JP2002008532A - Manufacturing method of color plasma display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a color plasma display panel that forms a phosphor layer corresponding to the highly fine patterns by applying phosphor paste on the rib patterns in precise positions by using a photosensitive resin film instead of a screen printing plate. SOLUTION: The manufacturing method comprises a process in which the photosensitive resin film 2 is adhered to the top face of ribs 13 in a state to cover the dielectric layer 12 of the rear substrate 1, a process in which openings 21 for applying the phosphor paste 4 on the photosensitive resin film 2 are formed, and a process in which the phosphor paste 4 is applied from the openings 21.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a color plasma display panel.

[0002]

2. Description of the Related Art Conventionally, a method of manufacturing a rear substrate of a color plasma display panel includes a step of laminating and forming an address electrode / white dielectric layer on a glass substrate and a step of forming an insulating material on the dielectric layer. Forming ribs,
There was a step of forming red, green, and blue phosphor layers on the dielectric layer surrounded by the ribs.

Here, in order to improve the image quality of a color plasma display panel, it is important to form the three color phosphor layers at predetermined positions with high accuracy. In recent years, in order to improve the definition of an image, pixels have been refined, and accordingly, the phosphor layer has also been refined. For this reason, a technique for forming a phosphor layer with high accuracy has become more important than ever. By the way, in order to form a phosphor layer with high accuracy, it is necessary to apply a phosphor paste at a predetermined position with high accuracy.

As a method of applying the phosphor paste, as shown in FIG. 3, first, a rib pattern (an upper surface shape and a position of the dielectric layer 12 surrounded by the rib 13) to which the phosphor paste 4 is applied is applied. A screen plate 100 having a corresponding opening 101 is prepared.
The alignment of the 0 opening pattern (shape and position of the opening 101) and the rib pattern on the rear substrate is performed.

Subsequently, an appropriate amount of the phosphor paste 4 is placed on the screen plate 100, and then the squeegee 5 pressed against the screen plate 100 is moved at a predetermined printing pressure (pressure at which the squeegee presses the screen plate). . Then, the phosphor paste 4 moves with the movement of the squeegee 5, and when the phosphor paste 4 passes through the opening 101, the phosphor paste 4 passes through the opening 101, and
(Screen printing step).

Here, in general, in screen printing, a condition that a gap of several mm exists between the screen plate and the substrate and that a squeegee is pressed against the screen plate are required. Under these conditions, screen printing is locally performed when the screen plate is deformed into a V-shape when viewed from the side, and the corner of the V-shape is in contact with the substrate. This is performed by continuously moving the position of the line contact with the substrate. Therefore, in the screen printing, the screen plate 100 is separated from the back substrate 1 at the same time when the phosphor paste 4 is applied from the opening 101. This is generally called "plate separation" in screen printing.

[0007] In addition, the characteristics of the separation of the printing plate have an important effect on the printing quality such as the releasability, bleeding, and positional accuracy of the phosphor paste, but the printing separation is an instantaneous operation, so that the management is performed accurately. It is often difficult. For this reason,
For the purpose of improving the image quality of a color plasma display panel, technology development has been carried out to improve the printability of a phosphor paste using a screen plate, including this plate separation characteristic.

[0008]

However, in the case of screen printing, since the screen plate receives the printing pressure of the squeegee, the shape and position of the opening pattern drawn on the screen plate change with time. was there. In addition, it is practically difficult to accurately control the gap and the printing pressure of the urethane rubber squeegee in response to the aging of the screen plate, and there is a high possibility that the printing position of the phosphor paste is shifted. There was a drawback.

[0009] Further, the screen plate is made by sticking a gauze (mesh) on a metal frame with a strong tension, and there is a limit in the positional accuracy of the pattern drawn thereon, and it is difficult to cope with a high definition pattern. There is a disadvantage that there is. Therefore, for example, it is extremely difficult to achieve high image quality (XGA class) image quality on a large screen with a diagonal of 42 inches, and even if the conventional method is improved, the position accuracy is limited to about 100 microns. .

[0010] That is, the screen printing method is basically realized by stretching the screen plate, and
Since the screen plate is locally dragged by the squeegee in the horizontal direction, there is a drawback that expansion and contraction and further deformation of the printed pattern cannot be avoided. In addition, there is a disadvantage that the pattern drawn on the screen plate expands and contracts and deforms as the number of times the screen plate is used increases.

[0011] If the opening pattern of the screen plate and the rib pattern are misaligned due to the above-mentioned defects, the phosphor paste flows into adjacent cells, causing color mixing at the time of panel light emission, and significantly deteriorating the display quality. There was a problem. Similarly, even if the phosphor paste does not enter the adjacent cells, if it is applied to the tops of the ribs, it may rub during assembly with the front plate, etc., so that the phosphor enters the adjacent cells, or There is a problem that the phosphor particles may bite between the rib and the front plate to break the rib, which causes a point defect at the time of light emission.

In order to solve the above-mentioned problems, the present invention uses a photosensitive resin film instead of a screen plate to apply a phosphor paste to a rib pattern with a high degree of positional accuracy, thereby coping with a high definition pattern. It is an object of the present invention to provide a method for manufacturing a color plasma display panel on which a phosphor layer formed is formed.

As a technique related to this problem, Japanese Patent Laid-Open Publication No. Hei 10-228864 discloses a method in which a photosensitive resin is filled between ribs and an opening is formed in the photosensitive resin. A method for manufacturing a back plate of a plasma display panel to be filled with a substance and a composition for forming the back plate have been proposed. However, this technique can fill the opening with the phosphor composition, but removes the photosensitive resin between the ribs that do not form an opening in order to fill the phosphor composition between all the ribs. If the pattern is made finer, it becomes difficult to remove the photosensitive resin, or there is concern about contamination of the inner wall of the cell, and the above-mentioned problem cannot be solved.

Similarly, Japanese Patent Application Laid-Open No. H11-179273 discloses
And JP-A-11-179278 propose a method of forming a phosphor layer using a transfer sheet provided with a photosensitive resin layer containing a phosphor on a base film so as to be peelable. However, this technique can transfer the photosensitive resin layer to the tip of the barrier, but it is necessary to push this photosensitive resin layer into the cells between the barriers. There is a concern that it is difficult to push the layer in, and the above-mentioned problem cannot be solved.

[0015]

According to a first aspect of the present invention, there is provided a method of manufacturing a color plasma display panel using a phosphor paste. Bonding the photosensitive resin film to the upper surface of the rib formed on the dielectric layer so as to cover the dielectric layer of the back substrate; and an opening for applying the phosphor paste to the photosensitive resin film. The method includes a step of forming a portion and a step of applying the phosphor paste from the opening.

In this case, since the positions of the opening pattern and the rib pattern of the photosensitive resin film coincide with each other,
The fluorescent paste can be accurately applied to the inner wall of the cell, and the display quality of the color plasma display panel can be improved.

According to a second aspect of the present invention, in the method of manufacturing a color plasma display panel according to the first aspect, the step of forming an opening for applying the phosphor paste to the photosensitive resin film includes: A step of exposing the photosensitive resin film through a glass mask created so that light is applied to a region where the opening is formed, and shower-developing the exposed photosensitive resin film, Forming the opening in the photosensitive resin film.

In this case, since the opening of the photosensitive resin film can be formed with high precision, the displacement between the opening pattern and the rib pattern can be more effectively prevented.

According to a third aspect of the present invention, in the method for manufacturing a color plasma display panel according to the first or second aspect, the hot roll presses the heated elastic body onto the object from above the photosensitive resin film. Using the method
It is a method of bonding the photosensitive resin film to the upper surface of the rib.

By doing so, the photosensitive resin film can be adhered to the upper surface of the rib in a flat state without wrinkles and the like, and as a result, the opening can be formed with high precision.

[0021] The invention described in claim 4 is the above-mentioned claims 1-3.
In the method for manufacturing a color plasma display panel according to any one of the above, when applying the phosphor paste from the opening, a squeegee or a dispenser is used.

As described above, by using the squeegee or the dispenser, the phosphor paste can be efficiently applied to the opening of the photosensitive resin film.

The invention according to claim 5 is the invention according to claims 1-4.
In the method for manufacturing a color plasma display panel according to any one of the above, after the phosphor paste is applied, the photosensitive resin film is mechanically separated from the ribs, and then the applied phosphor paste is dried. There is a method having a step of causing

In this case, since the photosensitive resin film is not deformed or hardly adheres to the ribs due to heat when drying the phosphor paste, the drying temperature can be set higher. Drying time can be shortened.

[0025] The invention of claim 6 provides the above-mentioned claims 1-4.
In the method for manufacturing a color plasma display panel according to any one of the above, after the phosphor paste is applied, the applied phosphor paste is dried while the photosensitive resin film covers the dielectric layer. And a step of mechanically peeling off the photosensitive resin film from the ribs after drying the applied phosphor paste.

In this way, since the dielectric layer not corresponding to the opening is covered with the photosensitive resin film, it is possible to prevent the phosphor paste from adhering to the dielectric layer other than the rib pattern. it can.

According to a seventh aspect of the present invention, in the method for manufacturing a color plasma display panel according to the fifth or sixth aspect, after forming a phosphor layer using the phosphor paste, phosphor pastes of different colors are formed. Is used to form different phosphor layers.

In this manner, the red, green, and blue phosphor pastes can be applied with high positional accuracy, and the display quality of the color plasma display panel can be improved.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method of manufacturing a color plasma display panel according to an embodiment of the present invention will be described with reference to the drawings. 1A and 1B are schematic enlarged cross-sectional views of a rear substrate of a color plasma display panel according to an embodiment of the present invention. FIG. 1A is a schematic enlarged cross-sectional view after a rib forming step, and FIG. 1B is a photosensitive resin film. The schematic enlarged cross-sectional view after the sticking step, (c) is the schematic enlarged cross-sectional view in the exposure step, and (d) is the schematic enlarged cross-sectional view after the developing step.

As shown in FIG. 1A, a back substrate 1 of a color plasma display panel is formed by firstly forming an address electrode 11 on a glass substrate 10 by using silver or aluminum.
Is patterned. Subsequently, a white dielectric layer 12 is formed on the address electrodes 11 and the glass substrate 10, mainly as a reflective layer of a phosphor layer described later. further,
On this white dielectric layer 12, ribs 13 made of an insulator are formed to isolate the discharge of each cell and define the gap facing the front plate.

Next, a procedure for forming a phosphor layer on the inner wall of a cell which is partitioned by the ribs 13 and corresponds to each of red (R), green (G), and blue (B) will be described. As shown in FIG. 2B, a photosensitive resin film (abbreviated as a dry film) is applied on the upper surface of the rib 13 by a hot roll method so as to cover the entire surface of the rear substrate on which the rib 13 is formed. Adhere (dry film sticking process).

Here, the photosensitive resin film 2 is a film obtained by molding a negative photosensitive resin into a film.
When the heated rubber roll is pressed against the upper surface, if there is an adherend on the lower surface, the rubber roll adheres to the adherend. For this reason, the photosensitive resin film 2 can adhere to the upper surface of the rib 13 while keeping the flatness, and can further cover the dielectric layer 12 without entering the gap between the ribs 13.

By doing so, the squeegee described later can move smoothly on the photosensitive resin film 2, so that the phosphor paste 4 can be uniformly applied. Further, since the photosensitive resin film 2 is only adhered to the upper surface of the rib 13, it is possible to prevent a problem that the photosensitive resin film 2 remains as a foreign substance in a gap between the ribs 13. Furthermore, the photosensitive resin film 2
Since the ribs 13 can be easily and mechanically peeled off without breaking, the productivity can be improved as compared with, for example, a case where the ribs 13 are removed using a chemical.

Subsequently, as shown in FIG. 3C, exposure is performed using a glass mask 3 on which a cell pattern to be coated with a phosphor paste is formed. Note that, for easy understanding, a portion where light is transmitted is shown in white, and a portion where light is blocked is shown in black. Here, the photosensitive resin film 2 is
Since it is stuck by the hot roll method without wrinkles or the like, exposure can be performed with extremely high precision.

Next, as shown in FIG. 4D, the glass mask 3 is removed, and the exposed dry film is shower-developed with a weak alkali, so that the dry film in the region where the phosphor is to be formed is removed. After being removed and dried, the exposed portion is removed and the opening 21 is formed.
As shown in the figure, since the side surface of the opening 21 is formed without a step from the side surface of the rib 13, when the phosphor paste is applied from the opening 21, the opening 21 is formed on the upper surface of the rib 13. Prevents phosphor paste from adhering.

Next, a process of printing the phosphor paste on the rear substrate 1 will be described with reference to FIG. 2A and 2B are schematic enlarged cross-sectional views of a back substrate of a color plasma display panel according to an embodiment of the present invention. FIG. 2A is a schematic enlarged cross-sectional view in a phosphor paste printing process, and FIG. FIG. 3C is a schematic enlarged sectional view after a paste drying step, and FIG. 4C is a schematic enlarged sectional view after a photosensitive resin film removing step.

As shown in FIG. 1A, first, an appropriate amount of the phosphor paste 4 is provided on the upper surface of the photosensitive resin film 2 performing the function of the screen plate 100, and the squeegee 5 is moved to open the opening. The phosphor paste 4 is placed on the entire portion 21 at a position where the phosphor paste 4 is printed.

Subsequently, the squeegee 5 generally made of an elastic material such as urethane rubber moves at a predetermined squeegee angle, printing pressure and squeegee speed from the left end to the right end of the photosensitive resin film 2. Here, the squeegee angle, the printing pressure, and the squeegee speed are part of the printing conditions, and are determined in advance in an evaluation test for determining the printing conditions. The printing conditions are usually determined by optimizing various parameters such as the characteristics of the phosphor paste 4 and the shape characteristics of the photosensitive resin film 2.

The photosensitive resin film 2 is bonded to the upper surfaces of the plurality of ribs 13 so as to form a plane close to a true plane.
Since it is adhered to the upper surface of the squeegee, there is no problem such as turning up, so that the squeegee described later can be moved smoothly. Then, since the squeegee moves smoothly, it is possible to prevent problems such as uneven printing of the phosphor paste.

Since the end of the opening 21 is bonded to the upper surface of the rib 13, the phosphor paste enters a region other than the rib pattern corresponding to the opening 21, for example, between the adjacent ribs 13. Such a problem can be prevented.

Further, as the printing conditions, it is not necessary to manage the gap in printing using the screen plate 100, so that the management can be easily performed.
It is possible to perform stable printing of the phosphor paste.

As shown in FIG. 3A, the printing state of the phosphor paste 4 is such that the upper surface position of the phosphor paste 4 is located lower than the upper surface position of the photosensitive resin film 2, that is, so-called scooping. In this case, the phosphor paste 4 adhering to the side surface of the opening 21 or the like may be used when the photosensitive resin film 2 is peeled off.
Problems such as scattering can be prevented. It should be noted that by performing the printing condition determination with high accuracy, it is possible to perform printing in a scrambled state.

Here, the means for applying the phosphor paste 4 to the openings 21 is not limited to the printing method using a squeegee, but may be applied using a dispenser. For example, when repairing a defective portion, the phosphor paste 4
, It is possible to work more efficiently than the printing method.

Subsequently, as shown in FIG. 3B, the back substrate 1 is heated and dried to evaporate the volatile components of the phosphor paste 4 to form a phosphor layer 41. Here, the volume of the phosphor layer 41 is smaller than that of the printed phosphor paste 4 due to evaporation of volatile components.

Next, as shown in FIG. 4C, the phosphor layer 41 can be formed in a predetermined rib pattern by mechanically peeling off the photosensitive resin film 2.
Here, since the photosensitive resin film 4 is bonded only to the upper surface of the rib 13, the photosensitive resin film 4 can be easily peeled off.
Moreover, the ribs 13 are not damaged. Further, until the phosphor paste 4 is dried and the phosphor layer 41 is formed,
Since the photosensitive resin film 2 is adhered to the upper surface of the rib 13, the phosphor layer 41 is not formed on the upper surface of the rib 13.

In the case where the photosensitive resin film 2 melts and enters between the ribs 13 when drying the phosphor paste 4, the photosensitive resin film 4 is printed after the phosphor paste 4 is printed. It is preferable to dry the phosphor paste 4 after the peeling. In this case, the photosensitive resin film 2 can be easily peeled off and the risk of breaking the ribs 13 can be eliminated.

The photosensitive resin film 2 can be formed by printing the phosphor paste 4 in a state where it has been removed, or by drying the phosphor paste 4 at a low temperature as preliminary drying to reduce the volume of the phosphor paste 4. Can be prevented from adhering to the upper surface of the rib 13 when peeling off.

As described above, according to the method of manufacturing a color plasma display panel of the present invention, the phosphor paste 4 is formed with high precision by forming openings in the photosensitive resin film 2 adhered to the upper surface of the ribs 13 with high accuracy. Since the printing can be performed with high accuracy even on the fine rib pattern, the image quality of the color plasma display panel can be improved.

Next, it is necessary to form the red, green and blue phosphor layers 41 on the color plasma display panel, but the phosphor pastes 4 of different colors are used by the same method as the above-mentioned manufacturing method. Thus, the phosphor layer 41 can be formed. Here, since the previously formed phosphor layer 41 is covered by the newly attached photosensitive resin film 2, there is a problem that the phosphor layer 41 is damaged or a phosphor paste of another color adheres and is mixed. Can be prevented.

The red, green and blue phosphor layers 4
After forming 1, the front plate and the rear substrate are combined with a glass frit or the like so as to form an airtight container, and after the inside is evacuated and baked, a discharge gas is filled therein, whereby a color plasma display panel can be manufactured.

[0051]

As described above, according to the present invention,
Cell areas where phosphor paste must not be applied are
Since the photosensitive resin film is adhered to the upper surface of the rib, it is reliably shielded from the rib pattern on which the phosphor layer is to be formed, so that it is possible to reliably prevent the phosphor paste from flowing into adjacent cells. As a result, it is possible to reduce a color mixing defect at the time of panel light emission due to mixing of phosphor pastes of different colors to a defect rate of almost 0%.

Further, since the opening of the photosensitive resin film is formed by a photo method using a glass mask, it can correspond to a high definition pattern. Furthermore, since the phosphor does not adhere to the upper surface of the rib, the phosphor may be mixed into an adjacent cell due to rubbing, or the phosphor may bite between the upper surface of the rib and the front plate when assembling with the front plate. It is possible to prevent the ribs from being mechanically broken by being inserted.

[Brief description of the drawings]

FIGS. 1A and 1B are schematic enlarged sectional views of a rear substrate of a color plasma display panel according to an embodiment of the present invention. FIG. 1A is a schematic enlarged sectional view after a rib forming step, and FIG. The schematic enlarged sectional view after a photosensitive resin film sticking process is shown, (c) is a schematic enlarged sectional view in an exposure process, and (d) is a schematic enlarged sectional view after a development process.

FIGS. 2A and 2B are schematic enlarged cross-sectional views of a back substrate of the color plasma display panel according to the embodiment of the present invention, and FIG. 2A is a schematic enlarged cross-sectional view in a phosphor paste printing step; () Shows a schematic enlarged cross-sectional view after the phosphor paste drying step, and (c) shows a schematic enlarged cross-sectional view after the photosensitive resin film removing step.

FIG. 3 is a schematic enlarged sectional view in a printing process using a screen plate in a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Back substrate 2 Photosensitive resin film 3 Glass mask 4 Phosphor paste 5 Squeegee 10 Glass substrate 11 Address electrode 12 Dielectric layer 13 Rib 21 Opening 41 Phosphor layer 100 Screen plate 101 Opening

Claims (7)

[Claims] 1. A method of manufacturing a color plasma display panel using a phosphor paste, comprising: forming a photosensitive resin film on an upper surface of a rib formed on a dielectric layer so as to cover the dielectric layer on a back substrate. Adhering; forming an opening for applying the phosphor paste to the photosensitive resin film; and applying the phosphor paste from the opening. A method for manufacturing a color plasma display panel. 2. The method for manufacturing a color plasma display panel according to claim 1, wherein the step of forming an opening for applying the phosphor paste to the photosensitive resin film includes forming the opening. A step of exposing the photosensitive resin film through a glass mask created so that light is applied to the region, and shower-developing the exposed photosensitive resin film, so that the photosensitive resin film Forming the opening, the method for manufacturing a color plasma display panel. 3. The method of manufacturing a color plasma display panel according to claim 1, wherein the hot elastic body is pressed against an object to be bonded from above the photosensitive resin film by using a hot roll method. A method of manufacturing a color plasma display panel, comprising bonding a photosensitive resin film to an upper surface of the rib. 4. The method of manufacturing a color plasma display panel according to claim 1, wherein a squeegee or a dispenser is used when applying the phosphor paste from the opening. A method for manufacturing a color plasma display panel. 5. The method for manufacturing a color plasma display panel according to claim 1, wherein the photosensitive resin film is mechanically separated from the ribs after the phosphor paste is applied. And drying the applied phosphor paste. 2. A method for manufacturing a color plasma display panel, comprising: 6. The method for manufacturing a color plasma display panel according to claim 1, wherein the photosensitive resin film covers the dielectric layer after the phosphor paste is applied. And drying the applied phosphor paste; and, after drying the applied phosphor paste, mechanically peeling off the photosensitive resin film from the ribs. Of manufacturing a color plasma display panel. 7. The method for manufacturing a color plasma display panel according to claim 5, wherein after forming a phosphor layer using the phosphor paste, different phosphors using phosphor pastes of different colors are used. A method for manufacturing a color plasma display panel, comprising forming a body layer.