JP4631356B2 - Drawing control method for liquid droplet ejection apparatus, liquid droplet ejection apparatus, and electro-optical device manufacturing method - Google Patents

Description

The present invention relates to a drawing control method for a droplet discharge device that performs drawing by discharging a functional liquid onto a workpiece while relatively moving a plurality of carriage units each having a functional droplet discharge head mounted on the workpiece, those concerning the manufacturing how the droplet discharge device and an electro-optical device.

2. Description of the Related Art Conventionally, as this type of droplet discharge device, one applied to a manufacturing apparatus for a color filter or an organic EL device is known (for example, see Patent Document 1). This droplet discharge device includes an X-axis table on which a workpiece (substrate) is mounted and a Y-axis table on which a functional droplet discharge head is mounted. The functional droplet discharge head is attached to the workpiece via the X-axis table. In addition to the relative movement (main scanning) in the X-axis direction, the functional liquid droplet ejection head is relatively moved (sub-scanning) in the Y-axis direction via the Y-axis table. Is discharged (drawn).
Since the droplet discharge device applied to the above manufacturing apparatus uses a special functional liquid, it is known that the life of the functional droplet discharge head is extremely shortened compared to the life of the device unlike a general printer. .
JP 2003-266673 A

In the above-described conventional droplet discharge device, it is necessary to perform drawing while moving the functional droplet discharge head relative to the workpiece in the X-axis direction and the Y-axis direction (main scanning and sub-scanning). There is a problem of long time. In such a case, it is conceivable to use a head unit that completes drawing in one main scan by using a plurality of functional droplet discharge heads that form one drawing line, as in a so-called line printer.
However, when processing a plurality of types of workpieces having different workpiece widths, particularly when setting the workpiece with center alignment, a situation in which only a specific functional liquid droplet ejection head is used frequently occurs. For this reason, when a part of functional droplet ejection heads that are frequently used reaches the end of their lives, the operation of the entire apparatus must be stopped to remove the entire head unit in order to replace it, and the production efficiency deteriorates. A problem occurs.

The present invention relates to a method for controlling drawing of a droplet discharge device capable of uniformizing the frequency of use of all-function droplet discharge heads, even if the number of use of functional droplet discharge heads varies depending on the workpiece width, and droplet discharge to provide a device and a manufacturing how the electro-optical device and an object.

  The drawing control method of the droplet discharge apparatus of the present invention has a functional droplet discharge head and a carriage equipped with the functional droplet discharge head, and is configured to be individually movable between the drawing area and the standby area. A drawing control method for a droplet discharge device that includes a plurality of carriage units and performs drawing processing in a drawing area while moving the plurality of carriage units relative to the workpiece, and is implemented according to the workpiece width of the workpiece. A unit number determining step for determining the number of carriage units to be operated, a usage frequency managing step for managing the usage frequency of the mounted functional liquid droplet ejection head for each carriage unit, and the determined number of units and functional liquid droplets Based on the usage frequency of the ejection head, the carriage unit used for actual operation is used so that the usage frequency is averaged among the plurality of functional droplet ejection heads. A unit selection step of selecting, and based on the selection result, among a plurality of carriage unit drawing area and the standby area, characterized by comprising a carriage moving step of moving selectively.

  In addition, the droplet discharge device of the present invention is a droplet that performs a drawing process in a drawing area while moving a plurality of carriage units each having a functional droplet discharge head mounted on a carriage relative to a workpiece in the X-axis direction. It is a discharge device, and a carriage moving means for individually moving a plurality of carriage units between the drawing area and the standby area in the Y-axis direction, and the number of carriage units provided for actual operation according to the workpiece width of the workpiece. Based on the unit number determining means to be determined, the usage frequency management means for managing the usage frequency of the mounted functional liquid droplet ejection head for each carriage unit, the determined unit number and the functional liquid droplet ejection head usage frequency, Unit selection that selects the carriage unit to be used for actual operation so that the frequency of use is averaged among multiple functional droplet discharge heads And a movement control means for controlling the carriage movement means, wherein the movement control means selectively moves a plurality of carriage units between the drawing area and the standby area based on the selection result. To do.

According to these configurations, the unit number determining means (in the unit number determining step) determines the number of carriage units necessary for drawing based on the work width of the work, and based on this determination, the unit selecting means In the unit selection step, a carriage unit to be used for drawing is selected from a plurality of carriage units. In this case, the selection by the unit selection means is performed so as to equalize the use frequency of each functional liquid droplet ejection head based on the use frequency information managed by the use frequency management means (use frequency management step). Then, the carriage movement means (carriage movement process) controlled by the movement control means moves one or more carriage units selected as described above to the drawing area and the remaining carriage units to the standby area.
As a result, since the carriage unit with a low use frequency of each function droplet discharge head to be mounted is preferentially operated, only a specific function droplet discharge head does not reach the end of its life due to drawing. For this reason, the functional liquid droplet ejection heads reach the end of service life almost simultaneously in units of carriage units, and all the carriage units are replaced at once, and the operation stop time of the liquid droplet ejection apparatus can be minimized.

  In these cases, it is preferable that the standby areas are arranged on both sides of the drawing area.

  The degree of freedom in selecting a carriage unit for actual operation can be increased, and the frequency of use of each functional droplet discharge head can be made more uniform.

  In this case, it is preferable to further include a storage step of storing the functional liquid droplet ejection heads of the carriage units moved to the standby area by the carriage movement step in a function maintaining state.

  In this case, a storage unit that stores the functional liquid droplet ejection head in a function maintaining state is disposed in the standby area, and the movement control unit causes the carriage unit that has moved to the standby area to face the storage unit. It is preferable.

  According to these configurations, the carriage unit (functional droplet discharge head) that has been moved to the standby area and is not used for actual operation can face the storage unit, and the protruding nozzles of each functional droplet discharge head can be dried. It is possible to prevent the function from being lowered.

  In this case, each of the carriage units is equipped with a plurality of functional liquid droplet ejection heads, and the unit selection means selects based on the usage frequency of the functional liquid droplet ejection heads that are most frequently used in each carriage unit. It is preferable to carry out.

  According to this configuration, when it is assumed that replacement is performed in units of carriage units, the carriage units can be selected appropriately.

  In this case, it is preferable that the usage frequency management means manages the usage frequency based on either the cumulative usage time or the cumulative number of shots of the functional liquid droplet ejection head.

  According to this configuration, data regarding the usage frequency of the functional liquid droplet ejection head can be easily obtained from the control unit, and the usage frequency can be appropriately evaluated and managed.

  In this case, it is preferable that the movement control means perform selective movement at the time of workpiece replacement.

  According to this configuration, since the carriage unit is moved within the free time when the workpiece is replaced, the carriage unit can be moved without hindering the drawing operation by the functional liquid droplet ejection head. For this reason, it is not necessary to stop the operation of the droplet discharge device for moving the carriage unit.

  In this case, the apparatus further includes an X-axis table that mounts the workpiece and moves the workpiece in the X-axis direction, and the plurality of carriage units can draw the maximum width of the workpiece that can be mounted on the X-axis table by a line printing method. It is preferable that the number of units is configured.

  According to this configuration, since there is no preliminary carriage unit, the space in the standby area can be minimized, and an increase in the size of the entire apparatus can be suppressed.

  A method for manufacturing an electro-optical device according to the present invention is characterized in that a film-forming portion made of functional droplets is formed on a workpiece using the above-described droplet discharge device.

  According to these configurations, the electro-optical device can be efficiently manufactured because the droplet discharge device that prevents the operation from being stopped as much as possible is used. As the electro-optical device (flat panel display), a color filter, a liquid crystal display device, an organic EL device, a PDP device, an electron emission device, and the like are conceivable. The electron emission device is a concept including a so-called FED (Field Emission Display) or SED (Surface-conduction Electron-Emitter Display) device. Further, as the electro-optical device, devices including metal wiring formation, lens formation, resist formation, light diffuser formation, and the like are conceivable.

  Hereinafter, a droplet discharge device of the present invention will be described with reference to the accompanying drawings. This droplet discharge device is incorporated into a so-called flat panel display production line, and by a droplet discharge method using a functional droplet discharge head, a color filter of a liquid crystal display device, a light emitting element that becomes each pixel of an organic EL device, etc. Is formed.

  As shown in FIGS. 1 and 2, the droplet discharge device 1 includes a machine base 2 and a carriage unit 23 in which a functional liquid droplet discharge head 3 (see FIG. 3) described later is incorporated. A drawing device 4 arranged on the machine base 2, a maintenance device 5 installed on both sides of the drawing device 4 on the machine base 2 and used for maintenance of the carriage unit 23, and a machine so as to cover them. A chamber device (not shown) mounted on the table 2 and a control device 56 (see FIG. 6) to be described later for comprehensively controlling each of the above-described constituent devices are provided.

  The drawing device 4 and the maintenance device 5 are respectively housed in the chamber device, and when the workpiece W is carried into the chamber device, the functional liquid droplets are discharged by the carriage unit 23 in an atmosphere of dry air or inert gas. That is, drawing is performed. In addition, when the operation of the droplet discharge device 1 is started, the maintenance device 5 is selectively exposed to restore the function of the carriage unit 23.

  The drawing device 4 has an XY movement mechanism 7 installed on the machine base 2. The X / Y movement mechanism 7 moves the carriage unit 23 relative to the workpiece W in the X-axis direction and the Y-axis direction. The X / Y table moves the workpiece W and moves it in the X-axis direction. 8 and a Y-axis table 11 (carriage moving means), which are installed so as to cross over each other and move seven carriage units 23 to be mounted in the Y-axis direction. The drawing device 4 includes various types of head recognition cameras (not shown) for recognizing the positions of the respective functional liquid droplet ejection heads 3 and a pair of alignment cameras 9 and 9 for measuring the alignment of the workpiece W. A device is provided.

  The X-axis table 8 includes a suction table 12 for sucking and mounting the workpiece W, a set table 14 including a θ table 13 for rotatably supporting the suction table 12 around the Z axis, and the set table 14 being slidable in the X-axis direction. The X-axis slider 15 supported on the X-axis, a pair of X-axis guide rails 16, 16 extending in the X-axis direction and guiding the slide of the X-axis slider 15, and the X-axis guide rails 16, 16 are provided side by side. A pair of X-axis linear motors (not shown) for driving the slider 15 and an X-axis linear scale (not shown) for grasping the position of the set table 41 are provided. When the X-axis linear motor is driven, the X-axis slider 15 slides along the X-axis guide rails 16 and 16, and the workpiece W placed on the suction table 12 reciprocates in the X-axis direction that is the main scanning direction. To do. The X-axis table 8 is provided with a regular flushing unit 19a and a dot dropout detection unit 19b behind the set table 14, and pre-drawing flushing units 19c and 19c are provided before and after the set table 14. ing.

  The Y-axis table 11 (carriage moving means) is stretched over a plurality of sets of left and right support stands 21 erected on the machine base 2 with the X-axis table 8 interposed therebetween, and a plurality of sets of support stands 21 in the Y-axis direction. A pair of front and rear Y-axis frames 22, 22, seven Y-axis sliders (not shown) that are slidably supported by the Y-axis frames 22, 22, and the Y-axis provided alongside the Y-axis frames 22, 22 A pair of Y-axis linear motors (not shown) for driving the sliders, seven bridge plates 20 spanned between the pair of Y-axis frames 22 and 22 via the Y-axis sliders, and suspended on each bridge plate 20 And seven carriage units 23 each mounted with the functional liquid droplet ejection head 3 and a Y-axis linear scale (not shown) for detecting the position of each carriage unit.

  The seven carriage units 23 include a first carriage unit 23a at the left end to a seventh carriage unit 23g at the right end. When the Y-axis linear motor is driven, the Y-axis slider moves on the Y-axis frame 22 together with the bridge plate 20 (and the carriage unit 23 suspended from the bridge plate 20). In this case, the first to seventh carriage units 23a to 23g can reciprocate individually in the Y-axis direction. Individual movement control of each carriage unit 23 will be described later.

  Each carriage unit 23 includes a suspended frame 24 suspended from the bridge plate 20, a θ-axis rotating mechanism 24 a incorporated in a lower portion of the suspended frame 24, and a carriage body 25 provided at the lower end of the θ-axis rotating mechanism 24 a And a functional liquid supply unit 26 (see FIG. 3) suspended from the bridge plate 20. On the bridge plate 20, an electrical unit (not shown) for driving the functional liquid droplet ejection head 3 provided for each carriage unit 23 is provided.

  FIG. 3 shows a total of seven carriage bodies 25 and a total of seven functional liquid supply units 26 mounted on each carriage unit 23. As shown in the figure, the carriage body 25 includes 12 plate-like head plates 27 made of stainless steel or the like that are parallelogram-like in top view and mounted on the head plate 27 via head holding members (not shown). And a functional liquid droplet ejection head 3. Each functional liquid droplet ejection head 3 is mounted such that its lower portion protrudes below the head plate 27.

  In each head plate 27, the twelve functional liquid droplet ejection heads 3 are arranged so that all the nozzle rows 28 (see FIG. 4) form one drawing line (partial drawing line). In this manner (actually partly overlaps in the Y-axis direction), they are arranged so as to be displaced in a staircase pattern in plan view. In addition, between the adjacent head plates 27, the functional liquid droplet ejection heads 3 located at the end portions of the functional liquid droplet ejection heads 3 have their nozzle rows 28 continuous (in this case also, some of them actually overlap in the Y-axis direction). In other words, one drawing line is formed in the seven carriage units 23 as a whole.

  As shown in FIG. 4, each functional liquid droplet ejection head 3 has a large number (for example, 180) of nozzles 31 for ejecting functional liquid droplets on its nozzle surface 32, and the large number of nozzles 31 are arranged in two rows. Nozzle row 28 is formed. Further, the functional liquid droplet ejection head 3 includes a pair of in-head flow paths 33 corresponding to the nozzle rows 28, and cavities (piezoelectric elements) (not shown) provided facing the in-head flow paths 33. And a pair of functional liquid inlets 34 connected to the in-head flow path 33. In the initial filling step, the functional liquid flows from the functional liquid introduction ports 34 by nozzle suction, and the in-head flow path 33 is filled with the functional liquid. When the cavity exerts a pump action and is driven to discharge, the nozzle 31 discharges the functional liquid in the in-head flow path 33 (discharge of functional liquid droplets). Due to the discharge of the functional liquid, the functional liquid droplet ejection head 3 that has consumed the functional liquid is supplied with a new functional liquid from the functional liquid supply unit 26 to the in-head flow path 33.

  With reference to FIG. 3 again, the functional liquid supply unit 26 will be described. Each functional liquid supply unit 26 is close to the carriage body 25 and has a tank carriage 35 having two upper and lower storage portions 35a (see FIG. 4), and twelve functions stored in the tank carriage 35 and storing the functional liquid therein. The liquid tank 36, 12 functional liquid supply tubes 43 (see FIG. 5) for connecting each functional liquid tank 36 and each functional liquid droplet ejection head 3, and 12 functional liquid supply tubes 43 are provided. 12 pressure regulating valves 37 mounted on the head plate 27. The tank carriage 35 accommodates a total of twelve functional liquid tanks 36 in parallel in each of the upper and lower accommodating portions 35a (only the upper accommodating portion is shown in the figure).

  The pressure adjustment valve 37 is a pressure reducing valve that adjusts the difference in water head pressure between the functional liquid tank 36 and the functional liquid droplet ejection head 3, and is arranged on the head plate 27 side in order to adjust the pressure immediately before the functional liquid droplet ejection head 3. It is mounted on. In the present embodiment, twelve pressure regulating valves 37 are arranged on the head plate 27 in a stepped shape in plan view, following the arrangement of the twelve functional liquid droplet ejection heads 3.

  As shown in FIG. 5, the functional liquid tank 36 is of a cartridge type, and includes a functional liquid pack 38 that stores therein a previously degassed functional liquid, and a substantially square cartridge case 41 that houses the functional liquid pack 38. And have. The functional liquid pack 38 is provided with a cylindrical resin supply port in a bag-like package in which two rectangular film sheets are laminated and heat-sealed. The functional liquid pack 38 can store the functional liquid in an airtight state, deforms as the functional liquid decreases, and can be used up to the end. A weight measuring unit 42 for detecting the weight of the functional liquid tank 36 is provided below each functional liquid tank 36.

  The functional liquid supplied from the functional liquid tank 36 is supplied to the functional liquid droplet ejection head 3 via the functional liquid supply tube 43. In addition, a functional liquid whose water head difference between the functional liquid tank 36 and the functional liquid droplet ejection head 3 is adjusted is supplied to the functional liquid droplet ejection head 3 by a pressure adjusting valve 37 provided in the functional liquid supply tube 43. Liquid dripping from the functional liquid droplet ejection head 3 is prevented.

  As shown in FIG. 2, the position where the X-axis table 8 and the Y-axis table 11 intersect with each other is a drawing area 44 for drawing on the workpiece W, and a plurality of carriage units 23 are used for drawing. The drawing moves to the drawing area 44, and functional droplets are ejected by each functional droplet ejection head 3 for drawing. On the other hand, both sides of the drawing area 44 are standby areas 45 where the maintenance device 5 is provided, so that the carriage unit 23 faces the maintenance device 5 and can wait in a function-maintaining state. Details of a drawing control method for selectively moving the carriage unit 23 between the drawing area 44 and the standby area 45 will be described later.

  Next, the maintenance device 5 will be described with reference to FIG. The maintenance device 5 according to the present embodiment includes a first maintenance unit 5 a disposed on the left side of the drawing device 4 and a second maintenance unit 5 b disposed on the right side of the drawing device 4. The first maintenance unit 5 a seals the nozzle surface 32 of the functional liquid droplet ejection head 3 to prevent the nozzle 31 from being dried when the liquid droplet ejection apparatus 1 is not in operation, and the nozzle 31 of the functional liquid droplet ejection head 3. A first storage / suction unit 46a (storage unit) for sucking and removing the functional liquid thickened from the first liquid, and a first wiping unit 47a for wiping off dirt adhering to the nozzle surface 32 of the functional liquid droplet ejection head 3. ing. Similarly, the second maintenance unit 5b includes a second storage / suction unit 46b (storage unit) and a second wiping unit 47b. In both maintenance parts 5a and 5b, the wiping units 47a and 47b are arranged on the inner side (the drawing device 4 side), and the storage / suction units 46a and 46b are arranged on the outer side.

  The first storage / suction unit 46a (storage unit) has seven subunits 48 corresponding to the seven carriage units 23 on a one-to-one basis. On the other hand, the second storage / suction unit 46 b (storage unit) is composed of only three subunits 48. Each subunit 48 includes 12 sealing caps (not shown) that also serve as a flushing box that receives the discarded discharge of the functional liquid droplet ejection head 3 and 12 functional caps that follow the functional liquid droplet ejection head 3. A cap base 51 arranged in a staircase shape, a cap lifting mechanism 52 that lifts and lowers the cap base 51, and a suction mechanism such as a suction pump or an ejector that is connected to each sealing cap and sucks the functional liquid droplet ejection head 3 (not shown) ) And a waste liquid tank (not shown) for collecting the waste liquid suctioned and removed by the suction mechanism.

  When drawing is suspended, the functional liquid droplet ejection head 3 (carriage unit 23) is moved to the maintenance position (standby area 45), and the sealing cap is located slightly away from the functional liquid droplet ejection head 3 at the functional liquid. The flushing (discarding discharge) of the droplet discharge head 3 is received. Further, when the droplet discharge apparatus 1 is not in operation, the cap base 51 is completely raised, and each sealing cap is in close contact with the nozzle surface 32 of each functional droplet discharge head 3 (capping). Thereby, all the nozzles 31 of each functional liquid droplet ejection head 3 are sealed to prevent the functional liquid from drying at each nozzle 31. And when restarting from this contact | adherence state, a suction mechanism is driven as needed and the functional liquid which thickened from the nozzle 31 is attracted | sucked. This suppresses thickening of the functional liquid and prevents so-called nozzle clogging. The suction operation by this suction mechanism is also used when initially filling the functional liquid.

  As shown in the figure, the first and second wiping units 47a and 47b include a unit main body 53 in which main parts are disposed, and a slide mechanism (not shown) that supports the unit main body 53 so as to be slidable in the X-axis direction. And each. The unit main body 53 is provided with a wiping sheet (not shown) that can be fed and wound up. The functional liquid droplet is fed while feeding the fed wiping sheet and moving the unit main body 53 in the X-axis direction by a slide mechanism. The nozzle surface 32 of the discharge head 3 is wiped off. By this wiping operation, the functional liquid adhering to the nozzle surface 32 of the functional liquid droplet ejection head 3 is removed, and flight bending or the like during functional liquid droplet ejection is prevented.

  Next, a control system of the droplet discharge device 1 will be described with reference to FIG. The droplet discharge device 1 includes a drawing unit 4 having a carriage unit 23, an X-axis table 8 and a Y-axis table 11, a maintenance device 5 having a first maintenance unit 5a and a second maintenance unit 5b, and various types of detection and management. The detection part 55 to perform and the control apparatus 56 which controls these collectively are provided.

  The detection unit 55 has a weight measurement unit 42 connected to each functional liquid tank 36. The weight measuring unit 42 measures the weight of the functional liquid tank 36 at predetermined intervals, and sends the measured value to the control device 56 as needed. This measurement value is based on a measurement value obtained by measuring the functional liquid tank 36 in a full liquid state. By subtracting the weight of the functional liquid tank 36 from the measured weight, the weight of the functional liquid in the tank (function (Liquid level) is being measured.

  The control device 56 includes a control unit 57 (movement control means) that is a main part of the control system, and a drive unit 58 that drives each unit of the device. The drive unit 58 includes a head driver 61 that discharges the functional droplet discharge head 3, an X-axis table driver 62 that drives the X-axis table 8, a Y-axis table driver 63 that drives the Y-axis table 11, and the maintenance device 5. It has a maintenance driver 64 for driving, and directly drives each of the above parts.

  The control unit 57 includes a CPU 65, ROM 66, RAM 67, hard disk 68, and interface 71, which are connected to each other via an internal bus 72. The ROM 66 stores various programs in addition to a discharge control program for controlling the drive frequency of each functional liquid droplet discharge head 3. The hard disk 68 includes a unit number determination program 73 (unit number determination means) for determining the required number of carriage units 23 and a use frequency management program 74 (use frequency management means) for managing the use frequency of the functional liquid droplet ejection head 3. And a unit selection program 75 (unit selection means) for selecting the carriage unit 23 to be used in actual operation is installed.

  The usage frequency management program 74 (usage frequency management means) includes a shot number program that counts the cumulative number of shots of each functional liquid droplet ejection head 3 based on the drive frequency of each functional liquid droplet ejection head 3 and each of these counts. Management for storing a usage time program for counting the cumulative usage time of the functional liquid droplet ejection head 3, a cumulative number of shots and a cumulative usage time for each functional liquid droplet ejection head 3, and a measurement value sent from the weight measurement unit And a data area. The management data area is divided for each carriage unit 23, and these count values and measurement values (management data) can be managed for each carriage unit 23. The measured value of each functional liquid tank 36 is constantly updated with new measured values sent from the weight measuring unit 42.

  When starting drawing on the workpiece W, the CPU 65 activates the unit number determination program 73 and calculates the necessary number of carriage units 23 based on the workpiece width. Next, the CPU 65 activates the unit selection program 75 and selects the carriage unit 23 suitable for drawing in light of the calculation result of the unit number determination program 73 and the management data of the use frequency management program 74.

  Next, the drawing control method of the droplet discharge device of the present embodiment will be described along the procedure of actually drawing on the workpiece W. In this drawing control method, by selectively moving the carriage unit 23 between the drawing area 44 and the standby area 45, the frequency of use of the functional liquid droplet ejection heads 3 is made uniform, and the respective functional liquid droplet ejection heads 3 are At the same time, the droplet discharge device 1 is controlled so as to reach the lifetime.

  This drawing control method includes a unit number determination step for determining the number of carriage units 23 to be used for drawing, a use frequency management step for managing the use frequency of each functional liquid droplet ejection head 3, a determination result of the number of units, and functional liquid droplets. From the unit selection process for selecting the carriage unit 23 based on the frequency of use of the ejection head 3, the carriage movement process for moving the selected carriage unit 23, and the storage process for storing the carriage unit 23 moved to the standby area 45. It has become.

  Prior to the start of drawing by the droplet discharge device 1, the workpiece W is introduced into the droplet discharge device 1 by a transfer robot (not shown). When the operator instructs the control unit 57 to execute drawing, the control unit 57 starts the unit number determination program 73 (unit number determination means). Then, the unit number determination program 73 requests the operator to input the length of the workpiece W in the Y-axis direction (work width) in order to determine the necessary number of carriage units 23 used for drawing. When the operator inputs the workpiece width to the control unit 57, the number of carriage units 23 required for drawing is determined (unit number determination step).

  Specifically, the required number of carriage units 23 is determined as follows. The workpiece (substrate) 6 in the set state has workpiece widths of 500 mm, 680 mm, 880 mm, 1100 mm, 1500 mm, and 1800 mm, while each carriage unit 23 has 271 each. Drawing is possible in the main scanning direction (X-axis direction) with a millimeter width. That is, in this embodiment, two carriage units 23 are assigned to drawing for a 500 mm workpiece W, three for 680 mm, four for 880 mm, and five for 1100 mm. In this case, six carriage units 23 are assigned to 1500 mm ones and six to 1,800 mm ones. As a result, it is possible to perform drawing only in the main scanning (forward movement), that is, the line printing method, over the entire area of the workpiece W of each workpiece width. Therefore, for example, when the workpiece width is input as 1100 mm, the unit number determination program 73 determines to perform drawing with the five carriage units 23.

  In the control unit 57, the usage frequency of the functional liquid droplet ejection head 3 is managed in real time (usage frequency management process). That is, the above-described use frequency management program 74 is always started during the operation of the droplet discharge device 1, and as the drawing work on the workpiece W progresses, the cumulative number of discharges of each functional droplet discharge head 3, etc. Various management data are updated sequentially. Further, when each functional liquid droplet ejection head 3 of the carriage unit 23 facing the maintenance device 5 performs flushing (discarding ejection) on the first or second storage / suction unit 46a, 46b, or performs nozzle suction by a suction mechanism. In such a case, these processes are converted into the number of shots, and the count value of the cumulative number of shots to which the converted value is added is held in the management data area.

  When the number of carriage units 23 is determined, a unit selection program 75 (unit selection means) is subsequently activated by the control unit 57. The unit selection program 75 selects the carriage unit 23 that actually operates based on the number of units determined in the unit number determination step (unit selection step). This selection is based on the count value of the cumulative number of shots of each functional liquid droplet ejection head 3 managed by the usage frequency management program 74 so that the usage frequency is averaged among the plurality of functional liquid droplet ejection heads 3. Do. Furthermore, in order to prevent the use of the carriage unit 23 including the functional liquid droplet ejection head 3 that has already reached the end of the selection, the selection is made among the plurality of functional liquid droplet ejection heads 3 mounted on each carriage unit 23. The function droplet discharge head 3 having the maximum use frequency is used as a reference. Note that details of the use frequency averaging between the functional liquid droplet ejection heads 3 by this selection will be described later.

  When the above selection is performed, the control unit 57 (movement control means) selectively moves the carriage unit 23 via the Y-axis table 11 (carriage movement means) (carriage movement process). At this time, the control unit 57 (movement control means) simultaneously retracts the carriage unit 23 not used for drawing to the standby area 45 so that only the carriage unit 23 used for drawing faces the drawing area 44. For example, in the above example, when drawing is performed with the five carriage units 23 b to f from the second to the sixth in total, the first carriage unit 23 a moves (retreats) to the standby area 45 on the opposite side beyond the drawing area 44. The second to sixth carriage units 23b to 23f are made to face the drawing area 44. In this case, the seventh carriage unit 23g stands by in the standby area 45 as it is.

  Then, each of the functional liquid droplet ejection heads 3 of the second to sixth carriage units 23b to 23f performs drawing on the workpiece W to be main scanned by the X-axis table 8. Drawing is performed by the line print method in order to shorten the tact time as described above. The carriage unit 23 is moved when the workpiece W is replaced so that the operation (drawing operation) of the apparatus is not stopped.

  In the storage process, the carriage unit 23 that is moving or waiting in the standby area 45 faces the subunits 48 of the first storage / suction unit 46a and the second storage / suction unit 46b and receives various maintenance. Each functional liquid droplet ejection head 3 is maintained in a function maintaining state. In the above example, the first and seventh carriage units 23a, b face the subunit 48 of the first storage / suction unit 46a and the second storage / suction unit 46b, and the functional liquid droplet ejection heads of both the carriage units 23a, 23g. 3 is protected from functional deterioration such as drying. In addition, when all the first to seventh carriage units 23 are used for drawing, this storage step is unnecessary. When each carriage unit 23 is introduced from the standby area 45 to the drawing area 44, the first or second wiping unit is removed after the capping by the sealing cap is released and the respective sub units 48 are flushed. Wiping of each functional liquid droplet ejection head 3 is performed at 47a and 47b.

  Next, the use frequency averaging of each functional liquid droplet ejection head 3 will be described in detail. 7 to 10 are schematic top views of the Y-axis table 11. Reference numerals 6 to 8 in the drawings indicate the usage frequency of each carriage unit 23 with numbers from 0 to 10 on the basis of the function liquid droplet ejection head 3 having the maximum usage frequency in each carriage unit 23. The reference numeral 0 indicates an unused carriage unit 23, and the reference numeral 10 indicates that the functional liquid droplet ejection head 3 having the highest usage frequency in the carriage unit 23 has reached the end of its life. Further, when one drawing operation is performed on the workpiece W, the use frequency increases by one.

  FIG. 4A shows the Y-axis table 11 in operation. The first to seventh carriage units 23a to 23g in operation are used at frequencies of about 6, 7, 8, 8, 8, 7, 6, respectively, and the third to fifth carriages closer to the center. Usually, the frequency of use of the units 23c to 23e increases. That is, since the fourth carriage unit 23d is always used for drawing (work width of 880 mm or more) using four or more carriage units 23, its use frequency is high. Further, the surrounding third carriage unit 23c and fifth carriage unit 23e are preferentially used in drawing with three or less carriage units 23 so that the usage frequency of the fourth carriage unit 23d does not protrude and become high. (For example, a combination of the first to third carriage units 23a to 23c or the fifth to seventh carriage units 23e to 23g is used). In the following description, it is assumed that a workpiece W having a workpiece width of 500 mm, 1100 mm, 880 mm, and 680 mm is sequentially introduced into the droplet discharge device 1 (Y-axis table 11) in this state to perform drawing. .

  When a workpiece W having a workpiece width of 500 mm is introduced as shown in FIG. 5B, the unit number determination program 73 determines the required number of carriage units as two. Subsequently, the unit selection program 75 selects the carriage unit 23 used for drawing, but selects the combination of the carriage units 23 that minimizes the use frequency addition value (actually, the cumulative shot number addition value). . In the above case, the combination of the first and second carriage units 23a and 23b and the combination of the sixth and seventh carriage units 23f and g are candidates. However, in the latter combination, the first to fifth carriage units 23a to 23e need to face the second storage / suction unit 46b in the waiting area 45 on the opposite side. Only four subunits 48 are provided, and the fourth and fifth carriage units 23d, e cannot be capped. For this reason, the unit selection program 75 selects the first and second carriage units 23a and 23b.

  When the first and second carriage units 23a and 23b perform drawing on the drawing area 44, as shown in FIGS. 6B and 6C, the frequency of use thereof is 6, 7 to 7, It becomes 8. Subsequently, when a workpiece W having a length in the Y-axis direction of 1100 mm is introduced as shown in FIG. 8A, the unit number determination program 73 determines the required number of the carriage units 23 as five. In this case, the unit selection program 73 selects a combination of the third to seventh carriage units 23c to 23g having the smallest use frequency addition value. When the third to seventh carriage units 23c to 23g face the drawing area 44 and perform drawing, as shown in FIGS. 8 (a) and 8 (b), the frequency of use is 8, 8, 8, From 7, 6 to 9, 9, 9, 8, 7.

  Next, when a work W having a work width of 880 mm is introduced as shown in FIG. 4C, the unit number determination program 73 determines the required number of carriage units 23 as four. Then, the unit selection program 75 selects any one of the combinations of the first to fourth carriage units 23a to 23d and the combinations of the fourth to seventh carriage units 23d to g with the smallest added value of the usage frequency. . In this case, the unit selection program 75 selects the latter combination in order to preferentially select the seventh carriage unit 23g farthest from the drawing area 44 and less frequently used. When the fourth to seventh carriage units 23d to 23g perform drawing, as shown in FIGS. 8 (c) and 9 (a), the frequency of use is 9, 9, 8, 7 to 10, 10, 9, 8 As a result of this drawing, among the functional liquid droplet ejection heads 3 mounted on the fourth and fifth carriage units 23d, e, the one that is used most frequently reaches the end of its life.

  In this state, a workpiece W having a work width of 880 mm or more that requires four or more carriage units 23 cannot be drawn in the line printing method without replacing the carriage unit 23, but a work of 680 mm or less is used. Drawing can be continued on the workpiece W having a width. That is, as shown in FIG. 9B, when a workpiece W having a workpiece width of 680 mm is introduced, the unit number determination program 73 determines that the required number of carriage units 23 is 3, and the unit selection program 75 is still The first to third carriage units 23a to 23c capable of drawing are selected. Then, as shown in FIGS. 9B and 10A, the usage frequencies of the first to third carriage units 23a to 23c are 7, 8, 9 to 8, 9, 10. Then, as shown in FIG. 10 (b), all the carriage units 23 that have faced the standby area 45 have the usage frequencies of 8, 9, 10, 10, 10, 9, and 8, respectively. The droplet discharge heads 3 are substantially averaged and reach the end of their lives, and each functional droplet discharge head 3 is subjected to batch replacement.

  Note that the determination of the frequency of use of the functional liquid droplet ejection head 3 is mainly based on the count value of the cumulative number of shots of each functional liquid droplet ejection head 3 because the count value can be easily acquired in the control unit. However, depending on not only the cumulative number of shots of each functional liquid droplet ejection head 3, but also any one of the accumulated usage time of each functional liquid droplet ejection head 3 and the measured value (remaining amount of functional liquid) of each functional liquid tank 36, The usage frequency may be determined.

  The above is the droplet discharge device of this embodiment. According to this embodiment, the carriage unit 23 with low usage frequency of each functional liquid tank 36 to be mounted can be preferentially operated, and the functional liquid droplet ejection head 3 reaches the lifetime almost simultaneously in units of the carriage unit 23. Can do. Thereby, all the carriage units 23 can be replaced at a time in anticipation of the lifetime of the functional liquid droplet ejection head 3. In addition, if the batch replacement is performed in this way, the operation stop time of the droplet discharge device 1 can be minimized and the product productivity can be improved. Further, since the standby areas 45 are arranged on both sides of the drawing area 44, the carriage unit 23 not used for drawing is retracted to the standby area 45 on the opposite side, and the other carriage units 23 are exposed to the drawing area 44. Can not draw. Thereby, the freedom degree of selection of the carriage unit 23 to be used for drawing can be increased.

  Next, as an electro-optical device (flat panel display) manufactured using the droplet discharge device 1 of this embodiment, a color filter, a liquid crystal display device, an organic EL device, a plasma display (PDP device), an electron emission device ( FED devices, SED devices), and active matrix substrates formed in these display devices will be described as an example for their structures and manufacturing methods. Note that an active matrix substrate refers to a substrate on which a thin film transistor, a source line electrically connected to the thin film transistor, and a data line are formed.

First, a method for manufacturing a color filter incorporated in a liquid crystal display device, an organic EL device or the like will be described. FIG. 11 is a flowchart showing the manufacturing process of the color filter, and FIG. 12 is a schematic cross-sectional view of the color filter 500 (filter base body 500A) of this embodiment shown in the order of the manufacturing process.
First, in the black matrix forming step (S101), a black matrix 502 is formed on a substrate (W) 501 as shown in FIG. The black matrix 502 is formed of metal chromium, a laminate of metal chromium and chromium oxide, resin black, or the like. A sputtering method, a vapor deposition method, or the like can be used to form the black matrix 502 made of a metal thin film. Further, when forming the black matrix 502 made of a resin thin film, a gravure printing method, a photoresist method, a thermal transfer method, or the like can be used.

Subsequently, in the bank formation step (S102), a bank 503 is formed in a state of being superimposed on the black matrix 502. That is, first, as shown in FIG. 12B, a resist layer 504 made of a negative transparent photosensitive resin is formed so as to cover the substrate 501 and the black matrix 502. Then, an exposure process is performed with the upper surface covered with a mask film 505 formed in a matrix pattern shape.
Further, as shown in FIG. 12C, the resist layer 504 is patterned by etching an unexposed portion of the resist layer 504 to form a bank 503. When the black matrix is formed from resin black, it is possible to use both the black matrix and the bank.
The bank 503 and the black matrix 502 therebelow serve as a partition wall portion 507b that partitions each pixel region 507a, and colored layers (film forming portions) 508R, 508G, and 508B are formed by the droplet discharge head 3 in a subsequent colored layer forming step. The landing area of the functional droplet is defined when forming the.

The filter substrate 500A is obtained through the above black matrix forming step and bank forming step.
In the present embodiment, as the material for the bank 503, a resin material whose surface is lyophobic (hydrophobic) is used. Since the surface of the substrate (glass substrate) 501 is lyophilic (hydrophilic), the droplets into each pixel region 507a surrounded by the bank 503 (partition wall portion 507b) in the colored layer forming step described later. The landing position accuracy is improved.

  Next, in the colored layer forming step (S103), as shown in FIG. 12 (d), functional droplets are ejected by the functional droplet ejection head 3, and each pixel region 507a surrounded by the partition wall portion 507b is placed. Let it land. In this case, the functional liquid droplet ejection head 3 is used to introduce functional liquids (filter materials) of three colors of R, G, and B to eject functional liquid droplets. Note that the three-color arrangement pattern of R, G, and B includes a stripe arrangement, a mosaic arrangement, and a delta arrangement.

Thereafter, the functional liquid is fixed through a drying process (a process such as heating), and three colored layers 508R, 508G, and 508B are formed. When the colored layers 508R, 508G, and 508B are formed, the process proceeds to the protective film forming step (S104), and as shown in FIG. A protective film 509 is formed so as to cover the upper surface.
That is, after the protective film coating liquid is discharged over the entire surface of the substrate 501 where the colored layers 508R, 508G, and 508B are formed, the protective film 509 is formed through a drying process.
Then, after forming the protective film 509, the color filter 500 moves to a film forming process such as ITO (Indium Tin Oxide) which becomes a transparent electrode in the next process.

  FIG. 13 is a cross-sectional view of a principal part showing a schematic configuration of a passive matrix liquid crystal device (liquid crystal device) as an example of a liquid crystal display device using the color filter 500 described above. By attaching auxiliary elements such as a liquid crystal driving IC, a backlight, and a support to the liquid crystal device 520, a transmissive liquid crystal display device as a final product can be obtained. Since the color filter 500 is the same as that shown in FIG. 12, the corresponding parts are denoted by the same reference numerals, and the description thereof is omitted.

The liquid crystal device 520 is roughly composed of a color filter 500, a counter substrate 521 made of a glass substrate, and a liquid crystal layer 522 made of STN (Super Twisted Nematic) liquid crystal composition sandwiched between them, The filter 500 is arranged on the upper side (observer side) in the figure.
Although not shown, polarizing plates are provided on the outer surfaces of the counter substrate 521 and the color filter 500 (surfaces opposite to the liquid crystal layer 522 side), and the polarizing plates located on the counter substrate 521 side are also provided. A backlight is disposed outside.

On the protective film 509 of the color filter 500 (on the liquid crystal layer side), a plurality of strip-shaped first electrodes 523 elongated in the left-right direction in FIG. 13 are formed at predetermined intervals. The color of the first electrode 523 A first alignment film 524 is formed so as to cover the surface opposite to the filter 500 side.
On the other hand, a plurality of strip-shaped second electrodes 526 elongated in a direction orthogonal to the first electrode 523 of the color filter 500 are formed on the surface of the counter substrate 521 facing the color filter 500 at a predetermined interval. A second alignment film 527 is formed so as to cover the surface of the two electrodes 526 on the liquid crystal layer 522 side. The first electrode 523 and the second electrode 526 are made of a transparent conductive material such as ITO.

The spacer 528 provided in the liquid crystal layer 522 is a member for keeping the thickness (cell gap) of the liquid crystal layer 522 constant. The sealing material 529 is a member for preventing the liquid crystal composition in the liquid crystal layer 522 from leaking to the outside. Note that one end of the first electrode 523 extends to the outside of the sealing material 529 as a lead-out wiring 523a.
A portion where the first electrode 523 and the second electrode 526 intersect with each other is a pixel, and the color layers 508R, 508G, and 508B of the color filter 500 are located in the portion that becomes the pixel.

  In a normal manufacturing process, patterning of the first electrode 523 and application of the first alignment film 524 are performed on the color filter 500 to create a portion on the color filter 500 side. Patterning of the electrode 526 and application of the second alignment film 527 are performed to create a portion on the counter substrate 521 side. Thereafter, a spacer 528 and a sealing material 529 are formed in the portion on the counter substrate 521 side, and the portion on the color filter 500 side is bonded in this state. Next, liquid crystal constituting the liquid crystal layer 522 is injected from the inlet of the sealing material 529, and the inlet is closed. Thereafter, both polarizing plates and the backlight are laminated.

  The droplet discharge device 1 according to the embodiment applies, for example, a spacer material (functional liquid) that constitutes the cell gap, and before the portion on the color filter 500 side is bonded to the portion on the counter substrate 521 side, the sealing material Liquid crystal (functional liquid) can be uniformly applied to the region surrounded by 529. Further, the printing of the sealing material 529 can be performed by the functional liquid droplet ejection head 3. Furthermore, the first and second alignment films 524 and 527 can be applied by the functional liquid droplet ejection head 3.

FIG. 14 is a cross-sectional view of a principal part showing a schematic configuration of a second example of a liquid crystal device using the color filter 500 manufactured in the present embodiment.
The liquid crystal device 530 is significantly different from the liquid crystal device 520 in that the color filter 500 is arranged on the lower side (the side opposite to the observer side) in the figure.
The liquid crystal device 530 is generally configured by sandwiching a liquid crystal layer 532 made of STN liquid crystal between a color filter 500 and a counter substrate 531 made of a glass substrate or the like. Although not shown, polarizing plates and the like are provided on the outer surfaces of the counter substrate 531 and the color filter 500, respectively.

On the protective film 509 of the color filter 500 (on the liquid crystal layer 532 side), a plurality of strip-shaped first electrodes 533 elongated in the depth direction in the figure are formed at predetermined intervals, and the liquid crystal of the first electrodes 533 is formed. A first alignment film 534 is formed so as to cover the surface on the layer 532 side.
A plurality of strip-shaped second electrodes 536 extending in a direction orthogonal to the first electrode 533 on the color filter 500 side are formed on the surface of the counter substrate 531 facing the color filter 500 at a predetermined interval. A second alignment film 537 is formed so as to cover the surface of the second electrode 536 on the liquid crystal layer 532 side.

The liquid crystal layer 532 is provided with a spacer 538 for keeping the thickness of the liquid crystal layer 532 constant and a sealing material 539 for preventing the liquid crystal composition in the liquid crystal layer 532 from leaking to the outside. Yes.
Similarly to the liquid crystal device 520 described above, a portion where the first electrode 533 and the second electrode 536 intersect with each other is a pixel, and the colored layers 508R, 508G, and 508B of the color filter 500 are located at the portion that becomes the pixel. Is configured to do.

FIG. 15 shows a third example in which a liquid crystal device is configured using a color filter 500 to which the present invention is applied, and is an exploded perspective view showing a schematic configuration of a transmissive TFT (Thin Film Transistor) type liquid crystal device. It is.
In the liquid crystal device 550, the color filter 500 is arranged on the upper side (observer side) in the figure.

The liquid crystal device 550 includes a color filter 500, a counter substrate 551 disposed so as to face the color filter 500, a liquid crystal layer (not shown) sandwiched therebetween, and an upper surface side (observer side) of the color filter 500. The polarizing plate 555 and the polarizing plate (not shown) arranged on the lower surface side of the counter substrate 551 are roughly configured.
A liquid crystal driving electrode 556 is formed on the surface of the protective film 509 of the color filter 500 (the surface on the counter substrate 551 side). The electrode 556 is made of a transparent conductive material such as ITO, and is a full surface electrode that covers the entire region where a pixel electrode 560 described later is formed. An alignment film 557 is provided so as to cover the surface of the electrode 556 opposite to the pixel electrode 560.

  An insulating layer 558 is formed on the surface of the counter substrate 551 facing the color filter 500, and the scanning lines 561 and the signal lines 562 are formed on the insulating layer 558 in a state of being orthogonal to each other. A pixel electrode 560 is formed in a region surrounded by the scanning lines 561 and the signal lines 562. In an actual liquid crystal device, an alignment film is provided on the pixel electrode 560, but the illustration is omitted.

  In addition, a thin film transistor 563 including a source electrode, a drain electrode, a semiconductor, and a gate electrode is incorporated in a portion surrounded by the cutout portion of the pixel electrode 560 and the scanning line 561 and the signal line 562. . The thin film transistor 563 is turned on / off by application of signals to the scanning line 561 and the signal line 562 so that energization control to the pixel electrode 560 can be performed.

  Note that the liquid crystal devices 520, 530, and 550 in the above examples are transmissive, but a reflective liquid crystal device or a transflective liquid crystal device is provided by providing a reflective layer or a transflective layer. You can also

  Next, FIG. 16 is a cross-sectional view of a main part of a display region (hereinafter simply referred to as a display device 600) of the organic EL device.

The display device 600 is schematically configured with a circuit element portion 602, a light emitting element portion 603, and a cathode 604 stacked on a substrate (W) 601.
In the display device 600, light emitted from the light emitting element portion 603 to the substrate 601 side is transmitted through the circuit element portion 602 and the substrate 601 and emitted to the observer side, and the light emitting element portion 603 is opposite to the substrate 601. After the light emitted to the side is reflected by the cathode 604, the light passes through the circuit element portion 602 and the substrate 601 and is emitted to the observer side.

  A base protective film 606 made of a silicon oxide film is formed between the circuit element portion 602 and the substrate 601, and an island-shaped semiconductor film 607 made of polycrystalline silicon is formed on the base protective film 606 (on the light emitting element portion 603 side). Is formed. In the left and right regions of the semiconductor film 607, a source region 607a and a drain region 607b are formed by high concentration cation implantation, respectively. A central portion where no positive ions are implanted is a channel region 607c.

  In the circuit element portion 602, a transparent gate insulating film 608 covering the base protective film 606 and the semiconductor film 607 is formed, and a position corresponding to the channel region 607c of the semiconductor film 607 on the gate insulating film 608 is formed. For example, a gate electrode 609 made of Al, Mo, Ta, Ti, W or the like is formed. On the gate electrode 609 and the gate insulating film 608, a transparent first interlayer insulating film 611a and a second interlayer insulating film 611b are formed. Further, contact holes 612a and 612b are formed through the first and second interlayer insulating films 611a and 611b and communicating with the source region 607a and the drain region 607b of the semiconductor film 607, respectively.

A transparent pixel electrode 613 made of ITO or the like is patterned and formed in a predetermined shape on the second interlayer insulating film 611b, and the pixel electrode 613 is connected to the source region 607a through the contact hole 612a. .
A power line 614 is disposed on the first interlayer insulating film 611a, and the power line 614 is connected to the drain region 607b through the contact hole 612b.

  Thus, the driving thin film transistors 615 connected to the pixel electrodes 613 are formed in the circuit element portion 602, respectively.

The light emitting element portion 603 includes a functional layer 617 stacked on each of the plurality of pixel electrodes 613, and a bank portion 618 provided between each pixel electrode 613 and the functional layer 617 to partition each functional layer 617. It is roughly structured.
The pixel electrode 613, the functional layer 617, and the cathode 604 provided on the functional layer 617 constitute a light emitting element. Note that the pixel electrode 613 is formed by patterning in a substantially rectangular shape in plan view, and a bank portion 618 is formed between the pixel electrodes 613.

The bank unit 618 is laminated on the inorganic bank layer 618a (first bank layer) 618a formed of an inorganic material such as SiO, SiO ₂ , TiO _{2, and the} like, and is made of an acrylic resin, a polyimide resin, or the like. It is composed of an organic bank layer 618b (second bank layer) having a trapezoidal cross section formed of a resist having excellent heat resistance and solvent resistance. A part of the bank unit 618 is formed on the peripheral edge of the pixel electrode 613.
An opening 619 that gradually expands upward with respect to the pixel electrode 613 is formed between the bank portions 618.

The functional layer 617 includes a hole injection / transport layer 617a formed in a stacked state on the pixel electrode 613 in the opening 619, and a light emitting layer 617b formed on the hole injection / transport layer 617a. Has been. In addition, you may further form the other functional layer which has another function adjacent to this light emitting layer 617b. For example, it is possible to form an electron transport layer.
The hole injection / transport layer 617a has a function of transporting holes from the pixel electrode 613 side and injecting them into the light emitting layer 617b. The hole injection / transport layer 617a is formed by discharging a first composition (functional liquid) containing a hole injection / transport layer forming material. A known material is used as the hole injection / transport layer forming material.

  The light emitting layer 617b emits light in red (R), green (G), or blue (B), and discharges a second composition (functional liquid) containing a light emitting layer forming material (light emitting material). Is formed. As the solvent (nonpolar solvent) of the second composition, a known material that is insoluble in the hole injection / transport layer 617a is preferably used, and such a nonpolar solvent is used as the second composition of the light emitting layer 617b. By using the light emitting layer 617b, the light emitting layer 617b can be formed without re-dissolving the hole injection / transport layer 617a.

  The light emitting layer 617b is configured such that the holes injected from the hole injection / transport layer 617a and the electrons injected from the cathode 604 are recombined in the light emitting layer to emit light.

  The cathode 604 is formed so as to cover the entire surface of the light emitting element portion 603, and plays a role of flowing current to the functional layer 617 in a pair with the pixel electrode 613. Note that a sealing member (not shown) is disposed on the cathode 604.

Next, a manufacturing process of the display device 600 will be described with reference to FIGS.
As shown in FIG. 17, the display device 600 includes a bank part forming step (S111), a surface treatment step (S112), a hole injection / transport layer forming step (S113), a light emitting layer forming step (S114), It is manufactured through an electrode formation step (S115). In addition, a manufacturing process is not restricted to what is illustrated, and when other processes are removed as needed, it may be added.

First, in the bank part forming step (S111), as shown in FIG. 18, an inorganic bank layer 618a is formed on the second interlayer insulating film 611b. The inorganic bank layer 618a is formed by forming an inorganic film at a formation position and then patterning the inorganic film by a photolithography technique or the like. At this time, a part of the inorganic bank layer 618 a is formed so as to overlap with the peripheral edge of the pixel electrode 613.
When the inorganic bank layer 618a is formed, an organic bank layer 618b is formed on the inorganic bank layer 618a as shown in FIG. The organic bank layer 618b is also formed by patterning using a photolithography technique or the like in the same manner as the inorganic bank layer 618a.
In this way, the bank portion 618 is formed. Accordingly, an opening 619 opening upward with respect to the pixel electrode 613 is formed between the bank portions 618. The opening 619 defines a pixel region.

In the surface treatment step (S112), a lyophilic process and a lyophobic process are performed. The regions to be subjected to the lyophilic treatment are the first stacked portion 618aa of the inorganic bank layer 618a and the electrode surface 613a of the pixel electrode 613. These regions are made lyophilic by plasma treatment using oxygen as a processing gas, for example. Is done. This plasma treatment also serves to clean the ITO that is the pixel electrode 613.
In addition, the lyophobic treatment is performed on the wall surface 618s of the organic bank layer 618b and the upper surface 618t of the organic bank layer 618b, and the surface is fluorinated (treated to be liquid repellent) by plasma treatment using, for example, tetrafluoromethane. )
By performing this surface treatment process, when the functional layer 617 is formed using the functional liquid droplet ejection head 3, the functional liquid droplets can be landed more reliably on the pixel area. It is possible to prevent the functional droplets from overflowing from the opening 619.

  Then, the display device base 600A is obtained through the above steps. The display device base 600A is placed on the suction table 12 of the droplet discharge device 1 shown in FIG. 1, and the following hole injection / transport layer forming step (S113) and light emitting layer forming step (S114) are performed. .

  As shown in FIG. 20, in the hole injection / transport layer forming step (S113), the first composition containing the hole injection / transport layer forming material is transferred from the functional liquid droplet ejection head 3 to each opening 619 that is a pixel region. Discharge inside. Thereafter, as shown in FIG. 21, a drying process and a heat treatment are performed to evaporate the polar solvent contained in the first composition, and a hole injection / transport layer 617a is formed on the pixel electrode (electrode surface 613a) 613.

Next, the light emitting layer forming step (S114) will be described. In this light emitting layer forming step, as described above, in order to prevent re-dissolution of the hole injection / transport layer 617a, the hole injection / transport layer 617a is used as a solvent for the second composition used in forming the light emitting layer. A non-polar solvent insoluble in.
However, since the hole injection / transport layer 617a has a low affinity for the nonpolar solvent, the hole injection / transport layer 617a has a low affinity even if the second composition containing the nonpolar solvent is discharged onto the hole injection / transport layer 617a. There is a possibility that the injection / transport layer 617a and the light emitting layer 617b cannot be adhered to each other, or the light emitting layer 617b cannot be applied uniformly.
Therefore, in order to increase the surface affinity of the hole injection / transport layer 617a with respect to the nonpolar solvent and the light emitting layer forming material, it is preferable to perform a surface treatment (surface modification treatment) before forming the light emitting layer. In this surface treatment, a surface modifying material which is the same solvent as the non-polar solvent of the second composition used in the formation of the light emitting layer or a similar solvent is applied on the hole injection / transport layer 617a, and this is applied. This is done by drying.
By performing such treatment, the surface of the hole injection / transport layer 617a is easily adapted to the nonpolar solvent. In the subsequent step, the second composition containing the light emitting layer forming material is added to the hole injection / transport layer. It can be uniformly applied to 617a.

  Then, as shown in FIG. 22, the second composition containing the light emitting layer forming material corresponding to one of the colors (blue (B) in the example of FIG. 22) is used as a functional droplet as a pixel region ( A predetermined amount is driven into the opening 619). The second composition driven into the pixel region spreads on the hole injection / transport layer 617a and fills the opening 619. Even if the second composition deviates from the pixel region and lands on the upper surface 618t of the bank portion 618, the upper composition 618t is subjected to the liquid repellent treatment as described above, so the second composition Things are easy to roll into the opening 619.

  Thereafter, by performing a drying process or the like, the second composition after discharge is dried, the nonpolar solvent contained in the second composition is evaporated, and as shown in FIG. 23, a hole injection / transport layer 617a is obtained. A light emitting layer 617b is formed thereon. In the case of this figure, a light emitting layer 617b corresponding to blue (B) is formed.

  Similarly, using the functional liquid droplet ejection head 3, as shown in FIG. 24, the same steps as in the case of the light emitting layer 617b corresponding to the blue (B) described above are sequentially performed, and other colors (red (R) and red (R) and A light emitting layer 617b corresponding to green (G) is formed. Note that the order in which the light-emitting layers 617b are formed is not limited to the illustrated order, and may be formed in any order. For example, the order of formation can be determined according to the light emitting layer forming material. In addition, the arrangement pattern of the three colors R, G, and B includes a stripe arrangement, a mosaic arrangement, a delta arrangement, and the like.

  As described above, the functional layer 617, that is, the hole injection / transport layer 617a and the light emitting layer 617b are formed on the pixel electrode 613. And it transfers to a counter electrode formation process (S115).

In the counter electrode forming step (S115), as shown in FIG. 25, a cathode 604 (counter electrode) is formed on the entire surface of the light emitting layer 617b and the organic bank layer 618b by, for example, vapor deposition, sputtering, CVD, or the like. In the present embodiment, the cathode 604 is configured by, for example, laminating a calcium layer and an aluminum layer.
On top of the cathode 604, an Al film, an Ag film as an electrode, and a protective layer such as SiO ₂ or SiN for preventing oxidation thereof are appropriately provided.

  After forming the cathode 604 in this way, the display device 600 is obtained by performing other processes such as a sealing process for sealing the upper part of the cathode 604 with a sealing member and a wiring process.

Next, FIG. 26 is an exploded perspective view of an essential part of a plasma display device (PDP device: hereinafter simply referred to as a display device 700). In the figure, the display device 700 is shown with a part thereof cut away.
The display device 700 is schematically configured to include a first substrate 701 and a second substrate 702 that are disposed to face each other, and a discharge display portion 703 that is formed therebetween. The discharge display unit 703 includes a plurality of discharge chambers 705. Among the plurality of discharge chambers 705, the three discharge chambers 705 of the red discharge chamber 705R, the green discharge chamber 705G, and the blue discharge chamber 705B are arranged to form one pixel.

Address electrodes 706 are formed in stripes at predetermined intervals on the upper surface of the first substrate 701, and a dielectric layer 707 is formed so as to cover the address electrodes 706 and the upper surface of the first substrate 701. On the dielectric layer 707, partition walls 708 are provided so as to be positioned between the address electrodes 706 and along the address electrodes 706. The partition 708 includes one extending on both sides in the width direction of the address electrode 706 as shown, and one not shown extending in the direction orthogonal to the address electrode 706.
A region partitioned by the partition 708 is a discharge chamber 705.

  A phosphor 709 is disposed in the discharge chamber 705. The phosphor 709 emits red (R), green (G), or blue (B) fluorescence. The red phosphor 709R is disposed at the bottom of the red discharge chamber 705R, and the green discharge chamber 705G. A green phosphor 709G and a blue phosphor 709B are arranged at the bottom and the blue discharge chamber 705B, respectively.

On the lower surface of the second substrate 702 in the drawing, a plurality of display electrodes 711 are formed in stripes at predetermined intervals in a direction orthogonal to the address electrodes 706. A dielectric layer 712 and a protective film 713 made of MgO or the like are formed so as to cover them.
The first substrate 701 and the second substrate 702 are bonded so that the address electrodes 706 and the display electrodes 711 face each other in a state of being orthogonal to each other. The address electrode 706 and the display electrode 711 are connected to an AC power source (not shown).
When the electrodes 706 and 711 are energized, the phosphor 709 emits light in the discharge display portion 703, and color display is possible.

In the present embodiment, the address electrode 706, the display electrode 711, and the phosphor 709 can be formed using the droplet discharge device 1 shown in FIG. Hereinafter, a process of forming the address electrode 706 on the first substrate 701 will be exemplified.
In this case, the following steps are performed with the first substrate 701 placed on the suction table 12 of the droplet discharge device 1.
First, a liquid material (functional liquid) containing a conductive film wiring forming material is landed on the address electrode formation region as a functional liquid droplet by the functional liquid droplet ejection head 3. This liquid material is obtained by dispersing conductive fine particles such as metal in a dispersion medium as a conductive film wiring forming material. As the conductive fine particles, metal fine particles containing gold, silver, copper, palladium, nickel, or the like, a conductive polymer, or the like is used.

  When the replenishment of the liquid material is completed for all the address electrode formation regions to be replenished, the address material 706 is formed by drying the discharged liquid material and evaporating the dispersion medium contained in the liquid material. .

By the way, although the formation of the address electrode 706 has been exemplified in the above, the display electrode 711 and the phosphor 709 can also be formed through the above steps.
In the case of forming the display electrode 711, as in the case of the address electrode 706, a liquid material (functional liquid) containing a conductive film wiring forming material is landed on the display electrode formation region as a functional droplet.
In the case of forming the phosphor 709, a liquid material (functional liquid) containing a fluorescent material corresponding to each color (R, G, B) is ejected as droplets from the droplet ejection head 3, and the corresponding color In the discharge chamber 705.

Next, FIG. 27 is a cross-sectional view of an essential part of an electron emission device (also referred to as an FED device or an SED device: hereinafter simply referred to as a display device 800). In the drawing, a part of the display device 800 is shown as a cross section.
The display device 800 includes a first substrate 801, a second substrate 802, and a field emission display unit 803 formed therebetween, which are disposed to face each other. The field emission display unit 803 includes a plurality of electron emission units 805 arranged in a matrix.

  On the upper surface of the first substrate 801, a first element electrode 806a and a second element electrode 806b constituting the cathode electrode 806 are formed so as to be orthogonal to each other. In addition, a conductive film 807 having a gap 808 is formed in a portion partitioned by the first element electrode 806a and the second element electrode 806b. That is, the first element electrode 806a, the second element electrode 806b, and the conductive film 807 constitute a plurality of electron emission portions 805. The conductive film 807 is made of, for example, palladium oxide (PdO), and the gap 808 is formed by forming after forming the conductive film 807.

  An anode electrode 809 that faces the cathode electrode 806 is formed on the lower surface of the second substrate 802. A grid-like bank portion 811 is formed on the lower surface of the anode electrode 809, and a phosphor 813 is disposed in each downward opening 812 surrounded by the bank portion 811 so as to correspond to the electron emission portion 805. Yes. The phosphor 813 emits fluorescence of any one of red (R), green (G), and blue (B), and each opening 812 has a red phosphor 813R, a green phosphor 813G, and a blue color. The phosphors 813B are arranged in the predetermined pattern described above.

  The first substrate 801 and the second substrate 802 configured as described above are bonded together with a minute gap. In this display device 800, electrons that jump out of the first element electrode 806 a or the second element electrode 806 b that are cathodes through the conductive film (gap 808) 807 are formed on the phosphor 813 formed on the anode electrode 809 that is an anode. When excited, it emits light and enables color display.

  Also in this case, as in the other embodiments, the first element electrode 806a, the second element electrode 806b, the conductive film 807, and the anode electrode 809 can be formed using the droplet discharge device 1 and each color. The phosphors 813R, 813G, and 813B can be formed using the droplet discharge device 1.

  The first element electrode 806a, the second element electrode 806b, and the conductive film 807 have the planar shape shown in FIG. 28A, and when these are formed, as shown in FIG. In addition, the bank portion BB is formed (photolithographic method), leaving portions where the first element electrode 806a, the second element electrode 806b, and the conductive film 807 are previously formed. Next, the first element electrode 806a and the second element electrode 806b were formed in the groove portion constituted by the bank portion BB (inkjet method using the droplet discharge device 1), and the solvent was dried to form a film. After that, a conductive film 807 is formed (an ink jet method using the droplet discharge device 1). Then, after forming the conductive film 807, the bank portion BB is removed (ashing peeling process), and the process proceeds to the above forming process. As in the case of the organic EL device described above, it is preferable to perform a lyophilic process on the first substrate 801 and the second substrate 802 and a lyophobic process on the bank portions 811 and BB.

  As other electro-optical devices, devices such as metal wiring formation, lens formation, resist formation, and light diffuser formation are conceivable. By using the droplet discharge device 1 described above for manufacturing various electro-optical devices (devices), various electro-optical devices can be efficiently manufactured.

It is a top view of a droplet discharge device. It is a top perspective view of a droplet discharge device. It is a top view of a carriage unit and a tank carriage. 2A is a top perspective view of a functional liquid droplet ejection head, and FIG. It is a side view of a functional liquid supply unit. It is a block diagram showing the control system of a droplet discharge apparatus. It is explanatory drawing explaining the drawing control method. It is explanatory drawing explaining the drawing control method. It is explanatory drawing explaining the drawing control method. It is explanatory drawing explaining the drawing control method. It is a flowchart explaining a color filter manufacturing process. (A)-(e) is a schematic cross section of the color filter shown to the manufacturing process order. It is principal part sectional drawing which shows schematic structure of the liquid crystal device using the color filter to which this invention is applied. It is principal part sectional drawing which shows schematic structure of the liquid crystal device of the 2nd example using the color filter to which this invention is applied. It is principal part sectional drawing which shows schematic structure of the liquid crystal device of the 3rd example using the color filter to which this invention is applied. It is principal part sectional drawing of the display apparatus which is an organic electroluminescent apparatus. It is a flowchart explaining the manufacturing process of the display apparatus which is an organic electroluminescent apparatus. It is process drawing explaining formation of an inorganic bank layer. It is process drawing explaining formation of an organic substance bank layer. It is process drawing explaining the process in which a positive hole injection / transport layer is formed. It is process drawing explaining the state in which the positive hole injection / transport layer was formed. It is process drawing explaining the process in which a blue light emitting layer is formed. It is process drawing explaining the state in which the blue light emitting layer was formed. It is process drawing explaining the state in which the light emitting layer of each color was formed. It is process drawing explaining formation of a cathode. It is a principal part disassembled perspective view of the display apparatus which is a plasma type display apparatus (PDP apparatus). It is principal part sectional drawing of the display apparatus which is an electron emission apparatus (FED apparatus). It is the top view (a) around the electron emission part of a display apparatus, and the top view (b) which shows the formation method.

Explanation of symbols

W Work 1 Droplet discharge device 3 Function droplet discharge head 8 X axis table 11 Y axis table 23 Carriage unit 36 Functional liquid tank 44 Drawing area 45 Standby area 46a First storage / suction unit 46b Second storage / suction unit 57 Control Part 73 Unit number determination program 74 Usage frequency management program 75 Unit selection program

Claims (11)

A plurality of carriage units each having a functional liquid droplet ejection head and a carriage on which the functional liquid droplet ejection head is mounted and configured to be individually movable between a drawing area and a standby area;
A drawing control method of a droplet discharge device that performs drawing by discharging a functional liquid onto the work in the drawing area while moving the plurality of carriage units relative to the work,
A unit number determination step for determining the number of units of the carriage unit to be used for actual operation according to the workpiece width of the workpiece;
A use frequency management step for managing the use frequency of the functional droplet discharge heads mounted for each carriage unit;
Based on the determined number of units and the usage frequency of the functional liquid droplet ejection head, a unit that selects the carriage unit to be used in actual operation so that the usage frequency is averaged among a plurality of functional liquid droplet ejection heads. A selection process;
A drawing control method for a droplet discharge device, comprising: a carriage moving step for selectively moving the plurality of carriage units between the drawing area and the standby area based on the selection result.   The drawing control method for a droplet discharge device according to claim 1, wherein the standby area is disposed on both sides of the drawing area.   The storage step of storing the functional liquid droplet ejection heads of the carriage units moved to the standby area by the carriage movement step in a function maintaining state is further provided. A drawing control method for a droplet discharge device. A liquid droplet ejection apparatus that performs drawing by ejecting a functional liquid onto the work in a drawing area while moving a plurality of carriage units each having a functional liquid droplet ejection head mounted on the carriage relative to the work in the X-axis direction. Because
Carriage moving means for individually moving the plurality of carriage units in the Y-axis direction between the drawing area and the standby area;
Unit number determining means for determining the number of units of the carriage unit to be used for actual operation according to the workpiece width of the workpiece;
Usage frequency management means for managing the usage frequency of the functional droplet discharge heads mounted for each carriage unit;
Based on the determined number of units and the usage frequency of the functional liquid droplet ejection head, a unit that selects the carriage unit to be used in actual operation so that the usage frequency is averaged among a plurality of functional liquid droplet ejection heads. Selection means,
Movement control means for controlling the carriage movement means,
The droplet control apparatus, wherein the movement control unit selectively moves the plurality of carriage units between the drawing area and the standby area based on the selection result.   The droplet discharge device according to claim 4, wherein the standby area is disposed on both sides of the drawing area. Each carriage unit is equipped with a plurality of functional liquid droplet ejection heads,
6. The droplet discharge according to claim 4, wherein the unit selection unit performs the selection based on a use frequency of the functional droplet discharge head that is used most frequently in each carriage unit. apparatus. In the standby area, a storage unit for storing the functional liquid droplet ejection head in a function maintaining state is disposed,
7. The liquid droplet ejection apparatus according to claim 4, wherein the movement control unit causes the carriage unit moved to the standby area to face the storage unit.   The liquid according to any one of claims 4 to 7, wherein the usage frequency management means manages the usage frequency based on either the cumulative usage time or the cumulative number of shots of the functional liquid droplet ejection head. Drop ejection device.   The liquid droplet ejection apparatus according to claim 4, wherein the movement control unit performs the selective movement when the workpiece is replaced. An X-axis table for mounting the workpiece and moving the workpiece in the X-axis direction;
10. The liquid according to claim 4, wherein the plurality of carriage units are configured with a number of units necessary for drawing a workpiece having a maximum width that can be mounted on the X-axis table. Drop ejection device.   11. A method for manufacturing an electro-optical device, comprising: using the droplet discharge device according to claim 4; and forming a film forming portion with the functional droplet on the workpiece.

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