JP3949783B2 - Display panel substrate manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a substrate for a display panel having fine barrier ribs used for various display panels including a plasma display panel.
[0002]
[Prior art]
The basic structure of a plasma display panel that is also applied to a wall-mounted television or the like is as shown in FIG. 6, for example. That is, the front panel A and the back panel B are overlapped so that the striped electrodes A1 and B1 formed on both panels face each other, and discharge is generated in the striped or grid-shaped partition walls C at the intersections. To emit light.
[0003]
The partition wall C is provided to prevent crosstalk of light and to make the contrast of the screen, and is very fine. For example, in the case of a stripe shape, it is required to be formed over the entire panel with a width of about 30 μm and a height of about 200 μm at intervals of about 100 μm. And inside the partition C of such a fine dimension, fluorescent substance is apply | coated and inert gas, such as Ne and Xe, is enclosed. Therefore, from the viewpoint of obtaining a complex and clear image, naturally, the fine pattern required for the partition wall C is made, and the amount of the phosphor applied is made constant, and it adheres closely to the front panel A to prevent leakage of the inert gas. From a viewpoint or the like, the dimensional accuracy of the partition wall C is required to be high.
[0004]
Conventionally, as a method for forming such partition walls C, a screen printing method or a sand blasting method has been adopted. In the screen printing method, an operation of printing a glass paste on a glass substrate and drying is repeated about 10 times by aligning each time, and a partition wall is formed by so-called overprinting. In the sand blasting method, a glass paste is applied to the front surface of a glass substrate, coated with a photoresist, exposed and developed, and then a portion not covered with a resist pattern is sand blasted to form partition walls.
[0005]
[Problems to be solved by the invention]
In the method of forming the partition wall by the screen printing method, it is difficult to form a fine pattern due to the alignment and the distortion of the screen every time, and this difficulty is a great obstacle especially when the screen is enlarged. Also, depending on the method of forming the partition wall by the sandblast method, the problem that the depth tends to be nonuniform can not be solved, and it is difficult to make a fine pattern and enlarge the screen. Furthermore, in any of the methods, it takes a long time to increase the dimensional accuracy, which is a factor that increases the manufacturing cost.
[0006]
Therefore, the present invention obtains a resin mold in which a stripe-shaped or lattice-shaped fine pattern as a consumable mold is formed from a mold as a master mold, and further adopts a method for transferring the fine pattern from the resin mold. An object of the present invention is to provide a method for manufacturing a display panel having partition walls with high dimensional accuracy that can solve the above-described problems and can be finely patterned and have a large screen.
[0007]
[Means for Solving the Problems]
As a means for achieving the above object, the present invention provides a first step of obtaining a resin mold in which a desired fine pattern is formed by injection molding according to a reference technique , and a liquid curable material is applied to the fine pattern forming surface of the resin mold. A display panel comprising: a second step of pouring a glass plate thereon after pouring; and a third step of removing the resin mold after curing the liquid curable material while pressing the liquid curable material. Provided is a method for manufacturing an industrial substrate.
[0008]
As a means for achieving the above object, the present invention provides a first step of obtaining a resin mold in which a desired fine pattern is formed by injection molding, and a partially vulcanized silicone on the fine pattern forming surface of the resin mold. A second step of placing a rubber film to transfer the fine pattern of the resin mold to the partially vulcanized silicone rubber film, and further providing a glass reinforcing material on the partially vulcanized silicone rubber film ; and the partially vulcanized silicone And a third step of removing the resin mold after the rubber film is cured. A method of manufacturing a display panel substrate is provided.
[0009]
The method for producing a display panel substrate according to claim 1, wherein the glass reinforcing material of the second step is provided by overlapping the glass plate as means for achieving the above object. I will provide a.
[0010]
The present invention provides a means for achieving the above object, the display panel substrate according to claim 1, characterized in that the provision of the glass reinforcement in the second step applying a coating layer of glassy A manufacturing method is provided.
[0011]
Further, according to the present invention, as means for achieving the above object, the display panel substrate according to claim 4 is a substrate for a plasma display panel or a method for manufacturing a display panel substrate according to claim 1. I will provide a.
[0012]
“Liquid” in the liquid curable material used in the invention described in the reference technology is not only a liquid curable material itself, but also a solution, dispersion liquid, sol, paste, etc. containing a curable material, resin This means that it has fluidity that can be poured into a mold. In addition, the “curing material” in the liquid curable material means a material that has a property of curing at room temperature or by heating, and the degree of “curing” is usually required for the partition portion of the display panel substrate. The rigidity and durability can be imparted.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the manufacturing method of the display panel substrate of the present invention will be described with reference to the drawings. 1 (a) to 1 (c) are schematic front views for explaining a production method described in the reference technique , and FIGS. 2 (a) to 2 (c) are for explaining the production method according to claim 1. FIG. is a schematic front view of FIG. 3 is a schematic front view for explaining a manufacturing method which is another embodiment of the production method according to claim 1, wherein, FIG. 4 is a another embodiment of the production method of claim 1, wherein FIG. 5 is a schematic front view for explaining the manufacturing method, and FIG. 5 is a schematic front view for explaining the manufacturing method according to the reference technique and claim 1 .
[0014]
First, a method for manufacturing a display panel substrate described in the reference technology will be described. In the first step, a resin mold 11 having a desired fine pattern 50 as shown in FIG. 1A is obtained by injection molding. The fine pattern 50 of the resin mold 11 is for forming a partition wall of a target display panel substrate, and the pattern of the partition wall forms an uneven inverted image. The fine pattern 50 of the resin mold 11 has a stripe shape or a lattice shape. For example, the fine pattern 50 is a stripe shape having a width of 60 μm, a depth of 200 μm, and an interval of about 160 μm. .
[0015]
As the injection molding method in this first step, a well-known injection technique may be applied. If the resin used can also be injection molded, phenol resin, urea resin, melamine resin, epoxy resin, unsaturated polyester resin, silicone Heat of thermosetting resin such as resin, urethane resin, vinyl chloride resin, polyethylene resin, polypropylene resin, polystyrene resin, ABS resin, AS resin, polyamide resin, polyacetal resin, methacrylic resin, polycarbonate resin, fluorine resin, polyester resin, etc. Any of the plastic resins can be used.
The mold used in this injection molding is a master mold for manufacturing the resin mold 11. For example, by finely processing the inner surface of the movable mold with a milling machine or a special tool, the fineness of the target resin mold 11 is obtained. This can correspond to the pattern 50.
[0016]
In the second step, as shown in FIG. 1B, first, the liquid curable material 12 is poured into the formation surface of the fine pattern 50 of the resin mold 11. As shown in FIGS. 1B and 1C, the liquid curable material 12 becomes the partition wall 2 of the display panel substrate after the curing is completed. As the pouring method, in addition to the method of casting the liquid curable material 12, a method such as brush coating can be applied. By pouring the liquid curable material 12 in this way, the liquid curable material 12 can be transferred in a state where the fine pattern 50 of the resin mold 11 is finely inverted as it is, and this transfer is completed by curing in the next step.
[0017]
As described above, the liquid curable material 12 used in this step is “liquid” and is “cured” alone or in combination with a curing agent, a catalyst, and other components that contribute to curing at room temperature or under heating. If it does, it will not restrict | limit in particular. However, since a resin mold is used as the mold, it is necessary to be able to be heat-cured at a lower temperature than conventional glass pastes so that the resin is not thermally deformed. Similarly, when a solvent is included in the components of the liquid curable material 12, it is necessary to consider the compatibility between the solvent and the resin mold. Examples of such a liquid curable material 12 include an inorganic silicon-containing polymer that undergoes a crosslinking reaction at room temperature or under heating to form a ceramic-like film, ceramic powder, cement such as alumina cement, water glass It is also possible to use an inorganic binder containing a kind or the like. In addition, since the liquid curable material 12 serves as the partition walls 2, a dark colorant such as black can be blended as necessary so as to be advantageous in obtaining the contrast of the display panel.
[0018]
Specific examples of such a liquid curable material 12 include a trade name HEATLES GLASS GS-600 series (Homer Technology Co., Ltd.) forming a silicon-containing polymer, polysilazanes such as perhydropolysilazane, for example, trade name Tonen Polysilazane ( Tonen Co., Ltd.), trade name of an inorganic binder, such as MR-100 series of Red Proof (Heatken Co., Ltd.).
[0019]
Next, after pouring the liquid curable material 12 into the resin mold 11 in this manner, the glass plate 13 is placed on top from above. As shown in FIGS. 1B and 1C, the glass plate 13 can be used as the glass substrate 3 on the back as it is.
[0020]
When placing the glass plate 13 in this second step, it is conceivable that air enters between the poured liquid curable material 12 and the glass plate 13 and remains as it is, for example, air gradually from one end to the other end. It is desirable to place the glass plate 13 so as to overlap the liquid curable material 12 while eliminating the above.
[0021]
In the third step, for example, the resin mold 11 is removed after being cured while being pressed by a heat press. By the process of this step, the fine pattern 50 of the resin mold 11 is transferred to the cured product of the liquid curable material 12 in a finely inverted state as it is. At the same time, the liquid curable material 12 and the glass plate 13 are fixed. Note that the pressing includes, in addition to applying pressure by a separate press, for example, pressure applied by the weight of the glass plate. In the case of pressing, a cushioning material having good thermal conductivity can be interposed in order to ensure a uniform pressing state.
[0022]
In the curing process in the third step, the curing temperature is selected according to the properties of the liquid curable material 12 used. Further, when selecting the curing temperature, the softening point of the resin mold 11 is also taken into consideration. For example, when polypropylene is used as the material of the resin mold 11, it is necessary to heat and cure at a temperature of 140 to 160 ° C., which is the softening point of polypropylene.
[0023]
After the curing is completed, the resin mold 11 is separated from the partition wall 2 and the glass plate 13. At this time, since the resin mold 11 has flexibility, it can be easily bent, so that the peeling operation can be performed smoothly. In consideration of peelability, the liquid curable material 12 may be peeled with a hardness that can maintain the uneven shape, and then recured. After peeling, the curing temperature may be further raised to completely cure. In this way, as shown in FIG. 1C, a display panel comprising the partition wall 2 having the fine pattern 60 in which the fine pattern 50 of the resin mold 11 is finely inverted and transferred, and the glass substrate 3 supporting the fine pattern 60. The substrate 10 for use can be obtained.
[0024]
Next, a method for manufacturing the display panel substrate according to claim 1 will be described. First, in the first step, the resin mold 11 is obtained in the same manner as in the manufacturing method described in the above-mentioned reference technique [see FIG. 2 (a)].
[0025]
Next, in the second step, as shown in FIG. 2B, a partially vulcanized silicone rubber film 15 is placed on the surface on which the fine pattern 50 of the resin mold 11 is formed, and a glass plate is used as a glass reinforcing material thereon. Lay 13 on top of each other. As shown in FIGS. 2B and 2C, the partially vulcanized silicone rubber film 15 becomes the partition wall 5 of the display panel substrate 10 after the curing is completed. Further, as shown in FIGS. 2 (b) and 2 (c), the glass plate 13 can be used as the glass substrate 3 on the back as it is, and the partially vulcanized silicone rubber film 15 (partition wall 5) at the time of manufacture. This improves the workability.
[0026]
The partially vulcanized silicone rubber film 15 used in this second step has a shape retaining property that does not hinder the workability of the film obtained by stopping the vulcanization reaction halfway without completing it. It means a silicone rubber film having such a property that it can be easily deformed by applying pressure. Therefore, by placing the partially vulcanized silicone rubber film 15 on the fine pattern 50 of the resin mold 11, the fine pattern 50 can be transferred in a finely inverted state as it is. This transfer is completed by curing in the next step.
[0027]
The partially vulcanized silicone rubber film 15 can be obtained by the following method, for example. After blending other ingredients into the unvulcanized silicone rubber raw material as necessary, it is put into a mold, heated while pressing, and partially vulcanized. The conditions for this partial vulcanization vary depending on the type of silicone rubber. For example, in the case of addition-type liquid silicone rubber (two-component type), the vulcanization reaction is completed in about 8 hours at 20 ° C. However, since the vulcanization reaction is completed in about 1 hour at 60 ° C., the vulcanization reaction is stopped in less than half time so that the above properties can be imparted. When the reaction is stopped in this way, it is immediately stored in a cold place to prevent further vulcanization reaction from proceeding. In addition to the time, the progress of the partial vulcanization reaction can be controlled by adjusting the heating temperature and adding a reaction inhibitor.
[0028]
As the silicone rubber raw material used here, a commercially available thermosetting type or room temperature curing type, one-component or two-component type, addition type or condensation type can be used. Other components include reaction inhibitors such as methylvinylcyclotetrasiloxane, acetylene alcohols, siloxane-modified acetylene alcohol, hydroperoxide; reinforcing silica, quartz powder, iron oxide, alumina, vinyl group-containing silicone resin And various additives such as pigments, heat-resistant agents, flame retardants, and adhesion improvers.
[0029]
As such partially vulcanized silicone rubber film 15, commercially available product names SOTEFA 50 (JIS A hardness 50), SOTEFA 70 (JIS A hardness 70), SH861U (JIS A hardness 60) (all are Toray Dow Corning Silicone Co., Ltd.), trade name TSE260-7U (Toshiba Silicone Corp.), trade name KE565K-U (JIS A hardness 60; Shin-Etsu Chemical Co., Ltd.) and the like can be used. The JIS A hardness shown here is the hardness after vulcanization is completed.
[0030]
Next, in the third step, the partially vulcanized silicone rubber film 15 is cured at room temperature or under heating, and then the resin mold 11 is removed. In selecting the temperature when heating at the time of curing, the softening point of the resin mold 11 is taken into consideration, and the curing is performed at a temperature lower than the softening point. By completing this curing reaction and peeling off the resin mold 11, the partition wall 5 having the fine pattern 60 in which the fine pattern 50 of the resin mold 11 is finely inverted and transferred as shown in FIG. A display panel substrate 10 made of a glass substrate 3 that supports it can be obtained.
[0031]
In such a manufacturing method, the glass plate 13 can be omitted as described in claim 3 . In that case, the partition wall 5 made of silicone rubber is used as the display panel substrate 10 as it is. In this case, as shown in FIG. 3, it is preferable to reinforce by forming a glassy coating layer 70 as a hard skin layer as a glass reinforcing plate on the surface where the fine pattern 60 is not formed. The glassy coating layer 70 can be formed, for example, by applying a material such as the above-mentioned HEATLESSGLASS by a spin coating method and curing it.
[0032]
In addition, as shown in FIG. 4, a glassy coating layer 71 can be formed on the surface of the partition wall 5. Since the starting material is a silicone rubber film in which the partition walls 5 are partially vulcanized, there is a possibility that low molecular weight substances remain inside the partition walls 5. Therefore, in such a case, the low molecular weight substance volatilizes during the manufacturing process of the display panel such as formation of address electrodes and phosphor coating, and there is a possibility that the operation may be hindered depending on the process contents. Because there is. The glassy coating layer 71 can be formed in the same manner as the glassy coating layer 70.
[0033]
The display panel substrate 10 thus obtained can be used to obtain a target display panel such as a plasma display panel by attaching an address electrode or applying a phosphor according to a conventional method. .
[0034]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited by these.
[0035]
Example 1
The manufacturing method described in the reference technique was applied to manufacture a plasma display panel substrate having striped barrier ribs as shown in FIG. Hereinafter, Example 1 is demonstrated based on FIG. First, a resin mold 11 made of polypropylene having a fine pattern 50 having a width of 60 μm, a height of 200 μm, and an interval of 160 μm was manufactured by injection molding, and this was placed on a stationary plate P1 of a heat press machine P. Next, a trade name HEATLESSGLASS (GS-600-1; containing isopropyl alcohol as a diluent) was applied as a liquid curable material 12 on the surface on which the fine pattern 50 of the resin mold 11 was formed by brush painting. Then, the glass plate 13 used as a board | substrate was set | placed on the application surface. Next, the movable platen P <b> 2 was lowered and heated and held at 130 ° C. for about 20 to 30 minutes while applying a pressure of about 15 g / cm ² from the top of the glass plate 13 to cure HEATLESSGLASS. After the curing was completed, the movable platen P2 was raised and the resin mold 11 was peeled off to obtain a plasma display panel substrate 10 as shown in FIG. When the surface of the plasma display panel substrate 10 was observed with a microscope, the fine pattern 50 of the fine pattern 60 having a width of 60 μm, a height of 200 μm, and an interval of 160 μm, in which the fine pattern 50 of the resin mold 11 was inverted and transferred as it was, was obtained. It was confirmed that it was formed.
[0036]
Example 2
The manufacturing method according to claim 1 was applied to manufacture a plasma display panel substrate having stripe-shaped partition walls as shown in FIG. Hereinafter, Example 2 is demonstrated based on FIG. First, a resin mold 11 made of polyester having a fine pattern with a width of 60 μm, a height of 200 μm, and an interval of 160 μm was manufactured by injection molding, and this was placed on a stationary plate P1 of a heat press machine P. Next, a product name SOTEFA 70 (thickness 0.5 mm) was placed as a partially vulcanized silicone rubber film 15 on the surface on which the fine pattern 50 of the resin mold 11 was formed. Then, the glass plate 13 used as a board | substrate was set | placed on the film. Next, the movable platen P2 was lowered, and heated and maintained at 150 ° C. for about 4 hours while applying a pressure of about 50 g / cm ² from above the glass plate 13 to cure the SOTEFA70. After the curing was completed, the movable platen P2 was raised and the resin mold 11 was peeled off to obtain a plasma display panel substrate 10 as shown in FIG. When the surface of the plasma display panel substrate 10 was observed with a microscope, the fine pattern 50 of the fine pattern 60 having a width of 60 μm, a height of 200 μm, and an interval of 160 μm, in which the fine pattern 50 of the resin mold 11 was inverted and transferred as it was, was obtained. It was confirmed that it was formed.
[0037]
【The invention's effect】
According to the reference technique and the manufacturing method according to claim 1 , a desired fine pattern is obtained by reversing and transferring a fine pattern of a master mold to a resin mold, and further reversing and transferring the fine pattern of the resin mold. A substrate for a display panel having partition walls made of can be obtained easily and in large quantities. The resin mold can be manufactured easily and in large quantities from the master mold. Since the resin itself as the raw material is inexpensive, the price can be set and maintained at a very low price, so that it can be a consumable mold. Therefore, if it becomes unusable due to clogging, etc. due to repeated use, it can be discarded and replaced with a new resin mold. Become cheap. Therefore, by applying the reference technique and the manufacturing method according to claim 1, it is possible to provide a display panel substrate that can be applied to a low-cost and high-quality plasma display panel and the like, and to achieve fine patterning. This makes it possible to apply to large screens.
[Brief description of the drawings]
FIG. 1 is a schematic front view for explaining a production method described in a reference technique .
FIG. 2 is a schematic front view for explaining the manufacturing method according to claim 1 ;
FIG. 3 is a schematic front view for explaining the manufacturing method according to claim 3 ;
FIG. 4 is a schematic front view for explaining another aspect of the manufacturing method according to claim 1 ;
FIG. 5 is a schematic front view for explaining the reference technique and the manufacturing method according to claim 1 ;
FIG. 6 is a schematic perspective view showing a structural example of a plasma display panel.

Claims (4)

A method for producing a substrate for a display panel , wherein a first step of obtaining a resin mold in which a desired fine pattern is formed by injection molding , and a partially vulcanized silicone rubber film is placed on the fine pattern forming surface of the resin mold transferring the fine pattern of the resin mold to the partial vulcanization silicone rubber film, and further a second step of providing a glass reinforcement on the part vulcanized silicone rubber film, curing the part vulcanized silicone rubber film And a third step of removing the resin mold, and a method for manufacturing a display panel substrate.  2. The method for manufacturing a display panel substrate according to claim 1, wherein the glass reinforcing material is provided by overlapping the glass plates.  2. The method for producing a display panel substrate according to claim 1, wherein the glass reinforcing material is applied by applying a glassy coating layer. The method for manufacturing a display panel substrate according to claim 1 , wherein the display panel substrate is a substrate for a plasma display panel.

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