Color filter, method of fabricating the same and Liquid-Crystal Display device

Abstract

A color filter having two-layered light-shielding sections without a black matrix is provided, which reduces the level difference from the colored materials for pixels with a simple method and makes it possible to remove the color layer on the said sections. A red color layer having stripe-shaped red pixel formation sections and a blue color layer having stripe-shaped blue pixel formation sections are overlapped to form two-layered light-shielding sections. A green color layer having island-shaped green pixel formation sections is overlapped with the red and blue color layers, placing the green pixel formation sections in the overlapped green pixel windows of the red and blue color layers. Only the peripheries of the green pixel formation sections are placed on the light-shielding sections to facilitate the removal of the peripheries by polishing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be readily carried into effect, it will now be described with reference to the accompanying drawings.

FIGS. 1A to 1C show the patterns of the color layers used in a prior-art color filter. FIG. 1A is an explanatory partial plan view of the red color layer, FIG. 1B is an explanatory partial plan view of the blue color layer, and FIG. 1C is an explanatory partial plan view of the green color layer.

FIG. 2 is an explanatory partial plan view of the prior-art color filter comprising the color layers of FIGS. 1A to 1C, which shows an example of the layout of the photo spacers.

FIG. 3A is an explanatory partial cross-sectional view along the line IIIA-IIIA in FIG. 2, and FIG. 3B is an explanatory partial cross-sectional view showing the state where the TFT substrate is coupled with the structure of FIG. 3A.

FIGS. 4A and 4B are explanatory partial plan views of the prior-art color filter of FIGS. 1A to 1C showing other examples of the layout of the photo spacers, respectively.

FIG. 5A is an explanatory partial cross-sectional view along the line VA-VA in FIG. 4A, and FIG. 5B is an explanatory partial cross-sectional view showing the state where the TFT substrate is coupled with the structure of FIG. 5A.

FIG. 6A is an explanatory partial cross-sectional view along the line VIA-VIA in FIG. 4A, and FIG. 6B is an explanatory partial cross-sectional view showing the state where the TFT substrate is coupled with the structure of FIG. 6A.

FIG. 7 is a partial plan view showing the structure of the TFT substrate coupled with the prior-art color filter of FIG. 2.

FIGS. 8A to 8C show the patterns of the color layers of a color filter according to a first embodiment of the invention. FIG. 8A is an explanatory partial plan view of the red color layer, FIG. 8B is an explanatory partial plan view of the blue color layer, and FIG. 8C is an explanatory partial plan view of the green color layer.

FIGS. 9A to 9C show the process steps of a method of fabricating the color filter according to the first embodiment of FIG. 2. FIG. 9A is an explanatory partial plan view of the filter showing the state where the red and blue color layers of FIGS. 8A and 8B are formed on the transparent glass plate. FIG. 9B is an explanatory partial plan view of the filter showing the state where the green color layer of FIG. 8C is formed on the structure of FIG. 9A. FIG. 9C is an explanatory partial plan view of the filter showing the state where the overlapped parts of the island-shaped green pixel formation sections with the light-shielding sections are removed by polishing from the state of FIG. 9B.

FIG. 10A is an explanatory partial cross-sectional view along the line XA-XA in FIG. 9B, and FIG. 10B is an explanatory partial cross-sectional view along the line XB-XB in FIG. 9C.

FIG. 11A is an explanatory partial cross-sectional view along the line XIA-XIA in FIG. 9B, and FIG. 11B is an explanatory partial cross-sectional view along the line XIB-XIB in FIG. 9C.

FIG. 12A is an explanatory partial plan view of the color filter according to the first embodiment, which shows an example of the layout of the photo spacers, and FIG. 12B is an explanatory partial cross-sectional view along the line XIIB-XIIB in FIG. 12A.

FIG. 13A is an explanatory partial plan view of the color filter according to the first embodiment, which shows another example of the layout of the photo spacers, and FIG. 13B is an explanatory partial cross-sectional view along the line XIIIB-XIIIB in FIG. 13A.

FIG. 14 is an explanatory partial cross-sectional view showing the state where the TFT substrate is coupled with the color filter according to the first embodiment shown in FIGS. 12A and 12B.

FIG. 15 is an explanatory partial cross-sectional view showing the state where the TFT substrate is coupled with the color filter according to the first embodiment shown in FIGS. 13A and 13B.

FIG. 16 is a partial plan view showing the structure of the TFT substrate coupled with the color filter according to the first embodiment of the invention.

FIG. 17 is an explanatory partial cross-sectional view of a LCD device comprising an opposite substrate using the color filter according to the first embodiment of the invention and the TFT substrate of FIG. 16 coupled with the opposite substrate, which shows the cross-sectional structure of the device along the line XVII-XVII in FIG. 16.

FIG. 18A is an explanatory partial cross-sectional view along the line XVIIIA-XVIIIA in FIG. 16, which shows the cross-sectional structure of the TFT substrate of FIG. 16, and FIG. 18B is an explanatory partial cross-sectional view along the line XVIIIB-XVIIIB in FIG. 16, which shows the cross-sectional structure of the TFT substrate of FIG. 16.

FIGS. 19A to 19C show the patterns of the color layers of a color filter according to a second embodiment of the invention. FIG. 19A is an explanatory partial plan view of the red color layer, FIG. 19B is an explanatory partial plan view of the blue color layer, and FIG. 19C is an explanatory partial plan view of the green color layer.

FIGS. 20A to 20C show the process steps of a method of fabricating the color filter according to the second embodiment of FIGS. 19A to 19C. FIG. 20A is an explanatory partial plan view showing the state where the red and blue color layers of FIGS. 19A and 19B are formed on the transparent glass plate. FIG. 20B is an explanatory partial plan view showing the state where the green color layer of FIG. 19C is formed on the structure of FIG. 20A. FIG. 20C is an explanatory partial plan view showing the state where the overlapped parts of the island-shaped green pixel formation sections with the light-shielding sections are removed by polishing from the state of FIG. 20B.

FIG. 21 is an explanatory partial cross-sectional view along the line XXI-XXI in FIG. 20B.

FIG. 22 is a partial plan view showing the structure of the TFT substrate coupled with one of color filters according to third and fourth embodiments of the invention.

FIG. 23A is an explanatory partial cross-sectional view of the TFT substrate along the line XXIIIA-XXIIIA in FIG. 22, and FIG. 23B is an explanatory partial cross-sectional view of the TFT substrate along the line XXIIIB-XXIIIB in FIG. 22.

Claims

1. A color filter comprising: a transparent support;a first color layer formed on the support;the first color layer having stripe-shaped first color pixel formation sections, second color pixel windows, and third color pixel windows which are arranged at predetermined intervals respectively;a second color layer formed to overlap with the first color layer;the second color layer having stripe-shaped second color pixel formation sections first color pixel windows, and third color pixel windows which are arranged at predetermined intervals, respectively; anda third color layer having island-shaped third color pixel formation sections apart from each other;wherein the first color pixel formation sections of the first color layer are overlapped with the first color pixel windows of the second color layer, thereby defining first color pixels; and the second color pixel formation sections of the second color layer are overlapped with the second color pixel windows of the first color layer, thereby defining second color pixels;wherein the third color pixel formation sections of the third color layer are arranged in the third color pixel windows of the first color layer and the third color pixel windows of the second color layer, the third color pixel windows of the first color layer being overlapped with the third color pixel windows of the second color layer, thereby defining third color pixels; andwherein overlapped parts of the first color layer and the second color layer function as light-shielding sections.

2. The color filter according to claim 1, wherein the first color pixel formation sections of the first color layer are arranged along a first direction at predetermined intervals and are extended along a second direction perpendicular to the first direction; and the second and third color pixel windows of the first color layer are defined by connection sections that connect the first color pixel formation sections adjacent to each other;and wherein the second color pixel formation sections of the second color layer are arranged along the first direction at predetermined intervals and are extended along the second direction; andthe first and third color pixel windows of the second color layer are defined by connection sections that connect the second color pixel formation sections adjacent to each other.

3. The color filter according to claim 1, wherein peripheries of the third color pixel formation sections are overlapped with the light-shielding sections to have overlapped widths of 5.0 μm or less.

4. The color filter according to claim 3, further comprising spacers arranged to bury or fill the overlapped peripheries of the third color pixel formation sections with the light shielding sections.

5. The color filter according to claim 1, wherein peripheries of the third color pixel formation sections are not overlapped with the light-shielding sections.

6. The color filter according to claim 5, further comprising spacers arranged on the light-shielding sections.

7. The color filter according to claim 1, wherein the first color layer is one of a red color layer and a blue color layer, and the second color layer is the other.

8. The color filter according to claim 1, wherein the first color layer or the second color layer is a red color layer.

9. A method of fabricating a color filter, comprising: forming a first color layer on a transparent support; the first color layer having stripe-shaped first color pixel formation sections, second color pixel windows, and third color pixel windows, which are arranged at predetermined intervals, respectively;forming a second color layer to overlap with the first color layer; the second color layer having stripe-shaped second color pixel formation sections, first color pixel windows, and third color pixel windows, which are arranged at predetermined intervals, respectively; andforming a third color layer having island-shaped third color pixel formation sections apart from each other;wherein in the step of forming the second color layer, the first color pixel formation sections of the first color layer are overlapped with the first color pixel windows of the second color layer, thereby defining first color pixels; and the second color pixel formation sections of the second color layer are overlapped with the second color pixel windows of the first color layer, thereby defining second color pixels;wherein in the step of forming the third color layer, the third color pixel formation sections of the third color layer are arranged in the third color pixel window of the first color layer and the third color pixel windows of the second color layer, the third color pixel windows of the first color layer being overlapped with the third color pixel windows of the second color layer, thereby defining third color pixels; andwherein overlapped parts of the first color layer and the second color layer function as light-shielding sections.

10. The method according to claim 9, wherein in the step of forming the first color layer, the first color pixel formation sections of the first color layer are arranged along a first direction at predetermined intervals and are extended along a second direction perpendicular to the first direction; the second color pixel windows and the third color pixel windows of the first color layer are defined by connection sections that connect the first color pixel formation sections thereof adjacent to each other;and wherein in the step of forming the second color layer, the second color pixel formation sections of the second color layer are arranged along the first direction at predetermined intervals and are extended along the second direction; andthe first color pixel windows and the third color pixel windows of the second color layer are defined by connection sections that connect the second color pixel formation sections thereof adjacent to each other.

11. The method according to claim 9, wherein in the step of forming the third color layer, peripheries of the third color pixel formation sections are overlapped with the light shielding sections to have overlapped widths of 5.0 μm or less.

12. The method according to claim 11, further comprising a step of forming spacers in such a way as to bury or fill the overlapped peripheries of the third color pixel formation sections with the light-shielding sections.

13. The method according to claim 9, wherein after the step of forming the third color layer is completed, a step of polishing the third color layer is carried out to remove peripheries of the third color pixel formation sections placed on the light-shielding sections.

14. The method according to claim 9, wherein the first color layer is one of a red color layer and a blue color layer, and the second color layer is the other.

15. The method according to claim 9, wherein the first color layer or the second color layer is a red color layer.

16. A color filter comprising: a transparent support;a first color layer formed on the support;the first color layer having stripe-shaped first color pixel formation sections and second-and-third color pixel windows, which are arranged at predetermined intervals along a first direction, respectively;a second color layer formed to overlap with the first color layer;the second color layer having stripe-shaped second color pixel formation sections and first-and-third color pixel windows, which are arranged at predetermined intervals along the first direction, respectively; anda third color layer having island-shaped third color pixel formation sections apart from each other;wherein the second color pixel formation sections of the second color layer are overlapped with second color pixel subwindows of the second-and-third color pixel windows of the first color layer: and the first-and-third color pixel windows of the second color layer are respectively overlapped with the first color pixel formation sections of the first color layer and third color pixel subwindows of the second-and-third color pixel windows thereof;wherein the third color pixel formation sections of the third color layer are respectively arranged in the third color pixel subwindows of the second-and-third color pixel windows of the first color layer and the third color pixel subwindows of the first-and-third color pixel windows of the second color layer, the third color pixel subwindows of the second-and third color pixel windows of the first color layer being overlapped with the third color pixel subwindows of the first and-third color pixel windows of the second color layer;wherein the first color pixel formation sections of the first color layer, which are overlapped with he first-and-third color pixel windows of the second color layer and the third color pixel formation sections of the third color layer, define first color pixels;the second color pixel formation sections of the second color layer, which are overlapped with the second-and-third color pixel windows of the first color layer and the third color pixel formation sections of the third color layer, define second color pixels;the third color pixel formation sections of the third color layer, which are overlapped with the second-and-third color pixel windows of the first color layer and the first and-third color pixel windows of the second color layer, define third color pixels; andwherein first light-shielding sections extending along the first direction are formed by overlapped parts of the first color and the second color layer;second light-shielding sections extending along a second direction perpendicular to the first direction are formed by overlapped parts of the first color layer and the second color layer, overlapped parts of the second color layer and the third color layer, and overlapped parts of the third color layer and the first color layer.

17. The color filter according to claim 16, wherein the second-and-third color pixel windows of the first color layer are defined by connection sections that connect the first color pixel formation sections adjoining to each other; and wherein the first-and-third color pixel windows of the second color layer are defined by connection sections that connect the second color pixel formation sections adjoining to each other.

18. The color filter according to claim 16, wherein peripheries of the third color pixel formation sections are overlapped with the first light-shielding sections to have overlapped widths of 5.0 μm or less.

19. The color filter according to claim 18, further comprising spacers arranged to bury or fill the overlapped peripheries of the third color pixel formation sections with the first light shielding sections.

20. The color filter according to claim 16, wherein peripheries of the third color pixel formation sections are not overlapped with first the light-shielding sections.

21. The color filter according to claim 20, further comprising spacers arranged on the first light-shielding sections.

22. The color filter according to claim 16, wherein the first color layer is one of a red color layer and a blue color layer, and the second color layer is the other.

23. The color filter according to claim 16, wherein the first color layer or the second color layer is a red color layer.

24. A method of fabricating a color filter, comprising: forming a first color layer on a transparent support: the first color layer having stripe-shaped first color pixel formation sections and second-and-third color pixel windows, which are arranged at predetermined intervals along a first direction, respectively:forming a second color layer to overlap with the first color layer: the second color layer having stripe-shaped second color pixel formation sections and first-and-third color pixel windows, which are arranged at predetermined intervals along the first direction, respectively: andforming a third color layer having island-shaped third color pixel formation sections apart from each other:wherein in the step of forming the second color layer, the second color pixel formation sections of the second color layer are overlapped with second color pixel subwindows of the second-and-third color pixel windows of the first color layer: and the first-and-third color pixel windows of the second color layer are respectively overlapped with the first color pixel formation sections of the first color layer and third color pixel subwindows of the second-and-third color pixel windows thereof:wherein in the step of forming the third color layer, the third color pixel formation sections of the third color layer are arranged in the third color pixel subwindows of the second-and-third color pixel windows of the first color layer and the third color pixel subwindows of the first-and-third color pixel windows of the second color layer, the third color pixel subwindows of the second-and-third color pixel windows being overlapped with the third color pixel subwindows of the first-and-third color pixel windows being overlapped;wherein the first color pixel formation sections of the first color layer, which are overlapped with the first-and third color pixel windows of the second color layer and the third color pixel formation sections of the third color layer, define first color pixels; the second color pixel formation sections of the second color layer, which are overlapped with the second-and-third color pixel windows of the first color layer and the third color pixel formation sections of the third color layer, define second color pixels;the third color pixel formation sections of the third color layer, which are overlappedwith the second-and-third color pixel windows of the first color layer and the first and-third color pixel windows of the second color layer, define third color pixels; andwherein first light-shielding sections extending along the first direction are formed by overlapped parts of the first color layer and the second color layer; andsecond light-shielding sections extending along a second direction perpendicular to the first direction are formed by overlapped parts of the first color layer and the second color layer, overlapped parts of the second color layer and the third color layer, and overlapped parts of the third color layer and the first color layer.

25. The method according to claim 24, wherein the second-and-third color pixel windows of the first color layer are defined by connection sections that connect the first color pixel formation sections adjoining to each other; and the first-and-third color pixel windows of the second color layer are defined by connection sections that connect the second color pixel formation sections adjoining to each other.

26. The method according to claim 24, wherein in the step of forming the third color layer, peripheries of the third color pixel formation sections are overlapped with the first light shielding sections to have overlapped widths of 5.0 μm or less.

27. The method according to claim 26, further comprising a step of forming spacers arranged to bury or fill the overlapped peripheries of the third color pixel formation sections with the first light-shielding sections.

28. The method according to claim 26, wherein after the step of forming the third color layer is completed, a step of polishing the third color layer is carried out to remove peripheries of the third color pixel formation sections placed on the first light-shielding sections.

29. The method according to claim 24, wherein the first color layer is one of a red color layer and a blue color layer, and the second color layer is the other.

30. The method according to claim 24, wherein the first color layer or the second color layer is a red color layer.

31. A liquid-crystal display device comprising: a first substrate having the color filter according to claim 1; and a second substrate having active elements for switching.

32. The device according to claim 31, wherein the device is designed to operate in a normally black mode; a common electrode formed on the second substrate comprises shielding sections for shielding electric field leaked from the second substrate: andthe shielding sections conduct their light-shielding operation in vicinities of scanning lines formed on the second substrate.

33. The device according to claim 31, wherein the first light shielding sections of the color filter are used for shielding light at corresponding locations to scanning lines formed on the second substrate: and the second light-shielding sections of the color filter are used for shielding light at corresponding locations to data lines formed on the second substrate.

34. The device according to claim 31, wherein the second light-shielding sections of the color filter are assigned to locations where backlight is shielded by wiring lines formed on the second substrate; and the first light-shielding sections of the color filter are assigned to locations where backlight is not shielded by wiring lines formed on the second substrate.