Liquid crystal display device

Abstract

This liquid crystal display device has a first substrate, a second substrate, a liquid crystal layer sandwiched between the first and second substrates, a seal, and a spacer. The seal includes: a first seal part having a linear shape in a first direction; a second seal part having a linear shape in a second direction; and a third seal part having a curved shape that smoothly connects the first seal part and the second seal part. When a second region is a region surrounded by the outer periphery of a first region for displaying an image, the third seal part, a first normal line that extends downward from the boundary point between the first seal part and the third seal part to the outer periphery of the first region, and a second normal line that extends downward from the boundary point between the second seal part and the third seal part to the outer periphery of the first region, and a third region is a region other than the first region and the second region, the spacer arrangement density is greater in the second region than in the third region.

Description

Technical Field

[0001] The present disclosure relates to a liquid crystal display device having a notch in its outer peripheral shape. The present disclosure also relates to a non-rectangular liquid crystal display device having a cutout in its outer peripheral shape.

Background Art

[0002] A liquid crystal display device is composed of a liquid crystal panel in which an array substrate having a TFT (Thin Film Transistor) and electrodes and a color filter substrate having a color material and a black matrix are bonded with a liquid crystal layer interposed therebetween, and a backlight which is a light source. In the liquid crystal panel, the distance between the array substrate and the color filter substrate is called a cell gap, and since the cell gap corresponds to the thickness of the liquid crystal layer, its variation greatly affects the transmittance of the liquid crystal layer. Therefore, unevenness of the cell gap (hereinafter referred to as gap unevenness) in the display area for displaying an image becomes a cause of display unevenness defect. As a countermeasure, spacers for sandwiching between two substrates and maintaining the cell gap within a certain range are arranged in the liquid crystal layer. In addition, the seal formed so as to surround the liquid crystal layer between the two substrates also plays a role of maintaining the cell gap in addition to the role of sealing the liquid crystal.

[0003] As the spacer, a columnar spacer formed by pattern exposure on the surface of the color filter substrate in contact with the liquid crystal may be used. Under normal conditions without external factors such as external force or temperature change, the columnar spacer is sandwiched between the array substrate and the color filter substrate and is deformed in a slightly crushed state, and its elastic force maintains the cell gap within a certain range. However, if the elastic force of the columnar spacer is too strong, when the liquid crystal contracts in a low-temperature environment, the columnar spacer cannot follow, and thus a low-temperature foaming defect in which bubbles are generated in the liquid crystal is likely to occur. Also, if the elastic force of the columnar spacer is too weak, when the liquid crystal expands in a high-temperature environment, the cell gap becomes larger than the height of the columnar spacer, and when the liquid crystal panel is installed upright, a high-temperature swelling defect in which the liquid crystal accumulates at the lower part of the panel is likely to occur.

[0004] As a countermeasure against these problems, a dual spacer structure in which two types of columnar spacers with different heights are formed may be used. In the dual spacer structure, under normal conditions without external factors such as external force or temperature change, the main spacer with a higher height functions to maintain the cell gap by contacting the array substrate and the color filter substrate, and the sub-spacer with a lower height does not contact the array substrate and does not function as a spacer. However, when the cell gap becomes smaller due to external factors such as external force or temperature change, the sub-spacer also contacts the array substrate and functions as a spacer, suppressing further reduction of the cell gap. Furthermore, by using the sub-spacer in combination, there is an advantage that it becomes easier to appropriately set the elastic force of the main spacer.

[0005] On the other hand, in recent years, in liquid crystal display devices, those having a non-rectangular shape called a special-shaped display have become widespread. The applications of special-shaped displays are various, such as automotive meter panels and mobile phones, and they have attracted attention from the viewpoints of functions and designs. However, in a special-shaped display, especially when it has a notch-shaped recess called a notch in the outer peripheral shape, the internal stress of members such as a glass substrate and a polarizing plate tends to concentrate there, and as a result, there is a problem that the cell gap locally varies around the notch, resulting in gap unevenness and display unevenness.

[0006] That is, in recent years, in liquid crystal display devices, the outer shape of the display device is not rectangular, and non-rectangular displays (sometimes referred to as special-shaped displays) have become widespread. The applications of non-rectangular displays are various, such as automotive meter panels and mobile phones, and they have attracted attention from the viewpoints of functions and designs. However, in the case of a special-shaped display having a notch in the outer peripheral shape, the internal stress of members such as a glass substrate and a polarizing plate tends to concentrate near the corner of the notch, and as a result, there is a problem that the cell gap locally varies around the notch, resulting in gap unevenness and display unevenness.

[0007] Regarding the countermeasures against the gap unevenness as described above, in Patent Document 1, in a liquid crystal panel of a curved-shaped special-shaped display having a non-rectangular planar shape including a notch, a form is shown in which the spacer arrangement density per unit area increases concentrically outward around the change point of the outer peripheral shape of the display area. Here, the spacer arrangement density indicates the sum of the areas of the columnar spacers arranged per unit area of the substrate surface in plan view, that is, the area density. Further, in Patent Document 2, in a rectangular liquid crystal panel having a liquid crystal injection step, a form is shown in which the columnar spacer arrangement density is increased at the corner portion on the opposite side of the injection port, or the elastic force of the spacer is increased by using a levee-shaped spacer. Further, in Patent Document 3, in a rectangular liquid crystal panel, a form is shown in which a dummy seal having only a spacer function and no function of sealing the liquid crystal is formed only at a position close to the corner.

[0008] That is, as countermeasures against the gap unevenness as described above, in Patent Document 1, in a liquid crystal panel of a curved-shaped non-rectangular display having a non-rectangular planar shape including a notch, a form is shown in which the spacer arrangement density per unit area increases concentrically outward around the change point of the outer peripheral shape of the display area. Here, the spacer arrangement density indicates the sum of the areas of the columnar spacers arranged per unit area of the substrate surface in plan view, that is, the area density. Further, in Patent Document 2, in a rectangular liquid crystal panel having a liquid crystal injection step, a form is shown in which the columnar spacer arrangement density is increased at the corner portion on the opposite side of the injection port, or the elastic force of the spacer is increased by using a levee-shaped spacer. Further, in Patent Document 3, in a rectangular liquid crystal panel, a form is shown in which a dummy seal having only a spacer function and no function of sealing the liquid crystal is formed only at a position close to the corner.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

[0010] However, the technology described in Patent Document 1 is premised on a curved special-shaped display and reduces the spacer arrangement density of the notch. Therefore, it is impossible to suppress display unevenness of the notch. In addition, due to the low sub-spacer arrangement density, the strength against external pressure becomes weak and unevenness occurs. Moreover, the technologies described in Patent Document 2 or Patent Document 3 are not related to special-shaped displays and do not describe any correspondence to notches.

[0011] That is, the technology described in Patent Document 1 is premised on a curved non-rectangular display and reduces the spacer arrangement density of the cutout portion. Therefore, it is impossible to suppress display unevenness of the cutout portion. In addition, due to the low sub-spacer arrangement density, the strength against external pressure becomes weak and unevenness occurs. Moreover, the technologies described in Patent Document 2 or Patent Document 3 are not related to non-rectangular displays and do not describe any correspondence to cutout portions. [Means for Solving the Problems]

[0012] The liquid crystal display device of the present disclosure includes a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate and having a concave portion with a curve in its outer peripheral shape, and a first spacer provided on a surface of the first substrate facing the liquid crystal layer to maintain the distance between the first substrate and the second substrate. In the liquid crystal display device, a region corresponding to the liquid crystal layer and displaying an image is defined as a first region, and a region corresponding to the liquid crystal layer and surrounded by a concave portion of the curve of the seal, an outer periphery of the first region, a first normal line dropped from a starting point of the concave portion of the curve of the seal to the outer periphery of the first region, and a second normal line dropped from an end point of the concave portion of the curve of the seal to the outer periphery of the first region is defined as a second region. When a region other than the first region and the second region corresponding to the liquid crystal layer is defined as a third region, in a plan view, an area occupied by the first spacer per unit area of the second region is larger than an area occupied by the first spacer per unit area of the third region.

[0013] (Application Example 1) The liquid crystal display device of the present disclosure includes a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate, and a spacer provided between the first substrate and the second substrate to maintain the distance therebetween. In this liquid crystal display device, the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion. The first seal portion and the second seal portion have a linear shape, and the third seal portion has a curved shape such as an arc shape. In a plan view of the liquid crystal display device, the region for displaying an image is defined as a first region (display region), and a second region is defined as the region surrounded by the third seal portion, the outer periphery of the first region, a first normal line dropped from the boundary point between the first seal portion and the third seal portion to the outer periphery of the first region, and a second normal line dropped from the boundary point between the second seal portion and the third seal portion to the outer periphery of the first region. A region other than the first region and other than the second region is defined as a third region. When the spacer arrangement density is defined as the ratio of the area occupied by the spacer per unit area in a plan view, in the liquid crystal display device of the present disclosure, the spacer arrangement density is larger in the second region than in the third region. In addition, in the liquid crystal display device of the present disclosure, when the inner angle formed by the first direction and the second direction exceeds 180°, the effect is particularly significant. The inner angle is the inner angle formed by two straight lines, that is, the angle on the center side of the display region. Further, in this specification, of one of the array substrate and the color filter substrate constituting the liquid crystal display device, the substrate on which the spacer is disposed during manufacturing is defined as the first substrate, and the other substrate is defined as the second substrate. In other words, in a liquid crystal display device having a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate and having a concave curve in its outer peripheral shape, and a spacer provided on the surface of the first substrate facing the liquid crystal layer to maintain the distance between the first substrate and the second substrate, a region corresponding to the liquid crystal layer and displaying an image is defined as a first region, and a region corresponding to the liquid crystal layer and surrounded by a concave curve of the seal, the outer periphery of the first region, a first normal line dropped from the starting point of the concave curve of the seal to the outer periphery of the first region, and a second normal line dropped from the ending point of the concave curve of the seal to the outer periphery of the first region is defined as a second region. When a region other than the first region and the second region corresponding to the liquid crystal layer is defined as a third region, in a plan view, the area occupied by the spacer per unit area of the second region is larger than the area occupied by the spacer per unit area of the third region. (Application Example 2) In the liquid crystal display device of the present disclosure, the spacer arrangement density in the second region may be uniform or non-uniform. When it is non-uniform, in the liquid crystal display device described in Application Example 1, the spacer arrangement density in the second region becomes smaller as it approaches the first normal line or the second normal line. (Application Example 3) Further, in the liquid crystal display device of the present disclosure, in the liquid crystal display device described in Application Example 1 or Application Example 2, the spacer arrangement density in the third region is characterized by being equal to or less than the minimum value of the spacer arrangement density in the second region. That is, the spacer arrangement density in the third region is the same as or smaller than the minimum value of the spacer arrangement density in the second region. (Application Example 4) Further, in the liquid crystal display device of the present disclosure, in the liquid crystal display device described in any one of Application Examples 1 to 3, the spacer arrangement density in the third region is characterized by being equal to or greater than the spacer arrangement density in the first region. That is, the spacer arrangement density in the third region is the same as or larger than the spacer arrangement density in the first region. (Application Example 5) Furthermore, in the liquid crystal display device of the present disclosure, in the liquid crystal display device according to any one of Application Examples 1 to 4, the spacer includes a first spacer and a second spacer having a height lower than that of the first spacer. (Application Example 6) Furthermore, in the liquid crystal display device of the present disclosure, in the liquid crystal display device according to any one of Application Examples 1 to 3, the spacer in the second region is a dummy seal formed of the same material as the seal. (Application Example 7) The liquid crystal display device of the present disclosure includes a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate, and a spacer provided on a surface of the first substrate facing the liquid crystal layer. In this liquid crystal display device, the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion. The first seal portion and the second seal portion have a linear shape, and the third seal portion has a curved shape such as an arc shape. In the liquid crystal display device, in a plan view, the region for displaying an image is defined as a first region (display region), and the region surrounded by the third seal portion, the outer periphery of the first region, a first normal line dropped from a boundary point between the first seal portion and the third seal portion to the outer periphery of the first region, and a second normal line dropped from a boundary point between the second seal portion and the third seal portion to the outer periphery of the first region is defined as a second region, and the region other than the first region and outside the second region is defined as a third region. In the liquid crystal display device of the present disclosure, before the second substrate is disposed opposite to the first substrate, the height of at least one spacer in the second region is higher than the height of the spacers in the third region. In the liquid crystal display device of the present disclosure, when the inner angle formed by the first direction and the second direction exceeds 180°, the effect is particularly large. The inner angle is the inner angle formed by two straight lines, that is, the angle on the center side of the display region. (Application Example 8) Furthermore, in the liquid crystal display device of the present disclosure, in the liquid crystal display device according to Application Example 7, before the second substrate is disposed opposite to the first substrate, the height of the spacers in the second region becomes lower as it approaches the first normal line or the second normal line. (Application Example 9) Further, in the liquid crystal display device of the present disclosure, in the liquid crystal display device described in Application Example 7 or Application Example 8, before the second substrate is disposed opposite to the first substrate, the height of the lowest spacer in the second region is equal to or greater than the height of the highest spacer in the third region. (Application Example 10) Further, in the liquid crystal display device of the present disclosure, in the liquid crystal display device described in any one of Application Examples 7 to 9, before the second substrate is disposed opposite to the first substrate, the height of the spacer in the third region is the same as or higher than the height of the first spacer in the first region. (Application Example 11) The liquid crystal display device of the present disclosure includes a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate, and a spacer provided on a surface of the first substrate facing the liquid crystal layer. In this liquid crystal display device, the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion. The first seal portion and the second seal portion have a linear shape, and the third seal portion has a curved shape such as an arc shape. In the liquid crystal display device, in a plan view, a region for displaying an image is defined as a first region, and a region surrounded by the third seal portion, the outer periphery of the first region, a first normal line dropped from a boundary point between the first seal portion and the third seal portion to the outer periphery of the first region, and a second normal line dropped from a boundary point between the second seal portion and the third seal portion to the outer periphery of the first region is defined as a second region, and a region other than the first region and other than the second region is defined as a third region. In the liquid crystal display device of the present disclosure, the spacer in the second region is disposed so as to overlap with a convex pattern provided in the second region on the surface of the first substrate facing the liquid crystal layer. Incidentally, in the liquid crystal display device of the present disclosure, when the inner angle formed by the first direction and the second direction exceeds 180°, the effect is particularly large. The inner angle is the inner angle formed by two straight lines, that is, the angle on the center side of the display region. (Application Example 12) The liquid crystal display device of the present disclosure includes a first substrate, a second substrate disposed opposite to the first substrate, a liquid crystal layer sandwiched between the first substrate and the second substrate, a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate, and a spacer provided on a surface of the first substrate facing the liquid crystal layer. In this liquid crystal display device, the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion. The first seal portion and the second seal portion are linear, and the third seal portion has a curved shape such as an arc shape. In the liquid crystal display device, in a plan view, a region where an image is displayed is defined as a first region, and a region surrounded by the third seal portion, an outer periphery of the first region, a first normal line dropped from a boundary point between the first seal portion and the third seal portion to the outer periphery of the first region, and a second normal line dropped from a boundary point between the second seal portion and the third seal portion to the outer periphery of the first region is defined as a second region, and a region other than the first region and other than the second region is defined as a third region. In the liquid crystal display device of the present disclosure, the spacers in the second region are arranged so as to face and overlap with convex patterns provided in the second region on the surface of the second substrate facing the liquid crystal layer. In the liquid crystal display device of the present disclosure, the effect is particularly significant when the inner angle formed by the first direction and the second direction exceeds 180°. The inner angle is the inner angle formed by two straight lines, that is, the angle on the center side of the display region.

Effects of the Invention

[0014] According to the present disclosure, by increasing the arrangement density of the spacers in the region between the portion where the outer peripheral shape of the seal surrounding the liquid crystal layer is concave and the display region, the elastic force of the spacers can be strengthened to suppress the occurrence of display unevenness due to gap unevenness.

[0015] That is, according to the present disclosure, by increasing the arrangement density of the spacers in the region between the portion where the inner angle of the seal surrounding the liquid crystal layer is 180° or more (the portion that can be regarded as having a cutout portion from a virtual rectangular display device) and the display region, the elastic force of the spacers can be strengthened to suppress the occurrence of display unevenness due to gap unevenness.

Brief Description of the Drawings

[0016]

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Mode for Carrying Out the Invention

[0017] Embodiment 1 The structure of the special-shaped display in Embodiment 1 will be described with reference to FIGS. 1 and 2. FIG. 1 is a plan view of a liquid crystal panel 101 used in the special-shaped display in Embodiment 1 of the present disclosure. In the liquid crystal panel 101, a seal 9 is arranged inside from the outer periphery, and a liquid crystal layer 3 is formed inside this. Further, the liquid crystal layer 3 includes a display area 4 for displaying an image. The liquid crystal panel 101 has an outer peripheral shape with notches formed at the upper right and upper left corners on the paper surface with respect to a rectangle, and the liquid crystal layer 3 and the display area 4 surrounded by the seal 9 also have a shape with notches. Note that the non-display area at the peripheral edge of the liquid crystal layer 3 surrounded by the seal 9 and the display area 4 is defined as a frame area 5. The outer peripheral shape of the corner part of the notch of the liquid crystal panel 101 shown in the area X surrounded by the dotted line has an outer peripheral shape with an R shape at the corner. This is a shape considering design, suppression of the occurrence of polarizer cracks due to stress concentration of the glass substrate and polarizer constituting the liquid crystal panel 101, and the workability of the outer shape of the glass substrate. However, depending on the outer peripheral shape, it may not be an R shape but a corner. Further, the seal 9 also has an outer peripheral shape with an R shape at the corner, which is not only for corresponding to the outer peripheral shape of the liquid crystal panel 101, but also because the R shape is easier to correspond to than a corner in order to make the width and height of the seal 9 constant.

[0018] FIG. 2 is a cross-sectional view showing the Y-Y cross-section of the liquid crystal panel 101 in FIG. 1. The liquid crystal panel 101 has a structure in which an array substrate 1 and a color filter substrate 2 sandwich and bond a liquid crystal layer 3 made of liquid crystal, and has a driving method of the FFS (Flinge Field Swithing) method. Although not shown, on the surface of the array substrate 1 facing the liquid crystal layer 3 corresponding to the display area 4 for displaying an image, pixels are formed in a matrix by perpendicular scanning signal lines and display signal lines, and a pixel electrode and a common electrode for driving the liquid crystal are formed in each pixel via an insulating layer, and a TFT (Thin Film Transistor), which is a switching element for applying a potential to the pixel electrode, is provided. On the other hand, on the surface of the color filter substrate 2 facing the liquid crystal layer 3, a colorant 6 having a color such as RGB corresponding to each pixel, a black matrix 7 for shielding wirings between pixels and areas of the TFT, and an overcoat film 8 for protecting the colorant 6 are formed. The black matrix 7 and the overcoat film 8 are further formed to extend to the frame area 5, and shield the periphery of the display area 4. Although not shown, polarizing plates are attached to the surfaces of the array substrate 1 and the color filter substrate 2 that do not face the liquid crystal layer 3, and alignment films for aligning the liquid crystal are formed on the surfaces of the array substrate 1 and the color filter substrate 2 that face the liquid crystal layer 3. The liquid crystal layer 3 is surrounded by a seal 9 and sealed between the array substrate 1 and the color filter substrate 2. Here, the distance between the array substrate 1 and the color filter substrate 2 is particularly called the cell gap 10. Since the liquid crystal is sealed so as to fill the cell gap 10, the cell gap 10 is equal to the thickness of the liquid crystal layer 3. As the seal 9, an elastic member such as silicone rubber is used. Therefore, the seal 9 plays a role of maintaining the cell gap 10 as well as a role of sealing the liquid crystal, and also serves as a spacer as described below.

[0019] On the surface of the color filter substrate 2 facing the liquid crystal layer 3, columnar spacers 11 are formed. The columnar spacers 11 are arranged so as to be sandwiched between the array substrate 1 and the color filter substrate 2, and function as a support member for maintaining the cell gap 10 within a certain range. The columnar spacers 11 are made of, for example, a UV photosensitive resin as a member and are formed by pattern exposure using a mask, so that they can be accurately arranged at desired positions. Since there is no liquid crystal in the portion where the columnar spacers 11 are present, and the liquid crystal does not align normally in the region around the columnar spacers 11, the vicinity of the columnar spacers 11 becomes a region where the control of transmitting or blocking the light of the backlight cannot be performed. Therefore, when the columnar spacers 11 are arranged in the display region 4, they are arranged so as to overlap with the black matrix 7 in a plan view and be blocked from light, taking care not to affect the displayed image. The columnar spacers 11 have a height larger than the assumed cell gap 10 before the array substrate 1 and the color filter substrate 2 are bonded together. When the array substrate 1 and the color filter substrate 2 are bonded together to form a predetermined cell gap 10, they are in a slightly compressed state. When the cell gap 10 becomes smaller due to an external force or a temperature change in the environment, the repulsive force suppresses further reduction, and when the cell gap 10 becomes larger, the compressed portion due to the bonding is restored and follows.

[0020] Next, the arrangement of the columnar spacers 11 around the notch in the first embodiment will be described. FIG. 3 is a plan view of the region X surrounded by the dotted line of the notch in FIG. 1. As described above, the liquid crystal panel 101 has an outer peripheral shape with a notch formed therein. The liquid crystal layer 3 surrounded by the seal 9 formed inside the outer periphery of the liquid crystal panel 101, and further, the display region 4 formed inside the seal 9 where an image is displayed also has a shape with a notch in the same manner. Here, the outer peripheral shape of the corner portion of the notch of the liquid crystal panel 101 is not a corner but an R shape from the viewpoints of design, crack prevention, and workability. Also, the seal 9 has an outer peripheral shape that is not a corner but an R shape so that the seal thickness and width can be easily controlled during seal formation. Furthermore, the outer peripheral shape of the display region 4 also has an R shape at the corners.

[0021] In Embodiment 1, when arranging the columnar spacers 11, the frame area 5 is divided into regions as follows. In FIG. 3, first, for the notch seal 9, the straight line portion formed vertically above the paper surface is defined as seal 9a, the curved concave portion is defined as seal 9b, and the straight line portion formed horizontally below the paper surface is defined as seal 9c. Further, the boundary point between seal 9a and seal 9b is point A, and the boundary point between seal 9b and seal 9c is point B. Also, the intersection points where the normal lines 15 and 16 of seal 9b dropped from point A and point B to the outer peripheral line 4a of the display area 4 intersect the outer peripheral line 4a are defined as point C and point D. At this time, the frame area 5 surrounded by the line segment AB, the line segment BD, the line segment DC, and the line segment CA is particularly defined as the frame area 5a. Furthermore, the region other than the display area 4 and other than the frame area 5a, that is, the frame area 5 sandwiched between seal 9a or seal 9c, which is the straight line portion of the seal, and the display area 4 is particularly defined as the frame area 5b.

[0022] Next, the arrangement of the columnar spacers 11 for each region described with reference to FIG. 3 is shown in FIG. 4. In FIG. 4, the columnar spacers 11a shown as circles are arranged at an equal pitch such that the number of arrangements per unit area is equal in the display area 4, the frame area 5a, and the frame area 5b. Further, the columnar spacers 11b shown as double circles are arranged only in the frame area 5a. Here, although the columnar spacers 11a and the columnar spacers 11b are shown with different representations for convenience of explanation, they are columnar spacers 11 of the same specification having the same cross-sectional area and height. That is, in the form shown in FIG. 4, compared with the display area 4 and the frame area 5b, the frame area 5a has the highest spacer arrangement density for the columnar spacers 11a and the columnar spacers 11b combined. Here, the spacer arrangement density refers to the sum of the areas of the columnar spacers 11 arranged per unit area of the substrate surface in a plan view, that is, the area density.

[0023] The form shown in Fig. 4 is an example of the present disclosure, and the spacer arrangement density and arrangement of the columnar spacers 11a and 11b may be freely set. For example, in the frame region 5a, no columnar spacer 11a is provided, and only the columnar spacer 11b is arranged at the same pitch as the columnar spacer 11a in the frame region 5b. At this time, by making the area of each columnar spacer 11b in plan view larger than the area of each columnar spacer 11a in plan view, the spacer arrangement density of the columnar spacer 11 in the frame region 5a may be set to be higher than that in the frame region 5b. That is, it is only necessary that the spacer arrangement density of the columnar spacer 11 is frame region 5b < frame region 5a.

[0024] Further, as an example of a further form, the spacer arrangement density of the columnar spacer 11 in each region may be changed corresponding to the generation region of the gap unevenness. For example, when the gap unevenness occurs only in the concave portion of the notch, the spacer arrangement density is set as display region 4 = frame region 5b < frame region 5a; when the gap unevenness occurs in the concave portion of the notch and then in the frame region 5 other than the notch portion, the spacer arrangement density is set as display region 4 < frame region 5b < frame region 5a; when the gap unevenness occurs in the concave portion of the notch and then in the display region 4, the spacer arrangement density may be set as frame region 5b < display region 4 < frame region 5a.

[0025] Next, the effects of Embodiment 1 will be described. In a liquid crystal panel, stress generated during member processing and panel manufacturing processes remains inside the glass substrate and polarizing plate. However, when the outer peripheral shape has a notch, this stress concentrates toward the corner portion of the notch, and the cell gap 10 tends to become narrow. As a result, gap unevenness, which is a local variation of the cell gap 10, may occur at the corner portion of the notch, and display unevenness with a different luminance from the surroundings may occur. According to the embodiment of the present disclosure, by increasing the spacer arrangement density of the columnar spacers 11 around the corner portion of the notch, the elastic force of the spacers can be increased, and the occurrence of this gap unevenness can be suppressed. There are other methods for suppressing gap unevenness around the corner portion of the notch. For example, there is a method of arranging a gap holding member such as a spacer or a dummy seal in place of the spacer in a region outside the seal 9. However, due to the narrowing of the bezel of recent liquid crystal panels, it has become difficult to secure a sufficient area for arranging the gap holding member in a region outside the seal 9. Also, there is a method of increasing the spacer arrangement density around the corner portion of the notch within the display area 4. However, in order to arrange the columnar spacers 11 within the display area 4, it is necessary to arrange them so as to overlap the black matrix 7. Considering that there are limitations on the size of one columnar spacer 11 in plan view and that the columnar spacer 11 may affect rubbing and there is a risk of rubbing defects occurring around the columnar spacer 11, there are significant constraints on further additionally arranging the columnar spacers 11, which are originally often arranged over the entire display area 4, only for the pixels around the corner portion of the notch. Embodiment 1 of the present invention increases the spacer arrangement density of the columnar spacers 11 without being restricted by the black matrix 7 or the like in a partial region of the bezel region 5 that does not affect display. It has a high degree of freedom in arrangement and has the merit of easily obtaining a large effect.

[0026] Embodiment 2 In Embodiment 1, a form was shown in which the spacer arrangement density of the columnar spacers 11 in the display area 4, the frame area 5a, and the frame area 5b was such that the frame area 5a had the highest spacer arrangement density. In the present Embodiment 2, the arrangement of the columnar spacers 11 within the area of the frame area 5a will be further described. FIG. 5 is a plan view showing the arrangement of the columnar spacers 11 within the area X of FIG. 1 in the present Embodiment 2. In FIG. 5, the areas of the display area 4, the frame area 5a, and the frame area 5b are set in the same manner as described in FIG. 3, and further, the columnar spacers 11a indicated by circles are arranged at equal pitches per area so that the number of arrangements per area is equal in the display area 4, the frame area 5a, and the frame area 5b, in the same manner as described in FIG. 4 in Embodiment 1. Further, the columnar spacers 11b indicated by double circles are arranged only in the frame area 5a. However, in the present Embodiment 2, the columnar spacers 11b are not evenly arranged at the pitch within the area of the frame area 5a, but are concentrated near the center of the corner portion of the notch.

[0027] In the liquid crystal panel, as described above, internal stress generated in the manufacturing process of members remains inside the glass substrate and polarizing plate. When the outer peripheral shape has a notch, it concentrates from both sides of the notch toward the corner portion of the notch, and the center of the corner portion of the notch is particularly likely to have a large variation in the cell gap 10. Therefore, by increasing the spacer arrangement density of the columnar spacers 11 particularly near the center of the corner portion of the notch even within the area of the frame area 5a, it becomes possible to more effectively suppress the variation of this cell gap 10. Although the columnar spacers 11b are concentrated near the center of the corner portion of the notch within the area of the frame area 5a, they are not limited to the center portion depending on the shape of the notch, and may be arranged in an area where the variation of the cell gap 10 is large. Further, depending on the shape of the notch, the area where the columnar spacers 11b are arranged may be a plurality of areas within the frame area 5a. In that case, the spacer arrangement density of the columnar spacers 11 may be arranged to decrease from the area where the columnar spacers 11b are arranged toward the end of the frame area 5a near it.

[0028] In Embodiments 1 and 2, as described above, the spacer arrangement density of the columnar spacer 11 indicates the sum of the areas of the columnar spacers 11 arranged per unit area of the substrate surface on which the spacers are arranged in a plan view. Therefore, even if the spacer arrangement density is the same, if the area in the plan view is large, that is, if it is cylindrical, a small number of columnar spacers 11 with a thick diameter may be arranged. Also, if the area in the plan view is small, that is, if it is cylindrical, a large number of columnar spacers 11 with a thin diameter may be arranged.

[0029] In a liquid crystal panel, a dual spacer structure may be used to further manage fluctuations in the cell gap 10. The dual spacer structure is provided with two types of columnar spacers 11 having different heights. While the main spacer with a high height always contacts the array substrate 1 and the color filter substrate 2 to maintain the cell gap 10, the sub spacer with a low height usually contacts only one of the array substrate 1 and the color filter substrate 2 and does not contribute to maintaining the cell gap 10. It only contacts both the array substrate 1 and the color filter substrate 2 and contributes to maintaining the cell gap 10 only when the cell gap 10 becomes narrower than a certain level. In Embodiments 1 and 2, for a liquid crystal panel adopting a dual spacer structure, by adopting the arrangement method of the columnar spacer 11 of the present disclosure for the arrangement of the main spacer with a high height, the effect of suppressing unevenness in the notch gap can be obtained. Also, within the display area 4, a dual spacer structure may be used, and within the frame area 5, only the main spacer may be arranged, and the arrangement method of the present disclosure may be adopted regarding the arrangement of the main spacer.

[0030] Embodiment 3 In Embodiments 1 and 2, a liquid crystal panel 101 in which unevenness in the gap at the corner of the notch is suppressed by increasing the spacer arrangement density in the frame area 5a compared to other areas has been described. In this Embodiment 3, a form is shown in which a dummy seal 21 having a spacer function is arranged in the frame area 5a instead of the columnar spacer 11.

[0031] FIG. 6 is a plan view showing the arrangement of the columnar spacers 11 and dummy seals 21 within region X of FIG. 1 in Embodiment 3. In FIG. 6, regions of the display region 4, the frame region 5a, and the frame region 5b are set in the same manner as described with reference to FIG. 3. Further, columnar spacers 11 indicated by circles are arranged in the display region 4 and the frame region 5b at equal pitches such that the number of arrangements per unit area is equal, as in Embodiment 1. In Embodiment 3, dummy seals 21 formed simultaneously with the seal 9 are arranged only in the frame region 5a. The dummy seal 21 is formed of the same material as the seal 9 and at the same time, and has the same height. However, the shape such as the area and width is not limited to that shown in FIG. 6 and may be set according to the situation. Also, in FIG. 6, a single dummy seal 21 is formed in the frame region 5b, but this is not limiting, and a plurality of dummy seals 21 may be formed, or the dummy seal 21 and the columnar spacer 11 may be arranged together. The seal 9 originally surrounds the liquid crystal in the liquid crystal layer 3 and seals it between the array substrate 1 and the color filter substrate 2, but at the same time also serves as a spacer for maintaining the cell gap 10 within a certain range. Therefore, as shown in Embodiment 3, by arranging a dummy seal 21 having the same height as the seal 9 in the frame region 5a, the dummy seal 21 can also function as a spacer for maintaining the cell gap 10 in the notch portion.

[0032] Embodiment 4 In Embodiments 1 and 2, a form in which the spacer arrangement density in the frame region 5a is made higher than that in the frame region 5b was shown. In Embodiment 4, a form in which the spacer height in the frame region 5a is made higher than that in the frame region 5b will be described. FIG. 7 is a plan view showing the arrangement of the columnar spacers 11 within region X of FIG. 1 in Embodiment 4, and FIGS. 8 and 9 are cross-sectional views showing the Z-Z cross-section of FIG. 7. Further, FIG. 8 shows the state before the array substrate 1 and the color filter substrate 2 are bonded together, and FIG. 9 shows the state after bonding. In FIG. 7, regions of the display region 4, the frame region 5a, and the frame region 5b are set in the same manner as described with reference to FIG. 3. Further, columnar spacers 11a indicated by circles are arranged in the display region 4 and the frame region 5b at an equal pitch such that the number of arrangements per area is equal, in the same manner as in Embodiment 1. In Embodiment 4, columnar spacers 11c having the same cross-sectional area as the columnar spacers 11a and a higher height are arranged only in the frame region 5a. In FIG. 7, the columnar spacers 11c are shown as squares for convenience of description, but the planar shape of the columnar spacers 11c is the same as that of the columnar spacers 11a. As shown in FIG. 8, before the array substrate 1 and the color filter substrate 2 are bonded together, the height hc of the columnar spacers 11c is higher than the height ha of the columnar spacers 11a (hc > ha). However, after the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 9, the columnar spacers 11c are more deformed and crushed than the columnar spacers 11a, so that they appear to have the same height (hc' = ha'). With such a configuration, in a state where the array substrate 1 and the color filter substrate 2 are bonded together, the columnar spacers 11c have a greater repulsive force for maintaining the cell gap 10 than the columnar spacers 11a, and the frame region 5a functions to maintain the cell gap 10 even when receiving a greater stress than the frame region 5b. Thus, increasing the height of the columnar spacers 11c arranged in the frame region 5a has the same effect as increasing the spacer arrangement density of the columnar spacers 11 arranged in the frame region 5a in Embodiment 1. In order to form the columnar spacers 11c having different heights, for example, a halftone mask having a gray color tone in addition to black and white may be used for the mask used for exposure in the process of forming the columnar spacers 11.

[0033] As another form of Embodiment 4, a convex pattern may be provided on the surface of the color filter substrate 2 facing the liquid crystal layer 3, and the columnar spacer 11c may be arranged so as to overlap with the pattern. FIGS. 10 and 11 are cross-sectional views showing the Z-Z cross-section of FIG. 7. Further, FIG. 10 shows the state before the array substrate 1 and the color filter substrate 2 are bonded together, and FIG. 11 shows the state after bonding. In this form, before the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 10, in the columnar spacers 11a and 11c, the height of the columnar spacer 11 itself is equal (hc = ha), but a pattern of the coloring material 6 is provided at the position where the columnar spacer 11c is arranged. Therefore, in the state where the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 11, the columnar spacer 11c is deformed and crushed more than the columnar spacer 11a by the thickness of the pattern of the coloring material 6 (hc’ < ha’), and the same effect as the form in which the columnar spacer 11c itself is made higher is achieved. This form can be realized, for example, by forming a pattern of the coloring material 6 also at the position where the columnar spacer 11 is arranged in the frame region 5b in the process of forming the coloring material 6 in the display region 4 of the color filter substrate 2. Alternatively, it may be formed with a photocurable type overcoat. In addition, providing a convex pattern on the surface of the array substrate 1 facing the liquid crystal layer 3 and arranging the columnar spacer 11c so as to overlap with the pattern also has the same effect. This form can be realized, for example, by forming an insulating film pattern for insulating the gate wiring and the source wiring of the array substrate 1 only at the position where the columnar spacer 11c in the frame region 5a is arranged.

[0034] As shown in Embodiment 4, increasing the height of the columnar spacer 11 within a certain region has the same effect as increasing the spacer arrangement density of the columnar spacer 11 shown in Embodiments 1 and 2. Therefore, the form of changing the spacer arrangement density of the columnar spacer 11 in the display region 4, the frame region 5a, and the frame region 5b shown in Embodiment 1 also has the same effect when the columnar spacers 11 with different heights of the columnar spacer 11 are arranged. Also, the form of changing the spacer arrangement density of the columnar spacer 11 within the region of the frame region 5a as in Embodiment 2 also has the same effect when the columnar spacers 11 with different heights of the columnar spacer 11 are arranged.

[0035] Embodiment 5 The structure of the non-rectangular display in Embodiment 5 will be described with reference to FIGS. 12 and 13. FIG. 12 is a plan view of a liquid crystal display device according to Embodiment 5 of the present disclosure. The liquid crystal display device is a liquid crystal panel 101 which is a non-rectangular display. In the liquid crystal panel 101, a seal 9 is arranged inside from the outer periphery, and a liquid crystal layer 3 is formed inside this. Further, the liquid crystal layer 3 includes a display region 4 for displaying an image. The liquid crystal panel 101 has an outer peripheral shape with cutout portions formed at the upper right and upper left corners on the paper surface with respect to a virtual rectangle, and the liquid crystal layer 3 and the display region 4 (the first region) surrounded by the seal 9 also have a shape with cutout portions. Note that the non-display region at the peripheral edge of the liquid crystal layer 3 surrounded by the seal 9 and the display region 4 is defined as a frame region 5. The frame region 5 is a region inside the seal 9 that does not contribute to the display. The outer peripheral shape of the corner portion of the notch of the liquid crystal panel 101 shown in the region S surrounded by the dotted line has a curved shape that smoothly changes at the corners where the sides intersect. This is a shape that takes into account design, suppresses the occurrence of polarizer cracks due to stress concentration in the glass substrate and polarizer that make up the liquid crystal panel 101, and the workability of the outer shape of the glass substrate. However, depending on the outer shape, it may not be a smooth curved shape but a corner where two straight lines intersect. Furthermore, the seal 9 also has an outer peripheral shape with a smooth curved shape at the corners. This is not only to correspond to the outer peripheral shape of the liquid crystal panel 101, but also because a smoother curved shape is easier to correspond to when forming the width and height of the seal 9 to be constant.

[0036] Figure 13 is a cross-sectional view showing the cross-section along α-α in FIG. 12 of the liquid crystal panel 101. The liquid crystal panel 101 has a structure in which an array substrate 1 and a color filter substrate 2 sandwich and bond a liquid crystal layer 3 made of liquid crystal, and has a driving method of the FFS (Fringe Field Switching) method. Although not shown, pixels are formed in a matrix on the surface of the array substrate 1 facing the liquid crystal layer 3 corresponding to the display region 4 by perpendicular scanning signal lines and display signal lines. A pixel electrode and a common electrode for driving the liquid crystal are formed in each pixel via an insulating layer, and a TFT (Thin Film Transistor), which is a switching element for applying a potential to the pixel electrode, is provided. On the other hand, on the surface of the color filter substrate 2 facing the liquid crystal layer 3, a color material 6 having a color such as RGB corresponding to each pixel, a black matrix 7 for shielding wiring between pixels and the region of the TFT, and an overcoat film 8 for protecting the color material 6 are formed. The black matrix 7 and the overcoat film 8 are further extended to the frame region 5 to shield the periphery of the display region 4. Although not shown, polarizers are attached to the surfaces of the array substrate 1 and the color filter substrate 2 that do not face the liquid crystal layer 3, and alignment films for aligning the liquid crystal are formed on the surfaces of the array substrate 1 and the color filter substrate 2 that face the liquid crystal layer 3. The liquid crystal layer 3 is surrounded by a seal 9 and sealed between the array substrate 1 and the color filter substrate 2. Here, the distance between the array substrate 1 and the color filter substrate 2 is particularly referred to as the cell gap 10. Since the liquid crystal is sealed so as to fill the cell gap 10, the cell gap 10 is equal to the thickness of the liquid crystal layer 3. An elastic member such as silicone rubber is used for the seal 9. Therefore, the seal 9 serves not only to seal the liquid crystal but also as a spacer to maintain the cell gap 10.

[0037] Columnar spacers 11 are formed on the surface of the color filter substrate 2 facing the liquid crystal layer 3. Therefore, in this embodiment, the color filter substrate 2 is the first substrate and the array substrate 1 is the second substrate. The columnar spacers 11 are arranged so as to be sandwiched between the array substrate 1 and the color filter substrate 2 and function as a support member to maintain the cell gap 10 within a certain range. The columnar spacers 11 are made of, for example, a UV photosensitive resin as a member and are formed by pattern exposure using a mask, so that they can be accurately arranged at desired positions. Since there is no liquid crystal in the portion where the columnar spacers 11 are located and the liquid crystal does not align normally in the region around the columnar spacers 11, the vicinity of the columnar spacers 11 becomes a region where the control of transmitting or blocking the light of the backlight cannot be performed. For this reason, when the columnar spacers 11 are arranged in the display area 4, they are arranged so as to overlap with the black matrix 7 in a plan view and be blocked from light, taking care not to affect the displayed image. The columnar spacers 11 have a height larger than the assumed cell gap 10 before the array substrate 1 and the color filter substrate 2 are bonded together, and are in a slightly compressed state when the array substrate 1 and the color filter substrate 2 are bonded together to form a predetermined cell gap 10. When the cell gap 10 becomes smaller due to an external force or a temperature change in the environment, the repulsive force suppresses further reduction, and when the cell gap 10 becomes larger, the amount compressed by the bonding is restored and follows.

[0038] Next, the arrangement of the columnar spacers 11 around the notch in Embodiment 5 will be described. FIG. 14 is a plan view of the region S surrounded by the dotted line of the notch in FIG. 12. As described above, the liquid crystal panel 101 has an outer peripheral shape with a notch formed therein. The liquid crystal layer 3 surrounded by the seal 9 formed inside the outer periphery of the liquid crystal panel 101, and further, the display region 4 formed inside the seal 9 where an image is displayed also has a shape with a notch. Here, the outer peripheral shape of the corner portion of the notch in the liquid crystal panel 101 has a curved shape that smoothly changes in an arc shape instead of a corner where straight lines intersect, from the viewpoints of design, crack prevention, and workability. Also, the seal 9 has an outer peripheral shape with a curved shape that smoothly changes instead of a corner so that it is easy to control the seal thickness and width during seal formation. Furthermore, the outer peripheral shape of the display region 4 also has a shape with a curved shape that smoothly changes at the corners.

[0039] In the fifth embodiment, when arranging the columnar spacers 11, the frame area 5 is divided as follows. In FIG. 14, first, for the seal 9 of the notch portion, the straight portion formed vertically upward on the paper surface is the second seal straight portion 99a, the curved concave portion is the third seal curved portion 99b, and the straight portion formed horizontally downward on the paper surface is the first seal straight portion 99c. That is, assuming the first direction is the direction along the x-axis and the second direction is the direction along the y-axis, the seal 9 of the notch portion includes a first seal portion (first seal straight portion 99c) extending in the first direction, a second seal portion (second seal straight portion 99a) extending in the second direction whose inner angle is 270° different from the first direction, and a third seal portion (third seal curved portion 99b) smoothly connecting the first seal portion and the second seal portion. Further, the boundary point between the second seal portion (second seal straight portion 99a) and the third seal portion (third seal curved portion 99b) is point A, and the boundary point between the third seal portion (third seal curved portion 99b) and the first seal portion (first seal straight portion 99c) is point B. Also, the intersection points where the second normal line 115 and the first normal line 116 dropped from point A and point B to the outer peripheral line 4a of the display area 4 intersect the outer peripheral line 4a are point C and point D. At this time, the frame area 5 surrounded by the line segment AB of the third seal portion, the line segment BD of the first normal line 116, the line segment DC which is the outer periphery of the first area, and the line segment CA of the second normal line 115 is defined as the corner frame area 55a (second area). Furthermore, the area other than the display area 4 (first area) and the corner frame area 55a (second area), that is, the frame area 5 sandwiched between the second seal straight portion 99a or the first seal straight portion 99c which is the straight portion of the seal and the display area 4 is specifically defined as the line portion frame area 55b (third area).

[0040] Next, FIG. 15 shows the arrangement of the columnar spacers 11 with respect to each region described with reference to FIG. 14. In FIG. 15, the columnar spacers 11a indicated by circles are arranged at equal pitches such that the number of arrangements per unit area is equal in the display region 4, the corner frame region 55a, and the line frame region 55b. Further, the columnar spacers 11b indicated by double circles are arranged only in the corner frame region 55a. Here, although the columnar spacers 11a and 11b are shown with different displays for convenience of explanation, they are columnar spacers 11 of the same specification having the same cross-sectional area and height. That is, in the form shown in FIG. 15, the columnar spacers 11 combining the columnar spacers 11a and 11b have the highest spacer arrangement density in the corner frame region 55a compared to the display region 4 and the line frame region 55b. Here, the spacer arrangement density refers to the sum of the areas of the columnar spacers 11 arranged per unit area of the substrate surface in a plan view, that is, the area density.

[0041] The form shown in FIG. 15 is an example of the present disclosure, and the spacer arrangement density and arrangement of the columnar spacers 11a and 11b may be freely set. For example, in the corner frame region 55a, the columnar spacer 11a is not provided, and only the columnar spacer 11b is arranged at the same pitch as the columnar spacer 11a in the line frame region 55b. At this time, by making the area of each columnar spacer 11b in a plan view larger than the area of each columnar spacer 11a in a plan view, the spacer arrangement density of the columnar spacers 11 in the corner frame region 55a may be set to be equal to or higher than the spacer arrangement density of the line frame region 55b. That is, it is sufficient that the spacer arrangement density of the columnar spacers 11 satisfies (spacer arrangement density in the line frame region 55b) ≦ (spacer arrangement density in the corner frame region 55a).

[0042] As a further example of the form, the spacer arrangement density of the columnar spacers 11 in each region may be changed corresponding to the occurrence region of the gap unevenness. For example, when the gap unevenness occurs only in the concave portion of the notch, (the spacer arrangement density in the display region 4) = (the spacer arrangement density in the linear frame region 55b) < (the spacer arrangement density in the corner frame region 55a). Also, when the gap unevenness occurs in the frame region 5 other than the notch following the concave portion of the notch, (the spacer arrangement density in the display region 4) < (the spacer arrangement density in the linear frame region 55b) < (the spacer arrangement density in the corner frame region 55a) may be set. Further, when the gap unevenness occurs in the display region 4 following the concave portion of the notch, (the spacer arrangement density in the linear frame region 55b) < (the spacer arrangement density in the display region 4) < (the spacer arrangement density in the corner frame region 55a) may also be set.

[0043] Next, the effects of Embodiment 5 will be described. In a liquid crystal panel, stress generated during the processing of members and the panel manufacturing process remains inside the glass substrate and polarizing plate. However, when there is a notch in the outer peripheral shape, that is, when the inner angle formed by the linear first seal portion and the second seal portion exceeds 180°, this stress concentrates toward the corner portion of the notch, and the cell gap 10 tends to become narrow. As a result, gap unevenness, which is a local variation of the cell gap 10, may occur at the corner portion of the notch, and display unevenness with a different luminance from the surroundings may occur. According to the embodiment of the present disclosure, by increasing the spacer arrangement density of the columnar spacers 11 around the corner portion of the notch, the elastic force of the spacers can be increased, and the occurrence of this gap unevenness can be suppressed. There are other methods for suppressing the gap unevenness around the corner portion of the notch. For example, there is a method of arranging a gap holding member such as a spacer or a dummy seal instead thereof in a region outside the seal 9. However, due to the narrowing of the bezel of recent liquid crystal panels, it has become difficult to secure a sufficient region for arranging the gap holding member in a region outside the seal 9. Also, there is a method of increasing the spacer arrangement density around the corner of the notch within the display area 4. However, in order to arrange the columnar spacers 11 within the display area 4, it is necessary to arrange them so as to overlap the black matrix 7. Considering that there are limitations on the size of one columnar spacer 11 in plan view, and that the columnar spacers 11 may affect rubbing and there is a risk of rubbing defects occurring around the columnar spacers 11, there are significant constraints on further additionally arranging the columnar spacers 11, which are originally often arranged over the entire display area 4, only around the pixels in the corner portion of the notch. Embodiment 5 of the present embodiment increases the spacer arrangement density of the columnar spacers 11 without being restricted by the black matrix 7 or the like in a partial region of the bezel region 5 that does not affect display. There is an advantage that the degree of freedom of arrangement is high and a large effect can be easily obtained. These effects are prominent when the inner angle formed by the first direction along which the first seal portion extends and the second direction along which the second seal portion extends is larger than 180°.In this embodiment, an example where the inner angle formed by the first direction and the second direction is 270° has been introduced. However, the closer this angle is to 360° rather than being greater than 180°, the stronger the effect of the present disclosure becomes.

[0044] Embodiment 6 In Embodiment 5, a form was shown in which the spacer arrangement density of the columnar spacers 11 in the display region 4, the corner frame region 55a, and the linear frame region 55b was such that the corner frame region 55a had the highest spacer arrangement density. In this Embodiment 6, the arrangement of the columnar spacers 11 within the region of the corner frame region 55a will be further described. FIG. 16 is a plan view showing the arrangement of the columnar spacers 11 within the region S of FIG. 12 in this Embodiment 6. In FIG. 16, the regions of the display region 4, the corner frame region 55a, and the linear frame region 55b are set in the same manner as described in FIG. 14, and further, the columnar spacers 11a indicated by circles are arranged at equal pitches so that the number of arrangements per unit area is equal in the display region 4, the corner frame region 55a, and the linear frame region 55b, in the same manner as described in FIG. 15 in Embodiment 5. Further, the columnar spacers 11b indicated by double circles are arranged only in the corner frame region 55a. However, in this Embodiment 6, the columnar spacers 11b are not evenly arranged at this pitch within the region of the corner frame region 55a, but are concentrated near the center of the corner portion of the notch portion (near the intersection of the straight line of the first seal portion and the straight line of the second seal portion). In short, the spacer arrangement density in the corner frame region 55a (the second region) is high at the center and becomes smaller as it approaches the first normal line 116 or the second normal line 115.

[0045] In the liquid crystal panel, as described above, internal stress generated during the processing of members and the panel manufacturing process remains inside the glass substrate and the polarizing plate. However, when the outer peripheral shape has a notch, the stress concentrates from both sides of the notch toward the corner portion of the notch, and the variation in the cell gap 10 is particularly likely to be large at the center of the corner portion of the notch. Therefore, by increasing the spacer arrangement density of the columnar spacers 11 particularly near the center of the corner portion of the notch even within the region of the corner frame region 55a, it becomes possible to more effectively suppress the variation in this cell gap 10. Note that although the columnar spacer 11b is concentratedly arranged near the center of the corner portion of the notch within the region of the corner frame region 55a, it is not limited to the center portion depending on the shape of the notch, and it may be arranged in a region where the variation in the cell gap 10 is large. Further, depending on the shape of the notch, the region where the columnar spacer 11b is arranged may be a plurality of regions within the corner frame region 55a. In that case, the spacer arrangement density of the columnar spacer 11 may be arranged to decrease from the region where the columnar spacer 11b is arranged toward the end of the corner frame region 55a close to it.

[0046] In Embodiments 5 and 6, as described above, the spacer arrangement density of the columnar spacer 11 indicates the sum of the areas of the columnar spacers 11 in a plan view arranged per unit area of the substrate surface on which the spacers are arranged. Therefore, even if the spacer arrangement density is the same, if the area in a plan view is large, that is, if it is cylindrical, a small number of thick-columnar spacers 11 may be arranged, and if the area in a plan view is small, that is, if it is cylindrical, a large number of thin-columnar spacers 11 may be arranged.

[0047] In a liquid crystal panel, a dual spacer structure may be used to further manage the variation of the cell gap 10. The dual spacer structure is provided with two types of columnar spacers 11 having different heights. While the main spacer with a higher height always contacts the array substrate 1 and the color filter substrate 2 to maintain the cell gap 10, the sub spacer with a lower height usually contacts only one of the array substrate 1 and the color filter substrate 2 and does not contribute to maintaining the cell gap 10. It only contacts both the array substrate 1 and the color filter substrate 2 and contributes to maintaining the cell gap 10 only when the cell gap 10 becomes narrower than a certain level. In Embodiments 5 and 6, for a liquid crystal panel adopting the dual spacer structure, by adopting the arrangement method of the columnar spacer 11 of the present disclosure for the arrangement of the main spacer with a higher height, the effect of suppressing the gap unevenness in the notch portion can be obtained. Also, within the region of the display area 4, a dual spacer structure may be used, and within the region of the frame area 5, only the main spacer may be arranged, and the arrangement method of the present disclosure may be adopted regarding the arrangement of the main spacer.

[0048] Embodiment 7 In Embodiments 5 and 6, a liquid crystal panel 101 in which the gap unevenness at the corner portion of the notch portion is suppressed by increasing the spacer arrangement density in the corner frame region 55a compared to other regions has been described. In this Embodiment 7, a form in which a dummy seal 21 having a spacer function is arranged in the corner frame region 55a instead of the columnar spacer 11 is shown.

[0049] FIG. 17 is a plan view showing the arrangement of the columnar spacer 11 and the dummy seal 21 within the region S of FIG. 12 in this Embodiment 7. In FIG. 17, regions of the display area 4, the corner frame region 55a, and the line frame region 55b are set in the same manner as described in FIG. 14. Further, in the display area 4 and the line frame region 55b, columnar spacers 11 indicated by circles are arranged at equal pitches so that the number of arrangements per unit area is equal, as in Embodiment 5. And in this Embodiment 7, the dummy seal 21 formed simultaneously with the seal 9 is arranged only in the corner frame region 55a. The dummy seal 21 is formed of the same material as the seal 9 and at the same time, and has the same height. However, the shape such as the area and width is not limited to that shown in Fig. 17, and may be set according to the situation. Also, in Fig. 17, one dummy seal 21 is formed alone in the linear frame edge region 55b, but it is not limited to this, and a plurality of dummy seals 21 may be formed, or the dummy seal 21 and the columnar spacer 11 may be arranged together. The seal 9 originally surrounds the liquid crystal in the liquid crystal layer 3 and seals it between the array substrate 1 and the color filter substrate 2, but at the same time also serves as a spacer for maintaining the cell gap 10 within a certain range. Therefore, as shown in the seventh embodiment, by arranging a dummy seal 21 having the same height as the seal 9 in the corner frame edge region 55a, the dummy seal 21 can also function as a spacer for maintaining the cell gap 10 in the notch portion.

[0050] Embodiment 8 In Embodiment 5 and Embodiment 6, a form in which the spacer arrangement density in the corner frame edge region 55a is higher than that in the linear frame edge region 55b was shown. In this Embodiment 8, a form in which the spacer height in the corner frame edge region 55a is higher than that in the linear frame edge region 55b will be described. FIG. 18 is a plan view showing the arrangement of the columnar spacers 11 within the region S of FIG. 12 in Embodiment 8, and FIGS. 19 and 20 are cross-sectional views showing the cross-section along β-β of FIG. 18. Further, FIG. 19 shows the state before the array substrate 1 and the color filter substrate 2 are bonded together, and FIG. 20 shows the state after bonding. In FIG. 18, similar to the description in FIG. 14, regions of the display region 4, the corner frame region 55a, and the line frame region 55b are set. Further, in the display region 4 and the line frame region 55b, columnar spacers 11a indicated by circles are arranged at equal pitches such that the number of arrangements per area is equal, similar to Embodiment 5. In Embodiment 8, columnar spacers 11c having the same cross-sectional area as the columnar spacers 11a and a higher height are arranged only in the corner frame region 55a. In FIG. 18, the columnar spacers 11c are shown as squares for convenience of description, but the planar shape of the columnar spacers 11c is the same as that of the columnar spacers 11a. As shown in FIG. 19, before the array substrate 1 and the color filter substrate 2 are bonded together, the height hc of the columnar spacers 11c is higher compared to the height ha of the columnar spacers 11a (hc > ha). However, after the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 20, the columnar spacers 11c are more deformed and crushed than the columnar spacers 11a, so that they appear to have the same height (hc' = ha'). With such a configuration, in the state where the array substrate 1 and the color filter substrate 2 are bonded together, the columnar spacers 11c have a greater repulsive force for maintaining the cell gap 10 than the columnar spacers 11a, and perform the function of maintaining the cell gap 10 even when the corner frame region 55a receives a greater stress than the line frame region 55b. Thus, increasing the height of the columnar spacers 11c arranged in the corner frame region 55a has the same effect as increasing the spacer arrangement density of the columnar spacers 11 arranged in the corner frame region 55a in Embodiment 5. In order to form columnar spacers 11c with different heights, for example, a halftone mask having a gray tone in addition to black and white may be used for the mask used for exposure in the process of forming the columnar spacers 11.

[0051] As another form of Embodiment 8, a convex pattern may be provided on the surface of the color filter substrate 2 facing the liquid crystal layer 3, and the columnar spacer 11c may be arranged so as to overlap with the pattern. FIGS. 21 and 22 are cross-sectional views showing the cross-section taken along the line β-β of FIG. 18. Further, FIG. 21 shows the state before the array substrate 1 and the color filter substrate 2 are bonded together, and FIG. 22 shows the state after bonding. In this form, before the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 21, in the columnar spacers 11a and 11c, the height of the columnar spacer 11 itself is equal (hc = ha), but a pattern of the coloring material 6 is provided at the position where the columnar spacer 11c is arranged. Therefore, in the state where the array substrate 1 and the color filter substrate 2 are bonded together, as shown in FIG. 22, the columnar spacer 11c is deformed and crushed more than the columnar spacer 11a by the thickness of the pattern of the coloring material 6 (hc' < ha'), and the same effect as the form in which the columnar spacer 11c itself is made higher is obtained. This form can be realized, for example, by forming a pattern of the coloring material 6 also at the position where the columnar spacer 11 is arranged in the frame area 55b of the line portion in the process of forming the coloring material 6 in the display area 4 of the color filter substrate 2. Alternatively, it may be formed with a photocurable type overcoat. In addition, providing a convex pattern on the surface of the array substrate 1 facing the liquid crystal layer 3 and arranging the columnar spacer 11c so as to overlap with the pattern also has the same effect. This form can be realized, for example, by forming an insulating film pattern for insulating the gate wiring and the source wiring of the array substrate 1 only at the position where the columnar spacer 11c in the corner frame area 55a is arranged.

[0052] As shown in Embodiment 8, increasing the height of the columnar spacer 11 within a certain region has the same effect as increasing the spacer arrangement density of the columnar spacer 11 shown in Embodiments 5 and 6. Therefore, the form of changing the spacer arrangement density of the columnar spacer 11 in the display region 4, corner frame region 55a, and line frame region 55b shown in Embodiment 5 also has the same effect when arranging columnar spacers 11 with different heights of the columnar spacer 11. Further, the form of changing the spacer arrangement density of the columnar spacer 11 within the region of the corner frame region 55a as in Embodiment 6 also has the same effect when arranging columnar spacers 11 with different heights of the columnar spacer 11.

[0053] Although Embodiments 1 to 8 have described the liquid crystal panel 101 having the driving method of the FFS method, the driving method of the liquid crystal is not limited to the FFS method, and the same effect can be achieved by other methods such as the TN (Twisted Nematic) method and the Inplain-Switching method. In addition, although the form in which the columnar spacer 11 is arranged on the color filter substrate 2 has been described, the same effect can be achieved by arranging it on the array substrate 1.

Explanation of Reference Numerals

[0054] 101 Liquid crystal panel 1 Array substrate 2 Color filter substrate 3 Liquid crystal layer 4 Display region 4a Outer peripheral line of the display region 5, 5a, 5b Frame region 6 Colorant 7 Black matrix 8 Overcoat film 9 Seal 9a, 9c Seal straight line portion 9b Seal curved line portion 10 Cell gap 11, 11a, 11b, 11c Columnar spacer 15, 16 Normal line 21 Dummy seal 55a Corner frame area 55b Linear frame area 99a Second seal straight part 99b Third seal curved part 99c First seal straight part 115 Second normal 116 First normal

Claims

1. a first substrate; a second substrate disposed opposite to the first substrate; a liquid crystal layer sandwiched between the first substrate and the second substrate; a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate; a spacer provided between the first substrate and the second substrate to maintain the distance between the first substrate and the second substrate, the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion; a region for displaying an image is defined as a first region; a region surrounded by the third seal portion, an outer peripheral line of the first region, a first normal line dropped from a boundary point between the first seal portion and the third seal portion to the outer peripheral line of the first region, and a second normal line dropped from a boundary point between the second seal portion and the third seal portion to the outer peripheral line of the first region is defined as a second region; when a region other than the first region and other than the second region is defined as a third region, a liquid crystal display device, wherein a spacer arrangement density, which is a ratio of an area occupied by the spacer per unit area in a plan view, is greater in the second region than in the third region.

2. The liquid crystal display device according to claim 1, wherein the spacer arrangement density in the second region decreases as it approaches the first normal line or the second normal line.

3. The liquid crystal display device according to claim 1 or claim 2, wherein the spacer arrangement density in the third region is equal to or less than a minimum value of the spacer arrangement density in the second region.

4. The liquid crystal display device according to any one of claims 1 to 3, wherein the spacer arrangement density in the third region is equal to or greater than the spacer arrangement density in the first region.

5. The liquid crystal display device according to any one of claims 1 to 4, wherein the spacer includes a first spacer and a second spacer having a height lower than that of the first spacer.

6. The liquid crystal display device according to any one of claims 1 to 3, wherein the spacer in the second region is a dummy seal formed of the same material as the seal.

7. a first substrate; a second substrate disposed opposite to the first substrate; a liquid crystal layer sandwiched between the first substrate and the second substrate; a seal disposed so as to surround the liquid crystal layer between the first substrate and the second substrate; a spacer provided on a surface of the first substrate facing the liquid crystal layer; the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion; a region for displaying an image is defined as a first region; a region surrounded by the third seal portion, an outer peripheral line of the first region, a first normal line dropped from a boundary point between the first seal portion and the third seal portion to the outer peripheral line of the first region, and a second normal line dropped from a boundary point between the second seal portion and the third seal portion to the outer peripheral line of the first region is defined as a second region; when a region other than the first region and other than the second region is defined as a third region; before the second substrate is disposed to face the first substrate, a height of at least one of the spacers in the second region is higher than a height of the spacers in the third region, a liquid crystal display device characterized by this.

8. before the second substrate is disposed to face the first substrate, the height of the spacers in the second region becomes lower as it approaches the first normal line or the second normal line, a liquid crystal display device according to claim 7, characterized by this.

9. before the second substrate is disposed to face the first substrate, a height of the lowest spacer in the second region is equal to or higher than a height of the highest spacer in the third region, a liquid crystal display device according to claim 7 or claim 8, characterized by this.

10. before the second substrate is disposed to face the first substrate, the height of the spacers in the third region is the same as or higher than a height of the first spacers in the first region, a liquid crystal display device according to any one of claims 7 to 9, characterized by this.

11. a first substrate; a second substrate disposed to face the first substrate; a liquid crystal layer sandwiched between the first substrate and the second substrate; a seal disposed between the first substrate and the second substrate so as to surround the liquid crystal layer; a spacer provided on a surface of the first substrate facing the liquid crystal layer; the seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion; a region for displaying an image is defined as a first region; The region surrounded by the third seal portion, the outer peripheral line of the first region, the first normal line dropped from the boundary point between the first seal portion and the third seal portion to the outer peripheral line of the first region, and the second normal line dropped from the boundary point between the second seal portion and the third seal portion to the outer peripheral line of the first region is defined as the second region. When the region outside the first region and outside the second region is defined as the third region, The spacer in the second region is arranged to overlap with a convex pattern provided in the second region on the surface of the first substrate facing the liquid crystal layer. A liquid crystal display device characterized by this.

12. A first substrate, A second substrate arranged to face the first substrate, A liquid crystal layer sandwiched between the first substrate and the second substrate, A seal arranged to surround the liquid crystal layer between the first substrate and the second substrate, And a spacer provided on the surface of the first substrate facing the liquid crystal layer. The seal includes a first seal portion extending in a first direction, a second seal portion extending in a second direction different from the first direction, and a third seal portion smoothly connecting the first seal portion and the second seal portion. The region for displaying an image is defined as the first region. The region surrounded by the third seal portion, the outer peripheral line of the first region, the first normal line dropped from the boundary point between the first seal portion and the third seal portion to the outer peripheral line of the first region, and the second normal line dropped from the boundary point between the second seal portion and the third seal portion to the outer peripheral line of the first region is defined as the second region. When the region outside the first region and outside the second region is defined as the third region, The spacer in the second region is arranged to face and overlap with a convex pattern provided in the second region on the surface of the second substrate facing the liquid crystal layer. A liquid crystal display device characterized by this.

Images