JPH1116503A - Bulkhead and phosphor forming laminated sheet for plasma display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a new bulkhead easily transferable onto a back glass plate for plasma display panel and a phosphor layer forming laminated sheet by forming a bulkhead glass layer and a phosphor layer on a plastic support film through an organic resin layer, and connectively covering the head top part of the glass layer with a protecting film layer. SOLUTION: An organic resin layer about 1-10 μm thick consisting of isobutyl methacrylate polymer or the like is formed on a support film (about 0.1-1.0 mm thick) consisting of a polyethylene terephthalate film or the like. A bulkhead glass layer is formed on the organic resin layer by photolithography utilizing photosensitive resin, and a phosphor layer is formed in the opening part (discharge space) of the layered product of the bulkhead glass layer by printing method. A protecting film about 20-20 μm thick consisting of polyethylene terephthalate or the like is formed on the head top part of the bulkhead glass layer, whereby the subjected laminated sheet is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated sheet for forming a partition wall and a phosphor layer of a plasma display panel (hereinafter referred to as "PDP"), and more particularly, to a method of forming a laminate on a plastic supporting film separate from a substrate glass for PDP. A new partition wall structure having a laminated structure of a partition glass layer and a phosphor layer formed through an organic resin layer, and a protective film covering them, and which can be easily transferred onto a rear glass plate for PDP; The present invention relates to a phosphor sheet-forming laminated sheet.

[0002]

2. Description of the Related Art In recent years, in the field of flat panel display devices such as televisions and computers, display devices with high precision and fine image quality such as a high-vision system have been developed, and the display means has been increased in size and miniaturized with high precision. And a plasma display system has been receiving attention as a countermeasure. The plasma display panel has a structure in which phosphors and electrodes are arranged in a large number of cells (micro discharge spaces) surrounded by two substrate glasses and partition walls provided therebetween, and the discharge gas is filled. The discharge gas is excited by the discharge between the electrodes in the cell, and the phosphor is emitted by ultraviolet rays generated when the discharge gas returns to the ground state, thereby forming pixels.

[0003] The partition walls of the PDP are required to have heat resistance that prevents interference between cells of light emission between the electrodes of the front glass and the rear glass and that keeps the distance between the two glass substrates constant. Also, recently, for a high-precision PDP capable of obtaining high-luminance light emission by making the discharge space as large as possible, the walls are steep and the width is narrow and the height is high, for example, the width of the partition is about 50 to 150 μm, and the height is About 100-200
A high aspect ratio having a thickness of about 50 μm and an opening width of about 50 to 300 μm is demanded.

[0004] As a method of forming the partition walls currently used in mass production lines, for example, a wet glass paste is passed through a patterned screen, and a screen is formed on a rear glass plate provided with electrodes and overcoat glass. Printing method (screen printing method), embedding a wet glass paste into the opening of the photosensitive resin layer (dry film) that has been exposed and developed on the back glass plate beforehand and patterned, dried, and then dried Or by burning and removing the glass paste at the same time as firing the glass paste to form a partition (photolithographic method), applying a wet glass paste to the entire back plate by screen printing or roll coating, drying, and the like. Laminate a dry film, expose and develop through a light-shielding film (mask), The dried glass paste below, cutting sandblast, removed and then eluted dry film to form a partition wall, and calcining (sandblasting) and the like are known to this.

[0005] However, these various methods are not always satisfactory as a partition wall forming means meeting the requirements of large size and high precision miniaturization, and the formation of the partition walls to meet such requirements is a problem of PDP. The production is the most complicated and the yield is low, which affects the performance and cost of the product, and the improvement has been called out in the industry.

In fact, for example, in the above screen printing method, the film thickness that can be formed by one printing is at most several tens of μm. In addition to the fact that this partition is not formed, this operation itself is very complicated, and there is also a disadvantage that dripping is accumulated in a large number of times of printing, and that the partition is likely to be partially chipped due to plate drying or the like. Therefore, it has become difficult to meet the demand for fine pitch of the partition walls.

In the photolithographic method, a small area P
Although DP can be used practically, there is a disadvantage that the larger the screen is and the higher the rive precision is, the more the trouble occurs during the elution or burning of the dry film and the yield is poor.

In the sand blasting method, there is a difference in the adhesion between the glass paste and the dry film depending on the conditions of application and drying of the glass paste. As the precision becomes higher, there is a risk that the dry film peels off during development or blasting. There are also problems such as dust of the removal partition wall material generated in large quantities during blasting and disposal of the blast material.

Further, in any of the above methods, since the wet glass paste must be handled in the PDP manufacturing process, deterioration of the atmosphere due to the organic solvent and treatment of the solvent in the process are avoided. There are no disadvantages.

Conventionally, a phosphor layer of a PDP is formed by firing a partition once by the above-described various methods, and then sequentially using a screen having the pattern in a discharge space surrounded by the partition. The operations of applying, exposing, and developing red, green and blue phosphor pastes are repeatedly performed, and the formation of such phosphor layers is also disadvantageous in that the process is long and the yield of PDP production is deteriorated. I have.

[0011]

SUMMARY OF THE INVENTION The present invention relates to a conventional PD
A large-capacity, high-precision PDP that meets the needs of the art by completely eliminating the various drawbacks described above in the formation of P partition walls.
To provide a new PDP partition wall and a laminated sheet for forming a phosphor layer, which can be manufactured more easily and with an improved yield.

The inventors of the present invention have conducted intensive studies for the above purpose, and as a result, the partition glass layer and the phosphor layer, which have been conventionally formed on the back glass substrate for PDP, have been separated from the above-mentioned substrate by an appropriate method. When they are simultaneously formed on a suitable support film, the formation itself can be carried out very easily and in a large area, so that a glass layer for a partition and a phosphor layer having excellent characteristics can be obtained with a good yield. It has been found that a desired high-precision partition wall and a phosphor layer can be easily formed by removing the film, easily transferring the film onto a rear glass substrate for PDP by, for example, thermocompression bonding, and then baking it in a conventional manner. Was. The present invention has been completed based on the above findings.

[0013]

According to the present invention, a plastic support film, a partition wall glass layer and a phosphor layer formed on the support film via an organic resin layer, and A partition sheet for a PDP and a laminated sheet for forming a phosphor layer, comprising a protective film layer that covers and covers the top of the head.

The partition wall of the PDP and the laminated sheet for forming a phosphor layer according to the present invention are based on the above-mentioned constitution.
The simplified process makes it possible to easily form a desired high-precision, large-capacity partition wall for PDP and a phosphor layer at the same time with a high yield. In addition, since the laminated sheet of the present invention uses a plastic which is lightweight, flexible and has no danger of breakage as compared with glass as a supporting film, it is excellent in handleability as well as PD.
Regardless of the area of the back glass substrate for P, a large area sheet can be created at a time, cut into an appropriate area according to needs and applied, and partition and phosphor layers of the same performance are applied to each substrate. There is an advantage that it can be easily formed and the variation in quality can be suppressed.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the laminated sheet of the present invention and a method for producing the same will be described in detail. As a support film constituting the sheet of the present invention, various films made of a flexible plastic can be used. Specific examples thereof include a polyethylene terephthalate (PET) film,
Polyethylene (PE) film, polystyrene (PS)
Examples thereof include a film and a polyvinyl alcohol (PVA) film. This support film is not particularly limited, but generally preferably has a thickness of about 0.1 to 1.0 mm.

In the present invention, first, an organic resin layer for connecting a partition glass layer and a phosphor layer described later is formed on the support film. This organic resin layer, assuming that it has the ability to connect the glass layer for the partition and the phosphor layer, the resin component and film thickness and the like can be determined as appropriate, but the organic resin layer is a layer immediately above the support film, That is, after transferring the laminated sheet of the present invention onto the back glass plate of the PDP,
In consideration of the fact that the lowermost portion is obtained when firing, it is particularly preferable that the thermal decomposition property is good and the film thickness is as thin as possible. As a resin component meeting such requirements, for example, an acrylic resin, particularly, an isobutyl methacrylate polymer is preferable, and its film thickness is usually preferably about 1 to 10 μm.

In the present invention, subsequently, a glass layer for forming a partition and a phosphor layer are formed on the organic resin layer for connection. The formation of the partition wall glass layer is not particularly limited, but generally can be preferably performed by a photolithographic method using a photosensitive resin. More specifically, first, a photosensitive resin layer is formed on the above-mentioned organic resin layer for connection, and this is exposed through a light-shielding film having a pattern opposite to that of the partition, and the exposed portion is developed and eluted to form a partition. An opening may be formed, a glass paste as a partition material may be embedded in this portion, and after drying, the remaining photosensitive resin layer may be finally removed.

In the above, the photosensitive resin layer may be a liquid compound (liquid resist) or a so-called dry film solid at room temperature, similar to those known to be used for a photomask of a normal printed circuit board. Either may be used. In the case of a liquid compound, the thickness of the organic resin layer for connection is controlled by appropriately controlling the film thickness so as to obtain a required partition wall height, according to a doctor blade method, a roll coating method, a reverse coating method, a spray coating method, or the like. And pre-dried. The dry film may be any one which can be developed with an organic or inorganic alkaline aqueous solution or the like after the subsequent exposure. Specific examples of commercially available dry films include, for example, "Oder" manufactured by Tokyo Ohka Co., and Nihon Gosei. "Alfo" manufactured by Kagaku and "Liston" manufactured by DuPont can be exemplified. Each of them is also advantageously used in the present invention, and can be laminated on the organic resin layer for connection using a laminator or the like according to a conventional method.

The operations such as exposure of the photosensitive resin layer such as the dry film, development of the exposed portion, and elution can be performed in accordance with ordinary photolithographic methods, and the photomask, developer and the like used are not particularly limited. Without any limitation, any of various general ones may be used. Thus, the photosensitive resin layer patterned in a pattern opposite to the partition layer remains on the connecting organic resin layer on the support film. It is generally preferable that the film thickness be about 100 to 300 μm.

The formation of the partition glass layer by embedding the glass paste into the pattern openings of the photosensitive resin layer is generally performed by adding a glass paste, usually a low melting glass powder and an inorganic filler to a solvent solution of an organic resin. This is performed using a paste-like material dispersed in (oil).

The low melting glass powder, the inorganic filler (hereinafter referred to as solid inorganic powder) and the oil in the glass paste used herein are not particularly limited in their components and mixing ratios. It can be similar to those used. For example, as a glass powder, lead-free glass or leaded glass that melts at about 450 to 600 ° C. and becomes glassy, and as an inorganic filler, black or white inorganic pigment, alumina, silica, etc. Powder and the like, and, as the organic resin, a cellulose resin, an acrylic resin, a water-soluble resin, etc., and as a solvent, butyl carbitol acetate or α-terpineol,
Each can be exemplified. These can be used alone or in combination of two or more.

The above-mentioned organic resin is generally contained in an amount of about 2 to 30% by weight, preferably about 5 to 20% by weight, in the obtained glass paste.
It can be used in the range of weight%. Solid inorganic powder is
It is suitably selected from the range of about 60 to 95% by weight of the obtained glass paste. The amount of the glass powder in the solid inorganic powder is preferably selected from a range of usually about 30 to 90% by weight.

The formation of the partition glass layer by embedding the glass paste is particularly advantageous in that the adhesion of the glass paste to the photosensitive resin layer other than the openings can be avoided.
It is preferable to use a doctor blade method, but without being limited thereto, for example, apply a glass paste to the entire surface including the patterned photosensitive resin layer by a normal method, and use a method other than the paste embedded in the pattern. Unnecessary paste can be removed by a method or the like, and further, a desired paste can be embedded by a repetitive printing method using a screen having the same pattern as the openings.

The glass paste thus embedded is
By drying according to a conventional method and forming a glass layer for the partition wall, finally, the remaining photosensitive resin layer is removed by a usual method, for example, by a washing operation using a diluted alkaline aqueous solution, or the like,
A glass layer for a partition having a necessary discharge space can be formed.

Next, in the present invention, a phosphor layer is formed in an opening (discharge space) of a laminate in which a glass layer for a partition is formed on the organic resin layer for connection obtained as described above. This can be performed by various methods generally used, such as a printing method, a photolithographic method, and a dry film method.

More specifically, in the above-mentioned printing method, a desired phosphor layer can be formed by, for example, sequentially printing red, green and blue phosphor pastes and then drying. In the photolithographic method and the dry film method, both the coating or lamination, exposure and development are repeated using a paste in which a phosphor is dispersed in a photosensitive resin or its dry film, so that a desired red color is formed in the discharge space. , Green and blue phosphor layers. The phosphor paste and the photosensitive resin used in each of the methods may be the same as those usually used, but in particular, in order to obtain a good phosphor powder layer along the partition walls, the thermal decomposition property is good. It is good to select a suitable resin component. As the resin component used in the phosphor paste,
For example, a cellulose resin or an acrylic resin may be used, and as an example of the photosensitive resin, for example, a methacrylic resin or an acrylic resin having a high acid value may be used.

Thus, it is possible to obtain a laminate in which the glass layer for the partition and the phosphor layer are formed on the support film via the organic resin layer for connection.

The barrier sheet and the laminated sheet for forming a phosphor of the present invention can be obtained by forming a protective film layer so as to cover and cover the top of the glass layer for the barrier wall of the laminate obtained above. Here, the film used as the protective film layer can be a plastic film such as ordinary polyethylene terephthalate or polyethylene, and has a mechanical strength capable of avoiding damage to the partition structure of the glass layer for the partition as much as possible. It is preferably selected from plastic films. Although the thickness is not particularly limited, it is usually 30 to 200 μm.
It is preferable to be within the range. The protective film layer can be formed by a general method, for example, a method using a thermocompression roll (laminator) or the like.

Thus, the intended partition wall of the plasma display panel and the laminated sheet for forming the phosphor of the present invention can be obtained.

The laminated sheet of the present invention is appropriately cut as needed, for example, on a back glass plate of a plasma display panel having a PDP glass substrate provided with electrodes and a dielectric layer, and a commercially available thermocompression roll (laminator) ) And the like, while removing the supporting film, thermocompression bonding, then peeling off the upper protective film, and finally, the glass used for the partition wall glass layer in order to obtain partition walls and phosphor layers having desired properties. By baking at a temperature suitable for the components, for example, about 500 to 650 ° C., desired partition walls and phosphor powder layers can be easily and efficiently formed on the back glass plate.

The laminated sheet of the present invention can be used not only for forming stripe-shaped partition walls of an AC-type plasma display panel, but also for forming partition walls having a DC-type cellular structure (# type).

[0032]

The present invention will now be described in further detail with reference to examples. In the examples, parts and% are based on weight.

[0033]

Example 1 "Diananal BR-6" manufactured by Mitsubishi Gas Chemical Company as an acrylic resin in butyl carbitol acetate
0 ”is dissolved by 10%, and 50 μm is used as a supporting film.
Apply on a PET film with a doctor blade,
The organic resin layer for connection was formed by drying at 50 ° C. for 30 minutes.

Next, a dry film (supporting film (100 μm), photosensitive resin layer (100 μm) and protective film (50 μm) manufactured by Tokyo Ohka Co., Ltd.
Thermocompression roll (laminator)
The two layers were laminated so that the photosensitive resin layers overlap each other while peeling off the protective film, thereby producing a laminate having a photosensitive resin layer thickness of 200 μm.

A photomask is superimposed on the laminate so as to have a diaphragm width of 100 μm and a discharge space of 200 μm, and is exposed through the mask with an exposure machine (parallel light type) using a metal halide lamp manufactured by Oak Co., Ltd. The support film on the exposure side was peeled off and the spray pressure was 1.5 kg /
Developing was performed using a 1.0% aqueous sodium carbonate solution using a developing device of cm ² to leave a photosensitive resin layer having a reverse pattern of the partition layer.

Next, as a partition wall material, a white glass paste of calcination type at 550 ° C. (in an oil obtained by dissolving a cellulose resin in a butyl carbitol acetate solvent,
Paste prepared by dispersing solid inorganic powder mainly composed of lead borosilicate glass powder having a softening point of 515 ° C. and a glass transition point of 550 ° C. and blending a white pigment and an inorganic filler)
Using a reverse coater, the paste is applied to the surface of the laminate having the photosensitive resin layer on which the pattern is formed, and the paste is embedded in the openings between the photosensitive resin layers. And dried for 30 minutes. The photosensitive resin layer was swelled and removed by dipping in a 5% aqueous solution of NaOH (40 ° C.).

On the other hand, as a phosphor paste, a commercially available phosphor (blue: “KX-501” manufactured by Kasei Opto Co., Ltd., B
aMgAl ₁₀ O ₁₇ , Eu ²⁺ , green: “P1-G1S” manufactured by Kasei Opto, Zn ₂ SiO ₄ : Mn, red: “KX-504” manufactured by Kasei Opto, ((Y, Gd) B
O ₃ : Eu)) was dispersed in butyl carbitol oil containing 10% of ethylcellulose, and a phosphor paste was prepared. The phosphor paste was screen-printed on a space (discharge space) from which the photosensitive resin had been removed, and dried. Is repeated three times, and the lower part of the discharge space and the glass layer wall portion for the partition wall
Phosphor layers of three colors were formed in a letter shape.

Next, a protective film (polyethylene terephthalate (PET) film, manufactured by Asahi Kasei Corporation, 50 μm) was thermocompressed as a top layer at a roll temperature of 120 ° C. using a heat roll manufactured by Taisei Laminator Co., Ltd. An inventive laminated sheet was obtained.

This sheet was pressed on a back plate of a PDP provided with electrodes and a dielectric layer with an organic resin layer for connection by a hot roll and baked at 550 ° C. to obtain a desired partition layer ( A thickness of 150 μm) and a U-shaped phosphor layer (20 μm) were formed in the discharge space.

The obtained partition layer sufficiently withstood the step of sticking to the front panel, which is the step of paneling, and the luminance life of the phosphor layer after paneling was 10,000 hours or more.

[0041]

Example 2 "Dyana R BR-9" manufactured by Mitsubishi Gas Chemical Company as an acrylic resin in butyl carbitol acetate
0 ”is dissolved by 10%, and 50 μm is used as a supporting film.
Apply on a PET film with a doctor blade,
The organic resin layer for connection was formed by drying at 50 ° C. for 30 minutes.

Next, "Photomar ET", a negative resist, manufactured by Okuno Pharmaceutical Co., Ltd., was applied on the connecting organic resin layer using a doctor blade,
It dried at ° C and formed a photosensitive resin layer (200 micrometers).

On the obtained laminate, a diaphragm width of 100 μm,
Photomasks are stacked so that the discharge space is 200 μm,
Exposure was performed through the mask with an exposure machine (parallel light type) using a metal halide lamp manufactured by Oak Co., Ltd., and then a 1.0% aqueous sodium carbonate solution was used with a developing machine having a spray pressure of 1.5 kg / cm ^2. And developed to leave a photosensitive resin layer having the reverse pattern of the partition layer.

Next, as a partition wall material, a black glass paste of baked at 580 ° C. (in an oil obtained by dissolving a cellulose resin in a butyl carbitol acetate solvent,
Softening point 525 ° C, glass transition point 560 ° C, yield point 500 ° C
The above pattern is formed by a reverse coater using a paste-like material prepared by dispersing a solid inorganic powder in which a black pigment and an inorganic filler are blended with a lead borosilicate glass powder as a main component. The paste was applied to the surface of the laminated body having the photosensitive resin layer, the paste was embedded in the openings between the photosensitive resin layers, and dried in a drying oven set at 150 ° C. for 30 minutes. The photosensitive resin layer is made of a 5% NaOH aqueous solution (40%).
C) to remove swelling.

On the other hand, as a phosphor paste, a commercially available phosphor (blue: “KX-501” manufactured by Kasei Opto Co., Ltd., B
aMgAl ₁₀ O ₁₇ , Eu ²⁺ , green: “P1-G1S” manufactured by Kasei Opto, Zn ₂ SiO ₄ : Mn, red: “KX-504” manufactured by Kasei Opto, ((Y, Gd) B
O ₃ : Eu)) and a negative resist “Photomar E
T "(manufactured by Okuno Pharmaceutical Co., Ltd.), and the phosphor paste was used. The phosphor paste was embedded in a space (discharge space) from which the photosensitive resin had been removed with a doctor blade, and dried, exposed and developed. By repeating this process three times, phosphor layers of three colors were formed in a U-shape on the lower part of the discharge space and the wall of the partition wall glass layer.

Next, a protective film (polyethylene terephthalate (PET) film, 50 μm, manufactured by Asahi Kasei Corporation) was thermocompressed at a roll temperature of 120 ° C. using a hot roll manufactured by Taisei Laminator Co., Ltd. as the uppermost layer. An inventive laminated sheet was obtained.

This sheet was pressed against the back plate of a PDP provided with electrodes and a dielectric layer with a connecting organic resin layer by a hot roll and baked at 550 ° C. to obtain a desired partition layer (thickness). 150 μm) and a U-shaped phosphor layer (20 μm) in the discharge space.

The obtained partition layer sufficiently withstands the step of sticking to the front panel, which is the step of paneling, and the luminance life of the phosphor layer after paneling was 10,000 hours or more.

Claims (1)

[Claims] 1. A plastic support film, a partition wall glass layer and a phosphor layer formed on the support film via an organic resin layer, and a protective film layer for connecting and covering the top of the partition wall glass layer. A partition sheet for a plasma display panel and a laminated sheet for forming a phosphor layer, comprising: