JPH09320458A - Manufacture of plasma display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide the manufacture of a plasma display panel, which forms the aforesaid panel excellent in surface smoothness, forms a dielectric layer free of scatter in film thickness, and to stabilize display operations. SOLUTION: This invention is concerned with the manufacture of a plasma display panel equipped with a dielectric layer sheathing an electrode layer formed over a glass substrate with respect to a discharge space, the manufacture includes firstly a process which heats and presses dry glass paste films 23 and 26 as thin as 15 to 50μm in an uncured condition laid in such a way as to cover the electrode layer so as to laminate them, and secondly a process which sinters the laminated dry glass paste films 23 and 26 so as to form them into the dielecric layer. Besides, the dry glass paste films 23 and 26 includes low melting point glass in an alkaline system the dielectric constant of which is less than 8, the electrode layer is formed out of a transparent conductive film, and of the laminated film of metallic films. Prior to the laminating process of the dry glass paste films 23 and 26, a process is also included, in which after the dry glass paste films 23 and 26 including low melting point glass in a non-alkaline system, have been heated, pressed and sheathes, and the aforesaid films are sintered, so that the electrode layer is thereby turned out to be a dielectric protection layer.

Description

Detailed Description of the Invention

[0001]

[0001]

[0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved method for manufacturing a plasma display panel, and more particularly to an improved method for forming a dielectric layer covering an electrode layer.

[0003]

[0002]

[0004]

2. Description of the Related Art As a dot matrix type flat display device, for example, a plasma display panel (PDP) is known. PDPs are widely used as display devices for personal computers, word processors, etc., and are capable of high-speed display and easy realization of large screens.
It is expected as a large flat display device of 0 inches or more.

[0005]

FIG. 2 shows a surface discharge type PDP having an AC drive type three-electrode structure, and the inner surface of the glass substrate 1 on the display surface side of a pair of glass substrates 1 and 2 facing each other through a discharge space 7. Is provided with a pair of sustain electrodes (sustain electrodes) X and Y arranged adjacent to each other in parallel with each other, a dielectric layer 5 that covers the sustain electrodes X and Y, and a protective layer 6 made of MgO that covers the dielectric layer 5. Each of the sustain electrodes X and Y is composed of a wide strip-shaped transparent conductive film 4 and a metal film 3 stacked to supplement the conductivity thereof.

[0006]

On the other hand, the barrier 10 is provided on the inner surface of the glass substrate 2 on the back side in a direction orthogonal to the sustain electrodes X and Y, and divides the discharge space 7 into unit light emitting regions.
An address electrode A provided in a direction orthogonal to the sustain electrodes X and Y, and a phosphor layer 8 of a predetermined emission color are provided on the glass substrate between them. Here, in the discharge space 7,
A discharge gas in which a small amount of xenon is mixed with neon is sealed.

[0007]

In displaying such a PDP, for example, a drive voltage exceeding a discharge starting voltage is applied to the sustain electrodes X and Y. As a result, surface discharge is generated in the surface direction of the dielectric layer 5, and predetermined wall charges are accumulated on the surface of the dielectric layer,
Discharge stops. After that, every time a sustain pulse having a polarity opposite to the wall charges is applied to the sustain electrodes X and Y alternately, surface discharge occurs, and the ultraviolet rays generated at this time excite the phosphor layer 8 to emit light.

[0008]

[0006]

[0009]

By the way, the dielectric layer 5
Are generally formed by a screen printing method. In this case, in order to obtain a dielectric layer having a predetermined thickness, it is necessary to repeat the steps of applying a low melting point glass paste and firing it several times. Therefore, variations in film thickness are likely to occur and display unevenness occurs. Further, since the screen mesh mark remains on the surface of the dielectric layer, interference fringes of the screen mesh mark are generated between the first layer and the second layer when, for example, two-layer printing is performed, which causes uneven light emission. Becomes

In view of the above problems, it is an object of the present invention to form a dielectric layer having excellent surface smoothness and uniform thickness to stabilize the display operation.

[0011]

[0007]

[0012]

According to a first aspect of the present invention, there is provided a method of manufacturing a plasma display panel including a dielectric layer that covers an electrode space formed on a glass substrate with respect to a discharge space. A step of stacking a dry glass paste film having an uncured thickness of 15 to 50 μm on a glass substrate so as to cover the layer by heating and pressurizing, and firing the stacked dry glass paste film to form a dielectric layer And a step of forming.

[0013]

The invention of claim 2 is the manufacturing method according to claim 1, characterized in that the dry glass paste film contains an alkaline low melting point glass having a relative dielectric constant of 8 or less.

[0014]

A third aspect of the present invention is the manufacturing method according to the second aspect, wherein the electrode layer comprises a laminated film of a transparent conductive film and a metal film, and the electrode layer is not formed before the step of laminating the dry glass paste film. The method is characterized by including a step of forming an electrode protective layer by heating, pressing and coating a dry glass paste film containing an alkaline low melting point glass, and then baking the dry glass paste film.

[0015]

[0010]

[0016]

In the method of manufacturing a plasma display panel according to the present invention, a step of heating and pressing a dry glass paste film having an uncured thickness of 15 to 50 μm on a glass substrate so as to cover the electrode layer, and laminating the dry glass paste film. Since the laminated dry glass paste film is fired to form the dielectric layer, the dielectric layer can be produced in a short time and has excellent surface smoothness. Also,
The dry glass paste film contains an alkali low melting point glass having a relative dielectric constant of 8 or less, and the electrode layer is heated to a dry glass paste film containing a non-alkali low melting point glass before the step of laminating the dry glass paste film.
Since it is configured to include a step of forming the electrode protective layer by applying pressure and coating and then baking, it is possible to prevent corrosion of the electrode.

[0017]

[0011]

[0018]

DETAILED DESCRIPTION OF THE INVENTION A method of manufacturing a plasma display panel according to an embodiment of the present invention will be described below with reference to FIG. FIG. 1 shows a manufacturing process of a glass substrate on the display surface side.

First, the sustain electrode forming step (see FIG. 1)
(A), (b)), tin oxide, I
A transparent conductive film such as TO is formed by vapor deposition or sputtering, a photoresist layer is formed on the transparent conductive film, exposed and developed through an electrode pattern mask, and the exposed and developed photoresist layer is used as a mask to form a transparent conductive film. The transparent electrode 21 is formed by etching. 2 of aluminum-copper alloy or aluminum / chromium on the transparent electrode 21
Forming a metal film consisting of layers by vapor deposition or sputtering,
A bus electrode 22 is formed by forming a photoresist layer thereon, exposing and developing it through an electrode pattern mask, and etching the metal film using the exposed and developed photoresist layer as a mask. In this way, the sustain electrode in which the transparent electrode 21 and the bus electrode 22 are laminated is provided.

[0020]

Next, an electrode protective layer forming step (FIG. 1 (c))
Then, after the dry glass paste film 23 containing the non-alkali low melting point glass (for example, low melting point glass containing lead oxide) is heated and pressed by the roller 25 and thermocompression bonded (the surface temperature of the roller and the glass substrate is 120). Baking at a predetermined temperature (about 500 to 600 ° C.). Here, the dry glass paste film 23 includes glass particles having an average particle size of about 3 μm, ceramic particles such as alumina,
A mixed slip made of an acrylic resin binder and a solvent such as toluene is formed into a film on a base film (a film made of PET) 24 coated with a release material by a doctor blade method or a calendar method.

[0021]

Next, a dielectric layer forming step (FIG. 1 (d))
Then, the dry glass paste film 26 containing an alkaline low melting glass (for example, low melting glass containing sodium oxide and boron oxide) having a relative dielectric constant of 8 or less is heated by a roller (the surface temperature of the roller and the glass substrate is 120). ℃
・ Pressurized and thermocompressed, and then at a predetermined temperature (500-
Baking at about 600 ° C. Here, the dry glass paste film 26 includes a doctor blade method, a calendar method, or the like in which a mixed slip made of glass particles having an average particle diameter of about 3 μm, ceramic particles such as alumina, a resin binder such as an acrylic resin, and a solvent such as toluene is used. The film is formed on the base film 24 coated with the release material. Further, next, in the protective layer 27 forming step (FIG. 1E), MgO is deposited on the dielectric layer by sputtering.

[0022]

[0014]

[0023]

According to the method of manufacturing a plasma display panel according to the present invention, a dielectric layer is formed by heating and pressurizing a dielectric layer on a base film coated with a release material, and then firing to form the dielectric layer. Since it is possible to produce a large number of PDPs in a short time, it is possible to obtain high productivity as compared with printing. Moreover, the adjustment range of the film thickness is large. Furthermore, the surface smoothness is superior to that of the dielectric layer formed by printing, and the difference in the in-plane and in-plane film thickness is reduced.
It is possible to suppress the uneven light emission.

[Brief description of drawings]

FIG. 1 is a diagram showing a method of manufacturing a plasma display panel according to an embodiment of the present invention.

FIG. 2 is a diagram showing a conventional surface-discharge type PDP having an AC drive type three-electrode structure.

[Explanation of symbols]

 1, 2 ・ ・ ・ Glass substrate 3 ・ ・ ・ Metal film 4 ・ ・ ・ Transparent conductive film 5 ・ ・ ・ Dielectric layer 6 ・ ・ ・ Protective layer 7 ・ ・ ・ ・ ・Discharge space 8 ・ ・ ・ Phosphor layer 10 ・ ・ ・ Barrier 20 ・ ・ ・ ・ ・ Front glass substrate 21 ・ ・ ・ Transparent electrode 22 ・ ・ ・ ・ ・ Bus electrode 25 ・ ・ ・ ・ ・ Roller 23 ・ ・ ・ ・ ・ Dry glass paste film 26 ・ ・ ・ ・ ・ Dry glass paste film 24 ・ ・ ・ Base film 27 ・ ・ ・ ・ ・ Protective layer

─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] March 17, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Detailed description of the invention

[Correction method] Change

[Correction contents]

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved method for manufacturing a plasma display panel, and more particularly to an improved method for forming a dielectric layer covering an electrode layer.

[0002]

2. Description of the Related Art As a dot matrix type flat display device, for example, a plasma display panel (PDP) is known. PDPs are widely used as display devices for personal computers, word processors, etc., and are capable of high-speed display and easy realization of large screens.
It is expected as a large flat display device of 0 inches or more.

FIG. 2 shows a surface discharge type PDP having an AC drive type three-electrode structure, and the inner surface of the glass substrate 1 on the display surface side of a pair of glass substrates 1 and 2 facing each other through a discharge space 7. Is provided with a pair of sustain electrodes (sustain electrodes) X and Y arranged adjacent to each other in parallel with each other, a dielectric layer 5 that covers the sustain electrodes X and Y, and a protective layer 6 made of MgO that covers the dielectric layer 5. Each of the sustain electrodes X and Y is composed of a wide strip-shaped transparent conductive film 4 and a metal film 3 stacked to supplement the conductivity thereof.

On the other hand, the barrier 10 is provided on the inner surface of the glass substrate 2 on the back side in a direction orthogonal to the sustain electrodes X and Y, and divides the discharge space 7 into unit light emitting regions.
An address electrode A provided in a direction orthogonal to the sustain electrodes X and Y, and a phosphor layer 8 of a predetermined emission color are provided on the glass substrate between them. Here, in the discharge space 7,
A discharge gas in which a small amount of xenon is mixed with neon is sealed.

In displaying such a PDP, for example, a drive voltage exceeding a discharge starting voltage is applied to the sustain electrodes X and Y. As a result, surface discharge is generated in the surface direction of the dielectric layer 5, and predetermined wall charges are accumulated on the surface of the dielectric layer,
Discharge stops. After that, every time a sustain pulse having a polarity opposite to the wall charges is applied to the sustain electrodes X and Y alternately, surface discharge occurs, and the ultraviolet rays generated at this time excite the phosphor layer 8 to emit light.

[0006]

By the way, the dielectric layer 5
Are generally formed by a screen printing method. In this case, in order to obtain a dielectric layer having a predetermined thickness, it is necessary to repeat the steps of applying a low melting point glass paste and firing it several times. Therefore, variations in film thickness are likely to occur and display unevenness occurs. Further, since the screen mesh mark remains on the surface of the dielectric layer, interference fringes of the screen mesh mark are generated between the first layer and the second layer when, for example, two-layer printing is performed, which causes uneven light emission. Becomes In view of the above problems, it is an object of the present invention to form a dielectric layer that is excellent in surface smoothness and has no unevenness in film thickness to stabilize the display operation.

[0007]

According to a first aspect of the present invention, there is provided a method of manufacturing a plasma display panel including a dielectric layer that covers an electrode space formed on a glass substrate with respect to a discharge space. A step of stacking a dry glass paste film having an uncured thickness of 15 to 50 μm on a glass substrate so as to cover the layer by heating and pressurizing, and firing the stacked dry glass paste film to form a dielectric layer And a step of forming.

The invention of claim 2 is the manufacturing method according to claim 1, characterized in that the dry glass paste film contains an alkaline low melting point glass having a relative dielectric constant of 8 or less.

A third aspect of the present invention is the manufacturing method according to the second aspect, wherein the electrode layer comprises a laminated film of a transparent conductive film and a metal film, and the electrode layer is not formed before the step of laminating the dry glass paste film. The method is characterized by including a step of forming an electrode protective layer by heating, pressing and coating a dry glass paste film containing an alkaline low melting point glass, and then baking the dry glass paste film.

[0010]

In the method of manufacturing a plasma display panel according to the present invention, a step of heating and pressing a dry glass paste film having an uncured thickness of 15 to 50 μm on a glass substrate so as to cover the electrode layer, and laminating the dry glass paste film. Since the laminated dry glass paste film is fired to form the dielectric layer, the dielectric layer can be produced in a short time and has excellent surface smoothness. Also,
The dry glass paste film contains an alkali low melting point glass having a relative dielectric constant of 8 or less, and the electrode layer is heated to a dry glass paste film containing a non-alkali low melting point glass before the step of laminating the dry glass paste film.
Since it is configured to include a step of forming the electrode protective layer by applying pressure and coating and then baking, it is possible to prevent corrosion of the electrode.

[0011]

DETAILED DESCRIPTION OF THE INVENTION A method of manufacturing a plasma display panel according to an embodiment of the present invention will be described below with reference to FIG. FIG. 1 shows a manufacturing process of a glass substrate on the display surface side. First, the sustain electrode formation step (FIG. 1A)
In (b)), a transparent conductive film such as tin oxide or ITO is formed on the front glass substrate 20 by vapor deposition or a sputtering method, a photoresist layer is formed thereon, and exposure / development is performed through an electrode pattern mask, The transparent electrode 21 is formed by etching the transparent conductive film using the exposed and developed photoresist layer as a mask. A metal film consisting of two layers of aluminum-copper alloy or aluminum / chromium is formed on the transparent electrode 21 by vapor deposition or sputtering, a photoresist layer is formed thereon, and exposure / development is performed through an electrode pattern mask. The bus electrode 22 is formed by etching the metal film using the exposed and developed photoresist layer as a mask. In this way, the sustain electrode in which the transparent electrode 21 and the bus electrode 22 are laminated is provided.

Next, an electrode protective layer forming step (FIG. 1 (c))
Then, after the dry glass paste film 23 containing the non-alkali low melting point glass (for example, low melting point glass containing lead oxide) is heated and pressed by the roller 25 and thermocompression bonded (the surface temperature of the roller and the glass substrate is 120). Baking at a predetermined temperature (about 500 to 600 ° C.). Here, the dry glass paste film 23 includes glass particles having an average particle size of about 3 μm, ceramic particles such as alumina,
A mixed slip made of an acrylic resin binder and a solvent such as toluene is formed into a film on a base film (a film made of PET) 24 coated with a release material by a doctor blade method or a calendar method.

Next, a dielectric layer forming step (FIG. 1 (d))
Then, the dry glass paste film 26 containing an alkaline low melting glass (for example, low melting glass containing sodium oxide and boron oxide) having a relative dielectric constant of 8 or less is heated by a roller (the surface temperature of the roller and the glass substrate is 120). ℃
・ Pressurized and thermocompressed, and then at a predetermined temperature (500-
Baking at about 600 ° C. Here, the dry glass paste film 26 includes a doctor blade method, a calendar method, or the like in which a mixed slip made of glass particles having an average particle diameter of about 3 μm, ceramic particles such as alumina, a resin binder such as an acrylic resin and a solvent such as toluene is used. The film is formed on the base film 24 coated with the release material. Further, next, in the protective layer 27 forming step (FIG. 1E), MgO is deposited on the dielectric layer by sputtering.

[0014]

According to the method of manufacturing a plasma display panel according to the present invention, a dielectric layer is formed by heating and pressurizing a dielectric layer on a base film coated with a release material, and then firing to form the dielectric layer. Since it is possible to produce a large number of PDPs in a short time, it is possible to obtain high productivity as compared with printing. Moreover, the adjustment range of the film thickness is large. Furthermore, the surface smoothness is superior to that of the dielectric layer formed by printing, and the difference in the in-plane and in-plane film thickness is reduced.
It is possible to suppress the uneven light emission.

Claims (3)

[Claims] 1. A method of manufacturing a plasma display panel comprising a dielectric layer covering an electrode layer formed on a glass substrate with respect to a discharge space, the method comprising the steps of: forming a dielectric layer on the glass substrate so as to cover the electrode layer. The method includes the steps of heating and pressing to laminate a dry glass paste film having an uncured state thickness of 15 to 50 μm, and firing the laminated dry glass paste film to form a dielectric layer. A method for manufacturing a plasma display panel, comprising: 2. The dry glass paste film comprises:
A method of manufacturing a plasma display panel, which comprises an alkali low melting point glass having a relative dielectric constant of 8 or less. 3. The electrode layer is formed of a laminated film of a transparent conductive film and a metal film, and the electrode layer is formed of a dry glass paste film containing non-alkali low melting point glass before the step of laminating the dry glass paste film. 3. The method for manufacturing a surface discharge plasma display panel according to claim 2, further comprising a step of heating and pressurizing to cover the film, and then baking to form an electrode protective layer.