KR100418866B1 - Method for forming function layer of flat plate device - Google Patents

Abstract

PURPOSE: A method for forming a function layer of a flat plate device is provided to easily form a function layer of a stripe type regardless of the thickness of the function layer by forming the entire surface layer in a molding groove of a molding roller. CONSTITUTION: The entire surface layer(L') of the thickness of the function layer(L) is formed on a substrate(P). The entire surface layer is pressurized by using the molding roller(1) in which a plurality of molding grooves(2) corresponding to the width and pitch of the function layer are formed. The molding groove is formed on a cylindrical drum by a photolithography process or a sandblasting process by using the molding roller.

Description

Functional layer formation method of flat panel device

TECHNICAL FIELD The present invention relates to the manufacture of flat plate elements, and more particularly, to a method of forming the functional layer.

As is well known, a flat plate element is a thin functional element formed by stacking a functional layer on a substrate, and the method of forming the functional layer is roughly classified into a thin film method and a thick film method.

The thin film method represented by the vapor deposition method has an advantage of obtaining a uniform and dense functional layer, but the process cost is very high and separate patterning is required. Is preferred.

The printing method is also divided into a pattern printing for forming a predetermined pattern and a front printing for forming an entire layer of a predetermined thickness. First, the pattern printing method is a screen on which a predetermined transmission pattern is formed as shown in FIG. The mask M formed is mounted on the substrate P, and the paste T is squeezed onto the mask M by using a squeegee S or the like to apply the mask T to the mask M. The screen printing method formed on the board | substrate P according to a pattern is mainly used.

On the other hand, as the front printing method, a mask (M) without a pattern is formed or a paste (T) is printed using only the squeeze (S) without the mask (M). For example, a doctor blade method, a roll coating method, a spray method, and a spin coatins method are used.

However, in the screen printing method using the mask M, the maximum thickness of the functional layer obtained by one printing is inevitably limited to the thickness of the mask M. FIG. In other words, the mask M is formed by laminating a binder through which a paste T cannot penetrate on a stainless steel mesh and photoetching it to form a permeable pattern, so that the thickness of the binder layer is masked. It becomes thickness of (M), and this becomes the maximum thickness of one layer.

As a result, the functional layer having a thickness below is inevitably dependent on the thin film method, and the thickness of the functional layer obtained by the printing method is basically an integer multiple of the thickness of the mask M.

In the case of a general functional layer, only one layer of printing can be obtained, but the functional layer formed between the two substrates P and the counter substrate (not shown), such as the partition B of the plasma display device PDP shown in FIG. The case is obtained only by several laminations.

In particular, in recent years, the allowable width of the partition wall B is gradually decreased due to the high resolution of the display device. The height of the partition wall B, which determines the discharge gap, can hardly be changed. Formation of the partition wall (B) for forming the element requires a stack of 7,8 or more times.

This results in repeated printing and drying of each layer and firing as needed, which not only consumes a lot of air and cost, but also causes the printed layer to collapse due to repeated press printing. There is also a problem that is not so high.

In addition, in case of PDP used in multi-screen device, even though the pitch between pixels is several mm, the partition B is formed by pattern printing. You will not see any difference in airborne.

On the other hand, although the electrode of the PDP or another device has a matrix structure and is formed in a simple stripe form, there has been no conventional method besides screen printing.

Accordingly, it is an object of the present invention to provide a method for easily forming a functional layer in the form of a stripe.

1 is a schematic side view showing a general screen printing method;

2 is a cross-sectional view showing the configuration of a laminated printed barrier rib,

3 (A) to (D) are sequential views showing the progress of the method of the present invention,

4 (A) to (D) is a sequential drawing showing a manufacturing process of the forming roller by a photolithography method,

5 (A) to (C) is a sequential view showing a manufacturing process of the forming roller by the sand blasting method,

6 is a partially perspective view showing the production of the forming roller by lamination;

7 (A) to (C) are cross-sectional views showing the shape of functional layers moldable by the present invention.

<Description of the code used in the main part of the drawing>

P: substrate L; L1-L3: functional layer

L ': front layer

1: Molding Roller

2; 2a to 2c: forming groove

8a, 8b: disk (of metal sheet)

The method according to the present invention to achieve this object is

The entire surface of the functional layer is formed on the substrate to form a front layer.

It is characterized by forming a functional layer by press molding the front layer with a forming roller having a plurality of forming grooves corresponding to the width and pitch of the functional layer.

Then, the functional layer of arbitrary thickness and arbitrary pitch can be formed by only one operation, so that not only the bulkhead of PDP having a large thickness but also the thin layer of electrode can be applied to the functional layer formed in the stripe shape. do.

EXAMPLE

Such specific features and effects of the present invention will become more apparent from the following description of the preferred embodiments with reference to the accompanying drawings.

In FIG. 3A, the material for forming the functional layer L is entirely formed on the substrate P to form the front layer L ′. The front layer L 'may be formed by printing, roll coating, spraying, or spin coating, and the thickness thereof is formed to have a small required height of the functional layer L.

After the front layer L 'is dried to a suitable extent for molding, the front layer L' is press-molded by a forming roller 1 having a plurality of forming grooves 2 as shown in Fig. 3B. The functional layer L is formed.

As shown in FIG. 3C, the width b1 of the forming groove 2 is the width b of the functional layer L, and the interval d1 therebetween is the interval between the functional layers L ( d). In this case, the thickness t of the front layer L 'is smaller than the required height h of the functional layer L as described above, so that the functional layer L is formed by moving into the molding groove 2 by press molding. do.

Since the front layer L 'is moved to form the functional layer L, there may be a material remaining in the movement path. Accordingly, the functional layer L suitable for the implementation of the method of the present invention is an electrode or the like. It will be an insulating layer such as a dielectric layer rather than a layer.

When the press forming of the functional layer L is completed and then fired, the functional layer L is completed as shown in FIG. 3 (D).

Such a method of the present invention can be applied as long as the stripe type functional layer L has a suitable width h and pitch d regardless of the thickness of the functional layer L. For example, a functional layer L having a height of several hundred μm or a thickness of several tens of μm, such as an electrode, may be formed by one press molding, such as a partition of a PDP (B of FIG. 2).

4 to 6 illustrate methods suitable for the production of the forming roller 1 used in the method of the present invention.

First, the method of FIG. 4 is photo lithography, and the photosensitive layer 4 is coated on the surface of a cylindrical metal drum (drum) 3 to be a material of the forming roller 1 as shown in FIG. 4 (A). Then, it selectively exposes through the mask 5.

Since the drum 3 is cylindrical, it may be preferable to use a rotation method for film formation or exposure of the photosensitive layer 4. Accordingly, in FIG. 4A, a line is formed through a band-shaped mask 5. (線) The photosensitive layer 4 of the drum 3 which the light source 6 rotates is exposed.

Then, the photosensitive layer 4 is developed by spraying the washing water W or the like in FIG. 4B, and the drum 3 is selectively etched by the etching solution Q in FIG. 4C.

Then, the remaining photosensitive layer 4 is removed by a method such as thermal decomposition to complete the forming roller 1 having the forming grooves 2 as shown in FIG. 4 (D).

On the other hand, shown in Figure 5 is a sand blasting (sand blasting) method, in Figure 5 (A) band form with a slit (slit) formed to selectively transmit a grit (Grit) on the drum (3) When the mask 5 'is positioned and the grit G is sprayed at high pressure while the drum 3 is rotated, the grit G passing through the slit 7 moves the drum 3 as shown in FIG. By selectively etching, the forming roller 1 having the forming grooves 2 formed thereon as shown in FIG. 5C is completed.

On the other hand, the configuration of FIG. 6 discloses a configuration method of the forming roller 1 which can be used more universally than the method of FIG. 4 or 5.

That is, the metal plate for the manufacture of safety razor blade, etc. is made of a thin plate within a few tens of micrometers, using this has a forming groove (2) of the width (b1) and the interval (d1) to be an integral multiple of the thickness of the metal sheet The forming roller 1 can be easily configured.

In Fig. 6, the forming roller 1 is composed of two diameter discs 8a and 8b, in which a small diameter disc 8a defines the inner end of the forming groove 2 and a large diameter disc 8b is formed. When the outer end is limited and each is laminated in one or plural as necessary, the configuration of the forming roller 1 having the forming grooves 2 of any size that is an integral multiple of the thickness of the original plates 8a and 8b becomes possible.

Here, the lamination thickness of the small diameter disk 8a becomes the width b1 of the shaping | molding groove 2, and the lamination thickness of the large diameter disk 8b becomes the space | interval d1 between the shaping | molding grooves 2 here.

Preferably, at least one through hole 9 is formed at a corresponding position of each of the original plates 8a and 8b, and is integrally formed with a tie bar (not shown) through the fastening hole. (1) can be configured. In addition, a method such as bonding or welding may be used.

Such a configuration of FIG. 6 is mainly preferred for forming the molding groove 2 of the rectangular cross section and thus the functional layer L of the rectangular cross section.

In addition to the angle of Figure 7 is shown the required cross-section of the various functional layer (L) and the shape of the forming groove (2) constituting the same.

The functional layer L1 of the trapezoidal cross section shown in FIG. 7A can be formed into a corresponding forming groove 2a, and the forming groove 2a can be mainly formed by a photolithography method.

The forming grooves 2b constituting the triangular functional layer L2 of FIG. 7B should be formed in a V shape, and the forming grooves 2b of the V type or U shape are formed by a photolithography method or a sandblasting method. Can be formed.

The functional layer L3 of FIG. 7C is a general form of the functional layer by lamination printing, and may be referred to as a normal distribution type or a Poisson type. It can be prepared by etching.

On the other hand, the functional layer (L) of the rectangular cross section described above may be formed in a somewhat similar form by a photolithography method or a sand blasting method, but the molding groove 2 of the most accurate rectangular cross section may be formed by the thin lamination method described with reference to FIG. 6. Can be.

As described above, according to the present invention, the stripe functional layer can be easily formed regardless of its thickness, thereby greatly reducing the manufacturing man-hours and costs of the flat panel device.

Claims (8)

In the method of forming a striped functional layer on a substrate of a flat panel device, Forming a front layer on the substrate with a thickness of the functional layer, Forming the functional layer by pressing the front layer with a forming roller having a plurality of forming grooves corresponding to the width and pitch of the functional layer. A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method of claim 1, The forming roller is formed by forming the forming groove by a photolithography method on a cylindrical drum. A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method of claim 1, The forming roller is formed by forming the forming groove by the sandblasting method on the cylindrical drum. A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method according to claim 2 or 3, The photolithography or sand blasting is performed through a band-shaped mask while rotating the cylindrical drum. A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method of claim 1, And the forming roller is formed by laminating a plurality of original plates made of a metal thin plate. The method according to any one of claims 1 to 5, The plurality of disks are composed of a small diameter disk defining the inner end of the forming groove and a large diameter disk defining the outer end A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method of claim 6, The small diameter and the large diameter disk is laminated one or more, respectively, The lamination thickness of the small diameter disc becomes the width of the forming groove, The lamination thickness of the large diameter disc sets the spacing between the forming grooves A method for forming a functional layer of a flat plate device characterized by the above-mentioned. The method of claim 5, At least one through hole is formed at a corresponding position of the plurality of discs to form an integral forming roller by fastening the tie bars through the through hole.

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