JPH10125219A - Manufacture of plasma display panel barrier plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plasma display panel(PDP) barrier plate which facilitates the enlargement of screen and can realize high definition by a simple manufacturing process wherein the barrier plate constituting a discharge display cell of the PDP can be molded with high precision for a short time. SOLUTION: A molded frame opening part having a barrier plate shaped recessed part is filled with a barrier plate molding composition containing a photo-curing resin. Then, the barrier plate molding composition, with which the molded frame opening part is filled, is firmly adhered to an insulation substrate having translucency. Subsequently, it is exposed from a back face of the insulation substrate through the medium of the insulation substrate, and a photo-curing resin contained in the barrier plate molding composition is cured so that the barrier plate molding composition in the mold is cured. Then, the insulation substrate provided by demolding the mold is integral with a barrier plate molding body to be burned.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art A plasma display panel (hereinafter, referred to as a PDP) used for a color display device for a thin large screen is used.
Abbreviated as) has a hermetic structure in which opposing electrode groups are provided in a space surrounded by partition walls called minute discharge display cells, and a dischargeable gas such as a rare gas is sealed in the space. A voltage is selectively applied between the opposing electrodes to generate plasma by discharge, and the plasma causes a phosphor in a discharge display cell to emit light, which is used as a light emitting element of a screen.

In general, a printing lamination method, a photolithography method, a sand blast method, and the like are known as a method of manufacturing a partition wall constituting the discharge display cell of the PDP.

In the printing lamination method, a predetermined shape of a discharge display cell is printed and formed on an insulating substrate as a pattern by a thick film printing method using a paste of a partition wall material. Is about 10 to 15 μm, so that printing and drying are repeated for about 100 to 20 μm.
This is for forming a partition of a discharge display cell requiring a height of about 0 μm.

However, in the printing lamination method, printing,
The drying process has to be repeated and laminated, so that the number of processes is extremely large, and furthermore, it is difficult to print accurately for each lamination, and there is a drawback that the production yield is poor.

In the photolithography method, an opening is formed by exposing a photosensitive resin layer provided on an insulating substrate through a pattern mask, and then developing the opening, filling the opening with an insulating paste, and forming a partition. To form.

[0007] Therefore, it is difficult to easily and accurately position the photomask even in the photolithography method, and furthermore, a development step is required after exposure, so that the mass productivity is low.

On the other hand, in the sand blast method, a glass layer having a predetermined thickness is formed on an insulating substrate, and the surface is sandblasted through a resist mask to remove portions of the glass layer other than the partition walls, thereby forming partition walls. is there.

However, even in the sandblasting method, after a photoresist is used for forming a resist mask,
Since sand blasting is performed, the manufacturing process is complicated, and it is difficult to form partition walls with high accuracy.
When the abrasive used for the blasting process is collected and used repeatedly, there is a problem that the abrasive force deteriorates due to abrasion deterioration of the abrasive, and there is a change over time, which makes it difficult to stably mass-produce.

Therefore, it has been difficult to easily manufacture partition walls for a plasma display panel having high precision and fine pitch by any of the conventionally known manufacturing methods.

[0011] In order to solve such a problem, after filling a partition-forming composition into a partition-forming mold having a partition-shaped recess, the composition is heated and cured to integrally form the partition on an insulating substrate. A method of forming a partition wall for a PDP was previously proposed (Japanese Patent Application No. 7-340124).

[0012]

The partition wall forming method proposed above can form a partition wall relatively accurately with a simple manufacturing process. However, the partition wall forming composition is filled into a partition wall mold and cured. Since the heat-curing method is used, it takes time for the partition wall molding composition filled in the partition wall mold to harden, and there is a problem in mass productivity, and thermal expansion between the partition wall mold and the insulating substrate due to heating. Due to the difference, the position of the partition wall is displaced, and there has been a problem that it is difficult to produce a high-precision partition wall with good reproducibility in a large-screen PDP.

[0013]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems, and an object of the present invention is to form a partition constituting a discharge display cell of a PDP in a simple manufacturing process in a short time with high accuracy and high reproducibility. It is an object of the present invention to provide a method for manufacturing a partition for a PDP capable of obtaining a partition for a PDP, which can easily realize a large screen and achieve a high definition.

[0014]

Means for Solving the Problems The present inventors have conducted intensive studies in view of the above-mentioned problems, and as a result, using a composition for forming a partition wall containing a photo-curable resin, the insulating substrate having a light-transmitting property was insulated from the back surface. It has been found that a partition can be easily formed in a short time by exposing it to ultraviolet light, visible light, infrared light, X-ray or electron beam through a substrate to cure the photocurable resin contained in the composition for forming a partition.

That is, according to the method for producing a partition for a PDP of the present invention, the composition for forming a partition containing a photocurable resin is filled into the opening of a mold having a recess having a partition shape, and then the opening of the mold is opened. By contacting the partition-forming composition filled in the portion with an insulating substrate having a light-transmitting property, and then exposing through the insulating substrate from the back surface of the insulating substrate, and curing the photocurable resin in the partition-forming composition. The partition wall molding composition in the mold is cured or exposed in the same manner as described above, and the partition wall molding composition in the vicinity of the close contact surface with the insulating substrate is first cured and then separately heated to form the partition wall in the mold. After the entire composition for use is cured, the molded partition wall integrated with the insulating substrate obtained by removing the mold is fired.

[0016]

According to the method for producing a partition wall for a PDP of the present invention, the partition wall molding composition containing a photocurable resin filled in a partition wall mold having a partition wall-shaped recess is adhered to the partition wall molding composition. Exposure is performed through the insulating substrate from the back side of the insulating substrate having a light-transmitting property to cure the photocurable resin in the composition for forming a partition, so that the composition for forming a partition in the vicinity of a close contact surface with the insulating substrate is used. First, it is cured in a short time, the position of the partition is accurately set, the alignment with the electrode group becomes easy, and the partition having a desired shape can be obtained only by performing a curing treatment using a partition forming mold, The manufacturing process can be significantly reduced, and the manufacturing cost can be significantly reduced.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION In the method for manufacturing a partition wall for a PDP of the present invention, the material of the partition wall mold having an opening formed in the partition wall is, specifically, an ultraviolet ray, a visible light ray, an infrared ray, an X-ray or an electron beam. Any exposure may be used as long as it does not deform at least during the exposure. For example, metal, ceramic, resin, rubber, and the like are preferable, and any of them can be used corresponding to the height, pitch, and shape of the partition wall. Although a molding die having a concave portion having the following shape can be used, a rubber die is most suitable.

If necessary, a surface treatment such as a release agent or a surface coating may be carried out to improve the releasability and prevent abrasion.

On the other hand, as the binder component used as the partition wall forming composition, various additives such as a thermoplastic resin, a solvent, a plasticizer, and a dispersant can be used with a photocurable resin as a main component.

The photo-curable resin is selected from the group consisting of ultraviolet light, visible light,
Any resin that can be cured by infrared rays, X-rays, electron beams, or the like may be used. For example, a radical polymerization type acrylic ultraviolet curing resin, a cation polymerization type epoxy or azo ultraviolet curing resin, or thiol-ene addition UV-curable resin, etc., among which acrylic UV-curable resin can be suitably used.

If the amount of the photocurable resin is less than 1 part by weight based on 100 parts by weight of the inorganic component in the partition wall forming composition, the strength of the cured product is low and the partition walls may be damaged.
If the amount exceeds 20 parts by weight, a residue may be generated at the time of firing, so 1 to 20 parts by weight is more preferable.

The ultraviolet-curable resin suitable as a photo-curable resin may contain acetophenones, benzophenones, organic peroxides, azo compounds, and thioxanthone as a curing catalyst.

On the other hand, examples of the thermoplastic resin that can be used as a binder component include methyl cellulose and ethyl cellulose.

The amount of the thermoplastic resin as a binder component containing the photocurable resin as a main component may be 20 parts by weight or less based on 100 parts by weight of the inorganic component in the partition wall forming composition. It is more preferable. If the amount exceeds the range, a residue may be generated during firing, which is not desirable.

Further, the solvent and the plasticizer are not particularly limited as long as they are compatible with the photocurable resin. For example, aromatic solvents such as toluene, xylene, benzene and phthalic acid ester; Examples include higher alcohols such as hexanol, octanol, decanol, and oxyalcohol, and esters such as acetate and glyceride.

In particular, the above-mentioned phthalic acid esters and oxyalcohols can be suitably used, and it is also possible to use two or more of the above-mentioned solvents and plasticizers in order to slowly volatilize the solvent and the plasticizer.

The content of the solvent and the plasticizer is preferably 15 parts by weight or less based on 100 parts by weight of the inorganic component in the composition for forming a partition wall in consideration of shrinkage during drying and firing. preferable.

Further, the dispersant is not particularly limited as long as it can improve the dispersibility of the inorganic component in the composition for forming a partition wall, but nonionic, anionic, cationic, and the like. Various betaine surfactants can be used, for example, polyethylene glycol alkyl ethers and alkyl sulfonates, polycarboxylates,
Alkyl ammonium salts and the like can be suitably used,
It is also possible to use two or more kinds in combination.

The content of the dispersant is 0.05 to 5 parts by weight or less based on 100 parts by weight of the inorganic component in the partition wall forming composition from the viewpoint of improving dispersibility and thermal decomposition. It is desirable.

As the inorganic raw material of the composition for forming a partition wall, not only known glass powders such as soda lime glass, low soda glass, lead alkali silicate glass, borosilicate glass, etc. Powders and various metal oxide powders for coloring, for example, alumina (Al
Oxide ceramics such as ₂ O ₃ ) and zirconia (ZrO ₂ ), non-oxide ceramics such as silicon nitride (Si ₃ N ₄ ), oxides of rare earth elements, and the third part of the periodic table.
An oxide of a group a element or the like may be added and mixed for use.

As the insulating substrate, a general light-transmitting glass substrate such as soda lime glass, low soda glass, lead alkali silicate glass, borosilicate glass and the like can be used.

It is to be noted that the insulating substrate may be formed by forming a stripe-shaped electrode group.

Next, in order to cure the above-mentioned partition wall forming composition filled in the partition wall forming die, first, the partition wall forming die and the insulating substrate are positioned and pressure-bonded, and the partition wall forming composition is brought into close contact with the insulating substrate. After that, from the back surface of the insulating substrate, through the insulating substrate, is exposed to X-rays or electron beams such as ultraviolet rays, visible rays, infrared rays, etc. to cure the partition wall forming composition, or to form the partition walls near the contact surface with the insulating substrate. Various curing methods can be applied, for example, exposing the composition for use to cure the vicinity of the contact surface first, and then heating and curing.

The baking may be carried out as long as the inorganic material in the composition for forming a partition used is densified and adheres to an insulating substrate. The baking temperature is not lower than the softening point of the composition for forming a partition and the softening point of the insulating substrate. The following temperatures are good, specifically 500
A temperature range of -600 ° C is preferred.

[0035]

EXAMPLES Next, the method for producing a partition wall for a PDP of the present invention was evaluated as follows. (Embodiment 1) First, the distance between the centers of the partition walls is 150
Using a rubber-made partition wall mold having a pitch of 26 μm equivalent to a 26-inch screen having a 150 μm height and a width of 30 μm, and having an open recess, 100 wt. 15 parts by weight of an acrylic ultraviolet curable resin, 5 parts by weight of butyl cellosolve acetate as a solvent, 3 parts by weight of a polycarboxylate as a dispersant, and 0.3 parts by weight of acetophenones as an ultraviolet curing catalyst Is filled.

Thereafter, an electrode having a width of 40 μm is
An insulating substrate made of high-strain-point, low-soda glass having a thickness of 2 mm and a screen equivalent to a 26-inch screen formed in a stripe shape at a pitch, and a partition wall mold filled with the partition wall-forming composition are positioned and pressure-bonded. The molding composition is brought into close contact with the insulating substrate.

Next, ultraviolet light of 160 W / cm was irradiated through the insulating substrate from the back surface of the insulating substrate having the above-mentioned partition mold pressed thereon using an ultraviolet irradiation device,
The composition was cured by passing through an irradiation section of an ultraviolet irradiation apparatus for 1 minute and exposing the composition.

After being sufficiently cured, the partition wall mold was released from the mold to obtain a partition wall molded body in close contact with the insulating substrate, and then baked at a maximum temperature of 580 ° C. for 1 hour to integrate the PDP with the insulating substrate. A partition wall was prepared.

The thus obtained partition wall molded body in close contact with the insulating substrate before firing was visually inspected with a stereoscopic microscope, and the deviation between the partition wall pitch and the electrode pitch formed on the insulating substrate was observed. No overlap was observed, and it was further confirmed that there was no abnormality in the fired PDP partition wall integrated with the insulating substrate.

(Example 2) After the partition wall forming composition produced in the same manner as in Example 1 was brought into close contact with an insulating substrate, ultraviolet rays of 120 W / cm were irradiated from the back surface of the insulating substrate through the insulating substrate. After passing through an irradiation part of an ultraviolet irradiation device for one minute and exposing to cure the vicinity of the contact surface of the composition for forming a partition with an insulating substrate, the composition is heated at a temperature of 100 ° C. for 10 minutes to sufficiently cure the remainder. After that, a PDP partition wall integrated with the insulating substrate was manufactured in the same manner as in Example 1.

The thus-obtained partition wall molded body in close contact with the insulating substrate and the fired PDP partition wall integrated with the insulating substrate were observed in the same manner as in the evaluation method of Example 1. No overlap was observed, and no abnormality was observed.

(Comparative Example) Using the partition wall mold used in Example 1, 15 parts by weight of an unsaturated polyester as a thermosetting resin and 100 parts by weight of a low melting glass powder in the opening, and polyoxy as a solvent were used. 5 parts by weight of alcohol, 3 parts of polyethylene glycol alkyl ether as dispersant
A partition wall molding composition comprising 0.3 parts by weight of an organic peroxide as a heat curing catalyst is charged.

Then, the above-mentioned composition for forming a partition was brought into close contact with the same insulating substrate as in Example 1, and then kept for 1 hour in a dryer heated to a temperature of 100 ° C. to prepare the composition for forming a partition. After curing, a PDP partition wall integrated with the insulating substrate was manufactured in the same manner as in Example 1.

Observation of the obtained partition wall molded body in close contact with the insulating substrate and the fired PDP partition wall integrated with the insulating substrate in the same manner as in the evaluation method of Example 1 showed that the partition wall was originally located between the electrodes. Should be formed,
A pitch shift in which the partition walls were formed overlapping the electrodes occurred, and it was confirmed that the positional accuracy of the partition walls was poor.

That is, in the comparative example, although the insulating substrate before firing and the opening of the mold filled with the composition for forming a partition were pressed before curing, the composition for forming a partition hardened. Takes a long time, the difference between the thermal expansion of the insulating substrate and the mold having the opening caused by the heating causes the electrode forming position and the partition wall forming position on the insulating substrate to be displaced from each other. In order to start, the pitch between the partition and the electrode does not match.

The present invention is not limited to the above-described embodiment.

[0047]

According to the method for producing a partition for a PDP of the present invention, a composition for forming a partition containing a photocurable resin is used.
Since the photocurable resin contained in the partition wall molding composition is cured by exposing through the insulating substrate from the back surface of the insulating substrate having a light-transmitting property, the partition wall is formed at a predetermined position where the partition wall mold is positioned on the insulating substrate. Since the molding composition is easily cured in a short time, there is no displacement of the pitch between the electrode provided on the insulating substrate and the partition formed on the insulating substrate, and the partition can be formed with high precision dimensions. In addition, the partition wall can be formed by a very small number of manufacturing steps including only one exposure step and, if necessary, an additional heating step, so that the manufacturing cost can be reduced and a large screen can be easily formed. It is possible to obtain a partition wall for a PDP that can realize high definition.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hirofumi Kishimoto 1-1-1, Yamashita-cho, Kokubu-shi, Kagoshima Inside the Kyocera Corporation's Kagoshima Kokubu Plant

Claims (2)

[Claims] 1. A method for filling a partition-forming composition containing a photocurable resin into a space of a partition-forming mold, and then filling the partition-forming composition filled in an opening of the partition-forming mold with an insulating substrate. The partition wall molded body constituting a discharge display cell of the plasma display panel adhered to the insulating substrate is then released from the partition wall molding die after being exposed and cured to the composition for partition wall molding through the insulating substrate and cured. A method of manufacturing a partition for a plasma display panel, comprising: obtaining the formed partition and firing and integrating the same with an insulating substrate. 2. A method for filling a partition-forming composition containing a photocurable resin into a space of a partition-forming mold, and then filling the partition-forming composition filled in an opening of the partition-forming mold with an insulating substrate. Then, the partition wall molding composition is exposed to light through the insulating substrate to cure the partition wall molding composition near the contact surface with the insulating substrate, and then heated to cure the entire partition molding composition. After removing the partition mold, obtaining a partition molded body constituting a discharge display cell of the plasma display panel adhered to the insulating substrate, firing and integrating the partition molded body with the insulating substrate. A method for manufacturing a partition for a plasma display panel.