JPH1154028A - Manufacture of base board for display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide inexpensively a base board for a plasma display panel, which has a barrier plate with a desired fine pattern. SOLUTION: A resin mold 11 to which a fine pattern is transcribed is obtained from a master die, by an injection molding method. A base board for a plasma display panel is obtained by flowing perhydropolysilazane 12 into the resin mold 11, applying heat pressing by a press machine P after placing a glass plate 13 on it and transcribing a fine pattern bar 50 of the resin mold to a hardening substance of perhydropolysilazane 12. Since an inexpensive resin mold can be made consumable, while a base board with a desired pattern can be obtained, by this manufacturing method, a manufacturing cost can be also reduced.

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 display panel substrate provided with fine partition walls used for various display panels including a plasma display panel.

[0002]

2. Description of the Related Art The basic structure of a plasma display panel, which is also applied to a wall-mounted television, is, for example,
As shown in FIG. That is, the front panel A and the back panel B are overlapped so that the striped electrodes A1 and B1 formed on both panels are opposed to each other, and a discharge is caused in the striped or grid-shaped partition C at the intersection. To emit light.

The partition C is provided to prevent crosstalk of light and to provide a contrast of a screen, and is very fine. For example, in the case of a stripe, a width of about 30 μm and a height of about 200 μm
And formed over the front surface of the panel at intervals of about 100 μm. Then, a phosphor is applied to the inside of the partition C having such fine dimensions, and an inert gas such as Ne or Xe is sealed therein. Therefore, from the viewpoint of obtaining a complicated and clear image, the fine pattern required for the partition wall C is of course required, the coating amount of the phosphor is made constant, and the leakage of the inert gas is prevented by being in close contact with the front panel A. From the viewpoint and the like, the dimensional accuracy of the partition wall C is required to be high.

Conventionally, a screen printing method or a sand blast method has been adopted as a method for forming such a partition C. In the screen printing method, an operation of printing a glass paste on a glass substrate and drying the glass paste is repeated about 10 times each time with positioning, and a partition is formed by so-called overprinting. In the sand blasting method, a glass paste is applied to the front surface of a glass substrate, coated with a photoresist, exposed and developed, and thereafter, a portion not covered with the resist pattern is sand blasted to form a partition.

[0005]

In the method of forming the partition wall by the screen printing method, it is difficult to form a fine pattern due to the alignment and the distortion of the screen each time, and this difficulty is a major obstacle particularly in increasing the screen size. Has become. Further, depending on the method of forming the partition walls by the sandblast method, the problem that the depth tends to be non-uniform cannot be mainly solved, and it is also difficult to form a fine pattern and enlarge the screen. Further, in any of the methods, it takes a long time to increase the dimensional accuracy, which causes a rise in manufacturing cost.

Therefore, the present invention employs a method of obtaining a resin mold having a consumable striped or lattice-shaped fine pattern from a mold serving as a master mold and transferring the fine pattern from the resin mold. Accordingly, it is an object of the present invention to solve the above-mentioned problem and to provide a method of manufacturing a display panel provided with a partition having a high dimensional accuracy capable of forming a fine pattern and a large screen.

[0007]

According to the present invention, as a means for achieving the above object, a first step of obtaining a resin mold having a desired fine pattern formed by injection molding according to claim 1; A second step of pouring the liquid curable material into the fine pattern forming surface of the above, further placing a glass plate thereon, and a third step of curing the liquid curable material while pressing the liquid curable material and removing the resin mold. The present invention provides a method for manufacturing a display panel substrate, comprising:

According to the present invention, as a means for achieving the above object, a first step of obtaining a resin mold having a desired fine pattern formed by injection molding according to claim 2; and forming a fine pattern of the resin mold. Secondly, a partially vulcanized silicone rubber film is placed on the surface, and a glass reinforcing material is further provided thereon.
And a third step of removing the resin mold after curing the partially vulcanized silicone rubber film. A method of manufacturing a display panel substrate, the method comprising:

According to the present invention, there is provided a display panel substrate according to claim 2, wherein as a means for achieving the above object, providing a glass reinforcing material in the second step comprises laying glass plates on top of each other. And a method for producing the same.

[0010] Further, according to the present invention, as a means for achieving the above object, the second step is to provide a glass reinforcing material by applying a vitreous coating layer. Provided is a method for manufacturing a substrate for use.

Further, the present invention provides a method for manufacturing a display panel substrate according to claim 1 or 2, which is a substrate for a plasma display panel according to claim 5 as means for achieving the above object.

The "liquid" in the liquid curable material used in the first aspect of the present invention means that the curable material itself is a liquid, a solution containing the curable material, a dispersed liquid, a sol,
It is a paste or the like and has a fluidity enough to be poured into a resin mold. Further, the `` cured material '' in the liquid curable material means a material having a property of curing at room temperature or by heating,
The degree of “curing” is such that rigidity and durability generally required for the partition wall portion of the display panel substrate can be imparted.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a display panel substrate according to the present invention will be described with reference to the drawings. 1 (a) to 1 (c) are schematic front views for explaining the manufacturing method according to claim 1, and FIGS. 2 (a) to 2 (c).
FIG. 4 is a schematic front view for explaining a manufacturing method according to claim 2; FIG. 3 is a schematic front view for explaining a manufacturing method which is another embodiment of the manufacturing method according to claim 2; FIG. 5 is a schematic front view for explaining a manufacturing method which is another embodiment of the manufacturing method according to the second aspect, and FIG. 5 is a schematic front view for explaining the manufacturing method according to the first and second aspects.

First, a method for manufacturing a display panel substrate according to the first aspect will be described. In the first step, a resin mold 11 having a desired fine pattern 50 as shown in FIG. 1A is obtained by injection molding. The fine pattern 50 of the resin mold 11 is for forming the partition of the target display panel substrate, and the pattern of the partition forms a reversed image of unevenness. The fine pattern 50 of the resin mold 11 has a stripe shape or a lattice shape. To give an example of the dimensions, the fine pattern 50 is a stripe shape having a width of 60 μm and a depth of 200 μm.
m and an interval of about 160 μm.

A well-known injection technique may be applied to the injection molding method in the first step, and a phenol resin, a urea resin, a melamine resin, an epoxy resin, an unsaturated polyester resin may be used as long as the resin used can be injection-molded. resin,
Thermosetting resins such as silicone resin and urethane resin, vinyl chloride resin, polyethylene resin, polypropylene resin,
Any of thermoplastic resins such as polystyrene resin, ABS resin, AS resin, polyamide resin, polyacetal resin, methacrylic resin, polycarbonate resin, fluororesin, and polyester resin can be used. The mold used in this injection molding is a master mold for manufacturing the resin mold 11. For example, the inner surface of the movable mold is finely machined with a milling machine or a special tool, so that the desired resin mold 11 can be finely molded. It can correspond to the pattern 50.

In the second step, as shown in FIG. 1B, first, the liquid hardening material 12 is poured into the surface of the resin mold 11 where the fine pattern 50 is formed. This liquid hardening material 12
As shown in FIGS. 1 (b) and 1 (c), after the curing is completed, the partition walls 2 of the display panel substrate are formed. As the pouring method, other than the method of casting the liquid curable material 12, a method such as brush coating can be applied. By pouring the liquid curable material 12 in this manner, the liquid curable material 12
0 can be transferred as it is in a finely inverted state, and this transfer is completed by curing in the next step.

As described above, the liquid curable material 12 used in this step is "liquid", and may be used alone or in combination with a curing agent, a catalyst, or other components contributing to curing at room temperature or under heating. There is no particular limitation as long as it "curs". However, since a resin mold is used as a mold, it must be capable of being heat-cured at a lower temperature than conventional glass paste so as not to thermally deform the resin. Similarly, when a solvent is included in the components of the liquid curable material 12, it is necessary to consider the compatibility between the solvent and the resin mold. Examples of such a liquid curable material 12 include inorganic silicon-containing polymers that form a film for ceramics, in which a crosslinking reaction proceeds at room temperature or under heating, ceramic powder, cement such as alumina cement, water glass. Inorganic binders containing the like can also be used. Further, since the liquid curable material 12 serves as the partition wall 2, it is advantageous in obtaining the contrast of the display panel.
If necessary, a dark colorant such as black can be blended.

A specific example of such a liquid curable material 12 is HEAT (trade name) which forms a silicon-containing polymer.
LESS GLASS GS-600 series (Homer Technology Co., Ltd.), polysilazanes such as perhydropolysilazane, for example, trade name Tonen polysilazane (Tonen Corporation), trade name of inorganic binder Red Proof MR-100 series (Ltd.) Thermal Research).

Next, after the liquid curable material 12 has been poured into the resin mold 11 in this manner, the glass plates 13 are placed on top of each other from above. This glass plate 13 is shown in FIGS.
As shown in FIG. 6, the glass substrate 3 on the back can be used as it is.

When the glass plate 13 is placed in the second step, it is conceivable that air enters between the poured liquid hardening material 12 and the glass plate 13 and remains as it is, so that, for example, from one end to the other end. It is desirable to place the glass plate 13 so as to overlap the liquid hardening material 12 while gradually removing air.

In the third step, the resin mold 11 is cured while being pressed by, for example, a heat press machine, and then the resin mold 11 is removed. By the processing in this step, the fine pattern 50 of the resin mold 11 is transferred to the cured product of the liquid curing material 12 in a state of being finely inverted as it is. At the same time, the liquid hardening material 12 and the glass plate 13 are fixed. In addition, the pressing is
In addition to applying pressure by a separate press machine, for example, the pressure applied by the weight of the glass plate is included. In the case of pressing, a cushion material having good heat conductivity can be interposed in order to ensure a uniform pressing state.

In the curing process in the third step, a curing temperature is selected according to the properties of the used liquid curing material 12. When selecting the curing temperature, the resin mold 11
Is also taken into account. For example, when polypropylene is used as the material of the resin mold 11, it is necessary to heat and cure at a temperature lower than 140 to 160 ° C., which is the softening point of polypropylene.

After the curing is completed, the resin mold 11, the partition 2 and the glass plate 13 are separated. At this time, since the resin mold 11 is flexible and can be easily bent, the peeling operation can be performed smoothly. In consideration of the releasability, the liquid curable material 12 may be peeled with such a hardness as to maintain the uneven shape, and then re-cured. After peeling, the curing temperature may be further increased to completely cure. In this manner, as shown in FIG. 1C, the partition 2 having the fine pattern 60 in which the fine pattern 50 of the resin mold 11 is precisely inverted and transferred, and the glass substrate 3 supporting the fine pattern 60
Can be obtained.

Next, a method of manufacturing the display panel substrate according to the second aspect will be described. First, in the first step, a resin mold 11 is obtained in the same manner as in the above-described manufacturing method of claim 1 (see FIG. 2A).

Next, in the second step, as shown in FIG. 2 (b), a partially vulcanized silicone rubber film 15 is placed on the surface of the resin mold 11 where the fine pattern 50 is formed, and a glass reinforcing material is placed thereon. And put the glass plates 13 on each other. The partially vulcanized silicone rubber film 15 is shown in FIG.
As shown in (b) and (c), it becomes the partition wall 5 of the display panel substrate 10 after the curing is completed. Also,
As shown in FIGS. 2 (b) and 2 (c), the glass plate 13 can be used as it is as the glass substrate 3 on the back side.
5 (partition wall 5) to improve workability.

The partially vulcanized silicone rubber film 15 used in the second step is stopped halfway without completing the vulcanization reaction, and the resulting film has a shape retaining property that does not impair workability. And a silicone rubber film having such properties that it can be easily deformed by applying pressure. Therefore, by placing the partially vulcanized silicone rubber film 15 on the fine pattern 50 of the resin mold 11, the fine pattern 50 can be transferred as it is precisely inverted. This transfer is completed by curing in the next step.

The partially vulcanized silicone rubber film 15 can be obtained, for example, by the following method. After blending other components as needed with the unvulcanized silicone rubber raw material, the mixture is placed in a mold, heated while being pressed, and partially vulcanized. The conditions of the partial vulcanization vary depending on the type of the silicone rubber. For example, in the case of an addition type liquid silicone rubber (two-component type), the vulcanization reaction is completed in about 8 hours at 20 ° C. And
At 60 ° C., the vulcanization reaction is completed in about one hour, so that the vulcanization reaction is stopped in less than half the time so that the above properties can be imparted. When the reaction is stopped in this way, it is immediately stored in a cool place to prevent further progress of the vulcanization reaction. The progress of the partial vulcanization reaction can be controlled not only by the time but also by adjusting the heating temperature and adding a reaction inhibitor.

The silicone rubber raw material used here may be a commercially available heat-curable or room temperature-curable type.
One-pack or two-pack, addition or condensation can be used. Other components include reaction inhibitors such as methylvinylcyclotetrasiloxane, acetylene alcohols, siloxane-modified acetylene alcohol, and hydroperoxide; reinforcing silica, quartz powder, iron oxide, alumina, and vinyl group-containing silicone resin. And various additives such as a pigment, a heat-resistant agent, a flame retardant, and an adhesion improver.

Such a partially vulcanized silicone rubber film 15 is commercially available under the trade name SOTEF.
A50 (JIS A hardness 50), SOTEFA70 (J
ISA hardness 70), SH861U (JIS A hardness 6)
0) (Dow Corning Toray Silicone Co., Ltd.), trade name TSE260-7U (Toshiba Silicone Co., Ltd.), trade name KE565K-U (JIS A hardness 60;
Shin-Etsu Chemical Co., Ltd.) can be used. Note that the JIS A hardness shown here is the hardness after vulcanization is completed.

Next, in the third step, after the partially vulcanized silicone rubber film 15 is cured at normal temperature or under heating, the resin mold 11 is removed. When selecting the temperature for heating during the curing, the resin is cured at a temperature lower than the softening point in consideration of the softening point of the resin mold 11. This curing reaction is completed, and the resin mold 11 is peeled off.
As shown in (c), the display panel substrate 10 including the partition 5 having the fine pattern 60 in which the fine pattern 50 of the resin mold 11 is minutely inverted and transferred and the glass substrate 3 supporting the same can be obtained. it can.

In such a manufacturing method, the glass plate 13 may not be used. In that case, the partition 5 made of silicone rubber is used as the display panel substrate 10 as it is. In this case,
As shown in FIG. 3, it is preferable to form a glassy coating layer 70 serving as a hard skin layer as a glass reinforcing plate on the surface on which the fine pattern 60 is not formed, and to reinforce the glassy coating layer. The vitreous coating layer 70 is formed, for example, by applying a material such as the above-described HEATLESS GLASS by spin coating and curing the material.
Can be formed.

Further, as shown in FIG. 4, a vitreous coating layer 71 can be formed on the surface of the partition wall 5. In this case, since the partition walls 5 are made of a partially vulcanized silicone rubber film as a starting material, there is a possibility that low molecular substances may remain inside the partition walls 5. Therefore, in such a case, the low-molecular substance is volatilized during the manufacturing process of the display panel, such as formation of the addressing electrode and coating of the phosphor, and the operation may be hindered depending on the content of the process. Because there is. The vitreous coating layer 71 can be formed in the same manner as the vitreous coating layer 70.

The display panel substrate 10 thus obtained is obtained by attaching address electrodes, applying a fluorescent material, etc. in a conventional manner to obtain a desired display panel such as a plasma display panel. be able to.

[0034]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, but it should not be construed that the invention is limited thereto.

Example 1 By applying the manufacturing method described in claim 1, a substrate for a plasma display panel having striped partition walls as shown in FIG. 6 was manufactured. Hereinafter, the first embodiment will be described with reference to FIG. First, a width of 60 μm and a height of 200 μm were obtained by injection molding.
A resin mold 11 made of polypropylene having a fine pattern 50 with a pitch of 160 μm and a pitch of 160 μm was manufactured, and this was placed on a fixed plate P 1 of a heat press P. Next, this resin mold 1
The liquid hardening material 12 is formed on the surface on which the fine pattern 50 is formed.
As HEATLESS GLASS (GS-
600-1; containing isopropyl alcohol as a diluent) by brushing. Thereafter, a glass plate 13 serving as a substrate was placed on the application surface. Next, the movable platen P
2 was lowered and heated and kept at 130 ° C. for about 20 to 30 minutes while applying a pressure of about 15 g / cm ² from above the glass plate 13 to cure HEATLESS GLASS.
After the curing is completed, the movable platen P2 is raised and the resin mold 1
1 was peeled off to obtain a plasma display panel substrate 10 as shown in FIG. Observation of the surface of the plasma display panel substrate 10 with a microscope revealed that the fine pattern 50 of the resin mold 11 was inverted and transferred as it was, having a width of 60 μm, a height of 200 μm, and a spacing of 160 μm.
It was confirmed that the partition walls 3 of the fine pattern 60 of m were formed.

Example 2 By applying the manufacturing method described in claim 2, a substrate for a plasma display panel having stripe-shaped partition walls as shown in FIG. 3 was manufactured. Hereinafter, a second embodiment will be described with reference to FIG. First, a width of 60 μm and a height of 200 μm were obtained by injection molding.
A polyester resin mold 11 having a fine pattern having a fine pattern of
Was placed on the fixed plate P1. Next, on the surface on which the fine pattern 50 of the resin mold 11 is formed, as a partially vulcanized silicone rubber film 15, the product name is SOTEFA70.
(Thickness: 0.5 mm). Thereafter, a glass plate 13 serving as a substrate was placed on the film. Next, the movable platen P2 is lowered, and heated and held at 150 ° C. for about 4 hours while applying a pressure of about 50 g / cm ² from above the glass plate 13, and the SOTE
FA70 was cured. After curing is completed, moveable plate P
2 was lifted, and the resin mold 11 was peeled off to obtain a plasma display panel substrate 10 as shown in FIG. Observation of the surface of the plasma display panel substrate 10 with a microscope revealed that the fine pattern 50 of the width 60 μm, the height 200 μm, and the interval 160 μm in which the fine pattern 50 of the resin mold 11 was inverted and transferred as it was.
It was confirmed that 0 partition walls 5 were formed.

[0037]

According to the manufacturing method of the first and second aspects, the fine pattern of the master mold is inverted and transferred to the resin mold, and the fine pattern of the resin mold is inverted and transferred. A display panel substrate having a partition wall having a desired fine pattern can be easily and mass-produced. The resin mold can be easily and mass-produced from the master mold, and since the resin itself as the raw material is originally inexpensive, the price can be set and maintained at a very low price, so that a consumable mold can be obtained. Therefore, if the product becomes unusable due to clogging or the like due to repeated use, it can be discarded and replaced with a new resin mold. Become cheap. Therefore, by applying the manufacturing method according to claims 1 and 2, it is possible to provide an inexpensive and high-quality display panel substrate that can be applied to a plasma display panel and the like. It can also be applied to large screens.

[Brief description of the drawings]

FIG. 1 is a schematic front view for explaining a manufacturing method according to the first embodiment.

FIG. 2 is a schematic front view for explaining the manufacturing method according to the second embodiment.

FIG. 3 is a schematic front view for explaining the manufacturing method according to claim 4;

FIG. 4 is a schematic front view for explaining another embodiment of the manufacturing method according to the second embodiment.

FIG. 5 is a schematic front view for explaining the manufacturing method according to claims 1 and 2;

FIG. 6 is a schematic perspective view showing a structural example of a plasma display panel.

[Explanation of symbols]

 2 Partition wall 3 Glass substrate 5 Partition wall 10 Display panel substrate 11 Resin mold 12 Liquid curing material 13 Glass plate 15 Partially vulcanized silicone rubber film 50 Fine pattern 60 Fine pattern 70 Glass reinforcing material

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[Procedure amendment]

[Submission date] August 18, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0017

[Correction method] Change

[Correction contents]

As described above, the liquid curable material 12 used in this step is "liquid", and may be used alone or in combination with a curing agent, a catalyst, or other components contributing to curing at room temperature or under heating. There is no particular limitation as long as it "curs". However, since a resin mold is used as a mold, it must be capable of being heat-cured at a lower temperature than conventional glass paste so as not to thermally deform the resin. Similarly, when a solvent is included in the components of the liquid curable material 12, it is necessary to consider the compatibility between the solvent and the resin mold. Examples of such a liquid curable material 12 include, in addition to an inorganic silicon-containing polymer that undergoes a crosslinking reaction at room temperature or under heating to form a ceramic-like film, ceramic powder, cement such as alumina cement, and water glass. Inorganic binders containing the like can also be used. Further, since the liquid curable material 12 serves as the partition wall 2, it is advantageous in obtaining the contrast of the display panel.
If necessary, a dark colorant such as black can be blended. ────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] August 27, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0003

[Correction method] Change

[Correction contents]

The partition C is provided to prevent crosstalk of light and to provide a contrast of a screen, and is very fine. For example, in the case of a stripe, a width of about 30 μm and a height of about 200 μm
Therefore, it is required to form the entire surface of the panel at intervals of about 100 μm. Then, a phosphor is applied to the inside of the partition C having such fine dimensions, and Ne, X
An inert gas such as e is sealed. Therefore, from the viewpoint of obtaining a complicated and clear image, the fine pattern required for the partition wall C is of course required, the coating amount of the phosphor is made constant, and the leakage of the inert gas is prevented by being in close contact with the front panel A. From the viewpoint and the like, the dimensional accuracy of the partition wall C is required to be high.

Claims (5)

[Claims] 1. A first step of obtaining a resin mold on which a desired fine pattern is formed by injection molding, and after pouring a liquid curable material into a fine pattern forming surface of the resin mold, a glass plate is further stacked thereon. A method for manufacturing a substrate for a display panel, comprising: a second step of placing the substrate; and a third step of removing the resin mold after the liquid curing material is cured while being pressed. 2. A first step of obtaining a resin mold on which a desired fine pattern is formed by injection molding, placing a partially vulcanized silicone rubber film on the fine pattern forming surface of the resin mold, and further reinforcing a glass reinforcing material thereon A second step of providing
And a third step of removing the resin mold after curing the partially vulcanized silicone rubber film. 3. The method for manufacturing a display panel substrate according to claim 2, wherein the provision of the glass reinforcing material is such that the glass plates are placed one on top of the other. 4. The method for manufacturing a display panel substrate according to claim 2, wherein providing the glass reinforcing material comprises applying a vitreous coating layer. 5. The method according to claim 1, wherein the substrate is a substrate for a plasma display panel.