JPH0822018A - Production of large-sized plane image forming device - Google Patents

Abstract

PURPOSE:To provide a process for producing a large-sized plane image forming device which has good reproducibility and is capable of making large-area display at a high yield. CONSTITUTION:An insulating substrate 2 is installed onto an auxiliary member 1 not formed with element forming elements 3 and the ends on at least one side of this auxiliary member 1 are formed higher by as much as the thickness of this insulating substrate 2 than the other parts, by which the front surface at the ends formed higher than the other parts of the auxiliary member 1 and the front surface of the insulating substrate 2 are made flat in the process for producing the image forming device for forming the element forming elements 3 on the insulating substrate 2. In addition, the ends formed higher than the other ends of the auxiliary member 1 and the ends on at least one side of the insulating substrate 2 are butted against each other. The central part of the part where the auxiliary member 1 and the insulating substrate 2 are aligned when the insulating substrate 2 is installed on the auxiliary member 1 and the central part of the element forming elements 3 are aligned. The element forming elements 3 are formed up to the ends on at least one side of the insulating substrate 2 butted against the ends of the auxiliary member 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a large-sized flat image forming apparatus, and more particularly to a method of manufacturing a large-sized flat image forming apparatus which enables a large-sized display by combining small panels which can be easily manufactured.

[0002]

2. Description of the Related Art Conventional flat image forming apparatuses include, for example, a gas discharge panel and a liquid crystal display panel known as a plasma display panel. As a manufacturing method thereof, a method of arranging an element forming element such as an electrode wiring in the central portion of a substrate having the same size as the panel size, and a method of arranging the element forming element in the central portion and cutting the substrate as shown in FIG. A method of connecting large substrates to form a large panel is known.

FIG. 6 is a diagram showing an example of a conventional method for manufacturing a large-sized flat image forming apparatus. FIG. 6A shows a state in which element forming elements are arranged and formed near the center of the substrate.
6B shows a state in which the ends of the substrate are cut and shaped, and FIG. 6C shows a state in which a plurality of substrates are connected and combined to form a large-sized panel.

[0004]

However, the above-mentioned conventional example has the following drawbacks.

In the case of the method of arranging the element forming element and the like in the center of the substrate having the same size as the panel size, it is not easy to make a large glass substrate into a completely uniform plane. Therefore, there is a problem that the manufacturing yield of the large-sized flat image forming apparatus is low and the cost is significantly higher than that of the small-sized flat image forming apparatus.

Also in the method of manufacturing a large-sized flat image forming apparatus by combining the small-sized flat image forming apparatus as shown in FIG. 6, when the end of the substrate where the element forming element is not formed is cut. Chips, cracks and the like are likely to occur, and the required accuracy of alignment when combining substrates is increased. Therefore, there are problems such as low yield and poor reproducibility.

Further, when the element forming elements and the like are formed up to the end portion of the substrate in advance without using the auxiliary member, the wire of the screen mask as the plate is cut or the mask is peeled off by the edge of the substrate when formed by the printing technique. In some cases, the yield was low. Further, when the element forming elements and the like are formed up to the end portion of the substrate by the photolithography technique, the resist or the like near the edge of the substrate rises, and it is difficult to form a uniform pattern.

Therefore, the present invention has been made in view of the above problems.
An object of the present invention is to provide a manufacturing method of a large-sized flat image forming apparatus which has a high yield, good reproducibility, and can display a large area.

[0009]

In order to achieve the above object, a method of manufacturing a large-sized flat image forming apparatus of the present invention is a method of manufacturing an image forming apparatus in which element forming elements are formed on an insulating substrate. Specifically, the insulating substrate is previously installed on an auxiliary member on which the element forming element is not formed,
At least one side end of the auxiliary member is formed higher than the other portion by the thickness of the insulating substrate, and the upper surface of the end formed higher than the other portion of the auxiliary member and the insulating substrate. When the upper surface is made flat and the end portion formed higher than the other portion of the auxiliary member is abutted with the end portion of at least one side of the insulating substrate, and the insulating substrate is placed on the auxiliary member. At least the insulating substrate in which the central portion of the portion where the auxiliary member and the insulating substrate are combined is aligned with the central portion of the element forming element, and the element forming element is abutted with the end portion of the auxiliary member. It is formed up to the end of one side.

In particular, when the element forming element is formed by a technique such as printing, the central portion of the element forming element is aligned with the central portion of the print effective area of the printing screen mask.

Further, in the method for manufacturing a large-sized flat image forming apparatus according to the present invention, when the element forming element is formed on the insulating substrate, a connection portion in which an alignment marker is brought into contact with the insulating substrate and the auxiliary member. It is possible to bond the plurality of insulating substrates by aligning the alignment marker on the side of the insulating substrate.

Further, in the method for manufacturing a large-sized flat image forming apparatus according to the present invention, a plurality of the insulating substrates having the element forming elements are planarly bonded on a common rear surface laminating plate to have a desired area. Display panel can be configured.

[0013]

[Action]

(1) An insulative substrate is placed on an auxiliary member, and at least one end of the insulative substrate is abutted with an end formed higher than the other portions of the auxiliary member, so that the element forming element of the auxiliary member is formed. Since the insulating substrate is formed up to the end of at least one side of the insulating substrate that abuts against the end, it is possible to connect a plurality of insulating substrates without cutting the end of the insulating substrate on which the element forming element and the alignment marker are formed. In addition, it is possible to manufacture a large flat image forming apparatus which has a high yield, good reproducibility, and can display a large area.

(2) Since the alignment marker is formed in the connection portion where the insulating substrate and the auxiliary member are butted to each other, and the plurality of insulating substrates are joined by aligning the alignment marker on the insulating substrate side, the insulating substrate is It is possible to manufacture a large-sized flat image forming apparatus that can be easily and accurately joined, has a high yield, has good reproducibility, and can display a large area.

(3) Since a plurality of insulating substrates on which element forming elements are formed are planarly bonded on a common back surface laminating plate to form a display panel having a desired area, the yield is high and the reproducibility is high. It is possible to manufacture a large-sized flat image forming apparatus capable of displaying a large area.

[0016]

The present invention will be described in detail below with reference to the first and second embodiments.

First, the first embodiment will be described. FIG. 1 shows a first method of manufacturing a large-sized flat image forming apparatus according to the present invention.
It is a figure showing an example. FIG. 1A is a cross-sectional view of a soda-lime glass auxiliary member 1, and FIG. 1B is a front view and a cross-section of a soda-lime glass auxiliary member 1 on which a soda-lime glass substrate 2a is installed. FIG. 1C is a front view of the state in which the substrate 2 is connected.

After the blue plate glass substrate 2a is placed on the blue plate glass auxiliary member 1 shown in FIG. 1 (a) so that the upper surface is flat as shown in FIG. 1 (b), the substrate is formed by a printing technique. 2a, the element forming element 3a and the substrates 2a, 2
A circular alignment marker 9a for alignment when joining b, 2c, and 2d is formed. The alignment marker 9a is formed at one position on each side of the connecting portion between the auxiliary member 1 and the substrate 2a, and is formed in a semicircular position. At this time, the center of the effective area 6 of the screen mask for printing, the center of the element forming element 3a, and the center of the auxiliary member 1 are substantially aligned with each other. Similarly, the element forming elements 3b, 3c, 3d and the alignment markers 9b, 9c, 9d are respectively attached to the substrates 2b, 2c, 2 respectively.
formed on d.

Thereafter, as shown in FIG. 1 (c), the semi-circular alignment markers 9a, 9b,
A gas discharge (plasma) type image forming apparatus is manufactured by aligning 9c and 9d so as to form a circular shape and joining the substrates 2a, 2b, 2c and 2d.

However, in the present invention, the auxiliary member is not limited to soda lime glass, but any structural material can be used as long as the heights of the upper surface of the substrate and the upper surface of the auxiliary member are the same, such as ceramics and quartz, and the auxiliary member can be applied. Can be used without particular limitation. The substrate is not limited to soda lime glass, but may be any insulating material such as ceramics and quartz.

Further, although the printing technique is used as the method for forming the element forming element, it may be a photolithography technique, a vacuum thin film forming technique, an etching technique or the like.

The present invention is applicable not only to a gas discharge (plasma) type planar image forming apparatus (PDP) but also to a fluorescent display tube (VF).
D), an image device that is a surface conduction electron-emitting device (SCE type), and a method for manufacturing the same.

The joining method of the present invention is not limited to the joining of panels divided into four, but can be applied to the joining of panels divided into two, three or five or more.

Next, a second embodiment of the present invention will be described. 2 and 3 are views showing a second embodiment of the method of manufacturing a large-sized flat image forming apparatus of the present invention, which is an image forming apparatus using a surface conduction electron-emitting device formed on a matrix wiring as an element forming element. is there. FIG. 2A is a diagram showing one of the four divided substrates, and FIG. 2B is an overall view of the substrate. 3 (a) is an enlarged view of the central portion of FIG. 2 (b), and FIG. 3 (b) is a sectional view of FIG. 2 (b).

First, the substrate 12a made of insulating soda lime glass
Are placed on the auxiliary member 11a made of insulating soda lime glass of the same material, and then Ag is sequentially printed on the substrate 12a by a printing technique.
A circular alignment marker 35 is formed on the connecting portion 4a between the substrate 12a and the auxiliary member 11a by forming the conductor X-direction wiring 13.
a is formed to have a thickness of 10 μm, the interlayer insulating film layer 14 made of glass paste is formed to have a thickness of 30 μm on the substrate 12a, the Y-direction wiring 15 of Ag conductor is formed to have a thickness of 10 μm on the substrate 12a, and XY-direction matrix wiring is formed. To do. At this time, the central portion of the matrix wiring region is located at the auxiliary member 11
a and the substrate 12a installed thereon are made to substantially coincide with the central portion when regarded as one body.

Next, the Ni element electrode 16 having a film thickness of 1000 Å
Are formed by a photolithography method and a vacuum deposition method in a pattern of electrode intervals of 2 μm, and a fine particle electron emission portion 17 made of Pd is formed to form an element forming element 18a.
Here, the distance from the edge of the soda lime glass substrate 12 on the side of the substrate connection portion 34 to the particle electron emission portion 17 in FIG. 3A is about 1 mm, and the edge of the soda lime glass substrate 12 on the alignment side. To the matrix wiring are each about 5 mm.

Similarly, the element forming elements 18b, 18
c, 18d, and alignment markers 35b, 35
c, 35d are formed on the substrates 12b, 12c, 12d.

After that, the substrates 12a, 12b, 12c, 1
2d is provided with a board connecting portion 34, and on the back side laminating plate 25, alignment markers 35a, 35b, 35c, 35 are provided.
Align so that d is circular, and glue 2
Join by 6. Further, through the frame member 23 installed on the substrate 12 by the frame member connecting portion 22, it is integrated with the face plate 20 on which the light emitting body 19 is formed to form an image forming element 24. The drive processing circuit 21 is connected to the matrix wiring portion.

In the first and second embodiments, the shape of the alignment marker has been described above as a circle, but the shape is not limited to a circle (including an ellipse), but may be a multiple circle (including an ellipse) or a polygon. good. Also, set the alignment marker to X
Although formed when the direction wiring 13 was formed, the interlayer insulating film layer 1
4, the Y-direction wiring 15 and the Ni element electrode 16 may be formed when any one of them is formed. Furthermore, the alignment marker may be formed at a position not in contact with the element forming element, may be at the center of the substrate connecting portion 34, or may be provided at a plurality of positions for one side alignment.

FIGS. 4 and 5 are views showing another embodiment of the auxiliary member in the method of manufacturing the large-sized flat image forming apparatus of the present invention. 4A is a front view, FIG. 4B is a sectional view taken along line AA ′, FIG. 5A is a front view, and FIG. 5B is a sectional view taken along line BB ′. When the auxiliary member has these shapes, the element forming element can be formed up to the end portions of the four sides of the substrate in FIG. 4 and up to the end portions of the three sides of the substrate in FIG. For this reason,
As compared with the auxiliary member described in the first and second embodiments of the present invention, the element forming element can be formed in a wider area on the substrate.

[0031]

As described above, the present invention has the effects described below.

(1) An insulating substrate is placed on the auxiliary member,
An end of at least one side of the insulative substrate in which the element forming element is in contact with the end of the auxiliary member by abutting the end of at least one side of the insulative substrate and the end formed higher than the other portion of the auxiliary member. By forming up to the part, it is possible to connect a plurality of insulating substrates without cutting the end of the insulating substrate on which the element forming element and the alignment marker are formed,
There is no wire breakage of the screen mask or damage to the mask, and there is no damage to the substrate due to chipping, cracking, etc.
There is an effect that it is possible to manufacture a large-scale flat image forming apparatus which has a high yield, good reproducibility, and can display a large area.

(2) An insulating substrate is formed by forming an alignment marker at a connecting portion where an insulating substrate and an auxiliary member are butted against each other, aligning the alignment marker on the insulating substrate side, and joining a plurality of insulating substrates. Can be easily joined with high precision, yield is high, reproducibility is good, and a large-scale flat image forming apparatus capable of displaying a large area can be manufactured.

(3) A plurality of insulating substrates having element forming elements are planarly bonded on a common rear surface laminating plate to form a display panel having a desired area, so that the yield is high and reproduction is possible. It is possible to manufacture a large-sized flat image forming apparatus which has good properties and can display a large area.

[Brief description of drawings]

FIG. 1 is a diagram showing a first embodiment of a method for manufacturing a large-sized flat image forming apparatus of the present invention.

FIG. 2 is a diagram showing a second embodiment of a method for manufacturing a large-sized flat image forming apparatus of the present invention.

FIG. 3 is a diagram showing a second embodiment of a method for manufacturing a large-sized flat image forming apparatus of the present invention.

FIG. 4 is a diagram showing another embodiment of the auxiliary member in the manufacturing method of the large-sized flat image forming apparatus of the present invention.

FIG. 5 is a diagram showing another embodiment of the auxiliary member in the method of manufacturing a large-sized flat image forming apparatus of the present invention.

FIG. 6 is a diagram showing an example of a method for manufacturing a conventional large-scale flat image forming apparatus.

[Explanation of symbols]

 1, 11a Auxiliary member 2, 12 Substrate 3, 18 Element forming element 4 Connection part between substrate and auxiliary member 6 Effective area of screen mask 7 Joining member 9, 35 Alignment marker 13 X-direction wiring 14 Inter-layer insulating film layer 15 Y direction Wiring 16 Ni Element electrode 17 Particulate electron emission section 19 Light emitter 20 Face plate 21 Drive processing circuit 22 Frame member connecting section 23 Frame member 24 Image forming element 25 Backside bonding plate 26 Adhesive 34 Board connecting section

Claims (3)

[Claims] 1. A method of manufacturing an image forming apparatus for forming an element forming element on an insulating substrate, wherein the insulating substrate is placed on an auxiliary member on which the element forming element is not formed, and at least one side of the auxiliary member is provided. The end portion is formed higher than the other portion by the thickness of the insulating substrate, and the upper surface of the end portion formed higher than the other portion of the auxiliary member and the upper surface of the insulating substrate are made flat, and When the insulating substrate is placed on the auxiliary member, the insulating member and the insulating member are insulated from each other by abutting an end portion formed higher than the other portion of the auxiliary member and an end portion of at least one side of the insulating substrate. The central portion of the portion where the substrate is combined with the central portion of the element forming element are aligned with each other, and the element forming element is formed up to at least one side edge of the insulating substrate that is abutted against the end portion of the auxiliary member. Large size, characterized by Method for manufacturing a surface image forming apparatus. 2. When forming the element forming element on the insulating substrate, an alignment marker is formed at a connecting portion where the insulating substrate and the auxiliary member are abutted, and the alignment marker on the side of the insulating substrate. The method for manufacturing a large-sized flat image forming apparatus according to claim 1, wherein the plurality of insulating substrates are bonded by aligning the two. 3. The display panel having a desired area is formed by planarly bonding a plurality of the insulating substrates having the element forming elements on a common back surface laminating plate. A method for manufacturing the large-sized flat image forming apparatus described.