Liquid crystal panel

Abstract

To provide a liquid crystal panel in which a spacer will not fall off easily and a pixel opening ratio is high.SOLUTION: A color filter substrate includes a color filter layer, and a plurality of spacers projecting toward a liquid crystal layer. The color filter layer includes at least a color filter of a first color, and a color filter of a second color that is adjacent to the color filter of the first color in a column direction. The color filter of the first color includes a first continuous pattern part disposed continuously so as to overlap with a first subpixel group arranged in a column direction, and a first projecting pattern part that projects in the column direction from the first continuous pattern part. The color filter of the second color includes a second continuous pattern part disposed continuously so as to overlap with a second subpixel group arranged in the column direction. The spacers include a color filter multilayer part including the first projecting pattern part and a part of the second continuous pattern part.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The following disclosure relates to a liquid crystal panel.

Background Art

[0002] As a liquid crystal display device, for example, a configuration including an active matrix substrate using active elements typified by thin film transistors (TFTs), a color filter substrate provided with color filters, and a liquid crystal layer sandwiched between the active matrix substrate and the color filter substrate is exemplified. In order to maintain the thickness of the liquid crystal layer, spacers are arranged between the active matrix substrate and the color filter substrate.

[0003] Examples of the spacer include a photospacer (PS) formed by photolithography, and it has been studied to stack a colored layer used for a color filter to form a photospacer (for example, Patent Documents 1 and 2).

[0004] Patent Document 1 discloses a color filter having a large number of columnar bodies on a colored layer that perform a gap control function between the color filter and a counter substrate, and the columnar bodies are formed by a photolithography process. As shown in FIG. 1(B), it is disclosed that the columnar body 4 is formed by stacking colored layers of red (R), green (G), and blue (B) (paragraph

[0010] ).

[0005] Patent Document 2 discloses a liquid crystal display element comprising: a first substrate having a first electrode formed thereon; a second substrate having a second electrode formed thereon; the first substrate and the second substrate being arranged opposite to each other with a liquid crystal layer sandwiched therebetween; a seal portion formed on the outer peripheral portion of the substrates except for a liquid crystal injection portion for injecting the liquid crystal layer between the two substrates; a plurality of colored layers formed in an effective pixel region on either one of the two substrates; and a spacer formed by laminating a spacer layer formed in the same process as the colored layer on the substrate on which the colored layer is formed, wherein the spacer is arranged in the vicinity of the liquid crystal injection portion (see FIGS. 4(a) and (b)).

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] In recent years, liquid crystal panels have been used as display panels for head-mounted displays (hereinafter, HMDs). As a display panel for an HMD, for example, a liquid crystal panel with a high resolution of 1000 ppi or more is used. Since the transmittance is low in the region where the spacer with the laminated colored layer is arranged, as the resolution of the liquid crystal panel increases, it is required to reduce the diameter of the spacer.

[0008] Conventionally, photo spacers with laminated coloring layers as disclosed in Patent Documents 1 and 2 have been used in large panels, and isolated pattern photo spacers have been the mainstream. However, in the case of an isolated pattern photo spacer with a laminated coloring layer, it is likely to peel off when the diameter is reduced. On the other hand, although it becomes difficult to peel off when the diameter of the photo spacer is increased, the pixel aperture ratio decreases. Therefore, there has been room for further consideration regarding spacers applicable to high-resolution liquid crystal panels.

[0009] The present invention has been made in view of the above situation, and an object thereof is to provide a liquid crystal panel in which the spacer is difficult to peel off and the pixel aperture ratio is high.

Means for Solving the Problems

[0010] (1) One embodiment of the present invention includes an active matrix substrate including a plurality of sub-pixels arranged in a row direction and a column direction, having pixel electrodes arranged for each of the sub-pixels, a color filter substrate, and a liquid crystal layer sandwiched between the active matrix substrate and the color filter substrate. The color filter substrate has a color filter layer and a plurality of spacers protruding toward the liquid crystal layer side. The color filter layer includes at least a color filter of a first color and a color filter of a second color adjacent to the color filter of the first color in the row direction. The color filter of the first color includes a first continuous pattern portion continuously arranged so as to overlap a first sub-pixel group arranged along the column direction among the plurality of sub-pixels, and a first protruding pattern portion protruding from the first continuous pattern portion in the row direction. The color filter of the second color includes a second continuous pattern portion continuously arranged so as to overlap a second sub-pixel group arranged along the column direction among the plurality of sub-pixels. The plurality of spacers include a color filter laminated portion including the first protruding pattern portion and a part of the second continuous pattern portion, a liquid crystal panel.

[0011] (2) Further, in one embodiment of the present invention, in addition to the configuration of (1) above, the color filter layer further includes a color filter of a second color and a color filter of a third color adjacent to the color filter of the first color on the opposite side in the row direction. The color filter of the third color includes a third continuous pattern portion continuously arranged so as to overlap with a third sub-pixel group arranged along the column direction among the plurality of sub-pixels, and a third protruding pattern portion protruding from the third continuous pattern portion in the row direction. At least one of the plurality of spacers includes the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion in the color filter laminate, a liquid crystal panel.

[0012] (3) Further, in one embodiment of the present invention, in addition to the configuration of (2) above, the maximum width of the third protruding pattern portion in the column direction is larger than the maximum width of the first protruding pattern portion in the column direction, a liquid crystal panel.

[0013] (4) Further, in one embodiment of the present invention, in addition to the configuration of any one of (1) to (3) above, the color filter of the first color is either a red color filter or a green color filter, a liquid crystal panel.

[0014] (5) Further, in one embodiment of the present invention, in addition to the configuration of any one of (2) to (4) above, the color filter of the first color is either a red color filter or a green color filter, the color filter of the second color is a blue color filter, and the color filter of the third color is the other of a red color filter or a green color filter, a liquid crystal panel.

[0015] (6) Further, in one embodiment of the present invention, in addition to the configuration of any one of (1) to (5) above, a part of the second continuous pattern portion is arranged on the side closest to the liquid crystal layer in the color filter laminate, a liquid crystal panel.

[0016] (7) Further, in an embodiment of the present invention, in addition to any of the configurations (1) to (6) above, the color filter substrate further has a black matrix laminated on the color filter layer. The black matrix includes a plurality of openings arranged for each sub-pixel and a light-shielding portion arranged around the plurality of openings. The plurality of spacers include spacers arranged at positions overlapping the light-shielding portion. The plurality of openings include a plurality of first openings overlapping the first continuous pattern portion and a plurality of second openings overlapping portions other than the above-mentioned part of the second continuous pattern portion. The plurality of second openings include second openings having an area smaller than that of the first openings. A liquid crystal panel.

[0017] (8) Further, in an embodiment of the present invention, in addition to any of the configurations (1) to (7) above, the color filter substrate has an overcoat layer arranged on the liquid crystal layer side of the color filter layer. The thickness of the overcoat layer is smaller than the thickness of the color filter laminated portion. A liquid crystal panel.

[0018] (9) Further, in an embodiment of the present invention, in addition to any of the configurations (1), (4), (6) to (8) above, the color filter laminated portion is formed by laminating the first protruding pattern portion and a part of the second continuous pattern portion. The thickness of the color filter laminated portion is smaller than twice the thickness of the first continuous pattern portion. A liquid crystal panel.

[0019] (10) Further, in an embodiment of the present invention, in addition to any of the configurations (2), (3) to (8) above, the color filter laminated portion is formed by laminating the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion. The thickness of the color filter laminated portion is smaller than three times the thickness of the first continuous pattern portion. A liquid crystal panel.

[0020] (11) Further, in an embodiment of the present invention, in addition to any of the configurations (1) to (10) above, the maximum width of the first protruding pattern portion in the column direction is 0.5 times or more and 1.5 times or less the width of the first continuous pattern portion in the row direction. A liquid crystal panel.

[0021] (12) Further, in an embodiment of the present invention, in addition to any of the configurations (1) to (11) above, the color filter layer further includes a color filter of a second color and a color filter of a third color adjacent to the color filter of the first color on the opposite side in the row direction. One sub-pixel overlapping with the color filter of the first color, one sub-pixel overlapping with the color filter of the second color, and one sub-pixel overlapping with the color filter of the third color constitute one pixel. The pixel density of the liquid crystal panel is 1000 ppi or more, and the plurality of spacers are arranged at a density of 1 or more and 1 or less per 1000 pixels. A liquid crystal panel.

[0022] (13) Further, in an embodiment of the present invention, in addition to any of the configurations (2), (3) to (8), (10) to (12) above, the plurality of spacers include a main spacer and a sub-spacer having a thickness thinner than that of the main spacer. The color filter laminated portion included in the main spacer is a laminate of the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion. The color filter laminated portion included in the sub-spacer is a laminate of the first protruding pattern portion or the third protruding pattern portion and a part of the second continuous pattern portion. A liquid crystal panel.

[0023] (14) Further, in an embodiment of the present invention, in addition to the configuration (13) above, one sub-pixel overlapping with the color filter of the first color, one sub-pixel overlapping with the color filter of the second color, and one sub-pixel overlapping with the color filter of the third color constitute one pixel. For 1000 pixels, the number of the sub-spacers is the same as or more than and 10 times or less the number of the main spacers. A liquid crystal panel.

Advantages of the Invention

[0024] According to the present invention, it is possible to provide a liquid crystal panel in which the spacer is difficult to peel off and the pixel aperture ratio is high.

Brief Description of the Drawings

[0025]

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Embodiments for Carrying Out the Invention

[0026] FIG. 1 is a plan schematic view of a liquid crystal panel according to an embodiment. FIG. 2 is a schematic cross-sectional view taken along the line X1-X2 of the liquid crystal panel shown in FIG. 1. Note that FIG. 1 is a plan schematic view of the liquid crystal panel 1000 observed from the color filter substrate 20 side. As shown in FIG. 1, the liquid crystal panel 1000 according to the embodiment includes a plurality of sub-pixels arranged in the row direction and the column direction. The above row direction refers to the left-right direction (0°-180° azimuth) when, for example, the right hand direction when observing the liquid crystal panel from the observer side is set as the 0° azimuth and the left hand direction is set as the 180° azimuth. The above column direction refers to the direction orthogonal to the above row direction, for example, the up-down direction (90°-270° azimuth) of the liquid crystal panel. For example, in the case of n rows and m columns, n×m sub-pixels are arranged in a matrix.

[0027] As shown in FIG. 2, the liquid crystal panel 1000 includes an active matrix substrate 10, a color filter substrate 20, and a liquid crystal layer 30 sandwiched between the active matrix substrate 10 and the color filter substrate 20.

[0028] The active matrix substrate 10 has pixel electrodes 12 arranged for each sub-pixel. The active matrix substrate 10 may include a support substrate 11, and the pixel electrodes 12 may be arranged on the support substrate 11. The support substrate 11 and the support substrate 21 described later are insulating substrates (also referred to as insulating substrates), and are preferably transparent substrates, such as glass substrates, plastic substrates, and the like.

[0029] Although not shown in the figure, the active matrix substrate 10 has, for example, a plurality of gate wirings (scanning lines) arranged parallel to each other, and a plurality of source wirings (signal lines) that intersect the plurality of gate wirings and are arranged parallel to each other. The plurality of gate wirings and the plurality of source wirings may be orthogonal. The gate wirings may be arranged along the row direction, and the source wirings may be arranged along the column direction. The plurality of source wirings and the plurality of gate wirings are formed in a matrix (lattice) shape as a whole so as to partition each pixel. The smallest unit of this lattice shape, that is, the region surrounded by the source wiring and the gate wiring (including the regions in the color filter substrate 20 and the liquid crystal layer 30 that overlap in plan view with the region surrounded by the source wiring and the gate wiring in the active matrix substrate 10) is referred to as a "sub-pixel" in this specification. For each sub-pixel, a TFT as a switching element is arranged at the intersection of the source wiring and the gate wiring. The pixel electrode 12 is electrically connected to, for example, the drain wiring of the TFT. Examples of the semiconductor layer of the TFT include amorphous silicon, polysilicon, and oxide semiconductors.

[0030] As display modes of the liquid crystal panel 1000, there are horizontal electric field modes such as FFS (Fringe Field Switching) mode and IPS (In Plane Switching) mode; and vertical electric field modes such as vertical alignment (VA). The above horizontal electric field mode is a display mode in which liquid crystal molecules in the liquid crystal layer are aligned parallel to the substrate surface when no voltage is applied, and the above vertical electric field mode is a display mode in which liquid crystal molecules in the liquid crystal layer are aligned perpendicular to the substrate surface when no voltage is applied. Since the liquid crystal panel according to the embodiment is likely to obtain a high transmittance, it is preferably a liquid crystal panel of the horizontal electric field mode, and more preferably the FFS mode.

[0031] When the liquid crystal panel 1000 is of the horizontal electric field mode, the counter electrode is formed on the active matrix substrate 10. In the case of the FFS mode, an insulating film is disposed between the pixel electrode and the counter electrode. When the liquid crystal panel 1000 is of the vertical electric field mode, the counter electrode is formed on the color filter substrate 20 (for example, on the side of the liquid crystal layer 30 from the color filter layer 22).

[0032] The liquid crystal layer 30 contains liquid crystal molecules, and controls the amount of transmitted light by changing the alignment of the liquid crystal molecules according to the potential difference between the pixel electrode and the counter electrode. As the above liquid crystal molecules, a nematic liquid crystal material showing nematic liquid crystallinity in a certain temperature range is preferable. The above liquid crystal molecules may have a positive or negative dielectric anisotropy, but preferably have a positive dielectric anisotropy from the viewpoint of being able to increase the response speed, and preferably have a negative dielectric anisotropy from the viewpoint of being able to increase the transmittance.

[0033] The color filter substrate 20 may have a support substrate 21, or may be laminated in the order of the support substrate 21, the black matrix 23, and the color filter layer 22.

[0034] As shown in FIG. 1, the black matrix 23 includes a plurality of openings 23a arranged for each sub-pixel and a light-shielding portion 23b arranged around the plurality of openings 23a. The black matrix 23 may be formed in a lattice pattern on the support substrate 21. As the black matrix 23, those commonly used in the field of liquid crystal panels, such as black photosensitive resin materials and metal materials, can be used.

[0035] FIG. 3 is a schematic plan view of the color filter substrate of FIG. 1 as viewed from the liquid crystal layer side. In FIG. 3, the black matrix 23 is omitted. As shown in FIG. 3, the color filter layer 22 includes at least a color filter 22A of a first color and a color filter 22B of a second color adjacent to the color filter 22A of the first color in the row direction. The color filter layer 22 may further include a color filter 22C of a third color adjacent to the color filter 22B of the second color on the side opposite to the color filter 22A of the first color in the row direction.

[0036] FIG. 4 is a schematic plan view of one color filter of the first color shown in FIG. 3. As shown in FIG. 4, the color filter 22A of the first color includes a first continuous pattern portion 22A-1 continuously arranged so as to overlap with a first sub-pixel group (1-A)x (see FIG. 1) arranged along the column direction among the plurality of sub-pixels, and a first protruding pattern portion 22A-2 protruding from the first continuous pattern portion 22A-1 in the row direction. At least one of the plurality of color filters 22A of the first color may include the first continuous pattern portion 22A-1 and the first protruding pattern portion 22A-2, and the color filter layer 22 may include a color filter 22A of the first color composed only of the first continuous pattern portion 22A-1.

[0037] The maximum width W of the first protruding pattern portion 22A-2 in the column direction 22A-2 is preferably not less than 0.5 times and not more than 1.5 times the width W of the first continuous pattern portion in the row direction. From the viewpoint of improving the adhesion of the spacer, the above W 22A-1 is preferably W 22A-2 is preferably W 22A-1It is preferably 0.5 times or more. From the viewpoint of securing the aperture ratio and preventing deterioration of the display quality of the liquid crystal panel, the above W 22A-2 is preferably 1.5 times or less of W 22A-1 . When the liquid crystal panel is 1000 ppi, the above W 22A-2 is more preferably 4.23 μm or more and 12.7 μm or less.

[0038] FIG. 5 is a plan schematic view of one color filter of the second color shown in FIG. 3. As shown in FIG. 5, the color filter 22B of the second color includes a second continuous pattern portion 22B-1 continuously arranged so as to overlap with a second sub-pixel group (1-B)x (see FIG. 1) arranged along the column direction among a plurality of sub-pixels. The color filter 22B of the second color may not include a protruding pattern portion protruding in the row direction from the second continuous pattern portion 22B-1.

[0039] FIG. 6 is a plan schematic view of one color filter of the third color shown in FIG. 3. As shown in FIG. 6, the color filter 22C of the third color may include a third continuous pattern portion 22C-1 continuously arranged so as to overlap with a third sub-pixel group (1-C)x (see FIG. 1) arranged along the column direction among a plurality of sub-pixels, and a third protruding pattern portion 22C-2 protruding in the row direction from the third continuous pattern portion 22C-1. At least one of the plurality of color filters 22C of the third color may include the third continuous pattern portion 22C-1 and the third protruding pattern portion 22C-2, and the color filter layer 22 may include a color filter 22C of the third color composed only of the third continuous pattern portion 22C-1.

[0040] The first continuous pattern portion 22A-1, the second continuous pattern portion 22B-1, and the third continuous pattern portion 22C-1 are preferably continuously arranged so as to overlap with a sub-pixel group arranged along the column direction along the source wiring of the active matrix substrate 10 when the color filter substrate 20 is bonded to the active matrix substrate 10.

[0041] The maximum width W of the third protruding pattern portion 22C-2 in the column direction22C-2 may be not less than 0.5 times and not more than 1.5 times the width W of the third continuous pattern portion 22C-1 in the row direction. When the liquid crystal panel has 1000 ppi, it is more preferable that the above W 22C-1 is not less than 4.23 μm and not more than 12.7 μm. 22C-2

[0042] The width W of the first continuous pattern portion 22A-1 in the row direction 22A-1 , the width of the second continuous pattern portion 22B-1, and the width W of the third continuous pattern portion 22C-1 22C-1 are preferably not less than 3 μm and not more than 15 μm, and more preferably not less than 4 μm and not more than 12 μm. In this specification, the widths of the first, second, and third continuous patterns in the row direction respectively refer to the average widths of the first, second, and third continuous patterns in the row direction excluding the protruding pattern portions.

[0043] From the viewpoint of ensuring a good color reproduction range, the thickness of the continuous pattern portion of the color filter of each color overlapping the opening is preferably not less than 0.5 μm and not more than 3 μm, and more preferably not less than 1 μm and not more than 2 μm. The thickness of the protruding pattern portion of the color filter of each color may be the same as the thickness of the continuous pattern portion of the color filter of each color.

[0044] The color filter substrate 20 has a plurality of spacers protruding toward the liquid crystal layer 30 side. The plurality of spacers include a color filter laminate portion including a first protruding pattern portion 22A-2 and a part of a second continuous pattern portion 22B-1. By laminating the first protruding pattern portion 22A-2 connected to the first continuous pattern portion 22A-1 with a part of the second continuous pattern portion of the second color filter 22A adjacent to the first color filter 22A to form a spacer, the spacer can be made difficult to peel off. Further, since the spacer is formed so as to overlap with the second continuous pattern portion of the second color filter 22B, the spacer can be arranged in a space-saving manner, and the pixel aperture ratio can be increased. The color filter laminate portion may include a third protruding pattern portion 22C-2 described later, in addition to the first protruding pattern portion 22A-2 and a part of the second continuous pattern portion 22B-1. In this specification, when the spacers PS2 and PS3 described later are not particularly distinguished, they are simply referred to as spacers.

[0045] FIG. 7 is a schematic cross-sectional view taken along the line X3-X4 of the liquid crystal panel shown in FIG. 1. As shown in FIG. 7, it is preferable that at least one of the plurality of spacers includes a first protruding pattern portion 22A-2, a part of a second continuous pattern portion 22B-1, and a third protruding pattern portion 22C-2 in the color filter laminate portion. Both the first protruding pattern portion 22A-2 and the third protruding pattern portion 22C-2 protrude toward the second continuous pattern portion 22B-1 side in a plan view, and three layers of the first protruding pattern portion 22A-2, a part of the second continuous pattern portion, and the third protruding pattern portion 22C-2 are laminated to form the color filter laminate portion. In this specification, a spacer including a color filter laminate portion in which three layers of color filters are laminated is also referred to as a spacer PS3 having a three-layer structure.

[0046] FIG. 8 is a schematic cross-sectional view taken along the X5-X6 line of the liquid crystal panel shown in FIG. 1. As shown in FIG. 8, the spacer PS2 includes a color filter laminate portion including a first protruding pattern portion 22A-2 and a part of a second continuous pattern portion 22B-1. The first protruding pattern portion 22A-2 protrudes toward the second continuous pattern portion 22B-1 in a plan view, and two layers of the first protruding pattern portion 22A-2 and a part of the second continuous pattern portion are laminated to form the color filter laminate portion. In this specification, a spacer including a color filter laminate portion in which two layers of color filters are laminated is also referred to as a spacer PS2 having a two-layer structure.

[0047] As shown in FIGS. 7 and 8, it is preferable that a part of the second continuous pattern portion is arranged on the side closest to the liquid crystal layer 30 in the color filter laminate portion for both the spacer PS3 and the spacer PS2.

[0048] FIG. 9 is an enlarged plan schematic view of the vicinity of the spacer PS3 of the liquid crystal panel shown in FIG. 1. As shown in FIG. 9, the plurality of spacers include a spacer arranged at a position overlapping the light-shielding portion 23b. In the display area where a plurality of sub-pixels are arranged, all of the plurality of spacers may be arranged at positions overlapping the light-shielding portion 23b.

[0049] As shown in FIG. 9, the plurality of openings 23a are arranged so as to overlap with the continuous pattern portions of the color filters of each color, and a part of the continuous pattern portion of the color filter of the corresponding color is exposed from one opening 23a. Note that the opening areas of the three sub-pixels included in one pixel 2 may be the same or different. Specifically, as shown in FIG. 1, the liquid crystal panel 1000 may include pixels 2 including three sub-pixels having different areas of the respective openings and pixels 2 including three sub-pixels having equal areas of the respective openings in a plan view. FIG. 9 shows an example in which the opening areas of the three sub-pixels included in one pixel 2 are different. As shown in FIG. 9, the area of the second opening 23a-2 disposed in two sub-pixels adjacent in the column direction with a spacer interposed therebetween may be smaller than the area of the first opening 23a-1 and / or the third opening 23a-3 disposed in sub-pixels of other colors.

[0050] The plurality of openings 23a include a plurality of first openings 23a-1 that overlap with the first continuous pattern portion 22A-1 and a plurality of second openings 23a-2 that overlap with a portion other than a part included in the color filter stack portion of the second continuous pattern portion 22B-1. As shown in FIG. 9, the plurality of second openings 23a-2 may include a second opening 23a-2 having an area smaller than the area of the first opening 23a-1. Since a part of the second continuous pattern portion 22B-1 is included in the color filter stack portion, the second opening 23a-2 provided so as to overlap with the second continuous pattern portion 22B-1 is arranged so as to avoid the location where the spacer is disposed and overlap with a portion other than a part included in the color filter stack portion of the second continuous pattern portion 22B-1. Therefore, the area of the second opening 23a-2 can be smaller than the area of the opening (the first opening 23a-1) that overlaps with a part of the continuous pattern portion of other colors.

[0051] Since the visibility of blue is low to the human eye, the spacer is preferably disposed on the blue second continuous pattern portion. Therefore, the color filter of the first color including the protruding pattern portion is preferably either a red color filter or a green color filter.

[0052] When the spacer has a three-layer structure, the color filter 22A of the first color is either a red color filter or a green color filter, the color filter 22B of the second color is a blue color filter, and the color filter 22C of the third color is preferably the other of the red color filter or the green color filter. Since the human eye has a high visibility for green, from the viewpoint of ensuring the transmittance (luminance) of the panel, it is preferable that the spacer avoids the green continuous pattern portion. When forming a spacer having a three-layer structure, the color filter of the first color and the color filter of the third color having the protruding pattern portion are preferably either a red color filter or a green color filter.

[0053] The plurality of spacers may include a main spacer and a sub-spacer having a thickness thinner than that of the main spacer. The color filter laminate portion included in the main spacer is a laminate of a first protruding pattern portion 22A-2, a part of a second continuous pattern portion 22B-1, and a third protruding pattern portion 22C-2. The color filter laminate portion included in the sub-spacer is a laminate of a first protruding pattern portion 22A-2 or a third protruding pattern portion 22C-2 and a part of a second continuous pattern portion 22B-1. That is, the plurality of spacers may include only the spacer PS3 having a three-layer structure or the spacer PS2 having a two-layer structure, or may include both the spacers PS3 and PS2.

[0054] By including a thick main spacer (spacer PS3), the thickness of the liquid crystal layer (cell thickness) can be ensured, and a pressing resistance for maintaining the cell pressure even when receiving external pressure can be obtained. Also, when the liquid crystal layer thermally contracts in a low-temperature environment, bubbles (low-temperature bubbles) may be generated, and spotty display defects may occur due to the bubbles. By including, in addition to the main spacer, a thin sub-spacer (spacer PS2), even when the liquid crystal layer thermally contracts, the cell thickness can be maintained by the sub-spacer, so that a balance between the pressing resistance and the low-temperature bubble prevention effect can be achieved.

[0055] For 1000 pixels, the number of the sub-spacers may be equal to or more than the number of the main spacers and may be 10 times or less.

[0056] As shown in FIG. 9, one sub-pixel 1-A overlapping with the color filter 22A of the first color, one sub-pixel 1-B overlapping with the color filter 22B of the second color, and one sub-pixel 1-C overlapping with the color filter 22C of the third color may constitute one pixel 2. The number of pixels per inch is also referred to as ppi (pixel per inch).

[0057] The pixel density of the liquid crystal panel 1000 is preferably 1000 ppi or more, and the plurality of spacers may be arranged at a density of 1 or more per 1000 pixels and 1 or less per one pixel. More preferably, the plurality of spacers are arranged at a density of 1 or more per 100 pixels and 1 or less per 9 pixels. The upper limit of the pixel density is, for example, 2000 ppi. Note that the number of the plurality of spacers is the total of the number of the spacers PS3 having a three-layer structure and the number of the spacers having a two-layer structure when both are included.

[0058] Even when applied to a high-definition liquid crystal panel with a pixel density of 1000 ppi or more, since the spacers are hardly peeled off and the pixel aperture ratio can be increased, the liquid crystal panel 1000 according to the embodiment is suitable as a liquid crystal panel for a head-mounted display. The pixel density of the liquid crystal panel 1000 may be 1200 ppi or more, or may be 1400 ppi or more.

[0059] As shown in FIG. 2, the color filter substrate 20 may have an overcoat layer 24 disposed on the liquid crystal layer 30 side of the color filter layer 22. By disposing the overcoat layer 24, the surface of the continuous pattern portion of each color can be flattened. Further, by disposing the overcoat layer 24, the thickness of the liquid crystal layer can be adjusted to be thinner than in the case of only the color filter layer 22. The overcoat layer 24 can be formed using, for example, a known transparent photosensitive resin or the like.

[0060] The thickness of the overcoat layer 24 is preferably smaller than the thickness of the color filter laminate portion. The thickness of the overcoat layer 24 is preferably 0.5 μm or more and 3 μm or less, more preferably 1 μm or more and 2 μm or less.

[0061] Note that the thickness of the color filter laminate portion refers to the thickness of the laminated portion where the continuous pattern portion and the protruding pattern portion of the color filter are laminated, and does not include the thickness of the overcoat layer or the alignment film. In the case of the spacer PS3 having a three-layer structure, the thickness of the color filter laminate portion refers to the thickness of the laminated portion of the first protruding pattern portion 22A-2, a part of the second continuous pattern portion 22B-1, and the third protruding pattern portion 22C-2. In the case of the spacer having a two-layer structure, the thickness of the color filter laminate portion refers to the thickness of the laminated portion of the first protruding pattern portion 22A-2 or the third protruding pattern portion 22C-2 and a part of the second continuous pattern portion 22B-1.

[0062] The manufacturing method of the color filter substrate will be described below. When the color filter substrate 20 has the black matrix 23, it is preferable to form the black matrix 23 on the support substrate 21 in advance, but the illustration is omitted here.

[0063] FIG. 10 is a plan schematic view for explaining the first step of the manufacturing method of the color filter substrate shown in FIG. 3. As shown in FIG. 10, a color filter 22A of the first color including the first continuous pattern portion 22A-1 and the first protruding pattern portion 22A-2 is patterned on the support substrate 21.

[0064] FIG. 11 is a cross-sectional schematic view taken along the line X3-X4 in FIG. 10. FIG. 12 is a cross-sectional schematic view taken along the line X5-X6 in FIG. 10. As shown in FIGS. 11 and 12, the first continuous pattern portion 22A-1 and the first protruding pattern portion 22A-2 are connected, and by first forming the color filter 22A of the first color on the support substrate, the adhesion of the spacer can be improved.

[0065] FIG. 13 is a schematic plan view for explaining the second step of the method for manufacturing the color filter substrate shown in FIG. 3. In FIG. 13, the case where the color filter 22C of the third color is formed next to the color filter 22A of the first color will be described. As shown in FIG. 13, the color filter 22C of the third color is patterned on the support substrate 21 with a space between the continuous pattern portions of one row in the row direction of the first continuous pattern portion 22A-1. When forming the spacer PS3 having a three-layer structure, the color filter 22C of the third color including the third continuous pattern portion 22C-1 and the third protruding pattern portion 22C-2 is patterned. The third protruding pattern portion 22C-2 is patterned so as to face the first protruding pattern portion 22A-2 in a plan view, that is, so as to protrude in a direction opposite to the protruding direction of the first protruding pattern portion 22A-2 in the row direction.

[0066] FIG. 14 is a schematic cross-sectional view taken along the line X3-X4 of FIG. 13. As shown in FIG. 14, the color filter 22C of the third color is formed so that the third protruding pattern portion 22C-2 overlaps the first protruding pattern portion 22A-2. Since the third continuous pattern portion 22C-1 and the third protruding pattern portion 22C-2 are connected, it is possible to make the spacer more difficult to peel off.

[0067] The maximum width of the third protruding pattern portion 22C-2 in the column direction may be smaller or larger than the maximum width of the first protruding pattern portion 22A-2 in the column direction as long as it overlaps the first protruding pattern portion 22A-2. In FIG. 13, the case where the maximum width of the third protruding pattern portion 22C-2 in the column direction is approximately the same as the maximum width of the first protruding pattern portion 22A-2 in the column direction is illustrated.

[0068] FIG. 15 is a schematic plan view for explaining another example of the second step of the method for manufacturing a color filter substrate. As shown in FIG. 15, the maximum width of the third protruding pattern portion 22C-2 in the column direction is larger than the maximum width of the first protruding pattern portion 22A-2 in the column direction. By adopting such an aspect, the spacer can be made more difficult to peel off. The third protruding pattern portion 22C-2 may cover the first protruding pattern portion 22A-2.

[0069] FIG. 16 is a schematic cross-sectional view taken along line X5-X6 of FIG. 13. As shown in FIG. 16, when forming the two-layer spacer PS2, the color filter 22C of the third color including only the third continuous pattern portion 22C-1 is patterned without including the third protruding pattern portion 22C-2.

[0070] FIG. 17 is a schematic plan view for explaining the third step of the method for manufacturing the color filter substrate shown in FIG. 3. As shown in FIG. 17, a color filter 22B of the second color including a second continuous pattern portion 22B-1 is formed between the first continuous pattern portion 22A-1 and the third continuous pattern portion 22C-1.

[0071] FIG. 18 is a schematic cross-sectional view taken along line X3-X4 of FIG. 17. As shown in FIG. 18, a three-layer spacer PS3 including a color filter laminated portion in which the first protruding pattern portion 22A-2, the third protruding pattern portion 22C-2, and the second continuous pattern portion 22B-1 are laminated in this order from the support substrate 21 side is formed.

[0072] FIG. 19 is a schematic cross-sectional view taken along line X5-X6 of FIG. 17. As shown in FIG. 19, a two-layer spacer PS2 including a color filter laminated portion in which the first protruding pattern portion 22A-2 and the second continuous pattern portion 22B-1 are laminated in this order from the support substrate 21 side is formed.

[0073] The stacking order of the color filter layers is not limited to the above method. In the case of the spacer PS3 with a three-layer structure, the stacking order of the first protruding pattern portion 22A-2, the second continuous pattern portion 22B-1, and the third protruding pattern portion 22C-2 is not particularly limited. Also, in the case of the spacer PS2 with a two-layer structure, the second continuous pattern portion 22B-1 and the first protruding pattern portion 22A-2 may be stacked in order from the side of the support substrate 21. On the other hand, from the viewpoint of further improving the adhesion of the spacer, it is preferable to form the color filter 22A of the first color or the color filter 22C of the third color including the continuous pattern portion and the protruding pattern portion on the support substrate (including the black matrix) as the first step. Therefore, in the case of the spacer PS3, at least one of the first protruding pattern portion 22A-2 and the third protruding pattern portion 22C-2 is preferably disposed closer to the support substrate 21 side than the second continuous pattern portion 22B-1. In the case of the spacer PS2, the first protruding pattern portion 22A-2 is preferably disposed closer to the support substrate 21 side than the second continuous pattern portion 22B-1.

[0074] As methods for patterning the color filter 22A of the first color, the color filter 22B of the second color, and the color filter 22C of the third color, methods such as forming by photolithography using a negative or positive photosensitive resin composition containing a colorant such as a pigment or dye of the first color, the second color, and the third color, respectively, can be mentioned.

[0075] Since the resin composition applied for the second and third color filters may flow slightly, the thickness of the second and third color filters may be slightly thinner than the thickness of the first color filter layer. Therefore, when the spacer is the spacer PS3 with a three-layer structure, as shown in FIG. 18, the thickness T of the color filter stacked portion including the first protruding pattern portion 22A-2, a part of the second continuous pattern portion 22B-1, and the third protruding pattern portion 22C-2 PS3 is smaller than three times the thickness T of the first continuous pattern portion 22A-1 may be.

[0076] When the spacer is the two-layer spacer PS2, as shown in Fig. 19, the thickness T of the color filter laminate including the first protruding pattern portion 22A-2 and a part of the second continuous pattern portion 22B-1 PS2 may be smaller than twice the thickness T of the first continuous pattern portion 22A-1 .

[0077] The thicknesses T PS2 , T PS3 of the spacers PS2 and PS3 can be adjusted by changing the solid content concentration and viscosity in the photosensitive resin composition used for each color filter.

[0078] Although not shown, alignment films may be disposed on the surfaces of the active matrix substrate 10 and the color filter substrate 20 on the liquid crystal layer 30 side, respectively. The alignment films may be subjected to alignment treatments such as rubbing and photo-alignment treatment.

[0079] A polarizing plate, a liquid crystal driver, a driving circuit, etc. can be mounted on the liquid crystal panel to form a liquid crystal display device. The polarizing plates are attached, for example, to the surfaces of the active matrix substrate 10 and the color filter substrate 20 on the sides opposite to the liquid crystal layer 30, respectively.

Examples

[0080] Hereinafter, the effects of the present invention will be described with reference to examples and comparative examples, but the present invention is not limited to these examples.

[0081] (Example 1) In Example 1, a liquid crystal panel with active matrix driving for an HMD of about 1200 ppi was fabricated. The size of one sub-pixel of red, blue, and green was set to 7 μm × 21 μm, and the size of one pixel composed of three sub-pixels was set to 21 μm × 21 μm. The display mode of the liquid crystal panel was FFS. As the active matrix substrate, a substrate having a TFT formed using amorphous silicon, polysilicon, an oxide semiconductor, etc., a gate wiring, a source wiring, a pixel electrode arranged for each sub-pixel, and a common electrode arranged via an insulating film with respect to the pixel electrode was prepared. No electrode was provided on the CF substrate.

[0082] On the transparent substrate serving as the support substrate of the CF substrate, a black matrix having an opening and a light-shielding portion was formed. As shown in FIG. 1, the black matrix was formed such that the opening became smaller in the sub-pixel where the spacer was to be arranged so that the spacer was hidden by the light-shielding portion.

[0083] In Example 1, the color filter of the first color was a red color filter, the color filter of the second color was a blue color filter, and the color filter of the third color was a green color filter. The formation order of the red, blue, and green color filters is not particularly limited, but in Example 1, they were formed in the order of the red (first color) color filter, the green (third color) color filter, and the blue (second color) color filter.

[0084] As a first step, as shown in FIGS. 10 and 11, a red color filter was formed on the support substrate on which the black matrix was formed. Assuming that the extending direction of the gate wiring is the row direction and the extending direction of the source wiring is the column direction, the red color filter includes a color filter having only a continuous pattern portion and a color filter including a continuous pattern portion along the extending direction of the source wiring and a protruding pattern portion protruding in the row direction from the continuous pattern portion. The thickness of the continuous pattern portion and the protruding pattern portion of the red color filter was set to 1.5 μm. The maximum width of the red protruding pattern portion in the column direction was made approximately the same as the width of the red continuous pattern portion in the row direction. One protruding pattern portion was formed for every 8 pixels in the red protruding pattern portion.

[0085] Next, as a second step, as shown in FIGS. 13 and 14, a green color filter was formed with an interval of one column in the row direction of the red color filter. Similar to the red color filter, the green color filter includes a color filter including a continuous pattern portion and a protruding pattern portion, and a color filter including only the continuous pattern portion. The thicknesses of the continuous pattern portion and the protruding pattern portion were set to 1.5 μm. The maximum width of the green protruding pattern portion in the column direction was made approximately the same as the width of the green continuous pattern portion in the row direction. Similar to the red protruding pattern portion, the green protruding pattern portion was formed at a ratio of one for every eight pixels.

[0086] Subsequently, as a third step, as shown in FIGS. 17 and 18, a blue color filter was formed between the red continuous pattern portion and the green continuous pattern portion. In Example 1, since a color filter laminated portion including a red protruding pattern portion and a green protruding pattern portion had already been formed at the planned location of the blue color filter, the blue color filter had only a continuous pattern portion without a protruding pattern portion. In this way, a color filter substrate having a three-layer spacer PS3 at a ratio of one for every eight pixels was formed. The difference between the thickness T of the spacer PS3 PS3 and the thickness of the first continuous pattern portion that does not constitute the spacer PS3 was 2.5 μm. An overcoat layer may be provided on the color filter layer as needed.

[0087] An alignment film was formed on the surfaces of the CF substrate and the active matrix substrate for alignment treatment, and then the CF substrate and the active matrix substrate were bonded together with a nematic liquid crystal material sandwiched therebetween so that the alignment films faced each other to produce a liquid crystal panel. Thereafter, polarizing plates were respectively attached to the surfaces of the CF substrate and the active matrix substrate on the side opposite to the liquid crystal layer, and a liquid crystal driver and a drive circuit were mounted to obtain a liquid crystal display device.

[0088] (Comparative Example 1) As Comparative Example 1, a liquid crystal display device having a conventional isolated pattern spacer was fabricated. FIG. 20 is a schematic plan view of the color filter substrate of Comparative Example 1 as viewed from the liquid crystal layer side. FIG. 21 is a schematic cross-sectional view taken along line X7-X8 of FIG. 20. In Comparative Example 1, a color filter layer 2022 including a red color filter 22A only in the first continuous pattern portion 22A-1, a blue color filter 22B only in the second continuous pattern portion 22B-1, and a green color filter 22C only in the third continuous pattern portion 22C-1 was fabricated, and an isolated pattern spacer PS1 was formed on the color filter layer 2022 to fabricate a color filter substrate 2020. The isolated pattern spacer PS1 was patterned by photolithography using a transparent resin, and the diameter of the spacer PS1 was 14 μm. The density of the spacer PS1 was formed at a ratio of 1 per 8 pixels in the same manner as in Example 1. Thereafter, a liquid crystal display device of Comparative Example 1 was fabricated in the same manner as in Example 1 using the color filter substrate 2020.

[0089] The liquid crystal display device of Example 1 was less likely to have the spacer peeled off and had a 4% improvement in transmittance compared to the liquid crystal display device of Comparative Example 1. Since the transmittance during black display did not change between Example 1 and Comparative Example 1, the liquid crystal display device of Example 1 had a higher display contrast by the amount of improvement in the transmittance than Comparative Example 1.

[0090] (Example 2) In Example 2, when forming the green color filter in the second step, as shown in FIG. 15, the maximum width of the green protruding pattern portion in the column direction was made larger than the maximum width of the red protruding pattern portion in the column direction, and a color filter substrate having a three-layer structure spacer PS3 at a ratio of 1 per 8 pixels was formed in the same manner as in Example 1 except that the green protruding pattern portion was formed to cover the red protruding pattern portion. Thereafter, a liquid crystal display device of Example 2 was fabricated in the same manner as in Example 1 using the color filter.

[0091] The liquid crystal display device of Example 2 was less likely to have spacers peeled off, had an improved transmittance, and a large display contrast as compared with the liquid crystal display device of Comparative Example 1. In Example 2, at 1200 ppi, the improvement effects of transmittance and contrast were about half that of Example 1, but since the spacers could be made less likely to be peeled off than in Example 1, it could be more preferably used at about 1400 ppi (sub-pixel size 6 μm × 18 μm).

[0092] (Example 3) In Example 3, a liquid crystal display device including both a spacer PS3 (main spacer) having a three-layer structure and a spacer PS2 (sub-spacer) having a two-layer structure was fabricated. In Example 3, when forming the green color filter in the second step, as shown in FIGS. 13 and 16, a color filter substrate was formed in the same manner as in Example 1, except that only a continuous pattern portion was formed without forming a protruding pattern portion in some of the green color filters.

[0093] The liquid crystal display device of Example 3 was less likely to have spacers peeled off, had a high transmittance and a high display contrast as compared with Comparative Example 1, in the same manner as the liquid crystal display device of Example 1. Furthermore, Example 3 could achieve a balance between pressure resistance and low-temperature bubble prevention effect.

Explanation of Reference Numerals

[0094] 1, 1-A, 1-B, 1-B: sub-pixels (1-A)x: First sub-pixel group (1-B)x: Second sub-pixel group (1-C)x: Third sub-pixel group 2: pixel 10: active matrix substrate 11, 21: support substrates 12: pixel electrode 20, 2020: color filter substrates 22: color filter layer 22A: color filter of the first color 22A-1: First continuous pattern portion 22A-2: First protruding pattern portion 22B: Color filter of the second color 22B-1: Second continuous pattern portion 22C: Color filter of the third color 22C-1: Third continuous pattern portion 22C-2: Third protruding pattern portion 23: Black matrix 23a, 23a-1, 23a-2, 23a-3: Apertures 23b: Light-shielding portion 24: Overcoat layer 30: Liquid crystal layer 1000: Liquid crystal panel PS1, PS2, PS3: Spacers

Claims

1. including a plurality of sub-pixels arranged in a row direction and a column direction, an active matrix substrate having pixel electrodes arranged for each of the sub-pixels, a color filter substrate, and a liquid crystal layer sandwiched between the active matrix substrate and the color filter substrate, the color filter substrate having a color filter layer and a plurality of spacers protruding toward the liquid crystal layer side, the color filter layer including at least a color filter of a first color and a color filter of a second color adjacent to the color filter of the first color in the row direction, the color filter of the first color including a first continuous pattern portion continuously arranged so as to overlap a first sub-pixel group arranged along the column direction among the plurality of sub-pixels, and a first protruding pattern portion protruding from the first continuous pattern portion in the row direction, the color filter of the second color including a second continuous pattern portion continuously arranged so as to overlap a second sub-pixel group arranged along the column direction among the plurality of sub-pixels, the plurality of spacers including a color filter laminated portion including the first protruding pattern portion and a part of the second continuous pattern portion, a liquid crystal panel.

2. the color filter layer further including a color filter of a third color adjacent to the color filter of the second color on the side opposite to the color filter of the first color in the row direction, the color filter of the third color including a third continuous pattern portion continuously arranged so as to overlap a third sub-pixel group arranged along the column direction among the plurality of sub-pixels, and a third protruding pattern portion protruding from the third continuous pattern portion in the row direction, at least one of the plurality of spacers including the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion in the color filter laminated portion, the liquid crystal panel according to claim 1.

3. the maximum width of the third protruding pattern portion in the column direction is larger than the maximum width of the first protruding pattern portion in the column direction, the liquid crystal panel according to claim 2.

4. the color filter of the first color is either a red color filter or a green color filter, the liquid crystal panel according to any one of claims 1 to 3.

5. The color filter of the first color is either a red color filter or a green color filter, The color filter of the second color is a blue color filter, The color filter of the third color is the other one of the red color filter or the green color filter, the liquid crystal panel according to claim 2 or 3.

6. A part of the second continuous pattern portion is disposed on the side closest to the liquid crystal layer in the color filter stack portion, the liquid crystal panel according to any one of claims 1 to 3.

7. The color filter substrate further has a black matrix laminated on the color filter layer, The black matrix includes a plurality of openings disposed for each sub-pixel and a light-shielding portion disposed around the plurality of openings, The plurality of spacers includes a spacer disposed at a position overlapping the light-shielding portion, The plurality of openings includes a plurality of first openings overlapping the first continuous pattern portion and a plurality of second openings overlapping a portion other than the part of the second continuous pattern portion, The plurality of second openings includes a second opening having an area smaller than that of the first opening, the liquid crystal panel according to any one of claims 1 to 3.

8. The color filter substrate has an overcoat layer disposed on the liquid crystal layer side of the color filter layer, The thickness of the overcoat layer is smaller than the thickness of the color filter stack portion, the liquid crystal panel according to any one of claims 1 to 3.

9. The color filter stack portion is formed by laminating the first protruding pattern portion and a part of the second continuous pattern portion, The thickness of the color filter stack portion is smaller than twice the thickness of the first continuous pattern portion, the liquid crystal panel according to claim 1.

10. The color filter stack portion is formed by laminating the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion, The thickness of the color filter stack portion is smaller than three times the thickness of the first continuous pattern portion, the liquid crystal panel according to claim 2 or 3.

11. The maximum width of the first protruding pattern portion in the column direction is 0.5 times or more and 1.5 times or less the width of the first continuous pattern portion in the row direction, the liquid crystal panel according to any one of claims 1 to 3.

12. The color filter layer further includes a color filter of a second color and a color filter of a third color that is adjacent to the color filter of the first color on the opposite side in the row direction. One sub-pixel overlapping with the color filter of the first color, one sub-pixel overlapping with the color filter of the second color, and one sub-pixel overlapping with the color filter of the third color constitute one pixel. The pixel density of the liquid crystal panel is 1000 ppi or more. The plurality of spacers are arranged at a density of one or more per 1000 pixels and one or less per one pixel. The liquid crystal panel according to any one of claims 1 to 3.

13. The plurality of spacers include a main spacer and a sub-spacer having a thickness thinner than that of the main spacer. The color filter laminate portion included in the main spacer is a laminate of the first protruding pattern portion, a part of the second continuous pattern portion, and the third protruding pattern portion. The color filter laminate portion included in the sub-spacer is a laminate of the first protruding pattern portion or the third protruding pattern portion and a part of the second continuous pattern portion. The liquid crystal panel according to claim 2 or 3.

14. One sub-pixel overlapping with the color filter of the first color, one sub-pixel overlapping with the color filter of the second color, and one sub-pixel overlapping with the color filter of the third color constitute one pixel. For 1000 pixels, the number of the sub-spacers is the same as or more than and 10 times or less than the number of the main spacers. The liquid crystal panel according to claim 13.

Images