JP3365030B2 - Manufacturing method of liquid crystal display device - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a liquid crystal display device.

[0002]

2. Description of the Related Art In a liquid crystal display device, two film substrates each having transparent electrodes formed on opposite surfaces thereof are bonded to each other via a sealing material, and a liquid crystal is placed between both film substrates inside the sealing material. There is an intervening structure. Further, in such a liquid crystal display device, there is a liquid crystal display device in which an end portion of one film substrate is projected from the other film substrate and a connection terminal is provided on the projected portion in order to achieve electrical connection to the outside. .

By the way, as one of the methods for manufacturing such a liquid crystal display device, two long or relatively large sheet-shaped base films for forming a plurality of film substrates are prepared and are transparent. After a predetermined pre-process such as an electrode forming process and a sealing material forming process, the two base films are attached to each other, and the two attached base films are attached by a cutter or the like before or after the liquid crystal injecting process. There is a method of manufacturing a plurality of liquid crystal display devices by cutting them.

However, in the conventional method of manufacturing such a liquid crystal display device, only one of the two bonded base films needs to be cut by a cutter or the like, but this cutting operation is very difficult. There was a problem. That is, of the two film substrates of the liquid crystal display device as the final product, one film substrate has an end protruding from the other film substrate, and the connecting terminal is provided on this protruding portion. The cut points of the base film of No. 1 do not coincide with each other. Moreover, the base film is formed of a thin film made of a resin such as polyethylene terephthalate (PET) or polyether sulfone (PES), and since sufficient processing accuracy cannot be obtained in cutting work,
It is very difficult to cut only one of the two bonded base films. As a result, when cutting only one of the two base films pasted together, make a cut in the part of the other base film where the connection terminals are provided, and scratch or completely cut the connection terminals in the same part. However, there is a problem that it is one of the factors that reduce the yield.

Therefore, recently, there has been considered a method of manufacturing a liquid crystal display device capable of preventing a cut from being formed in a portion provided with a connection terminal. This manufacturing method will be described with reference to FIGS. 11 to 13, in which the end portion of one (rear side) film substrate is projected from the other (front side) film substrate, and the connection terminal is provided on this protruding portion. A case of manufacturing a liquid crystal display device will be described. First, a rear side base film 1 as shown in FIG. 11 for forming a plurality of rear side film substrates and a front side base film 2 as shown in FIG. 12 for forming a plurality of front side film substrates are formed. prepare. The base films 1 and 2 are formed into a long shape (or a relatively large sheet shape) by a thin film made of a resin such as PET or PES, and sprocket holes 3 and 4 are formed at both widthwise ends thereof. .

The remaining portion of the rear side base film 1 except for the widthwise end portions and the portions corresponding to every other sprocket holes 3 in the longitudinal direction is the film substrate forming region 1
It is 1. On the upper surface of the film substrate forming area 11, a total of 18 sealing materials 12 are formed by printing, six in the width direction of the rear side base film 1 and three in the longitudinal direction. A liquid crystal inlet 13 is provided on the left side of the sealing material 12 in FIG. Before forming the sealing material 12, the upper surface of the film substrate forming region 11 is covered with the film shown in FIG.
As shown in FIG. 3B, a rear transparent electrode 14 made of ITO or the like is patterned, and the alignment film 1 is formed on the upper surface thereof.
5 is formed and a predetermined alignment treatment is performed. A connection terminal 16 is patterned on the upper surface of the film substrate forming region 11 in the right side portion (upper side portion in FIG. 11) of the sealing material 12 in FIG. 13B.

On the other hand, at predetermined 6 positions in the width direction of the front side base film 2, that is, at the portions corresponding to the portions of the rear side base film 1 where the connection terminals 16 are provided, the slits 21 are formed by punching the rear side base film. Film 1
The film substrate forming region 11 is formed so as to extend over the entire length of the film substrate forming region 11. Before or after forming the slits 21, a transparent electrode 22 for the front side made of ITO or the like is patterned on the lower surface of the front side base film 2 as shown in FIG. 13B. An alignment film 23 is formed on the lower surface and a predetermined alignment treatment is performed. Further, a cloth material (not shown) for electrically connecting the front side base film 2 and the rear side base film 1 is formed by printing on each predetermined portion of the lower surface of the front side base film 2. There is.

After preparing the rear side base film 1 and the front side base film 2 as described above, a spacer (not shown) is sprayed inside the sealing material 12 of the rear side base film 1 if necessary. And so on. Next, as shown in FIGS. 13 (A) and 13 (B), the rear side base film 1 is exposed through the slit 21 to expose the portion of the rear side base film 1 where the connection terminals 16 are provided. The side base film 1 and the front side base film 2 are overlapped with each other with the sealing material 12 interposed therebetween. Next, heat treatment is performed to cure the sealing material 12, and thereby the rear side base film 1 and the front side base film 2 are bonded together. Next, FIG.
As shown by the alternate long and short dash line in (A), the both base films 1 and 2 that have been bonded together are cut by a cutter or the like not shown. That is, cutting of both base films 1 and 2 in the width direction is performed along the arrangement of the liquid crystal injection ports 13, and cutting in the longitudinal direction is performed along the upper edge 21a of the slit 21 in FIG. 13 (A). Then, the base films 1 and 2 attached to each other are cut so as to contact with the slit 21 while avoiding the connection terminal 16 exposed through the slit 21, and the portion where the connection terminal 16 is provided corresponds to the width of the slit 21. It is projected as much as you do. Therefore, the connection terminal 1
It is possible to prevent a cut from being formed in the portion provided with 6, and it is possible to improve the yield without damaging or completely cutting the connection terminal 16 in the portion. As a result, a plurality of cells constituting the liquid crystal display device are obtained, and the liquid crystal injection port 13 is exposed on the side surface. Then, liquid crystal (not shown) is injected through the liquid crystal injection port 13, and then resin (not shown) is applied to the liquid crystal injection port 13 and sealed. The connecting terminal 16 is projected from the board and is connected to the protruding portion.
A liquid crystal display device provided with is manufactured.

[0009]

However, in the conventional manufacturing method of such a liquid crystal display device, when the slit 21 is formed in the front side base film 2 by punching, as shown in FIG. Burrs 24 may be formed on the lower surface of the front side base film 2, and the burrs 24 may be removed and adhered to the surface of the alignment film 23 in a post-process after punching, particularly in the case where the alignment treatment process is performed after this. In such a case, the flash 2 is formed in the display area of the liquid crystal display device as the final product.
Therefore, there is a problem in that the display quality is deteriorated due to a gap defect, a black dot defect, or the like. Further, in the conventional method of manufacturing such a liquid crystal display device, since the slit 21 is formed only in the front side base film 2, the thermal expansion coefficients of both base films 1 and 2 are different from each other depending on the presence or absence of the slit. 21
The coefficient of thermal expansion of the front side base film 2 in which the slits are formed is smaller than the coefficient of thermal expansion of the rear side base film 1 in which the slits are not formed. As a result, after the base films 1 and 2 are overlapped with each other with the seal material 12 interposed therebetween, the seal material 12 is cured to form the base films 1 and 2.
When heat treatment is performed to bond the two to each other, the bonded base films 1 and 2 are warped, which not only adversely affects the subsequent steps, but also between the two film substrates of the liquid crystal display device as the final product. There is a problem that the gap becomes non-uniform and the display quality is deteriorated. An object of the present invention is to provide a method of manufacturing a liquid crystal display device capable of eliminating the inconvenience caused by burrs caused by punching. Another object of the present invention is to perform heat treatment to bond both base films,
It is an object of the present invention to provide a method for manufacturing a liquid crystal display device, which can prevent both base films that have been bonded together from warping.

[0010]

The invention according to claim 1 is
A liquid crystal display device is manufactured in which two film substrates are bonded together, and at least one film substrate of the two film substrates is made to project an end portion from the other film substrate, and a connection terminal is provided at the projecting portion. In doing so, one base film for forming a plurality of the one film substrate, and the other base film for forming a plurality of the other film substrate is prepared, the film substrate of the one base film Length of forming area
A connection terminal corresponding to the connection terminal of the one of the film substrate in the direction provided predetermined set, the base film of the other, off
Leave uncut parts on both outer sides in the longitudinal direction of the film substrate formation area.
The strip-shaped notch that has the base fill of the one side
Formed to correspond to a predetermined set of connection terminals of the beam, after the attachment between the base film of the base film of the one other, the bonding two base films, the switching
Cut widthwise inside both ends of the recess, then
A plurality of the liquid crystal display devices are manufactured by cutting one or the other base film in the longitudinal direction with a predetermined width . The invention according to claim 1
Then, before laminating the one base film and the other base film, forming a cut portion corresponding to the shape of the cut portion of the other base film in the one base film, the one base film after the attachment between the other base film and, with this bonding two base films, the two base film
It is possible to cut in the width direction inside both ends of the cut portion formed in the .

[0011]

According to the invention of claim 1, wherein, when formed by punching a cut portion of the strip-shaped with uncut portion to a predetermined portion, by internal incisions are held in the same position, the cut Burrs are continuously formed on the inner periphery of the part and on the other base film adjacent to the inner part of the portion, which makes the burr strong and difficult to remove in the post-punching step. It can be resolved. Further, according to the invention of claim 2, since the corresponding strip-shaped notches each having a not-cut portion in each part are formed in both base films, the coefficient of thermal expansion of both base films is almost the same. It can be the same, and therefore, even if heat treatment is performed to bond both base films, both bonded base films can be prevented from warping.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, one embodiment of the present invention will be described with reference to FIGS.
1 to 14 are denoted by the same reference numerals, and the description thereof will be omitted as appropriate. In this embodiment, as shown in FIG. 2, punching is performed at predetermined six positions in the width direction of the front side base film 2, that is, at the portions corresponding to the portions of the rear side base film 1 where the connection terminals 16 are provided. ,
A strip-shaped cut portion 31 is formed so as to extend in the longitudinal direction of the film substrate formation region 11 of the rear side base film 1. In this case, an uncut portion 32 is formed at each central portion of both ends of the cut portion 31. Therefore, the inside of the cut portion 31 is not removed but is held at the same position. As a result, as shown in FIG. 4, burrs 33 are formed around the inner lower surface of the cut portion 31 and on the lower surface of the front side base film 2 adjacent thereto.
34 are continuously formed, so that the burrs 33 and 34 come into contact with each other to increase their strength, and it is difficult to remove the burrs even in the post-punching step, particularly in the case where there is an alignment treatment step. Therefore, the burrs 33 and 34 are not removed and attached to the surface of the alignment film 23, and the inconvenience caused by the burrs generated by punching can be eliminated. In FIG. 4, the reference numeral 44 indicates a punch of a punching device described below.

Now, the punching device will be described with reference to FIG. This punching device has an upper die 41
And a lower mold 42. In the upper die 41, a punch plate 45 having a punch 44 is provided on the lower surface of a mounting plate 43, and a stripper plate 47 is provided on the lower surface of the punch plate 45 around the punch 44 via a spring 46 so as to be vertically movable. The height of the stripper plate 47 is adjustable and the height of the stopper 48 is adjustable. In this case, the lower shape of the punch 44 is such that a strip-shaped cut portion 31 having an uncut portion 32 at each central portion of both ends can be formed. In the lower die 42, a die plate 52 is provided on the upper surface of the mounting plate 51, a die hole 53 is provided at a position facing the punch 44 of the die plate 52, and a punch escape to the mounting plate 51 at a portion corresponding to the die hole 53. The structure is provided with holes 54.

When forming a predetermined cut on the front side base film 2 with this punching device, first,
The upper mold 41 descends. Then the stripper plate 47
The lower surface of the punch plate 45 is pressed against the upper surface of the die plate 52 via the front side base film 2, the spring 46 contracts, and a predetermined cut is formed in the front side base film 2 by the lower part of the punch 44, and then the lower surface of the punch plate 45. Contacts the stopper 48. In this case, the pressing amount of the punch 44 with respect to the front side base film 2 is adjusted by the stopper 48. After this, upper mold 4
When 1 rises, one punching ends.

After preparing the front side base film 2 and the rear side base film 1 in which the notches have been formed as described above, both base films 1 and 2 are treated in an untreated post-process, and necessary. Accordingly, spacers (not shown) are sprayed inside the sealing material 12 of the rear side base film 1 by using a spray or the like. Next, FIG.
As shown in (A) and (B), the inside of the cutout portion 31 of the front side base film 2 is placed inside the rear side base film 1
In a state of facing the portion where the connection terminal 16 of
Rear base film 1 and front base film 2
And are overlapped with each other via the sealing material 12. Next, heat treatment is performed to cure the sealing material 12, and thereby the rear side base film 1 and the front side base film 2 are bonded together.

Next, as shown by the alternate long and short dash line in FIG. 3 (A), the both base films 1 and 2 thus bonded are cut by a cutter or the like not shown. That is, both base films 1 and 2 are cut in the width direction along the arrangement of the liquid crystal injection ports 13, and cut in the longitudinal direction along the upper cut 31a of the cut portion 31 in FIG. Then, the base films 1 and 2 that have been bonded together are cut so as to avoid the connection terminal 16 and come into contact with the cut portion 31, the inside of the cut portion 31 is removed, and the portion where the connection terminal 16 is provided is cut. The protrusion corresponds to the width of the portion 31. As a result, a plurality of cells constituting the liquid crystal display device are obtained, and the liquid crystal injection port 13 is exposed on the side surface. Then, a liquid crystal (not shown) is injected through the liquid crystal injection port 13, and then a resin (not shown) is applied to the liquid crystal injection port 13 and sealed. A liquid crystal display device is manufactured which is projected from the substrate and the connection terminals 16 are provided on the projected portion.

Next, another embodiment of the present invention will be described with reference to FIG.
As described with reference to FIGS. 8A to 8C, in these figures, the same reference numerals are given to the same names as those in FIGS. 1 to 3, and the description thereof will be appropriately omitted. In this embodiment, as shown in FIG. 6, predetermined six positions in the width direction of the rear side base film 1,
That is, the lower portion of the sealing material 12 in FIG. 6 (see FIG. 8).
The left side portion in (B)), the notch portion 6 having the uncut portion 62 at each central portion of both ends by punching.
1 is formed. The width and length of the cut portion 61 are the same corresponding to the width and length of the cut portion 31 of the front side base film 2. Further, the notch 61a on the lower side of the notch 61 shown in FIG.
The upper notch 31a of the notch 31 shown in FIG. 7 and the upper notch 31a are arranged on the same plane in correspondence with each other, as shown in FIG. 8B.

After preparing the rear side base film 1 and the front side base film 2 as described above, both base films 1 and 2 are treated in the unprocessed post-process, and the rear side base film 1 is treated as necessary. Spacers (not shown) are sprayed inside the sealing material 12 of the base film 1 by using a spray or the like. Next, as shown in FIGS. 8A and 8B,
With the inside of the cutout 31 of the front side base film 2 and the portion of the rear side base film 1 where the connection terminals 16 are provided facing each other, the rear side base film 1 and the front side base film 2 are sealed with each other. Overlap through. Next, heat treatment is applied to the sealing material 1
2 is cured, whereby the rear side base film 1 and the front side base film 2 are bonded together. In this case, since both base films 1 and 2 have cut portions 61 and 31 having the same width, the same length, and the same number,
Both base films 1 and 2 can have substantially the same coefficient of thermal expansion, and therefore even if heat treatment is performed to cure the sealant 12 and bond the base films 1 and 2, the bonded base films 1, 2 can be prevented from warping, and by extension, both base films 1,
The inconvenience caused by the warp of 2 can be eliminated.

Next, as shown by the alternate long and short dash line in FIG. 8 (A), the both base films 1 and 2 thus bonded are cut by a cutter or the like not shown. That is, the cutting of both base films 1 and 2 in the width direction is performed along the arrangement of the liquid crystal injection ports 13, and the cutting in the longitudinal direction is both cut portions 6.
1 and 31 of each upper notch 61 in FIG.
b, 31a, avoiding the connection terminal 16,
Both the base films 1 and 2 that have been bonded are cut so as to contact the respective cut portions 61 and 31, the insides of both cut portions 61 and 31 are removed, and the portion where the connection terminal 16 is provided becomes the cut portion 31. It is projected by the amount corresponding to the width. Further, an unnecessary portion of the front side base film 2 facing the inside of the cut portion 61 of the rear side base film 1 is removed. As a result, a plurality of cells constituting the liquid crystal display device are obtained, and the liquid crystal injection port 13 is exposed on the side surface. Then, a liquid crystal (not shown) is injected through the liquid crystal injection port 13, and then a resin (not shown) is applied to the liquid crystal injection port 13 and sealed. A liquid crystal display device is manufactured which is projected from the substrate and the connection terminals 16 are provided on the projected portion.

In the above-described embodiment, the strip-shaped cut portion 31 is formed in the front side base film 2 so as to extend in the longitudinal direction of the film substrate forming region 11 of the rear side base film 1. It is not limited. For example, as shown in FIG.
Is formed so that both ends thereof are located on both outer sides of the film substrate forming region 11 of the rear side base film 1 and is cut on each inner side of both ends of the cut portion 31 as shown by a chain line. Good. Also, as shown in FIG.
A film-shaped substrate forming region 1 of the rear side base film 1 is provided at both ends of a strip-shaped cut portion 31 formed of two parallel cut portions having both end portions left as they are.
It may be formed so as to be located on both outer sides of 1, and may be cut on each inner side of both end portions of the cut portion 31 as shown by a chain line. The same applies to the other embodiments described above.

Further, in the above-mentioned one embodiment, the both base films 1 and 2 which have been bonded together are cut as shown by a chain line in FIG. 3 (A), and liquid crystal is injected through the liquid crystal injection port 13 of each cut piece. However, the present invention is not limited to this. For example, the bonded base films 1 and 2 are cut only in the width direction along the arrangement of the liquid crystal injection ports 13, and in this state, the liquid crystal is injected through the liquid crystal injection port 13 of each cut piece, and then the liquid crystal injection is performed. The inlet 13 is sealed, and then each cut piece is cut into the cut portion 31 at the upper cut 3 in FIG.
You may make it cut | disconnect along 1a. By doing so, liquid crystal injection and liquid crystal injection port sealing can be efficiently performed. Further, the liquid crystal may be arranged inside the sealant 12 by a supply means such as printing before the base films 1 and 2 are attached to each other. The same applies to the other embodiments described above.

[0022]

As described in the foregoing, according to the first aspect of the invention, the other of the base film, so to form a cut portion of the strip-shaped with uncut portion in a part,
Burrs are continuously formed on the inner periphery of the cut portion and on the other base film adjacent to the cut portion. Therefore, the burr has high strength and is difficult to remove in the post-punching step, and therefore the inconvenience caused by the burr generated by punching is caused. Can be resolved. Further, according to the invention of claim 2, since the corresponding strip-shaped notches each having a not-cut portion in each part are formed in both base films, the coefficient of thermal expansion of both base films is almost the same. It can be the same, and therefore, even if heat treatment is performed to bond both base films, both bonded base films can be prevented from warping.

[Brief description of drawings]

FIG. 1 is a plan view of a part of a rear side base film used in an embodiment of the present invention.

FIG. 2 is a plan view of a part of a front side base film used in the same embodiment and an enlarged view of a part thereof.

FIG. 3A is a plan view of a part of a state where both base films are bonded together and an enlarged view of a part thereof in the same embodiment, and FIG. 3B is a sectional view taken along line BB thereof.

FIG. 4 is a partial cross-sectional view of a front side base film used in the same example in which a notch is formed.

FIG. 5 is a schematic cross-sectional view of a punching device for forming a cut portion on the front side base film in the same embodiment.

FIG. 6 is a partial plan view of a rear side base film used in another embodiment of the present invention.

FIG. 7 is a plan view of a part of a front side base film used in the other example and an enlarged view of a part thereof.

FIG. 8A is a plan view of a part of a state in which both base films are attached to each other in the other embodiment, and FIG.
-A sectional view taken along line B.

FIG. 9 is a partial plan view of a front side base film shown for explaining a modified example of the invention.

FIG. 10 is a plan view of a part of a front side base film shown for explaining another modification of the present invention.

FIG. 11 is a plan view of a part of a rear side base film used in a conventional example.

FIG. 12 is a plan view of a part of a front side base film used in the conventional example.

FIG. 13 (A) is a partial plan view showing a state in which both base films are bonded together in the same conventional example, and FIG.
Sectional drawing which follows the B line.

FIG. 14 is a partial cross-sectional view of a state where a slit is formed in the front side base film used in the conventional example.

[Explanation of symbols]

1 Rear side base film 2 Front side base film 16 connection terminals 31 notch 32 Uncut part

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP 62-92916 (JP, A) JP 59-37524 (JP, A) JP 58-181022 (JP, A) JP 59- 157616 (JP, A) JP 1-154023 (JP, A) JP 5-107517 (JP, A) JP 60-8828 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) G02F 1/13-1/141

Claims (2)

(57) [Claims] 1. The two film substrates are bonded together, and at least one of the two film substrates has an end portion projected from the other film substrate, and a connection terminal is provided on the protruding portion. When manufacturing a liquid crystal display device, one of the one base film for forming a plurality of the one film substrate, and the other base film for forming a plurality of the other film substrate is prepared, the one of the one Base film film substrate
A predetermined set of connection terminals corresponding to the connection terminals of the one film substrate are provided in the longitudinal direction of the formation region, and the other base film is provided on both outer sides in the longitudinal direction of the film substrate formation region.
The strip-shaped notched part with the uncut part on the one side
Corresponding to a predetermined set of connection terminals on the base film of
Then , the one base film and the other base film are bonded together, and then both the bonded base films are cut in the width direction inside both ends of the cut portion.
And then extend the one or the other base film.
A method of manufacturing a liquid crystal display device, wherein a plurality of the liquid crystal display devices are manufactured by cutting the liquid crystal display device with a predetermined width in a hand direction . 2. Before the one base film and the other base film are bonded together, a cut portion corresponding to the shape of the cut portion of the other base film is formed in the one base film, and the one base film is formed. base film and after the bonding the other of the base film, both the base film to match this bonding, the both base of
Width inside both ends of the notch formed in the film
The method of manufacturing a liquid crystal display device according to claim 1, wherein the liquid crystal display device is cut in a direction .