JP2003123638A - Manufacturing method of color plasma display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make flat the surface of the front substrate of the plasma display panel and prevent break of the bulkhead and crack of the protection film or the like at the pasting with the rear substrate. SOLUTION: A transparent electrode 5 and a trace electrode 6 are arranged in nearly parallel on the glass substrate 3 and the glass substrate 3 including these electrodes is covered by a first transparent dielectric layer 7. On this insulation layer a color filter 9 layer divided by a black stripe 8 is arranged and a second transparent dielectric layer 10 is formed on the color filter 9 that includes a black stripe 8 excluding the crossing parts of the black stripe with the trace electrode 6, and after calcination, a third transparent dielectric layer 11 is covered on whole face, and by coating the protection film 12 over the third transparent dielectric layer, the front substrate 1 is formed. Thereby, the protection film 12 surface of the front substrate 1 becomes flat and break of the bulkhead 15 and crack of the protection film 12 or the like at the pasting of the front substrate 1 and the rear substrate 2 can be prevented, and occurrence of display defect such as a dark point of the color PDP can be prevented.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a color plasma display panel (hereinafter referred to as a color PDP), and particularly to the generation of cracks in a transparent dielectric layer and a protective film of a front substrate when the front substrate and the rear substrate are combined. The present invention relates to a method for manufacturing a front substrate of a color PDP capable of preventing the occurrence of collapse of partition walls of the rear substrate.

[0002]

2. Description of the Related Art A PDP is a display that performs a display operation by exciting and emitting a phosphor by ultraviolet rays generated by gas discharge to obtain visible light. Among them, the AC type is excellent in brightness, luminous efficiency, and life, and various techniques have been disclosed regarding its structure and manufacturing method.

An example of a conventional method for manufacturing a color PDP will be described with reference to FIGS. 3 and 4. Figure 3 (a)
[Fig. 3] is a process flow chart of the front substrate, and Fig. 3B is a process flow diagram of the rear substrate. 4 is a cross-sectional view of the color PDP manufactured by the process of FIG. 3, and FIG.
It is sectional drawing along BB 'of (a).

Referring to FIG. 3A, in the method of manufacturing the front substrate, first, the glass substrate 53 for the front substrate 51 is washed (step 21). A transparent electrode 55 made of ITO or the like and a trace electrode 56 made of Cr, Ag or the like are sequentially formed on the glass substrate 53 (step 22). Next, a first transparent dielectric layer 57 made of low melting point lead glass is formed on the glass substrate 53 so as to cover the transparent electrode 55 and the trace electrode 56.
Are formed by a thick film printing method (step 23). Then, after forming black stripes 58 on the first transparent dielectric layer 57 (step 24), color filters 59 are formed by screen printing between the black stripes 58 (step 25). The color filter 59 is for improving the contrast in the bright place and the color purity of the emission color of the phosphor while suppressing the decrease in the brightness of the panel to the minimum. A filter with a corresponding transmission spectrum is formed. afterwards,
A second low melting point lead glass on the color filter 59
The transparent dielectric layer 61 is formed by a thick film printing method (step 2).
6) Do. Then, a protective film 62 made of MgO is formed by sputtering or the like so as to cover the second transparent dielectric layer 61 (step 27) to form the front substrate 51.

Referring to FIG. 3B, in the method of manufacturing the back substrate 52, first, the glass substrate 54 for the back substrate 52 is washed (step 41). Cr on this glass substrate 54
A data electrode 63 made of Ag or Ag is formed (step 42). Next, a dielectric layer 64 made of a material composed of low melting point lead glass and a white pigment is formed on the glass substrate 54 by a thick film printing method so as to cover the data electrodes 63 (step 4).
3). Subsequently, a partition wall 65 made of a mixture of low melting point lead glass and alumina is formed on the dielectric layer 64 by a sandblast method or the like (step 44) to form a discharge space. Next, for each discharge cell, the phosphor 66 corresponding to the emission color of each cell is formed by the screen printing method (step 45), and the back substrate 52 is formed.

The front substrate 51 and the rear substrate 52 formed in the above process are bonded to each other to hermetically seal the discharge space, and a dischargeable gas such as He, Ne and X is contained therein.
The color PDP is manufactured by enclosing the mixed gas of e.

[0007]

As shown in FIG. 4B, the bonding surface of the front substrate 51 of the PDP manufactured by the above process with the rear substrate 52 is formed of the trace electrode 56 and the black stripe 58. Since the intersection point is thicker by either of the film thicknesses, the intersection point is in a raised state even if the second transparent dielectric layer is laminated thereon. Therefore, when it is combined with the back substrate 52, there is a problem that it locally contacts the partition wall 65, and the partition wall 65 is broken or the protective film 62 and the second transparent dielectric layer are cracked. Further, there is a problem that the gap between the front substrate and the rear substrate is partially increased. These are dark spots when the color PDP is turned on,
This has been a cause of display defects such as light emission spots.

As a method for solving the above-mentioned problems of the prior art, Japanese Patent Laid-Open No. 2001-118514 discloses that the surface of the dielectric layer forming the protective film of the front substrate is flattened by chemical mechanical polishing (CMP). After that, a technique of depositing a protective film (MgO) has been proposed. In this technique, the surface of the protective film on the front substrate is flattened. Therefore, in this technique, it is possible to prevent the destruction of partition walls or the generation of cracks in the protective film and the dielectric layer when the front substrate and the rear substrate are combined. Although the effect is enhanced, there are problems that the cost increases due to polishing and the variation in the polishing thickness of the dielectric layer increases.

One of the main objects of the present invention is a method for manufacturing a color PDP, in which a front surface of a color PDP is suppressed in which a partition wall is broken or a MgO film or a dielectric layer is cracked when a front substrate and a rear substrate are combined. To provide a substrate.

Another object of the present invention is to suppress the destruction of partition walls or the generation of cracks in the MgO film and the dielectric layer, which occur when the front substrate and the rear substrate are combined, in the method for manufacturing a color PDP, and to prevent dark spots and light emission. An object of the present invention is to provide a color PDP that reduces the occurrence of display defects such as spots.

[0011]

A method of manufacturing a color PDP according to the present invention comprises a first electrode and a second electrode on a light-transmissive first substrate.
Electrodes are arranged substantially parallel to each other, a first substrate including the first electrode and the second electrode is covered with a first dielectric layer, and a striped pattern having a predetermined width is formed on the first dielectric layer. A front substrate formed by arranging a color filter layer partitioned by an insulating layer and further covering the color filter layer with a third dielectric layer, and a first substrate and a second electrode on the second substrate. The third electrode is arranged so as to be substantially orthogonal to the second electrode including the third electrode.
A back substrate having a fourth dielectric layer coated on the substrate, and a partition wall formed on the dielectric layer along the third electrode.
Including a step of attaching the dielectric layer and the partition wall as opposed surfaces, except that the stripe-shaped insulating layer and the second electrode are not provided on the color filter layer between the color filter layer and the third dielectric layer. And the second dielectric layer is formed before forming the third dielectric layer.

In the structure of the method for manufacturing a color PDP of the present invention described above, after the stripe-shaped insulating layer is formed, the surface of the stripe-shaped insulating layer is a convex surface at the intersection of the stripe-shaped insulating layer and the second electrode. The surface of the color filter layer including the surface of the insulating layer having a stripe shape other than the intersecting portion is planarized by the second dielectric layer.

In the structure of the method for manufacturing a color PDP of the present invention described above, the third dielectric layer is formed by overcoating with the same material. When this third dielectric layer is formed by overcoating with the same material, as in the case of forming the second dielectric layer, a predetermined overcoating at the intersection of the striped insulating layer and the second electrode is performed. The overcoating in the layer can further improve the planarization of the top surface of the third dielectric layer.

In the method for manufacturing a color PDP of the present invention, a protective film (MgO) formed on the surface of the third dielectric layer of the front substrate without being planarized by chemical mechanical polishing or the like.
The surface of the film can be flattened. As a result, when the front substrate and the rear substrate are bonded together, the contact between the partition wall portion and the protective film of the front substrate becomes a surface contact, and the destruction of the partition wall and the generation of cracks in the protective film and the transparent dielectric layer are suppressed. It is possible to prevent display defects such as dark spots and light emission spots of the PDP.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Next, an embodiment of a method for manufacturing a color PDP of the present invention will be described with reference to the drawings. FIG. 1A is a process flow diagram of the front substrate.
(B) is a process flow diagram of the rear substrate. Also, FIG.
2B is a cross-sectional view of the color PDP manufactured in the process of FIG. 1, and FIG. 2B is a cross-sectional view taken along the line AA ′ of FIG.

Referring to FIG. 1A, in the method of manufacturing the front substrate 1, first, the glass substrate 3 (light transmissive) for the front substrate 1 is washed (step 1). A transparent electrode 5 made of ITO or the like and a trace electrode 6 made of Cr, Ag or the like are sequentially formed on the glass substrate 3 (step 2). The transparent electrode 5 and the trace electrode 6 are formed substantially parallel to each other.

Next, a first transparent dielectric layer 7 made of low melting point lead glass is formed on the glass substrate 3 so as to cover the transparent electrodes 5 and the trace electrodes 6 by a thick film printing method (step 3). Subsequently, a black stripe 8 (insulating layer) is formed on the first transparent dielectric layer 7 (step 24), and then a color filter 9 having a thickness of about 1 to 3 μm is formed by screen printing between the black stripes 8 (step). 25) The material of the color filter 9 is iron oxide for red, chromium for green, cobalt-aluminum-titanium-chromium, etc.
For blue, materials such as cobalt-aluminum type and vanadium-zirconium type can be used.

Then, a second transparent dielectric layer 10 made of low melting point lead glass is formed on the color filter 9 by a thick film printing method (step 6). The present invention is characterized by the method of forming the second transparent dielectric layer 10. As shown in FIG. 2B, the second transparent dielectric layer 10 has a black stripe 8
And is selectively formed on the color filter 9 layer other than the intersection of the trace electrodes 6. The second transparent dielectric layer 10
For the formation, a screen plate is used in which the openings of the screen plate located at the intersections of the trace electrodes 6 and the black stripes 8 are closed. By using this screen plate, the second transparent dielectric layer 10 can be selectively printed in a recessed portion between the intersections of the black stripes 8 and the trace electrodes and then baked to form the second transparent dielectric layer 10. By forming the second transparent dielectric layer 10, the surface of the layer on which the color filter 9 is formed is flattened by the second transparent dielectric layer 10.

Next, a third transparent dielectric layer 11 made of low melting point lead glass is formed on the flattened surface by a screen printing method (step 7) and then fired. The front substrate 1 is formed by forming a protective film 12 made of MgO by vapor deposition or the like so as to cover the third transparent dielectric layer 11 (step 8). The third transparent dielectric layer 1
1 is formed by repeating coating 2-3 times. The above-mentioned first transparent dielectric layer 7, second transparent dielectric layer 10 and third transparent dielectric layer 11 made of low melting point lead glass are light transmissive.

Referring to FIG. 1B, in the method of manufacturing the back substrate 2, first, the glass substrate 4 for the back substrate 2 is washed (step 11). The data electrode 13 made of Cr, Ag or the like is formed on the glass substrate 4 (step 12).
The data electrode 13 is arranged so as to be orthogonal to the trace electrode 6 on the front substrate. Subsequently, a dielectric layer 14 made of a material made of low melting point lead glass and a white pigment is formed on the glass substrate 4 by a thick film printing method so as to cover the data electrodes 13 (step 13). The glass substrate 4 may be light transmissive or not.

Next, barrier ribs 15 made of a mixture of low melting point lead glass and alumina are formed on the dielectric layer 14 by a sand blast method or the like (step 14) to form discharge spaces. The dimensions of the completed partition wall 15 are about 50 to 80 μm in width and 100 to 150 μm in height.

Next, for each discharge cell, the phosphor 16 corresponding to the emission color of each cell is formed by the screen printing method (step 15) to form the rear substrate 2.

The front substrate 1 and the rear substrate 2 formed in the above steps are bonded to each other to hermetically seal the discharge space, and a dischargeable gas, for example, a mixed gas of He, Ne and Xe is sealed inside the discharge space. A color PDP is manufactured.

The surface of the protective film 12 of the front substrate 1 of the color PDP manufactured by the present invention is, as shown in FIG.
It is flattened. Therefore, when the front substrate 1 and the rear substrate 2 are combined, the partition 15 portion and the protective film 12 of the front substrate 1 are in surface contact with each other, so that the partition 15 is broken or the protective film 12 and the third transparent dielectric are formed. It is possible to provide a color PDP in which the generation of cracks in the layer 11 is suppressed and the occurrence of display defects such as dark spots and light emission spots is reduced.

In the above-described embodiment of the present invention, when the third transparent dielectric layer 11 is overcoated, the black stripe 8 and the trace electrode 6 of the overcoated layer are not overcoated. By forming the uncoated portion, it is possible to further improve the flatness of the surface of the uppermost layer of the third transparent dielectric layer 11 forming the protective film.

[0026]

As described above, the color P of the present invention is used.
In the method of manufacturing the DP, the transparent dielectric layer is filled in the recessed portion of the black stripe between the intersections of the black stripe of the front substrate and the trace electrode, and the transparent dielectric layer is formed thicker. Thereby, the surface of the underlying transparent dielectric layer forming the protective film is flattened, and the surface of the protective film is also flattened. As a result, when the front substrate and the rear substrate are bonded together, the contact between the partition wall portion and the protective film of the front substrate becomes a surface contact, and the destruction of the partition wall and the generation of cracks in the protective film and the transparent dielectric layer are suppressed. PDP dark spot,
The effect of preventing the occurrence of display defects such as light emission spots can be obtained.

[Brief description of drawings]

FIG. 1 is a process flow diagram for explaining an embodiment of a method for manufacturing a color PDP of the present invention, (a) is a process flow diagram of a front substrate, and (b) is a process flow of a rear substrate. It is a figure.

2 is a cross-sectional view of a color PDP manufactured by the process of FIG.

3A and 3B are process flow diagrams for explaining an example of a conventional color PDP manufacturing method, FIG. 3A is a process flow diagram of a front substrate, and FIG. 3B is a process flow diagram of a rear substrate. .

4 is a cross-sectional view of a color PDP manufactured by the process of FIG.

[Explanation of symbols]

1,51 Front substrate 2,52 Rear substrate 3, 4, 53, 54 glass substrate 5,55 Transparent electrode 6,56 Trace electrode 7,57 First transparent dielectric layer 8,58 black stripes 9,59 color filter 10,61 Second transparent dielectric layer 11 Third transparent dielectric layer 12,62 protective film 13,63 data electrodes 14,64 Dielectric layer 15,65 partitions 16,66 phosphor

Claims (6)

[Claims] 1. A first substrate having a first electrode and a second electrode arranged substantially parallel to each other on a light-transmissive first substrate, and a first substrate including the first electrode and the second electrode is a first substrate. And a color filter layer partitioned by a stripe-shaped insulating layer having a predetermined width on the first dielectric layer, and further disposing the color filter layer on the third dielectric layer. A front substrate formed by coating with a second electrode, and a second substrate on which a third electrode is disposed so as to be substantially orthogonal to the first electrode and the second electrode, and the second electrode including the third electrode is disposed. A substrate having a fourth dielectric layer coated on the substrate and a partition wall formed on the fourth dielectric layer along the third electrode; and the third dielectric layer and the partition wall. Including the step of laminating as a facing surface, the color filter between the color filter layer and the third dielectric layer. A second dielectric layer is formed on the core layer before forming the third dielectric layer, except for an intersection of the striped insulating layer and the second electrode. Method for manufacturing a color plasma display panel. 2. After forming the stripe-shaped insulating layer,
The surface of the stripe-shaped insulating layer at the intersection of the stripe-shaped insulating layer and the second electrode is a convex surface, and the stripe-shaped insulating layer other than the cross-shaped portion is formed by the second dielectric layer. The method of manufacturing a color plasma display panel according to claim 1, wherein the surface of the color filter layer including the surface of the insulating layer is planarized. 3. The method of manufacturing a color plasma display panel according to claim 1, wherein the third dielectric layer is formed by applying multiple layers of the same material. 4. The third dielectric layer is formed by applying multiple layers of the same material, and when the predetermined multiple application layer of the third dielectric layer is formed, the third dielectric layer and the stripe-shaped insulating layer are formed. The method of manufacturing a color plasma display panel according to claim 1, wherein the predetermined overlapping coating is not performed on the intersection of the second electrodes. 5. The low melting point lead glass is used as a material for the first dielectric layer, the second dielectric layer and the third dielectric layer. The method for manufacturing a color plasma display panel according to any one of claims. 6. The method of manufacturing a color plasma display panel according to claim 1, further comprising a step of forming a protective film on the surface of the third dielectric layer of the front substrate. Method.