JP3591910B2 - Manufacturing method of cell barrier for plasma display panel - Google Patents

Description

[0001]
[Industrial applications]
The present invention relates to a method for manufacturing a cell barrier of a plasma display panel (hereinafter, referred to as PDP) including a plurality of discharge spaces formed by cell barriers.
[0002]
[Prior art]
Conventionally, as a method of manufacturing a cell barrier of a PDP, a method of patterning a glass paste on a glass substrate by a screen printing method, and then firing the same, has been used. Baking is performed after laminating by repeating drying several tens of times, for example. In order to improve the accuracy of the barrier shape, the method to be provided a lipophilic polymer layer in a portion provided cell barrier on the glass substrate (JP-A-5-166460), etc. have been proposed.
[0003]
[Problems to be solved by the invention]
However, in the above-mentioned conventional manufacturing method, the manufacturing apparatus is not special and the process is easy. On the other hand, the number of processes is increased, and the shape of the cell barrier by screen printing collapses before firing, and the number of times of printing is repeated. However, there is a problem in that the shape precision tends to be deteriorated as the number increases, and there is a problem that the precision is inferior. As a result, there is a problem that it is difficult to obtain a high-definition image as the performance of the display panel.
[0004]
Therefore, an object of the present invention is to provide a new manufacturing method which can solve the above-mentioned drawbacks of the prior art and can manufacture a more accurate cell barrier easily, quickly and stably. .
[0005]
[Means for Solving the Problems]
In order to achieve the above object, a method for manufacturing a cell barrier of a plasma display panel according to the present invention includes disposing a front plate and a back plate having cell barriers constituting a plurality of discharge spaces so as to face each other in parallel. and have you to a method of manufacturing the set and cell barriers of the plasma display panel comprising, characterized in that it comprises from the following (a) ~ (D).
(A) A shaping sheet manufacturing process for obtaining a shaping sheet in which a resin layer corresponding to an inverted concavo-convex shape is fixed to a base material, and a cell barrier portion composed of a large number of cell barriers having a trapezoidal cross section .
(B) An application step of applying a glass paste to a glass substrate surface.
(C) after filling the glass paste into the sheet recess shaped sheet by pressing the shaped sheet while the glass paste not dry a solvent vehicle of the glass paste to the glass substrate coated, sheet recess A forming step in which the shaped sheet is peeled off before the glass paste filled therein is dried, and the glass paste on the surface of the glass substrate is formed into a cell barrier shape.
(D) A firing step of firing the formed glass paste.
[0006]
Hereinafter, a method for manufacturing a cell barrier of a plasma display panel according to the present invention will be described in detail with reference to the drawings.
[0007]
In the manufacturing method of the present invention, first, a shaped sheet having an irregular shape reverse to the shape of the PDP cell barrier portion is manufactured. The shaping sheet is a mold having an ionizing radiation-curable resin layer having a sheet recess formed on a film substrate, and the sheet recess having a shape opposite to the shape of the PDP cell barrier portion.
[0008]
FIG. 3 is a conceptual diagram illustrating an example of the apparatus for manufacturing the shaped sheet. The roll intaglio 4 has a plate recess 41 having a shape corresponding to a cell barrier portion composed of a number of cell barriers, and is rotated in the direction of the arrow. There, the film base material 21 is appropriately supplied by a transfer means, pressed against the roll intaglio by the pressing roll 51, conveyed synchronously in contact with the roll intaglio, separated from the roll intaglio by the peeling roll 52, and conveyed. Is done. It should be noted that clearance adjustment between the pressing roller and the peeling roll with the intaglio roll can be performed.
[0009]
The ionizing radiation-curable resin 3 is supplied to the roll intaglio 4 and the film substrate 21 by an appropriate means so as to fill at least the plate recess 41 of the roll intaglio. In the figure, the ionizing radiation-curable resin is directly supplied to the roll intaglio by the coating device 6 from below the roll intaglio. Then, the film substrate is brought into contact with the roll intaglio, and the ionizing radiation curable resin on the film substrate and the roll intaglio is sandwiched between the film substrate and the roll intaglio, and the film substrate side is irradiated by the ionizing radiation irradiation device 7. To cure the ionizing radiation-curable resin interposed between the film substrate and the roll intaglio. The ionizing radiation-curable resin is cured to form the ionizing radiation-curable resin layer 22 fixed to the film substrate. Next, when the film substrate is peeled from the roll intaglio by a peeling roll, the ionizing radiation-curable resin layer is peeled off together with the film substrate, and the ionizing radiation-curable resin layer is shaped into a portion other than the cell barrier portion (discharge space). Thus, the shaped sheet 2 in which the sheet concave portion 23 formed by the ionizing radiation-curable resin layer forms a cell barrier portion is obtained.
[0010]
Here, the relationship between the desired cell barrier shape and the shapes of the sheet concave portions of the shaped sheet and the plate concave portions of the roll intaglio will be described. In FIG. 2, (a) shows the roll intaglio 4 and the plate recess 41, (b) shows the shaped sheet 2 and the sheet recess 23 obtained from the roll intaglio of (a), and (c) shows the shape of (b). 1 shows a cell barrier 1 obtained from a shaped sheet. The roll intaglio has a plate recess corresponding to the shape of the cell barrier portion. In other words, if the plate recess 41 of the roll intaglio 4 is intuitively a recessed portion and a recessed space, the plate recessed portion has the same shape as the portion (discharge space) other than the cell barrier portion. Portions (projections) other than the plate recesses have the same shape as the cell barrier portions. On the other hand, in the shaping sheet 2, the concave space of the sheet concave portion 23 has the same shape as the cell barrier portion. In addition, it is possible to make a shaped sheet from a planographic intaglio sheet, but for convenience of explanation, the plate surface of the roll intaglio is flattened in FIG. 2 (a).
[0011]
The film substrate 2 described above may be a film having flexibility and ionizing radiation transparency. For example, a film made of a resin such as polyethylene terephthalate, polyester such as polyethylene naphthalate, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyamide, polyimide, polystyrene, ethylene-ethylene acetate copolymer, and polyvinyl alcohol. No. Among them, a polyethylene terephthalate film is particularly preferable in consideration of workability, strength, cost, and the like.
[0012]
As shown in FIG. 3, the ionizing radiation-curable resin can be supplied and supplied directly to the roll intaglio by a roll coating method. Alternatively, the ionizing radiation-curable resin can be supplied directly from a die such as a T-die to the roll intaglio. Before the material comes into contact with the roll intaglio, the material may be applied to the film substrate in advance by a roll coating method or the like and supplied.
[0013]
Further, as the ionizing radiation-curable resin used in the present invention, a polymer, a prepolymer, or a monomer which undergoes a cross-linking polymerization reaction by ionizing radiation to be solidified is used.
Specifically, a radical polymerization system (here, (meth) acryloyl) comprising a compound having a (meth) acryloyl group such as (meth) acrylamide, (meth) acrylonitrile, (meth) acrylic acid, and (meth) acrylic acid ester Means acryloyl or methacryloyl. The same shall apply hereinafter.), Epoxy, cyclic ether, cyclic acetal, lactone, vinyl monomer, cationic polymerization system comprising a combination of a cyclic siloxane with an aryldiazonium salt, a diaryliodonium salt, etc., and a thiol group. For example, a compound having trimethylolpropane trithioglycolate, trimethylolpropane trithiopropionate, or a polyene / thiol system composed of pentaerythritol tetrathioglycol and a polyene compound can be used.
[0014]
Examples of the monofunctional monomer of the radical polymerization-based (meth) acrylate compound include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, methoxyethyl (meth) acrylate, methoxybutyl (meth) acrylate, Butoxyethyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, N, N-dimethylaminomethyl (meth) acrylate, N, N-dimethylaminoethyl (meth) acrylate, N, N-diethylaminoethyl (meth) acrylate, N, N-diethylaminopropyl (meth) acrylate, N, N-dibenzylaminoethyl (meth) acrylate, lauryl (meth) acrylate, isophonyl (meth) acrylate, ethyl carbitol (meth) acrylate, Enoxyethyl (meth) acrylate, phenoxy polyethylene glycol (meth) acrylate, tetrahydroxyfurfuryl (meth) acrylate, methoxytripropylene glycol (meth) acrylate, 2- (meth) acryloyloxyethyl-2-hydroxypropyl phthalate, 2- ( (Meth) acryloyloxypropyl hydrogen phthalate and the like.
[0015]
Examples of the radical polymerization type polyfunctional monomer include, for example, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, and dipropylene glycol di (meth) acrylate. (Meth) acrylate, neopentyl glycol di (meth) acrylate, 1,6-hexyldiol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, tripropylene glycol Di (meth) acrylate, bisphenol A-di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate Pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, glycerin polyethylene oxide tri (meth) acrylate, tris (meth) acryloyloxyethyl Phosphate and the like.
[0016]
Examples of radical polymerization prepolymers include (meth) acrylates such as alkyd (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, and polybutadiene (meth) acrylate. , Unsaturated polyester and the like.
[0017]
Among these compounds containing a (meth) acryloyl group, a compound containing an acryloyl group, that is, an acrylate has a higher polymerization reaction rate. Therefore, when the production speed of coating and forming the ionizing radiation-curable resin layer is emphasized, acrylate is more preferable than methacrylate.
[0018]
As the radical polymerization-based ionizing radiation-curable resin, one or a combination of two or more of the above compounds may be used as necessary.
[0019]
Here, as a photopolymerization initiator in the case of curing by ultraviolet rays, benzoin, benzoin methyl ether, acetophenone, benzophenone, Michler's ketone, diphenyl sulfide, dibenzyl disulfide, diethyl oxide, triphenylbiimidazole, isopropyl-N, N- One or more of dimethylaminobenzoate and the like can be used in a range of 0.1 to 10 parts by weight based on 100 parts by weight of the ionizing radiation-curable resin.
[0020]
Here, in a composition containing the ionizing radiation-curable resin, ethyl acetate, butyl acetate, cellosolve acetate are used as a solvent for dissolving the ionizing radiation-curable resin, adjusting the viscosity and the like, and having coating suitability. One or two or more of esters such as ketones such as acetone, methyl ethyl ketone and ethyl isobutyl ketone, and alcohols such as methyl alcohol, ethyl alcohol and isopropyl alcohol can be arbitrarily used.
[0021]
As the ionizing radiation, electromagnetic waves such as visible light, ultraviolet light, X-rays, and electron beams or particle beams are used. For practical use, ultraviolet rays or electron beams are mainly used.
As the ultraviolet light source, a light source such as a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a low-pressure mercury lamp, a carbon arc, a black light, and a metal halide lamp is used.
[0022]
As the electron beam source, various electron beam accelerators such as a Cockcroft-Walton type, a bande graph type, a resonance transformer type, an insulating core transformer type, or a linear type, a dynamitron type, and a high frequency type are used, and 100 to 1000 keV, preferably Irradiating an electron having an energy of 100 to 300 keV can be used.
The irradiation dose is usually 0.5 to 30 Mrad.
[0023]
In addition, as an irradiation method of ionizing radiation, first, it is also possible to cure the ionizing radiation-curable resin layer by irradiating an ultraviolet ray to at least the surface so that at least the surface is touch-dried, and then completely cure it with an electron beam. .
[0024]
The shaped sheet obtained as described above is used as a shaping mold, and a glass frit made of PbO or the like, a heat-resistant pigment, or the like, dispersed in an organic vehicle, applied to a glass substrate by an appropriate means, with respect to a glass paste. Then, the glass paste is pressed to form a desired cell barrier shape.
[0025]
As an application means in the application step of applying the glass paste to the glass substrate, an extrusion method such as a T- die, a method using a gap by a blade (see FIG. 8 ), or the like can be appropriately used. In FIG. 1 (a), coating the glass paste by a T-die.
[0026]
Then, as the forming process of the glass paste, while the solvent vehicles of the glass paste dries, as in FIG. 1 (b), by pressing a shaped sheet 2 coated glass paste, a sheet recess shaped sheet Is filled with a glass paste, and if necessary, the convex surface of the ionizing radiation-curable resin layer of the shaped sheet is brought into contact with the glass substrate until it comes into contact with the glass substrate. Next, as shown in FIG. 1 (c), while the glass paste filled in the sheet recesses not dry, when peeling off the shaped sheet, the glass paste remains in a state of being formed into a glass substrate side. FIG. 4 shows a shaped sheet 2 and a cell barrier 1 on a glass substrate 10 formed by the shaped sheet 2. Note that the inner surface of the sheet concave portion is appropriately adjusted with a material such as an ionizing radiation-curable resin layer to reduce the wettability to the glass paste from the surface of the glass substrate, so that the glass paste remains on the glass substrate side at the time of peeling.
[0027]
Thus, a glass paste capable of forming a desired cell barrier shape at a desired height on a glass substrate in a single operation is formed, and when this is fired under predetermined firing conditions, a cell barrier having a desired shape is obtained. . Then, the back plate and the front plate on which the cell barrier is formed are sealed to obtain a PDP having a cell barrier structure as shown in FIG.
[0028]
One of the features of the present invention is that a cell barrier having a desired shape can be formed at a desired height by a single patterning process on a glass substrate. The cross section shown in FIG. In addition, since the area of the front surface of the cell barrier at the portion to be joined to the front plate can be reduced, there is an advantage that the pixel area can be increased and the brightness can be improved by improving the aperture ratio of the PDP.
[0030]
[Action]
According to the manufacturing method of the present invention, first, a shaped sheet corresponding to a cell barrier portion serving as a shaped die of a glass paste and an inverted uneven shape is manufactured. In this case, the ionizing radiation-curable resin filled in the roll intaglio provides a highly accurate shaping sheet serving as a shaping mold for the glass paste. Then, by pressing the shaped sheet against a glass paste applied almost uniformly on a glass substrate, the glass paste is pushed into the sheet recess and filled, and then, when the shaped sheet is peeled off, the glass paste is removed. Due to the difference in wetting between the sheet concave portion and the glass substrate, the glass paste is formed and remains on the glass substrate side. Since the shape of the glass paste formed on the glass substrate is formed corresponding to the shape of the sheet concave portion, by setting the shape of the sheet concave portion to the shape of the target cell barrier portion, one time with respect to the glass substrate. A glass paste having a desired shape is formed on a glass substrate in the processing. Then, the desired cell barrier is obtained by firing.
[0031]
【Example】
Next, the present invention will be described in more detail with reference to specific examples.
[0032]
<< Example 1 >>
As manufacturing <br/> film substrate type sheet, polyethylene terephthalate film having a thickness of 25 [mu] m (manufactured by Toray Industries (Inc.): T-60) on one surface of a shaped sheet manufacturing apparatus shown in FIG. 3, as follows use b Lumpur intaglio and ionizing radiation curable resin composition, and to obtain a shaped sheet provided female cell barrier of the cell barriers and reverse uneven shape on one surface of the film substrate under the following conditions Was.
[0033]
Roll intaglio Sectional shape of the plate surface: vertical section is a trapezoid separated (see FIG. 6 ) Horizontal section is a stripe-shaped cell pitch P: 200 μm
Cell groove width W: upper bottom 180 μm, lower bottom 150 μm
Cell depth D: 150 μm
[0034]
Ionizing radiation curable resin composition 90 parts by weight of pentaerythritol triacrylate 10 parts by weight of urethane acrylate oligomer
Irradiation conditions Irradiation of 10 Mrad electron beam with a curtain beam type electron beam irradiation device.
Next, a glass paste in which a low-melting glass frit, a heat-resistant pigment, and the like are dispersed in an organic binder is applied on a glass substrate to a thickness of 100 μm by a blade coating method. The shaped sheet obtained above was pressed from above, then the shaped sheet was peeled from the glass substrate, and a molded glass paste was formed on the glass substrate. Next, the glass substrate to which the glass paste transferred in the shape of the cell barrier was applied was fired under the conditions of a peak temperature of 585 ° C. and a heating time of 15 minutes to form a cell barrier on the PDP glass substrate.
[0037]
<< Example 2 >>
In Example 1, a cell barrier was formed on a glass substrate in the same manner as in Example 1, except that the roll intaglio, the ionizing radiation-curable resin composition, and the irradiation conditions for producing the shaped sheet were as follows.
[0038]
Roll intaglio Sectional shape of the plate surface: vertical section is a trapezoid separated (see FIG. 7 ) Horizontal section is a square cell pitch P: 500 μm
Cell groove width W: upper bottom 450 μm, lower bottom 100 μm
Cell depth D: 150 μm
[0039]
Ionizing radiation-curable resin composition 90 parts by weight of pentaerythritol triacrylate 10 parts by weight of urethane acrylate oligomer 2-hydroxy-2-methyl-1-phenylpropan-1-one (Darocur 1173, manufactured by Merck) 7 parts by weight
Irradiation conditions High-pressure mercury lamp with ozone, 160 W / cm × 2 lamps
【The invention's effect】
As described in detail above, according to the method for manufacturing a cell barrier of the present invention, a cell barrier of any shape with high accuracy can be simply, quickly and stably manufactured by a single patterning process. Moreover, Ri by the fact that the shape of the cell barrier trapezoidal shape, the area of the cell barrier surface of the front plate side of the PDP can be reduced, thereby facilitating even higher definition of the PDP.
[Brief description of the drawings]
1A is a conceptual diagram showing a coating process, FIG. 1B is a conceptual diagram showing a first half of a molding process, and FIG.
FIG. 2 is a cross-sectional view showing the relationship between a roll intaglio, a shaped sheet, and an example of an obtained cell barrier shape.
FIG. 3 is a conceptual diagram illustrating an example of a manufacturing apparatus used in a shaped sheet manufacturing process.
Sectional view illustrating an example shape of Figure 4 shaped sheet and a cell barrier corresponding thereto.
FIG. 5 is a conceptual diagram of a cross section obtained by sealing a back plate and a front plate having a cell barrier to form a panel.
FIG. 6 is a cutaway perspective view showing an example of a plate concave shape of a roll intaglio .
FIG. 7 is a cutaway perspective view showing another example of the plate concave shape of the roll intaglio .
FIG. 8 is a conceptual diagram showing another method of the application step .
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Cell barrier 2 Shaped sheet 21 Film base 22 Ionizing radiation curable resin layer 23 Sheet concave part 3 Ionizing radiation curable resin 4 Roll concave part 41 Plate concave part 51 Pressing pressure roll 52 Peeling roll 6 Coating device 7 Ionizing radiation irradiating device 8 Glass paste 9 Blade 10 Glass substrate

Claims (1)

In a method for manufacturing a cell barrier of a plasma display panel, a front panel and a rear panel having a cell barrier constituting a plurality of discharge spaces are arranged so as to face each other in parallel, the following (A) To (D), a method for manufacturing a cell barrier of a plasma display panel.
(A) A shaping sheet manufacturing process for obtaining a shaping sheet in which a resin layer corresponding to an inverted concavo-convex shape is fixed to a base material, and a cell barrier portion composed of a large number of cell barriers having a trapezoidal cross section .
(B) An application step of applying a glass paste to a glass substrate surface.
(C) after filling the glass paste into the sheet recess shaped sheet by pressing the shaped sheet while the glass paste not dry a solvent vehicle of the glass paste to the glass substrate coated, sheet recess A forming step in which the shaped sheet is peeled off before the glass paste filled therein is dried, and the glass paste on the surface of the glass substrate is formed into a cell barrier shape.
(D) A firing step of firing the formed glass paste.

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