JP2004348999A - Manufacturing method of plasma display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a plasma display device with high quality by eliminating defects of a bonding state of a sheet getting uneven in the case a lengthwise panel-making material sheet with a panel-making material layer formed on a base film is used. <P>SOLUTION: By structuring a width of a base film 31a larger than a substrate 30 so that the base film of a dielectric sheet 31 exists between an end of the substrate 30 and an upper press fitting roll 32 and press fitting a dielectric layer precursor 31b of the dielectric sheet 31 on the substrate 30 with the upper press fitting roll 32, the dielectric layer precursor 31b is bonded on the substrate 30. In this structure, degradation of the upper press fitting roll 32 is restrained, and defects of the bonding state of the sheet getting uneven can be eliminated. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method of manufacturing a plasma display device, and more particularly to a method of manufacturing a plasma display device using a long panel material sheet having a panel material layer formed on a base film.
[0002]
[Prior art]
2. Description of the Related Art In recent years, a panel of a typical plasma display device as a display device suitable for a thin type includes, for example, as shown in FIG.
[0003]
The front plate 1 forms a plurality of display electrodes including a transparent electrode 4 and a bus electrode 5 and a black stripe 6 on a front substrate 3 made of glass, and forms a dielectric layer 7 so as to cover them. , And a dielectric protection layer 8 made of MgO.
[0004]
The back plate 2 has a plurality of address electrodes 10 formed on a back substrate 9 made of glass in a direction intersecting the display electrodes of the front plate 1, and a dielectric layer 11 covering the address electrodes 10. And forming a partition 12 on the dielectric layer 11 and coating and forming a red (R) green (G) blue (B) phosphor layer 13 between the partitions 12. I have.
[0005]
By disposing the front plate 1 and the rear plate 2 to face each other and sealing the periphery with a sealing member, a discharge space is formed therebetween, and a discharge gas 14 (for example, Ne-Xe) is formed in the discharge space. Mixed gas) at a pressure of 53200 Pa (400 Torr) to 79800 Pa (600 Torr). In the actual product, the front plate 1 and the rear plate 2 are arranged in a state where the address electrodes 10 and the display electrodes are opposed to each other so as to be orthogonal to each other. It is shown rotated by 90 ° with respect to the face plate 2.
[0006]
The plasma display panel having such a configuration generates an ultraviolet ray by discharging between display electrodes, irradiates the ultraviolet ray to the phosphor layer 13 and converts the ultraviolet ray into visible light of each color, thereby forming an image including a color display. The plasma display panel performs display, and a plasma display device is configured by attaching a drive circuit to the plasma display panel configured as described above.
[0007]
By the way, in the process of manufacturing a panel of such a plasma display device, a bus electrode on a front panel, a black stripe, an address electrode on a dielectric layer or a rear panel, a dielectric layer, a partition, or the like, or a transparent electrode is formed. In the case of forming a dry film resist or the like used for forming a partition wall or the like, a method of laminating a long panel component material sheet having a panel component material layer formed on a base film is used (see Non-Patent Document 1). ).
[0008]
FIG. 5 is a conceptual diagram for explaining a laminating step using a panel constituent material sheet. In FIG. 5, reference numeral 15 denotes a long panel component material sheet. The panel component material sheet 15 has a configuration in which a panel component material layer 15b is formed on a base film 15a, and a cover film 15c is disposed thereon. Reference numeral 16 denotes a substrate of the panel described above.
[0009]
As shown in FIG. 5, the long panel component material sheet 15 is arranged in the state of a roll 17 wound into a film, and the long panel component material sheet 15 sequentially fed from the roll 17 is First, the cover film 15c is peeled, and the peeled cover film 15c is wound around a cover film roll 18.
[0010]
Next, a cut is made by the inter-substrate processing cutter 19 in the panel constituent material layer 15b in the section A located between the substrates 16 which are continuously sent, and the unnecessary part of the panel constituent material layer 15b is removed with a tape or the like. Next, the upper press roll 20 and the lower press roll 21 are sandwiched by the upper press roll 20 and the lower press roll 21 with the base film 15a, the panel component material layer 15b formed on the base film 15a, and the substrate 16 being pressed. By sending the substrate 16 and the panel constituent material sheet 15 in synchronization with the rotation of 21, the panel constituent material layer 15b is attached to the substrate 16. Next, the base film 15a is cut off at a section A corresponding to the space between the substrates 16 and separated by the cutter 22, and then the base film 15a is peeled off, so that the panel forming material layer 15b is adhered to the substrate 16. Reference numeral 23 denotes a feed roller.
[0011]
[Non-patent document 1]
Electronic Journal Co., Ltd., "2001 FPD Technology Encyclopedia", published October 25, 2000, P596
[0012]
[Problems to be solved by the invention]
By the way, when manufacturing a panel of a plasma display device which is a large-sized display device by the manufacturing method of the laminating process using such a panel constituent material sheet, in the laminating process, the state of affixing the sheet due to deterioration of a pressure bonding roll is reduced. A non-uniformity may occur, and as a result, the panel constituting material layer adhered to the substrate becomes a non-uniform layer, which adversely affects the display quality of the plasma display device.
[0013]
The present invention has been made in view of these problems, and solves a problem in that when a long panel component material sheet in which a panel component material layer is formed on a base film is used, the attached state of the sheet becomes uneven. And a high-quality plasma display device.
[0014]
[Means for Solving the Problems]
In order to solve such a problem, the present invention is configured such that the width of the base film is larger than that of the substrate so that the base film of the panel constituent material sheet exists between the end of the substrate and the pressure roll. The panel component material layer of the panel component material sheet is pressure-bonded to the substrate by a roll, so that the panel component material layer is attached to the substrate.
[0015]
With this configuration, it is possible to suppress the deterioration of the pressure-bonding roll, eliminate the problem that the attached state of the sheet becomes uneven, and provide a high-quality plasma display device.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
The invention according to claim 1 of the present invention uses a long panel component material sheet having a panel component material layer formed on a base film, and feeds the panel component material onto a substrate while sequentially feeding the panel component material sheet. When a panel constituting material layer is formed on a substrate by attaching a layer, the width of the base film is set to be larger than that of the substrate so that the base film of the panel constituting material sheet exists between the end of the substrate and the pressure roll. The panel forming material layer is attached to the substrate by pressing the panel forming material layer of the panel forming material sheet onto the substrate with the press roll.
[0017]
Hereinafter, a method of manufacturing a plasma display device according to an embodiment of the present invention will be described with reference to the drawings of FIGS.
[0018]
First, the front plate uses a high strain point glass substrate for plasma display generated by the float method, and an ITO film is formed on the substrate by ion sputtering or the like, and a resist is formed thereon to form a desired shape. After patterning, etching is performed to form an ITO pattern, and the resist is stripped to form a transparent electrode. Note that SnO ₂ or the like can also be used as a transparent electrode material.
[0019]
Next, a bus electrode is formed. Using a photosensitive black paste, after forming a film by a screen printing method or the like, using a photosensitive Ag paste, forming a film by a screen printing method or the like, and irradiating ultraviolet light through an exposure mask having a desired pattern, A bus electrode pattern is formed by a development process, and baked at a temperature of about 600 ° C. to remove the resin component in the paste and to melt the glass frit to form a bus electrode. Note that the Ag layer is not limited to one layer, and a plurality of layers may be stacked. If the conductive layer is mainly composed of Ag, the formation method using a paste is not necessary.
[0020]
Next, a black stripe is formed. After forming a photosensitive black paste by a screen printing method or the like, irradiating ultraviolet light through an exposure mask having a desired pattern, a bus electrode pattern is formed by a development process, and baked at a temperature of about 600 ° C. Then, the resin component in the paste is removed, and the glass frit is melted to form a black stripe. The black stripe may be formed simultaneously with the base black layer of the bus electrode. Further, if it is black, it is not necessary to use a forming method using a paste. Further, a black stripe may be formed before forming the bus electrode.
[0021]
Next, a dielectric layer is formed. FIG. 1 is a schematic view showing a laminating step according to the present embodiment.
[0022]
In FIG. 1, reference numeral 30 denotes a substrate such as a multi-panel substrate having a size capable of obtaining a plurality of front plates, on which electrodes and black stripes are formed as described above.
[0023]
31 is a dielectric sheet is a panel construction material long sheet, the dielectric sheet 31, on the base film 31a such as _{PET, PbO-B 2 O 3 -SiO} 2 based glass or the like as the panel structure material layer Is formed by applying a dielectric layer precursor 31b made of a material mainly composed of, for example, to form a sheet, and then covering the surface with a cover film such as PET, and winding the core around a core to form a dielectric roll. First, the cover film is peeled from the dielectric sheet 31 unwound from the dielectric roll. At this time, the peeled cover film is wound up on a cover film roll.
[0024]
Next, a cut is made in the dielectric layer precursor 31b in the section X corresponding to an unnecessary portion which is not formed as a panel component and located between the substrates 30 by a panel component component processing cutter. The cut is made so that the dielectric layer precursor 31b is completely cut and the base film 31a is not cut. Next, unnecessary portions that do not become components of the section X where the cut is made are removed with a tape or the like.
[0025]
Next, a base film 31a, a dielectric layer precursor 31b formed on the base film 31a, and a substrate 30 are formed by an upper pressure roller 32 and a lower pressure roller 33 whose surfaces are made of an elastic material such as a heat-resistant rubber. The substrate 30 and the dielectric sheet 31 are fed and adhered in synchronization with the rotation of the upper pressure roll 32 and the lower pressure roll 33 while being thermocompressed. Next, a portion of the base film 31a corresponding to the space between the substrates 30 is cut off by a cutter or the like, and then the base film 31a is peeled off.
[0026]
Here, the width of the base film 31a is configured to be larger than that of the substrate 30 so that an extension 31c of the base film 31a of the dielectric sheet 31 exists between the end of the substrate 30 and the upper pressure roll 32. The upper pressure roll 32 does not directly contact the end of the substrate 30. Reference numeral 34 denotes a roller for feeding the substrate 30.
[0027]
Next, the resin component in the dielectric layer precursor 31b is removed by baking at a temperature of about 600 ° C. and the glass frit is melted to form a dielectric layer. Note that the dielectric layer may be formed twice.
[0028]
Next, a dielectric protection layer is formed on the substrate 30 by depositing MgO or the like by a vacuum deposition method or a sputtering method. The front plate is completed as described above.
[0029]
Next, a method of forming the back plate will be described. First, a high strain point glass substrate for a plasma display generated by a float method is used, and an address electrode is first formed on the substrate. Using a photosensitive Ag paste, a film is formed by a screen printing method or the like, and after irradiating ultraviolet light through an exposure mask having a desired pattern, a bus electrode pattern is formed by a development process. The resin component in the paste is baked to remove the solvent, and the glass frit is melted to form an address electrode. Note that the address electrode is not limited to one layer, and may be configured by laminating a plurality of layers. Further, the conductive layer may not be formed using a paste containing Ag as a main component.
[0030]
Next, a base dielectric layer is formed. The PbO-B ₂ O ₃ -SiO ₂ system paste a main agent and glass of deposited by a technique such as a screen printing method or die coating method, the resin component in the paste by firing at a temperature of about 600 ° C. The medium is removed and the glass frit is melted to form a base dielectric layer. The base dielectric layer may be formed by laminating and firing a base dielectric layer precursor using a dielectric sheet molded without using a paste, similarly to the front plate.
[0031]
Next, a partition is formed. A photosensitive paste mainly composed of an aggregate such as Al ₂ O ₃ and glass frit is formed into a film by a printing method, a die coating method, or the like, and is irradiated with ultraviolet light through an exposure mask having a desired partition pattern, followed by a development process. By baking at a temperature of about 550 ° C., the resin component in the partition wall film is removed, and the glass frit is melted to form the partition wall. After a resist having abrasion resistance is formed in a desired partition pattern on the partition film formed by using a non-photosensitive paste, unnecessary portions are removed by sandblasting or the like, and patterning is performed. It may be formed by the following method.
[0032]
Next, a phosphor layer is formed. Each color phosphor paste composed of a resin component, a solvent, and the like, red, green, and blue phosphor powders is sequentially applied between the partition walls by a dispenser method, and dried at a temperature of about 90 ° C., and then about 500 ° C. Baking at the temperature described above to remove the solvent component to form each color of the phosphor layer. The coating method may be a printing method or a line jet method. The rear plate is completed as described above.
[0033]
The front plate and the back plate formed as described above are arranged to face each other, the periphery thereof is sealed with a sealing material, and a discharge gas such as Ne-Xe is sealed at a pressure of 53200 Pa (400 Torr) to 79800 Pa (600 Torr). Thereby, the plasma display panel is completed. A plasma display device is formed by attaching a drive circuit to the panel.
[0034]
By the way, in the laminating process, as a result of examining the problem that the attached state of the sheet becomes non-uniform, the upper pressure roll 32 and the lower pressure roll 33 use the base film 31a and the dielectric layer precursor formed on the base film 31a. When the body 31b and the substrate 30 are sandwiched and thermocompression-bonded, the pressure applied to the upper compression roll 32 and the lower compression roll 33 in the portion where the base film 31a, the dielectric layer precursor 31b, the substrate 30 and the like are present and where it is not present Are different, the upper pressure roll 32 and the lower pressure roll 33 are deformed, and it has been found that this is a factor that causes the sheet to be stuck in a non-uniform state.
[0035]
FIGS. 2 and 3 show the situation, FIG. 2 is a view showing the situation in the present embodiment, and FIG. 3 is a view showing the situation when there is no extension 31c of the base film 31a. . As shown in FIG. 3, the stress applied to the upper press roll 32 and the lower press roll 33, particularly the stress applied to the upper press roll 32, concentrates on a portion corresponding to the end of the substrate 30. Streaks or cracks are formed on the press roll 32. This is caused by the difference in hardness between the substrate 30 which is a glass material and the upper pressure roller 32 made of an elastic material such as rubber, and even when the corner of the substrate 30 is chamfered, Since the portion is sharp, the portion where the substrate 30 and the upper pressure roll 32 are in direct contact is significantly deteriorated. Then, it has been found that when streaks or cracks occur in the upper pressure-bonding roll 32, the temperature distribution and pressure distribution of the upper pressure-bonding roll 32 change, and the sheet attachment state becomes non-uniform.
[0036]
If the size of the substrate 30 is different, the streaks or cracks of the upper pressure roll 32 may come on the dielectric layer precursor 31b. The generated streaks and cracks directly affect the state of sheet attachment, and thus deteriorate the display quality of the plasma display device. Furthermore, in the multi-plane trimming process for obtaining a plurality of front and back plates from a large-sized substrate, if the edge of the substrate after the cutting is not chamfered, the occurrence of streaks and cracks increases. Since the roll 33 is deteriorated, it is necessary to frequently exchange the upper press roll 32 and the lower press roll 33 in order to maintain quality, which causes a cost increase in a laminating process.
[0037]
On the other hand, as in the present embodiment shown in FIG. 2, the base film 31a is formed such that an extension 31c of the base film 31a of the dielectric sheet 31 exists between the end of the substrate 30 and the upper pressure roll 32. The width is configured to be larger than the substrate 30, and the upper pressure roll 32 does not directly contact the end of the substrate 30, and the damage of the upper pressure roll 32 in the laminating process is reduced. , The display quality of the plasma display device can be prevented from deteriorating, and the upper pressure roll 32 and the lower pressure roll 33 do not need to be frequently replaced for quality maintenance, thereby realizing cost reduction in the laminating process. be able to.
[0038]
【The invention's effect】
As described above, according to the present invention, the width of the base film is configured to be larger than the substrate so that the base film of the panel constituent material sheet exists between the end portion of the substrate and the pressure roll, and the pressure roll serves as By bonding the panel component material layer of the panel component material sheet to the substrate, the panel component material layer is attached to the substrate. Damage to the pressure roll during the lamination process is reduced, and the deterioration of the sheet attachment state is reduced. However, it is possible to prevent the display quality of the plasma display device from deteriorating, and it is not necessary to frequently replace the pressure roll for maintaining the quality, thereby realizing cost reduction in the laminating process.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a method for manufacturing a plasma display device according to an embodiment of the present invention; FIG. 2 is a cross-sectional view showing main steps in the manufacturing method; FIG. FIG. 4 is a schematic diagram showing a panel configuration of a plasma display device. FIG. 5 is a conceptual diagram for explaining a laminating method.
Reference Signs List 30 Substrate 31 Dielectric sheet 31a Base film 31b Dielectric layer precursor 31c Extension 32 Upper pressure roll

Claims (1)

Using a long panel component material sheet in which a panel component material layer is formed on a base film, the panel component material layer is attached to a substrate while sequentially feeding the panel component material sheet, and the panel component material layer is formed on the substrate. When forming the base film, the width of the base film is configured to be larger than the substrate so that the base film of the panel constituent material sheet exists between the end portion of the substrate and the pressure roll, and a panel is formed on the substrate by the pressure roll. A method for manufacturing a plasma display device, comprising: bonding a panel constituent material layer to a substrate by pressing a panel constituent material layer of a constituent material sheet.

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