JPH07161298A - Manufacture of plasma display panel and plasma display panel - Google Patents

Abstract

PURPOSE:To easily manufacture a plasma display panel high accurate in large size having a partition of uniform shape, relating to a method of manufacturing a PDP(plasma display panel). CONSTITUTION:In the case of manufacturing a PDP(plasma display panel) having partitions 29 for dividing discharge space, the first glass paste P1 and the second glass paste P2, having a larger content of binder as compared with this first glass paste P1, are successively applied onto a substrate 21, and a partition forming glass paste layer 29a of double layer structure is formed. Next by pattern exposure of a sensitized register material, cutting masks 61 are formed on the glass paste layer 29a. Next by a sand blast method, the glass paste layer 29a is partially cut. Next by baking the glass paste layer 29a after cutting, the partition 29 is formed.

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). A surface discharge PDP suitable for full-color matrix display with a phosphor is
It is drawing attention as a thin display device that replaces a CRT, and its high definition and large screen are being promoted in order to expand its application 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.

The PDP 10 illustrated in FIG. 6 has a three-electrode structure in which a pair of display electrodes X, Y and an address electrode A correspond to a unit light emitting region EU of matrix display, and is classified according to the arrangement form of phosphors. Surface discharge type P called reflective type
It is 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 provided by a dielectric layer 17 for AC driving that uses wall charges to maintain discharge. Coated for 30. On the surface of the dielectric layer 17, a protective film of MgO having a thickness of about several thousand liters is used.
A membrane 18 is provided.

Since the display electrodes X and Y are disposed on the display surface H side with respect to the discharge space 30, the surface discharge is made wide and the shielding of the display light is minimized. The transparent conductive film 41 has a wide width and the bus metal film 42 has a narrow width to supplement the conductivity.

On the other hand, the address electrode A for selectively emitting light in the unit light emitting region EU is provided with the glass substrate 21 on the back side.
The display electrodes X and Y are arranged on the upper side at a constant pitch.

Between each address electrode A, 100 to 15
Stripe-shaped barrier ribs 29 having a height of about 0 μm are provided, whereby the discharge spaces 30 are divided into unit light emitting regions EU in the line direction (extension direction of the display electrodes X and Y), and the discharge spaces 30 are formed. The gap size is specified. Further, the glass substrate 21 covers the inner surface on the back surface side including the upper surface of the address electrode A and the side surface of the partition 29,
Phosphors 28 of three primary colors of R (red), G (green) and B (blue) are provided. The alphabets R, G, and B in the figure indicate the emission colors of the phosphors 28. The phosphor 28 is excited by the ultraviolet rays emitted by the discharge gas in the discharge space 30 during surface discharge to emit light.

Each pixel (dot) EG constituting the display screen
Are associated with three unit light emitting regions EU having the same area and 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 are defined.
And define address discharge cells for selecting display or non-display. As a result, among the phosphors 28 that are continuous in the extension direction of the address electrode A, each unit light emitting area EU
The portion corresponding to can be selectively made to emit light, and R,
Full-color display is possible by combining G and B.

In the PDP 10 having the above-mentioned structure, the glass substrate 11 and the glass substrate 11 are provided with predetermined constituent elements separately,
It is manufactured by a series of steps in which the glass substrates 11 and 21 are arranged opposite to each other to seal the periphery of the gap, and exhaust the inside and fill the discharge gas.

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

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

[0012]

In pattern printing by the screen printing method, it is difficult to reduce the width and array pitch of the partition walls 29, and it is not possible to expect high definition of the display. Further, when trying to increase the size of the display surface H, it becomes impossible to make the positional relationship between the partition walls 29 and the address electrodes A uniform over the entire display surface H due to the contraction of the screen mask or the like. Further, in order to obtain the barrier ribs 29 having a predetermined height, it is necessary to perform overprinting (paste lamination) about ten times, and the shape is likely to be lost during printing and firing, which may cause a discharge problem.

Therefore, it is conceivable to provide a low melting point glass layer (so-called solid film) that uniformly covers the glass substrate 21 and partially cut it using the sandblast method to form the partition wall 29. In that case, the glass paste may be evenly applied and fired before cutting.
Then, the cutting rate becomes too large, and it becomes difficult to control the cutting time. That is, it is advantageous to cut the low-melting-point glass layer in the paste state before firing to achieve proper cutting.

However, in the cutting of the glass paste layer, if the content and type (material) of the binder are selected so as to increase the cutting rate, the adhesiveness between the cutting mask made of the photosensitive resist material and the glass paste layer is lowered. However, if the content or type of the binder is selected so that the partition wall having a predetermined shape cannot be obtained due to peeling of the cutting mask and the adhesiveness is increased, there is a problem that the cutting rate becomes small.

As the cutting rate becomes smaller, the machining time becomes longer and the productivity is lowered. If the blast pressure is increased in order to avoid it, the cutting in the surface direction will be promoted, resulting in a great improvement in precision. I can't hope.

The present invention has been made in view of the above problems, and an object thereof is to easily manufacture a high-definition and large-sized plasma display panel having partition walls of uniform shape. Further, the inventions of claims 4 and 6 also aim to increase the brightness of the display and improve the contrast.

[0017]

In order to solve the above-mentioned problems, the manufacturing method according to the invention of claim 1 is a plasma display panel 1 having partition walls 29 for partitioning a discharge space 30, as shown in FIG. At the time of manufacturing, the first glass paste P1 and the second glass paste P2 having a binder content higher than that of the first glass paste P1 are sequentially applied on the substrate 21 to form the partition wall forming glass paste layer 29a. A step of forming a cutting mask 61 on the glass paste layer 29a by pattern exposure of a photosensitive resist material, a step of partially cutting the glass paste layer 29a by a sandblast method, and a step of cutting the glass paste layer 29a. And a step of forming the partition wall 29 by firing the glass paste layer 29a.

The manufacturing method according to the invention of claim 2 is the substrate 2
A step of applying first and second glass pastes P1 and P2 having different kinds of binders in order on 1 to form a glass paste layer 29a for forming partition walls having a multi-layer structure, and a pattern exposure of a photosensitive resist material. A step of forming a cutting mask 61 on the glass paste layer 29a, a step of partially cutting the glass paste layer 29a by a sandblast method, and a step of firing the glass paste layer 29a after cutting to form the partition 29. And a step of forming.

In the manufacturing method according to the third aspect of the present invention, the binder of the first glass paste P1 is an ethylcellulose-based organic material, and the binder of the second glass paste P2 is an acrylic-based organic material.

In the manufacturing method according to the invention of claim 4, a bright color pigment is added to the first glass paste P1, and the second glass paste P1 is added.
A dark pigment is added to the glass paste P2. In the manufacturing method according to the invention of claim 5, after applying the first glass paste P1 and before applying the second glass paste P2, a third glass paste for enhancing the adhesiveness between the pastes. The step of applying P3 is provided.

In the PDP according to the sixth aspect of the present invention, the barrier ribs 29 partitioning the discharge space 30 occupy most of them, the light-colored lower glass layer 291, the dark-colored top glass layer 292, and the bonding strength between them are enhanced. And an intermediate glass layer 293 for

[0022]

The partition 29 is formed by applying a glass paste, which is a mixture of glass frit and a binder, to a predetermined thickness, providing a cutting mask 61, partially cutting it by a sandblast method, and then firing it. .

At this time, as shown in FIGS. 3 (a) and 3 (b), the smaller the content of the binder in the glass paste, the higher the cutting rate, but on the other hand, the adhesion to the cutting mask 61 ( Peel strength) decreases. Therefore, if the glass paste having a small content of the binder is applied relatively thickly and then the glass paste having the large content of the binder is applied thinly, the cutting rate is large as a whole,
Moreover, it is possible to obtain the partition-forming glass paste layer 29a having good adhesion to the cutting mask 61. That is, the partition 29 can be efficiently formed while preventing the mask peeling during cutting.

[0024]

1 is a sectional view showing a structure of a main part of a PDP 1 according to the present invention, FIG. 2 is a sectional view showing each state of a manufacturing stage of the PDP 1 of FIG. 1, and FIGS. 3 (a) and 3 (b) are It is a graph which shows the 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 the 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 overlapping the transparent conductive film 41, a dielectric layer 17 covering the display electrodes X and Y, a MgO film 18, a glass substrate 21 on the back side, a display electrode X, Address electrode A orthogonal to Y, discharge space 30
It is composed of a stripe-shaped partition wall 29 that defines the gap size 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 into unit light emitting regions 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 wall 2
The arrangement pitch of 9) is about 150 μm.

As shown in FIG. 2, when the PDP 1 is manufactured on the glass substrate 21 side, the thickness is 5 to 30 μm by the thick film method.
After forming the address electrode A having a thickness of about the same, the partition 29 is formed by the following procedure.

First, the 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,
Then, the second low melting point glass paste P2 is added to 10 to 40 μm
It is applied to a thickness of about m to form a glass paste layer 29a having a two-layer structure (the upper layer has a thickness of about 5 to 20% of the whole) whose lower layer is sufficiently thicker than the upper layer [FIG. 2 (a)]. .

At this time, the first low melting point glass paste P
As No. 1, a binder is used, for example, an ethyl cellulose-based organic substance, and a paste having a content of about 0.8 to 1.2 wt% is used. On the other hand, as the second low-melting glass paste P2, the binder is the same ethyl cellulose-based organic material as the first low-melting glass paste P1, but the content thereof is larger than that of the first low-melting glass paste P1. About 5 to 2.0 wt% of the paste, or the binder is an acrylic organic substance, and the content is 2.0 to
A paste of about 3.0 wt% is used.

As a method of applying each paste P1 and P2, a screen printing method, a bar coater method, an applicator method or the like can be used. Even if an organic solvent is mixed with the paste to facilitate the application. Good. When the screen printing method is used, it is necessary to perform overprinting several times especially when applying the paste P1, but it is easy to make the thickness of the glass paste layer 29a uniform.

Next, a dry film-shaped negative type photosensitive resist material having a thickness of about 30 to 50 μm is applied to the glass paste layer 2 at a temperature of about 80 to 100 ° C. using a laminator.
The surface of 9a is pressure-bonded, and pattern exposure and development processing are performed to form a stripe-shaped 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 is formed by using a laminator.
Can be easily obtained. Further, by using the negative resist material, the cutting mask 61 having a large elastic modulus and excellent durability can be obtained.

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

Generally, the glass paste is brittle and the cutting rate is large as the content of the binder is small. However, as shown in FIG. 3 (a), in the paste composed of the ethicellulose binder, the peel strength representing the adhesiveness with the cutting mask 61 is significantly reduced as the content of the binder is decreased, and The mask peeling is likely to occur.

Further, as shown in FIG. 3B, in the paste made of an acrylic binder, the degree of decrease in peel strength is relatively small even if the content of the binder is reduced and the cutting rate is increased. That is, the acrylic binder is superior to the ethicellulose binder in terms of adhesion to the cutting mask 61. However, in terms of cutting rate, the ethicellulose binder is more advantageous than the acrylic binder.

By the way, the glass paste layer 29a, which is the object of cutting in this embodiment, is 80 to 9 as described above.
Most of the lower side occupying 5% is made of the first glass paste P1 having a relatively small binder content, and the cutting mask 61
Since the surface layer portion in contact with is made of the second glass paste P2 having a large binder content, the layer has a high cutting rate as a whole and good adhesion with the cutting mask 61. In particular, when the binder of the second glass paste P2 is made of an acrylic type, the adhesiveness is further enhanced as compared with the case where it is made of an ethyl cellulose type. Therefore, mask peeling does not occur during cutting, and it is possible to remove unnecessary glass paste with good yield and in a short time.

When the cutting by the sand blasting is completed, the glass paste layer 29a after patterning is formed into 5 layers.
Baking is performed at a temperature of about 50 to 580 ° C. This gives 1
The partition wall 29 having a thickness of about 00 to 150 μm is obtained. Since the binder is diffused from the glass paste layer 29a during firing, the first and second low melting point glass pastes P1, P
If the composition excluding the binder in 2 is the same, the partition wall 2
9 is a homogeneous low melting point glass layer.

After the partition 29 is formed,
The PDP 1 is completed by providing the phosphors 28 between the partition walls 29, and stacking the glass substrate 21 and the glass substrate 11 on which the display electrodes X and Y are separately provided.

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

In FIG. 4, PDP 1b is a surface discharge type PDP having a reflection type three-electrode structure.
The structural difference from the PDP 1 is that the partition wall 29 is colored. That is, the partition 29 of the PDP 1b
Is composed of a light-colored (highly light-colored) lower glass layer 291, which occupies most of it, a dark-colored top glass layer 292, and a transparent intermediate glass layer 293 sandwiched therebetween. The lower glass layer 291 has a thickness of 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 fluorescent substance 28, and by making it a bright color, the reflectance of light is increased, so that the brightness of the display can be increased.
The top glass layer 292 is a portion facing the display surface H,
By making this a dark color, the display contrast can be enhanced. 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, in forming the partition 29, first, a low melting point obtained by adding, for example, a white pigment (titanium oxide, aluminum oxide, magnesium oxide, etc.) to the glass substrate 21 on the back side on which the address electrode A is 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 the screen printing method is used as the 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 improved.

Next, on the low melting point glass paste P1,
For example, an uncolored low melting point glass paste P3 to which no pigment is added is thinly applied, and then a low melting point glass paste P2 to which a dark color pigment (iron oxide, cobalt oxide, etc.) is added is applied to a predetermined thickness. The kind and content of the binder of the low melting point 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 the cutting in the subsequent process, and can be selected similarly to the low-melting glass paste P1, for example.

As described above, three kinds of low melting point glass pastes P
1, P3, P2 are applied in this order to provide 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 is provided and the glass paste layer 2 is formed by the sandblast method.
9a is partially cut. At this time, the difference in the filler hardly affects the machinability. That is, if the binder of the paste is properly selected, the machinability can be optimized irrespective of the coloring, and like the example of FIG. 2, masking is prevented and the glass paste layer 29a is efficiently patterned. can do.

Then, the glass paste layer 29a after cutting
Is fired to complete the formation of the partition 29. At the time of this firing, the low melting point glass paste P3 plays a role of enhancing the adhesion between the low melting point glass paste P1 and the low melting point glass paste P2. That is, the binder disappears by firing, the low melting point glass paste P1 becomes the lower glass layer 291, and the low melting point glass paste P2 becomes the top glass layer 292.
Then, there is a slight difference in expansion coefficient and softening point due to the difference in pigment type. Such a difference in physical properties causes peeling between the lower glass layer 291 and the top glass layer 292 and a decrease in adhesion strength. However, by interposing the low melting point glass paste P3, the adjacent glass layers 291 and The difference in characteristics becomes small, and peeling and reduction in adhesion strength can be suppressed.

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

According to the present invention, a transmissive surface discharge type PDP in which a phosphor 28 is arranged 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 display brightness and improve the contrast. Claim 6
According to the invention, the mechanical strength of the partition wall can be increased.

[Brief description of 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 manufacturing process of the PDP of FIG.

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

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

FIG. 5 is a cross-sectional view showing a state of manufacturing the PDP of FIG.

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

[Explanation of symbols]

 1, 1b PDP (Plasma Display Panel) 21 Glass Substrate (Substrate) 29 Partition 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

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masafumi Tianjin 1015 Kamiodanaka, Nakahara-ku, Kawasaki-shi, Kanagawa Fujitsu Limited

Claims (6)

[Claims] 1. A partition wall (29) defining a discharge space (30).
A method for manufacturing a plasma display panel (1) having: a first glass paste (P1) on a substrate (21);
A step of sequentially applying a second glass paste (P2) having a higher binder content than that to form a glass paste layer (29a) for forming barrier ribs having a multi-layer structure, and pattern exposure of a photosensitive resist material A step of forming a cutting mask (61) on the glass paste layer (29a) by a sandblasting method, and the glass paste layer (2) by a sandblast method.
9a) is partially cut, and the glass paste layer (29a) after cutting is fired to form the barrier ribs (29). 2. A partition wall (29) defining a discharge space (30).
A method of manufacturing a plasma display panel (1) having a plurality of layers, wherein a substrate (21) is coated with first and second glass pastes (P1) and (P2) having different types of binders in order, A step of forming a glass paste layer (29a) for forming partition walls, a step of forming a cutting mask (61) on the glass paste layer (29a) by pattern exposure of a photosensitive resist material, and a sandblast method. , The glass paste layer (2
9a) is partially cut, and the glass paste layer (29a) after cutting is fired to form the barrier ribs (29). 3. The binder of the first glass paste (P1) is an ethylcellulose-based organic material, and the binder of the second glass paste (P2) is an acrylic-based organic material. Of manufacturing plasma display panel of. 4. The first glass paste (P1) contains a light-colored pigment, and the second glass paste (P2) contains a dark-colored pigment. 4. The method for manufacturing a plasma display panel according to any one of 3 above. 5. A third glass paste (P3) for increasing the adhesion between the pastes after applying the first glass paste (P1) and before applying the second glass paste (P2). ) Is applied, The manufacturing method of the plasma display panel of Claim 4 characterized by the above-mentioned. 6. A discharge space (3) is provided on a rear substrate (21).
0) is a plasma display panel (1) having a partition wall (29), wherein the partition wall (29) comprises a light lower glass layer (291) occupying most of the partition and a dark top glass layer (). 292),
An intermediate glass layer (29
3) A plasma display panel comprising: