JPH10326562A - Method for forming barrier for display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a barrier into the predetermined shape by forming a substrate for display panel with a barrier material layer having flexibility, which can be engraved by tool, and engraving the barrier material with a mold having the predetermined shape, and heating it. SOLUTION: A glass paste, which is obtained by mixing a low melting point glass powder, a resin binder, a high boiling point solvent and a low boiling point solvent, is used so as to perform the screen printing to the barrier material. Or, the glass paste is previously formed into a soft film-like green sheet, and this green sheet is cut at an appropriate size, and laminated on a substrate 1 for display panel. A barrier forming layer 6 is formed by pushing a mold cylinder 3 at a constant pressure from over the partitioning wall material layer 2, and while rolling it in the arrow F direction. The barrier forming layer 6 and the substrate 1 are dried together so as to eliminate the solvent, and heating is performed so as to burn the resin binder, and the low melting point glass powder is melted so as to obtain an integrally solidified barrier. The number of grooves 5 on a circumferential surface of a mold cylinder 3 is set in response to the size of the display panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of forming a partition (rib) of a display panel, and more particularly to a method of forming a partition of a display panel suitable for forming a partition of a plasma display panel (PDP) of a matrix display system. .

[0002]

2. Description of the Related Art PDPs are used as display panels having partition walls.
A conventional method for forming a partition will be described with reference to an example. P
DP is a self-luminous display panel in which a pair of glass substrates are arranged at very small intervals, and the periphery is sealed to form a discharge space inside.

[0003] In such a PDP, the discharge space is usually partitioned by partition walls. For example, as a typical matrix display system, an AC type P electrode of a three-electrode surface discharge type is used.
The DP has a size of 21 inches, and partition walls having a height of about 100 to 200 μm and a width of about 30 to 50 μm are provided in parallel at intervals of about 200 μm in a display area of the screen. As a material for the partition wall, a low-melting glass is usually used.

Conventionally, a screen printing method or a sandblasting method has been used as a method for forming such a partition.

[0005]

However, the screen printing method has a problem that it is difficult to align the screen as the area of the PDP increases, and the screen is distorted, so that the partition pattern is distorted. In addition, since the material for the partition is scraped off by spraying the cutting medium, there is a problem that the material is wasteful and the apparatus becomes large. For this reason, there has been a demand for the appearance of a partition forming method which is simpler and can be realized at low cost.

The present invention has been made in view of such circumstances, and a soft partition wall material layer is formed on the entire surface of a substrate, and a female mold of the partition wall is embossed on the soft partition wall material layer. It is intended to provide a method for forming a partition of a display panel.

[0007]

According to the present invention, an embossable flexible partition material layer is formed on a display panel substrate, and the partition material layer is stamped with a mold having a predetermined shape. A method for forming a partition of a display panel, wherein a partition having a predetermined shape is formed by performing a heat treatment.

According to the present invention, the partition material layer having flexibility which can be embossed is embossed with a mold having a predetermined shape.
Since the partition having a predetermined shape is formed by performing the heat treatment, the pitch and the size of the partition in the display panel can be formed uniformly. Further, since the partition can be formed in one step, the display panel can be manufactured at low cost. In addition, since the mold can be stamped at room temperature, there is no need to heat the mold, which allows the mold to be stamped in a room temperature environment. Special considerations in terms of sex,
Also, there is no need to consider the effects of mold heat, such as the need to use a special partition material, or the heat of the partition material during stamping, making it easier to manufacture the mold and select the partition material. It is.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In the present invention, a mold having a predetermined shape means a mold corresponding to the shape of an uncured partition before being subjected to a heat treatment. This mold is desirably a cylindrical mold in which a female mold of the partition wall is formed on the circumferential surface of the cylindrical body. Using such a cylindrical mold, the cylindrical mold is pressed against the partition material layer. It is desirable to form the partition material layer into a partition shape by rolling while rolling.

The partitioning material having the embossable flexibility includes a glass powder, a resin binder for binding the glass powder and giving the partitioning material layer an embossable flexibility, and easy handling. It is desirable to use a glass paste mixed with an organic solvent for performing the above.

The embossable and flexible partition material layer can be formed by screen printing, coating with a doctor blade, a bar coater, a roll coater or the like. Alternatively, this partition wall material layer is formed by forming a glass paste in advance as a soft sheet (film) green sheet and laminating the glass green sheet on a substrate in a single layer or multiple layers. You may.

Examples of the material of the glass powder include oxides such as silicon oxide, lead oxide, zinc oxide, boron oxide and calcium oxide. This glass powder is desirably used with a particle size of about 1 μm.

When the partition wall material layer is formed of a green sheet, the resin binder is not limited as long as it is a resin capable of binding glass powder and giving strength and flexibility to the green sheet. May be
For example, as such a resin binder, a vinyl-based resin such as polyvinyl chloride, polyvinyl butyral, or polyvinyl alcohol that is soft at normal temperature, or a plasticizer such as dibutyl phthalate that gives more flexibility to these vinyl-based resins. Additives or softened resins obtained by adding a plasticizer such as dibutyl phthalate or glycerin to a hard resin such as polyethylene or polymethyl methacrylate can be used.

A plasticizer for imparting flexibility to such a glass paste makes it possible to soften a relatively hard resin such as nitrocellulose, polymethyl methacrylate or the like and use it as a partition wall material.

The above-mentioned organic solvent is a solvent having a low boiling point (high vapor pressure) which volatilizes in natural drying (drying at normal temperature), and a high boiling point (low vapor pressure) which does not volatilize at normal temperature but volatilizes at a high temperature of 60 to 160 ° C.
It is desirable to use two types of solvents, a solvent and a solvent.

The low-boiling-point solvent is used to make the partition wall material into a paste and facilitate the formation of the partition wall material layer by printing or the like. After the partition wall material layer is formed, it is volatilized quickly by natural drying and disappears. It is desirable to use one that does. As the low melting point solvent, for example, ketones such as acetone and methyl ethyl ketone, and alcohols such as ethyl alcohol can be used.

The high-boiling-point solvent is used for imparting flexibility and fluidity to the partition wall material in a liquid state so that when pressed against a mold, the partition wall material layer can be rapidly deformed in accordance with the mold. It is desirable to use a material that disappears when the partition material layer is fired. As the high boiling point solvent, for example, diethylene glycol monoethyl ether acetate, terpineol or the like can be used.

It is desirable that the mold having a predetermined shape has a structure in which a projection corresponding to the bottom of the partition is wedge-shaped so that the material of the partition can easily enter the recess corresponding to the top of the partition. In addition, the wedge-shaped structure further has a structure in which the tip of the wedge-shaped projection has a depression, thereby forming a layer of the same material as the material of the partition at the bottom of the partition, and omitting the step of covering the address electrode with a dielectric layer. You may make it.

Alternatively, in a mold having a predetermined shape, spacers may be provided at both ends to form a layer of the same material as the material of the partition at the bottom of the partition. Even in such a case, the step of covering the address electrode with the dielectric layer can be omitted.

Hereinafter, the present invention will be described in detail based on an embodiment shown in the drawings. Note that the present invention is not limited to this. First, an AC type three-electrode surface discharge type PDP in which a partition is formed by the partition forming method of the present invention.
1 is shown in FIG.

In an AC type three-electrode surface discharge type PDP, soda lime glass is used for the glass substrate 21 on the back side,
A plurality of address electrodes A are formed thereon in parallel, and the address electrodes A are covered with a dielectric layer (the dielectric layer is not shown).

Partitions 23 are provided between the address electrodes, and grooves (grooves) between the partitions 23 are provided on the side and bottom surfaces for red (R), green (G), and blue for color display. The phosphor layers 24R, 24G, 24B of (B) are sequentially formed.

On the glass substrate 25 on the front side, a pair of sustain electrodes X and Y are formed for each line of display in a direction perpendicular to the address electrodes A. And the surface of the dielectric layer 26 is covered with Mg.
A protective film 27 made of O is deposited.

The glass substrate 21 on the back side and the glass substrate 25 on the front side are adhered to each other to seal the periphery, and X
Gases such as e and Ne are mixed. One pixel (pixel) of the display is composed of three sub-pixels arranged in the line direction.

FIG. 2 is an explanatory view showing a method for forming a partition of a display panel according to the present invention. In this figure, 1 is a substrate for a display panel, 2 is a partition material layer, 3 is a mold cylinder, 4 is a female mold of a bulkhead formed on the circumferential surface of the mold cylinder 3, and 5 is a female mold of a bulkhead. A groove corresponding to the shape of the partition wall,
Reference numeral 6 denotes a partition wall-shaped layer formed into a partition wall shape.

As described above, the substrate 1 has a plurality of address electrodes A formed in parallel on a rear glass substrate 21 made of soda-lime glass shown in FIG. Next, a partition is formed by the partition forming method of the present invention. The partition wall material layer 2 is formed on the substrate 1 by screen printing so as to have a constant thickness.

The partition wall material is a glass paste in which a glass powder, a resin binder, a high-boiling solvent and a low-boiling solvent are mixed. The glass powder is a low-melting glass powder, the resin binder is polyvinyl butyral, Methyl ethyl ketone is used as the boiling point solvent, and terpineol is used as the high boiling point solvent.

The weight components at the time of screen printing were 50 parts by weight of a low melting point glass powder, 1 part by weight of polyvinyl butyral,
After 50 parts by weight of methyl ethyl ketone and 12 parts by weight of terpineol, after the screen printing, methyl ethyl ketone as a low boiling point solvent was removed by natural drying to form a soft partition wall material layer 2 having embossable flexibility.

The partition wall material layer 2 is prepared by preparing the above-mentioned glass paste as a soft film-like green sheet in advance and cutting it into a suitable size to form a single layer or a multi-layer on the substrate 1. Alternatively, they may be formed by lamination.

The mold cylinder 3 is a cylindrical body made of chromium, and has a partition wall female shape 4 formed on the circumferential surface. The pitch of the groove 5 corresponds to the pitch of the address electrode A shown in FIG.

The partition-shaped layer 6 is formed by rolling the die cylinder 3 in the direction indicated by the arrow F in the figure while pressing the mold cylinder 3 from above the partition material layer 2 at a constant pressure. The length of the mold cylinder 3 indicated by G in the figure and the number of grooves 5 on the circumferential surface are appropriately set according to the area of the partition wall material layer 2, that is, the size of the display panel.

For example, a plurality of grooves 5 are provided in the mold cylinder 3, and the mold cylinder 3 is rolled in the direction shown by the arrow F while pressing the mold cylinder 3 to form a plurality of partitions, and then the mold cylinder 3 is moved in the direction of the arrow G. The partition wall may be formed so as to be shifted and rolled in the direction shown by the arrow F while pressing again.

Alternatively, using a mold cylinder 3 having a length corresponding to the lateral width of the substrate, grooves 5 are provided in the mold cylinder 3 by the number of partitions of the entire substrate, and the arrow F is pressed while pressing the mold cylinder 3. Alternatively, all the partition walls may be formed at a time by rolling in the direction indicated by.

By pressing the partition material layer 2 while rotating the mold cylinder 3 in this manner, the partition material layer 2 is formed as the partition shape layer 6, and then the formed partition shape layer 6 is formed together with the substrate 1. After drying in a high-temperature chamber to eliminate terpineol as a high-boiling solvent, the partition wall-shaped layer 6 is subjected to a heat treatment together with the substrate 1, that is, baked to form partition walls. By this calcination, polyvinyl butyral as a resin binder is eliminated by burning, and finally a partition wall in which the low-melting glass powder is melted and solidified integrally is obtained.

Incidentally, a release material such as a fatty acid amide may be added to the partition wall material in order to improve the releasability from the mold cylinder 3. Regarding the improvement of the releasability, Teflon powder is composite-plated on the surface of the female mold 4 of the partition wall,
You may make it improve the peelability with a partition material.

FIG. 3 shows details of the female mold 4 of the partition wall. As shown in this figure, the convex portion 11 corresponding to the partition bottom of the female mold 4 of the partition is formed in a wedge shape so that the cross-sectional area becomes smaller as going forward. Thereby, as shown by an arrow H in the figure, the material of the partition wall can easily enter the groove 5 which is a concave portion corresponding to the top of the partition wall.

The partition forming layer 6 is formed by the female mold 4 so that the lower portion is widened. When the protrusions 11 corresponding to the bottom of the partition wall are formed in a wedge shape, the material of the partition wall is easily filled in the groove 5, so that the work time can be reduced.

To shorten the work time, the female shape 4 of the partition wall or the substrate 1 is heated to lower the viscosity of the partition wall material, thereby increasing the filling speed of the partition wall material into the groove 5.
Work time can be further reduced.

FIG. 4 shows another example of the female mold 4 of the partition wall. In this example, as shown in the figure, the convex portion 11 corresponding to the partition bottom of the female mold 4 of the partition is formed in a wedge shape and has a recess 1 at the tip.
2 are provided. The depression 12 is for forming a dielectric layer 13 of the same material as the partition wall material at a position corresponding to the depression 12, that is, at the bottom of the partition wall.

As a result, the material of the partition wall can easily enter the groove 5, and the dielectric layer 13 can be automatically formed at the bottom of the partition wall. Therefore, the step of covering the address electrode with the dielectric layer can be omitted.

FIG. 5 shows an example in which spacers are provided on the female mold 4 of the partition wall. In this example, as shown in the figure, spacers 15 are provided at both ends of the female mold 4 of the partition. The spacer 15 has a dielectric layer 16 made of the same material as the partition wall material at the bottom of the partition wall.
Is formed.

When the partition mold 4 is positioned on the partition material layer 2 (see FIG. 5A) and the partition material layer 2 is pressed by the partition mold 4, the substrate 1 and the substrate 1 are separated due to the presence of the spacer 15. A gap is formed between the partition wall and the female mold 4 (see FIG. 5B). When the female mold 4 of the partition wall is released from the partition wall forming layer 6 by this gap, a dielectric material of the same material as the partition wall material is formed on the bottom of the partition wall. The body layer 16 is formed (see FIG. 5C).

Thus, the dielectric layer 16 can be automatically formed at the bottom of the partition. Therefore, the step of covering the address electrode with the dielectric layer can be omitted.

In FIG. 5, it has been described that the female mold 4 of the partition wall is formed on the circumferential surface of the mold cylinder 3.
When the substrate 1 is a small substrate, a female mold of the partition wall is formed in a flat shape, and the flat female mold is pressed against the partition material layer 2 like a seal, so that the partition material layer 2 is formed. It may be formed into a partition shape.

As described above, the soft partition wall material layer is embossed with the female mold of the partition wall and the partition wall material layer is formed into the shape of the partition wall, whereby the partition walls having a uniform pitch and size can be formed in one step. It can be easily formed.

Since the embossing is performed at room temperature, there is no need to heat the mold, so that the embossing operation can be performed in a normal temperature environment. Also, since there is no need to heat the mold, it is necessary to use a special material for the mold, special consideration in terms of mold accuracy, mold releasability, etc., or use of a special partition material. It is not necessary to consider the influence of the heat of the mold and the influence of the heat of the partition wall material at the time of stamping. Therefore, it is easy to manufacture the mold and select the partition wall material.

In this example, an AC type three-electrode surface discharge type PDP has been described as an example of a display panel. However, the present invention is not limited to this. The present invention can be applied to a panel.

[0048]

According to the present invention, since the partition is formed by the mold, the pitch and the size of the partition in the display panel can be formed uniformly. In addition, since a partition can be formed by one operation, a display panel can be manufactured at low cost. In addition, since the mold can be stamped at room temperature, there is no need to heat the mold. This allows the mold to be stamped in a room temperature environment. Since there is no need to consider the above, it is easy to manufacture a mold and to select a partition wall material.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a configuration of an AC type three-electrode surface discharge type PDP in which a partition is formed by a partition forming method of the present invention.

FIG. 2 is an explanatory view showing a method of forming a partition of a display panel according to the present invention.

FIG. 3 is an explanatory view showing details of a female mold of a partition wall.

FIG. 4 is an explanatory view showing another example of the female type of the partition wall.

FIG. 5 is an explanatory diagram showing an example in which a spacer is provided on a female mold of a partition wall.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Display panel substrate 2 Partition material layer 3 Type cylinder 4 Partition female 5 Groove 6 Partition shape layer 11 Partition female projection 12 Depression of female tip of partition 13, 16, 26 Dielectric layer 15 Spacer 21 Rear glass substrate 23 Partition wall 24R, 24G, 24B Phosphor layer 25 Front glass substrate 27 Protective film A Address electrode X, Y Sustain electrode

Claims (6)

[Claims] An embossable flexible partition wall material layer is formed on a display panel substrate, and the partition wall material layer is stamped with a mold having a predetermined shape and subjected to a heat treatment. Forming a partition wall of a display panel. 2. The method according to claim 1, wherein the mold having the predetermined shape is a cylindrical mold having a female mold of a partition wall formed on a circumferential surface of a cylindrical body.
2. The method according to claim 1, wherein the embossing of the partition wall material layer is performed by rolling while pressing the cylindrical mold against the partition wall material layer. 3. The method according to claim 1, wherein the partition wall material layer is a glass green sheet. 4. The method according to claim 1, wherein the mold having the predetermined shape has a structure in which a protrusion corresponding to a bottom of the partition has a wedge shape. 5. The mold having a predetermined shape has a structure in which a tip of a convex portion corresponding to a bottom of a partition has a depression, thereby forming a layer of the same material as the material of the partition at the bottom of the partition. The method for forming a partition of a display panel according to claim 4. 6. The method according to claim 1, wherein spacers are provided at both ends of the mold having the predetermined shape, whereby a layer of the same material as the material of the partition is formed at the bottom of the partition. .