JP4059040B2 - Method for manufacturing plasma display panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a plasma display panel known as a display device.
[0002]
[Prior art]
In a plasma display panel (hereinafter referred to as PDP), an ultraviolet ray is generated by gas discharge, and a phosphor is excited by this ultraviolet ray to emit light, thereby displaying an image.
[0003]
PDPs are broadly classified into AC types and DC types in terms of drive. There are surface discharge types and counter discharge types in terms of discharge types, but they are manufactured with higher definition, larger screens, and structural simplicity. Therefore, at present, the surface discharge type PDP having a three-electrode structure is mainly used.
[0004]
The structure is such that a plurality of display electrodes composed of scan electrodes and sustain electrodes are formed, and a front plate in which a dielectric is formed to cover the display electrodes, and a plurality of back plates in which data electrodes are formed orthogonal to the display electrodes. Are arranged opposite to each other with a plurality of barrier ribs in between, and the intersection of the display electrode and the data electrode in the space defined by the front plate, the rear plate and the barrier rib is used as a discharge cell, and the phosphor layer is formed in the discharge cell. It is equipped with. Then, the phosphor is made to emit light with ultraviolet rays generated by the discharge in the discharge cell to display an image. Since the phosphor layer can be made relatively thick, it is suitable for color display using a phosphor.
[0005]
Such a plasma display device can display at a higher speed than a liquid crystal panel, has a wide viewing angle, is easy to enlarge, and is self-luminous so that the display quality is high. Recently, the flat panel display has attracted particular attention and is used for various purposes as a display device in a place where many people gather and a display device for enjoying a large screen image at home.
[0006]
[Problems to be solved by the invention]
In a PDP, when a front plate and a back plate are placed opposite to each other with a partition wall in between to form a discharge cell, for example, the thickness variation of the dielectric layer formed on the front plate is large or formed on the back plate. If the height variation of the barrier ribs is large, the contact state between the barrier ribs and the dielectric layer becomes non-uniform, and a large stress acts locally. As a result, the barrier ribs are chipped or the dielectric layer is damaged. There was a case where a problem of cracks occurred. In such a case, mixed colors and bright spots in the image and a withstand voltage failure at the time of driving are caused, which adversely affects the image display of the PDP.
[0007]
The present invention has been made in view of such a current situation, and realizes a PDP capable of good image display by improving the contact accuracy between the dielectric layer formed on the front plate and the partition formed on the back plate. The purpose is to do.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, a method of manufacturing a plasma display panel according to the present invention includes a front plate formed with a display electrode composed of a scan electrode and a sustain electrode, a dielectric covering the display electrode, and a data electrode. A method of manufacturing a plasma display panel, wherein a plurality of back plates formed so as to intersect with an electrode are arranged to face each other with a plurality of partition walls interposed therebetween, wherein the dielectric layer has the display electrode on the surface thereof The concave portion is formed by laminating a second dielectric layer having a hole on the first dielectric layer, and the concave portion of the first dielectric layer is formed. The softening point temperature is set higher than the softening point temperature of the second dielectric layer, and the front plate and the back plate are bonded to face each other and / or the discharge gas is sealed inside the PDP. Exhaust process to exhaust the interior before The heating is performed at, by softening only the second layer of the dielectric layer, the partition wall, in the portion in contact with the dielectric layer, characterized in that to bury at least a part thereof in the dielectric layer Is.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
That is, according to the first aspect of the present invention, a display plate including a scan electrode and a sustain electrode, a front plate formed with a dielectric covering the display electrode, and a data electrode intersect with the display electrode. A method of manufacturing a plasma display panel in which a plurality of back plates formed in such a manner are arranged to face each other with a plurality of partition walls interposed therebetween, wherein the dielectric layer has a recess overlapping the display electrode on the surface thereof. The recess is formed by laminating a second dielectric layer having a hole on the first dielectric layer, and the softening point temperature of the first dielectric layer is It is configured to be higher than the softening point temperature of the second dielectric layer, and the front plate and the back plate are bonded to face each other and / or the inside is exhausted before the discharge gas is sealed inside the PDP. Due to the heating performed in the exhaust process By softening the only eye dielectric layer, a partition wall, in the portion in contact with the dielectric layer, a method of manufacturing a plasma display panel, characterized in that to bury at least a part thereof to the dielectric layer.
[0016]
Hereinafter, embodiments of the present invention will be described, but the embodiments of the present invention are not limited thereto.
[0017]
(Embodiment 1)
A PDP according to an embodiment of the present invention will be described below with reference to the drawings.
[0018]
FIG. 1 is a perspective view showing a schematic configuration of a PDP according to Embodiment 1 of the present invention. The front plate 1 has a structure in which a transparent and insulating substrate 3 such as glass provided with a plurality of display electrodes 2 is covered with a dielectric layer 4 and a protective film 5 made of an MgO deposited film. The display electrode 2 is a pair of a scan electrode 6 and a sustain electrode 7 facing each other with a discharge gap MG. The scan electrode 6 is formed of a transparent electrode 6a and, for example, Cr / Cu / Cr or Ag formed thereon. The sustain electrode 7 is composed of a transparent electrode 7a and an opaque bus electrode 7b formed on the same, such as Cr / Cu / Cr or Ag. Is.
[0019]
The back plate 8 is provided with a plurality of data electrodes 11 covered with a dielectric layer 10 on an insulating substrate 9 such as glass, and the data electrodes 11 between the data electrodes 11 on the dielectric layer 10 are provided. 11, a stripe-shaped partition wall 12 is provided in parallel with the substrate 11, and a phosphor layer 13 is provided over the surface of the dielectric layer 10 and the side surface of the partition wall 12.
[0020]
The front plate 1 and the back plate 8 are arranged to face each other with the discharge space 14 interposed therebetween so that the scan electrodes 6 and the sustain electrodes 7 and the data electrodes 11 are orthogonal to each other.
[0021]
The discharge space 14 is filled with at least one kind of rare gas of helium, neon, argon, and xenon as a discharge gas, and is partitioned by the partition wall 12 and the data electrode 11 and the display electrode 2 (the scanning electrode 6 and the scanning electrode 6). The discharge space 14 at the intersection with the sustain electrode 7) operates as a discharge cell 15.
[0022]
Here, the dielectric layer 4 is provided with a recess 16 for each discharge cell 15 on the surface so that the display electrode 2 and a part of the dielectric layer 4 overlap each other. It can be obtained by laminating a second dielectric layer 4b having a hole on the body layer 4a.
[0023]
Further, for example, a material whose softening point temperature of the second dielectric layer 4b is within ± 60 ° C. with respect to the sealing temperature and / or the exhaust temperature in the manufacturing process of the plasma display panel is used.
[0024]
FIG. 2A shows an enlarged view of the front plate 1 viewed from the discharge cell 15 side inside the PDP. FIG. 2B is a cross-sectional view taken along the line XX in FIG. Further, the position where the partition wall 12 abuts against the front plate 1 is indicated by a dotted line in FIG. Although the protective film 5 is omitted in FIG. 2, the protective film 5 is actually formed so as to cover the surface of the dielectric layer 4 including the bottom and side surfaces of the recess 16.
[0025]
Here, conventionally, when the front plate and the back plate are arranged opposite to each other with the barrier ribs between them in order to form discharge cells, the thickness variation of the dielectric layer formed on the front plate and the barrier ribs formed on the back plate Due to the height variation, the contact state between the partition walls and the dielectric layer becomes non-uniform, which may cause problems such as chipping of the partition walls or cracks in the dielectric layer. In the PDP, color mixture, luminescent spots, and breakdown voltage are poor, which causes the quality of the display image to be remarkably lowered. However, in the configuration of the present embodiment shown in FIGS. Since the softening point temperature of the second dielectric layer 4b is within ± 60 ° C. with respect to the sealing temperature and / or the exhaust temperature, the front plate 1 and the rear plate 8 are bonded to face each other. And / or PDP To the heating of the discharge gas into PDP performed in the exhausting step for exhausting the interior prior to encapsulation, the second layer of the dielectric layer 4b is softened. Here, even when the ultimate temperature of the dielectric layer 4b during heating is lower than the softening point temperature of the dielectric layer 4b, if it is within 60 ° C., a sufficiently softened state can be obtained. In addition, it has been experimentally confirmed that when the temperature reached by the dielectric layer 4b during heating exceeds 60 ° C. above the softening point temperature of the dielectric layer 4b, it flows and becomes inconvenient. Here, the temperature range of ± 60 ° C. is determined from the viewpoint of obtaining an appropriate softened state of the dielectric layer 4b for relaxing the uneven contact state of the partition walls 12 as described above. Even if it is somewhat out of this range, it is obvious that it falls within the scope of the present invention.
[0026]
Further, the sealing temperature in the sealing step is related to the softening point temperature of the frit glass for sealing, and it is preferable to take the above viewpoint into consideration when selecting the material of the frit glass.
[0027]
Further, in order to bring the second dielectric layer 4b into the softened state as described above, the temperature reached by the second dielectric layer 4b is set within ± 60 ° C. with respect to the softening point temperature. The process preferably includes a sealing process. This is a process in which the front plate 1 and the back plate 8 are first arranged to face each other in the sealing step, and at this stage, the second dielectric layer 4b and the partition 12 are in a non-contact state. This is because mitigation is effective in suppressing the occurrence of “chips” and “cracks”.
[0028]
As described above, in the present embodiment, since the dielectric layer 4b is softened, the thickness variation of the dielectric layer 4 formed on the front plate 1 and the partition wall 12 formed on the back plate 8 are reduced. Due to the height variation, when the front plate 1 and the back plate 8 are bonded to face each other, the contact state between the partition wall 12 and the dielectric layer 4 becomes uneven, and the partition wall 12 and the second dielectric layer Even in the case where a portion that strongly contacts with 4b is generated, the partition wall 12 is buried in the softened second dielectric layer 4b, so that the partition wall 12 and the second dielectric layer 4b The contact state is uniform. As a result, the occurrence of “chips” and “cracks” in the partition wall 12 and the second dielectric layer 4b is suppressed, and as a result, a PDP capable of displaying a good image can be realized.
[0029]
Here, when the entire dielectric layer 4 is softened, for example, “cracking” or “impregnation of dielectric material” may occur in the protective film 5 formed on the dielectric layer 4. The function of the protective film 5 in the PDP deteriorates, and if the degree of the deterioration is significant, the PDP image display will be significantly adversely affected. Therefore, even if the softening point temperature of the first dielectric layer 4a is set higher than the softening point temperature of the second dielectric layer 4b, the second dielectric layer 4b is softened. It is preferable that the first dielectric layer 4a is not softened. That is, the dielectric layer 4 has a structure in which the first dielectric layer 4a and the second dielectric layer 4b are provided with a recess 16 on the surface, and is softened by a sealing process and / or an exhaust process. Since only the second dielectric layer 4b is used, the protective film 5 formed on the first dielectric layer 4a serving as the bottom surface of the recess 16 has a “crack” or the like as described above. Problems such as “impregnation of dielectric material” do not occur. Here, in the configuration of the present embodiment, since the discharge generation region is limited to the recess 16, even if the dielectric layer 4 b is softened, the region involved in the discharge, that is, the protection at the bottom surface of the recess 16. The film 5 is not affected at all and therefore does not adversely affect the image display.
[0030]
Here, a mechanism in which the discharge is restricted only to the recess 16 in the present embodiment will be described. In the discharge cell 15, since the thickness of the dielectric layer 3 is different between the recess 16 and the other region, the capacitance as a capacitor differs between the recess 16 and the other region, and the discharge start voltage is different. Is also different. That is, since the charges easily accumulate in the recess 16 and the discharge start voltage is low, it is easy to generate and maintain the discharge. In other regions, the charges are difficult to accumulate and the discharge voltage is high, so that the discharge is generated. , Maintenance is suppressed. As described above, the region of the discharge 17 in the discharge cell 15 is limited to the recess 16 as shown in FIG. This restricts the discharge region from being unnecessarily widened, and also has the effect of suppressing the occurrence of so-called erroneous discharge, in which discharge is generated between adjacent discharge cells 15 during high definition.
[0031]
Further, as shown in FIG. 2, the dielectric layer 4 has a structure in which a concave portion 16 is formed on the surface by a first dielectric layer 4a and a second dielectric layer 4b. Therefore, for example, the dielectric constant of the dielectric layer 4 can be selected by appropriately selecting the materials of the first dielectric layer 4a and the second dielectric layer 4b while maintaining the softening point temperature. Further, since characteristics such as transmittance and withstand voltage characteristics can be changed in the thickness direction, it is possible to provide means for improving the characteristics.
[0032]
Further, the dielectric layer 4 is not limited to two layers as shown in FIG. 2, and even when there are two or more layers, the recess 16 is formed, and at least one of the two or more dielectric layers is formed. As long as the structure is softened, and preferably the dielectric layer that forms the bottom surface of the recess 16 is not softened, the same effects as those of the above-described embodiment can be obtained.
[0033]
In the above, the case where the boundary of the two-layer structure of the first dielectric layer 4a and the second dielectric layer 4b is a “plane” is an example. The PDP manufactured by the method of manufacturing a PDP of the present invention has a certain thickness because the first dielectric layer 4a and the second dielectric layer 4b are fused together. Even in the case of having a “layer”, the same effect as described above can be obtained.
[0034]
(Embodiment 2)
A PDP according to another embodiment of the present invention will be described below with reference to the drawings. FIG. 4 is a perspective view showing a schematic configuration of a PDP according to the second embodiment of the present invention. The same components as those shown in FIG. In the present embodiment, as the dielectric layer 4, a protrusion 4 c that surrounds the discharge cell 15 except for the four corners 15 a is provided on the surface. It is obtained by forming a second dielectric layer 4b in an island shape (land shape) on the dielectric layer 4a. The partition wall 12 is in contact with the second dielectric layer 4b, that is, the protruding portion 4c.
[0035]
Further, a material that has a softening point temperature of the second dielectric layer 4b within ± 60 ° C. with respect to a sealing temperature and / or an exhaust temperature in the manufacturing process of the plasma display panel is used. Here, for the same reason as described in the first embodiment, the softening point temperature of the second dielectric layer 4b is preferably lower than the softening point temperature of the first dielectric layer 4a.
[0036]
FIG. 5 shows a partially enlarged view of the front plate viewed from the discharge cell 15 side inside the PDP.
[0037]
Also in the configuration shown in the second embodiment, the contact accuracy between the protruding portion 4c, which is the second dielectric layer 4b, and the partition wall 12 is improved, and the discharge is a discharge surrounded by the protruding portion 4c. It is limited within the region of the cell 15, and the first dielectric layer 4a, which is the dielectric layer 4 in the discharge region, does not soften, and the protective film 5 formed thereon is “cracked”. It is possible to obtain the same effect as the configuration shown in the first embodiment, such as the absence of such a problem.
[0038]
【The invention's effect】
As described above, according to the present invention, the contact accuracy between the dielectric layer formed on the front plate and the partition formed on the back plate is improved, and a PDP capable of displaying a good image can be realized.
[Brief description of the drawings]
FIG. 1 is a cross-sectional perspective view showing a schematic configuration of a plasma display panel according to a first embodiment of the present invention. FIG. 2 is a partially enlarged view of a front plate of the plasma display panel according to the first embodiment of the present invention. FIG. 4 is a sectional perspective view showing a schematic configuration of a plasma display panel according to a second embodiment of the present invention. FIG. 4 is a sectional perspective view showing a schematic configuration of the plasma display panel according to the second embodiment of the present invention. Partial enlarged view of the front panel of the plasma display panel according to 2 [Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Front plate 2 Display electrode 3 Substrate 4 Dielectric layer 4a First dielectric layer 4b Second dielectric layer 4c Projection part 5 Protective film 6 Scan electrode 6a Transparent electrode 6b Bus electrode 7 Sustain electrode 7a Transparent Electrode 7b Bus electrode 8 Back plate 11 Data electrode 12 Partition 15 Discharge cell 16 Recess

Claims (1)

A plurality of front plates formed with a display electrode composed of scan electrodes and sustain electrodes, a dielectric covering the display electrodes, and a back plate formed with a plurality of data electrodes so as to intersect the display electrodes. A plasma display panel manufacturing method in which the partition walls are arranged opposite to each other,
The dielectric layer includes a concave portion overlapping the display electrode on a surface thereof,
The recess is formed by laminating a second dielectric layer having a hole on the first dielectric layer,
The softening point temperature of the first dielectric layer is higher than the softening point temperature of the second dielectric layer,
Only the second dielectric layer is heated by a sealing process in which the front plate and the rear plate are bonded to face each other and / or in an exhaust process in which the inside of the PDP is exhausted before the discharge gas is sealed. By softening
A method for manufacturing a plasma display panel, wherein at least a part of a partition wall is buried in a dielectric layer in a portion where the partition wall is in contact with the dielectric layer .

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