JP3350184B2 - Plasma display panel manufacturing method and plasma display panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a plasma display panel (PDP). Surface discharge type PDP suitable for full color matrix display by phosphor
Attention has been paid to a thin display device that replaces a CRT, and its high definition and large screen are being promoted in order to expand applications in the field of high-definition video.

[0002]

2. Description of the Related Art FIG. 6 is an exploded perspective view of a general surface discharge type PDP, and shows a basic structure of a portion corresponding to one pixel EG.

[0006] The PDP 10 illustrated in FIG. 6 has a three-electrode structure in which a pair of display electrodes X and Y and an address electrode A correspond to a unit light-emitting region EU of a matrix display. Discharge type P called reflection type
DP.

The display electrodes X and Y for surface discharge are provided on the glass substrate 11 on the display surface H side, and a discharge space is formed by a dielectric layer 17 for AC drive for maintaining discharge using wall charges. 30 coated. On the surface of the dielectric layer 17, MgO having a thickness of about several thousand
A membrane 18 is provided.

Since the display electrodes X and Y are arranged on the display surface H side with respect to the discharge space 30, the display electrodes X and Y are formed of a Nesa film or the like in order to widen the surface discharge and minimize the shielding of display light. A transparent conductive film 41 having a large width and a bus metal film 42 having a small width for supplementing the conductivity thereof.

On the other hand, an address electrode A for selectively emitting light in the unit light emitting region EU is provided on the glass substrate 21 on the rear side.
Above, they are arranged at a constant pitch so as to be orthogonal to the display electrodes X and Y.

[0007] Between each address electrode A, 100 to 15
A stripe-shaped partition wall 29 having a height of about 0 μm is provided, whereby the discharge space 30 is partitioned in the line direction (extending direction of the display electrodes X and Y) for each unit light emitting area EU. The gap size is specified. Further, the glass substrate 21 covers the inner surface on the back side including the upper surface of the address electrode A and the side surface of the partition wall 29,
The phosphors 28 of three primary colors of R (red), G (green), and B (blue) are provided. Letters R, G, and B in the figure indicate the emission colors of the respective phosphors 28. The phosphor 28 emits light when excited by ultraviolet rays emitted by the discharge gas in the discharge space 30 during surface discharge.

Each pixel (dot) EG constituting the display screen
Are associated with three unit light emitting regions EU of the same area arranged in the line direction. In each unit light emitting region EU, a surface discharge cell (main discharge cell for display) is defined by the display electrodes X and Y, and the display electrode Y and the address electrode A
Thus, an address discharge cell for selecting display or non-display is defined. As a result, of the phosphors 28 continuous in the direction in which the address electrodes A extend, each unit light emitting area EU
Can selectively emit light at a portion corresponding to R,
Full color display is possible by a combination of G and B.

In the PDP 10 having the above structure, predetermined components are separately provided for each of the glass substrates 11 and 21,
It is manufactured by a series of steps of arranging the glass substrates 11 and 21 to face each other, sealing the periphery of the gap, and exhausting the inside and filling the discharge gas.

At this time, first, the address electrode A is provided on the glass substrate 21, and then the partition wall 29 and the phosphor 28 are provided in this order. By selecting the formation order in this manner, the address electrode A can be easily formed by using the thick film method, and the luminance can be increased by providing the phosphor 28 so as to cover the side surface of the partition 29. .

Conventionally, the partition wall 29 is formed by applying a glass paste obtained by mixing a low melting point glass frit and a binder in a stripe shape using a screen printing method;
It was formed by the subsequent firing step. That is,
The partition 29 having a predetermined plane pattern was obtained by pattern printing using a screen mask.

[0012]

In the pattern printing by the screen printing method, it is difficult to reduce the width and the arrangement pitch of the partition walls 29, so that a high definition display cannot be expected. Further, when the display surface H is to be enlarged, it is impossible to make the arrangement relationship between the partition walls 29 and the address electrodes A uniform over the entire display surface H due to shrinkage of the screen mask or the like. Furthermore, in order to obtain the partition wall 29 having a predetermined height, it is necessary to perform about ten times of overprinting (paste lamination), and the shape may easily be lost at the time of printing and firing, which may hinder discharge.

Therefore, it is conceivable to provide a low-melting glass layer (so-called solid film) that uniformly covers the glass substrate 21, and to partially cut the low-melting glass layer by sandblasting to form the partition wall 29. In that case, the cutting may be performed after uniformly applying and firing the glass paste,
Then, the cutting rate becomes too large, and it becomes difficult to control the cutting time. That is, cutting the low-melting glass layer in the paste state before firing is advantageous in achieving perfect cutting.

However, when cutting the glass paste layer, if the content and type (material) of the binder are selected so as to increase the cutting rate, the adhesion between the cutting mask made of a photosensitive resist material and the glass paste layer is reduced. However, there is a problem in that the partitioning of the cutting mask occurs, a partition having a predetermined shape cannot be obtained, and conversely, if the content or type of the binder is selected so as to increase the adhesiveness, the cutting rate decreases.

[0015] As the cutting rate decreases, the time required for machining increases and the productivity decreases. If the blast pressure is increased to avoid this, the cutting in the surface direction proceeds, so that significant higher definition can be achieved. I can't hope.

The present invention has been made in view of the above-mentioned problems, and has as its object to easily manufacture a high-definition and large-sized plasma display panel having partition walls having a uniform shape. In particular, the fourth and sixth aspects of the present invention also aim to improve display brightness and improve contrast.

[0017]

According to a first aspect of the present invention, there is provided a plasma display panel having a partition wall for partitioning a discharge space, as shown in FIG. At the time of manufacturing, a first glass paste P1 and a second glass paste P2 thinner than the first glass paste P2 and having a high binder content are sequentially applied on the substrate 21 to form a partition having a multilayer structure. A cutting mask 6 is formed on the glass paste layer 29a by the step of forming the glass paste layer 29a and the pattern exposure of the photosensitive resist material.
1, a step of partially cutting the glass paste layer 29a by a sand blast method, and firing the cut glass paste layer 29a to form the partition wall 2
9 is formed.

According to a second aspect of the present invention, there is provided a manufacturing method comprising:
1 on a first glass paste P1 containing a binder.
And then by-passing the first glass paste P1.
Of the peel strength when the content is reduced compared to the
Glass pace containing binder with low percentage of
P2 is applied thinner than the first glass paste P1, so that the overall cutting rate is high and the
A step of forming a glass paste layer 29a for forming a partition having a multilayer structure with good adhesion, a step of forming a cutting mask 61 on the glass paste layer 29a by pattern exposure of a photosensitive resist material, and a step of sandblasting A step of partially cutting the glass paste layer 29a by a method and a step of firing the cut glass paste layer 29a to form the partition wall 29 are provided.

According to a third aspect of the present invention, the binder of the first glass paste P1 is an organic substance of an ethyl cellulose type, and the binder of the second glass paste P2 is an organic substance of an acrylic type.

In a manufacturing method according to a fourth aspect of the present invention, a light-colored pigment is added to the first glass paste P1, and
And a dark pigment is added to the glass paste P2. The manufacturing method according to claim 5, wherein after applying the first glass paste P1, before applying the second glass paste P2, a third glass paste for improving the adhesion between the pastes. A step of applying P3 is provided.

[0021] In the PDP according to the sixth aspect of the present invention,
Partition wall 29 for partitioning the discharge space 30, the lower glass layer 29 1 made of low-melting glass doped with pigments of light colors the majority, <br/> top glass layer consisting of low-melting glass doped with dark pigment 292 , and uncolored without adding pigment
The lower glass layer and the top glass made of low melting point glass
Scan layer intermediate glass layer 29 3 that consists for increasing the bonding strength. According to a seventh aspect of the present invention, there is provided the manufacturing method, wherein the glass paste layer of the partition wall material provided on the substrate is formed by photoresist.
Is a method of manufacturing a plasma display panel, which is covered with a cutting mask formed by patterning and is cut by sandblasting to form a partition wall, wherein the glass paste layer is formed on a first glass paste layer by a film. The second glass paste layer has a small thickness and a large binder content.

[0022]

The partition wall 29 is formed by applying a glass paste obtained by mixing a glass frit and a binder to a predetermined thickness, providing a cutting mask 61, partially cutting by a sand blast method, and then firing. .

At this time, as shown in FIGS. 3A and 3B, the lower the binder content in the glass paste, the higher the cutting rate, but on the other hand, the adhesiveness to the cutting mask 61 ( Peel strength). Therefore, if the glass paste with a low binder content is applied relatively thickly and then the glass paste with a high binder content is applied thinly, the cutting rate as a whole is large,
In addition, it is possible to obtain the glass paste layer 29a for forming partition walls having good adhesion to the cutting mask 61. That is, it is possible to efficiently form the partition wall 29 while preventing mask peeling during cutting.

[0024]

1 is a cross-sectional view showing the structure of a main part of a PDP 1 according to the present invention, FIG. 2 is a cross-sectional view showing each state of the PDP 1 in FIG. 1 in a manufacturing stage, and FIGS. It is a graph which shows a binder dependence characteristic of a cutting rate and peel strength.

The PDP 1 is a surface discharge type PDP having a three-electrode structure called a reflection type, and has a glass substrate 1 on the display surface side.
1. Display electrodes X and Y composed of a transparent conductive film 41 and a bus metal layer 42 superposed thereon, a dielectric layer 17 covering the display electrodes X and Y, an MgO film 18, a glass substrate 21 on the back side, and a display electrode X, Address electrode A orthogonal to Y, discharge space 30
And a stripe-shaped partition wall 29 for defining the gap size of the light emitting element, and a phosphor 28 of a predetermined emission color.

The partition walls 29 are arranged between the address electrodes A so as to divide the discharge space 30 in the line direction for each unit light emitting area EU. The width of each partition 29 is about 50 μm, and the interval between each partition 29 is about 100 μm.
That is, the size of the unit light emitting region EU in the line direction (the partition 2
9 is about 150 μm.

As shown in FIG. 2, when manufacturing the PDP 1 on the glass substrate 21 side, 5 to 30 μm
After the formation of the address electrode A having a thickness of the order of magnitude, the partition 29 is formed by the following procedure.

First, a first low-melting glass paste P1 is applied to a thickness of about 150 to 200 μm so as to uniformly cover the surface of the glass substrate 21 including the address electrodes A.
Subsequently, the second low-melting glass paste P2 is coated with 10 to 40 μm.
m to form a glass paste layer 29a having a two-layer structure in which the lower layer is sufficiently thicker than the upper layer (the thickness of the upper layer is about 5 to 20% of the whole) (FIG. 2A). .

At this time, the first low melting point glass paste P
As 1, a paste is used in which the binder is, for example, an ethylcellulose-based organic substance and the content thereof is about 0.8 to 1.2 wt%. On the other hand, as the second low-melting-point glass paste P2, the binder is the same ethylcellulose-based organic substance as the first low-melting-point glass paste P1, but its content is larger than that of the first low-melting-point glass paste P1. The paste or the binder of about 5 to 2.0 wt% is an acrylic organic substance, and the content thereof is 2.0 to 2.0 wt%.
A paste of about 3.0 wt% is used.

The pastes P1 and P2 can be applied by a screen printing method, a bar coater method, an applicator method, or the like, and even if an organic solvent is mixed with the pastes to facilitate the application. Good. In the case of using the screen printing method, it is necessary to repeat printing several times particularly when applying the paste P1, but it is easy to make the thickness of the glass paste layer 29a uniform.

Next, a negative photosensitive resist material in the form of a dry film having a thickness of about 30 to 50 μm is applied to a glass paste layer 2 at a temperature of about 80 to 100 ° C. using a laminator.
The surface of the substrate 9a is pressed and subjected to pattern exposure and development to form a striped cutting mask 61 having a width corresponding to the partition wall 29 (FIG. 2B). At this time, a photosensitive resist material may be provided by a roll coater method or the like, but a thick and uniform cutting mask 61 can be formed by using a laminator.
Can be easily obtained. Further, by using a negative resist material, a cutting mask 61 having a large elastic modulus and excellent durability can be obtained.

Subsequently, the glass paste layer 29a is partially cut by a sand blast method (FIG. 2C).
That is, cutting powder (for example, SiC) having a roughness of about # 400 to # 600 is mixed with dry air (or nitrogen gas), and the glass paste layer 29a and the cutting mask 61 are formed under a pressure of about 1.5 to 3 kg / cm ^2. Spray on the surface. The cutting is continued until the address electrode A is completely exposed.

Here, in general, the glass paste is brittle as the binder content is small, and the cutting rate is large. However, as shown in FIG. 3 (a), the paste of ethyl Le cellulose <br/> scan based binder, as the content of the binder is reduced, the peel strength is greatly representative of the adhesion between the cutting mask 61 And the mask is easily peeled off during cutting.

Further, as shown in FIG. 3B, in the paste made of an acrylic binder, even if the binder content is reduced and the cutting rate is increased, the degree of decrease in the peel strength is relatively small. That is, an acrylic binder, in terms of adhesion to the cutting mask 61, superior to ethyl Le cellulose <br/> scan based binder. However, in terms of cutting rates, ethyl Le cellulosic binder is advantageous than an acrylic binder.

Incidentally, the glass paste layer 29a to be cut in this embodiment has a thickness of 80 to 9 as described above.
Most of the lower side, which accounts for 5%, is made of the first glass paste P1 having a relatively low binder content.
Is made of the second glass paste P2 having a high binder content, so that the layer has a high cutting rate as a whole and has good adhesion to the cutting mask 61. In particular, when the binder of the second glass paste P2 is made of an acrylic material, the adhesion is further improved as compared with the case where the binder is made of an ethiscellulose material. For this reason, mask peeling does not occur during cutting, and unnecessary glass paste can be removed with good yield in a short time.

When the cutting by the sandblasting is completed, the glass paste layer 29a after patterning is
Baking at a temperature of about 50 to 580 ° C. This gives 1
The partition 29 having a thickness of about 00 to 150 μm is obtained. Since the binder dissipates from the glass paste layer 29a during firing, the first and second low melting point glass pastes P1, P
2 except for the binder, the partition wall 2
9 becomes a homogeneous low melting point glass layer.

After the formation of the partition 29,
The phosphor 28 is provided between the partition walls 29, and the glass substrate 21 and the glass substrate 11 on which display electrodes X and Y are separately provided are overlapped to complete the PDP 1.

FIG. 4 is a cross-sectional view showing a structure of a main part of a PDP 1b according to another embodiment, and FIG. 5 is a cross-sectional view showing a state of the PDP 1b of FIG. 4 at a manufacturing stage. In these drawings, components corresponding to those in FIGS. 1 and 4 are denoted by the same reference numerals regardless of the difference in the material and the shape.

In FIG. 4, a PDP 1b is a reflection type surface discharge type PDP having a three-electrode structure.
The structural difference from the PDP 1 is that the partition walls 29 are colored. That is, the partition 29 of the PDP 1b
Is composed of a light-colored (high-brightness) lower glass layer 291 occupying the majority, a dark-colored top glass layer 292, and a transparent intermediate glass layer 293 interposed therebetween. The thickness of the lower glass layer 291 is about 70 to 130 μm,
The thickness of the top glass layer 292 is about 20 to 30 μm, and the thickness of the intermediate glass layer 293 is about 10 μm.

The lower glass layer 291 is covered with the phosphor 28, and by making this a bright color, the reflectance of light is increased, so that the display brightness can be increased.
The top glass layer 292 is a portion facing the display surface H,
By making this a dark color, the contrast of display can be increased. The intermediate glass layer 293 is provided to prevent the lower glass layer 291 and the top glass layer 292 from peeling off.

In FIG. 5, when forming the partition wall 29, first, for example, a white pigment (titanium oxide, aluminum oxide, magnesium oxide, etc.) is added to a low melting point glass substrate 21 on which the address electrodes A are provided. The glass paste P1 is applied thickly. At this time, the binder content of the low-melting-point glass paste P1 is selected so that the cutting rate becomes large as in the example of FIG.

When a screen printing method is used as a coating method, a paste made of glass frit having large particles (about 20 μm) may be used. According to this, the number of times of printing can be reduced and the productivity can be increased.

Next, on the low melting point glass paste P1,
For example, a non-colored low-melting glass paste P3 to which no pigment is added is thinly applied, and then a low-melting glass paste P2 to which a dark pigment (iron oxide, cobalt oxide, etc.) is added is applied to a predetermined thickness. The kind and content of the binder in the low-melting glass paste P2 are selected so that the peak strength is large. The type and content of the low-melting glass paste P3 can be appropriately selected within a range that does not hinder cutting in a later step, and may be selected in the same manner as, for example, the low-melting glass paste P1.

As described above, three kinds of low melting point glass pastes P
1, P3, and P2 are sequentially applied to form a glass paste layer 29a having a multilayer structure, and then a cutting mask 6 is formed on the glass paste layer 29a by pattern exposure of a photosensitive resist material.
1 and a glass paste layer 2 by a sand blast method.
9a is partially cut. At this time, the difference between the fillers hardly affects the machinability. That is, if the binder of the paste is appropriately selected, the machinability can be optimized irrespective of the coloring, and the glass paste layer 29a can be efficiently patterned while preventing the mask peeling as in the example of FIG. can do.

Then, the cut glass paste layer 29a
Is fired to complete the formation of the partition wall 29. During this firing, the low-melting glass paste P3 plays a role in increasing the adhesion between the low-melting glass paste P1 and the low-melting glass paste P2. That is, the binder disappears by firing, the low melting glass paste P1 becomes the lower glass layer 291 and the low melting glass paste P2 becomes the top glass layer 292.
Then, there is a slight difference in expansion coefficient and softening point caused by different types of pigments among these. Such a difference in physical properties causes separation between the lower glass layer 291 and the top glass layer 292 and a decrease in adhesion strength. However, the interposition of the low-melting glass paste P3 allows the adjacent glass layers to have different properties. The difference in characteristics is reduced, and peeling and reduction in adhesion strength can be suppressed.

In the above embodiment, the address electrodes A
Although it has been described that the cutting is performed until the electrodes are exposed, the cutting may be finished at an appropriate time before the address electrodes A are exposed in order to suppress the damage of the address electrodes A. Also,
After providing a thin electrode protection layer covering the address electrode A in advance,
The partition 29 may be formed.

According to the present invention, a transmission type surface discharge type PDP in which a phosphor 28 is disposed on the glass substrate 11 on the display surface H side,
And various other PDPs.

[0048]

According to the present invention, a high-definition and large-sized plasma display panel having partition walls having a uniform shape can be easily manufactured.

According to the fourth aspect of the present invention, it is possible to increase the brightness of display and improve the contrast. Claim 6
According to the invention, the mechanical strength of the partition can be increased.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a structure of a main part of a PDP according to the present invention.

FIG. 2 is a cross-sectional view showing each state of the PDP of FIG. 1 at a manufacturing stage.

FIG. 3 is a graph showing binder-dependent characteristics of a cutting rate and a peel strength.

FIG. 4 is a cross-sectional view illustrating a structure of a main part of a PDP according to another embodiment.

FIG. 5 is a cross-sectional view illustrating a state of a manufacturing step of the PDP of FIG. 4;

FIG. 6 is an exploded perspective view of a general surface discharge type PDP.

[Explanation of symbols]

 1, 1b PDP (Plasma Display Panel) 21 Glass substrate (substrate) 29 Partition wall 29a Glass paste layer 30 Discharge space 61 Cutting mask 291 Lower glass layer 292 Top glass layer 293 Intermediate glass layer P1 First glass paste P2 Second glass Paste P3 Third glass paste

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Masafumi Amanu 1015 Kamikodanaka, Nakahara-ku, Kawasaki City, Kanagawa Prefecture Inside Fujitsu Limited (56) References JP-A-7-45190 (JP, A) JP-A-4-95328 (JP, A) JP-A-5-266791 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01J 9/02 H01J 11/02

Claims (7)

(57) [Claims] 1. A method for manufacturing a plasma display panel having a barrier rib partitioning the discharge space, on a substrate, a first glass paste, thinner than that
And applying a second glass paste having a large binder content in order to form a glass paste layer for forming a partition having a multilayer structure, and pattern exposure of a photosensitive resist material to form a glass paste layer on the glass paste layer. A step of forming a cutting mask, a step of partially cutting the glass paste layer by a sand blast method, and a step of firing the glass paste layer after cutting to form the partition walls. Manufacturing method of a plasma display panel. 2. A method for manufacturing a plasma display panel having a partition for partitioning a discharge space, comprising: forming a first glass paste containing a binder on a substrate;
Applying, followed by a binder of said first glass paste
% Reduction in peel strength when content is reduced compared to
A second glass paste containing a binder with a small
Apply thinner than the first glass paste to make the whole
High cutting rate and good adhesion to the cutting mask
Forming a glass paste layer for forming a partition having a simple multilayer structure, forming a cutting mask on the glass paste layer by pattern exposure of a photosensitive resist material, and forming the glass paste layer by sandblasting. A method of manufacturing the plasma display panel, comprising: a step of partially cutting the glass paste layer; and a step of firing the glass paste layer after the cutting to form the partition walls. 3. The plasma display panel according to claim 2, wherein the binder of the first glass paste is an organic substance of ethylcellulose, and the binder of the second glass paste is an organic substance of acrylic. Method. 4. The method according to claim 1, wherein the first glass paste contains a light-colored pigment, and the second glass paste contains a dark-colored pigment. Of manufacturing a plasma display panel. 5. After applying the first glass paste,
5. The method according to claim 4, wherein a third glass paste is applied before the second glass paste is applied to enhance the adhesion between the pastes. 6. A plasma display panel having a partition wall for partitioning a discharge space on a substrate on a back side, wherein the partition wall is formed by adding a light-colored pigment which occupies most of the partition wall.
Lower glass layer made of melting point glass , adding dark pigment
Top glass layer made of low melting glass
The lower glass made of uncolored low-melting glass that is not added
A plasma display panel, characterized in that the intermediate glass layer or et structure for increasing the bonding strength of the the layer top glass layer. 7. A plasma display panel in which a glass paste layer of a partition wall material provided on a substrate is covered with a cutting mask formed by patterning a photoresist and cut by sandblasting to form a partition wall. Wherein the glass paste layer is formed by forming a second glass paste layer having a smaller thickness and a large binder content on the first glass paste layer. Of manufacturing a plasma display panel.