glass substrate 131 are overlapped so that the pixel electrode 103 and the common electrode 133 face each other. As shown in FIG.
For example, using a press machine P, the first glass substrate 101
And the second glass substrate 103 are pressed so as to approach each other.

[0005] Then, in a state where the first glass substrate 101 and the second glass substrate 103 are pressed against each other, a heat treatment is performed by, for example, a heater HT, and the seal pattern 13 is pressed.
By curing 5, the first glass substrate 101 and the second glass substrate 103 are fixedly held to each other. Here, an empty cell EC is defined between the first glass substrate 101 and the second glass substrate 103 by the seal pattern 135 corresponding to the pixel region.
Note that the sealant is made of a thermosetting material and is configured to be cured by heat treatment.However, a sealant containing an ultraviolet curable resin may be used as the sealant. By irradiating ultraviolet rays instead of heat treatment, the sealant is cured.

Actually, as shown in FIG. 9A, a number of empty cells EC are defined between the first glass substrate 101 and the second glass substrate 103, and each empty cell EC is defined. EC
Along the boundary of the first glass substrate 101 and the second glass substrate 1 using, for example, a diamond cutter D.
A scribe line SL is formed on the surface of No. 03. Here, among the scribe lines SL, FIG.
The scribe line SL extending in the horizontal direction in (a) is formed so as to be aligned with the opening surface of the liquid crystal injection hole 135b of each empty cell EC. Then, by cutting the first glass substrate 101 and the second glass substrate 103 along these scribe lines SL, as shown in FIG. 9B, the empty cells EC are separated.

Subsequently, as shown in FIG. 10, a plurality of empty cells EC are set in an injection jig 150 such that their liquid crystal injection holes 135b are aligned on one plane, and as shown in FIG. Then, together with the liquid crystal tank 155 filled with the liquid crystal E, it is housed in the vacuum chamber VC, and the inside of the vacuum chamber VC is evacuated. Next, when the inside of the vacuum chamber VC reaches a predetermined degree of vacuum, as shown in FIG. 11B, the injection jig 150 is moved and the liquid crystal injection port 135 of each empty cell EC is moved.
b is immersed in the liquid crystal E in the liquid crystal tank 155. Thereafter, when the inside of the vacuum chamber VC is returned to the atmospheric pressure, each empty cell EC is filled with the liquid crystal E to form a liquid crystal cell LC.

Then, as shown in FIG. 12 (a), each liquid crystal cell LC is set in a press jig 161 with its liquid crystal inlet 135b slightly protruding upward, and each liquid crystal cell LC is set at a predetermined pressure. The cell LC is pressed for a certain period of time to wipe off excess liquid crystal EA coming out of the liquid crystal inlet 135b.
As shown in (b), for example, an end sealant ES is applied so as to cover the liquid crystal injection port 135b, and the end sealant is cured by irradiation of ultraviolet rays or heat treatment.
Thus, the liquid crystal cell LC, that is, the liquid crystal device is completed.

[0009]

However, the above-described method of manufacturing a liquid crystal device has the following problems.

First, the sides of the first glass substrate 101 and the second glass substrate 131 having the liquid crystal injection port 135b need to be cut so that the opening surfaces of the liquid crystal injection ports 135b are aligned. In such a case, the extraction electrode cannot be formed on the surface of the glass substrate, so that the degree of freedom in designing the liquid crystal device is reduced.

Second, since there are a large number of steps (difficult to automate) and the manufacturing steps are complicated, the manufacturing cost is increased and the manufacturing time is long. In particular,
When manufacturing a small liquid crystal cell, it takes time to set the empty cell EC and the liquid crystal cell LC on the injection jig and the press jig. When the empty cell EC is not properly set in the injection jig (when the liquid crystal injection holes 135b are not aligned on one plane), the liquid crystal injection holes 135b are not immersed in the liquid crystal E, and the liquid crystal injection failure occurs. Will occur. Moreover, these steps are difficult to automate and require skill even in manual work.

Thirdly, the surface of the empty cell EC or the liquid crystal cell LC is apt to be damaged because many steps are involved in setting it into an injection jig or a press jig and pressing. In particular,
After the scribe line SL is formed on the glass substrate or cut by breaking, the cutting powder (dust at the time of cutting) of the glass substrate
Is attached to the surface of the glass substrate, and the surface of the glass substrate and the like are more easily damaged in the subsequent steps.
On the other hand, a washing step may be added in order to remove chips, but the number of steps is increased, and it is difficult to completely remove chips even by the washing step.

Fourth, in the vicinity of the seal pattern 135 and the end seal portion, the orientation of the liquid crystal is easily disturbed. In the case of a large liquid crystal device, this disorder of the alignment of the liquid crystal is hardly a problem, but in the case of a small liquid crystal device, the distance from the seal pattern or the end seal portion to the display portion is relatively short. Therefore, since the resistance of the liquid crystal changes due to the disorder of the orientation of the liquid crystal, the display is disturbed.

In view of the above points, the present invention provides a liquid crystal device which can be manufactured in a short time with a small number of steps, and has a reduced size by reducing scratches on the surface of a glass substrate. It is intended to provide a way.

[0015]

According to the first aspect of the present invention, at least one of a pair of glass substrates for defining at least one pixel region is provided with a pixel region having a pixel region. Forming a ridge that surrounds the outer periphery; forming a seal pattern on the surface of the one glass substrate or the other glass substrate so as to extend along the outside of the ridge; A liquid crystal injecting step of dropping liquid crystal into a space defined inside the ridge, and the pair of glass substrates are determined by the height of the ridge with the ridge and the seal pattern inside. This is achieved by a method for manufacturing a liquid crystal device, comprising: a bonding step of laminating at a predetermined interval; and a sealing step of curing the seal pattern.

According to the first aspect of the present invention, the liquid crystal is injected into each space (liquid crystal cell) defined by the ridges at a time before the liquid crystal cells are separated from each other. This eliminates the need to align and hold the open surfaces of the liquid crystal injection ports of each liquid crystal cell. Therefore, the number of steps is small,
Since the manufacturing cost can be reduced, the manufacturing time can be shortened, and the handling of each liquid crystal cell is easy, it is particularly suitable for manufacturing a small liquid crystal cell. Further, since a liquid crystal injection port is not required for each liquid crystal cell, an extraction electrode can be formed on the entire periphery of the liquid crystal cell, so that the degree of freedom in design is increased. Further, since the press in each step can be performed by a non-contact press using atmospheric pressure or liquid pressure, scratches on the glass substrate surface can be further reduced.

Further, since the sealing step is performed by curing the seal pattern, it is not necessary to set each liquid crystal cell on a press jig as in the prior art, and it is not necessary to extrude the liquid crystal. The time required for the liquid crystal device is greatly reduced, and the manufacturing time of the liquid crystal device is also reduced, so that the production efficiency of the liquid crystal device is improved.

Furthermore, since the liquid crystal is sealed in the space defined by the ridge, the liquid crystal does not come into direct contact with the seal pattern. Therefore, a correct display can be performed without disturbing the alignment of the liquid crystal or a change in resistance due to the seal pattern. This makes it possible to arrange the ridges and the seal pattern as close as possible to the image area, so that a so-called seal margin is almost unnecessary. Therefore, the size of the liquid crystal cell with respect to the image area can be minimized, and the amount of liquid crystal sealed in the liquid crystal cell can be reduced.

Further, since there is no need to collect and reuse the extra liquid crystal once injected into the liquid crystal cell as in the prior art,
Liquid crystal contamination due to repeated injection can be prevented,
The liquid crystal can be injected in a clean state. Furthermore, since the seal pattern itself need only have a sealing function and does not need to have rigidity, the width can be reduced as much as possible, and the entire liquid crystal cell can be configured to be even smaller.

According to a second aspect of the present invention, in the configuration of the first aspect, the bonding step is performed under atmospheric pressure. According to the configuration of claim 2, when bonding a pair of glass substrates in the bonding step, a vacuum chamber or the like is not required, so that the configuration is simple, easily and quickly, and at low cost. The bonding of the glass substrates is performed.

According to a third aspect of the present invention, in the structure of the first aspect, the bonding step is performed under reduced pressure. According to the configuration of the third aspect, when a pair of glass substrates are bonded in the bonding step, air can be prevented from entering between the glass substrates and mixing the air bubbles into the liquid crystal cell.

According to a fourth aspect of the present invention, in any one of the first to third aspects, the liquid crystal dropped in the liquid crystal injecting step has the same volume as the space defined inside the ridge. It is characterized by being volume. According to the configuration of claim 4,
In the liquid crystal injection step, the liquid crystal dropped into the space defined by the ridges has the same volume as the space, so that in the subsequent bonding step, the liquid crystal may overflow from the space. Without any voids in the space,
The liquid crystal will be filled.

According to a fifth aspect of the present invention, in any one of the first to third aspects, the liquid crystal dropped in the liquid crystal injecting step has a volume smaller than a volume of a space defined inside the ridge. It is characterized by having a large volume. According to the configuration of claim 5, in the liquid crystal injecting step, the liquid crystal dropped into the space defined by the ridge is slightly larger than the volume of the space. Excess liquid crystal overflows from the space, between the ridge and the seal pattern, and presses the seal pattern outward. Therefore, the extra liquid crystal is held inside the seal pattern, and does not flow out beyond the seal pattern.

According to a sixth aspect of the present invention, in any one of the first to fifth aspects, the method further comprises forming the ridge.
Before the formation of the seal pattern, a step of forming a second protrusion by providing an interval corresponding to the width of the seal pattern outside the protrusion is provided. According to the configuration of claim 6, in the bonding step, when the liquid crystal overflowing from the space defined by the ridges presses the seal pattern, the second ridges move the seal pattern in the width direction. Is regulated, and the deformation of the seal pattern to the outside is prevented, so that the seal pattern is held at a predetermined width.

According to a seventh aspect of the present invention, in the configuration of the sixth aspect, the second protrusion is formed on the other glass substrate. According to the configuration of the seventh aspect, in the bonding step, when the protrusions and the second protrusion approach the seal pattern from directions opposite to each other, extra liquid crystal is formed. When the seal pattern is pressed beyond the edge of the second protrusion, the seal pattern is pushed outward beyond the edge opposite to the second ridge. Accordingly, the seal pattern is held at a predetermined width by the second ridge, and the second ridge is securely adhered to the surface of one of the glass substrates via the seal pattern.

According to an eighth aspect of the present invention, in the configuration of any one of the first to seventh aspects, the sealant constituting the seal pattern is a UV curable resin, and the curing of the seal pattern in the sealing step is performed by using an ultraviolet ray. It is characterized by being performed by irradiation. According to the configuration of claim 8, in the sealing step, by irradiating the entire surface with ultraviolet rays, the sealant is cured, and the periphery of each liquid crystal cell is sealed with the cured seal pattern. The sealing can be performed easily and in a short time as compared with the sealing by the end sealing agent in the pressing step.

In a ninth aspect of the present invention, in any one of the first to seventh aspects, the sealant constituting the seal pattern is a thermosetting material, and the curing of the seal pattern in the sealing step is performed by: It is characterized by being performed by heat treatment. According to the configuration of the ninth aspect, in the sealing step, by performing the heat treatment on the whole, the sealant is hardened, and the periphery of each liquid crystal cell is sealed by the hardened seal pattern. The sealing can be performed easily and in a short time as compared with the sealing with the end sealant by the pressing step.

According to a tenth aspect of the present invention, in any one of the first to ninth aspects, after the sealing step, a pair of glass substrates is formed outside each seal pattern or the second ridge. It is characterized by including a separation step of cutting and separating each pixel region. According to the configuration of the tenth aspect, by separating each liquid crystal cell in the separation step, a plurality of liquid crystal devices are manufactured, and the productivity is improved.

According to an eleventh aspect of the present invention, in any one of the first to tenth aspects, the liquid crystal cell defined by the first seal pattern has a diagonal length of 1 cm or less. According to the configuration of claim 11, a liquid crystal device including a small liquid crystal cell is manufactured. At this time, each liquid crystal cell is defined by a ridge surrounding a pixel region, and Since the distance between the substrates (hereinafter, referred to as cell thickness) is maintained by the height of the ridge portion, the entire size is small, so that a substantially uniform cell thickness can be obtained in the entire pixel region.

As described above, according to the present invention, the ridge is formed inside the seal pattern defining each liquid crystal cell, and the liquid crystal is dropped into the space defined by the ridge. The space is sealed by bonding a pair of glass substrates and curing the seal pattern. As a result, the liquid crystal cells are separated from each other, and the liquid crystal is not injected into each liquid crystal cell. Seal. Therefore, in order to seal each liquid crystal cell, the liquid crystal device can be easily and quickly manufactured in a short time as compared with a case where excess liquid crystal is extruded by a press jig and sealing is performed by an end sealant as in the related art. Can be manufactured. Further, since the liquid crystal cell is defined by the ridge, the liquid crystal sealed in the liquid crystal cell does not contact the seal pattern. Thus, the liquid crystal does not contact the seal pattern, the orientation of the liquid crystal is disturbed, and the resistance of the liquid crystal does not change. Accordingly, correct display is performed, and there is almost no need for a so-called seal margin around the pixel region. Therefore, the liquid crystal cell is configured to be small.

[0031]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a liquid crystal device according to an embodiment of the present invention will be described. In one embodiment of the method for manufacturing a liquid crystal device according to the present invention, as shown in the flowchart of FIG.
A liquid crystal device can be manufactured.

First, the following steps are performed as a preliminary stage. In step 1, a height corresponding to the actual gap of the liquid crystal cell is formed on the surface of one of the pair of glass substrates so as to surround the outer periphery of each pixel region forming the display unit or the light control unit. And forming a sealing pattern by applying a sealing agent on one or the other surface of the glass substrate so as to extend along the outside of the ridge in step 2. I do. Here, the ridge portion is made of a solid material. Further, each of the seal patterns completely surrounds the corresponding pixel region and ridge, and does not include a liquid crystal injection port or the like. still,
The surface of both glass substrates is not sprayed with the conventional GC agent, but may be sprayed with the GC agent.

Thereafter, the following steps are performed as a liquid crystal injection step. In step 3, a liquid crystal having a volume approximately equal to or slightly larger than the volume of the space is dropped into a space (liquid crystal cell) defined by the ridge. As a result, the liquid crystal is filled in the liquid crystal cell defined in each pixel region.

Next, the following steps are performed as a bonding step. In step 4, the two substrates are placed facing each other and overlapped. Thereby, each glass substrate is held at a predetermined interval by the height of the ridge.
At that time, when each liquid crystal cell has a diagonal length of, for example, 1 cm or less, a substantially uniform cell thickness can be obtained. In this case, the bonding of the substrates is performed under atmospheric pressure or reduced pressure.

Subsequently, the following steps are performed as a sealing step. In step 5, the seal pattern is cured while the liquid crystal cell is pressed again by the pressing step. Here, the sealant forming the seal pattern is, for example, a UV-curable resin or a thermosetting material, and is configured to be cured by ultraviolet irradiation or heat treatment. Thus, when a UV-curable resin is used as the sealant, the seal pattern can be cured by ultraviolet irradiation, and when a thermosetting material is used as the sealant, the seal pattern can be cured by heat treatment.

Finally, the following steps are performed as a separation step. In step 6, the liquid crystal cell is separated for each pixel region by cutting a pair of glass substrates by scribing and breaking outside each seal pattern. Thus, a liquid crystal device having one pixel region is completed.

As described above, according to the method of manufacturing a liquid crystal device according to the present invention, since the seal pattern has no liquid crystal injection port, the conventional press end sealing step including extrusion of liquid crystal is not required. Therefore, the manufacturing time of the liquid crystal device can be shortened, and the extraction electrode can be formed all around the liquid crystal cell, so that the degree of freedom in designing the liquid crystal device is increased, and the liquid crystal is sealed by the ridge. Since there is no contact with the pattern, no disturbance in the alignment of the liquid crystal occurs.

FIGS. 2 and 3 show a first embodiment of the method for manufacturing a liquid crystal device according to the present invention. In the preliminary stage, as shown in FIG. 2A, a glass substrate 1 having a size of, for example, 150 mm square and a thickness of 0.5 mm and having a plurality of pixel pattern electrodes made of an ITO film in each pixel region.
0, a ridge 11 having the same height as a desired cell thickness is formed on the surface of the glass substrate 10 so as to completely surround the outer periphery of each pixel region. In FIGS. 2A to 2C, only one pixel region is shown for simplification of the drawing. However, actually, a plurality of pixel regions are vertically and horizontally formed on the glass substrate 10. They are arranged side by side.

Here, a plurality of ridges 11 are arranged vertically and horizontally so as to surround the area (pixel area) of each pixel pattern electrode formed of the ITO film on the glass substrate 10.
For example, it is formed in an 8 mm square. The ridge portion 11 is selected to have a height of 5 μm and a width of 10 μm, for example, using a solid material, for example, Optmer NN777 manufactured by JSR. In addition, as long as the protruding portion 11 is a solid material, the protruding portion 11 may be formed of, for example, a cured material of the same sealant as the seal pattern 12 described later, or an arbitrary solid material such as a mylar film.

Next, as shown in FIG. 2B, a seal pattern 12 is formed on the surface of the glass substrate 10 by, for example, a dispenser D so as to extend along the outside of the ridge 11. The seal pattern 12 includes the ridge 1
1 and is formed so as to be in contact with the outer edge of the projection 1, and as shown in FIG. Here, the sealant constituting the seal pattern 12 is made of a UV curable material, for example, XNR5614 manufactured by Nagase Chiba Co., Ltd., and the width of the seal pattern 12 after bonding the substrates is 0.1 to 0.3 mm. It is applied on the glass substrate 10 so as to have a degree.

Subsequently, as shown in FIG. 2 (b), in a liquid crystal injection step, a space (liquid crystal cell) defined by the ridge 11 is formed on the surface of the glass substrate 10 in the space. A liquid crystal 13 having a volume equal to or slightly larger than the volume is dropped.
In this case, since the size of the liquid crystal cell is small, it is important to control the volume of the liquid crystal 13 with high accuracy in order to manufacture a liquid crystal cell having a uniform cell thickness. Therefore, the drop of liquid crystal is
Inkjet method or bubble jet (registered trademark)
A method is desirable. Note that another system such as a dispenser system may be used as long as the volume of the liquid crystal can be controlled with high accuracy. Here, it is difficult to make the volume of the liquid crystal dropped exactly the same as the volume of the liquid crystal cell, but by making the volume of the liquid crystal slightly larger than the volume of the liquid crystal cell, bubbles are mixed in the liquid crystal cell. Can be prevented.

Thereafter, in the bonding step, the ridge 11
The glass substrate 10 on which the seal pattern 12 is formed and the liquid crystal 13 is dropped is placed in a vacuum chamber 20 together with a glass substrate (opposite substrate) 14 having a common electrode in each pixel region as shown in FIG. The vacuum chamber 20 is housed, and the vacuum chamber 20 is evacuated and evacuated to be superimposed on each other. This reduced pressure prevents bubbles from remaining in the liquid crystal cell. Note that a vacuum pack or the like can be used instead of the vacuum chamber 20.

Here, for example, the two substrates 10 and 14 are overlapped so as to be completely parallel to each other, and
In a state in which the liquid crystal 13 in the liquid crystal 13 is slightly raised due to surface tension, the liquid crystal 13 in the counter substrate 1
When the substrates are overlapped so that the substrates 4 and 4 are in contact with each other, or when the opposing substrate 14 is in contact with the surface of the liquid crystal 13 from one side of the liquid crystal cell, bubbles are unlikely to remain. Lamination may be performed. Also, even if some air bubbles remain in the liquid crystal cell,
If no bubbles remain in the pixel region, there is substantially no deterioration of the display due to the bubbles, so that the substrates can be similarly bonded under atmospheric pressure.

Next, as shown in FIG. 3 (e), in a state where the bonded glass substrate 10 and the counter substrate 14 are pressed by a pressing step, the air bubbles therein are preferably settled down for a while. And then irradiate with ultraviolet UV. Thus, the seal pattern 12 is cured, and the glass substrate 10 and the counter substrate 14 are bonded to each other and fixedly held. In this case, in the pressing step, when the substrates are bonded under reduced pressure, the pressure may be simply returned to the atmospheric pressure. Location near the outer periphery of the substrate (location that is not used for actual devices and is later cut off)
If a seal pattern (closed so as to surround the element and a substantially vacuum state inside) is formed separately, the pressing effect is further enhanced.

In this pressing step, as shown in FIG. 3F, the extra liquid crystal 13 in the liquid crystal cell
Extruded from the gap formed by the ITO electrode on the counter substrate. At this time, since the seal pattern 12 is not completely cured, the liquid crystal 13 extrudes the seal pattern 12 so that the seal pattern 12 is deformed outward, thereby absorbing excess overflow of the liquid crystal 13. If the volume of the liquid crystal 13 dropped into the liquid crystal cell is smaller than the volume of the liquid crystal cell, bubbles remain in the liquid crystal cell, or the cell thickness is increased near the center of the liquid crystal cell due to the high viscosity of the liquid crystal. Since the sealant may be thinned or may enter the liquid crystal cell due to the negative pressure, the volume of the liquid crystal 13 dropped is about the same as or slightly larger than the volume of the liquid crystal cell as described above. Is preferred.

Here, even if the seal pattern 12 is deformed by such extra liquid crystal 13, the seal pattern 12 has a sufficient sealing function such as an oxygen barrier property and the liquid crystal 13 inside the ridge 11. On the other hand, it does not affect the orientation or the electrical characteristics. Therefore, the liquid crystal 13 in the liquid crystal cell 13 is
Since there is no direct contact with the seal pattern 12, there is no disturbance in the orientation or a change in the resistance, and a correct display can be performed. Note that, in order to further complete the effect of the seal pattern 12 by the ultraviolet irradiation, an annealing process may be performed after the ultraviolet irradiation.

Finally, separation is performed for each liquid crystal cell defined by the seal pattern 12. By scribing and breaking the glass substrate 10 and the counter substrate along the outside of the seal pattern 12 using, for example, a diamond cutter C, as shown in FIG. Each liquid crystal device 15 is completed.

FIG. 4 shows a second embodiment of the method for manufacturing a liquid crystal device according to the present invention. In FIG. 4, the manufacturing method of the liquid crystal device is different from the method shown in FIGS. 2 to 3 in that a seal pattern 16 is formed on the opposite substrate 14 instead of the seal pattern 12 formed on the surface of the glass substrate 10. Only in that it is different. According to such a configuration, similar to the manufacturing method of FIGS.
When the liquid crystal device is manufactured and the extra liquid crystal 13a in the liquid crystal cell is extruded from the gap between the edge of the ridge 11 and the opposing substrate 14 in the pressing step, the extruded liquid crystal 13a Penetrates between the seal pattern 16 and the opposing substrate 14 and the opposing substrate 14 of the seal pattern 16
Does not impair the adhesion to

FIG. 5 shows a third embodiment of the method for manufacturing a liquid crystal device according to the present invention. In FIG. 5A, the method of manufacturing the liquid crystal device is different from the method shown in FIGS. 2 and 3 in that the glass substrate 10 and the opposing ridge 11 are formed on the surface of the glass substrate 10. Only at the point where the ridges 11a and 11b are formed on both of the substrates 14,
It has a different configuration. According to such a configuration, the liquid crystal device is manufactured in the same manner as the manufacturing method of FIGS.
3a is pushed out from the gap between the butting portions of these ridges 11a and 11b, and the opposing substrate 14
The liquid crystal 13a is extruded uniformly over the entire circumference of the liquid crystal cell without being affected by the shape of the electrode pattern formed on the surface of the glass substrate 10 of the seal pattern 12.
In addition, the adhesion to the opposing substrate 14 can be reliably ensured.

FIG. 6 shows a fourth embodiment of the method for manufacturing a liquid crystal device according to the present invention. In FIG. 6, the manufacturing method of the liquid crystal device is different from the method shown in FIGS.
At a predetermined interval corresponding to the width of the seal pattern 12,
The configuration is different only in that the second protrusion 17 is formed. According to such a configuration, FIGS.
The liquid crystal device is manufactured in the same manner as the manufacturing method of the above, and the extra liquid crystal 13a in the liquid crystal cell is formed in the pressing step.
Is extruded from the gap between the edge of the ridge 11 and the opposing substrate 14, the extruded liquid crystal is regulated by the seal pattern 12 being regulated in the width direction by the second ridge 17. Due to 13a, the seal pattern 12 is not deformed outward in the width direction. Therefore, since the width of the seal pattern 12 can be reduced, the entire liquid crystal cell can be configured to be small.

FIG. 7 shows a fifth embodiment of the method for manufacturing a liquid crystal device according to the present invention. In FIG. 7A, the manufacturing method of the liquid crystal device is different from the method shown in FIG. 6 in that the second projection 17 formed on the surface of the glass The configuration is different only in that the second ridge 17a is formed. According to such a configuration, the liquid crystal device is manufactured in the same manner as the manufacturing method of FIG. 6, and the extra liquid crystal 13a in the liquid crystal cell faces the edge of the ridge 11 in the pressing step. When extruded from the gap between the substrate 14 and the substrate 14, as shown in FIG. 7B, the seal pattern 12 is regulated in the width direction by the second ridge 17a, so that the extruded liquid crystal 13a is formed. As a result, the seal pattern 12 is not deformed outward in the width direction, and the extruded liquid crystal 13
a, the seal pattern 12 is moved to the second ridge 17a.
Is pushed out from the gap between the edge of the glass substrate 10 and the glass substrate 10, so that the adhesion between the seal pattern 12 and the glass substrate 10 and the counter substrate 14 is not impaired.

In the above embodiment and specific examples,
Ridges 11, 11a, 11b and second ridges 17, 1
7a and the seal patterns 12, 16 are formed in a substantially rectangular shape, but are not limited thereto, and if necessary,
It may be formed in another shape. In the embodiments and the specific examples described above, the pressing process generally uses a pressing jig or a pressing machine, or a method of providing a cushion member such as urethane rubber on these pressing surfaces is adopted. The method is not limited to this, and a method of applying pressure in a non-contact manner at least on one side by a gas pressure of air or nitrogen or a liquid pressure of water or the like, or a method of applying pressure by a vacuum pack or the like is also possible.

Further, in the above embodiment and specific example, the individual liquid crystal devices 15 are separated from each other by the glass substrate 10.
The opposing substrate 14 is formed by scribing and breaking using, for example, a diamond cutter C. However, the present invention is not limited to this. The substrate and the counter substrate may be cut. In this case, almost no chips are generated at the time of cutting, and no breaking is required. Therefore, a liquid crystal device with less damage can be manufactured.

In the above-described embodiments and examples, the sealant forming the seal patterns 12 and 16 is made of a UV-curable resin. However, the present invention is not limited to this. May be. In this case, the sealant is hardened by heat treatment, and this heat treatment may use not only a heater but also an oven or a hot plate. Further, in the above-described embodiments and specific examples, the liquid crystal cell is not provided with the GC agent. However, for example, the GC agent may be dispersed in each pixel region of the glass substrate 10 or the counter substrate 14.

The liquid crystal device manufactured by the method for manufacturing a liquid crystal device according to the present invention is, for example, a liquid crystal display, particularly a small liquid crystal display, a spatial light modulator for a writing light source for an instant film or photographic paper, and an optical pickup device for a CD / DVD. It covers all products including a camera aperture / shutter, a liquid crystal optical shutter for a laser printer, a liquid crystal lens, a liquid crystal prism, a liquid crystal optical head, a liquid crystal sensor, and the like.

[0056]

As described above, according to the method of manufacturing a liquid crystal device according to the present invention, the following advantages can be obtained. 1) The number of steps is reduced, so that manufacturing cost and manufacturing time can be reduced. In particular, it is suitable as a method for manufacturing a small liquid crystal cell having a small display (or light control) area. 2) Since the conventional press end sealing step is unnecessary, the degree of freedom in designing the extraction electrode is increased. Therefore, for example, an extraction electrode can be provided on the entire periphery of the liquid crystal cell. 3) Since scribing and breaking in the separation step of generating cutting chips, which are the main cause of the generation of scratches, are the final steps in the manufacturing process of the liquid crystal device, minimizing damage to the glass substrate surface of the liquid crystal cell. Can be. 4) All pressing steps can be performed by a non-contact pressing step using atmospheric pressure or liquid pressure. Therefore, scratches on the glass substrate surface of the liquid crystal cell can be further suppressed. 5) Since the liquid crystal injection port is sealed by curing the curable liquid 22 by ultraviolet irradiation or heat treatment, it is not necessary to extrude the liquid crystal or set it in a press jig as in the related art, and the manufacturing time of the liquid crystal device is reduced. Be shortened. 6) Since the liquid crystal 13 in the liquid crystal cell does not come into direct contact with the seal patterns 12 and 16 around the liquid crystal cell, there is no disturbance in the orientation of the liquid crystal 13 and no change in electrical characteristics such as resistance. Therefore, there is no need to provide a seal margin around each pixel region as in the related art, and the ridge 11 and the seal patterns 12, 1 are provided as much as possible with respect to the boundary of each pixel region.
Since it is possible to bring 6 closer, the liquid crystal cell and the entire liquid crystal device 15 can be made compact. Further, since the liquid crystal cell is configured in a small size, the volume of the liquid crystal 13 dropped into the liquid crystal cell can be reduced, and the consumption of the liquid crystal can be reduced. Since the liquid crystal is extruded, collected, and injected again, the liquid crystal is not contaminated by repeated injection. 7) By providing the second ridges 17, 17a, the width of the seal pattern 12 is regulated by the second ridges 17, 17a. Therefore, the seal pattern 1
Since the width of 2 can be made as small as possible, the entire liquid crystal cell can be made even smaller.

As described above, according to the present invention, it is possible to produce the glass substrate in a short time with a small number of steps, to reduce the scratches on the surface of the glass substrate, and to reduce the size of the glass substrate. A method for manufacturing a liquid crystal device can be provided.

[Brief description of the drawings]

FIG. 1 is a flowchart showing each step in one embodiment of a method for manufacturing a liquid crystal device according to the present invention.

FIG. 2 is a schematic diagram (first half) sequentially showing a first specific example of a method for manufacturing a liquid crystal device according to the present invention.

FIG. 3 is a schematic diagram (second half) sequentially illustrating a first specific example of a method for manufacturing a liquid crystal device according to the present invention.

FIG. 4 is a schematic view showing a state before a substrate bonding step of a second specific example of the method for manufacturing a liquid crystal device according to the present invention.

FIG. 5 is a schematic view showing a state of (a) before a substrate bonding step and (b) after a substrate bonding step of a third specific example of the method for manufacturing a liquid crystal device according to the present invention.

FIG. 6 is a schematic view showing a state before a substrate bonding step of a fourth specific example of the method for manufacturing a liquid crystal device according to the present invention.

FIGS. 7A and 7B are schematic diagrams showing (a) a state before a substrate bonding step and (b) a state after a substrate bonding step in a fifth specific example of the method for manufacturing a liquid crystal device according to the present invention.

FIGS. 8A and 8B are diagrams showing a manufacturing process of a general liquid crystal display device, wherein FIG. 8A shows a process of arranging a spacer agent on a first substrate, and FIG. It is a figure which shows the arrangement | positioning process.

9A and 9B are diagrams showing a process following the process of FIG. 7 for manufacturing a general liquid crystal display device, wherein FIG. 9A shows a state in which both substrates are superimposed, and FIG. FIG.

FIG. 10 is a view showing a step following the step shown in FIG. 8 in the process of manufacturing a general liquid crystal display device.

FIG. 11 is a view showing a step following the step shown in FIG. 9 in the process of manufacturing a general liquid crystal display device.

12A and 12B are diagrams illustrating a process following the process of FIG. 10 for manufacturing a general liquid crystal display device, in which FIG. 12A illustrates a state in which the liquid crystal device is placed in a vacuum chamber, and FIG. It is a figure which shows a mode that injection | pouring is performed.

13A and 13B are views showing a step following the step shown in FIG. 11 of a manufacturing process of a general liquid crystal display device, wherein FIG. 13A shows a step of wiping off excess liquid crystal, and FIG. 13B shows a step of sealing an injection port of the liquid crystal device. It is a figure showing a process.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Glass substrate 11, 11a, 11b Ridge 12, 16 Seal pattern 13 Liquid crystal 14 Counter substrate 15 Liquid crystal device 16 Seal pattern 17, 17a Second ridge 20 Vacuum chamber

Claims (11)

[Claims] A step of forming, on a surface of at least one of a pair of glass substrates to define at least one pixel region, a protruding portion surrounding an outer periphery of the pixel region; A step of forming a seal pattern on the surface of the substrate or the other glass substrate so as to extend along the outside of the ridge; and a liquid crystal that drops liquid crystal into a space defined inside the ridge. An injecting step, a laminating step of laminating the pair of glass substrates with a predetermined interval determined by a height of the ridge portion with the ridge portion and the seal pattern inside, and a sealing for curing the seal pattern. A method for manufacturing a liquid crystal device, comprising: a stopping step. 2. The method according to claim 1, wherein the bonding step is performed under atmospheric pressure. 3. The method according to claim 2, wherein the bonding step is performed under reduced pressure. 4. The liquid crystal according to claim 1, wherein the liquid crystal dropped in the liquid crystal injecting step has the same volume as the volume of a space defined inside the ridge. 3. The method for manufacturing a liquid crystal device according to item 1. 5. The liquid crystal display according to claim 1, wherein the liquid crystal dropped in the liquid crystal injection step has a volume slightly larger than a volume of a space defined inside the ridge. A method for manufacturing the liquid crystal device according to any one of the above. 6. After forming the ridge, and before forming a seal pattern, the second ridge is formed at an interval corresponding to the width of the seal pattern outside the ridge. 2. The method according to claim 1, further comprising a forming step.
6. The method for manufacturing a liquid crystal device according to any one of items 1 to 5. 7. The method according to claim 6, wherein the second ridge is formed on the other glass substrate. 8. The sealant according to claim 1, wherein the sealant forming the seal pattern is a UV curable resin, and the curing of the seal pattern in the sealing step is performed by ultraviolet irradiation. 13. A method for manufacturing a liquid crystal device according to 9. The sealant according to claim 1, wherein the sealant forming the seal pattern is a thermosetting material, and the curing of the seal pattern in the sealing step is performed by heat treatment. 13. A method for manufacturing a liquid crystal device according to 10. The method according to claim 1, further comprising, after the sealing step, a separating step of cutting a pair of glass substrates outside each seal pattern or the second ridge to separate the pair of glass substrates into pixel regions. The method for manufacturing a liquid crystal device according to claim 1, wherein: 11. The method for manufacturing a liquid crystal device according to claim 1, wherein the liquid crystal cell defined by the first seal pattern has a diagonal length of 1 cm or less.