JP2000067756A - Manufacture of plasma display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize a plasma display panel allowing no deformation of its substrate in spite of a smaller outside pressure than a gas pressure within the plasma display panel, and having superior display performance by bonding top parts of its partition walls with an adhesive material mixture. SOLUTION: In this plasma display, a front plate 116 and a back plate 106 are bonded with an adhesive material provided on top parts of partition walls, while a discharge gas having a pressure more than 500 Torr is sealed in a PDP panel. In a forming process of an adhesive layer 5 on the top parts of the partition walls, a resin material 1 is embedded into groove parts between the partitions, before application of the adhesive material onto the top parts of the partition walls. Thereby, the adhesive material in the adhesive material applying process is not adhered/remained on side faces of the partition walls and the like but is applied only to the top parts of the partition walls, so that damage to a phosphor is avoided when the front plate 116 and the back plate 106 are bonded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a plasma display panel which has a small substrate deformation and good display performance.

[0002]

2. Description of the Related Art As an example of a plasma display panel, an AC type plasma display panel (hereinafter referred to as PDP) as shown in FIG. 2 has been known.

[0003] A panel configuration of a conventional PDP and its operation will be described below with reference to the drawings. In FIG. 2, 11
6 is a front plate and 106 is a back plate. PDP 101 is
The front plate 116 and the back plate 106 are positioned opposite to each other, and are sealed between their outer peripheral edges by a sealing member (not shown) made of low-melting glass to form a gas discharge space. A rare gas (mixed gas such as helium, xenon, or neon) having a pressure of about 500 Torr is sealed in the closed space.

The back plate 106 includes a back glass 107, an address electrode 108 formed on the surface of the back glass 107, and a back plate dielectric 1 formed so as to cover the address electrode 108.
09, a plurality of partition walls 110, and RGB phosphors 111 applied between the partition walls 110. Here, the partition 110 is a means for partitioning the gas discharge space.

[0005] The space 112 thus partitioned serves as a light emitting area, and the phosphor 111 is applied to each of the light emitting areas. The partition 110 and the address electrode 108 are formed in the same direction, and the bus electrode 1
03 and the transparent electrode 114 are orthogonal to the address electrode.

[0006] The PDP 101 configured as above is
By applying a voltage to the address electrode 108 and the display electrode 103 at an appropriate timing, it corresponds to a display pixel.
Discharge occurs in the space 112 divided by the partition 110,
Ultraviolet rays are generated, and the RGB phosphor 11 excited by the ultraviolet rays
1 emits visible light, which is displayed as an image.

Next, a method for manufacturing such a conventional PDP will be described. The display electrode 103 in FIG. 2 generally has a two-layer structure of a wide transparent electrode and a narrow opaque bus electrode. First, with respect to the front glass 102,
ITO (Indium Tin Oxide) or SnO
₂ and a silver or Cr—Cu—Cr 103 as a bus electrode are formed thereon by photolithography, and a front plate dielectric film 104 is formed so as to cover the transparent electrode 114 and a magnesium oxide is formed thereon. Protective film 105 made of
Is formed.

As for the back plate 106, an address electrode 108 is formed on a back glass 107, a back plate dielectric 109 is formed to cover the address electrode 108, baked, and a partition material is formed on one surface by printing. After the film is formed, a portion where the partition 110 is not formed is removed by a sand blast method or the like, and the partition 110 in a line shape is formed through a firing process. After that, the fluorescent material 111 is filled between the partition walls 110 by a printing method or the like, dried, and fired to manufacture.

After the sealing member 9 made of low melting point glass or the like is applied to the periphery of the front plate 101 or the rear plate 106 completed in this way, the front plate 116 and the rear plate 106 are coated.
And firing. As a result, the low-melting glass is heated and melted. After cooling at room temperature, the gas in the outside and the inside of the PDP are exhausted, and a discharge gas such as xenon or neon is sealed at a gas pressure of about 500 Torr.
To complete the PDP 101.

The sealing member is usually applied only to the periphery of the PDP, and does not adhere to the top of the partition wall and the front plate. Even when the internal gas is discharged or after the discharge gas is filled, the gas pressure inside the PDP is always lower than the external pressure, so that the front plate and the rear plate may be deformed inward due to the difference. Since the top of the partition wall and the front plate are partially supported and supported, there is no problem in strength or the like.

[0011]

However, in the above-mentioned conventional configuration, the air above the air pressure is low, such as in an airplane during flight.
When used in a place where the atmospheric pressure is lower than 760 Torr, the pressure difference of the gas inside the PDP with respect to the external pressure increases, and the difference in the gas pressure causes the substrate to be deformed. As a result, the discharge also spreads to the adjacent portion separated by the partition, so that an erroneous discharge or the like is induced in the adjacent portion, thereby causing a problem that the display resolution is reduced.

In such a case, it is conceivable to apply a sealing paste to the top of the partition wall and adhere it to the front plate to prevent deformation of the substrate. The sealing paste contains a low melting point lead glass, a polymer resin, and a solvent. When the sealing paste is applied to the top of the partition, the solvent in the sealing paste permeates the phosphor layer together with the polymer resin and the low-melting glass. The low-melting glass penetrating into the phosphor layer not only inhibits light emission from the phosphor, but also causes deterioration of the phosphor and significantly lowers the display quality of the PDP.

As described above, conventionally, it has been extremely difficult to bond the front plate and the back plate with an adhesive applied to the top of the partition without affecting the phosphor layer.

An object of the present invention is to provide a display device in which the top of a partition wall is adhered with high precision by an adhesive member so that the substrate is not deformed even when the outside air pressure is small relative to the gas pressure inside the PDP. It is an object of the present invention to provide a method for producing a PDP.

[0015]

According to a first aspect of the present invention, there is provided a first panel substrate, a second panel substrate facing the first panel substrate, and a first and a second panel substrates. A sealing portion provided between the outer peripheral edges of the first and second panel substrates for forming a gas discharge space between the second panel substrate and the second panel substrate; A method of manufacturing a plasma display panel, comprising: a partition partitioning the discharge space; an adhesive member that bonds an upper end of the partition to an inner surface of the first panel substrate; and a phosphor provided in a groove between the partition walls. A first step of embedding a resin material in a groove between the partition walls, a second step of applying the entire surface of the adhesive member after the first step, and embedding in a groove section between the partition walls after the second step Resin material and part of the adhesive member Characterized in that it comprises a third step of simultaneously separating and removing.

By embedding a resin material in the groove between the partition walls prior to the application of the adhesive member to the upper end portions of the partition walls, the adhesive member in the adhesive member application step is applied only to the upper end portions of the partition walls without adhering and remaining on the side surfaces of the partition walls. Therefore, it is possible to avoid damage to the phosphor when the front plate and the back plate are bonded.

Thus, even when the external pressure is smaller than the gas pressure, the top of the partition wall is bonded with the bonding member so that the substrate is not deformed, and the PDP has good display performance.
Can be manufactured.

The invention according to claim 2 is characterized in that at least a part of the surface layer on the top of the partition wall is exposed before the second step.

Thus, the application of the adhesive member to the top of the partition wall in the third step can be surely performed, and a PDP with a better display quality can be manufactured.

The invention according to claim 3 is characterized in that the resin material is a sheet material containing at least a polymer resin and a plasticizer.

According to this configuration, it is possible to easily manufacture a sheet having a characteristic of flexibly conforming to the shape of the partition wall when embedding the groove in the groove between the partition walls, and to evenly embed the sheet on the entire back plate on which the partition wall is formed. , PD with better display quality
P can be manufactured.

According to a fourth aspect of the present invention, the sheet material is formed on an organic film as a base material.

According to this configuration, when the sheet material is formed by a doctor blade method or the like, the sheet material can be formed by using the carrier material as a carrier film, and the sheet material can be formed on the entire back plate including embedding in the groove between the partition walls. Enables pasting without damage. As a result, it is possible to manufacture a PDP having better display quality.

The invention according to claim 5 is characterized in that a release layer is provided between the base material and the sheet material.

With this configuration, the base material can be easily peeled off after the sheet material is adhered to the entire surface of the back plate on which the partition walls are formed. As a result, it is possible to manufacture a PDP with higher display quality.

The invention according to claim 6 is characterized in that the sheet material has a release layer on the surface.

With this configuration, when simultaneously removing and removing the sheet-like resin material embedded in the groove between the partition walls and the adhesive member applied thereon, a release layer is formed on the surface of the sheet material in advance. By doing so, the separation and removal can be facilitated. As a result, it is possible to manufacture a PDP with higher display quality.

[0028] The invention according to claim 7 is characterized in that when embedding the sheet material into the groove between the partition walls, the resin material which is heat-softening by heating is used.

With this configuration, when the sheet-like resin material is embedded in the groove between the partition walls, the sheet material is appropriately softened by heat and is embedded over the details of the groove between the partition walls. As a result, it is possible to manufacture a PDP with higher display quality.

The invention according to claim 8 is characterized in that pressure is used when the sheet material is embedded in the groove between the partition walls.

With this configuration, when embedding the sheet-like resin material into the groove between the partition walls, the sheet material is pressed into the details of the groove between the partition walls by pressure. As a result, it is possible to manufacture a PDP with higher display quality.

The invention according to claim 9 is characterized in that the adhesive member contains at least a low-melting glass material and a polymer resin.

According to this structure, it is possible to realize the preparation of an optimum paste when the entire surface is applied in the second step, and to perform the stable bonding step without affecting the entire surface plate, the partition walls and the phosphor in the fifth step. Enable.
As a result, it is possible to manufacture a PDP with higher display quality.

The invention according to claim 10 is characterized in that the entire surface of the adhesive member is applied by a screen printing method.

According to this configuration, it is possible to apply and form an adhesive member having a uniform thickness on the entire surface of the resin material embedded in the top of the partition and the groove of the partition in the second step. As a result, it is possible to manufacture a PDP having better display quality.

An eleventh aspect of the present invention is characterized in that a step of drying the adhesive member applied over the entire surface after the second step is performed immediately after the application.

Drying and removing the organic solvent component in the applied adhesive member coating has the effect of improving and stabilizing the adhesion of the coating layer of the adhesive member on the top of the partition wall.
When simultaneously removing the adhesive member applied to the surface of the resin material layer embedded in the groove between the partition walls in the process, it is possible to leave the applied layer of the adhesive member on the top of the partition wall and to uniformly peel off. As a result, it is possible to manufacture a PDP having better display quality.

[0038]

BEST MODE FOR CARRYING OUT THE INVENTION A method of manufacturing a plasma display panel according to the present invention includes a step of forming a resin material between partitions formed on a substrate, and a step of forming a resin material on the partition between the partitions. The method includes a step of forming an adhesive member and a step of forming a discharge space between the partition walls while leaving the adhesive member formed on the partition wall.

According to this method, the adhesive member can be formed on the upper part of the partition wall with high precision and easily, the strength of the panel is increased, and even if the outside air pressure is smaller than the gas pressure inside the panel, the substrate is deformed. And excellent display becomes possible.

A step of forming a resin material between the partition walls formed on the substrate, a step of forming an adhesive member on the partition wall where the resin material is formed between the partition walls, and a step of forming an adhesive member on the partition wall. The method includes a step of forming a discharge space between the partition walls while leaving the formed adhesive member, and a step of forming a phosphor in at least a part of the discharge space formed between the partition walls.

According to this method, the phosphor is formed after the adhesive member is formed on the upper part of the partition walls, so that a PDP having no damage to the phosphor and having better display performance can be realized.

Hereinafter, an embodiment of a method of manufacturing a plasma display panel according to the present invention will be described with reference to the drawings.

In this embodiment, (a) first step: resin embedding step, (b) second step: surface polishing step, (c) third step
Step: adhesive layer applying step, (d) fourth step: sheet peeling step, (e) fifth step: phosphor inserting step, (f) sixth step: bonding step, and (a) first step , (C) the third step, and (d) the fourth step alone. This will be described sequentially below.

(A) First Step: Resin Embedding Step The first step is a step of embedding the thermo-softening resin material 1 in the groove between the partition walls 110 formed on the substrate. In this step, for example, a polymer resin,
The polymer resin material is selected in consideration of the width and height of the organic solvent, the plastic material, and the groove between the partition walls, and an appropriate blended and mixed paint for forming the sheet is formed into a release layer 2 such as PE.
It is applied on a T (polyethyl terephthalate) film.

After the application, the coating is dried to remove the solvent, and a sheet-like heat-softening resin material is formed. In this case, the thickness of the sheet may be set to be equal to the height of the partition wall, but it is preferable that the thickness of the sheet is further set to 20 μm or more. Then, a sheet-like heat-softening resin material is embedded in the groove between the partition walls by laminating the sheet with the back plate having the partition walls formed on the substrate using, for example, a laminator. At this time, the temperature and pressure of the transfer roll 3 at the time of bonding are set according to the width and height of the groove between the partition walls.

(B) Second Step: Surface Polishing Step The second step is a step of peeling and removing the surface layer of the sheet embedded in the groove between the partition walls. In this step, for example, by polishing the tape uniformly using a tape polishing method using a tape polishing paper 4 until the top of the partition wall appears, and furthermore, polishing the top of the partition wall by several μm in order to suppress variations in the partition wall height. Is desirable. Further, it is more desirable to wash the polishing debris or the polishing material after the polishing is completed or simultaneously with the polishing step.

(C) Third Step: Adhesive Layer Application Step The third step is a step of applying an adhesive member to the top of the partition wall formed on the substrate. In this step, for example, as an adhesive member, a low-melting glass, a polymer resin, a solvent and a coefficient of expansion with the glass, fluidity and the like, are appropriately selected,
The prepared and mixed paste is selectively applied only to the top of the partition wall by, for example, a printing method. Or Figure 1
As shown in (c), the adhesive layer 5 may be formed by applying the composition on the front surface of the substrate. Thus, the adhesive layer 5 can be easily formed. After the application of the adhesive member, it is dried to remove the solvent. In this way, the adhesive member is formed at least on the top or top of the partition.

In this case, the mixing of the polymer resin is not always essential, but it is desirable to mix them from the viewpoint of shape stability and the like. However, it is desirable that all of the polymer resin has disappeared at the end of the fifth step. In order to more completely eliminate the polymer resin, for example, at the same time as drying of the solvent or after drying of the solvent, one of the polymer resins is removed. A part disappearing step may be included. Further, a part of the low melting glass may be melted.

(D) Fourth Step: Sheet Peeling Step The fourth step is a step of removing the sheet and the adhesive member coating layer in the grooves between the partition walls. In this step, for example, the sheet-like thermosoftening resin material embedded in the groove between the partition walls is continuously peeled off by peeling it off from the end of the substrate. At this time, it is desirable that the peeling direction is parallel to the partition wall. In this way, a discharge space is formed between the partition walls, and the adhesive member is formed only at the upper end of the partition wall.

(E) Fifth Step: Phosphor Inserting Step The fifth step is a step of applying a phosphor ink between the partition walls formed with the adhesive member at the upper end of the partition walls.

For the phosphor ink, for example, a dispersion mixture of a phosphor powder and a dispersant such as an organic solvent is used. However, it is more desirable that the polymer resin is appropriately mixed in order to perform the dispersion more reliably.

As a method of applying the phosphor ink, for example, a printing method is used. In order to carry out the printing method, it is necessary to bring the printing screen into contact with the adhesive member formed in the fourth step. There is a possibility that the application shape of the adhesive member is broken by this contact. To avoid these,
By applying the phosphor ink directly to the center of the partition wall from the nozzle, the phosphor can be inserted without contact, which is more desirable.

Thus, the phosphor 111 is formed in at least a part of the discharge space between the partition walls.

(F) Sixth Step: Adhesion Step In the first to fifth steps, a substrate having an adhesive member applied to the upper end of the partition and a phosphor applied between the partitions is completed. After the sealing frit is applied to the peripheral portion, the present substrate and, for example, an opposing substrate (front plate 11
6) and fired at a predetermined temperature.

Through the above steps, a panel in which at least a part of the periphery and the top of the partition wall are adhered is completed.

As described above, according to the present embodiment, the panel substrates are bonded to each other via the bonding member provided at the uppermost end of the partition wall. By embedding a resin material in the groove between the partition walls prior to the application of the adhesive member to the upper end portions of the partition walls, the adhesive member in the adhesive member application step is applied only to the upper end portions of the partition walls without adhering and remaining on the side surfaces of the partition walls. Damage to the phosphor when the face plate and the back plate are bonded can be avoided, and the performance of the plasma display panel can be improved.

[0057]

As described above, according to the present invention, an adhesive member can be formed on the upper part of a partition wall with high precision and easily, the strength of the panel is increased, and the external pressure is smaller than the gas pressure inside the panel. Even if there is no deformation of the substrate, excellent display is possible.

Further, since the phosphor is formed after forming the adhesive member on the upper part of the partition, a PDP having no damage of the phosphor and having better display performance can be realized.

[Brief description of the drawings]

FIGS. 1A to 1F are process diagrams showing a method of manufacturing a plasma display panel according to an embodiment of the present invention.

FIG. 2 is a perspective view showing the structure of a plasma display panel.

[Description of Signs] 1 Thermosoftening resin material 2 Release layer 3 Roll 4 Tape abrasive paper 5 Adhesive layer

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Yoshiki Sasaki, Inventor 1006 Kazuma Kadoma, Osaka Prefecture, Matsushita Electric Industrial Co., Ltd. 72) Inventor Noriyuki Kirihara 1006 Kadoma Kadoma, Kazuma, Osaka Prefecture Inside Matsushita Electric Industrial Co., Ltd. AA04 EE01

Claims (13)

[Claims] A first panel substrate, a second panel substrate facing the first panel substrate, and the first panel substrate for forming a gas discharge space between the first and second panel substrates.
A sealing portion provided between the outer peripheral edges of the second panel substrate, a partition partitioning the gas discharge space provided on the second panel substrate, and a top portion of the partition and the first panel substrate. A method for manufacturing a plasma display panel, comprising: an adhesive member for bonding an inner surface; and a phosphor provided in a groove between the partition walls, wherein a first step of embedding a resin material in the groove section between the partition walls; A second step of applying the adhesive member over the entire surface after one step, and a third step of simultaneously removing and removing a part of the resin material and the adhesive member embedded in the groove between the partition walls after the second step. A method for manufacturing a plasma display panel, comprising: 2. The method of manufacturing a plasma display panel according to claim 1, wherein at least a part of a surface layer of the partition wall is exposed before the second step. 3. The method according to claim 1, wherein the resin material is a sheet material containing at least a polymer resin and a plasticizer. 4. The method according to claim 3, wherein the sheet material is formed on an organic film as a base material. 5. The method for manufacturing a plasma display panel according to claim 4, further comprising a release layer between said base material and said sheet material. 6. The method for manufacturing a plasma display panel according to claim 4, wherein a release layer is provided on a surface of said sheet material. 7. The method of manufacturing a plasma display panel according to claim 1, wherein when embedding the sheet material in the groove between the partition walls, a resin material which is heat-softening by heating is used. 8. The method of manufacturing a plasma display panel according to claim 1, wherein a pressure is used when embedding the sheet material in the groove between the partition walls before the first step. 9. The method according to claim 1, wherein the adhesive member contains at least a low-melting glass material and a polymer resin.
3. The method for manufacturing a plasma display panel according to item 1. 10. The method according to claim 1, wherein in the second step, the adhesive member is applied by a screen printing method. 11. The method according to claim 10, further comprising, after the second step, a step of drying the entire surface of the adhesive member immediately after the application. 12. A step of forming a resin material between the partition walls formed on the substrate, a step of forming an adhesive member on the partition wall where the resin material is formed between the partition walls, and a step of forming an adhesive member on the partition wall. A method for manufacturing a plasma display panel, comprising a step of forming a discharge space between the partition walls while leaving the formed adhesive member. 13. A step of forming a resin material between the partition walls formed on the substrate, a step of forming an adhesive member on the partition wall where the resin material is formed between the partition walls, and a step of forming an adhesive member on the partition wall. A plasma comprising a step of forming a discharge space between the partition walls while leaving the formed adhesive member, and a step of forming a phosphor in at least a part of the discharge space formed between the partition walls. Display panel manufacturing method.