Radiation imagery chemistry: process – composition – or product th – Radiation modifying product or process of making – Screen other than for cathode-ray tube
Reexamination Certificate
2000-10-06
2003-06-24
McPherson, John A. (Department: 1756)
Radiation imagery chemistry: process, composition, or product th
Radiation modifying product or process of making
Screen other than for cathode-ray tube
C430S287100, C349S106000
Reexamination Certificate
active
06582862
ABSTRACT:
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of Japanese patent application Serial No. P11-288802 filed on Oct. 8, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a high photo-sensitivity curable resin that can be hardened(cured) by a little exposure amount, a high photo-sensitivity curable resin composition containing such a photo-curable resin, and a production method thereof.
The present invention also relates to a high photo-sensitivity curable resin having a high as well as a high sensitivity, which has no risk of bringing about undesired increase of the molecular weight or the viscosity in storage, use, or handling, such as a photo-curing resin with a good storage property, and a production method thereof.
The present invention also relates to a photo-curable resin composition containing the photo-curable resin with the high sensitivity and high stability, capable of easily adjusting or evening the film thickness of a coated film without the risk of viscosity increase in storage or coating, and a production method thereof.
Moreover, the present invention relates to a high sensitivity and transparent photo-curable resin, a high sensitivity and transparent photo-curable resin composition containing such a photo-curable resin, and their production methods.
Still further, the present invention relates to a color filter and a liquid crystal display panel with little color irregularity and contrast irregularity, with a protection film of a color layer and a spacer of a liquid crystal layer formed by using the photo-curable resin composition mentioned above.
2. Description of the Related Art
Recently, as a flat display for a personal computer, color liquid crystal display devices have been propagated rapidly. As shown in
FIG. 1
, a color liquid crystal display device
101
, in general, has a structure wherein a color filter
1
and an electrode substrate
2
such as a TFT substrate are faced with each other so as to provide a gap part
3
of about 1 to 10 &mgr;m, with a liquid crystal compound L filled in the gap part
3
and the periphery thereof sealed by a sealing member
4
. The color filter
1
comprises a structure including a black matrix layer
6
formed in a predetermined pattern for blocking the light in the boundary part between the pixels, a color layer
7
with a plurality of colors (in general, three primary colors including red (R), green (G), and blue (B)) arranged in a predetermined order for forming each pixel or recently, a color filter, a protection film
8
, and a transparent electrode film
9
successively laminated on a transparent substrate
5
in this order from the side close to the transparent substrate. Moreover, an alignment layer
10
is provided on the inner surface side of the color filter
1
and the electrode substrate
2
facing thereto. Furthermore, pearls
11
having a constant particle size are dispersed as a spacer in the gap part
3
for constantly and homogeneously maintaining the cell gap between the color filter
1
and the electrode substrate
2
. A color image can be obtained by controlling the light transmittance of the pixels colored in each color or the liquid crystal layer behind the color filter.
The protection film
8
formed in the color filter serves for protecting the color layer and for flattening the color filter in the case a color layer is provided in the color filter. In a color liquid crystal display device, in the case the flatness of the transparent electrode film
9
is deteriorated due to existence of gag irregularity derived from the waviness on the surface of the transparent substrate of the color filter, gap irregularity among the R, G and B pixels, or gap irregularity within each pixel, color irregularity or contrast irregularity is generated so as to give rise to a problem of the image quality deterioration. Therefore, a high flatness is required to the protection film.
In the case the fine particle-like pearls
11
as shown in
FIG. 1
are dispersed as the spacer, the pearls are dispersed randomly, independent from being behind the black matrix layer
6
or behind the pixels. In the case the pearls are disposed in the display area, that is, in the pixel part, a back lighting beam transmits the pearl part, and further, the orientation of the liquid crystal is disturbed in the vicinity of the pearls so that the display image grade is deteriorated remarkably. Then, as shown in
FIG. 2
, instead of dispersing the pearls, column-shaped spacers
12
having a height corresponding to the cell gap are formed on the inner surface side of the color filter in the area coinciding with the black matrix layer
6
.
The above-mentioned protection film
8
and the column-shaped spacers
12
can be formed with a resin. In consideration of the adhesion property and the sealing property of the sealing part, the protection film
8
is preferably one capable of covering only the area of the transparent substrate with the color layer formed thereon. Moreover, the column-shaped spacers
12
need to be formed accurately in the area with the black matrix layer formed, that is, in the non-display area. Therefore, the protection film and the column-shaped spacers came to be formed with a photo-curing resin capable of easily limiting the area to be hardened by a photo mask.
Furthermore, in the case the surface applied with a photo-curing resin is developed with an organic solvent after exposure for forming the protection film or the column-shaped spacers, since handling and the waste liquid process are troublesome so that it is not satisfactory in terms of economy and stability, a photo-curing resin allowing an alkaline development after exposure has been developed by introducing an acid functional group in a photo-curing resin.
As an alkaline-soluble photo-curing resin, for example, o-cresol novolak epoxy acrylate, or the like, having about 2,000 weight average molecular weight is known. The resin has a carboxylic acid group defining the alkaline solubility. However, since the resin uses a monomer component as an acryloyl group defining the curing property, the reliability in film formation is low. For example, it involves the risk of the residual monomer unit elution to the liquid crystal part. Furthermore, the film thickness may be reduced due to a large amount of the elution in the alkaline development.
Moreover, as all method for introducing a radical polymerizable group such as an acryloyl group into the molecular structure of a compound or providing the photo curing property, for example, a method Of introducing a radical polymerizable group such as a methacryloyl group to an end by reacting of diols with excessive diisocyanate for preparing a reaction product with an isocyanate group remaining on the end, and reacting the isocyanate group of the reaction product with 2-hydroxyl ethylmethacrylate for producing urethane acrylate, is known. However, according to the method, as a principle, a (meth)acryloyl group can be introduced to only both ends of the molecular structure. Furthermore, although a method of radical polymerization by partially containing a compound having two or more radical polymerizable groups in a molecular such as a (meth)acryloyl group can be conceivable, the content of the radical polymerizable group cannot be controlled as well as a problem of gellation is also involved.
As mentioned above, although it is convenient to form the protection film and the column-shaped spacers of a color film with a photo-curing resin, it is difficult to control the amount of the alkaline soluble group such as a carboxyl group and the radical polymerizable group such as a (meth)acryloyl group according to the conventional photo-curing resin in consideration of the curing property and the alkaline solubility thereof.
According to the undisclosed knowledge obtained by the study of the present inventor, since the amount of the alkaline soluble carboxyl group and the radical polymerizable (meth)acryloyl group can be adjusted freely according to a copolymer r
Nakamura Kazuhiko
Sega Shunsuke
Dai Nippon Printing Co. Ltd.
Keefer Timothy J.
McPherson John A.
Wildman Harrold Allen & Dixon
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