U.S. patent application number 09/357827 was filed with the patent office on 2001-09-20 for method and system for fabricating an electrooptical device.
Invention is credited to NISHI, TAKESHI, TERAMOTO, SATOSHI.
Application Number | 20010022646 09/357827 |
Document ID | / |
Family ID | 11979305 |
Filed Date | 2001-09-20 |
United States Patent
Application |
20010022646 |
Kind Code |
A1 |
NISHI, TAKESHI ; et
al. |
September 20, 2001 |
METHOD AND SYSTEM FOR FABRICATING AN ELECTROOPTICAL DEVICE
Abstract
Techniques for successively fabricating liquid crystal cells at
low cost, using two resinous substrates wound on their respective
rolls. A color filter and an electrode pattern are formed by
printing techniques. Furthermore, an orientation film is printed.
These manufacturing steps are carried out successively by rotating
various rolls.
Inventors: |
NISHI, TAKESHI; (KANAGAWA,
JP) ; TERAMOTO, SATOSHI; (KANAGAWA, JP) |
Correspondence
Address: |
NIXON PEABODY, LLP
8180 GREENSBORO DRIVE
SUITE 800
MCLEAN
VA
22102
US
|
Family ID: |
11979305 |
Appl. No.: |
09/357827 |
Filed: |
July 21, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09357827 |
Jul 21, 1999 |
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08566143 |
Dec 1, 1995 |
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5929961 |
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Current U.S.
Class: |
349/187 |
Current CPC
Class: |
G02F 1/133516 20130101;
G02F 1/1333 20130101; G02F 1/133305 20130101 |
Class at
Publication: |
349/187 |
International
Class: |
G02F 001/13 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 11, 1995 |
JP |
7-18713 |
Claims
What is claimed is:
1. A system for fabricating an electrooptical device comprising: a
first roll around which a first substrate is wound; a second roll
around which a second substrate is wound; a third roll around which
a base film is wound; three sets of rolls to form color filters on
a front surface of said base film; a set of pressure rolls to stick
said first substrate on a rear surface of said base film; a
dripping device to drip an electrooptical material over the first
substrate; a set of rolls to stick said second substrate over said
color filters on said front surface of said base film with said
electrooptical material interposed therebetween in order to form a
substrate assembly; and a cutter to cut said substrate
assembly.
2. A system according to claim 1, wherein said base film comprises
polyethylene terephthalate.
3. A system according to claim 1, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
4. A system according to claim 1, wherein said electrooptical
material is a liquid crystal material.
5. A system according to claim 1, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
6. A system according to claim 1 further comprising: means for
forming an overcoat film over said color filters; and means for
forming first electrode patterns over said overcoat film.
7. A system according to claim 1 further comprising: means for
forming a first orientation film over said first substrate; and a
furnace for heating said first orientation film.
8. A system according to claim 7 further comprising a set of rolls
for rubbing a surface of said heated first orientation film.
9. A system according to claim 1 further comprising means for
forming a sealing material over said first substrate.
10. A system according to claim 1 further comprising: means for
forming said electrode patterns over said second substrate; means
for forming a second orientation film over said second electrode
patterns; and a furnace for heating said second orientation
film.
11. A system for fabricating an electrooptical device comprising: a
first roll around which a first substrate is wound; means for
drawing said first substrate out of said first roll; a second roll
around which a second substrate is wound; means for drawing said
second substrate out of said second roll; a third roll around which
a base film is wound; means for drawing said base film out of said
third roll; three sets of rolls to form color filters over a front
surface of said base film; a set of pressure rolls to stick said
first substrate on a rear surface of said base film having said
color filters thereon; a set of rolls to form forming first
electrode patterns over said first substrate having said color
filters thereon; a set of rolls to stick said second substrate over
said color filters on said front surface of said base film in order
to form a substrate assembly; and a cutter to cut said substrate
assembly into a plurality of cells.
12. A system according to claim 11, wherein said base film
comprises polyethylene terephthalate.
13. A system according to claim 11, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
14. A system according to claim 11, further comprising a dripper to
dispose a liquid crystal material over said first substrate.
15. A system according to claim 11, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
16. A system according to claim 11 further comprising means for
forming an overcoat film over said color filters.
17. A system according to claim 11 further comprising: means for
forming a first orientation film over said first substrate; and a
furnace for heating said first orientation film.
18. A system according to claim 17 further comprising a set of
rolls for rubbing a surface of said heated first orientation
film.
19. A system according to claim 11 further comprising means for
forming a sealing material over said first substrate.
20. A system according to claim 11, further comprising: means for
forming second electrode patterns over said second substrate; means
for forming a second orientation film over said second electrode
patterns; and a furnace for heating said second orientation
film.
21. A system for fabricating an electrooptical device comprising: a
three set of rolls for forming color filters on a front surface of
a flexible base film; a set of rolls to stick a first flexible
substrate on said rear surface of said flexible base film with an
adhesive film interposed therebetween; a set of rolls to form an
overcoat film over said first flexible substrate; a set of rolls to
form first electrode patterns over said first substrate having said
color filters thereon; a dripper for disposing an electrooptical
material over said first electrode patterns; a set of rolls for
bonding said first flexible substrate to a second flexible
substrate with said electrooptical material interposed therebetween
to form a substrate assembly; and a cutter for cutting said
substrate assembly to form a plurality of electrooptical cells.
22. A system according to claim 21, wherein said base film
comprises polyethylene terephthalate.
23. A system according to claim 21, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
24. A system according to claim 21, wherein said electrooptical
material is a liquid crystal material.
25. A system according to claim 21, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
26. A system according to claim 21 further comprising: a set of
rolls to form a protective film over said color filters and for
forming said adhesive film on a rear surface of said flexible base
film; and means for peeling off said protective film.
27. A system according to claim 21 further comprising: means for
forming a first orientation film over said first substrate; and a
furnace for heating said first orientation film.
28. A system according to claim 27 further comprising a set of
rolls for rubbing a surface of said heated first orientation
film.
29. A system according to claim 21 further comprising means for
forming a sealing material over said first substrate.
30. A system according to claim 21 further comprising: means for
forming second electrode pattern over said second substrate; means
for forming a second orientation film over said second electrode
pattern; and a furnace for heating said second orientation
film.
31. A method for fabricating an electrooptical device comprising
steps of: drawing a base film out of a roll around which a base
film is wound; forming color filters on a front surface of said
base film; drawing a first substrate out of a roll around which
said first substrate is wound; sticking said first substrate on a
rear surface of said base film having said color filters thereon;
forming first electrode patterns to over said first substrate;
drawing a second substrate out of a roll around which said second
substrate is wound; sticking said second substrate over said first
substrate to form a substrate assembly; and cutting said substrate
assembly into a plurality of cells.
32. A method according to claim 31 further comprising a step of
forming an overcoat film over said color filters.
33. A method according to claim 32 wherein said overcoat film
comprises transparent resin.
34. A method according to claim 31 further comprising steps of:
forming a first orientation film over said first electrode
patterns; heating said first orientation film; and rubbing a
surface of said heated first orientation film.
35. A method according to claim 31 further comprising at least a
step of forming a sealing material over said first substrate.
36. A method according to claim 31 further comprising steps of:
forming second electrode patterns over said second substrate;
forming a second orientation film over said second electrode
patterns; and heating said second orientation film.
37. A method according to claim 31, wherein said base film
comprises polyethylene terephthalate.
38. A method according to claim 31, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
39. A method according to claim 31, further comprising a step of
disposing an electrooptical material over said first electrodes
patterns.
40. A method according to claim 31, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
41. A method for fabricating an electrooptical device comprising
steps of: drawing a base film out of a roll around which a base
film is wound; forming color filters on a front surface of said
base film; drawing a first substrate out of a roll around which
said first substrate is wound; sticking said first substrate on a
rear surface of said base film having said color filters thereon;
forming an overcoat film over said color filters and said first
substrate; forming first electrode patterns to over said overcoat
film; drawing a second substrate out of a roll around which said
second substrate is wound; sticking said second substrate over said
first substrate to form a substrate assembly; and cutting said
substrate assembly into a plurality of cells.
42. A method according to claim 41 wherein said overcoat film
comprises transparent resin.
43. A method according to claim 41 further comprising steps of:
forming a first orientation film over said first electrodes
pattern; heating said first orientation film; and rubbing a surface
of said heated first orientation film.
44. A method according to claim 41 further comprising at least a
step of forming a sealing material over said first substrate.
45. A method according to claim 41 further comprising steps of:
forming second electrode patterns over said second substrate;
forming a second orientation film over said second electrode
patterns; and heating said second orientation film.
46. A method according to claim 41, wherein said base film
comprises polyethylene terephthalate.
47. A method according to claim 41, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
48. A method according to claim 41, further comprising a step of
disposing an electrooptical material over said first electrode
patterns.
49. A method according to claim 48, wherein said electrooptical
material is a liquid crystal material.
50. A method according to claim 41, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
51. A method for fabricating an electrooptical device comprising
steps of: forming color filters on a front surface of a flexible
base film; forming a protective film over said color filters;
forming an adhesive film on a rear surface of said flexible base
film; sticking a first flexible substrate to said flexible base
film with said adhesive film interposed therebetween; removing said
protective film from said first flexible substrate; forming a
transparent resin film over said color filters and said first
flexible substrate; disposing an electrooptical material over said
resin film; bonding said first flexible substrate to a second
flexible substrate with said electrooptical material interposed
therebetween to form a substrate assembly; and cutting said
substrate assembly to form a plurality of electrooptical cells.
52. A method according to claim 51 further comprising steps of:
forming a first orientation film over said first electrodes
pattern; heating said first orientation film; and rubbing a surface
of said heated first orientation film.
53. A method according to claim 51 further comprising at least a
step of forming a sealing material over said first substrate.
54. A method according to claim 51 wherein said protective film and
said adhesive film are stuck on both sides of base film,
respectively, using a pair of rolls.
55. A method according to claim 51 further comprising steps of:
forming second electrode patterns over said second substrate;
forming a second orientation film over said second electrode
patterns; and heating said second orientation film.
56. A method according to claim 51, wherein said base film
comprises polyethylene terephthalate.
57. A method according to claim 51, wherein said first and second
substrates comprise a material selected from the group consisting
of polyethylene terephthalate, polyethylene naphalate, polyethylene
sulfite, polyimide, and polyarylate.
58. A method according to claim 51, wherein said electrooptical
material is a liquid crystal material.
59. A method according to claim 51, wherein said electrooptical
device is selected from a passive matrix type display device and an
active matrix type display device.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of fabricating
liquid-crystal electrooptical devices using flexible film
substrates and also to a system for fabricating such liquid-crystal
electrooptical devices using flexible film substrates.
[0003] 2. Description of the Related Art
[0004] A liquid-crystal electrooptical device is known as a thin,
small-sized, lightweight display device. The liquid-crystal
electrooptical device comprises a pair of substrates spaced several
micrometers from each other and a liquid crystal material held
between the substrates. The substrates are required to transmit
visible light and so glass substrates are generally used as the
substrates. The glass substrates have the required optical
characteristics. In addition, they are inexpensive.
[0005] The liquid-crystal electrooptical device must meet the
following technical requirements: (1) It is small in size and
lightweight; and (2) the cost of fabricating the liquid-crystal
electrooptical device is reduced and its productivity is
improved.
[0006] Of these requirements, the requirement (1) is that the
liquid-crystal electrooptical device is made thinner and lighter in
weight. A known configuration which satisfies these requirements
uses resinous substrates (generally known also as plastic
substrates) transmitting light.
[0007] Where resinous substrates are employed, reductions in size
and weight can be accomplished. Since the substrates themselves
have flexibility, a physical stress can be applied to them, or they
can be used in a curved state. These kinds of usage can further
extend the application of the liquid-crystal electro-optical
device.
[0008] However, where resinous substrates are used, a reduction in
fabrication cost and an improvement in the productivity are not
accomplished.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide
techniques for fabricating liquid-crystal electrooptical devices,
using flexible substrates, at low cost and with high
productivity.
[0010] A system for fabricating liquid crystal cells according to
the present invention comprises a first roll on which a first
flexible substrate has been wound, a second roll on which a second
flexible substrate has been wound, means for forming a liquid
crystal material layer on the surface of the first substrate, and
means for bonding together the first and second substrates
206,201.
[0011] A specific example of the structure of the above-described
system is shown in FIG. 1, where a first flexible substrate 206 has
been wound on a first roll 119. A second flexible substrate 201 has
been wound on a second roll 101. A dripping device 135 acts to drip
a liquid crystal material onto the surface of the first substrate
206. A set of rolls, 137 and 138, is the means for bonding together
the first and second substrates 206,201.
[0012] The flexible substrates can be made from PET (polyethylene
terephthalate), PEN (polyethylene naphthalate), PES (poly-ethylene
sulfite), polyimide, or PAR (polyarylate).
[0013] A method of fabricating liquid crystal cells according to
the present invention consists of preparing a first flexible
substrate wound on a first roll, preparing a second flexible
substrate wound on a second roll, and squeezing a liquid crystal
material between the first and second substrates to form an
elongated liquid crystal cell.
[0014] Another method of fabricating liquid crystal cells according
to the present invention consists of winding a flexible substrate
on a roll, printing an orientation film on the substrate, orienting
molecules of the orientation film, spraying spacers on the
orientation film, and printing a sealing material. These
manufacturing steps are effected successively.
[0015] A specific example of the above-described method is
illustrated in FIG. 1. An orientation film 209 is formed on the
flexible substrate 206 by rolls 127 and 128, the substrate 206
being wound on the roll 119. Spacers 211 are sprayed. A sealing
material (not shown) is printed.
[0016] Other objects and features of the invention will appear in
the course of the description thereof, which follows.
BRIEF DESCRIPTION OF THE DRAWING
[0017] FIG. 1 is a schematic diagram of a system for fabricating
liquid-crystal electrooptical devices according to the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The present example is a production system capable of
producing liquid-crystal electrooptical devices in succession, each
electrooptical device using flexible resinous substrates. This
fabrication system is schematically shown in FIG. 1 and intended to
produce the flexible resinous substrates wound on rolls 101 and
119, for constructing each liquid-crystal electrooptical
device.
[0019] First, a manufacturing step regarding resinous substrates
wound around the roll 119 is described. In this example, resinous
substrate coiled around the roll 119 consist of film of PET
(polyethylene terephthalate). A three-colored (R, G, and B) filter
203 is printed on the surface of the RET film 200 drawn out of the
roll 112. This PET film acts as a base in forming the color filter
203. The color filter 203 is formed by means of three sets of rolls
113. Where the manufactured liquid crystal display is a monochrome
display, these three sets of rolls are not necessary.
[0020] After forming the color filter 203, a protective film 205
wound on a roll 115 is formed so as to cover the color filter 203
previously formed. A self-adhesive film 204 wound on a roll 116 is
stuck on the rear side of the base, i.e., on the opposite side of
the surface on which the colored filter is formed. This series of
manufacturing steps is performed, using a pair of pressure rolls,
117 and 118.
[0021] Then, another PET film 206 which is wound on the roll 119
and forms a base is stuck via the self-adhesive film 204 by means
of a set of pressure rolls, 120 and 121. Subsequently, the
protective film 205 is peeled off by a roll 123 and wound on a roll
122.
[0022] Thereafter, an overcoat film 207 is printed by a set of
rolls, 123 and 124, to flatten the irregularities created by the
formation of the color filter 203. This overcoat film 207 is made
from a resinous material transparent to light.
[0023] A required electrode pattern 208 is printed, using a set of
rolls, 125 and 126. The electrode pattern 208 is made from a
conductive ink.
[0024] Then, an orientation film 209 is printed by the use of a set
of rolls, 127 and 128. The orientation film 209 is passed through a
heating furnace 129 to bake it. As a result, a solidified
orientation film 210 is obtained.
[0025] The orientation film 210 is passed between rolls 130 and 131
to rub the surfaces of the orientation film 210. In this way, the
molecules of the film are oriented. Then, spacers are sprayed from
a spacer dispenser 132 to place the spacers 211-on the oriented
film 210.
[0026] Thereafter, a sealing material (not shown) is printed to
bond together opposite substrates and to prevent the liquid crystal
material from leaking from the spacing between the substrates.
[0027] Subsequently, the liquid crystal material is dripped, using
the liquid crystal material-dripping device 135, to form a liquid
crystal material layer 212. In this manner, one substrate is
completed. The manufacturing steps described thus far are
successively carried out by rotating the various rolls.
[0028] The other substrate is manufactured in the manner described
below. A desired electrode pattern 213 is formed on the PET film
201 drawn out of the roll 101 by a pair of rolls 102 and 103. Then,
an orientation film 214 is printed through the use of a pair of
rolls 104 and 105. The film is baked by a heating furnace 108, so
that a solidified orientation film 215 is formed. Thereafter, the
substrate is passed between a pair of rolls 109 and 110 and guided
to the rolls 137 and 138 to form a cell.
[0029] The liquid crystal cell is formed on the PET film pair by
the steps described thus far. This PET film pair is passed between
a pair of rolls 137 and 138 to bond together the films, using a
sealing material.
[0030] Then, heating is done within a heating furnace 139 to cure
the sealing material, thus completing bonding of the substrates.
The resulting substrate assembly is cut into desired size with a
cutter 150. In this way, a liquid crystal cell is completed.
[0031] The manufacturing steps described thus far are performed in
succession by rotating the various rolls. By cutting the substrate
assembly with the cutter 150, liquid crystal cells are successively
fabricated.
[0032] In the present example, passive liquid crystal cells are
manufactured. It is also possible to fabricate active liquid
crystal cells by fabricating nonlinear devices and TFTs
simultaneously by printing techniques.
[0033] In the present example, liquid crystal cells are formed on
PET films which are industrially often used like magnetic tape.
Besides PET, PEN (polyethylene naphthalate), PES (polyethylene
sulfite), polyimide, and PAR (polyarylate) can be used.
[0034] Where PET or PES film is used, birefringence may take place,
in which case the image displayed on the device may be adversely
affected. On the other hand, neither PES film nor PAR film induces
birefringence and they satisfy the optical characteristics which
every display device must meet.
[0035] In the present invention, when flexible liquid crystal cells
are manufactured, flexible substrates wound on rolls are used.
Consequently, liquid crystal cells can be manufactured in
succession.
* * * * *