WO2009130896A1 - プラズマディスプレイパネルの製造方法 - Google Patents
プラズマディスプレイパネルの製造方法 Download PDFInfo
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- WO2009130896A1 WO2009130896A1 PCT/JP2009/001843 JP2009001843W WO2009130896A1 WO 2009130896 A1 WO2009130896 A1 WO 2009130896A1 JP 2009001843 W JP2009001843 W JP 2009001843W WO 2009130896 A1 WO2009130896 A1 WO 2009130896A1
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- metal oxide
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- base film
- particles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J11/00—Gas-filled discharge tubes with alternating current induction of the discharge, e.g. alternating current plasma display panels [AC-PDP]; Gas-filled discharge tubes without any main electrode inside the vessel; Gas-filled discharge tubes with at least one main electrode outside the vessel
- H01J11/10—AC-PDPs with at least one main electrode being out of contact with the plasma
- H01J11/12—AC-PDPs with at least one main electrode being out of contact with the plasma with main electrodes provided on both sides of the discharge space
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J11/00—Gas-filled discharge tubes with alternating current induction of the discharge, e.g. alternating current plasma display panels [AC-PDP]; Gas-filled discharge tubes without any main electrode inside the vessel; Gas-filled discharge tubes with at least one main electrode outside the vessel
- H01J11/20—Constructional details
- H01J11/34—Vessels, containers or parts thereof, e.g. substrates
- H01J11/40—Layers for protecting or enhancing the electron emission, e.g. MgO layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J9/00—Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
- H01J9/02—Manufacture of electrodes or electrode systems
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49126—Assembling bases
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49155—Manufacturing circuit on or in base
Definitions
- the present invention relates to a method for manufacturing a plasma display panel.
- PDPs Plasma display panels
- FPDs flat panel displays
- an AC drive surface discharge type PDP adopts a three-electrode structure, and has a structure in which two glass substrates of a front plate and a back plate are arranged to face each other at a predetermined interval.
- the front plate includes a display electrode formed of a stripe-shaped scan electrode and a sustain electrode formed on a glass substrate, a dielectric layer that covers the display electrode and functions as a capacitor for storing electric charges, and the dielectric And a protective film having a thickness of about 1 ⁇ m formed on the layer.
- the back plate was applied in a display cell partitioned by the partition walls, a plurality of address electrodes formed on the glass substrate, a base dielectric layer covering the address electrodes, partition walls formed thereon. It is comprised with the fluorescent substance layer which light-emits each in red, green, and blue.
- the front plate and the back plate are hermetically sealed with their electrode forming surfaces facing each other, and a discharge gas of neon (Ne) -xenon (Xe) is discharged at a pressure of 53 kPa to 80.0 kPa in the discharge space partitioned by the barrier ribs. It is enclosed.
- PDP discharges by selectively applying a video signal voltage to the display electrode, and the ultraviolet rays generated by the discharge excite each color phosphor layer to emit red, green and blue light, thereby realizing color image display (See Patent Document 1).
- the role of the protective layer formed on the dielectric layer of the front plate is to protect the dielectric layer from ion bombardment due to discharge and to emit initial electrons for generating address discharge.
- Etc. Protecting the dielectric layer from ion bombardment plays an important role in preventing an increase in discharge voltage, and emitting initial electrons for generating an address discharge is an address discharge error that causes image flickering. It is an important role to prevent.
- Patent Document 2 an attempt has been made to improve electron emission characteristics by mixing impurities in the protective layer.
- impurities are mixed in the protective layer and the electron emission characteristics are improved, at the same time, charges are accumulated on the surface of the protective layer, and the attenuation rate at which the charge decreases as time goes by as a memory function increases. Therefore, it is necessary to take measures such as increasing the applied voltage to suppress this.
- the protective layer has a high electron emission ability and a low charge decay rate as a memory function, that is, a high charge retention characteristic. There was a problem.
- a dielectric layer is formed so as to cover the display electrodes formed on the substrate, and a front plate in which a protective layer is formed on the dielectric layer, and a discharge space is formed in the front plate. And a back plate provided with barrier ribs for partitioning a discharge space, and forming a protective layer for the front plate
- the protective layer forming step includes forming a base film by depositing a base film on the dielectric layer, and applying a metal oxide paste containing metal oxide particles, an organic component, and a diluting solvent to the base film.
- a paste film forming process for forming a metal oxide paste film, an exposure development process for exposing and developing the paste film to leave the paste film in a predetermined pattern shape on the base film, and a process before remaining on the base film A metal oxide particle adhering step of removing organic components by baking the paste film and adhering metal oxide particles onto the base film, and the metal oxide particle content is 1 .5% by volume or less and containing a photopolymerization initiator, a water-soluble cellulose derivative, and a photopolymerizable monomer as organic components.
- a paste film containing metal oxide particles in a predetermined pattern shape can be formed on the base film, so that the metal oxide particles can be dispersed uniformly and uniformly in the plane on the base film. It can be made to adhere and the coverage distribution of metal oxide particles can be made uniform. As a result, it is possible to realize a PDP having improved display characteristics of low power consumption, high definition and high brightness, which has improved electron emission characteristics and charge retention characteristics.
- FIG. 1 is a perspective view showing the structure of a PDP manufactured by the PDP manufacturing method according to the embodiment of the present invention.
- FIG. 2 is a cross-sectional view showing the configuration of the front plate of the PDP.
- FIG. 3 is a flowchart showing a process for forming a protective layer of the PDP.
- FIG. 4 is a diagram showing the results of cathodoluminescence measurement of crystal particles.
- FIG. 5 is a graph showing the characteristics of the electron emission performance and Vscn lighting voltage of the PDP in the embodiment of the present invention.
- FIG. 6 is a graph showing the relationship between the crystal grain size and the electron emission performance.
- FIG. 7 is a characteristic diagram showing the relationship between the crystal grain size and the partition wall breakage probability.
- FIG. 8 is a diagram showing an example of aggregated particles and particle size distribution.
- FIG. 1 is a perspective view showing a structure of a PDP 1 manufactured by the PDP manufacturing method according to the embodiment of the present invention.
- the front plate 2 made of the front glass substrate 3 and the like and the back plate 10 made of the back glass substrate 11 and the like are arranged to face each other, and the outer peripheral portion thereof is hermetically sealed with a sealing material made of glass frit or the like.
- a discharge gas such as neon (Ne) and xenon (Xe) is sealed in the discharge space 16 inside the PDP 1 at a pressure of 53.3 kPa to 80.0 kPa.
- a pair of strip-like display electrodes 6 made up of scanning electrodes 4 and sustain electrodes 5 and black stripes (light shielding layers) 7 are arranged in a plurality of rows in parallel with each other.
- a dielectric layer 8 serving as a capacitor is formed on the front glass substrate 3 so as to cover the display electrode 6 and the light shielding layer 7, and a protective layer 9 made of magnesium oxide (MgO) is formed on the surface.
- MgO magnesium oxide
- a plurality of strip-like address electrodes 12 are arranged in parallel to each other in a direction orthogonal to the scanning electrodes 4 and the sustain electrodes 5 of the front plate 2.
- Layer 13 is covering.
- barrier ribs 14 having a predetermined height for partitioning the discharge space 16 are formed.
- a phosphor layer 15 is formed in the groove between the barrier ribs 14. The phosphor layer 15 emits red, green, and blue light by ultraviolet rays.
- a discharge cell is formed at a position where the scan electrode 4 and the sustain electrode 5 and the address electrode 12 intersect to form a pixel for color display.
- FIG. 2 is a cross-sectional view showing the configuration of the front plate 2 of the PDP 1 in the embodiment of the present invention, and FIG. 2 is shown upside down with respect to FIG.
- a display electrode 6 including a scanning electrode 4 and a sustain electrode 5 and a black stripe (light shielding layer) 7 are formed in a pattern on a front glass substrate 3 manufactured by a float method or the like.
- Scan electrode 4 and sustain electrode 5 are made of transparent electrodes 4a and 5a made of indium tin oxide (ITO), tin oxide (SnO 2 ), and the like, and metal bus electrodes 4b and 5b formed on transparent electrodes 4a and 5a, respectively. It is comprised by.
- ITO indium tin oxide
- SnO 2 tin oxide
- metal bus electrodes 4b and 5b formed on transparent electrodes 4a and 5a, respectively. It is comprised by.
- the metal bus electrodes 4b and 5b are used for the purpose of imparting conductivity in the longitudinal direction of the transparent electrodes 4a and 5a, and are formed of a conductive material mainly composed of a silver (Ag) material.
- the dielectric layer 8 includes a first dielectric layer 81 provided on the front glass substrate 3 so as to cover the transparent electrodes 4a and 5a, the metal bus electrodes 4b and 5b, and the light shielding layer 7, and a first dielectric layer.
- the second dielectric layer 82 formed on the body layer 81 has at least two layers.
- the protective layer 9 includes a base film 91 and aggregated particles 92 distributed on the base film 91.
- the base film 91 is made of magnesium oxide (MgO) or magnesium oxide (MgO) containing aluminum (Al) on the dielectric layer 8.
- aggregated particles 92 in which a plurality of crystal particles of magnesium oxide (MgO), which is a metal oxide, are aggregated are distributed on the base film 91 in a discrete and almost uniform manner over the entire surface. Aggregated particles 92 are adhered to base film 91 at a coverage of 2% to 12%.
- an image of a region corresponding to one discharge cell divided by the barrier ribs 14 is captured by a camera and trimmed to the size of one cell of x ⁇ y. After that, the captured image after trimming is binarized into black and white data, and thereafter the area a of the black area by the aggregated particles 92 is obtained based on the binarized data, and is calculated by the formula a / b ⁇ 100 as described above. It is obtained by doing.
- the scan electrode 4 and the sustain electrode 5 and the black stripe (light shielding layer) 7 are formed on the front glass substrate 3.
- the transparent electrodes 4a and 5a and the metal bus electrodes 4b and 5b are formed by patterning using a photolithography method or the like.
- the transparent electrodes 4a and 5a are formed using a thin film process or the like, and the metal bus electrodes 4b and 5b are solidified by baking a paste containing a silver (Ag) material at a predetermined temperature.
- the black stripe (light-shielding layer) 7 is formed by screen printing a paste containing a black pigment or forming a black pigment on the entire surface of the front glass substrate 3 and then patterning and baking using a photolithography method. It is formed by.
- a dielectric paste is applied on the front glass substrate 3 by a die coating method or the like so as to cover the display electrodes 6 including the scanning electrodes 4 and the sustain electrodes 5 and the black stripes (light-shielding layer) 7. Material layer) (not shown) is formed. Thereafter, the dielectric paste film is baked and solidified to form the dielectric layer 8 that covers the scan electrode 4, the sustain electrode 5, and the black stripe (light shielding layer) 7.
- the dielectric paste is a paint containing a dielectric material such as glass powder, a binder and a solvent.
- a base film 91 made of magnesium oxide (MgO) is formed on the dielectric layer 8 by a vacuum deposition method.
- the display electrode 6, the light shielding layer 7, the dielectric layer 8, and the base film 91 which are predetermined constituent elements other than the aggregated particles 92 of the PDP 1 in the present invention are formed on the front glass substrate 3.
- FIG. 3 is a flowchart showing a process for forming the protective layer 9 of the PDP 1.
- a sintered body of magnesium oxide (MgO) containing aluminum (Al) is obtained.
- a base film 91 mainly made of magnesium oxide (MgO) is formed on the dielectric layer 8 by a vacuum deposition method as a raw material.
- aggregated particles are adhered to discretely form aggregated particles 92 in which crystal particles of magnesium oxide (MgO) serving as metal oxide particles are aggregated on the unfired base film 91 formed in the base film deposition step A2. Enter step A3.
- MgO magnesium oxide
- the aggregated particle adhesion step A3 includes the following steps. That is, in the paste film forming step A31, a metal oxide paste of a photopolymerization composition composed of metal oxide particles that are magnesium oxide (MgO) crystal particles, an organic component, and a diluting solvent is applied onto the base film 91. Thus, a paste film is formed. Next, in the exposure development step A32, the paste film formed on the base film 91 is exposed and developed to leave the paste film in a predetermined pattern shape on the base film 91. Further, in the metal oxide particle adhesion step A33, organic components in the metal oxide paste are removed by baking the remaining paste film, and aggregated particles 92 in which metal oxide crystal particles are aggregated on the base film 91 are formed. A deposited protective layer 9 can be formed. As a result, the protective layer 9 composed of the base film 91 and the aggregated particles 92 can be formed.
- MgO magnesium oxide
- a negative photomask in which a predetermined pattern shape is formed using an actinic ray having a predetermined wavelength that activates a photopolymerization initiator such as an ultraviolet ray, an excimer laser, an X-ray, or an electron beam. And exposing the metal oxide paste.
- development processing is performed using water, and an unexposed portion is dissolved and removed, whereby a paste film containing metal oxide particles is formed on the base film 91 so as to have a predetermined pattern shape.
- an ultraviolet irradiation apparatus generally used in the photolithography method, an exposure apparatus used when manufacturing a semiconductor and a liquid crystal display device, and the like can be used.
- water can be used for the developing solution, and examples of the developing method include a dipping method, a rocking method, a shower method, a spray method, a paddle method, and the like.
- the firing process in the metal oxide particle forming step A33 is performed in a predetermined temperature profile and atmosphere of several hundred degrees C so that the organic components in the paste film remaining on the base film 91 are thermally decomposed and volatilized.
- a drying process for drying the paste film is included as a pre-process of the exposure development process A32.
- the metal oxide paste has a content of metal oxide particles contained in the paste of 1.5% by volume or less, as an organic component, It contains a photopolymerization initiator, a water-soluble cellulose derivative, and a photopolymerizable monomer. Further, the metal oxide particles dispersed in the metal oxide paste are basically dispersed as crystal particles as primary particles, but these primary particles form several aggregate particles in the paste. These aggregated particles are formed on the base film 91.
- magnesium oxide (MgO) is the main component of the base film 91.
- the base film 91 has high sputter resistance performance for protecting the dielectric layer 8 from ion bombardment.
- the electron emission performance may not be so high. That is, in the conventional PDP, the protective layer 9 mainly composed of magnesium oxide (MgO) is often formed in order to achieve both of a certain level of electron emission performance and sputtering resistance performance.
- the electron emission performance is dominantly controlled by the metal oxide crystal particles. Therefore, the base film 91 is not necessarily made of magnesium oxide (MgO), and other materials having excellent sputtering resistance performance such as aluminum oxide (Al 2 O 3 ) may be used.
- magnesium oxide (MgO) crystal particles as the metal oxide crystal particles, but other crystal particles have high electron emission performance like magnesium oxide (MgO).
- MgO magnesium oxide
- the same effect can be obtained by using crystal particles of metal oxides such as strontium (Sr), calcium (Ca), barium (Ba), and aluminum (Al). Therefore, the crystal particles are not particularly limited to magnesium oxide (MgO).
- the display electrode 6, the black stripe (light shielding layer) 7, the dielectric layer 8, the base film 91, and the aggregated particles 92 of magnesium oxide (MgO) are formed on the front glass substrate 3.
- the back plate 10 is formed as follows. First, the structure for the address electrode 12 is formed by a method of screen printing a paste containing silver (Ag) material on the rear glass substrate 11 or a method of patterning using a photolithography method after forming a metal film on the entire surface. A material layer to be a material is formed. The address layer 12 is formed by firing this material layer at a predetermined temperature. Next, a dielectric paste is applied to the back glass substrate 11 on which the address electrodes 12 are formed by a die coating method so as to cover the address electrodes 12 to form a dielectric paste film. Thereafter, the base dielectric layer 13 is formed by firing the dielectric paste film.
- the dielectric paste is a paint containing a dielectric material such as glass powder, a binder and a solvent.
- the partition wall material layer is formed by applying a partition wall forming paste containing the material of the partition wall 14 on the base dielectric layer 13 and patterning it into a predetermined shape. Thereafter, the partition wall 14 is formed by firing the partition wall material layer.
- a method of patterning the partition wall paste applied on the base dielectric layer 13 a photolithography method or a sand blast method can be used.
- the phosphor layer 15 is formed by applying a phosphor paste containing a phosphor material on the base dielectric layer 13 between the adjacent barrier ribs 14 and on the side surfaces of the barrier ribs 14 and baking it.
- the front plate 2 and the back plate 10 having predetermined constituent members are arranged to face each other so that the display electrodes 6 and the address electrodes 12 are orthogonal to each other, and the periphery thereof is sealed with a glass frit, so that a discharge space is obtained.
- 16 is filled with a discharge gas containing neon (Ne), xenon (Xe), or the like, thereby completing the PDP 1.
- the content of metal oxide particles contained in the paste is 1.5% by volume or less, and as an organic component, a photopolymerization initiator, a water-soluble cellulose derivative, It contains a photopolymerizable composition such as a photopolymerizable monomer.
- photopolymerization initiator known ones can be used, for example, benzophenones, benzoins, benzoin alkyl ethers, acetophenones, aminoacetophenones, benzyls, benzoin alkyl ethers, benzyl alkyl ketals. , Anthraquinones, ketals, thioxanthones and the like.
- the photopolymerization initiator is suitably used in the photopolymerizable composition in the range of 0.1 to 5% by volume, more preferably in the range of 0.5 to 2% by volume.
- the photopolymerization initiator is less than 0.1% by volume, the curability by exposure decreases. Further, when the photopolymerization initiator exceeds 5% by volume, patterning defects such as deterioration in resolution due to development are observed.
- the water-soluble cellulose derivative may be a known one and is not particularly limited, and examples thereof include hydroxyethyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl cellulose, ethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose and the like. These may be used singly or in combination of two or more.
- This water-soluble cellulose derivative functions as a binder resin, but has high transmittance for actinic rays irradiated to activate photopolymerization initiators such as ultraviolet rays, excimer lasers, X-rays and electron beams to initiate the polymerization reaction. Highly accurate pattern formation is possible.
- the water-soluble cellulose derivative is suitably used in the range of 5 to 20% by volume, more preferably in the range of 8 to 12% by volume in the photopolymerizable composition.
- the water-soluble cellulose derivative is less than 5% by volume, when coating is performed by a screen printing method, the frictional force between the squeegee and the screen plate increases, so that squeegee knocking occurs and printability is reduced.
- the water-soluble cellulose derivative exceeds 20% by volume, a phenomenon such that a combustion residue tends to remain when firing and removing the organic component after forming the metal oxide paste film is observed.
- the dilution solvent is not particularly limited as long as it can be dissolved in the water-soluble cellulose derivative.
- the photopolymerizable monomer may be a known one and is not particularly limited.
- This photopolymerizable monomer is suitably used in the range of 3 to 15% by volume, more preferably in the range of 5 to 10% by volume in the photopolymerizable composition.
- the photopolymerizable monomer is less than 3% by volume, curing is insufficient during exposure and pattern peeling occurs during development. Further, when the photopolymerizable monomer exceeds 15% by volume, the resolution is deteriorated and patterning failure is observed, which is not preferable.
- the photopolymerizable composition of the present invention may contain an ultraviolet absorber, a sensitizer, a sensitizer, a polymerization inhibitor, a plasticizer, a thickener, an organic solvent, a dispersant, and an antifoaming agent as necessary.
- Additives such as organic or inorganic suspending agents can be added.
- Sensitizer is added to improve sensitivity to light.
- Specific examples of such sensitizers include 2,4-diethylthioxanthone, isopropylthioxanthone, 2,3-bis (4-diethylaminobenzal) cyclopentanone, and 2,6-bis (4-dimethylaminobenzal).
- Polymerization inhibitor is added to improve thermal stability during storage.
- Specific examples of such polymerization inhibitors include hydroquinone, monoesterified hydroquinone, N-nitrosodiphenylamine, phenothiazine, pt-butylcatechol, N-phenylnaphthylamine, 2,6-di-tert-butyl-p. -Methylphenol, chloranil, pyrogallol and the like.
- Plasticizer can be added to improve printability.
- examples include dibutyl phthalate (DBP), dioctyl phthalate (DOP), polyethylene glycol, glycerin, butyl tartrate and the like.
- the antifoaming agent is added to reduce bubbles in the photopolymerizable composition and to reduce pores in the metal oxide paste film.
- an antifoaming agent include alkylene glycol-based, silicon-based and higher alcohol-based antifoaming agents such as polyethylene glycol (molecular weight 400 to 800).
- the organic components listed above may be prepared in the form of a paste or liquid, and the metal oxide and the diluent solvent may be well kneaded with three rolls, coated on a support film, dried, and sheeted and laminated on a substrate. . Further, it may be used by patterning by coating and drying directly on a substrate, exposing and developing using a screen printing method or the like.
- the support film When used in the form of a sheet, examples of the support film include a flexible film made of a synthetic resin film such as polyethylene terephthalate having a thickness of 15 to 125 ⁇ m, polyethylene, polypropylene, polycarbonate, and polyvinyl chloride. If necessary, this support film may be subjected to mold release treatment such as silicon (Si) treatment so that transfer to a substrate or the like is facilitated.
- a protective film may be attached to the sheet having such a photopolymerizable composition in order to improve stability when not in use.
- a polyethylene terephthalate film, a polypropylene film, a polyethylene film, or the like having a thickness of about 15 to 125 ⁇ m coated or baked with silicon can be used.
- hydroxypropyl cellulose as a water-soluble cellulose derivative was mixed in a diethylene glycol monobutyl ether and terpineol diluting solvent, stirred and dissolved while heating to obtain a hydroxypropyl cellulose solution.
- this solution was returned to room temperature, and further photopolymerization was initiated with 2-methacryloyloxyethyl-2-hydroxypropyl phthalate (trade name HO-MPP, manufactured by Kyoeisha Chemical Co., Ltd.) as a photopolymerizable monomer.
- 2-methacryloyloxyethyl-2-hydroxypropyl phthalate trade name HO-MPP, manufactured by Kyoeisha Chemical Co., Ltd.
- 2-methyl-1 [4- (methylthio) phenyl] -2-morpholinopropan-1-one (trade name IR-907, manufactured by Ciba Geigy Co., Ltd.) and diethylthioxanthone (trade name DETX- S, manufactured by Nippon Kayaku Co., Ltd.) was added and dissolved to prepare an organic vehicle.
- This organic vehicle and magnesium oxide (MgO) particles as metal oxide particles are mixed and dispersed by a three-roll mill to prepare a photopolymerizable composition.
- diethylene glycol monobutyl ether and terpineol were further added to adjust the viscosity, followed by filtration using a 30 ⁇ m filter to prepare a metal oxide paste.
- Table 1 shows the composition (1), the composition (2), and the composition (3) with different contents in the metal oxide paste. In these compositions, in the exposure and development process. The adhesion to the substrate and the resolution were evaluated.
- the metal oxide paste prepared as described above is screen-printed on a substrate on which the scan electrode 4, the sustain electrode 5, the light shielding layer 7, the dielectric layer 8, and the base layer 91 are formed.
- actinic rays were irradiated through a negative type pattern forming photomask, and the metal oxide paste film was exposed at an exposure amount of 100 mJ / cm 2 . Then, it developed with the city water hold
- the “break point” is the time until the paste is completely dissolved in the developer when the photopolymerizable composition paste is developed without exposure.
- the photomask for pattern formation is made of a glass substrate that transmits actinic rays, and includes a light-shielding portion coated or dyed with a black pigment or paint that absorbs actinic rays, and a transmission portion that transmits actinic rays.
- the transmissive part is formed in nine different widths of 200 ⁇ m, 150 ⁇ m, 100 ⁇ m, 75 ⁇ m, 50 ⁇ m, 40 ⁇ m, 30 ⁇ m, 20 ⁇ m, and 10 ⁇ m, and each has five of the same width. A total of 90 pieces are provided in the light shielding portion. Transmission parts having the same width are adjacent to each other with an interval twice as large as the width. That is, in the case of the transmissive part having a width of 50 ⁇ m, the transmissive part having a width of 50 ⁇ m and the light shielding part having a width of 100 ⁇ m are alternately provided.
- the light shielding portion is formed in nine different widths of 200 ⁇ m, 150 ⁇ m, 100 ⁇ m, 75 ⁇ m, 50 ⁇ m, 40 ⁇ m, 30 ⁇ m, 20 ⁇ m, and 10 ⁇ m. A total of 90 pieces of 5 pieces each are provided in the transmission part.
- the light shielding portions having the same width are adjacent to each other with an interval twice as large as the width. That is, in the case of the light shielding portion having a width of 50 ⁇ m, the light shielding portions having a width of 50 ⁇ m and the transmission portions having a width of 100 ⁇ m are alternately provided.
- the adhesion was evaluated at the convex portions and the resolution was evaluated at the concave portions.
- Adhesion was evaluated based on the pattern obtained with such a photomask. As described above, when the paste film is exposed, if the photocuring is sufficiently performed, five convex portions having a width of 200 ⁇ m, 150 ⁇ m, 100 ⁇ m, 75 ⁇ m, 50 ⁇ m, 40 ⁇ m, 30 ⁇ m, 20 ⁇ m, and 10 ⁇ m are formed on the substrate. It is formed. However, when the photocuring at the bottom of the paste film is insufficient, the latent image portion is eluted in the developer, and no convex portion is formed on the substrate.
- the adhesive is observed by observing whether or not the line-shaped convex portions formed on the substrate are hardened by light transmitted through nine kinds of transmission portions having different widths and are sufficiently adhered after development. Was evaluated. And, for example, when exposed at 50 mJ / cm 2 , the line width of the transmissive part on the pattern side corresponding to the smallest convex part that can be formed in a state where all of the nine transmissive parts are in close contact with the substrate. ( ⁇ m) was observed.
- the pattern after development of the composition (1) has a good pattern of 10 ⁇ m adhesion and 10 ⁇ m resolution, but the composition (2) has a sufficient photopolymerization reaction. Therefore, the pattern was peeled off during development, and the metal oxide paste film pattern could not be formed.
- the photopolymerization reaction proceeded to the light-shielding portion, so that a good concave portion could not be formed, and good resolution could not be obtained.
- the metal oxide paste of the composition (1) in Table 1 when used, a metal with a predetermined coverage over the entire surface of the base film 91 is obtained by performing exposure and development through a mask pattern having a predetermined shape. It becomes possible to disperse and arrange the oxide aggregated particles 92. Further, the aggregated particles 92 of the metal oxide can be distributed with the optimum coverage only for the pixels.
- the coverage of the aggregated particles 92 of magnesium oxide (MgO) is preferably in the range of 2% to 12% because of its discharge characteristics.
- the content of magnesium oxide (MgO) particles in the metal oxide paste is 0 based on the film thickness range that can be formed by screen printing. A range of 0.01% to 1.5% by volume is preferred.
- the content of metal oxide particles contained in the paste is 1.5% by volume or less, A photopolymerization initiator, a water-soluble cellulose derivative, and a photopolymerizable monomer are included as organic components.
- Prototype 1 is a PDP formed with a protective layer 9 made only of a magnesium oxide (MgO) film
- prototype 2 is a protective layer 9 made of magnesium oxide (MgO) doped with impurities such as aluminum (Al) and silicon (Si).
- the PDP 1 in which the sample 3 is formed is a PDP 1 according to the present invention, which is a PDP 1 in which agglomerated particles 92 of crystal particles made of metal oxide are attached on a base film 91 of magnesium oxide (MgO).
- Prototype 3 when the cathode luminescence was measured using magnesium oxide (MgO) crystal particles as the metal oxide, it had the characteristics shown in FIG.
- the electron emission performance is a numerical value indicating that the larger the electron emission performance, the greater the amount of electron emission.
- the initial electron emission amount can be measured by a method of measuring the amount of electron current emitted from the surface by irradiating the surface with ions or an electron beam, but it is difficult to evaluate the surface of the front plate 2 in a non-destructive manner.
- a numerical value called a statistical delay time which is a measure of the probability of occurrence of discharge, was measured.
- the reciprocal of the numerical value is integrated, it becomes a numerical value that corresponds linearly to the amount of initial electron emission, and here, this numerical value is used for evaluation.
- the delay time at the time of discharge means a time when the discharge is delayed from the rising edge of the pulse. It is considered that the discharge delay is mainly caused by the fact that initial electrons that become a trigger when the discharge is started are not easily released from the surface of the protective layer 9 into the discharge space 16.
- a voltage value (hereinafter referred to as a Vscn lighting voltage) applied to the scan electrode 4 necessary for suppressing the charge emission phenomenon when the PDP 1 is produced is used. That is, a lower Vscn lighting voltage indicates a higher charge retention capability. Since this can be driven at a low voltage even in the panel design of the PDP, it is possible to use components having a small withstand voltage and capacity as the power source and each electrical component. In a current product, an element having a withstand voltage of about 150 V is used as a semiconductor switching element such as a MOSFET for sequentially applying a scanning voltage to a panel. Therefore, it is desirable to suppress the Vscn lighting voltage to 120 V or less in consideration of fluctuation due to temperature.
- FIG. 5 The results of investigating these electron emission performance and charge retention performance are shown in FIG. In FIG. 5, the electron emission performance on the horizontal axis is shown with reference to the electron emission performance in the prototype 1.
- the Vscn lighting voltage can be reduced to 120 V or less, and the electron emission performance is 6 times or more better than that of the prototype 1. .
- the electron emission performance and the charge retention performance of the protective layer 9 of the PDP are contradictory.
- the film forming conditions of the protective layer 9 are changed, and the protective layer 9 is formed by doping impurities such as aluminum (Al), silicon (Si), and barium (Ba) as in the prototype 2.
- impurities such as aluminum (Al), silicon (Si), and barium (Ba) as in the prototype 2.
- the electron emission performance can be improved, but the Vscn lighting voltage also increases as a side effect.
- the protective layer 9 that satisfies both the electron emission performance and the charge retention performance is realized for a PDP in which the number of scanning lines increases and the cell size tends to decrease due to high definition. be able to.
- the particle diameter means an average particle diameter
- the average particle diameter means a volume cumulative average diameter (D50).
- FIG. 6 shows an experimental result of examining the electron emission performance in the prototype 3 of the present invention described in FIG. 5 by changing the particle diameter of the magnesium oxide (MgO) crystal particles.
- the particle size of the magnesium oxide (MgO) crystal particles is the average particle size when the particle size distribution is measured in a reagent grade 1 or higher ethanol solution using a Microtrac HRA particle size distribution meter. The crystal particles are measured by observing them with a scanning electron microscope (SEM).
- the top part of the partition wall 14 is damaged by the presence of crystal particles in the portion corresponding to the top part of the partition wall 14 of the back panel 10 that is in close contact with the protective layer 9 of the front panel 2. It has been found that a phenomenon occurs in which the corresponding cell does not normally turn on and off when the material is placed on the phosphor layer 15. The phenomenon of the partition wall breakage is unlikely to occur unless the crystal particles are present at the portion corresponding to the top of the partition wall 14, so that the probability of breakage of the partition wall 14 increases as the number of attached crystal particles increases.
- FIG. 7 is a diagram showing a result of experiments on the relationship between partition wall breakage in the prototype 3 according to the present invention described with reference to FIG. 5 by spraying the same number of crystal particles having different particle sizes per unit area.
- the partition wall breakage probability increases rapidly, but when the crystal particle diameter is smaller than 2.5 ⁇ m, the partition wall breakage probability is relatively small. It can be seen that it can be suppressed.
- the aggregated particles 92 in which the crystal particles are aggregated preferably have a particle size of 0.9 ⁇ m or more and 2.5 ⁇ m or less. In actual mass production, it is necessary to consider variations in the production of crystal grains and variations in production when the protective layer 9 is formed.
- FIG. 8 is a diagram showing an example of the particle size distribution of the aggregated particles 92 used in the PDP 1 in the embodiment of the present invention.
- Aggregated particles 92 have a distribution as shown in FIG. From the electron emission characteristics shown in FIG. 6 and the partition wall failure characteristics shown in FIG. 7, it is possible to use aggregated particles 92 having a volume cumulative average diameter (D50) that is an average particle diameter in the range of 0.9 ⁇ m to 2 ⁇ m. desirable.
- D50 volume cumulative average diameter
- the PDP 1 having the protective layer 9 formed using the metal oxide paste according to the embodiment of the present invention has a characteristic that is 6 times or more that of the prototype 1 as the electron emission performance, As the holding performance, a Vscn lighting voltage of 120 V or less can be obtained. As a result, it is possible to realize the protective layer 9 of the PDP 1 in which the number of scanning lines increases and the cell size tends to decrease due to high definition. As a result, it is possible to realize a PDP that satisfies both electron emission performance and charge retention performance, has high-definition and high-luminance display performance, and has low power consumption.
- the aggregated particles 92 of magnesium oxide (MgO) are adhered at a coverage of 2% to 12%.
- MgO magnesium oxide
- the agglomerated particles 92 of magnesium oxide (MgO) must be present in each discharge cell in order to reduce variation in characteristics. For that purpose, it is necessary to adhere to the entire surface of the base film 91. It was found that when the coverage is small, the in-plane variation tends to increase, and the variation in the adhesion state of the aggregated particles 92 between the discharge cells increases. As a result of experiments conducted by the present inventors, it was found that in-plane variation can be suppressed to about 4% or less when magnesium oxide (MgO) aggregated particles 92 are adhered so that the coverage is 4% or more. . Further, even when the aggregated particles 92 of the magnesium oxide (MgO) crystal particles are adhered so that the coverage is 2% or more, the in-plane variation can be suppressed to about 6%, and there is no practical problem. I understood it.
- the aggregated particles 92 of the magnesium oxide (MgO) crystal particles so that the coverage is in the range of 2% to 12%, and more preferably the coverage is 4 It is desirable to adhere the agglomerated particles 92 so as to be in the range of% to 12%.
- the content of magnesium oxide (MgO) particles in the metal oxide paste is preferably in the range of 0.01 volume% to 1.5 volume%.
- the present invention is useful for realizing a PDP having high-definition and high-luminance display performance and low power consumption.
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Abstract
Description
図1は、本発明の実施の形態におけるPDPの製造方法により製造されたPDP1の構造を示す斜視図である。前面ガラス基板3などよりなる前面板2と、背面ガラス基板11などよりなる背面板10とが対向して配置され、その外周部をガラスフリットなどからなる封着材によって気密封着されている。PDP1内部の放電空間16には、ネオン(Ne)およびキセノン(Xe)などの放電ガスが53.3kPa~80.0kPaの圧力で封入されている。前面板2の前面ガラス基板3上には、走査電極4および維持電極5よりなる一対の帯状の表示電極6とブラックストライプ(遮光層)7が互いに平行にそれぞれ複数列配置されている。前面ガラス基板3上には表示電極6と遮光層7とを覆うようにコンデンサとしての働きをする誘電体層8が形成され、さらにその表面に酸化マグネシウム(MgO)などからなる保護層9が形成されている。
2 前面板
3 前面ガラス基板
4 走査電極
4a,5a 透明電極
4b,5b 金属バス電極
5 維持電極
6 表示電極
7 ブラックストライプ(遮光層)
8 誘電体層
9 保護層
10 背面板
11 背面ガラス基板
12 アドレス電極
13 下地誘電体層
14 隔壁
15 蛍光体層
16 放電空間
81 第1誘電体層
82 第2誘電体層
91 下地膜
92 凝集粒子
Claims (2)
- 基板上に形成した表示電極を覆うように誘電体層を形成するとともに前記誘電体層上に保護層を形成した前面板と、前記前面板に放電空間を形成するように対向配置されかつ前記表示電極と交差する方向にアドレス電極を形成するとともに前記放電空間を区画する隔壁を設けた背面板とを有するプラズマディスプレイパネルの製造方法であって、
前記前面板の前記保護層を形成する保護層形成工程は、
前記誘電体層上に下地膜を蒸着して形成する下地膜形成工程と、
前記下地膜に、金属酸化物粒子と有機成分と希釈溶剤とを含む金属酸化物ペーストを塗布して金属酸化物ペースト膜を形成するペースト膜形成工程と、
前記ペースト膜を露光、現像して前記下地膜上に所定のパターン形状にペースト膜を残存させる露光現像工程と、
前記下地膜上に残存した前記ペースト膜を焼成することにより前記有機成分を除去して前記金属酸化物粒子を前記下地膜上に付着させる金属酸化物粒子付着工程とを備え、
前記金属酸化物ペーストとして、前記金属酸化物粒子の含有量が1.5体積%以下で、前記有機成分には、光重合開始剤と、水溶性セルロース誘導体と、光重合性単量体とを含むものを用いることを特徴とするプラズマディスプレイパネルの製造方法。 - 前記金属酸化物ペースト中に含まれる前記金属酸化物粒子の含有量が0.01体積%以上であるものを用いることを特徴とする請求項1に記載のプラズマディスプレイパネルの製造方法。
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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EP09735476A EP2187423A4 (en) | 2008-04-24 | 2009-04-22 | METHOD FOR MANUFACTURING PLASMA DISPLAY PANEL |
US12/676,995 US8051549B2 (en) | 2008-04-24 | 2009-04-22 | Method for producing plasma display panel |
CN2009801005067A CN102741964A (zh) | 2008-04-24 | 2009-04-22 | 等离子显示面板的制造方法 |
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JP2008113559A JP5141358B2 (ja) | 2008-04-24 | 2008-04-24 | プラズマディスプレイパネル用金属酸化物ペースト及びプラズマディスプレイパネルの製造方法 |
JP2008-113559 | 2008-04-24 |
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US (1) | US8051549B2 (ja) |
EP (1) | EP2187423A4 (ja) |
JP (1) | JP5141358B2 (ja) |
KR (1) | KR101038587B1 (ja) |
CN (1) | CN102741964A (ja) |
WO (1) | WO2009130896A1 (ja) |
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EP2187423A4 (en) | 2011-04-20 |
US8051549B2 (en) | 2011-11-08 |
JP5141358B2 (ja) | 2013-02-13 |
KR20100041879A (ko) | 2010-04-22 |
EP2187423A1 (en) | 2010-05-19 |
KR101038587B1 (ko) | 2011-06-03 |
JP2009266528A (ja) | 2009-11-12 |
US20110126398A1 (en) | 2011-06-02 |
CN102741964A (zh) | 2012-10-17 |
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