JP2000251696A - Discharge cell forming method for plasma display panel, phosphor-forming material sheet and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a discharge cell having a phosphor of a PDP(plasma display panel) with high accuracy for adapting it for enhancing the precision of the PDP and for increasing the size thereof, to realize miniaturization and reduction of the scale of a manufacturing device, to eliminate material loss, to improve a yield and to reduce the manufacturing cost. SOLUTION: An unset barrier rib forming material layer 50 having flexibility and a phosphor forming material layer 100 on it are formed on a glass substrate 14, and a roller whereon grooves 80 corresponding to barrier ribs 18 are formed is pressingly rolled on the barrier rib forming material layer 50 and the phosphor forming material layer 100, so that projections of the barrier rib forming material corresponding to the barrier ribs 18 are formed. At that time, the phosphor-forming material of the phosphor-forming material layer is supplied into the grooves (discharge cells) between the projections, and is dried and baked.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming discharge cells in a plasma display panel (hereinafter abbreviated as PDP), and more particularly to a plasma display panel suitable as a thin and large-screen high-definition color display device, and an implementation of the method. And a method for manufacturing the sheet.

[0002]

2. Description of the Related Art A PDP used for a thin, large-screen, high-definition color display device or the like is provided with a pair of electrodes regularly arranged on two opposing glass substrates, and an N-electrode therebetween.
It has a structure in which a gas mainly composed of e or the like is sealed. A large number of small discharge spaces called discharge cells are formed by fine barrier ribs (partitions) on the rear substrate of the two glass substrates (the front substrate and the rear substrate). Phosphors are lined on the inner walls of these discharge cells. An electrode facing the discharge cell space is provided on the facing front substrate. Plasma is generated by the discharge between the electrodes, and the phosphor in the discharge cell emits light by the plasma to be used as a light emitting element of a screen.

In general, as a method of manufacturing a barrier rib (partition) for forming a discharge cell of a PDP, a printing lamination method and a sand blast method are known. In the printing lamination method, a process of printing and drying a glass paste on a rear substrate by a screen printing method is repeated until a height required for the barrier rib is reached.

In the sand blast method, a thick film of a barrier rib forming material (glass paste) is formed on a rear substrate, a subtractive resist pattern is formed on the thick film by a lithographic method, and a barrier rib forming material at a resist opening is formed. This is a method of removing by sandblasting (injecting fine particles mixed with compressed air at high speed and performing physical etching). Here, the resist pattern is removed after forming the barrier ribs.

The barrier rib patterns formed by such various methods are fired at a high temperature to become glass barrier ribs, and a phosphor film (having a thickness of 20 to 30 μm) is formed in each discharge cell in the next phosphor formation step. ) Is formed. A screen printing method has been conventionally used for forming the phosphor film. In this screen printing method, a phosphor paste in which a phosphor, an organic binder, a solvent and the like are kneaded is supplied to the fired inner wall of the barrier rib by the screen printing method.

At this time, it goes without saying that the phosphor paste of a color corresponding to the color of the discharge cell is supplied into the barrier rib forming the corresponding discharge cell. That is, R (red), G
The phosphor pastes of (green) and B (blue) are applied to the corresponding discharge cells by printing three times, one by one, by a screen printing method, and the corresponding phosphor pastes are poured into predetermined discharge cells. This is to dry it.

[0007] Instead of the screen printing method, a photolithography method using a photosensitive phosphor paste has been studied. In this method, R, G, and B phosphor pastes are sequentially applied, and processes such as exposure, development, and washing are repeated for each phosphor paste.

[0008]

The conventional method for forming a barrier rib has the following problems. First, in the printing lamination method, since the thickness of a film that can be formed by one printing is up to several tens of μm, the thickness required for the barrier rib is 100 μm.
In order to obtain a height of 200 μm, printing and drying need to be repeated many times, generally about 10 times. Therefore, there is a problem that productivity is extremely low. In addition, since the coating formed by screen printing has a concave peripheral portion and a convex central portion, sagging of the cross-sectional shape accumulates and the bottom portion of the barrier rib is widened when applied repeatedly many times. For this reason, there is a limit in increasing the density of the barrier ribs, and further, there is a limit in pitch accuracy due to distortion and life of the screen (printing plate), and it has been difficult to increase the size, increase the definition, and mass-produce the PDP. .

On the other hand, the sand blasting method involves complicated steps such as formation and removal of a resist pattern, and particularly when the screen is enlarged, the size of an exposure apparatus and a sand blasting apparatus becomes large, resulting in a significant increase in equipment cost. Furthermore, material loss due to sandblast etching is large. For this reason, there is a problem that the production cost increases.

[0010] Further, both the printing lamination method and the sand blast method have a common problem that the shape of the molded body is easily deformed by shrinkage during firing in a subsequent step. In general, the shrinkage during firing can be reduced to some extent by increasing the content of the glass powder contained in the barrier rib forming material. However, in this case, the flowability of the barrier rib forming material decreases. For this reason, there has been a problem that the moldability of the micromachined surface is reduced and the shape of the molded body, that is, the fidelity of the shape is deteriorated.

In order to solve the problems peculiar to the conventional printing lamination method and the sand blast method, a pressure molding method in which a flat mold is pressed against a thick film of a barrier rib forming material formed on a substrate, a thin film pattern forming method, and the like. It is conceivable to use a photolithography technique widely used in the art.

The pressure molding method using a flat mold is an excellent method for solving the problems of the printing method and the sand blast method. However, the basic problem is that when the flat mold is peeled from the substrate, a glass paste is used. However, there is a problem that it is easy to be partially peeled off from the substrate. For this reason, various measures are required to improve the adhesion between the glass substrate and the glass paste. For this reason, it is necessary to restrict the selection of the material or to add a new process. Further, it is difficult to manufacture a large precision mold corresponding to an increase in the size of the substrate, and the cost of the apparatus becomes enormous.

The photolithography method uses a photosensitive glass paste, and is characterized in that high-resolution and precise rib formation is possible. However, this method involves the application / drying of photoresist, UV exposure, development, cleaning,
The drying and process are complicated and long, require extra materials such as photoresist and developer, require expensive and large floor occupancy equipment such as exposure equipment, developing equipment, and cleaning equipment. As compared with the photosensitive glass paste, the ratio of the resin to the glass is increased and the shrinkage ratio during firing is increased, the amount of material loss is large, and the like, resulting in an increase in cost.

Further, the conventional method for applying the phosphor paste has the following problems. First, the method of applying the phosphor paste by the screen printing method is to fix the phosphor paste poured into the discharge cell to the inner wall of the rib using its own physical properties, so that the thickness of the phosphor is uniform. Is not necessarily guaranteed, and it is difficult to control the film thickness. Also, due to the handling problems such as the life, operability, and cleaning of the screen mask used for screen printing, large and large PD
There is a problem that it is not suitable for mass production of P.

In the method of applying a phosphor by photolithography, steps such as exposure, development, and cleaning are complicated. In addition, since two-thirds of the phosphor paste of each color applied to the entire surface of the glass substrate are removed by development, not only the utilization efficiency of the phosphor paste deteriorates, but also the removed phosphor paste is expensive, so that it is collected. Need to be done. Further, since the surface of the glass substrate has irregularities due to the pattern of the barrier ribs, it is difficult to remove the phosphor paste after the exposure, and the remaining phosphor paste is mixed with phosphors of other colors, so that color mixing is likely to occur. Was.

Further, in the conventional method, it is necessary to perform firing twice in total after the firing of the barrier ribs and after the application of the phosphor paste. This firing step requires the longest processing time among all steps because it involves heating and cooling. For this reason, there is also a problem that the entire processing time becomes extremely long because the two firing treatments are performed, the productivity is deteriorated, and the production cost is increased.

The present invention has been made in view of such circumstances, and a barrier rib (partition) for forming a discharge cell of a PDP and a phosphor layer can be formed with high precision.
Suitable for high-definition and large-sized P, simplifying the process, enabling downsizing and downsizing of manufacturing equipment, preventing material loss, improving yield, and reducing manufacturing costs. It is a first object of the present invention to provide a method for forming a discharge cell of a PDP. It is a second object of the present invention to provide a sheet of a phosphor-forming material used for carrying out this method.
A third object is to provide a method for manufacturing this sheet.

[0018]

According to the present invention, a first object is to provide a plasma display panel having a large number of discharge cells in which a pair of glass substrates provided with electrodes are separated by barrier ribs and a phosphor layer is formed on the inner surface. (A) forming a flexible uncured barrier rib forming material layer on at least one surface of the glass substrate on which the electrodes are formed; (b) forming a pitch equal to the pitch of the discharge cells. Forming a phosphor forming material layer on which the phosphor forming material is arranged on the barrier rib forming material layer; (c) forming grooves corresponding to barrier ribs on the outer peripheral surface of the phosphor forming material layer and the barrier rib forming material layer; Forming a ridge corresponding to the barrier rib on the glass substrate by rolling the formed roller; (d) a phosphor-forming material and a barrier rib-forming material processed into a ridge in the step (c). Forming a discharge cell in which a phosphor layer is formed on the inner surface by drying and baking. A method for forming a discharge cell of a plasma display panel, comprising:

That is, a roller having an uneven pattern (groove pattern) obtained by inverting the unevenness of the barrier rib on the outer peripheral surface is pressed against the barrier rib forming material while rotating. As the barrier rib forming material, a material which satisfies the required properties for forming a barrier rib by adding an additive such as alumina, tin oxide, titanium oxide, or zirconium oxide to a glass paste can be used. There are various types of PDPs such as an AC surface discharge type, a DC discharge type, and a hybrid type. According to the method of the present invention, a rib parallel to a stripe-shaped electrode, It is possible to form a rib having an appropriate structure corresponding to the PDP method, such as a rib perpendicular to the electrode or a grid-like rib.

The surface of the phosphor-forming material layer is preferably coated with a release material for improving the releasability from the roller. The release material may be, for example, talc powder or Teflon (registered trademark) additive powder, a paste containing these powders,
A spray liquid in which these powders are dispersed in oil is suitable,
This is thinly applied with a spray or a roll coater. Further, it is preferable that the barrier rib forming material layer and the phosphor forming material layer are softened by being immersed in the solvent vapor for a certain period of time, and adjusted to an optimum hardness before rolling with a roller. The release agent may be applied after softening by the solvent vapor.

Here, the solvent may be any one which is compatible with the resin binder contained in the glass paste. For example, an aromatic solvent such as toluene, a higher alcohol, or the like is used. The softening of the glass paste by this solvent vapor
When the release material is coated, it is preferable to perform the coating before the coating for uniform softening. However, when the release material has a property of passing a solvent, the coating may be performed after the coating of the release material.

The barrier rib forming material layer is conveniently formed by laminating a glass paste sheet for ribs previously formed in a sheet shape on a glass substrate. However, it may be formed by applying and drying a liquid glass paste for ribs. The glass paste for ribs used in these is preferably white. This is because the light emitted in the discharge cells is reflected and guided to the PDP surface to improve the light use efficiency.

The barrier ribs are usually formed on the rear glass substrate. However, when the ribs are formed on the front glass substrate by the PDP method, the method of the present invention can be applied to the front glass substrate. Since the ribs can have various forms such as stripes and lattices, it goes without saying that the groove pattern on the surface of the roller corresponds to this. For example, an annular groove is formed in a roller when forming a striped rib, and a grid-shaped groove is formed in a roller when forming a grid-shaped rib.

The peripheral surface of the roller and the glass substrate need to move at the same speed without slippage at the contact portion. For this purpose, the two are relatively linearly moved while keeping the peripheral speed of the roller equal to the relative linear movement speed of the glass substrate relative to the roller. The roller may be relatively moved only once in one direction, or may be reciprocated once or a plurality of times through the same path (path). By passing the same path a plurality of times in this manner, the groove can be formed gradually deeper in the rib forming material layer, and the rib forming material and the phosphor forming material adhere to the roller and peel off from the glass substrate. Can be prevented.

The pressing force of the roller against the glass substrate is:
20 to 200 kg / c based on the axial contact width of the roller
should be m. The pressing force should be changed depending on conditions such as the diameter of the roller, that is, the radius of curvature, and the hardness of the rib forming material layer. If the pressing force is 20 kg / cm or less, the convex portion of the roller cannot enter the rib forming material layer sufficiently deep, and it becomes difficult to increase the height of the barrier rib. If it is 200 kg / cm or more, the roller shaft is distorted, and the difference in pressing force between the vicinity of the center in the width direction of the roller and both sides becomes large, making it difficult to form a uniform rib.

The roller diameter is suitably 30 to 500 mm.
If the diameter is less than 30 mm, the roller is easily distorted,
If it is 0 mm or more, the contact area of the roller with the rib forming material layer becomes large, and this contact portion becomes close to surface contact, so that the rib forming material remains in the groove of the roller and easily peels off from the glass substrate.

The relative linear movement speed of the roller with respect to the glass substrate is preferably the same as the relative peripheral speed of the roller with respect to the glass substrate, and is 0.02 to 2.0 m / min (meter / meter).
Minutes). When the speed is set to 0.02 m / min or less, productivity is remarkably deteriorated. When the speed is set to 2.0 m / min or more, the rib-forming material and the phosphor-forming material are easily separated from the glass substrate, and the roller groove can be deepened. Or the ribs cannot be raised sufficiently high.

A groove formed in the roller, ie, a circumferential ring
Grooves and grid-like grooves are easily separated from the rib forming material layer
Should be. For example, a cut perpendicular to the length of the groove
The surface should be trapezoidal or chevron with a wide opening.
No. That is, the opening width of the groove is W_T, Bottom width W_BThe depth
H, pitch (pitch in the width direction of the groove) is L_PAs 0 <
W _B/ W_T<1.0, 0.1 <H / W_T<3.0, 0.1
<(W_T+ W_B) / 2L_PIt is better to be <1.0.

After a roller is rolled on the phosphor forming material layer and the barrier rib forming material layer to form a ridge corresponding to the barrier rib (step (c)), black reflection is performed on the phosphor forming material layer on the upper surface of the barrier rib. A step of forming a prevention material layer may be added. In this case, the processing of the black antireflection layer (black mask) formed on the front glass substrate becomes unnecessary,
It's easy. This black anti-reflection material layer can be easily added by a technique such as screen printing.

The phosphor forming material layer formed in the step (b) can be formed on the surface of the barrier rib forming material layer by printing.
If a black anti-reflection material is included in the phosphor forming material layer at a position corresponding to the barrier rib, the black anti-reflection layer can be formed together with the barrier rib and the phosphor layer in the same single firing step. Is further improved.

If the phosphor forming material layer is formed by laminating a prepared sheet instead of printing, the processing efficiency is improved and the workability is good. The sheet of the phosphor forming material used here is formed by arranging phosphor forming materials of different colors corresponding to the respective discharge cells. The sheet includes a black anti-reflection material at a position corresponding to the barrier rib. You may leave.

According to the present invention, the second object is achieved by a phosphor-forming material sheet in which phosphor-forming materials of different colors are sandwiched between a pair of upper and lower peelable support films corresponding to respective discharge cells. it can. This sheet can be manufactured by the following method.

That is, a third object is a method for producing a sheet of a phosphor-forming material used in the method of claim 20, wherein (a) forming a release layer on a lower support film; (C) printing a phosphor of a first color to a uniform thickness over the entire upper surface of the first color; (c) rolling the roller having a groove formed at the position of the discharge cell corresponding to the first color by rolling the first color. Collecting the phosphors in the grooves to form projections of the first color and drying;
(d) a phosphor of a second color is printed on the upper surface of the release layer except for the protrusions; (e) a roller having grooves formed at positions of the discharge cells corresponding to the first and second colors. (F) collecting the phosphor of the second color in the groove to form a projection of a second color adjacent to the projection of the first color, and drying; Printing a phosphor on the upper surface of the release layer except for the first and second protrusions, and drying; (g) laminating the upper support film via the release layer; Can be achieved.

[0034]

FIG. 1 is an exploded perspective view showing an example of the structure of a PDP.
FIG. 2 is a view showing an embodiment of an apparatus used to carry out the method of the present invention, FIG. 3 is a view for explaining the principle, FIG. 4 is a partially enlarged view of the roller, and FIGS. FIG. 8 is a diagram showing a cross section different from FIG.
FIG. 4 is a perspective view showing a grid-like groove pattern of a roller. First, the structure of the PDP will be described with reference to FIG.

The PDP 10 shown in FIG. 1 is of an AC surface discharge type. In this PDP 10, first, data electrodes (address electrodes) 14 are formed in a stripe shape (interdigital shape) on a rear glass substrate 12, and the upper surface of the data electrode (address electrode) 14 is formed thereon.
6 covered with an insulating layer. A barrier rib (barrier) 18 having a height of about 0.1 mm (100 μm) is formed on the back dielectric layer 16 by a method described later. Here, the electrode 14 is formed in the vertical direction of the PDP 10 and the barrier rib 1
Reference numeral 8 is located between two electrodes 14 which are parallel to and adjacent to the electrode 14.

Next, a phosphor 22 is applied to the side surface of the barrier rib 18 and the groove 20 surrounded by the data electrode 14. In the case of the PDP 10 for color display, the phosphors 22 applied to the adjacent grooves 20 are arranged so as to be red, green, and blue. This vertically long groove 20 becomes a discharge space, that is, a discharge cell.

On the front glass plate 24, transparent electrodes 26 are formed in stripes (interdigital) in the horizontal direction. The entire surface of the glass substrate 24 including the transparent electrode 26 is covered with a transparent dielectric layer 28, and an MgO protective film 30 is further deposited thereon. In this PDP 10, the MgO protective film 30
A black mask 32 made of a black dielectric is formed in a lattice shape on the substrate to increase image contrast and improve image quality. That is, portions other than the openings of the discharge cells corresponding to the pixels are covered with the black mask 32.

Next, a method according to the present invention, that is, a method for forming the discharge cells 20 on the back glass substrate 12 by the barrier ribs 18 and the phosphors 22 will be described with reference to FIGS. According to the present invention, as shown in FIG. 3, a rib forming material layer 50 and a phosphor forming material layer 100 are formed on a glass substrate 12 on which an electrode 14 has been formed in advance and covered with a dielectric layer 16, and these are held on a carrier 52. By moving the roller 54 placed in a direction perpendicular to the moving direction of the carrier 52 to the rib forming material layer 50 and the phosphor forming material layer 100, the groove pattern formed on the roller 54 is changed. This is to be transferred to the rib forming material layer 50 and the phosphor forming material layer 100. Then, by drying and firing, the barrier ribs 18 are formed.
And the phosphor 20.

In FIG. 3, reference numeral 56 denotes a motor for rotating the roller 54.
Of the transfer speed V. That is, when the radius of the roller 54 (for example, the average value of the radius of the outermost circumference and the radius with respect to the bottom of the groove) is R, and the rotational angular velocity is ω (radian / second), Rω = V.

An apparatus for performing this method can be configured as shown in FIG. In FIG. 2, reference numeral 58 denotes a carriage for moving the carrier 52. The carriage 58 is movable on a horizontal rail 60, and the carrier 52 is fixed horizontally on the upper surface thereof. Trolley 5
8 is linearly moved by a feed screw 64 rotated forward and reverse by a motor 62. In addition, the suction negative pressure sucked by the suction air pump 66 is guided to the surface of the transfer table 52, and the glass substrate 12 is held on the upper surface of the transfer table 52 by the suction negative pressure.

The roller 54 and the motor 56 are supported by a support shaft 68.
It is held at one end of a support arm 70 held swingably. The other end of the support arm 70 is pressed downward from above by a balance spring 72, and is pressed upward from below by a piston rod 74a of an air cylinder 74. The pressurized air of a pressurized air pump 76 is guided to the air cylinder 74 via a control valve 78,
The pressing force of the support arm 70 of FIG.
Can be controlled by Therefore, the pressing force of the roller 54 against the rib forming material layer 50 can be controlled by the control valve 78.

It is desirable that the gap between the roller 54 and the glass substrate 12 can be set with high precision. For example, an auxiliary roller (for example, an area for providing a sealing material for airtightness between the front and back glass substrates can be used) on the support arm 70 on the surface of the transfer table 52 or on the surface near both side edges of the glass substrate 12 (an auxiliary roller ( (Not shown) so that the gap between the roller 54 and the glass substrate 12 can be adjusted by the height of the auxiliary roller. The gap size can be adjusted by providing annular convex portions at both ends of the roller 54 in contact with the surfaces near both side edges of the glass substrate 12 and appropriately setting the height of the convex portions.

The groove pattern of the roller 54 used here is as follows.
It is needless to say that it corresponds to the shape of the rib 18 to be formed.
When the stripe-shaped ribs 18 shown in FIG. 1 are formed, an annular groove 80 formed at the same interval (pitch) as the ribs 18 is used as shown in FIG. Such rollers 54 have different diameters, for example, as shown in FIGS.
The seed disks 82 and 84 can be manufactured by alternately stacking the center disks 86 so as to coincide with each other.

When a rectangular groove 80 is formed as shown in FIG. 5, the difference between the radius of the small-diameter disk 82 and the diameter of the large-diameter disk 84 is the depth of the groove, that is, the height H. the thickness of the groove 80 opening width W _T and bottom width W _B next to both discs 82,
The total thickness of 84 is the pitch L _P of the grooves 80.

Since the sectional shape of the groove 80 corresponds to the sectional shape of the rib 18, the sectional shape of the rib 18 can be changed by changing the sectional shape. FIG.
According to the groove 80 having a rectangular cross section, the rib 18 having a substantially rectangular cross section is used.
Can be formed. FIG. 6 shows an inverted trapezoidal groove 80A.
FIG. 7 shows an inverted chevron groove 80B. The groove 80A can be formed by performing linear chamfering on both sides of the trapezoidal circular plate 84A to form a slanted peripheral portion, and alternately stacking this with the small-diameter circular plate 82A. Similarly, the grooves 80B may be formed by chamfering the peripheral edges of both surfaces of the large-diameter disk 84B in a circular shape in cross section, and alternately stacking them with the small-diameter disks 82B.

When the ribs 18 are formed in a lattice, a roll 54 having a groove pattern shown in FIG. 8 is used. That is, the groove frusto pyramidal projection 88 having a pitch L _P and the opening width W _T and the bottom width W _B corresponding to the discharge cell formed on the outer peripheral surface, perpendicular to each other between the projection 88 80C ,
The roll 54 on which 80C 'is formed is used.

Next, the rib forming step will be described with reference to FIGS. FIG. 9 is a flowchart of this process, and FIG. 10 is an explanatory diagram of each process. First, as described above, the back glass substrate 12 on which the electrodes 14 and the back dielectric layer 16 are formed is prepared (Step 500 in FIG. 9). FIG. 10A shows the glass substrate 12. On the surface of the glass substrate 12, FIG.
As shown in (B), the rib forming material layer 50 (see FIGS. 2 and 3)
Is formed (Step 502).

As a method of forming the rib forming material layer 50, laminating a green sheet for a rib on the surface of the glass substrate 12 is convenient for good workability and is convenient for achieving a uniform thickness. This green sheet is a sheet in which a glass paste for ribs is sandwiched between protective sheets in the form of a sheet of uniform thickness. The protective sheet is peeled off and used. Instead of a green sheet,
Liquid rib glass paste may be applied to the glass substrate 12 to a uniform thickness and dried (step 5).
02A).

The glass paste for ribs used here has glass powder and a resin binder as main components, and an appropriate additive and solvent are added thereto to obtain desired characteristics. The glass powder contains sulfur (S), selenium (Se), and alum in addition to the silicate, and particularly contains lead oxide for the purpose of lowering the melting point. Various sintering aids are also added. The particle size of the powder is set to several tens of microns (μm) to sub-micron. As the resin binder, vinyl ether, methacrylate, urea resin, phenol resin, epoxy resin, unsaturated polyester resin, etc., and their precursors are used. The amount of the resin binder is 10 to 20 parts by weight based on 100 parts by weight of the glass powder.

The additives may include a curing accelerator, a plasticizer, a dispersant, a wetting improver, a leveling agent, an antifoaming agent, an antioxidant, an ultraviolet absorber and the like. The solvent only needs to be compatible with the resin binder, and toluene, xylene,
Aromatic solvents such as phthalic acid esters, higher alcohols such as hexanol, octanol and oxyalcohol, and esters such as acetic acid esters are used.

Next, on this rib forming material layer 50, FIG.
The phosphor forming material layer 100 is formed as shown in FIG.
The phosphor forming material layer 100 is formed by forming phosphor forming material pastes (phosphor pastes) of R, G, and B in a stripe shape at intervals corresponding to the barrier ribs 18. The sheet can be laminated (step 504). Instead of the phosphor sheet, a phosphor paste may be applied by stripe printing or the like and dried (step 504A). The paste of the phosphor-forming material used here has substantially the same configuration and physical properties as the glass paste for ribs, and uses phosphor powder (particle size: 3 to 5 μm) instead of glass powder.

The glass substrate 12 on which the rib-forming material layer 50 and the phosphor-forming material layer 100 are formed as described above is left in a solvent vapor for a certain period of time to soften the rib-forming material layer 50 and the phosphor-forming material layer 100. Then, the workability by the roll 54 is improved (Step 506). Then, a releasing agent 102 (FIG. 10) is applied to the surface of the phosphor forming material layer 100.
(C) is applied by spraying or the like (step 508), and the roller 54 is rolled (step 51).
0).

Since a groove pattern is formed on the roller 54, the rib forming material and the phosphor forming material flow and gather in the grooves 80 (80A to 80C, see FIGS. 4 to 8) of the groove pattern. As shown in FIG. 10D, a ridge 104 having a cross-sectional shape corresponding to the shape of the groove 80 of the roller 54 is formed. At this time, if the fluidity of the rib-forming material is set to be greater than the fluidity of the phosphor-forming material, the rib-forming material can be smoothly placed in the groove 80 of the roller 54 while the phosphor-forming material remains between the adjacent grooves 80. It is possible to collect within.

The roller 54 may be rolled only once,
The same path (path) may be reciprocated once or plural times (step 112). Since the release agent is applied to the phosphor forming material layer 100, the rib forming material and the phosphor forming material do not adhere to the roll 54. Note that the release agent 102 may be applied to the surface of the roller 54 in advance. Further, it may be applied to both the roller 54 and the phosphor forming material layer 100. The total thickness of the rib forming material layer 50 and the phosphor forming material layer 100 should be determined in consideration of the cross-sectional area of the groove 80 of the roller 54. The cross-sectional area of the groove 80 should be determined in consideration of the amount of shrinkage of the rib forming material after firing so that the shape of the ridge 104 after firing becomes the rib 18 having a desired height and width.

After the ridges 104 of the rib forming material are formed by the rolling pressure of the roller 54, the glass substrate 12 is sequentially placed in a drying furnace and a firing furnace (step 514). The drying furnace and the baking furnace may be the same, and the drying and the baking may be performed by sequentially raising the temperature according to a preset program. Here, the rib forming material and the phosphor forming material forming the ridge 104 are dried and further fired to form a glass substrate with the barrier ribs 18 and the phosphor 22 (step 516).

Here, prior to firing of the rib forming material 50 and the phosphor forming material 100, a black antireflection layer 106, for example, a liquid of a black dielectric may be applied to the top surface of the ridge 104 by printing or the like. Good ((E) in FIG. 10, step 518 in FIG. 9). By doing so, the black anti-reflection layer 106 can be fired together with the rib forming material 50 and the phosphor forming material 100, and the firing process can be simplified.

Instead of applying the black anti-reflection layer 106 on the phosphor forming material 100, the rib forming material 50
And after firing the phosphor forming material 100 (step 51).
4), the top surface of the rib 18 is scraped (FIG. 10 (F),
Step 520), the unnecessary phosphor forming material 10 on the top surface
After removing 0, a black anti-reflection layer 108 may be applied to the top surface (FIG. 10G, step 522).

[0058]

[Other Embodiments] FIG. 11 is an explanatory view of each step of another embodiment. In this embodiment, a black anti-reflection layer, that is, a black mask is formed on each rib at the same time as the formation of the rib and the phosphor.

First, the back glass substrate 12 on which the electrodes 14 and the back dielectric layer 16 are formed is prepared (FIG. 11A). A glass paste for a rib is applied on the glass substrate 12 and dried to form a rib forming material layer 50 (FIG. 11).
(B)). Instead of applying and drying the glass paste, a green sheet of the glass paste may be laminated on the surface of the glass substrate 12. The phosphor forming material layer 110 is formed on the rib forming material layer 50 thus formed (FIG. 11C). This phosphor forming material layer 110 is
8 includes a black anti-reflection material 112.

The phosphor forming material layer 110 can be formed, for example, by applying phosphor forming materials of different colors and a black anti-reflection material in a stripe shape by printing, for example. Instead of printing, a sheet in which the phosphor-forming material and the black anti-reflection material are arranged at predetermined positions may be prepared in advance, and this sheet may be laminated on the rib-forming material layer 50.

9 and 10, the paste is softened (step 506), the release agent is applied (step 508), and the roller 54 is rolled (steps 510 and 512). As a result, the ridge 110 is formed as shown in FIG. On the upper surface of the ridge 110, a layer 112A in which the black antireflection layer 112 is rolled is formed. The roller 54 is reciprocated as needed (step 512), and dried and fired (step 51).
4), a glass substrate 12 with ribs and phosphor can be obtained (step 516). This rib has a black mask on the upper surface.

[0062]

FIG. 12 is a process diagram of one method for forming a sheet of a phosphor forming material, and FIGS. 13 to 15 are explanatory diagrams thereof. This sheet laminates the entire surface of the rib forming material layer 50 instead of forming the fluorescent forming material layers 100 and 110 on the surface of the rib forming material layer 50 by printing in the above-described embodiment.

This sheet 120 is manufactured as follows. First, the lower support film 122 is prepared (Step 600 in FIG. 12), and the release agent layer 124 is applied thereon (Step 602). On top of this, a first color, for example, R (red)
Of the phosphor forming material paste 126R is uniformly printed to a uniform thickness (FIG. 13A, step 604). The roller 130 having the slit 128 corresponding to the phosphor application position of the R color is pressed against the phosphor forming material paste 126R (step 606). As a result, the phosphor-forming material paste 126R is collected in the slots 128 and the ridges 1 are formed.
32R (FIG. 13B).

Next, the phosphor forming material paste 126G is applied to a second color, for example, G (green) except for the projections 132R by printing (step 608), and the roller 134 is pressed (step 610). The roller 134 has slits 136 corresponding to the application positions of the R ridges 132R and G.
Are formed. By rolling this roller 134, the G paste 126G is collected in the slit 136 (FIG. 13C). As a result, a G ridge 132G adjacent to the R ridge 132R is formed (FIG. 13D).

Next, the phosphor forming material paste 126B of B (blue), which is the third color, is printed at the corresponding position (step 612), and the entire upper surface of the lower release layer 124 is coated with the phosphor paste (126R, 126G, 126B) (132)
R, 132R, 132B) (FIG. 13)
(E)). After forming the upper release layer 138 thereon (step 614), the upper support film 140 is overlaid thereon (FIG. 14F, step 616). Upper release layer 1
38 may be applied to the upper support film 140 side and then the upper support film 140 may be laminated. In this way, the ridges (13) of the phosphor paste (126R, 126G, 126B) are sandwiched between the upper and lower support films 140, 122.
2R, 132G, and 132B) are arranged in a stripe shape, and a sheet 120 of phosphor forming material, that is, a stripe sheet is completed (step 618).

When this sheet 120 is used, the lower support film 122 is peeled off (FIG. 14G) and laminated on the rib forming material layer 50 formed on the glass substrate 12 (FIG. 14H). ). Then, the upper support film 140 may be peeled off. Generally, when rolling the rollers 130 and 134 (steps 606 and 610), the first and second
It is inevitable that the phosphor pastes 126R, 126G of the colors (R, G) slightly remain on the surfaces other than the slits 128, 136. Therefore, the phosphor pastes 126R, 126G, and 126B remain thin on the lower support film 122 and are mixed. However, since the lower support film 122 is peeled off, the mixed phosphor pastes 126R, 126G,
126B adheres to the lower support film 122 and is removed.

A roller 146 having slits 144 corresponding to the ribs is pressed against the phosphor forming material layer 142 laminated on the rib forming material layer 50 (FIG. 14 (I)). As a result, the rib forming material layer 50 and the phosphor forming material layer 142 are collected in the slit 144 and
As shown in (J), a ridge 148 is formed. The ridges 148 and the grooves between the ridges 148 are covered with the phosphor forming material pastes 126R, 126G, and 126B. After curing these by drying and baking, or
If the upper surface of the ridge 148 is shaved before firing and then dried and fired, the phosphor can be removed from the top surface of the ridge 148 as shown in FIG.

[0068]

According to the present invention, a flexible uncured barrier rib forming material layer 12 is formed on a glass substrate, and a phosphor forming material layer is formed on the barrier rib forming material layer. By rolling a roller having a groove pattern corresponding to the barrier ribs into the barrier rib forming material layer and the phosphor forming material layer, a convex rib of the barrier rib forming material corresponding to the barrier rib is formed, and the rib inner wall surface and the discharge cell are formed. A phosphor forming material can be supplied into the inside. For this reason, this is dried and fired to form a barrier rib with a phosphor, so that a discharge cell with a phosphor can be formed with high precision, which is suitable for increasing the definition and size of a PDP.

Further, the number of steps is reduced, and in particular, the barrier ribs and the phosphor can be formed by one firing, so that
The manufacturing apparatus can be reduced in size and size. Further, all the materials of the barrier rib forming material layer formed on the glass substrate are gathered together on the ridges and used as barrier ribs, and all the phosphor forming materials are used, so that the material loss of the barrier rib forming material and the phosphor forming material is reduced. Since no generation occurs and the number of steps is small, the production yield is increased, and the production cost can be significantly reduced.

According to the invention of claims 18 to 21, a black anti-reflection material is provided on the phosphor forming material layer so as to correspond to the rib, and the black anti-reflection layer is simultaneously formed on the rib upper surface in the barrier rib forming step. From this, processing of the black matrix formed on the front glass substrate becomes unnecessary or simple, and P
DP productivity is further improved. According to the invention of claim 22, a sheet of the phosphor-forming material used in the present invention is obtained.
According to the twenty-third aspect of the present invention, a method for manufacturing a sheet of the phosphor-forming material is obtained.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a structural example of a PDP.

FIG. 2 shows an embodiment of an apparatus used to carry out the method of the present invention.

FIG. 3 is a diagram illustrating the principle.

FIG. 4 is a partially enlarged view of a roller.

FIG. 5 is a cross-sectional view of a cross-sectional shape of a roller groove taken along a roller central axis.

FIG. 6 is a cross-sectional view of another cross-sectional shape of the groove of the roller taken along the central axis of the roller.

FIG. 7 is a cross-sectional view of another cross-sectional shape of the groove of the roller taken along the central axis of the roller.

FIG. 8 is a perspective view showing a grid-like groove pattern of a roller.

FIG. 9 is a flowchart of a rib forming step.

FIG. 10 is an explanatory view of each step.

FIG. 11 is an illustration of a process according to another embodiment.

FIG. 12 is a process chart showing a method for forming a sheet of a phosphor forming material.

FIG. 13 is an explanatory diagram of the process.

FIG. 14 is an explanatory view of the process.

FIG. 15 is an explanatory diagram of the process.

[Explanation of symbols]

 Reference Signs List 10 PDP (Plasma Display Panel) 12 Back glass substrate 14 Data electrode 16 Back dielectric layer 18 Barrier rib 20 Barrier rib groove (discharge space, discharge cell) 22 Phosphor 24 Front glass substrate 50 Barrier rib forming material layer 54 Roller 56 Roller driving Motors 80, 80A to 80C Roller grooves 86, 102 Release agent 100, 110, 142 Phosphor-forming material layer 104, 110, 148 Ridge 106, 112A Black anti-reflection layer 120 Phosphor-forming material sheets 126R, 126G, 126B phosphor forming material paste 130, 134, 146 roller

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Shinya Yamazaki 1005 Koizono, Ayase-shi, Kanagawa Fuji Micrographics Co., Ltd. (72) Inventor Takashi Utsumi 1005 Koizono, Ayase-shi, Kanagawa Fuji Micrographics Co., Ltd. F term (reference) 5C027 AA09 5C028 FF16 HH14 5C040 FA01 FA02 GA03 GB02 GB06 GF02 GF03 GF18 GF19 GG01 GG03 GG09 GH07 JA19 JA20 KA08 KB24 LA14 MA02 MA04 MA22 MA23 MA24 MA25 MA26

Claims (23)

[Claims] 1. A method for forming a discharge cell of a plasma display panel having a large number of discharge cells separated by barrier ribs between a pair of glass substrates on which electrodes are formed and having a phosphor layer formed on an inner surface thereof. Forming a flexible uncured barrier rib forming material layer on the surface of the one glass substrate on which the electrodes are formed; (b) a phosphor forming material in which the phosphor forming materials are arranged at the same pitch as the discharge cells. Forming a layer on the barrier rib forming material layer; (c) forming the phosphor forming material layer and the barrier rib forming material layer;
Forming a ridge corresponding to the barrier rib on the glass substrate by rolling a roller having a groove corresponding to the barrier rib formed on the outer peripheral surface; (d) the fluorescent light processed into the ridge in the step (c). Forming a discharge cell having a phosphor layer formed on an inner surface thereof by drying and firing the body forming material and the barrier rib forming material. . 2. The discharge cell of a plasma display panel according to claim 1, further comprising: (b-1) a step of coating the surface of the phosphor-forming material layer with a release material after the step (b). Forming method. 3. The method according to claim 1, wherein the step (b) is followed by a step following the step (b-2): (b-2) leaving the glass substrate in a solvent vapor of the barrier rib forming material and the phosphor forming material for a predetermined time to form a barrier rib; Adjusting the hardness of the material and the phosphor forming material; and forming a discharge cell of the plasma display panel. 4. The method according to claim 2, wherein the glass substrate is left in a solvent vapor of the barrier rib forming material and the phosphor forming material for a predetermined time after the step (b-1). Adjusting the hardness of the barrier rib forming material and the phosphor forming material; and forming a discharge cell of the plasma display panel. 5. The plasma display panel according to claim 1, wherein the barrier rib forming material layer in step (a) is formed by laminating a green sheet of a glass paste for a rib on a glass substrate. Discharge cell forming method. 6. The method according to claim 1, wherein the barrier rib forming material layer in the step (a) is formed by applying a glass paste for a rib on a glass substrate and drying the glass paste. Cell formation method. 7. The method for forming a discharge cell of a plasma display panel according to claim 1, wherein the barrier rib is formed on a glass substrate on a back surface. 8. The plasma display panel according to claim 1, wherein the electrodes are formed in a stripe shape on the glass substrate, and the roller has a plurality of annular grooves on its outer peripheral surface to form striped barrier ribs. Discharge cell forming method. 9. The method according to claim 8, wherein the roller is rolled with an annular groove between the striped electrodes. 10. The method according to claim 8, wherein the roller is rolled with its annular groove perpendicular to the stripe-shaped electrodes. 11. A roller having grooves perpendicular to each other in a circumferential direction and an axial direction on an outer peripheral surface thereof, and forming a grid-like barrier rib by rolling the roller into a phosphor forming material layer and a barrier rib forming material layer. Item 8. The method for forming a discharge cell of a plasma display panel according to any one of Items 1 to 7. 12. The method according to claim 1, wherein the roller in step (c) is reciprocally moved reciprocally through the same path while making its peripheral speed coincide with the relative linear movement speed of the glass substrate. A method for forming a discharge cell of a display panel. 13. The pressing pressure of the roller against the glass substrate is set to 20 to 200 with respect to the axial contact width of the roller.
The method for forming a discharge cell of a plasma display panel according to claim 1, wherein the pressure is kg / cm. 14. The method according to claim 1, wherein the diameter of the roller is 30 to 500 mm. 15. The discharge cell formation of the plasma display panel according to claim 1, wherein a relative movement speed of the glass substrate with respect to the roller and a relative peripheral speed of the roller with respect to the glass substrate are set to 0.02 to 2.0 m / min. Method. 16. The method according to claim 1, wherein the groove of the roller is provided.
Sets the opening width to W _T, Bottom width W_B, Depth H, pitch
To L_PAs 0 <W_B/ W_T<1.0, 0.1 <H / W_T
<3.0, 0.1 <(W_T+ W_B) / 2L_P<1.0, and
Of forming a discharge cell of a plasma display panel. 17. The method of claim 1, wherein step (c).
And (c-1) a step of forming a black anti-reflection material layer on the phosphor forming material layer on the upper surface of the barrier rib. 18. The method according to claim 1, wherein the phosphor forming material layer of step (b) has a black anti-reflection material at a position corresponding to the barrier rib. 19. The method according to claim 1, wherein the phosphor forming material layer is formed by printing on the surface of the barrier rib forming material layer. 20. The method according to claim 1, wherein the phosphor-forming material layer is formed by laminating a sheet in which phosphor-forming materials of different colors are arranged corresponding to respective discharge cells to the barrier rib-forming material layer. A method for forming a discharge cell of a plasma display panel. 21. The phosphor-forming material layer sheet has a black anti-reflection material at a position corresponding to the barrier rib.
A method for forming a discharge cell of a plasma display panel. 22. A phosphor-forming material sheet used in the method according to claim 20, wherein phosphor-forming materials of different colors are sandwiched between a pair of upper and lower peelable support films corresponding to respective discharge cells. A sheet of a phosphor-forming material, characterized in that: 23. A method for producing a phosphor-forming material sheet used in the method of claim 20, comprising: (a) forming a release layer on the lower support film; and (b) forming a release layer on the entire upper surface of the release layer. Printing the phosphor of one color to a uniform thickness; (c) rolling the phosphor of the first color by rolling a roller having a groove formed at the position of the discharge cell corresponding to the first color; (D) printing a phosphor of a second color on the upper surface of the release layer except for the protrusions; and (e) printing the first color and the phosphor on the upper surface of the release layer; By rolling a roller having a groove formed at the position of the discharge cell corresponding to the second color, the phosphor of the second color is collected in the groove, and the second phosphor adjacent to the convex portion of the first color is collected. (F) printing a phosphor of the last color on the upper surface of the release layer excluding the first and second protrusions and drying; (g) passing through the release layer Up Laminating the lifting film:
A method for producing a sheet of a phosphor-forming material.