Optical waveguides – With optical coupler – Input/output coupler
Reexamination Certificate
1998-11-25
2001-04-03
Lee, John D. (Department: 2874)
Optical waveguides
With optical coupler
Input/output coupler
C347S051000, C347S088000, C385S147000
Reexamination Certificate
active
06212317
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a color filter used for a color liquid crystal display cell and a device of the same, specially to a method of manufacturing a color filter that will not generate a transfer displacement and a device of manufacturing the same.
2. Description of the Related Art
FIG. 9
is a schematic illustration of a conventional laser irradiation device
7
. And,
FIG. 10
is a graph to illustrate a relation between the irradiation width of laser beams radiated from the laser irradiation device
7
and the energy density (intensity) thereof.
The laser irradiation device
7
as shown in
FIG. 9
includes a laser oscillator
8
in which semiconductor devices are incorporated, and a single axis laser beam radiated from an outgoing beam aperture
8
a
of this laser oscillator
8
is reflected by mirrors
9
a
,
9
b
, and
9
c
in this order, and guided to an irradiation point P.
By using this type of the laser irradiation device
7
, laser beams are irradiated on a color film sheet
50
, as shown in
FIG. 6
, which is disposed on a color transfer support of a glass substrate or the like, whereby a color filter is formed.
The color film sheet
50
includes a base film
3
, photothermal conversion layer
4
, and color ink layer
2
, which are laminated in this order. The base film
3
employs a drawn resin of a polyethylene terephthalate (PET) or the like. The photothermal conversion layer
4
employs a mixture of a resin binder and a carbon powder, which has the property to absorb light and convert it into heat. The color ink layer
2
employs a resin binder with a pigment added thereto, which assumes one of the three kinds of colors, R (red), G (green), and B (blue).
The foregoing color film sheet
50
is disposed in a tight contact on a color transfer support
1
shown in
FIG. 6
, laser beams are irradiated locally from above the base film
3
, and the color ink layer
2
is transferred onto the color transfer support
1
.
FIG. 11
illustrates a moving device
60
to move the color transfer support
1
. This moving device
60
moves a part on which the color transfer support
1
is placed, and the laser irradiation device
7
is used always in a fixed state.
The moving device
60
is comprised of a support mount
62
, a substrate absorbing plate
61
, and a linear motor driving unit
66
. Further, the linear motor driving unit
66
includes a coil body
63
, a slide yoke
64
, and a magnet
65
. The substrate absorbing plate
61
is placed on the support mount
62
, and the color transfer support
1
is absorbed and fixed on the substrate absorbing plate
61
, while in use. And, the coil body
63
is a coil for a linear motor, in which a coil
63
a
is wound up on a bobbin. The upper sides of jaws
63
b
,
63
c
projected on both ends of the coil body
63
are fixed on the lower sides of the support mount
62
.
In order to operate the moving device
60
, controlling the direction of a magnetic force of the magnet
65
induces a force that acts on the coil body
63
in the sliding direction, and the force thereby moves the color transfer support
1
in a X direction, accompanied with the support mount
62
.
Though not illustrated, a linear motor driving unit having the similar mechanism to the foregoing is provided on both the ends of the moving device
60
, in order to move the entire body of the moving device
60
in a Y direction.
However, when the laser irradiation device
7
as shown in
FIG. 9
is used, optical components (mirrors) intervening between the outgoing beam aperture
8
a
of the laser oscillator
8
and the irradiation point P are assembled and adjusted by a single optical axis; and therefore, not only the productivity is low, but also there has been created an abnormality of edges in the transfer pattern to the color transfer support
1
by the color ink layer
2
, which is a problem.
That is, as recognized from the graph illustrated in
FIG. 10
, a displacement of the irradiation point P causes a difference in the intensity of the laser beams. Concretely, the graph shown in
FIG. 10
is called as the Gaussian distribution, the intensity becomes highest at the center position C of the laser beams, and the intensity is s sharply weakened as the irradiation point is displaced from the center position C. In particular, to the color ink layer
2
transferred to the color transfer support
1
, the laser beams are irradiated within the transfer width (irradiation width) L that is illustrated by the two dotted lines in
FIG. 10
, and the intensity at the edges become lowest within the transfer width L. Accordingly, the color ink layer
2
cannot be melted sufficiently at the edges, the intensity differences at the boundaries become high as well, the boundaries become unclear, and there has been created an abnormality of the edges in the transfer pattern.
On the other hand, when the moving device
60
as shown in
FIG. 11
is used, a heat generated from the coil body
63
is transferred from the support mount
62
to the substrate absorbing plate
61
, and further to the color transfer support
1
; and thereby, there has been created an abnormality in the transfer accuracy of the color filter.
That is, a heat generated from the coil body
63
heats the color transfer support
1
, which generates a temperature gradient on the surface of the color film sheet
50
disposed on the color transfer support
1
. Thereby, the temperature of the center of the color transfer support
1
becomes high, whereby, the elongation of the center of the color transfer support
1
becomes large as compared to the other part thereof. When a transfer is conducted while the elongation is generated, the color filter (color ink layer
2
) has created a displacement in the pitch thereof when the temperature reduces to a normal and the elongation is reduced to the original state.
The extent of displacement in the pitch becomes about 0.8 &mgr;m, when the temperature gradient of 1 degree per 100 mm is given. In practice, since there is the temperature difference of about 10 degree between the center of the color transfer support
1
and the edge thereof, there has been created an error of about 8 &mgr;m. In manufacturing the foregoing color filter, the pitch has to be arranged within the allowance of ±3 &mgr;m, and the foregoing moving device
60
can exceed this error range, which created a problem.
SUMMARY OF THE INVENTION
The present invention has been made to solve the foregoing problems, and it is therefore an object to provide a method of manufacturing a color filter, whereby a color filter whose transfer pattern has a clear edge and a high accuracy can be formed on the color transfer support and the efficiency of production can be enhanced, and a device of manufacturing the same.
The method of manufacturing a color filter of this invention includes the steps of: disposing a color film sheet having a color ink layer of a specific color of a plurality of colors on a color transfer support; irradiating laser beams simultaneously to a plurality of positions where a color pattern of a color of the color ink layer contained in the color film sheet is formed; melting the color ink layer at parts equivalent to a plurality of the color patterns to transfer to the color transfer support; and thereafter peeling the color film sheet from the color transfer support.
In this case, a color filter can be formed such that after the color filter of the specific color is transferred, the color film sheet having the color ink layer of a different color is disposed on the color transfer support, and an irradiation position of the laser beams is shifted to a position where the color pattern of the color of the color ink layer is transferred.
Further, the device of manufacturing a color filter is such that in a state that a color film sheet having a color ink layer of a specific color of a plurality of colors is disposed on a color transfer support, laser beams for melting the color ink layer are irradiated to
Hayashi Yuzo
Ikeda Kaoru
Takeshita Naoki
Alps Electric Co. ,Ltd.
Brinks Hofer Gilson & Lione
Lee John D.
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