JP2002237253A - Method for forming partition wall of thin display device - Google Patents

Abstract

(57) [Problem] When a partition of a thin display device is formed by a transfer method, there is a problem that a partition having a high aspect ratio cannot be formed. SOLUTION: In a method of forming a partition 16 on a panel substrate by transferring a partition material 14 filled in a groove of a transfer intaglio 13 onto a panel substrate 11, the transfer intaglio is formed at a predetermined position on the panel substrate. A protrusion 12 having a height equal to or less than the opening width of the groove and lower than the depth of the groove is formed in advance,
The grooves of the transfer intaglio filled with the partition wall material are aligned with the protrusions on the substrate. In this state, the transfer intaglio is overlapped with the panel substrate. A partition (material) is formed on the panel substrate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of forming a partition of a thin display device, and more particularly, to a method of forming a partition in a thin display device such as a field emission display (FED) or a plasma display panel (PDP) by a transfer method. On how to do.

[0002]

2. Description of the Related Art Partition walls of a thin display device are formed to maintain a distance between a rear substrate and a front substrate, to insulate between the two substrates, and to define a display portion. That is, a field emission display (FED) has a plurality of electron-emitting devices (emitters) arranged on a rear substrate,
The anode and the front substrate on which the phosphor surface is formed are opposed to each other,
In a display device in which the peripheries of both substrates are sealed with a sealing material and the inside is evacuated, electrons emitted from the emitter are accelerated by the positive voltage applied to the anode, collide with the phosphor surface, and Is excited to emit light for display. In this device, since the inside is in a vacuum, atmospheric pressure is applied to the back and front substrates, and the partition walls have a function of maintaining the interval between the two substrates. Furthermore, in order to accelerate electrons emitted from the emitter, a potential of several hundred volts to several kilovolts is applied between the two substrates.
It also has the function of maintaining insulation between both substrates.

In a plasma display (PDP), a discharge gas space formed between a front substrate and a rear substrate is divided into cells by partitions, and a phosphor is provided in the cells. Is a device that excites and emits a phosphor to display. The partition in the device functions to separate the discharge and confine the discharge and ultraviolet light generated by the discharge and visible light of phosphor emission in a desired cell.

The partition wall of the FED is required to have an aspect ratio of the partition wall of about 1:20, which is very high with respect to the width of the partition wall. For this reason, a practical method capable of being sufficient for mass production has not been developed, and in the actual FED, a method in which a thin film of glass having a thickness of about 50 μm is cut into strips and bonded is used.

Various methods have been proposed for forming the partition walls of the PDP, and typical methods include a lamination printing method, a sand blast method, an embedding method, a photolithography method, and a transfer method. The transfer method is expected as a method capable of reducing the manufacturing cost in large-scale mass production.

FIGS. 4A to 4F are explanatory views showing a method of forming a partition by a conventional transfer method in the order of steps. In forming the partition, first, a substrate 41 made of glass or the like as shown in (a) (not shown in the figure, but an electrode or an electrode and a dielectric layer covering the electrode are provided on the partition forming surface side). Is formed), and a transfer intaglio 42 in which grooves of a predetermined pattern are formed in rubber, resin or metal as shown in FIG. Then, first, as shown in (c), the groove of the transfer intaglio 42 is filled with the partition wall material 43. When filling the partition material 43 into the transfer intaglio 42,
Filling the transfer intaglio 42 so that the partition material 43 exists not only in the grooves of the transfer intaglio 42 but also on the transfer intaglio 42 as shown in the figure increases the adhesion between the substrate 41 and the partition material 43 and improves transfer performance. I do. Next, as shown in (d), the substrate 41 and the transfer intaglio 42 filled with the partition wall material 43 are aligned. In the state where the positions are matched, as shown in FIG.
1 and the transfer intaglio 42 are brought into close contact with each other. At that time, the transfer intaglio 4
It is desirable to apply a force from the upper surface of 2 using a roll or a press. Next, as shown in (f), the transfer intaglio plate 42 is separated from the partition wall material adhered on the substrate 41, and then the partition wall material is baked, whereby the partition walls 44 are formed on the substrate 41.

[0007]

As described above, in the formation of the partition wall by the transfer method, since the partition wall material needs to be transferred onto the substrate and separated from the transfer intaglio after the partition wall material is brought into close contact with the substrate, the partition wall material is required. When the frictional force between the partition wall material and the transfer intaglio is larger than the adhesive force between the material and the substrate, the partition wall material cannot be transferred to the substrate. In particular, as the aspect ratio (the ratio of the height of the barrier ribs to the width of the barrier ribs) increases, the adhesive force between the barrier rib material and the substrate does not change, but the frictional force between the barrier rib material and the transfer intaglio increases. Also, it becomes difficult to transfer the partition walls to the substrate since the separation of the partition walls becomes difficult. In order to reduce the frictional force between the partition wall material and the transfer intaglio, a method of applying a release agent to the transfer intaglio before filling the partition intaglio into the transfer intaglio, or increasing the thickness of the partition wall material on the transfer intaglio. Although a method and a method of applying a tacky material on a substrate in advance have been tried, there was a problem that a sufficient effect was not obtained, and the partition wall material was not transferred and remained on the transferred intaglio.

In particular, in the case of the FED, a phosphor is applied between the partition walls, and light emission is observed through the phosphor. Therefore, a property of transmitting light between the partition walls is required. In order to absorb the electrons, it is necessary to expose the anode between the partition walls, and the partition material cannot be placed on the transfer intaglio, making it difficult to form a partition having a large aspect ratio. There has been a demand for a method for easily producing a partition having a high ratio.

An object of the present invention is to easily form a partition having a large aspect ratio from such a conventional situation.

[0010]

As a method for stably forming a partition wall having a large aspect ratio, the inventors of the present invention have proposed a method in which the width of the groove is smaller than the opening width of the groove formed in the transfer intaglio. It has been found that the above-mentioned problem can be easily solved by forming a projection lower than the depth on the substrate to be transferred in advance and increasing the adhesion of the partition wall material by the bonding force of the projection.

According to the first aspect of the present invention, there is provided a method of forming a partition on a panel substrate by transferring a partition material filled in a groove of the transfer intaglio onto the panel substrate. A protrusion having a width equal to or less than the opening width of the groove formed in the lower portion and having a height lower than the depth of the groove is formed in advance, and the groove of the transfer intaglio filled with the partition material is aligned with the protrusion on the substrate. In this state, the panel substrate and the transfer intaglio are overlapped, and thereafter, the transfer intaglio is separated from the panel substrate to form a partition having the projection as a core material (base) on the panel substrate.

According to the second aspect of the present invention, the panel substrate and the transfer intaglio are formed of a translucent material, and the partition material includes a photocurable material, and after the partition material is transferred onto the display panel substrate. Irradiating light of a wavelength at which the photocurable material is cured from one or both of the surface of the display panel substrate where the protrusions are not formed, the surface of the transfer intaglio where the grooves are not formed, and the photocurable partition walls The method is characterized in that the material is cured and a photocurable partition wall material is adhered to the protrusion.

According to a third aspect of the present invention, the projection is dark.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described using a partition wall of a PDP as an example.

FIGS. 1A to 1H are explanatory views showing a partition forming method according to a first embodiment of the present invention in the order of steps.
First, as shown in FIG.
(Although not shown in the figure, an electrode or an electrode and a dielectric layer covering the electrode may be formed on the partition wall forming surface side) at a predetermined position on the partition wall forming surface, as shown in FIG. Such a plan view forms a stripe-shaped or lattice-shaped projection. The projection corresponds to a partition, but a transfer intaglio 1 made of, for example, silicone rubber, having a groove corresponding to a partition pattern as shown in FIG.
3 is formed to be smaller than the opening width of the concave groove and smaller than the depth dimension of the concave groove. Since the aspect ratio is low, the method for forming the protrusions 12 may be selected and used from general partition wall forming methods, that is, a lamination printing method, a sand blast method, an embedding method, a photolithography method, a transfer method, and the like. It is necessary to have a strength that does not deform the transfer of the partition wall material. For this purpose, as a material for the projections 12, a glass paste is mixed with a thermosetting resin that is cured by heat, and after formation, a heat treatment is performed, or a photocurable photosensitive agent is mixed with the glass paste, and after formation, the photosensitive material is exposed to light. By irradiating light to a wavelength at which the agent cures, the strength can be increased. In addition,
As long as the pattern of the projections 12 is the same as the groove pattern of the transfer intaglio 13, it may be arranged in a dot shape without being a continuous pattern. The projections 12 may be made of a porous material obtained by mixing a glass paste with a large amount of filler, or may be subjected to physical or chemical etching such as sand blasting to form irregularities on the surface and increase the surface area. It is more preferable to further enhance the adhesiveness with the adhesive.

In the step (d), the groove material of the transfer intaglio 13 is filled with the partition wall material 14. Depending on the filling method, the partition wall material 14 remains around the groove. However, in the present invention, it is not necessary to use the partition wall material 14 attached to other than the concave groove to enhance the adhesion to the substrate as in the conventional example. , (E)
As shown in (1), a step of removing using a blade 15 or the like is provided. It is more preferable to use the partition wall material 14 that becomes white with high translucency or high reflectance after firing in order to increase the emission luminance. Therefore, in the case of a light-transmitting partition, a material having a refractive index close to that of the glass powder in the glass paste is mixed. In the white partition, a white pigment such as alumina or titanium oxide is mixed into the glass paste.

In the next step (f), the projections of the panel substrate 11 and the grooves of the transfer intaglio 13 filled with the partition wall material 14 are aligned. When a structure is transferred onto a projection, the transfer intaglio tends to follow the position of the lower projection. Displacement is unlikely to occur, and positioning work is easy. In the next step (g), the transfer intaglio 1
3 is brought into close contact with the panel substrate 11. At this time, pressure using a roll or a press may be applied from the upper surface of the transfer intaglio 13.

In the next step (h), an operation of separating the transfer intaglio 13 from the panel substrate 11 is performed. At this time, the partition material transferred onto the panel substrate is replaced by the protrusions 1 on the panel substrate.
2 is connected to the panel substrate 11 by the bonding force.
Therefore, the adhesion with the transfer intaglio 13 is hardly peeled off. Thus, the partition 16 having a high aspect ratio is formed on the panel substrate 11. Thereafter, the panel substrate 11 on which the partition walls are formed is fired at a predetermined temperature to complete the partition walls.

FIGS. 2A to 2E are explanatory views showing a partition forming method according to a second embodiment of the present invention in the order of steps.
Also in the second embodiment, the projections 22 are previously formed on the panel substrate 21 as shown in FIG.
The panel substrate 21 is formed of a translucent material. Also,
The transfer intaglio is also formed of a translucent material, and the partition wall material contains a photocurable photosensitive agent. FIG. 2B shows a process in which the groove of the translucent transfer intaglio 24 is filled with a partition material containing a photocurable photosensitive agent (hereinafter referred to as a photosensitive partition material).
Thereafter, as shown in (c), the projection 22 on the panel substrate 21 is aligned with the concave groove of the transfer intaglio 24, and as shown in (d), the panel substrate 21 is transferred to the transfer intaglio 24.
In close contact. The operation of filling the partition intaglio material into the individual transfer intaglio and the operation of positioning and intimately attaching the transfer intaglio to the panel substrate are not different from those of the first embodiment, but in the second embodiment, After the 21 is brought into close contact with the transfer intaglio 24, light having a wavelength at which the photocurable photosensitive agent contained in the photosensitive partition wall material 23 is cured mainly from the transfer intaglio 24 side or both sides or one of the panel substrate 21 side. Irradiation cures the photosensitive partition wall material 23. Due to this curing, the photosensitive partition wall material is adhered to the projection 22 on the panel substrate, and the adhesion to the panel substrate is strengthened. Thereafter, as shown in (e), when the transfer intaglio is separated from the panel substrate, a partition wall 25 having a projection as a core material is formed on the panel substrate 21 on the panel substrate. Thereafter, baking is performed to complete the partition.

FIGS. 3A to 3E are explanatory views showing a method of forming a partition wall according to a third embodiment of the present invention in the order of steps. The feature of the third embodiment is that the projections 32 on the panel substrate are formed of a dark material, and the other steps are the same as those of the first and second embodiments, and therefore, those steps are the same. Description of the steps is omitted. The dark color of the projection 32 is preferably black having a low reflectance from the viewpoint of the contrast of the panel. In order to make the glass black, one or more black pigments of oxides such as iron, nickel, cobalt and manganese are mixed into the glass paste forming the projections. By this dark projection, like FED,
This is effective for increasing the contrast when a partition is formed on the inner surface of the substrate on the viewing surface side. The partition wall material 33 is preferably translucent or white from the viewpoint of improving luminance, and a photosensitive partition wall material is used when the projections 32 and the partition wall material 33 are to be more firmly bonded.

In the above description, the application of the present invention has been mainly described with respect to the method of filling the transfer intaglio with the partition wall material and transferring the same. However, the partition wall material is applied to the substrate on which the protrusions are formed, and a predetermined predetermined amount is applied from above. The method can also be widely applied to a method of pressing an intaglio having grooves formed in the pattern.

[0022]

According to the first to third aspects of the present invention,
A partition having a large aspect ratio for a display device can be easily manufactured by using a transfer method.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a partition forming method according to a first embodiment in the order of steps.

FIG. 2 is an explanatory view showing a partition forming method according to a second embodiment in the order of steps.

FIG. 3 is an explanatory view showing a partition forming method according to a third embodiment in the order of steps.

FIG. 4 is an explanatory diagram showing a partition forming method by a conventional transfer method in the order of steps.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Panel board 12 Projection 13 Transfer intaglio 14 Partition material 15 Blade 23 Photosensitive partition material

Continuation of the front page F term (reference) 5C027 AA09 5C040 GF13 GF18 GF19 JA19 KA16 KB19 MA23 MA24

Claims (3)

[Claims] After filling a partition material into a groove of a transfer intaglio having a groove of a predetermined pattern, the partition material of the transfer intaglio is transferred onto a display panel substrate, and a partition is formed on the display panel substrate. In the method of forming a partition of a thin display device, a protrusion having a width smaller than an opening width of a groove formed in the transfer intaglio and smaller than a depth dimension of the groove is previously formed at a predetermined position on the display panel substrate. After forming and transferring the partition material filled in the grooves of the transfer intaglio onto the display panel substrate in a state where the grooves of the transfer intaglio are aligned with the protrusions on the display panel substrate, the transfer intaglio is removed. A method for forming a partition of a thin display device, comprising forming a partition having a projection as a core material on the panel substrate, away from the display panel substrate. 2. The method according to claim 2, wherein the panel substrate and the transfer intaglio are formed of a light-transmissive material, and the partition material includes a photo-curable material, and after transferring the partition material onto a display panel substrate, By irradiating light having a wavelength at which the photocurable material is cured, the surface of the display panel substrate on which the protrusions are not formed, the surface of the transfer intaglio where the grooves are not formed, or both. 2. The method according to claim 1, wherein the photo-curable partition wall material is cured, and the photo-curable partition wall material is adhered to the protrusion. 3. The method according to claim 1, wherein the protrusion is dark.