Method for forming a film, film forming device, liquid discharge device, method for manufacturing a color filter, display device having a color filter, method for manufacturing a display device, display device, and electronic apparatus

Abstract

To provide a device and a method for forming a film by discharging a liquid material with a liquid discharge head or the like, such as an ink jet head, and which can reduce the unevenness resulting from variation of the amount of the discharged liquid material. To provide a device and a method for forming a film by discharging a liquid material and which can increase process efficiency while suppressing the increase of costs, even if the liquid material is discharged onto various objects. When a color filter is manufactured, nozzles 27 of a liquid discharge head 22 discharge filter element materials onto filter-element-forming regions 7 . In this instance, one color of the filter element materials is discharged while the liquid discharge head 22 is swept in the longitudinal direction L of a mother substrate 12 . The other colors are discharged while the liquid discharge head 22 is swept in the width direction M of the mother substrate 12.

1 ] A method for forming a film by discharging a liquid material onto the surface of an object with a liquid discharge means, the method comprising: 
 a first sweeping step of discharging a plurality of droplets of the liquid material onto the surface of the object while the liquid discharge means sweeps over the object in a first direction with respect to the object, along the surface of the object; and a second sweeping step of discharging a plurality of droplets of the liquid material onto the surface while the liquid discharge means sweeps over the object in a second direction different from the first direction with respect to the object, along the surface of the object.    
     
     
         2 ] A method for forming a film according to  claim 1 , wherein the object is rotated to be oriented in a direction different from one sweeping step to the other so that the first direction and the second direction intersect each other with respect to the object.  
     
     
         3 ] A film forming device comprising: liquid discharge means for discharging droplets of a liquid material onto the surface of an object; and shifting means for relatively moving the object and the liquid discharge means, along the surface of the object, 
 wherein the liquid discharge means is relatively moved in at least two directions with respect to the object along the surface of the object, and the liquid discharge means discharges the droplets one after another while moving in any direction of said at least two directions.    
     
     
         4 ] A film forming device according to  claim 3 , further comprising orientation means for orienting the object in at least two directions by rotating the object.  
     
     
         5 ] A liquid discharge device for discharging a liquid material onto an object, comprising: 
 a liquid discharge head for discharging the liquid material; shifting means for relatively moving the liquid discharge head and the object in a direction along the surface of the object, the liquid discharge head and the object opposing each other; and orientation means for horizontally orienting the object,    wherein the orientation means is capable of horizontally orienting the object in at least two different directions.    
     
     
         6 ] A liquid discharge device according to  claim 5 , wherein the orientation means comprises a plurality of observing means for observing different portions of the object, and some of the observing means are used for observing the object in one orientation and the other observing means are used for observing the object in the other orientation.  
     
     
         7 ] A liquid discharge device for discharging a liquid material onto an object, comprising: 
 a liquid discharge head for discharging the liquid material; shifting means for relatively moving the liquid discharge head and the object in a direction along the surface of the object, the liquid discharge head and the object opposing each other; and orientation means for horizontally orienting the object,    wherein the sweeping direction in which the liquid discharge head moves while discharging the liquid material onto the object and the orientation of the object oriented by the orientation means have at least two orientation relationships.    
     
     
         8 ] A liquid discharge device according to  claim 7 , wherein the orientation means comprises a plurality of observing means for observing different portions of the object, and some of the observing means are used in one orientation relationship and the other observing means are used in the other orientation relationship.  
     
     
         9 ] A liquid discharge device for discharging a liquid material onto an object to form a film, comprising: 
 a liquid discharge head for discharging the liquid material; shifting means for relatively moving the liquid discharge head and the object in a direction along the surface of the object, the liquid discharge head and the object opposing each other; and orientation means for horizontally orienting the object,    wherein the sweeping direction in which the liquid discharge head moves while discharging the liquid material onto the object is changed with respect to the orientation of the object oriented by the orientation means, during operation.    
     
     
         10 ] A liquid discharge device according to  claim 9 , wherein the orientation means comprises a plurality of observing means for observing different portions of the object, and some of the observing means are used before the sweeping direction is changed and the other observing means are used after the sweeping direction is changed.  
     
     
         11 ] A liquid discharge device according to  claim 10 , wherein the observing means is capable of observing a plurality of portions of the object.  
     
     
         12 ] A method for manufacturing a color filter in which filter elements are formed by discharging a liquid material onto an object, the method comprising: 
 a first discharge step of continuously discharging droplets of the liquid material onto the object, in a first sweeping direction; and    a second discharge step of continuously discharging droplets of the liquid material onto the object, in a second sweeping direction different from the first sweeping direction.    
     
     
         13 ] A method for manufacturing a color filter according to  claim 12 , wherein, in the first discharge step, first filter elements having a first color are formed in a first region of the object; and 
 wherein, in the second discharge step, second filter elements having a second color different from the first color are formed in a second region of the object, different from the first region.    
     
     
         14 ] A method for manufacturing a color filter according to  claim 13 , wherein the filter elements comprise three types of filter elements having three colors, and one type of the filter elements, having one color exhibiting the strongest color shading resulting from the sweeping direction is discharged in one of the discharge steps and the other types having the other two colors are discharged in the other discharge step.  
     
     
         15 ] A method for manufacturing a color filter according to  claim 12 , wherein each of the filter elements is formed of a plurality of droplets of the liquid material, and some of the plurality of droplets are discharged in the first discharge step and the other droplets are discharged in the second discharge step.  
     
     
         16 ] A display device comprising a color filter having filter elements formed by discharging a liquid material onto an object, 
 wherein the color filter includes droplets of the liquid material which are continuously discharged in a plurality of sweeping directions.    
     
     
         17 ] A display device according to  claim 16 , wherein the filter elements comprise a plurality of types of filer elements having different colors from each other, the types of filter elements being formed by continuously discharging droplets of the liquid material in sweeping directions different from each other.  
     
     
         18 ] A display device according to  claim 17 , wherein the filter elements comprise three types of filter elements having three colors, and one type of the filter elements having one color exhibiting the strongest color shading resulting from the sweeping direction is discharged in a sweeping direction different from the sweeping direction in which the other types, having the other two colors, are discharged.  
     
     
         19 ] A display device according to  claim 16 , wherein the filter elements are formed by mixing droplets of the liquid material which are continuously discharged in different sweeping directions.  
     
     
         20 ] A display device according to  claim 16 , further comprising a liquid crystal panel, wherein the color filter and the liquid crystal panel are laid one upon the other.  
     
     
         21 ] A display device according to  claim 16 , further comprising an EL layer, wherein the color filter and the EL layer are laid one upon the other.  
     
     
         22 ] An electronic apparatus comprising a display device as set forth in  claim 16 .  
     
     
         23 ] A method for manufacturing a display device having steps for discharging a liquid material onto a substrate to form a film comprising: 
 a first discharge step of continuously discharging droplets of a liquid material onto an substrate, in a first sweeping direction; and    a second discharge step of continuously discharging droplets of the liquid material onto the substrate, in a second sweeping direction different from the first sweeping direction.    
     
     
         24 ] A method for manufacturing a display device according to  claim 23 , wherein discharged droplets of the liquid material form display dots.  
     
     
         25 ] A method for manufacturing a display device according to  claim 24 , wherein each of the display dots is formed of a plurality of droplets of the liquid material, and some of the plurality of droplets are discharged in the first discharge step and the other droplets are discharged in the second discharge step.  
     
     
         26 ] A display device comprising display dots formed by discharging a liquid material onto an object, 
 wherein the display dots each include droplets of the liquid material which are continuously discharged in a plurality of sweeping directions.    
     
     
         27 ] A display device according to claims  26 , wherein the display dots are formed by mixing droplets of the liquid material which are continuously discharged in different sweeping directions.  
     
     
         28 ] An electronic apparatus comprising a display device as set forth in  claim 26.