JPH08273538A - Manufacture of cell barrier for plasma display panel - Google Patents

Abstract

PURPOSE: To manufacture a cell barrier of a certain shape accurately, easily, quickly and stably. CONSTITUTION: Ionization-radiation setting resin is packed into the depressed portions of a roll intaglio having a plate surface that matches the shape of a cell barrier portion 1, and a film base is contacted with the roll intaglio, during which the ionization radiation setting resin is set by application of ionizing radiation to form an ionizing radiation setting resin layer; thereafter, the ionization radiation setting resin layer is peeled from the roll intaglio, together with the film base, to obtain a type sheet having sheet depressions which constitute unevenness that is the reverse of the cell barrier portion. Glass paste 8 is applied to the surface of a glass substrate 10. After a shape-imparting sheet 2 is pressed into contact with the glass substrate to which the glass paste was applied, the shape-imparting sheet is peeled and the glass paste is molded into a cell barrier shape. The glass paste molded is baked.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a cell barrier of a plasma display panel (hereinafter referred to as PDP) having a plurality of discharge spaces formed by the cell barrier.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing a cell barrier of a PDP, a method of patterning a glass paste on a glass substrate by a screen printing method and then firing the glass paste has been used. In order to obtain it, printing and drying are carried out, for example, by repeating dozens of times, and then laminated and then fired. In addition, in order to improve the accuracy of the barrier shape, a method of providing a new oil-based polymer layer on a portion of the glass substrate where the cell barrier is provided (Japanese Patent Laid-Open No. Hei 5-
No. 166460) has been proposed.

[0003]

However, in the above-described conventional manufacturing method, the manufacturing apparatus is not special and the steps are easy, but the number of steps is large, and the shape of the cell barrier formed by screen printing is fired. The shape accuracy tends to deteriorate as the number of times printing is repeated increases, and there is a problem in that it is inferior in sophistication. As a result, there is a problem in that it is difficult to obtain a high-definition image as the performance of the display panel.

Therefore, the present invention aims to solve the above-mentioned drawbacks of the prior art, and to provide a new manufacturing method capable of manufacturing a cell barrier with higher accuracy simply, quickly and stably. To aim.

[0005]

In order to achieve the above object, a method of manufacturing a cell barrier of a plasma display panel according to the present invention comprises a front plate and a back plate having cell barriers forming a plurality of discharge spaces. A method of manufacturing a cell barrier of a plasma display panel in which the cells are arranged so as to face each other in parallel is constituted by the following (A) to (D). (A) using a roll intaglio having a plate indentation corresponding to the shape of the cell barrier portion, at least the plate indentation of the roll intaglio is filled with an ionizing radiation curable resin, the film substrate is contacted with the roll intaglio, contact The ionizing radiation curable resin that is present between the film base material and the roll intaglio is cured to form an ionizing radiation curable resin layer while A step of manufacturing a shaped sheet, in which a resin layer is peeled off together with a film base material from a plate concave portion to obtain a shaped sheet having a cell concave portion and a concave portion of a sheet having an uneven shape. (B) A coating step of coating the glass paste on the surface of the glass substrate. (C) A molding step in which the shaping sheet is pressed against the glass substrate coated with the glass paste, the shaping sheet is peeled off, and the glass paste on the surface of the glass substrate is shaped into a cell barrier shape. (D) A firing step of firing the formed glass paste.

Hereinafter, a method of manufacturing a cell barrier of a plasma display panel according to the present invention will be described in detail with reference to the drawings.

The manufacturing method of the present invention is as follows.
A shaped sheet having an uneven shape opposite to the shape of the cell barrier portion is manufactured. The shaped sheet is a mold having an ionizing radiation curable resin layer having a sheet recess formed on a film substrate, and the sheet recess having a shape opposite to the PDP cell barrier section shape.

FIG. 3 is a conceptual diagram showing an example of an apparatus for manufacturing the shaped sheet. The roll intaglio 4 has a plate recess 41 having a shape corresponding to a cell barrier portion composed of a large number of cell barriers,
It is rotating in the direction of the arrow. There, the film base material 21 is appropriately supplied by a transfer means, pressed against the roll intaglio by the pressing pressure roll 51, and synchronously conveyed in contact with the roll intaglio, and separated from the roll intaglio by the peeling roll 52 and conveyed. To be done. It is possible to adjust the clearance between the pressing roll and the peeling roll with the intaglio roll.

Such roll intaglio 4 and film substrate 2
1, the ionizing radiation curable resin 3 is supplied by an appropriate means so as to fill at least the plate recess 41 of the roll intaglio. In the figure, the ionizing radiation curable resin is directly supplied to the roll intaglio by the coating device 6 from below the roll intaglio. Then, the film base material is brought into contact with the roll intaglio plate, and the ionizing radiation curable resin on the film base material and the roll intaglio plate is sandwiched between the film base material and the roll intaglio plate by the ionizing radiation irradiation device 7 and the film base material side. To irradiate ionizing radiation to cure the ionizing radiation curable resin interposed between the film base material and the roll intaglio. When the ionizing radiation curable resin is cured, it becomes the ionizing radiation curable resin layer 22 that is fixed to the film base material. Next, when the film substrate is peeled from the roll intaglio by a peeling roll, the ionizing radiation curable resin layer is peeled together with the film substrate, and the ionizing radiation curable resin layer has a shape other than the cell barrier portion (discharge space). The shaped sheet 2 in which the sheet recessed portion 23 formed by the ionizing radiation curable resin layer has the shape of the cell barrier portion is obtained.

Here, the relationship between the intended cell barrier shape and the shapes of the sheet recess of the shaping sheet and the plate recess of the roll intaglio will be described. In FIG. 2, (a) shows the roll intaglio 4 and its plate recess 41, (b) shows the shaped sheet 2 obtained from the roll intaglio of (a) and its sheet recess 23, and (c) shows (b).
1 shows a cell barrier 1 obtained from the shaped sheet of FIG. The roll intaglio plate has a plate recess corresponding to the shape of the cell barrier. That is, if the plate recess 41 of the roll intaglio 4 is intuitively a recessed part and has a recessed space, the plate recessed part has the same shape as the part other than the cell barrier part (discharge space), and conversely, The part (projection) other than the plate recess has the same shape as the cell barrier part. On the other hand, in the shaped sheet 2, the recessed space of the seat recessed portion 23 has the same shape as the cell barrier portion. Although it is possible to make a die sheet from a planographic intaglio plate, the roll intaglio plate surface is flattened in FIG. 2A for convenience of explanation.

The above-mentioned film base 2 may be a film which is flexible and transparent to ionizing radiation. For example, a film made of a resin such as polyester such as polyethylene terephthalate and polyethylene naphthalate, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyamide, polyimide, polystyrene, ethylene-ethylene acetate copolymer, polyvinyl alcohol, etc. Can be mentioned. Above all,
Considering the processability, strength, cost, etc., a polyethylene terephthalate film is particularly preferable.

The ionizing radiation curable resin can be supplied and filled by directly supplying it to the roll intaglio by a roll coating method as shown in FIG. 3, or directly from a die such as a T die to the roll intaglio. Before the film base material comes into contact with the roll intaglio, the film base material may be applied and formed in advance by a roll coating method or the like and supplied.

Further, as the ionizing radiation curable resin used in the present invention, a polymer, a prepolymer or a monomer which undergoes a cross-linking polymerization reaction by an ionizing radiation to be solidified is used. Specifically, (meth) acrylamide,
A radical polymerization system composed of a compound having a (meth) acryloyl group such as (meth) acrylonitrile, (meth) acrylic acid, and (meth) acrylic acid ester (where (meth) acryloyl means acryloyl or methacryloyl. The same), epoxy, cyclic ether,
A cationic polymerization system comprising a combination of cyclic acetal, lactone, vinyl monomer, cyclic siloxane and aryl diazonium salt, diaryl iodonium salt, etc., a compound having a thiol group, for example, trimethylolpropane trithioglycolate, trimethylolpropane trithioproto A polyene / thiol system composed of pionate, pentaerythritol tetrathioglycol and a polyene compound can be used.

Examples of the monofunctional monomer of the radical polymerization type (meth) acrylate compound include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, methoxyethyl (meth) acrylate and methoxybutyl (meth). ) Acrylate, butoxyethyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, N, N-dimethylaminomethyl (meth) acrylate, N, N-dimethylaminoethyl (meth) acrylate, N, N-diethylaminoethyl (meth ) Acrylate, N, N-diethylaminopropyl (meth) acrylate, N, N-dibenzylaminoethyl (meth) acrylate, lauryl (meth) acrylate, isophonyl (meth) acrylate, ethylcarbitol (meth) acrylate Relate, phenoxyethyl (meth) acrylate, phenoxypolyethylene glycol (meth) acrylate, tetrahydroxyfurfuryl (meth) acrylate, methoxytripropylene glycol (meth) acrylate, 2- (meth) acryloyloxyethyl-2-hydroxypropyl phthalate, Two
-(Meth) acryloyloxypropyl hydrogen phthalate and the like.

Further, as the radical polymerization type polyfunctional monomer, for example, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate,
Propylene glycol di (meth) acrylate, dipropylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, 1,6-hexyldiol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, Tetraethylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, bisphenol A-di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, pentaerythritol tri (Meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) ac , Glycerin polyethylene oxide tri (meth) acrylate, tris (meth)
Examples thereof include acryloyloxyethyl phosphate.

Examples of radical polymerization prepolymers include (meth) acrylates such as alkyd (meth) acrylates, urethane (meth) acrylates, epoxy (meth) acrylates, polyester (meth) acrylates and polybutadiene (meth) acrylates. ) Acrylates and unsaturated polyesters.

Among these compounds containing a (meth) acryloyl group, a compound containing an acryloyl group, that is, an acrylate has a higher polymerization reaction rate. Therefore, when importance is attached to the production rate of coating and forming the ionizing radiation curable resin layer, acrylate is preferable to methacrylate.

As the radical polymerization type ionizing radiation curable resin, the above compounds may be used alone or in admixture of two or more.

Here, as a photopolymerization initiator in the case of curing by ultraviolet rays, benzoin, benzoin methyl ether, acetophenone, benzophenone, Michler's ketone, diphenyl sulfide, dibenzyl disulfide, diethyl oxide, triphenyl biimidazole, isopropyl-N. , N-dimethylaminobenzoate, etc. may be used alone or in combination in the range of 0.1 to 10 parts by weight with respect to 100 parts by weight of the ionizing radiation curable resin.

Here, ethyl acetate and butyl acetate are used as a solvent for dissolving the ionizing radiation-curable resin in the composition containing the ionizing radiation-curable resin and adjusting the viscosity of the resin to impart coating suitability. 1, esters such as cellosolve acetate, ketones such as acetone, methyl ethyl ketone and ethyl isobutyl ketone, alcohols such as methyl alcohol, ethyl alcohol and isopropyl alcohol 1
It is also possible to use one kind or a mixture of two or more kinds.

The ionizing radiation includes visible light, ultraviolet light,
Electromagnetic waves such as X-rays and electron beams or particle beams are used. Ultraviolet rays or electron beams are mainly used in practice. As the ultraviolet ray source, a light source such as a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a low-pressure mercury lamp, a carbon arc, a black light, and a metal halide lamp is used.

As the electron beam source, various electron beam accelerators such as Cockcroft-Walton type, Van de Graaff type, resonance transformer type, insulating core transformer type, linear type, dynamitron type, high frequency type, etc. are used, and 100 to 1000 keV are used. ,
Preferably, one that irradiates with an electron having an energy of 100 to 300 keV can be used. The irradiation dose is usually 0.5 to 30 Mrad.

As a method of irradiating with ionizing radiation, first, the ionizing radiation-curable resin layer is cured by irradiating it with ultraviolet rays so that at least the surface is dry to the touch, and then completely cured with an electron beam. It is possible.

The shaped sheet obtained as described above is used as a shaping mold, and a glass frit made of PbO or the like, a heat resistant pigment or the like, which is applied onto a glass substrate by an appropriate means, is dispersed in an organic vehicle. The glass paste is pressed against the paste to form a desired cell barrier shape.

As a coating means in the coating step of coating the glass paste on the glass substrate, an extrusion method such as T-die or a method utilizing a gap by a blade (see FIG. 11) can be appropriately used. In FIG. 3A, the glass paste is applied by a T die.

Next, in the step of molding the glass paste, the shaping sheet 2 is pressed against the coated glass paste as shown in FIG. 3 (b) before the solvent of the vehicle of the glass paste dries, and the shaping sheet is formed. The sheet concave portion is filled with the glass paste, and if necessary, the convex surface of the ionizing radiation-curable resin layer of the shaping sheet is brought into contact until it comes into contact with the glass substrate. Next, as shown in FIG. 3C, if the shaping sheet is peeled off before the glass paste filled in the sheet recesses is dried, the glass paste remains on the glass substrate side in a molded state. FIG. 4 shows a shaping sheet 2 and a glass substrate 1 molded by the shaping sheet 2.
Cell barrier 1 on 0 is shown. Since the inner surface of the recessed portion of the sheet is appropriately adjusted with a material such as an ionizing radiation curable resin layer so as to be less wetted by the glass paste than the surface of the glass substrate, the glass paste remains on the glass substrate side at the time of peeling.

Thus, a glass paste capable of forming a desired cell barrier shape at a desired height is formed on a glass substrate by a single operation, and if the glass paste is fired under predetermined firing conditions, the cell barrier having the desired shape is formed. Is obtained. Then, the back plate having the cell barrier and the front plate are sealed to obtain a PDP having a cell barrier structure as shown in FIG.

The present invention is characterized in that a cell barrier having a desired height and a desired shape can be formed by a single patterning process on a glass substrate, and the cross section as shown in FIG. The trapezoidal shape makes it possible to reduce the area of the front surface of the cell barrier at the portion joined to the front plate, so that the pixel area can be increased.
There is an advantage that the brightness can be improved by improving the aperture ratio of the DP.

In FIG. 4, the shape of the cell barrier is a trapezoidal shape in which the opposing cell barriers forming the cell are separated from each other. The shape of the shaped sheet 2 is illustrated in FIGS. 6 to 8. FIG. 6 shows a triangular shape in which opposing cell barriers are separated from each other, and FIG. 7 shows a separated rectangular parallelepiped shape.
Is a curved shape that is convex toward the separated front plate side, for example, a semi-elliptical shape. The cross sections of these cell barriers show, for example, the vertical cross sectional shape of the cell barrier forming one side of the cell surrounded by four sides, and the planar shape of the cell does not matter.

[0030]

According to the production method of the present invention, the ionizing radiation-curable resin with which the roll intaglio plate is filled can highly accurately obtain a shaping sheet which is a shaping mold for the glass paste. And
By pressing this shaping sheet against the glass paste applied almost uniformly on the glass substrate, the glass paste is pushed into the concave portion of the sheet to be filled, and then the shaping sheet is peeled off to obtain a sheet of the glass paste. Due to the difference in wetness between the concave portion and the glass substrate, the glass paste is molded and remains on the glass substrate side. Since the shape of the glass paste formed on the glass substrate is formed in correspondence with the shape of the sheet recessed portion, by making the shape of the sheet recessed portion into the desired cell barrier portion shape, A glass paste having a desired shape is formed on the glass substrate by the processing. Then, by firing, the target cell barrier is obtained.

[0031]

EXAMPLES Next, the present invention will be described in more detail with reference to specific examples.

Example 1 Manufacturing of Shaped Sheet As a film substrate, a shaped sheet manufacturing apparatus shown in FIG. 3 was formed on one side of a 25 μm thick polyethylene terephthalate film (T-60 manufactured by Toray Industries, Inc.). , Using a roll intaglio and ionizing radiation curable resin composition in which the plate recess has a regular square pyramid-shaped recess space as described below, and under the following conditions, the cell barrier and the female mold of the reverse concavo-convex cell barrier part are A shaped sheet provided on one side of the film substrate was obtained.

Cross-sectional shape of roll intaglio plate surface: trapezoid with separated vertical cross-section [see FIG. 9] Horizontal cross-section is stripe-shaped Cell pitch P: 200 μm Cell groove width W: Upper bottom 180 μm, lower bottom 150 μm Cell depth D: 150 μm

Ionizing radiation-curable resin composition pentaerythritol triacrylate 90 parts by weight Urethane acrylate oligomer 10 parts by weight

Irradiation conditions Irradiate an electron beam of 10 Mrad with a curtain beam type electron beam irradiation device.

Next, a glass paste prepared by dispersing a low-melting-point glass frit, a heat-resistant pigment and the like in an organic binder was applied on a glass substrate by a blade coating method to a film thickness of 100 μm, and then applied on the glass substrate. The shape-imparting sheet obtained above was pressed onto the glass paste, and then the shape-imparting sheet was peeled from the glass substrate to form the molded glass paste on the glass substrate. Next, the glass substrate on which the glass paste transferred in the cell barrier shape was applied was fired under conditions of a peak temperature of 585 ° C. and a heating time of 15 minutes to form a cell barrier on the PDP glass substrate.

Example 2 A cell barrier was prepared in the same manner as in Example 1 except that the roll intaglio, the ionizing radiation-curable resin composition, and the irradiation conditions for producing the shaped sheet were changed as follows. Was formed on a glass substrate.

Cross-sectional shape of roll intaglio plate : trapezoid with separated vertical section [see FIG. 10] Horizontal section is square Cell pitch P: 500 μm Cell groove width W: Upper bottom 450 μm, lower bottom 100 μm Cell depth D: 150 μm

Ionizing radiation curable resin composition pentaerythritol triacrylate 90 parts by weight Urethane acrylate oligomer 10 parts by weight 2-hydroxy-2-methyl-1-phenylpropan-1-one (Merck & Co., Darocur 1173) 0.7 Parts by weight

Irradiation conditions High pressure mercury lamp with ozone, 160 W / cm x 2 lamps

[0041]

As described above in detail, according to the cell barrier manufacturing method of the present invention, a cell barrier having a high precision and an arbitrary shape can be formed.
A single patterning process enables simple, rapid, and stable manufacture. Moreover, the shape of the cell barrier can be a trapezoidal shape other than the rectangular parallelepiped shape, the area of the cell barrier surface on the front plate side of the PDP can be reduced, and high definition of the PDP is facilitated.

[Brief description of drawings]

1A is a coating process, FIG. 1B is a first half of a molding process,
(C) is a conceptual diagram showing the latter half.

FIG. 2 is a cross-sectional view showing an example of the relationship between an intaglio roll, a shaping sheet, and an obtained cell barrier shape.

FIG. 3 is a conceptual diagram showing an example of a manufacturing apparatus used in a shaped sheet manufacturing process.

FIG. 4 is a cross-sectional view showing an example of a shape sheet and a shape of a corresponding cell barrier (a trapezoid whose cross section is separated).

FIG. 5 is a conceptual diagram of a cross section in which a back plate having a cell barrier and a front plate are sealed to form a panel.

FIG. 6 is a cross-sectional view showing another example of the shaped sheet corresponding to the shape of the cell barrier (triangular shape whose cross section is separated).

FIG. 7 is a cross-sectional view showing another example of the shaped sheet corresponding to the shape of the cell barrier (rectangular shape whose cross section is separated).

FIG. 8 is a cross-sectional view showing another example of the shaped sheet corresponding to the shape of the cell barrier (convex curve with separated cross section).

9A and 9B are a sectional view and a perspective view showing an example of a plate recess shape of a roll intaglio plate.

FIG. 10 is a cross-sectional view and a perspective view showing another example of the plate recess shape of the roll intaglio plate.

FIG. 11 is a conceptual diagram showing another method of the coating step.

[Explanation of symbols]

 1 Cell Barrier 2 Shaped Sheet 21 Film Substrate 22 Ionizing Radiation Curable Resin Layer 23 Sheet Recess 3 Ionizing Radiation Curable Resin 4 Roll Intaglio 41 Plate Recess 51 Pressing Roll 52 Peeling Roll 6 Coating Device 7 Ionizing Radiation Irradiation Device 8 Glass paste 9 Blade 10 Glass substrate

Claims (1)

[Claims] 1. A method of manufacturing a cell barrier of a plasma display panel, comprising a front plate and a back plate having cell barriers forming a plurality of discharge spaces, which are arranged so as to face each other in parallel. A method of manufacturing a cell barrier for a plasma display panel, comprising the following steps (A) to (D): (A) using a roll intaglio having a plate indentation corresponding to the shape of the cell barrier portion, at least the plate indentation of the roll intaglio is filled with an ionizing radiation curable resin, the film substrate is contacted with the roll intaglio, contact The ionizing radiation curable resin that is present between the film base material and the roll intaglio is cured to form an ionizing radiation curable resin layer while A step of manufacturing a shaped sheet, in which a resin layer is peeled off together with a film base material from a plate concave portion to obtain a shaped sheet having a cell concave portion and a concave portion of a sheet having an uneven shape. (B) A coating step of coating the glass paste on the surface of the glass substrate. (C) A molding step in which the shaping sheet is pressed against the glass substrate coated with the glass paste, the shaping sheet is peeled off, and the glass paste on the surface of the glass substrate is shaped into a cell barrier shape. (D) A firing step of firing the formed glass paste.