JP3563633B2 - Method of manufacturing substrate for plasma display device - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a substrate for a plasma display device (plasma display panel: hereinafter referred to as a PDP) used for a high-precision and inexpensive thin color display device for a large screen and the like, and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, CRTs, which have been widely used as image display devices, have the disadvantage that they have a large volume and weight and require a high voltage. Due to the recent spread of multimedia, light-emitting diodes (LEDs) and liquid crystals are used as information interfaces. A flat image display device having features such as a display element (LCD), a large screen such as a PDP, a high image quality, a thin and light weight, and an installation location can be selected has been developed, and the range of use thereof has been expanding.
[0003]
As such a planar image display device, a PDP utilizing plasma emission, in particular, has attracted attention as a light emitting element of a color image display device for a large screen.
[0004]
Such a PDP is provided with a plurality of partitions 2 on a back plate 1 as shown in FIG. 1 and a phosphor 4 is applied between the partitions 2 to form discharge display cells 5. An address electrode 3 is provided. On the other hand, a discharge electrode 7 is provided on a transparent front plate in a direction perpendicular to the address electrode 3. It is what was joined to. Then, a voltage is selectively applied between the address electrode 3 and the discharge electrode 7 to generate plasma by discharge, and the ultraviolet light emitted from the plasma causes the phosphor 4 formed on the inner wall of the discharge display cell 5 to emit light. And is used as a light emitting element of an image display device.
[0005]
In the method of manufacturing the PDP, a large number of partitions 2 are formed parallel to one surface of a back plate 1 and address electrodes 3 are provided at the bottom of the discharge display cells 5 between the partitions 2. A body 4 is applied, and a front plate 6 provided with a transparent electrode as a discharge electrode 7 is joined on the partition wall 2, and a rare gas is sealed in the discharge display cell 5 to form a PDP.
[0006]
Here, various manufacturing methods have been proposed to manufacture the partition walls 2 at a fine pitch and with high precision. For example, it is well known that a paste made of a partition wall material is repeatedly printed and dried on the back plate 1 in a pattern of the partition walls 2 by a screen printing method, and stacked to a predetermined height to form the partition walls 2.
[0007]
Alternatively, a barrier rib material is formed in a layer on the back plate 1 with a predetermined thickness, a resist film is applied to the barrier rib material layer, a resist mask is formed by a photolithography method, and the resist mask is formed by sandblasting through the resist mask. It has also been proposed to form a partition 2 having a desired shape by grinding and removing a necessary portion (see Japanese Patent Application Laid-Open No. 9-29638).
[0008]
Furthermore, there has been proposed a method in which a mold having a concave portion conforming to the shape of the partition wall 2 is prepared, and the mold is filled with the partition wall material, pressed on the back plate 1, and then released (Japanese Patent Laid-Open No. Hei 1-1-1). No. 137534).
[0009]
[Problems to be solved by the invention]
However, in the above-mentioned PDP substrate, there is a problem that the phosphor 4 applied to the side surface of the partition wall 2 hangs down to the bottom surface side, and the luminous intensity cannot be increased.
[0010]
In the method of manufacturing a PDP substrate described above, in the printing and laminating method, printing and laminating are repeated many times, so that the number of steps is increased, and it is difficult to form the partition walls 2 with high precision. .
[0011]
Furthermore, the process is also complicated in the sandblasting method, and it is difficult to form the partition walls 2 with high accuracy.
[0012]
In the method of forming the partition 2 using a mold, the partition 2 can be easily formed with high precision. However, since the shape of the mold is transferred as it is, the mold is formed at an extremely high level. When a PDP substrate having a large area is required, it is difficult to manufacture a mold.
[0013]
[Means for Solving the Problems]
In view of the above problems, the present invention provides a back plate having a partition wall by providing a blade having an uneven portion corresponding to the partition wall shape in a mold of an extruder, and extruding a raw material through the die. And a step of curing the obtained molded body.
Further, a sliding mark extending on a side surface of the partition wall in a direction parallel to a main surface of the back plate is provided.
Further, on the back plate, an address electrode is formed using a conductive metal of silver, nickel, or aluminum, or an alloy thereof, or a conductive paste obtained by mixing a small amount of glass with the alloy. .
Further, the uneven portion of the blade is characterized in that a hard thin film of TiC or hard carbon is formed on the surface of a metal material, or zirconia ceramics is used.
[0014]
The present invention also provides a step of applying a slurry forming a partition on the main surface of the back plate or forming the back plate itself with a plastic material, and forming a blade having an uneven shape matching the partition shape on the main surface of the back plate. A method for manufacturing a substrate for a plasma display device, comprising the steps of forming a partition on the main surface by relatively moving the two while pressing against each other, and curing the partition.
[0015]
Further, the present invention provides a back plate having a partition wall by providing a blade having an uneven portion corresponding to the partition wall shape in a mold of an extruder, and extruding a raw material through the die to form a back plate having a partition wall. A method for manufacturing a substrate for a plasma display device, comprising a step of curing a molded body.
[0016]
Further, the present invention provides a method of forming a green sheet while supplying a slurry onto a moving sheet, wherein the slurry supply section is provided with a blade having irregularities matching the partition shape, and the partition is formed by passing the blade. A method for manufacturing a substrate for a plasma display device, comprising a step of forming a green sheet provided and curing the obtained formed body.
[0017]
[Action]
According to the present invention, a simple process is used for forming a partition by using a blade having an uneven portion conforming to the shape of the partition and moving the blade while pressing the blade or extruding or forming a sheet using the blade. Can be manufactured. In addition, the partition walls can be formed with high accuracy only by forming only the concave and convex portions of the blade with high accuracy. Therefore, a PDP substrate having high-precision partition walls can be obtained in a simple process.
[0018]
Further, in the PDP substrate manufactured by such a method, there is a trace of sliding with the uneven portion of the blade on the side surface of the partition wall, which can prevent the applied phosphor from dripping.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a method of manufacturing a PDP according to the present invention will be described with reference to the drawings.
[0020]
FIG. 1 is a sectional view of a PDP substrate according to the present invention. The back plate 1 is an insulating substrate made of soda lime glass or various ceramics. A plurality of mutually parallel partition walls 2 are formed on the back plate 1 to form a discharge display cell 5 and an address electrode 3 is formed on the bottom thereof. .
[0021]
Then, a phosphor 4 is applied to the display cell 5 and a front plate 6 provided with a discharge electrode 7 is joined to the partition 2 to form a plasma display device.
[0022]
Further, as shown in FIG. 2, on the side surface of the partition wall 2, there are a large number of sliding marks 2a extending in a direction parallel to the main surface of the back plate 1. The sliding marks 2a are formed by a manufacturing method described later, and are minute concave and convex grooves. The presence of such sliding traces 2a makes it difficult for the phosphor 4 applied on the side surface to hang down in the bottom direction, thereby increasing the luminous intensity when used as a PDP.
[0023]
The method of manufacturing such a PDP substrate is as follows.
[0024]
First, as shown in FIG. 3, a blade 10 for forming the partition 2 is prepared. The blade 10 is a plate-like body made of metal or ceramics such as zirconia, and has a high-precision uneven portion 11 conforming to the shape of the partition wall 2 at its tip.
[0025]
Next, as shown in FIG. 4A, a slurry-like partition wall material 12 having a predetermined viscosity is applied to the main surface of the back plate 1. Thereafter, as shown in FIG. 4B, the blade 10 is moved in the direction of the arrow while pressing the uneven portion 11 of the blade 10 on the partition wall material 12. At this time, the partition wall material 12 is scraped off according to the shape of the uneven portion 11 of the blade 10, so that a large number of parallel partition walls 2 can be formed. In this step, the back plate 1 may be moved instead of moving the blade 10, and in short, both may be moved relatively.
[0026]
Finally, if the partition walls 2 are cured by performing a heat treatment under a predetermined condition, a PDP substrate can be manufactured.
[0027]
In the above manufacturing method, the slurry-like partition wall material 12 is applied. However, the back plate 1 itself is formed of a plasticizer having a predetermined viscosity, and the blade 10 is directly pressed against the main surface and moved. The partition 2 can also be formed. Here, in order to make the back plate 1 have a predetermined viscosity, the back plate 1 may be formed of glass and melted by heating, or may be formed of a ceramic or glass to which a predetermined binder is added.
[0028]
Extrusion molding is used as a manufacturing method of the reference example of the present invention.
[0029]
As shown in FIG. 5, the blade 10 is attached so as to cover the opening 21 of the mold 20 for the extrusion molding machine, and a predetermined raw material is supplied from the opening 21 covered by the uneven portion 11 of the blade 10. By extrusion molding, the back plate 1 provided with the partition walls 2 can be formed, and by baking or heat curing under predetermined conditions, a PDP substrate can be obtained.
[0030]
Further, as a manufacturing method of the reference example of the present invention, sheet molding can be performed. The green sheet 33 is formed on the sheet 31 by supplying the slurry 32 from the slurry supply unit 30 onto the moving sheet 31 as shown in FIG. By providing the slurry 32 through the blade 10 in the supply unit 30, a green sheet 33 having a partition shape can be obtained. Thereafter, the green sheet 33 is cut into a predetermined shape, and is fired or cured by heating to obtain a PDP substrate.
[0031]
According to such a manufacturing method of the present invention, the partition wall 2 can be formed by a very simple process by using the blade 10 having the uneven portion 11. In addition, if the concave and convex portions 11 are formed with high precision, the partition walls 2 can also be formed with high precision.
[0032]
Further, according to the manufacturing method of the present invention, the sliding marks 2a along the moving direction of the blade 10 are present on the side surfaces of the partition walls 2 and the like. Dropping can be prevented, and the luminous intensity can be increased.
[0033]
It is preferable that the particularly uneven portion 11 of the blade 10 be made of a material having excellent wear resistance, such as using a metal material such as stainless steel, forming a hard thin film such as TiC or hard carbon on the surface, or using zirconia or the like. It is preferable to use ceramics. Further, as shown in FIG. 4 (b), it is preferable that the thickness of the blade 10 is slightly bent when the blade 10 is pressed against the back plate 1.
[0034]
The address electrodes 3 provided on the PDP substrate are formed in advance between the back plate 1 and the partition wall material 12 in the step shown in FIG. 4A, and each address is formed in the step shown in FIG. The partition 2 may be formed between the electrodes 3.
[0035]
As the partition wall material 12 that can be used in the present invention, any material may be used as long as it becomes glassy after firing and can maintain airtightness, ceramics, or a mixture thereof. For example, a mixture of a low-melting glass powder and an oxide ceramic powder can be used as an inorganic component, and a mixture of the inorganic component, a solvent, and an organic additive is appropriately prepared according to the molding conditions of the partition wall 2. Can be used.
[0036]
As the low melting point glass powder, various glass materials containing a silicate as a main component and one or more of lead, sulfur, selenium, alum and the like can be used. The particle size of the ceramics or glass powder is preferably several tens of microns to sub-micron, and specifically, is preferably in the range of 0.2 to 10 μm, and more preferably in the range of 0.2 to 5 μm. .
The solvent is not particularly limited as long as it is compatible with the organic additive, and two or more solvents can be used in combination to slowly volatilize the solvent.
As the organic additive, a thermoplastic resin or a reactive curable resin such as an ultraviolet curable resin, a photocurable resin, and a thermosetting resin can be used. Other examples include various organic substances such as a dispersant, a release agent, a curing agent, a lubricant, and a plasticizer.
[0037]
Further, as the substrate used as the back plate 1 of the present invention, a transparent glass substrate such as soda lime glass, low soda glass, lead alkali silicate glass, borosilicate glass or the like can be used. It is desirable that they be similar. In particular, a high strain point low soda glass is preferable.
[0038]
The address electrodes 3 formed on the back plate 1 are made of a conductive metal such as silver (Ag), nickel (Ni), aluminum (Al), or an alloy thereof, or a small amount of glass on the conductive metal or its alloy. It can be formed using a mixed conductive paste.
[0040]
Further, in this step, an inorganic or organic adhesive can be used at the interface between the partition wall material 12 and the back plate 1. For example, a silane coupling agent, a titanate coupling agent, and an aluminate coupling agent can be used. Among them, a highly reactive silane coupling agent is preferable.
[0041]
【Example】
First, an address electrode 3 having a width of 80 μm and a stripe shape of 360 μm were formed on a back plate 1 made of 42-inch soda lime glass having a thickness of 2.8 mm using an electrode paste containing Ag as a main component by a thick film printing method. The entire surface was formed at a pitch and baked to produce a back plate 1 with address electrodes 3.
[0042]
On the other hand, as shown in FIG. 2, a blade 10 having a partition-shaped uneven portion 11 having a vertex width of 40 μm, a height of 200 μm, and a pitch of 360 μm was prepared.
[0043]
As shown in FIG. 5, the blade 10 is attached so as to cover the opening 21 of the mold 20 for the extrusion molding machine, and a predetermined raw material is supplied from the opening 21 covered by the uneven portion 11 of the blade 10. By extrusion molding, the back plate 1 provided with the partition walls 2 can be formed, and by baking or heating and curing under predetermined conditions, a PDP substrate can be obtained.
[0044]
Next, after the rear plate 1 on which the partition walls 2 are formed is debindered while being maintained at a predetermined temperature, the firing atmosphere is appropriately changed according to the main components of each material, and the rear plate 1 is fired at a temperature of 550 to 600 ° C. for 10 minutes. A PDP substrate in which the partition walls 2 were integrated was produced.
[0045]
As for the PDP substrate for evaluation thus obtained, the partition wall 2 was observed through a monitor screen enlarged and projected by a CCD camera from the direction in which the partition wall 2 was in contact with the front plate 6, and no cracks were observed on the surface of the partition wall 2. It was a good PDP substrate.
[0046]
On the other hand, as a comparative example, first, a back plate 1 with address electrodes 3 similar to the example was manufactured. Thereafter, a dielectric layer was formed on the back plate 1 by screen printing, and then printing and drying were repeated 15 times by screen printing to form the partition 2. Thereafter, the binder was removed and baked to produce a PDP substrate of a comparative example.
[0047]
Thereafter, as a result of evaluation in the same manner as in Example 1, cracks were detected at 16 unspecified portions of the partition wall 2, and a good PDP substrate could not be obtained.
[0048]
【The invention's effect】
As described above, according to the method for manufacturing a PDP substrate of the present invention, a partition can be formed with high accuracy in a simple process by forming a partition using a blade having an uneven portion that matches the shape of the partition. it can.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a PDP substrate according to the present invention. FIG. 2 is a perspective view of the PDP substrate according to the present invention. FIG. 3 shows a blade used in the method of manufacturing a PDP substrate of the present invention. It is a perspective view.
FIGS. 4A and 4B are perspective views showing a method of manufacturing a PDP substrate according to a reference example of the present invention.
FIG. 5 is a perspective view illustrating a method for manufacturing a PDP substrate of the present invention.
FIG. 6 is a perspective view illustrating a method for manufacturing a PDP substrate according to a reference example of the present invention.
[Explanation of symbols]
1: Back plate 2: Partition wall 3: Address electrode 4: Phosphor 5: Display cell 6: Front plate 7: Discharge electrode 10: Blade 11: Irregular part 12: Partition material layer

Claims (4)

A mold having an uneven portion conforming to the shape of a partition wall is provided in a mold of an extruder, and a raw material is extruded through the mold to form a back plate having a partition wall, and the obtained molded body is cured. A method for manufacturing a substrate for a plasma display device, comprising the steps of: A side surface of the partition wall, claim 1 plasma display device substrate manufacturing method according to characterized in that it has a sliding mark extending parallel to the major direction of the back plate. 2. The address electrode according to claim 1, wherein the back plate is formed of a conductive metal such as silver, nickel, or aluminum, or an alloy thereof, or a conductive paste obtained by mixing a small amount of glass with the alloy. A method for manufacturing a substrate for a plasma display device. 2. The manufacturing method according to claim 1, wherein the uneven portion of the blade is made of a metal material on which a hard thin film of TiC or hard carbon is formed or a zirconia ceramic is used. Method.

Images