Patent Application
20080007581
a) and (b) are schematic views for the operation method of an ink jet printing apparatus according to a second method.
a), (b), (c) and (d) are schematic views showing manufacturing steps of a color filter using an ink jet printer.
A method of manufacturing an optical device, a method of manufacturing a color filter, and a method of manufacturing an organic EL device of the invention are to be described specifically with reference to the drawings.
A substrate as an object of coating is mounted on the substrate transporting stage 2. The substrate includes optical devices such as a color filter and an organic electroluminescence device, as well as devices having a fine pattern such as a wiring circuit substrate, biochip, etc. The substrate transporting stage 2 moves along a predetermined transporting direction 11 of the substrate transporting stage. The transporting direction 11 of the substrate transporting stage is in parallel with a main scanning direction.
The ink jet head unit 14 moves on the ink jet head moving shaft 4 along the main scanning direction. The ink jet head unit moving shaft 4 is in perpendicular to the scanning direction 11 of the ink jet head unit. The ink jet head unit is subjected to sub-scanning along the ink jet head unit moving shaft.
Hereinafter, the direction for sub-scanning of the ink jet head unit is defined as a first direction and the direction for main scanning of the ink jet head unit is defined as a second direction.
The substrate transporting stage 2 has vacuum attraction holes for fixing the substrate 1 which can fix the substrate with no protrusion from the surface of the substrate. This can approach the gap between the substrate 1 and the ink jet head 13 to minimum.
The discharge control section 9 incorporates a memory section (not illustrated) for storing measured values for the linearity of a trace in the movement of the ink jet head unit.
This enables to grasp the linearity at an optimal position on the first direction axis of the ink jet head unit and even when the ink jet head unit 14 is not linear relative to the first direction axis at a desired position, the coating accuracy can be amended by changing the discharge timing of the nozzle in accordance with the linearity at that position (displacement).
Displacement of the orientation of the ink jet head from the predetermined direction is referred to as a rotational displacement of the ink jet head. Accordingly, an ink jet coating device has a θ adjust mechanism 15 for amending the displacement in the rotating direction (hereinafter also referred to as θ direction). The θ adjust mechanism 15 can generally adjust a direction for the entire plural ink jet heads upon mounting the plural ink jet heads on the ink jet head unit.
Two detection means (inverted microscope 7) for detecting the rotational displacement of the ink jet head are shown in
The ink jet heads 13 are arranged in parallel along the first direction. Further, since the width of the ink jet head main body is larger than the range for the nozzles, adjacent ink jet heads are arranged in a zig-zag state being displaced along the second direction. Accordingly, ink discharging can be made linear at a good accuracy by changing the discharging timing of nozzles belonging to the ink jet head in accordance with the distance in the second direction present between the ink jet head and an ink jet head adjacent therewith.
Ink is discharged from each of the nozzles 132, and the discharging timing, the number of times and the ink discharge amount of each of the nozzles can be controlled independently.
Now, description is to be made mainly for the manufacturing step for preferred embodiments of the invention. The optical device according to the invention includes various members used as optical parts constituting a display screen of an indication display.
For an optical device as an object of the invention, for example, a color filter constituting a display screen of a color liquid crystal display can be exemplified, in which an ink film forms a coloring ink layer for coloring transparent light, and the coloring ink layer is of plural colors having different colors on every regions.
Further, for the optical device, the organic electroluminescence device can also be exemplified, in which the discharged ink forms an organic light emitting layer. Further, according to the invention, an optical device having organic light emitting layers of plural colors having a different colors on every regions can be manufactured.
In addition, the manufacturing method of the optical device of the invention can be applied in the same manner to the manufacturing method of circuit substrates, thin film transistors, micro lenses, biochips, etc.
The substrate is used as a support substrate for printed products. The kind of the substrate is different depending on the aimed optical device and, for example, known transparent substrate materials such as glass substrates, quartz substrate, plastic substrates, and dry films can be used. Among all, the glass substrate is excellent in view of transparency, strength, heat resistance, and weather proofness in the application use of color filters and organic EL devices.
In the invention, an ink is applied to a substrate by an ink jet printing apparatus to form an optical device. For preventing color mixing (or mixing) between different types of ink to each other, a partition wall is preferably formed on the substrate.
The partition wall has a function of parting the surface of the substrate into plural regions and preventing color mixing of an ink discharged to each of the plural regions. For preventing color mixing, a partition wall showing a predetermined ink repelling effect is desirably used. There can be shown, for example, a method of forming a partition wall with a resin composition portion containing an ink repellent, a method of applying a plasma treatment to a partition wall formed with a resin composition thereby providing the ink repellency, a method of forming a partition wall together with a photocatalyst layer and providing the ink repellency to the partition wall by a photocatalytic effect.
Further, in a case where the optical device is a color filter or an organic EL device constituting the display screen of a display, contrast at the display screen can be improved by providing a light shielding property to the partition wall. In any case, it is necessary to incorporate a resin binder and an ink repellent as essential ingredients, in a case of forming the partition wall with the resin composition.
In addition, an additive having compatibility, for example, a leveling agent, a chain transfer agent, a stabilizer, a sensitizing dye, a surfactant, a coupling agent, etc. can be optionally added to the resin composition.
The partition wall can be formed using a resin composition by a printing method, a photolithographic method, or a transfer method. In a case of forming the partition wall by photolithography, a photosensitive resin composition formed by providing the photosensitivity to a resin composition is used. Further, in a case of forming the partition wall by the printing method, a resin composition such as a thermosetting resin composition can be used.
At first, description is to be made to a case of forming a partition wall by the printing method. A resin composition (hereinafter referred to as a printing material) is printed on a substrate by using a printing apparatus. The printing material comprises a resin binder and an ink repellent as an essential ingredient and, further, contains a crosslinker and a solvent. Further, a black pigment and the additive described above may also be added. The critical surface tension of the printing material is, preferably, from 30 to 40 mN/m. In a case where it is less than 30 mN/m, the printed resin composition is liable to undergo the effect of unevenness on the substrate surface. In a case where it exceeds 40 mN/m, the printability is worsened. Successively, the printing material is heated within a range from 100° C. to 250° C. for 1 min to 60 min.
Description is to be made to a case of forming the partition wall by a photolithographic method. A resin composition (hereinafter referred to as a photosensitive resin composition) is coated on a substrate by using a spin coater, slit coater, etc. The photosensitive resin composition is generally classified into a positive type and a negative type. In a case of the negative type photosensitive resin composition, it contains a resin binder, a monomer, a photopolymerization initiator, and the ink repellent described above. In a case of the positive type photosensitive resin composition, it includes a positive type photosensitive resin, and the ink repellent described above. A crosslinker, a black pigment, a pigment, a solvent, and an additive may further be added optionally to the photosensitive resin composition. The critical surface tension of the photosensitive resin composition is, preferably, from 30 to 40 mN/m. In a case where it is less than 30 mN/m, the coated resin composition is liable to undergo the effect of unevenness on the substrate surface. In a case where it exceeds 40 mN/m, the coatability of the resin composition is worsened.
Successively, the substrate coated at one surface with the photosensitive resin composition is exposed by using a mask of the partition wall pattern. The substrate is developed by a developer to remove an unnecessary photosensitive resin composition and the partition wall is formed on the substrate. In a case where the critical surface tension of the coated resin composition is 30 to 40 mN/m or less, since the ink repellent properly concentrates to the surface during development, development for the lower portion of the resin composition proceeds more compared with an upper portion. As a result, since the partition wall is tapered inversely, it provides an effect that the shape of the ink film discharged and formed by using the ink discharging apparatus is flattened. Then, the partition wall is heated at 100° C. to 250° C. for about 3 min to 60 min.
The resin binder contained in the ink printing material or the photosensitive resin composition secures to fix the partition wall to the substrate and provides an ink resistance to the partition wall. As the binder resin, those resins containing amino group, amide group, carboxyl group, or hydroxyl group are preferred. Specifically, they include, cresol—novolac resin, polyvinyl phenol resin, acryl resin, or methacryl resin. The resin binders may be used each alone or two or more of may be mixed.
The ink repellent contained in the printing material or the photosensitive resin composition provides the partition wall with the ink repellent property to the ink. As the ink repellent, a compound having a portion showing the compatibility with the resin binder and a portion having an ink repellent property for the resin composition can be used. The ink repellent having both of such portions emerges to the partition wall surface along with time or by heating. Then, it remains to the partition wall surface with the portion showing the solubility with the resin binder being on the inner side and the portion having the ink repellent property being on the outside and provides the optimal critical surface tension to the surface. For the portion having the water repellency, fluoro alkyl group can be used, perfluoroalkyl group being more preferred. For the portion showing the compatibility with the resin binder, known oleophilic polymers such as those having alkyl group or alkylene group, polyvinyl alcohol, etc. can be used.
In addition, as the ink repellent, fluoro-containing compounds or silicon-containing compounds to be described later can be used together. Examples of the fluoro-containing compounds include, specifically, vinylidene fluoride, vinyl fluoride, ethylene trifluoride or fluoro resin such as copolymers thereof. Further, the fluoro-containing compounds can be used each alone or two or more of them may be used in combination. The silicon-containing compounds include those having organic silicon in the main chain or on the side chain and include silicon resins and silicone rubber containing siloxane ingredient. Further, the silicon-containing compounds can be used each alone or two or more of them may be used in combination. Further, the fluoro-containing compounds and the silicon-containing compounds, or other ink repellent ingredients may also be used in combination. The ink repellent is contained in the resin composition preferably by 0.01% by weight to 10% by weight.
The black pigment provides the partition wall with a light shielding property to improve the contrast on the display screen. As the black light shielding member, black pigment, black dye, carbon black, aniline black, graphite, iron black, titanium oxide, inorganic pigment, and organic pigment can be used. The black light shielding members may be used each alone or two or more of them may be mixed.
As examples of the solvent, dichloromethane, dichloroethane, chloroform, acetone, cyclohexanone, ethyl acetate, 2-methoxy ethanol, 2-ethoxy ethanol, 2-butoxy ethanol, 2-ethyl ethoxy acetate, 2-butoxy ethyl acetate, 2-methoxy ethyl ether, 2-ethoxy ethyl ether, 2-(2-ethoxyethoxy)ethanol, 2-(2-butoxyethoxy)ethanol, 2-(2′-ethoxyethoxy)ethyl acetate, 2-(2-butoxyethoxy)ethyl acetate, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, diethylene glycol dimethyl ether, tetrahydrofuran, etc. can be used. The amount of the solvent to be used is desirably such that it can form a uniform coating film with no pinholes or coating unevenness upon printing or coating on the substrate. For the content ratio of the solvent, it is preferred that the amount of solvent is 50 to 97% by weight based on the entire weight of the resin composition.
As the monomer applicable to the photosensitive resin composition, monomers or oligomers having vinyl group or allyl group, and molecules having vinyl group or allyl group on one terminal end or on the side chain can be used. They include, specifically, (meth)acrylic acid and salt thereof, (meth)acrylic acid esters, (meth)acrylamides, maleic acids anhydride, maleic acid ester, itaconic acid ester, styrenes, vinyl ethers, vinyl esters, N-vinyl heterocyclic rings, allyl ethers, allyl esters, and derivatives thereof. Preferred compounds include, for example, relatively low molecular weight polyfunctional acrylates such as pentaerythritol triacrylate, trimethylol propane triacrylate, pentaerythritol tetraacrylate, ditrimethylol propane tetracrylate, ditrimethylol propane tetraacrylate, and dipentaerythritol penta and hexa acrylates. Monomers may be used each alone or two or more of them may be mixed. The amount of the monomer can be within a range from 1 to 200 parts by weight and, preferably, from 50 to 150 parts by weight based on 100 parts by weight of the binder resin.
Examples of the photopolymerization initiator include benzophenone compounds such as benzophenone, 4,4′-bis(dimethylamino)benzophenone, 4,4′-bis(diethylamino)benzophenone. Further, as the photopolymerization initiator, acetophenone derivatives such as 1-hydroxycyclohexyl acetophenone, 2,2-dimethoxy-2-phenylacetophenone, and 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropane-1-on may also be used. Further, thioxanthone derivatives such as thioxanthone, 2,4-diethylthioxantone, 2-isopropylthioxantone, or 2-chlorothioxantone may also be used. Further, they may be anthraquinone derivatives such as 2-methyl anthraquinone, 2-ethyl anthraquinone, 2-t-butyl anthraquinone, and chloro anthraquinone. Further, benzoin ether derivatives such as benzoin methyl ether, benzoin ethyl ether, or benzoin phenyl ether can also be used. Further, they include acylphosphine derivatives such as phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide, rofin dimmers such as 2-(o-chlorophenyl)-4,5-bis(4′-methylphenyl)imidazolyl dimer, N-arylglycines such as N-phenylglycine, organic azides such as 4,4′-diazide calchone, and 3,3′,4,4′-tetra(tert-butylperoxy carboxy)benzophenone, and quinone diazide group-containing compound, etc. The photopolymerization initiator may be used alone or two or more of them may be mixed together. The amount of the photopolymerization initiator can be within a range from 0.1 to 50 parts by weight and, preferably, from 1 to 20 parts by weight based on 100 parts by weight of the binder resin.
As the additive, for example, a leveling agent, a chain transfer agent, a stabilizer, a sensitizing dye, a surfactant, or a coupling agent can be added.
Successively, an ink is applied to a substrate by an ink jet printing apparatus to form an optical device. In the following, a method of manufacturing a color filter of RBG three colors having a coloring ink layer is to be described, for example, in a case of forming a color filter as an optical device. Instead of the coloring ink layer, an organic light emitting layer can also be formed.
As described above, for a manufacturing method of the color filter by using the ink jet printing apparatus, a method of discharging an ink while aligning the direction of the ink applied in a stripe shape and the main scanning direction in parallel with each other (the first method described above) has been known. Further it has been known a method of discharging the ink while aligning the direction of the ink applied in a stripe shape and the main scanning direction in perpendicular to each other (second method described above).
Ink jet heads 42 for jetting coloring inks of RBG three colors are arranged respectively (three in total). The ink jet head 42 is disposed such that nozzles are arranged substantially in perpendicular to the main scanning direction (second direction 44).
The three ink jet heads constitute a not separable integral single ink jet head unit. The ink jet head unit is caused to scan in the second direction to form a coloring ink layer 43 for RBG three colors (
In this case, upon discharge from the nozzle, it was necessary to conduct discharging operation for the adjacent nozzles simultaneously for maintaining a predetermined pixel density, this resulted in the problem of making the discharging amount instable or worsening the accuracy due to the effect of vibrations between the nozzles to each other which are present in the vicinity. The foregoing problem has been overcome according to the invention by adopting the following constitution. Details for the mechanism are shown below.
In the first aspect, the invention provides a method of manufacturing an optical device of printing and forming an optical device constituted by arranging plural elongate pixels on a substrate on every pixels by using an ink jet head, determining plural discharging positions to the inside of each of the pixels, determining plural discharging positions to positions different from each other in the longitudinal direction of the pixel, and repeating the unit step of discharging and printing an ink to each of the plural discharging positions, thereby printing the pixels the ink jet head having plural nozzles corresponding to the plural discharging positions, and the plural nozzles discharging inks on every nozzles, specifying each of the plural nozzles by a natural number n counted sequentially from the end of the pixel, defining a surplus as b when dividing the natural number n with the repetitive number a (b is an integer satisfying: 0≦b≦a−1), and corresponding the surplus b to each of the plural nozzles,
the unit step being a step of selectively discharging the ink from one or more of the nozzles corresponding to the surplus b of a specified value and printing the same at the discharging position, and
repeating the unit step for all the elements b of the assembly B thereby printing the pixel, while defining the assembly B for the surplus b as: B={b|b is an integer satisfying: 0≦b≦a−1}, thereby printing the pixel.
According to the invention, a number n (natural number starting from 1) is sequentially allocated to the nozzles orderly from the one present at the end on every nozzles of the ink jet head (refer to
The repetitive number a is previously set before printing and selected from natural numbers of 2 or more.
In a case where the repetitive number a is excessively large, this results in a problem of complicating the discharging operation or worsening the accuracy, or increasing the size of the ink jet head. On the other hand, in a case where it is excessively small, effects of vibrations between each of the nozzles (crosstalk) can not be decreased sufficiently. Accordingly, the repetitive number a is preferably a natural number of any one of 3 to 5.
Then, after setting the number of discharging condition on every nozzles, an optional number (B1) is selected from the natural numbers of 0 to (a−1) and the ink is selectively discharged only from the nozzles where the number is equal with the surplus (referred to as initial discharge). With such a constitution, the effect of discharging vibrations of adjacent nozzles can be lowered, compared with the case of simultaneous discharge from all the nozzles. Further, since the nozzles conducting the discharging operation simultaneously are always separated by (a)×(distance between the adjacent nozzles to each other), this does not vary the effect of the nozzle discharging vibrations, and “variation of discharge” derived from “vibration in the effect of crosstalk” can be minimized.
Further, the number set as described above is set to another number (B2) again and the ink is discharged selectively only from the nozzle where another number and the parameter for the discharging condition are equal (next discharge). Then, since the nozzle used for the first discharge and the nozzle used for the next discharge are different, the effect of discharging vibrations of the nozzle can be decreased compared with the case of continuous discharge from the identical nozzle.
Further, “a further number (B3)” different from “another number” is selected, and discharge can be conducted in the same manner. “Further number (B3)” is preferably a number that is different from the number (B1) at the first discharge except for the case: a=2. By changing the number periodically stable discharge can be attained. As an example,
Further in the second aspect of the invention, nozzles are preferably arranged as described below. In a method of printing the pixel by repeating the unit step continuously while relatively moving the plural nozzles and the substrate in the lateral direction of the pixel, two or more nozzles having the value for the surplus b identical with each other are arranged to the ink jet head so as to reach the discharging positions at an identical timing, while the nozzles having the value for the surplus b different from each other are arranged to the ink jet head so as to reach the discharging positions at timings different from each other.
Specifically, in a case of selecting an optional nozzle n in the ink jet head, and defining the position of the nozzle along the second direction as Y(n), the position Y(n+a) for the nozzle at (n+a)th position from the end of the ink jet head is made equal with Y(n).
While the nozzle position Y(n) up to n=1−a can be set optionally, it is preferably arranged by the method to be described later. As an example,
As described above, since the nozzle at an optional nth position and the nozzle at the (n+a)th position always conduct discharge simultaneously, the discharged ink is applied linearly to the substrate at a good accuracy by arranging the nozzles as described above in the ink jet head.
Further, by arranging the adjacent nozzles being displaced from each other in the second direction, the effect that vibrations of the nozzle used for discharge remain for a while after discharge to give vibrations to the adjacent nozzle can be minimized compared with a case of arranging all the nozzles on a linear line.
The method described above is particularly effective in a case of manufacturing an optical device using a piezo type ink jet head and adopting the second method. According to the method, an optical device having a stripe pattern such as a color filter at high quality not causing color mixing, blanking failure, etc. can be provided.
Further, discharge is preferably conducted as described below.
A method of manufacturing an optical device as in the first or second aspect of the invention of
specifying each of the plural nozzles in the ink jet head with a natural number n counted sequentially from the end of the pixel, specifying the repetitive number a,
calculating a surplus bn of a nozzle according to equation (1) and equation (2),
providing a time T[sec],
defining the surplus b that the ink jet head specifies at that time as a function β[T] represented by an equation (3),
advancing the time T upon starting discharge, and conducting discharge from the nozzles for the entire ink jet head so as to satisfy an equation (4) at an arbitrary time T:
(in which (x)mod(y) is a function deriving an integer as a surplus when dividing an integer x with an integer y. f(x) is a function deriving an integer by cutting off the decimal fraction of a real number (x) and
π is a positive real number (unit: sec)).
According to the equation (3), β(T) is: β(T)=0 at T=0 (sec), β(T)=1 at T=π (sec), β(T)=2 (excluding a case where a=2) at T=2π (sec), increases periodically each by one on every π(sec) unless exceeding:β(T)=a−1, and β(T)=0 after further lapse of π(sec) at:β(T)=a−1. As an example,
Further, in the method 3, it is desired to conduct discharge as described below. A method of manufacturing an optical device as described in the third aspect of the invention wherein the method includes; specifying each of the plural nozzles in the ink jet head by a natural number n counted sequentially from the end of the pixel, and defining the position of the nozzle along the second direction as Y(n),
arranging the nozzle belonging to the ink jet head and situated at an (n+a)th position from the end of the inkjet head so as to satisfy an equation (5),
conducting discharge in each of the nozzles (excluding the nozzles at n=(multiple number of a)) so as to satisfy an equation (6), defining the ingredient along the second direction in the speed of the main scanning of the ink jet head as V[m/sec], selecting an optional nozzle in the ink jet head, and defining the number counted from the nozzle present at the extreme end of the ink jet head that the nozzle belongs to:
Y(n+a)=Y(n) (5)
Y(bn+2)−Y(bn+1)=Vπ (6)
In the fourth method, nozzles are at first arranged to the ink jet head based on the same method as described above. All the nozzles are arranged such that the position Y(n) of the nth nozzle in the second direction is identical with the position Y(n+a) in the second direction of the next nozzle separated by the number of a in the second direction to form a pattern by nozzles repeating on every number of a in the ink jet head.
Further, β(T) is set in the same manner as the third aspect of the invention. Then, nozzles are arranged so as to satisfy the equation (6) for all the nozzles excluding the nozzle at n=(multiple number of a) and discharge is conducted.
That is, assuming the main scanning speed as V[m/sec], nozzles are arranged, in principle, such that nozzle distance (161, 162) between the adjacent nozzles in the second direction is displaced by Vπ[m] (
However, in a case of nozzles at: n=multiple number of a (a=3, n=3, 6, 9, 12 in a case shown in
Successively, after lapse of time π into a next state (T=π), discharge is conducted simultaneously only from the nozzle 104 at surplus bn=1 in the ink jet head 103. In this case, the ink jet head 103 has moved from the initial state by a distance (Vπ[m]) of the speed component V along the second direction of the main scanning speed multiplied by time π (sec). Accordingly, by previously arranging for the nozzle 102 and the nozzle 104 at the positions along the second direction being displaced by Vπ[m], the ink could be applied to the identical position in the second direction also in the discharge at the next state (T=π) with that of the ink discharged in the initial state. Further, also in the discharge in the next state (T=2π), discharge is conducted simultaneously only from the nozzle 106 at surplus bn=2 in the ink jet head 105. In this case, the ink jet head 105 has moved by a distance (2 Vπ) of the speed component V along the second direction of the main scanning speed multiplied by time 2π (sec). Then, by arranging the nozzle 102 and the nozzle 106 at the positions along the second direction being previously displaced by 2 Vπ, the ink could be applied to the identical position in the second direction with that for the ink discharged in the initial state.
According to the invention, a stripe pattern could be formed accurately while suppressing the occurrence of crosstalk by not conducting discharge simultaneously from the nozzles in the ink jet head and by displacing the nozzle position by a predetermined position depending on the surplus for the nozzle and the main scanning speed.
Successively, a fifth method is to be described. According to the method, the pixel is printed in the second method described above while controlling the timing of ink discharge based on the length of the pixel width, the distance between the plural nozzles to each other, and the moving speed of the nozzle and the substrate.
Specifically, in this aspect the invention provides a method of manufacturing an optical device of specifying each of nozzle projection images upon projection of the plural nozzles on a line showing the second direction (lateral direction of pixel) with a sequence U as counted from the top end in the second direction (lateral direction of pixel), defining the distance between each of the nozzle projection images as D, the width of the pixel as L, the moving speed as V and the timing at which ink is started to discharge from the nozzle with the value “1” for the sequence U as T1start and starting discharge from a nozzle corresponding to the sequence U of a specified value at a timing TUstart satisfying the following equation (7), printing the ink to the position described above, and then stopping the discharge thereof at a timing TUstop satisfying a following equation (8)
T
U
Start
=T
1
start+(U−1)×D/V (7)
T
U
stop
=T
U
Start
+L/V (8)
According to the fifth method, plural nozzles are projected on a line showing the second direction for all the nozzles. Then, the sequence of the respective nozzle projection images in the second direction is defined as sequence U. In this case, the sequence U at the nozzle discharging for the first time is defined as 1.
According to the method, since the timing TUstart for starting the discharge from the nozzle at the sequence U is displaced in accordance with the sequence U from T1start by an (inter-nozzle projection image distance D)/V, discharge can be started in any nozzle always at the instance the nozzle reaches an aimed pixel.
Further, according to the method, since the discharge stopping timing TUstop for the sequence U is displaced from TUstart by a (pixel width L)/V in accordance with the sequence U, discharge can be stopped in any nozzle always at the instance where passage of the nozzle on the aimed pixel has been completed. Then, in any nozzle, the discharge time (TUstop−TUstart) is equal with L/V.
According to the method, an elongate pixel can be formed at high accuracy and with no occurrence of failure such as “whitening” or “color shading” while displacing the timing at which each of the nozzles substantially conducts discharge and reducing the interference of vibrations between the nozzles to each other.
In addition, besides these methods, an optical element can be formed by the following method:
At first ink is discharged for one pixel only from selected nozzles among all nozzles; subsequently ink is discharged only from other selected nozzles; and a pixel is formed by repeating these processes.
The selected nozzles may be further separated nozzles equal to or more than 2.
In a case of forming a color filter as an optical device, discharge is conducted by using a coloring ink from a ink jet printing apparatus. The coloring ink can optionally contain a coloring pigment, a solvent, and a resin binder. As the solvent and the resin binder, same materials as those described for “Formation of partition wall” can be used.
The followings can be used as the coloring pigment in accordance with the color.
The red coloring pigment includes, C.I. Pigment Violet 19, C.I. Pigment Violet 23, C.I. Pigment Violet 29, C.I. Pigment Violet 30, C.I. Pigment Violet 37, C.I. Pigment Violet 40, C.I. Pigment Violet 50, C.I. Pigment Red 7, C.I. Pigment Red 9, C.I. Pigment Red 14, C.I. Pigment Red 41, C.I. Pigment Red 48:1, C.I. Pigment Red 48:2, C.I. Pigment Red 48:3, C.I. Pigment Red 48:4, C.I. Pigment Red 97, C.I. Pigment Red 122, C.I. Pigment Red 123, C.I. Pigment Red 146, C.I. Pigment Red 149, C.I. Pigment Red 177, C.I. Pigment Red 178, C.I. Pigment Red 180, C.I. Pigment Red 184, C.I. Pigment Red 185, C.I. Pigment Red 187, C.I. Pigment Red 192, C.I. Pigment Red 200, C.I. Pigment Red 202, C.I. Pigment Red 208, C.I. Pigment Red 210, C.I. Pigment Red 216, C.I. Pigment Red 220, C.I. Pigment Red 221, C.I. Pigment Red 223, C.I. Pigment Red 226, C.I. Pigment Red 227, C.I. Pigment Red 240, C.I. Pigment Red 246, C.I. Pigment Red 255, C.I. Pigment Red 264, C.I. Pigment Red 272, etc. Further, a mixture of C.I. Pigment Red 254 and C.I. Pigment Red 177 can also be used.
Further, as the green coloring pigment, C.I. Pigment Green 7, and C.I. Pigment Green 36 can be used. Further, a mixture of C.I. Pigment Green 36 and C.I. Pigment Yellow 150, C.I. Pigment Yellow 139, or C.I. Pigment Yellow 13 can be used.
Further, the blue coloring pigment includes C.I. Pigment Blue 15, C.I. Pigment Blue 15:3, C.I. Pigment Blue 15:4, C.I. Pigment Blue 15:6, C.I. Pigment Blue 22, C.I. Pigment Blue 60, etc. Further, the pigments mentioned above may also be used as a mixture of two or more of them.
In a case of forming an organic EL device as the optical device, an ink containing an organic light emitting material is used and discharged from a ink jet printing apparatus. The ink may optionally contains an organic light emitting material, a solvent, and a resin binder. For the solvent and the resin binder, same materials as those described above for (Formation of partition wall) can be used.
The organic light emitting material includes organic light emitting material soluble to organic solvent such as coumarin, perylene, pyran, anthrone, porphylene, quinacrydone, N,N′-dialkyl substituted quinacridone, nathalimide, N,N′-diaryl substituted pyrolopyrrole, iridium complex type, those organic light emitting materials dispersed in polymers such as polystyrene, polymethyl methacrylate, and polyvinyl carbazole, and polymeric organic light emitting materials such as polyarylene, polyarylene vinylene or polyfluorene types.
The first aspect of the invention provides a method of manufacturing an optical device of printing and forming an optical device constituted by arranging plural elongate pixels on a substrate on every pixels by using an ink jet head, determining plural discharging positions to the inside of each of the pixels, determining the plural discharging positions to positions different from each other in the longitudinal direction of the pixels, repeating the unit step of discharging and printing an ink to each of the plural discharging positions, thereby printing the pixels;
the ink jet head having plural nozzles corresponding to the plural discharging positions,
the plural nozzles discharging inks on every nozzles,
specifying each of the plural nozzles with a natural number n counted sequentially from the end of the pixel, defining a surplus as b when dividing the natural number n with a repetitive number a (b is an integer satisfying: 0≦b≦a−1), corresponding the surplus b to each of the plural nozzles,
the unit step being a step of selectively discharging the ink from one or more of the nozzles corresponding to the surplus b of a specified value and printing the same at the discharging position,
defining an assembly B for the unit step of conducting discharge from the nozzle corresponding to the surplus b as: B={b|b is an integer satisfying 0≦b≦a−1}, and
repeating the unit step for all the elements b contained in the assembly B thereby printing the pixel.
That is, the first aspect of the invention provides a method used in a case of manufacturing an optical device by the second method using an ink jet printing apparatus having a single or two or more ink jet heads.
The first aspect of the invention provides a method of manufacturing an optical device constituting by arranging plural elongate pixels. The pattern formed by arranging plural elongate pixels include a stripe pattern and a grid pattern.
In the first aspect of the invention, plural discharging positions are defined at different positions along the longitudinal direction of a pixel in the inside of the elongate pixel for a specified pixel.
In the first aspect of the invention, a repetitive number a is at first set. Further, a number n from 1 to N is allocated sequentially to the nozzles arranged by the number of N to the ink jet head from the nozzle present at an extreme end.
Then, a surplus b is allocated to each of nozzles such that the nozzles by the number of N belong to any of predetermined repetitive numbers a. Specifically, n is divided with the repetitive number a to determine a surplus, which is set as a surplus b to each of the nozzles. In this way, the surplus b selected from 0 to (a−1) is provided to all the nozzles 1-N.
Among the nozzles belonging to the ink jet head, discharge is conducted only from the nozzle having a surplus b equal with an optional integer (as B1) selected from integers of 0 or more and (a−1) or less. The step is referred to as a unit step.
Successively, discharge is conducted only from the nozzles having the surplus b equal with an optional integer (as B2) different from B1 selected from integers of 0 or more and (a−1) or less.
Further, discharge can be conducted successively only from the nozzles having a surplus b equal with an optical integer (as B3) different from B2 selected from integers of 0 or more and (a−1) or less.
Then, the unit step is conducted for an assembly B={b| 0≦b≦a−1} for all the surplus b satisfying: 0≦b≦a−1.
As described above, by determining a specified integer and conducting discharge simultaneously only from the nozzles having a surplus equal with the integer and a step of changing the integer alternately, the distance for the nozzles conducting discharge simultaneously is always kept at: repetitive number a×(nozzle distance).
Accordingly, effects of vibrations between nozzles conducting discharge simultaneously can be decreased or eliminated compared with a case of conducting discharge from all the nozzles simultaneously.
The second aspect of the invention provides a method of manufacturing an optical device of repeating the unit step continuously while relatively moving the plural nozzles and the substrate in the lateral direction of pixel in the method of printing the pixel as described above, wherein,
the plural nozzles are disposed in the ink jet head, the ink jet head and the substrate are moved relatively in the lateral direction of the pixel, thereby moving the plural nozzles and the substrate relatively in the lateral direction of the pixel,
two or more of nozzles having the values of the surplus b identical with each other are disposed in the ink jet head so as to reach the discharge positions at an identical timing, while the nozzles having the values of the surplus b are different from each other are disposed in the ink jet head so as to reach the discharging positions at timings different from each other, and
the unit step is a step of starting ink discharge selectively from two or more of the nozzles reaching the discharging positions and conducting printing at the discharging positions along with relative movement of the ink jet head and the substrate in the lateral direction, at the timing when two or more of the nozzles having values of the surplus b identical with each other reach the discharging positions.
That is, in the second aspect of the invention, the ink jet head is moved relatively in the lateral direction of the elongate pixel on the basis of simultaneously conducting discharge from plural nozzles having an identical surplus b.
Then, in the second aspect of the invention, not only the discharge is conducted at the same timing from two or more of the nozzles where the values of surplus b are identical with each other upon ink discharge but also the operation is conducted such that they reach the discharging positions simultaneously.
The second aspect of the invention can be practiced by arranging the nozzles belonging to the ink jet head while periodically displacing them in the lateral direction of the pixel (hereinafter referred to also as a second direction) in accordance with the surplus b of the nozzle on the basis of arranging them at a uniform distance substantially in the longitudinal direction of the pixel (hereinafter referred to as first direction) as a whole. With such an arrangement, since the positional components in the second direction are equal in each of the positional components of the nozzles where the surplus b is equal, the discharging timing is identical with the nozzles having the equal surplus b upon scanning the ink jet head along the second direction.
In other words, nozzles are arranged such that two or more of the nozzles where the values of surplus b are identical reach the discharging positions at an identical timing. Specifically, the position of the nth nozzle along the second direction when allocating the number to the nozzle is made identical or substantially identical with the position of the (n+a)th nozzle along the second direction by the method described above.
Then, expressing the position of the nozzle in the second direction when the number n is allocated to the nozzle by the method described above as Y(n), Y(n+a) is made equal with Y(n). Further, an optional position can be set from the position (Y(1)) of the first nozzle along the second direction to the position (Y(a−1)) of the (a−1)th nozzle along the second direction.
According to the second aspect of the invention, in “the step of conducting discharge simultaneously only from the nozzles having a specified surplus b” of the first aspect of the invention, an ink discharged in the step has been applied linearly to the substrate at a good accuracy. Accordingly, in the manufacture of an optical device having a stripe pattern such as a color filter, a product at high quality with no occurrence of color mixing or whitening failure can be provided.
The third aspect of the invention provides a method of manufacturing an optical device according to the first or the second aspect, wherein the method includes, specifying each of the plural nozzles in the ink jet head with a natural number n counted sequentially from the end of the pixel, specifying a repetitive number a, calculating a surplus bn of a nozzle according to an equation (1) and an equation (2), providing a time T[sec], defining the surplus b that the ink jet head specifies at that time as a function β[T] represented by an equation (3), advancing the time T upon starting discharge, and conducting discharge from the nozzles for the entire ink jet head so as to satisfy an equation (4) at an arbitrary time
(in which (x)mod(y) is a function deriving an integer as a surplus when dividing an integer x with an integer y. f(x) is a function deriving an integer by cutting off a decimal fraction of a real number (x) and n is a positive real number (unit: sec)).
That is, in the third aspect of the invention, the surplus b for the nth nozzle is set as bn when allocating the number to the nozzle by the method described above. Further, the surplus b for discharge is defined as a function β(T) that changes with time T. π can be selected from optional real numbers previously.
Then, at a certain time T, discharge is conducted simultaneously only from the nozzles at the positions satisfying the equation (4). In this case, β(T) is represented by the equation (3)
The fourth aspect of the invention provides a method of manufacturing an optical device of specifying the plural nozzles in the ink jet head with a natural number n counted sequentially from the end of the pixel, defining the position of the nozzle in the second direction as Y(n),
arranging nozzles belonging to the ink jet head and situated at (n+a)th position from the end of the in jet head so as to satisfy an equation (5),
conducting discharge in each of the nozzles (excluding the nozzles at n=(multiple number of a)) so as to satisfy an equation (6), defining the ingredient along the second direction in the speed of the main scanning of the ink jet head as V[m/sec] , selecting an optional nozzle in the ink jet head, and defining the number counted from the nozzle present at the extreme end of the ink jet head that the nozzle belongs to:
Y(n+a)=Y(n) (5)
Y(bn+2)−Y(bn+1)=Vπ (6)
That is, in the fourth aspect of the invention nozzles are at first arranged in the ink jet head based on the same method as described in the second aspect of the invention. All the nozzles are arranged such that the position Y(n) in the second direction of the nth nozzle is identical with the position Y(n+a) in the second direction of the next nozzle separated by the number of a to form a pattern of nozzles repeating on every number of a in the ink jet head.
Further, β(T) is set in the same manner as the third aspect of the invention. Then, nozzles are arranged so as to satisfy the equation (5) for all the nozzles excluding the nozzle at n=(multiple number of a) and discharge is conducted.
That is, assuming the main scanning speed as V[m/sec], nozzles are arranged, in principle, such that nozzle distance (161, 162) between the adjacent nozzles in the second direction are displaced by Vπ[m] (
However, in a case of nozzles at: n=multiple number of a (a=3, n=3, 6, 9, 12 in a case shown in
Successively, in the next state (T=π) after lapse of time π (sec), discharge is conducted simultaneously only from the nozzles 104 at surplus bn=1 in the ink jet head 103. In this case, the ink jet head 103 has moved from the initial state by a distance (Vπ[m]) of the speed component V along the second direction of the main scanning speed multiplied by time π (sec). Accordingly, by arranging the nozzle 102 and the nozzle 104 at the positions along the second direction being previously displaced by Vπ[m], the ink could be applied also in the discharge in the next time (T=2π) to the identical position in the second direction with that for the ink discharged in the initial state. Further, also in the discharge in the next state (T=2π), the ink is discharged simultaneously only from the nozzles 106 at the surplus bn=2 in the ink jet head 105. In this case, the ink jet head 105 has moved by a distance (2 Vπ) for the speed component V along the second direction of the main scanning speed multiplied by a time 2π (sec). Then, by arranging the nozzle 102 and the nozzle 106 at the position along the second direction being previously displaced by 2 Vπ, the ink could be applied also in the discharge in the next state (T=2π) to the identical position in the direction with that for the ink discharged in the initial state.
According to the invention, since discharged is not conducted simultaneously from the nozzles in the ink jet head, a stripe pattern could be formed accurately while suppressing the occurrence of crosstalk and by displacing the nozzle position by a predetermined position depending on the discharging condition parameter and the main scanning speed.
The fifth aspect of the invention provides a following method of manufacturing an optical device.
A method of manufacturing an optical device of printing and forming an optical device constituted by arranging plural elongate pixels on a substrate on every pixels by using an ink jet head;
determining plural discharging positions to the inside of each of the pixels, determining the plural discharging positions to positions different from each other in the longitudinal direction of the pixel, and repeating unit step of discharging and printing an ink to each of the plural discharging positions, thereby printing the pixels,
the ink jet head having plural nozzles corresponding to the plural discharging positions, and the plural nozzles discharging inks on every nozzles, wherein
at first ink is discharged for one pixel only from selected nozzles among all nozzles,
subsequently ink is discharged only from other selected nozzles, and
a pixel is formed by repeating these processes.
Accordingly, effects of vibrations between nozzles conducting discharge simultaneously can be decreased or eliminated compared with a case of conducting discharge from all the nozzles simultaneously.
The sixth aspect of the invention provides a following method of manufacturing an optical device according to the fifth aspect of the invention.
The selected nozzles may be separated nozzles equal to or more than 2.
Accordingly, effects of vibrations between nozzles conducting discharge simultaneously can be decreased or eliminated compared with a case of conducting discharge from all the nozzles simultaneously.
The seventh aspect of the invention provides a method of manufacturing a color filter of forming a coloring ink layer on a substrate by using the manufacturing method of the optical device according to the first aspect of the invention described above.
According to this aspect of the invention, a color filter having a good linear accuracy of the coloring ink layer can be manufactured in the manufacture of the color filter having a stripe-like coloring ink layer using the second method described above. Accordingly, “color mixing”, “whitening”, and “color shading” in the coloring ink layer caused by the failure of the hitting accuracy of the ink could be prevented.
The eighth aspect of the invention provides a method of manufacturing a color filter according to the seventh aspect described above wherein the substrate is a glass substrate. A color filter-excellent in heat resistance, whether proofness, and chemical resistance could be provided by the containment of the pigment in the ink.
The ninth aspect of the invention provides a method of manufacturing a color filter according to the seventh aspect described above, wherein the ink is a coloring ink containing a coloring pigment of a color selected from red, blue and green. A color filter excellent in the heat resistance, weather proofness and chemical resistance could be provided by the incorporation of the pigment in the ink.
The tenth aspect of the invention provides a method of manufacturing a color filter according to the seventh aspect described above, wherein inks for red, blue, and green are discharged simultaneously as the coloring layers by using an ink jet head unit having ink jet heads discharging coloring inks of red (R), blue (B), and green (G). A color filter of a RGB three colors not causing color shading, color mixing, and whitening for any of the colors could be manufactured by using the manufacturing method of the optical device described above in the discharge of any of RGB three colors.
The eleventh aspect of the invention provides a method of manufacturing a color filter according to the fifth aspect described above, wherein partition walls for parting the surface of the substrate into plural regions are disposed on the substrate, and inks are discharged into a plural regions from the ink jet head. A color filter of high quality while reliably preventing the occurrence of color mixing by disposing the partition walls for parting into the plural regions on the substrate and discharging the coloring inks into the plural regions.
The twelfth aspect of the invention is a method of manufacturing a color filter according to the ninth aspect described above, wherein the partition wall is formed of a resin containing a black pigment. Since the partition wall shields the light passing through the partition wall by the incorporation of the black pigment in the partition wall, it has an effect acting as a black matrix. Accordingly, a color filter of good contrast could be provided.
The 13th aspect of the invention provides a method of manufacturing a color filter according to the ninth aspect described above wherein the partition wall is formed of a resin containing an ink repellent ingredient. Since the partition wall includes the ink repellent ingredient, the effect of the partition wall of preventing color mixing is enhanced and a color filter of higher quality could be provided.
The 14th aspect of the invention provides a method of manufacturing a color filter according to the seventh aspect, wherein the viscosity of the coloring ink is from 2 to 20·mPa·s. By setting the viscosity of the coloring ink to 2 mPa·s or more, the effect of the crosstalk in the ink jet head can be decreased to prevent color mixing or the like. Further, by setting the viscosity of the coloring ink to 20 mPa·s or less, the shape of the coloring ink layer can be made favorable to decrease the color shading.
The 15th aspect of the invention provides a method of manufacturing a color filter according to the seventh aspect described above, wherein the coloring ink layer is formed into a stripe-like repetitive pattern or a grid-like repetitive pattern such that the pattern for each of colors is in parallel with the first direction (direction perpendicular to the main scanning direction). By forming the coloring ink layer into a stripe-like repetitive pattern or a grid-like repetitive pattern in parallel with the first direction, a coloring ink layer could be formed at a good accuracy and efficiently by using the method of manufacturing the optical device described above.
The 16th aspect of the invention provides a method of manufacturing an organic electroluminescence device as described above, wherein an organic light emitting layer is formed on the substrate by the method of manufacturing the optical device according to any one of first to sixth aspects described above. According to this aspect, an organic electroluminescence device of good linear accuracy for the organic light emitting layer could be prepared in the manufacture of the organic electroluminescence device having the stripe-like organic light emitting layer using the second method described above. Accordingly, “color mixing”, “whitening”, and “color shading” in the organic light emitting layer caused by the failure of the hitting accuracy of the ink could be prevented.
The 17th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 16th aspect described above, wherein the substrate is a glass substrate or a film-like substrate. An organic electroluminescence device of excellent heat resistance, weather proofness and chemical resistance could be provided by the use of the glass substrate. Further, it was possible to manufacture an organic EL device having flexibility by the use of the film-like substrate.
The 18th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 16th aspect described above, wherein the ink is an ink containing an organic light emitting material of a color selected from red, blue and green. By using the method of manufacturing the optical device described above in the discharge of at least one of RGB three colors, an organic EL device of RGB three colors not causing color shading (light emission unevenness), color mixing, whitening for each of the colors could be manufactured by using the method of manufacturing the optical device described above.
The 19th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 18th aspect described above, wherein inks for red, blue and green are discharged simultaneously as the organic light emitting layers by using an ink jet head unit having ink jet heads for discharging red, blue and green inks. By using the method of manufacturing the optical device also for the discharging any of the RGB three colors, an organic EL device of RGB three colors not causing color shading (light emitting unevenness), color mixing, and whitening in the organic light emitting layer for all the colors could be manufactured.
The 20th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 16th aspect described above, wherein partition walls for parting the surface of the substrate into plural regions are disposed on the substrate, and inks are discharged into plural regions from the ink jet head. By providing the partition walls for parting into plural regions on the substrate and discharging inks into the plural regions, an organic EL device of high quality could be provided while reliably preventing color mixing.
The 21th aspect of the invention is a method of manufacturing an organic electroluminescence device according to the 20th aspect described above, wherein the partition wall is formed of a resin containing a black pigment.
Since the partition wall shields the light passing through the partition wall by the incorporation of the black pigment in the partition wall, it has an effect acting as a black matrix. Accordingly, an organic EL device filter of good contrast could be provided.
The 22th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 20th aspect described above wherein the partition wall is formed of a resin containing an ink repellent ingredient. Since the partition wall includes the ink repellent ingredient, the effect of the partition wall of preventing color mixing is enhanced and an organic EL device of higher quality could be provided.
The 23st aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 16th aspects described above, wherein the viscosity of the coloring ink is from 2 to 20 mPa·s. By setting the viscosity of the coloring ink to 2 mPa·s or more, the effect of the crosstalk in the ink jet head can be decreased to prevent color mixing or the like. Further, by setting the viscosity of the coloring to 20 mPa·s or less, the shape of the organic light emitting layer can be made favorable to decrease the color shading.
The 24th aspect of the invention provides a method of manufacturing an organic electroluminescence device according to the 16th aspect described above, wherein the organic light emitting layer is formed into a stripe-like repetitive pattern or a grid-like repetitive pattern such that the pattern for each of colors is in parallel with the first direction (direction perpendicular to the main scanning direction). By forming the organic light emitting layer into a stripe-like repetitive pattern or a grid-like repetitive pattern in parallel with the first direction, the organic light emitting layer could be formed at a good accuracy and efficiently by using the method of manufacturing the optical device described above.
The method of manufacturing the optical device of the invention is to be described specifically for a method of manufacturing a color filter as an example with reference to the drawings.
The resin composition is exposed to a stripe-like or grid-like pattern through a photomask. Further, development is conducted by applying a liquid developer to the substrate. The partition walls 182 are formed so as to form predetermined regions for preventing color mixing of inks in the subsequent discharge by an ink jet printing apparatus.
Further, a heat treatment is applied to the substrate 181 in an oven at 2000C for 10 min (post bake) to harden the partition wall 182. In this step, the ink repellent contained in the partition wall 182 is localized to the upper surface of the partition wall to enhance the color mixing preventive effect of the partition wall 182.
Successively, as shown in
The coloring ink layer 183 just after discharge has a shape raised upwards due to the surface tension thereof as shown in
Successively, the entire substrate was heat treated (post bake) being heated at 190° C. for 30 min to evaporize the solvent. Then, as shown in
Successively, an example of manufacturing an organic EL device as an optical device is to be described specifically for an embodiment of the invention.
Each of the ingredients was mixed in the ratio described above and stirred and dissolved to prepare a photosensitive resin composition A used for forming partition walls.
Non-alkali glass (“#1737” manufactured by Coning Co.) was used as a substrate. After forming an ITO film on the substrate by a sputtering method to 150 nm thickness, the ITO film was patterned by a photolithographic method and a wet etching method to form an electrode layer on the side of the substrate.
The photosensitive resin composition A was coated on the substrate over the entire surface in a thin film shape of 5.0 μm thickness and then pre-baked. Then, using a photomask having a grid-like pattern, exposure was conducted at 50 mJ/cm2 by a super high pressure mercury lamp. Development was conducted with an aqueous 10% sodium carbonate solution for 30 sec to form the partition wall of the resin composition into a stripe shape. The substrate was placed in an oven and applied with heat hardening treatment.
An aqueous solution of 3,4-polhethylene dioxythiophene (PEDOT) was coated on the substrate by a spin coating method to form a hole transporting material layer.
A toluene solution of 1.0 wt % polyarylenevinylene having polyarylenevinylene as an organic light emitting material was prepared as an ink. The ink was printed to the opening of the partition wall disposed on the substrate by using an ink jet printing apparatus to form an organic light emitting layer.
Then, a Ca film was formed as an electron injection layer of a sealing side electrode layer to a thickness of 5 nm on the organic light emitting medium layer. Then, an ITO film was formed as a transparent electrode layer on the organic light emitting medium layer formed with the Ca film by a sputtering method to 100 nm thickness. Finally, sealing was conducted by using a UV-curable resin to form an organic EL device.
Then,
In
172 represents a stage controller for controlling a substrate transporting stage. 173 represents a trigger controller for controlling the timing for starting discharge. 174 represents an encoder controller for controlling the positional information of the substrate transporting stage. 175 represents a head driver for controlling driving and operation of an ink jet head (or ink jet head unit). 176 represents a memory for storing the discharge pattern information. 177 represents a pattern calculation generator for sending the discharge pattern information stored in the memory 176 to the ink jet head 178 based on the information from a trigger controller 173 and the encoder controller 174.
In a case of manufacturing a color filter described above, it is necessary that a portion of plural nozzles arranged in the ink jet head does not conduct discharge. When discharge is conducted from all the nozzles, an ink discharged from the nozzle present on a line along the lateral direction of the pixel for the grid-like partition wall rides over the partition wall to cause occurrence of failure such as “color mixing”.
Accordingly, in a case of
Particularly, in a case of a piezoelectric device type (piezo type) ink jet head, the amount of the ink discharged from the nozzles undergoes the effect by vibrations of nozzles present in the vicinity and increases or decreases.
Accordingly, among plural nozzles present in the vicinity of a certain nozzle, in a case where one or more of nozzles stand still, the discharging amount changes as compared with the case where all the nozzles in the vicinity conduct discharge. Accordingly, in a case where the nozzles conducting discharge and the nozzles not conducting discharge are present unevenly, the amount of the ink discharged is different depending on the position of the nozzle to cause color shading.
Further, since the shape of the partition wall includes a linear pattern along the lateral direction of the pixels, nozzles at n=4, 8, 12 do not conduct discharge for preventing color mixing.
In the initial state, among the nozzles of the ink jet head, nozzles at bn=1 are selected as nozzles used for discharge. However, the nozzles at n=4 can not be used for discharge since they situate at the position overlapping the linear pattern wall. After all, nozzles at n=1, 7, 10, 13 are used for discharge. Then, while not discharging nozzles are adjacent continuously by the number of five for the nozzles at n=1, 7, 13 (nozzles of the same discharging pattern are present in plurality also below the nozzle at n=16), not discharging nozzles are present in adjacent only by the number of three for the nozzles at n=7.
Then, since the discharging state of the continuously adjacent nozzles are different between the nozzles at n=1, 7, 13 (nozzles satisfying: n=2a×m (integer of 0 or more)+1) and nozzles at n=10 (nozzles satisfying: n=2a×m+4), the ink discharging amounts are different from each other to cause color shading.
Further, in the next state, among the nozzles in the ink jet head, nozzles at bn=2 are selected as the discharging nozzles. However, since the nozzles at n=8 are present at the position overlapping the linear pattern of the partition wall, they can not be used. After all, the nozzles at n=2, 5, 11, 14 are used for discharging. Then, while not discharging nozzles are adjacent continuously by the number of five for the nozzles at n=5, 11, not discharging nozzles are present in adjacent only by the number of three for the nozzles at n=2, 14.
Then, since the discharging state of the continuously adjacent nozzles are different between the nozzles at n=5, 11 (nozzles satisfying: n=2a×m (integer of 0 or more)+5) and nozzles at n=2, 14 (nozzles satisfying: n=2a×m+2), the amounts of ink discharged are different from each other to also cause color shading.
In the further subsequent state, among the nozzles in the ink jet head, nozzles at bn=0 are selected as the discharging nozzles. However, nozzles at n=12 can not be used for discharge since they are present at the positions overlapping the linear pattern of the partition wall. After all, nozzles at n=3, 6, 9, 15 are used for discharge. Then, while not discharging nozzles are in adjacent continuously by the number of five for the nozzles at n=3, 9, 12, not discharging nozzles are present in adjacent only by the number of three for the nozzles at n=10.
Then, since the discharging state of continuously adjacent nozzles are different between the nozzles at n=3, 9, 12 (nozzles satisfying: n=2a×m (integer of 0 or more)+3) and the nozzles at n=10 (nozzles satisfying: n=2a×m+4), the amounts of ink discharged are different to each other and it also causes color shading.
Further, since the shape of the partition wall includes a linear pattern along the lateral direction of the pixels, nozzles at n=4, 8, 12 do not conduct discharge for preventing color mixing.
That is, in this case, for the shape of the partition walls, the distance between the linear patterns along the lateral direction of the pixels in the longitudinal direction of the pixel and (repetitive number a)×distance between adjacent nozzles) are made equal.
In the initial state, among the nozzles in the ink jet head, nozzles at bn=1 are selected as the discharging nozzles. Accordingly, nozzles at n=1, 5, 9, 13 are used for discharge.
Not discharging nozzles for preventing color mixing are not included in the nozzles discharging in the initial state.
In the next state, among the nozzles in the ink jet head, nozzles at bn=2 are selected as nozzles used for discharge. Accordingly, nozzles at n=2, 6, 10, 14 are used for discharge. Not discharging nozzles for preventing color mixing are not included in the discharging nozzles in the initial state.
In a further subsequent state, among the nozzles in the ink jet head, nozzles at bn=3 are selected as the nozzles used for discharge. Accordingly, nozzles at n=3, 7, 11, 15 are used for discharge. The not discharging nozzles for preventing color mixing are not included in the nozzles discharging in the initial state.
In a further subsequent step, among the nozzles in the ink jet head, nozzles at bn=0 are selected as the nozzles used for discharge. Accordingly, nozzles at n=4, 8, 12, 16 are selected. However, since all the nozzles are those not used for discharge for preventing color mixing and, after all, none of the nozzles conducts discharge in a state where bn=3.
As described above, by making the substantial distance between the nozzles used for charging to each other equal with the distance of the linear patterns of the partition wall shape to each other along the lateral direction of the pixel in the longitudinal direction of the pixel, any of the nozzles used for discharge is in a uniform state with a view point of the effects of vibrations undergoing from the nozzles in the vicinity. Accordingly, the discharging amount of ink discharged does not fluctuate depending on the nozzles and color shading or the like is not caused.
That is, even when the discharging nozzle and the partition wall pattern are not completely aligned, the effect of the method can be provided so long as the distance between the patterns of the partition wall is a several integer multiple of the distance between the discharging nozzles at a state bn.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006-187652 | Jul 2006 | JP | national |
