JPH09147754A - Plasma display device substrate and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily form fine bulkheads on a plasma display device substrate with high accuracy. SOLUTION: A mixture 21 of ceramic or glass powder, a solvent, and an organic additive is filled in the recesses 20a of a molding die 20, the projections 20b of the molding die 20 are coated with an electrode material 22, and a plasma display device substrate is manufactured in the process for connecting the mixture 21 and the electrode material 22 to one face of a back plate 10 made of ceramic or glass.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a substrate for a plasma display device used for a high-precision, inexpensive, thin, large-screen color display device and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In a plasma display device used for a thin large-screen color display device or the like, opposed electrodes are provided in a space surrounded by partition walls called minute display cells, and discharge of rare gas or the like is performed in the space. It has a structure in which possible gas is sealed, and generates plasma by discharging between facing electrodes,
The phosphor emits light by the plasma and is used as a light emitting element of a screen.

As shown in FIG. 3, a specific structure is one in which a large number of partition walls 11 are formed on one surface of a back plate 10 to form cells 13 between the partition walls 11, and electrodes 12 are provided on the bottom surface of the cells 13. Is a substrate 1. For this substrate 1, a phosphor is applied to the inner wall surface 13a of the cell 13, and a front plate 14 having one electrode 15 is bonded onto the partition wall 11 of the substrate 1 to form the cell 13
By enclosing the gas in the plasma display device, a plasma display device can be constructed.

When the substrate 1 for the plasma display device is manufactured, a large number of electrodes 1 are formed on the back plate 10 in advance.
The partition 11 is formed between the electrodes 12 after forming the partition 2. As a method for manufacturing the partition 11, a printing lamination method, a green sheet multilayer lamination method, or the like is known.

In the printing lamination method, a partition 11 having a predetermined pattern is formed on the back plate 10 by printing using a paste of a material forming the partition 11 by a thick film printing method. Since it is about 10-15 μm,
The partition 11 which requires a height of about 100 to 200 μm is formed by repeating printing and drying (see Japanese Patent Application Laid-Open No. 2-213020).

Further, the green sheet multilayer laminating method is
A plurality of green sheets perforated in a predetermined shape are laminated and fixed so that the partition 11 has a required height (see JP-A 1-213936).

[0007]

However, the plasma display device substrate 1 obtained by the above-described manufacturing method has the partition wall 1
Since the step of forming the electrode 1 and the step of forming the electrode 12 are different from each other, there is a problem that a positional deviation between the partition wall 11 and the electrode 12 is likely to occur and the substrate 1 with high accuracy cannot be obtained. Moreover, as shown in FIG. 3, it is unavoidable that there is a gap between the electrode 12 and the partition wall 11, and the discharge region is narrow because the electrode 12 is provided only on a part of the bottom surface of the cell 13. There was a problem of low luminous efficiency.

Further, when the partition wall 11 is manufactured, the printing and laminating method must repeat the printing and drying steps many times in order to form the partition wall 11 with a predetermined height, which is an extremely process. Since the number is large, and moreover, it is necessary to print with high accuracy for each stack, the yield is very low.
Further, the partition 11 is easily deformed due to the positional deviation during printing,
Further, due to the elongation of the printing plate, the dimensional accuracy of the partition wall 11 has a maximum difference of about 0.35 mm between the measured values when measuring the size of 1000 cells in 45 columns, which satisfies the demand for high definition. I couldn't.

On the other hand, in the green sheet multilayer laminating method, although the plurality of perforated green sheets can be collectively laminated and fixed to form the partition wall 11, the cell 1 is formed.
If the partition 11 is narrowed with respect to the opening of the cell 13 in order to make the pitch of 3 finer and to increase the definition of the screen, the opening area is increased and the strength of the green sheet is reduced. There was a problem that high-precision positioning was sometimes difficult.

In addition to this, there is a manufacturing method by a sandblast method, but it is difficult to form the partition wall 11 with high accuracy.

Therefore, it has been difficult to manufacture the substrate 1 for a large-sized plasma display device having a high precision and a fine pitch at a low cost by a simple process by any of the above manufacturing methods.

[0012]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object thereof is to manufacture a substrate for a plasma display device in a single molding process with a high yield and to obtain a smooth surface without deformation. It is an object of the present invention to provide a substrate for a plasma display device, which can obtain a highly accurate partition wall having a predetermined height and can easily realize a large screen of 40 inches or more, and a manufacturing method thereof.

[0013]

A substrate for a plasma display device according to the present invention comprises a back plate made of ceramics or glass and a plurality of partition walls made of ceramics or glass, and the entire bottom surface of a cell formed between the partition walls. It is characterized in that it is provided with an electrode.

Further, in the method for manufacturing a substrate for a plasma display device according to the present invention, a mixture of ceramic or glass powder, a solvent and an organic additive is filled in the concave portion of the molding die, and the convex portion of the molding die is formed. It is characterized in that it comprises a step of applying an electrode material to the portion and joining the mixture and the electrode material to a back plate made of ceramics or glass.

[0015]

According to the plasma display device substrate of the present invention, by forming the electrode on the entire bottom surface of the cell, it is possible to eliminate the positional deviation between the electrode and the partition wall, and to widen the discharge region to enhance the luminous efficiency. it can.

Further, according to the method for manufacturing a substrate for a plasma display device of the present invention, since the partition wall is molded by filling the mixture of the powder of ceramics or glass and the binder into the molding die, the surface state of the partition wall is good. In addition, the dimensional accuracy of the molding die is directly reflected on the molded body, and a large-sized substrate can be easily manufactured in one molding process.

Further, since the partition wall and the electrode are integrally molded, the process can be simplified, and the substrate having the electrode on the entire bottom surface of the cell can be easily manufactured, and the displacement of the partition wall and the electrode can be eliminated. .

[0018]

Embodiments of the present invention will be described below.

As shown in FIG. 1, a substrate 1 for a plasma display device has a plurality of partition walls 11 made of ceramics or glass on one surface of a back plate 10 made of ceramics or glass.
And the cells 13 are formed between the partition walls 11. The electrode 12 is provided on the entire bottom surface of the cell 13, and the electrode 12 and the partition wall 11 are in close contact with each other with no gap.

On the substrate 1, the inner wall surface 13a of the cell 13 is formed.
After the phosphor is applied to the plasma display device, the front plate 14 having the electrodes 15 covers the upper end of the partition wall 11 as shown in FIG. Then, by discharging between the electrodes 12 and 15, the phosphor applied to the inner wall surface 13a of the cell 13 can emit light.

At this time, since the electrode 12 is provided on the entire bottom surface of the cell 13, the discharge region is widened and the luminous efficiency can be improved. Further, the positional deviation between the partition wall 11 and the electrode 12 can be eliminated, and the highly accurate substrate 1 can be obtained.

Next, a method of manufacturing the substrate 1 will be described.

First, as shown in FIG. 2A, the partition wall 11
The molding die 20 having the concave portions 20a conforming to the shape is prepared, and the electrode material 22 forming the electrode 12 is applied to the convex portions 20b between the concave portions 20a of the molding die 20. Specifically, a mixture of a metal paste or metal powder forming the electrode material 22 and a binder composed of a solvent and an organic additive is applied.
As an application method, the electrode material 22 is applied to another flat plate and the like, and the convex portion 20b of the molding die 20 is applied to the electrode material 22 for transfer, or screen printing or roller coating is applied to the convex portion 20b of the molding die 20. The electrode material 22 may be applied by, for example, the like.

Next, the partition wall 1 is placed in the recess 20a of the molding die 20.
A mixture 21 of ceramics or glass powder and a binder of a solvent and an organic additive is filled as a material forming No. 1. At this time, in FIG. 2A, the surface of the electrode material 22 and the surface of the mixture 21 are on the same plane, but the electrode material 22 may be covered with the mixture 21. In either case, the mixture material 21 and the electrode material 22 are There should be no gap between them.

On the other hand, a back plate 10 made of ceramics or glass is prepared separately, and this back plate 10 is used for the molding die 2 described above.
The mixture 21 and the electrode material 22 filled with 0 are pressed against the upper surfaces of the electrode material 22 and dried to solidify the mixture 21 and the electrode material 22. Then, as shown in FIG.
By separating 0, the partition wall 11 and the electrode 12 are transferred onto the back plate 10. Finally, by co-firing the whole, the substrate 1 for plasma display device shown in FIG. 1 can be manufactured.

In the above example, the partition wall 11 and the electrode 12 were joined to the back plate 10 in an unfired state and finally co-fired. However, after the partition wall 11 and the electrode 12 were solidified in advance and separately fired, It can also be joined to the back plate 10 by thermocompression bonding or adhesion. That is, the partition wall 11 and the electrode 12 may be bonded to the back plate 10 at any stage of the members being unbaked, debindered, or sintered.

According to the manufacturing method of the present invention as described above, since the partition wall 11 and the electrode 12 can be simultaneously formed at once, the manufacturing process can be extremely simplified. Moreover, the partition wall 11 is the mold 2
Since the shape of the concave portion 20a of 0 is transferred, a fine shape can be formed with high accuracy. As a result, in the manufacturing method of the present invention,
High accuracy can be achieved so that the maximum difference between the measured values when measuring the size of 1000 cells in 45 columns is 0.05 mm or less.

Here, the ceramic powder forming the partition wall 11 is alumina (Al ₂ O ₃ ) or zirconia (Zr).
Oxide ceramics such as O ₂ ) and silicon nitride (Si ₃
N ₄ ), aluminum nitride (AlN), silicon carbide (Si
Any of non-oxide ceramics such as C) can be used, and various sintering aids can be added to these ceramic powders in desired amounts.

[0029] As the sintering aid is silica (SiO ₂₎ to alumina powder, calcia (CaO), yttria (Y ₂ O ₃₎ and magnesia (MgO) or the like, the zirconia powder yttria (Y ₂ O ₃ ) and cerium (C
e), dysprosium (Dy), ytterbium (Y
b) and other rare earth element oxides, silicon nitride powders such as yttria (Y ₂ O ₃ ) and alumina (Al ₂ O ₃ ), and aluminum nitride powders such as Group 3a element oxides of the periodic table ( RE ₂ O ₃ ) and the like, and boron (B) and carbon (C) and the like in desired amounts can be added to the silicon carbide powder.

When the partition wall 11 is made of glass powder, the main component is silicate, and lead (Pb), sulfur (S),
Various glasses containing one or more of selenium (Se), alum, and the like can be used.

The ceramic or glass powder having a particle size of several tens of microns to submicrons can be suitably used, specifically, 0.2 to 10 μm, preferably 0.2 to 5 μm. Good in the range.

Further, as organic additives added to these ceramic powder or glass powder, urea resin,
Examples thereof include melamine resin, phenol resin, epoxy resin, unsaturated polyester resin, alkyd resin, urethane resin, ebonite, and polysiloxy silicate. The partition material 21 can be solidified by curing these organic additives by means such as heat curing, ultraviolet irradiation curing, and X-ray irradiation curing. It should be noted that heat curing is optimal from the viewpoint of work and equipment, and particularly from the viewpoint of pot life, it is preferable to use unsaturated polyester resin as the organic additive.

The content of the organic additive must be such that the viscosity does not become high in order to maintain the fluidity and moldability of the mixture of the ceramic or glass powder and the sintering aid. On the other hand, it is desirable to have sufficient shape retention at the time of curing. From this point of view, 0.5 parts by weight or more relative to 100 parts by weight of the ceramic or glass powder, and 35 parts by weight or less from the viewpoint of shrinkage of the molded body due to curing are preferable, and the shrinkage during firing is particularly preferable. Considering it, 1 to 15 parts by weight is most suitable.

The solvent added to the mixture 21 is not particularly limited as long as it is compatible with the organic additive, and examples thereof include aromatic compounds such as toluene, xylene, benzene and phthalic acid ester. Solvents, higher alcohols such as hexanol, octanol, decanol, and oxyalcohol, or esters such as acetic acid ester and glyceride can be used.

Above all, the phthalic acid ester, oxyalcohol and the like can be preferably used, and in addition, two or more kinds of the above solvents can be used in combination in order to slowly volatilize the solvent. Is required to be 0.1% by weight or more per 100 parts by weight of the ceramic or glass powder in order to maintain the shape retention of the molded product from the viewpoint of moldability, while the ceramic or glass powder and the organic additive are added. Since it is desirable to lower the viscosity of the mixture of products,
The amount is preferably 35 parts by weight or less, and most preferably 1 to 15 parts by weight in consideration of shrinkage during drying and firing.

Further, the electrode material 22 in the present invention is A
It can be prepared by using a paste of g, Pd, Pt, Au, W or the like alone or a combination of a plurality thereof, or a mixture of these metal powders and a binder made of a solvent and an organic additive.

The molding die 20 in the present invention may be of any type as long as it does not hinder the curing of the organic additive, and the material is not particularly limited. For example, metal or resin,
Alternatively, rubber or the like can be used, and if necessary, surface treatment such as surface coating may be performed in order to improve releasability and prevent wear.

The back plate 10 is an unsintered green sheet or a sintered body, and its material is not particularly limited.
For example, it is desirable that the coefficient of thermal expansion be close to that of the partition material 21 by using various ceramic green sheets, various glass substrates, porcelain substrates, and the like.

The mixture 21 or the electrode material 22 and the back plate 10 can be joined by pressure bonding without any intervening therebetween, but an inorganic or organic adhesive may be used. It is possible.

Further, various coupling agents such as a silane coupling agent, a titanate coupling agent, and an aluminate coupling agent for improving the adhesiveness when the mixture 21 or the electrode material 22 and the back plate 10 are pressure-bonded. A silane coupling agent is preferable because of its high reactivity.

Further, for the pressure bonding of the mixture 21, the electrode material 22 and the back plate 10, it is desirable to use a device of hydrostatic pressure from the viewpoint of applying a uniform pressure.
The pressure range does not deform the mold, and the pressure range depends on the strength of the mold. For example, when a mold made of silicone rubber is used, it is desirable to perform the pressurizing condition at about 100 g / cm ^2. .

In order to improve the dispersibility of the ceramic or glass powder in the mixture 21, for example, polyethylene glycol ether, argyl sulfonate,
A surfactant such as a polycarboxylic acid salt or an alkylammonium salt may be added, and its content is 0.1% based on 100 parts by weight of the ceramic or glass powder from the viewpoint of improving dispersibility and thermal decomposability. 05 to 5 parts by weight is desirable.

Further, a curing catalyst called a curing reaction accelerator or a polymerization initiator may be added to the binder in the mixture 21. As the curing catalyst, an organic peroxide or an azo compound can be used, and examples thereof include ketone peroxide, diacyl peroxide, peroxyketal, peroxyester, hydroperoxide, peroxycarbonate, t-butylperoxide. Examples thereof include organic peroxides such as oxy-2-ethylhexanoate, bis (4-t-butylcyclohexyl) peroxydicarbonate and dicumyl peroxide, and azo compounds such as azobis and isobutyronitrile.

Although the trapezoidal partition wall 11 is shown in FIGS. 1 and 2, the present invention is not limited to this example.

[0045]

Example 1 First, an Ag paste was applied as an electrode material 22 on a flat plate, and the convex portion 20b of the molding die 20 was pressed against the flat plate,
The electrode material 22 was applied and dried. On the other hand, as the mixture 21 forming the partition wall 11, as shown in Table 1, the average particle size of 0.2 to
A slurry was prepared by adding 10 μm (preferably 0.2 to 5 μm) of glass powder, various solvents, an organic additive and a small amount of a dispersant, and mixing this mixture 21 with the recess 20 a of the molding die 20.
And degassed.

The glass rear plate 10 was placed on this surface, pressed and dried, and after confirming that the mixture 21 and the electrode material 22 were solidified and bonded to the rear plate 10, the mold 20 was released. Thereafter, the whole was baked at 500 to 700 ° C. to produce a substrate 1 for a plasma display device.

[0047]

[Table 1]

Example 2 A mixture 21 having the composition shown in Table 2 was used, and when the mixture 21 was filled in the molding die 20, the electrode material 22 was covered so as to cover the electrode material 22. A device substrate 1 was produced.

[0049]

[Table 2]

Example 3 W paste was used as the electrode material 22, and alumina having an average particle size of 0.2 to 5 μm was used as the mixture 21 as shown in Table 3.
Using zirconia, the firing temperature is 1450 to 1600 ° C.
A substrate 1 for a plasma display device was produced in the same manner as in Example 1 except for the above.

[0051]

[Table 3]

Comparative Example On the other hand, as a comparative example, the electrodes 12 are formed by screen printing on the glass rear plate 10 by the conventional printing method.
In the meantime, screen printing and drying were repeated 10 times to form the partition walls 11 and then baking was performed at 500 to 700 ° C. to manufacture the substrate 1 for plasma display device (No. 19).

No. 1 obtained as described above. 1-19
Table 4 shows the results of observing the shape of the partition wall 11, the presence or absence of cracks, and the positional deviation from the electrode 12 with respect to the sample of Table 2 with a binocular microscope.
Shown in From this result, No. In No. 19, the shape of the partition wall 11 was unclear, and a positional deviation from the electrode 12 was recognized. On the other hand, the present invention example (No. 1 to 1)
8) shows that there is no positional deviation between the electrode 12 and the partition wall 11,
The shape of was also good. In addition, No. Nos. 6, 12, and 18 had a large amount of solvent, and thus the partition wall 11 was slightly crushed.

In the above embodiment, the back plate 1 made of glass is used.
Although 0 was used, similar results were obtained even when various ceramics such as alumina were used.

[0055]

[Table 4]

[0056]

As described above, according to the present invention, a back plate made of ceramics or glass is provided with a plurality of partition walls made of ceramics or glass, and an electrode is formed on the entire bottom surface of the cell formed between the partition walls. By configuring the substrate for a plasma display device by including the above, it is possible to increase the discharge area to improve the light emission efficiency, and to eliminate the positional deviation between the partition wall and the electrode.

Further, according to the present invention, a mixture of ceramics or glass powder, a solvent and an organic additive is filled in the concave portion of the molding die, and the electrode material is applied to the convex portion of the molding die. By manufacturing a substrate for a plasma display device from the step of joining the mixture and the electrode material to one surface of a back plate made of ceramics or glass, it is possible to easily form a partition wall with high precision and fine shape. Since the electrode and the partition can be formed at the same time, the manufacturing process can be simplified and the cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a substrate for a plasma display device of the present invention.

2A and 2B are views for explaining a method of manufacturing a substrate for a plasma display device of the present invention.

FIG. 3 is a cross-sectional view showing a conventional substrate for a plasma display device.

[Explanation of symbols]

 1: Substrate 10: Back plate 11: Partition wall 12: Electrode 13: Cell 14: Electrode 15: Front plate 20: Mold 20a: Recess 20b: Convex 21: Mixture 22: Electrode material

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Hisami Sakai 22 Kyocera Corporation, 5-5 Higashinokitainouemachi, Yamashina-ku, Kyoto-shi, Kyoto

Claims (2)

[Claims] 1. A plasma display device comprising a back plate made of ceramics or glass, a plurality of partition walls made of ceramics or glass, and electrodes provided on the entire bottom surface of cells formed between the partition walls. substrate. 2. A mixture of ceramics or glass powder and a solvent and an organic additive is filled in a concave portion of a molding die, and an electrode material is applied to the convex portion of the molding die to prepare the mixture and the electrode material. A method for manufacturing a substrate for a plasma display device, which comprises the step of bonding a substrate to a back plate made of ceramics or glass.