JPH09326233A - Manufacture of gas discharge panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing process of a gas discharge panel capable of suppressing the formation of an air collection part on the lower side of a phosphor layer. SOLUTION: A partition 42 is vertically formed on one surface 52 of a dielectric layer 48 (one surface of a back plate 38). A projection 69 is formed in a part of a peak 58 of the partition 42. As the forming process of a phosphor layer, phosphor paste 70 is applied from the peak 58 side of the partition 42 to form a phosphor layer 56 on the one surface 52 of the dielectric layer 48 and the side surface 54 of the partition 42. By these processes, a color plasma display panel is manufactured. Therefore, in the phosphor layer forming process, phosphor paste 70 is coated so that a gap 78 is formed between the partition 42 and the projection 69 based on difference in height between the projection 69 and the peak 58 of the partition 42 in the position in the periphery of the projection 69.

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 gas discharge panel for color display in which a phosphor layer is provided in a discharge space.

[0002]

2. Description of the Related Art For example, a gas discharge panel for color display such as a color plasma display is provided between a pair of substrates arranged in parallel with each other and a plurality of partitions formed by partition walls standing on one surface of one substrate. Of the discharge space, a predetermined phosphor layer provided in each of the plurality of discharge spaces, and a discharge electrode for generating a discharge in each of the discharge spaces. The phosphor layer is any one of three colors of red (RED), green (GREEN), and blue (BULE) in a multicolor display panel, and a phosphor of a predetermined one color in a single color display. A blend of a plurality of (for example, the above three colors in white display) phosphors is provided in a predetermined discharge space. Therefore, when a gas discharge such as xenon gas is generated in a desired discharge space, the phosphor layer is excited by ultraviolet rays generated by the discharge and emits light (that is, converted into visible light corresponding to each phosphor). ), And a desired image such as a character, a symbol, or a figure is displayed. Since such a gas discharge panel is a flat plate type and can be easily thinned, it is considered as an image display device which replaces a CRT.

In the gas discharge panel for color display as described above, in order to obtain high brightness, the area of the phosphor layer is increased to increase the conversion efficiency from excitation light to visible light and at the same time in the discharge space. It is necessary to avoid light blocking by the phosphor layer itself when visible light is emitted from the. Further, in order to obtain a wide viewing angle, it is necessary to sufficiently increase the amount of visible light emitted obliquely without being blocked by the partition walls over a wide angle range. Therefore, in the gas discharge panel, the phosphor layer is applied not only on one surface of the one substrate but also on the side surface of the partition wall, and the light is emitted from the other side of the pair of substrates on which the phosphor layer is not provided. It is desired that the so-called reflection type structure is provided.

[0004]

By the way, in the gas discharge panel of the reflection type structure as described above, for example, by using a printing method such as screen printing, as shown in FIGS. 1 (a) to 1 (e), The phosphor layer is formed by the step of applying the phosphor into the partition wall and the flow over time based on the rheology (ie, fluidity and surface tension) of the phosphor paste. It should be noted that the gas discharge panel is provided with a discharge electrode or the like for generating a discharge in the discharge space, and is provided with a dielectric layer or the like covering the discharge electrode when AC driving is performed.
Also, they are omitted in FIG. 2 described later. Hereinafter, a method for forming the phosphor layer will be described with reference to FIG. First, for example, a predetermined glass paste is repeatedly screen-printed on the substrate 10 using a predetermined partition pattern, laminated, and fired at a predetermined temperature, so that one surface of the substrate 10 as shown in FIG. Multiple discharge spaces 3 on 12
Long or lattice-shaped partition wall 14 for partitioning 0
To form The partition wall 14 may be formed by applying a glass paste to the entire surface, drying or removing the binder, and then removing unnecessary portions by sandblasting or the like.

Next, using a mask 16 on which a predetermined phosphor pattern is formed, a phosphor paste 18 corresponding to a desired emission color is sequentially screen-printed at a predetermined position between the partition walls 14 to thereby obtain a phosphor. Form a layer. At this time, as shown in FIG. 1 (b), the phosphor paste 18 pushed out to the partition wall 14 by sliding the squeegee 20 on the mask 16, as shown in FIG. When the mask 16 separates from the top 22 of the partition 14 (releases the plate), it adheres to the upper portion of the side surface 26 of the partition 14 corresponding to the peripheral portion of the non-emulsion portion 24 of the mask 16.
Since the amount of the phosphor paste 18 discharged and adhered by sliding of the squeegee 20 is usually not enough by one squeezing, a predetermined amount is adhered by repeatedly performing squeezing. The phosphor paste 18 thus adhered to the upper portion of the side surface 26 of the partition 14 is directed toward the one surface 12 of the substrate 10 by its own weight and its own rheology, as shown by arrows in FIGS. 1 (c) and 1 (d). run down. Then, as shown in FIG. 1 (e), the phosphor paste 18 which has flowed down from the pair of opposing side surfaces 26 has one surface 12 thereof.
By integrating the above, the side surfaces 26, 26
The phosphor paste 18 is applied on one surface 12 of the substrate 10.

That is, in the above-described manufacturing method, the phosphor paste 18 is applied to the entire surface of the partition wall 14 except for the top portion 22 by utilizing its own weight and its own rheology. In the case of multi-color display, the steps shown in FIGS. 1B to 1E are performed by using a mask 16 for applying the phosphor paste 18 at different positions. This is performed for each type of phosphor paste 18. And
In order to remove the binder that has been blended to form a paste, for example, by heating at a predetermined temperature equal to or higher than the thermal decomposition temperature of the binder, a layer of only phosphor particles that emit visible light by ultraviolet excitation ( That is, a phosphor layer) is formed. In the figure, the sliding direction of the squeegee 20 is a direction perpendicular to the longitudinal direction of the partition wall 14, but may be a direction along the longitudinal direction.

However, some gas discharge panels have a cell structure in which the discharge spaces 30 are independent by the barrier ribs 14, such as a grid cell. In manufacturing such a gas discharge panel, when the phosphor layer is formed according to the manufacturing process as described above, the phosphor paste 18 forms the top portion 22 of the partition wall 14 as shown for one cell in FIG. 2 (a). First, it is transferred and attached in the vicinity of the boundary portion with the side surface 26 (that is, the overlapping portion of the fluorescent paste 18 and the top portion 22 of the top portion 22 of the partition wall 14 that is brought into contact with the mask 16). Therefore, as shown in FIG. 2 (b), when the plate is released (immediately after coating), the phosphor paste 18
May block the open surface of the discharge space 30, which is combined with a front plate (not shown).

In such a case, the phosphor paste 18
Due to its relatively high viscosity, it flows down while blocking the discharge space 30, so that air is trapped between the applied phosphor paste 18 and the one surface 12 of the substrate 10, and the air is trapped in the subsequent heat treatment step. As the air is expanded, a large air pocket 32 or a minute air pocket is formed between the phosphor layer 28 and the one surface 12 as shown in FIG. 2 (c). Therefore, since the volume of the discharge space 30 varies depending on the size of the air pocket 32, there is a problem in that the discharge characteristics become non-uniform and cells in which display discharge and address discharge do not occur under the desired conditions occur. It was In addition, the inner wall surface forming the phosphor layer 28 and the discharge space 30 (the side surface 26 of the partition wall 14 and the one surface 1 of the substrate 10).
There is also a problem that the adhesion area with 2) becomes small and the adhesion strength cannot be sufficiently obtained. Generally, the phosphor layer 28 does not contain a binder for positively adhering to the inner wall surface, and therefore the size of the adhering area governs the adhering strength. When the adhesion strength of the phosphor layer 28 is lowered in this way, the phosphor that has fallen off due to vibration applied during manufacturing or after completion of the panel may block the discharge space to cause a non-lighting defect or move to another cell. This will cause defective color mixing.

Further, if the air pocket 32 is present as described above, the thickness of the phosphor layer 28 may be unevenly distributed in the discharge space 30. In general, in a thickness range of a normal phosphor layer 28 formed in a gas discharge panel (for example, about 50 μm or less for a discharge space 30 having a width of several hundreds μm), the thickness and the luminance have a linear relationship. Therefore, there is also a problem that the brightness becomes non-uniform due to the uneven thickness. This is especially noticeable at high viewing angles. Further, the closer to the cathode electrode in the DC type discharge panel, and the closer to the dielectric (eg MgO layer etc.) on the display electrode in the surface discharge AC panel, the greater the contamination of the fluorescent substance due to the sputtering of the discharge electrode. There is also a problem that the uneven thickness of the layer 28 causes a difference in luminance reduction speed.

When the elongated barrier ribs 14 are formed, the air in the discharge space 30 escapes along the longitudinal direction of the barrier ribs 14 so that the above problem is unlikely to occur, but when the cell pitch is small, When the flow-down velocity after application is varied due to non-uniformity of the viscosity of the phosphor paste 18, the discharge space 30 may be partially blocked and the air pocket 32 may be generated.

The air pool 32 as described above is
As the distance between the partition walls 14 is made smaller for higher definition,
This is likely to occur because the opening area of the discharge space 30 becomes small, and as the viscosity of the phosphor paste 18 is increased in order to make the phosphor layer 28 as thick as possible and secure high brightness, the partition wall 14 is increased.
This is remarkable because the amount of paste required for the phosphor paste 18 adhering to the upper part of the above to flow down increases and the fluidity of the phosphor paste 18 is reduced.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a gas discharge panel capable of suppressing the formation of air pockets under the phosphor layer. It is to provide a manufacturing method.

[0013]

In order to achieve such an object, the gist of the method for manufacturing a gas discharge panel of the present invention is to: (a) to form a plurality of discharge spaces on one surface of a substrate. A partition wall forming step of standing up the partition wall, and (b) a convex portion forming step of forming a plurality of convex portions on a part of the top portion of the partition wall,
(c) After the convex portion forming step, a phosphor layer forming step of forming a phosphor layer on one surface of the substrate and on the side surface of the partition by applying a phosphor paste from the top side of the partition, To include.

[0014]

According to this structure, after the partition forming step of forming the partition on one surface of the substrate, the convex forming step of forming the convex on a part of the top of the partition, and the convex forming step. A gas discharge panel is manufactured by a process including a phosphor layer forming process of forming a phosphor layer on one surface of the substrate and on the side surface of the partition by applying the phosphor paste from the top side of the partition. Therefore, in the phosphor layer forming step, at the position of the peripheral portion of the convex portion, the phosphor paste is formed so that a gap is formed between the convex portion and the top of the partition wall based on the height difference between the convex wall and the partition wall. Is applied.

By the above, since the discharge space is suppressed from being blocked by the phosphor paste during the application of the phosphor paste, when the phosphor paste flows down along the side surface of the partition wall, the inside of the discharge space is suppressed. Air is discharged to the upper side of the phosphor paste through the above gap and does not remain on the lower side, that is, between the phosphor paste and one surface of the substrate. Therefore, formation of air pockets on the lower side of the phosphor layer is suppressed.

[0016]

Another aspect of the present invention is preferably such that the plurality of convex portions are respectively provided on a part of tops of the partition walls forming the discharge spaces in all the discharge spaces separated from each other. There is something. By doing so, since the convex portions are provided for all of the individual discharge spaces that are separated from each other, it is possible to suppress the occurrence of air pockets below the phosphor layer in all the discharge spaces. .

Further, preferably, in the method for manufacturing a gas discharge panel described above, (d) convex portions are removed by removing the plurality of convex portions after the phosphor paste is applied in the phosphor layer forming step. It further includes steps. In this case, since the convex portion is removed after the application of the phosphor paste is completed, the convex portion is formed so that the difference in height from the top of the partition is relatively large. In addition, since a large gap is not formed between a front plate provided on the top side of the partition wall to form an airtight discharge space, crosstalk due to individual discharge spaces not being completely separated. No problem occurs.

Further, preferably, in the convex portion removing step, heat treatment is performed at a predetermined temperature in order to form a phosphor layer from the phosphor paste in the phosphor layer forming step, so that the plurality of convex portions are simultaneously formed. This is a heat treatment step of decomposing and removing a part. By doing so, the convex portion is simultaneously decomposed and removed by the heat treatment for removing the binder from the phosphor paste to form the phosphor layer, and thus it is not necessary to separately provide a step for removing the convex portion. .

Also, preferably, the convex portion has a surface texture that is less lyophilic to the phosphor paste than the partition wall. With this configuration, the phosphor paste is less likely to adhere to the surface of the convex portion, so that the gap between the phosphor paste and the partition wall is formed more reliably. The term “lyophilicity” refers to the affinity (or affinity) between a solid and a liquid, that is, the degree of the interaction. The lower the lyophilicity, the weaker the interaction, and the more the solid surface becomes. Liquid makes it hard to wet. It should be noted that low lyophilicity is synonymous with large contact angle and low wet tension, and all means that liquid hardly adheres to a solid surface. The same effect can be obtained by replacing “low” with these words.

Further, preferably, in the method for manufacturing the gas discharge panel, (e) a top coat layer having a surface texture that is less lyophilic to the phosphor paste than the barrier rib is formed on the top of the barrier rib. A top coating step is further included, and the convex portion is provided on the top coating layer. By doing so, the lyophilicity of the entire top of the barrier ribs is reduced and the phosphor paste is less likely to adhere, so that the phosphor paste applied from the top side of the barrier walls quickly flows down along the side surface. As a result, it is further suppressed that the discharge space is blocked during the application.

Also, preferably, a small amount of fine ceramic powder is contained as a shape-retaining material in the plurality of convex portions. In this case, since the shape retention of the convex portion is enhanced, the spread of the paste or the like for forming the convex portion during the formation thereof is suppressed from reaching the side surface of the partition. Therefore, the side wall of the partition wall is kept in a state where the contact angle with the phosphor paste is sufficiently small,
A phosphor layer having a sufficient thickness can be formed on the side surface. In addition,
The plurality of protrusions can be formed by directly printing, transferring, or applying a predetermined paste to the top of the partition wall by a roll coating method or the like, but when the shape retention material is not included, it is formed on the top. Immediately after the heating, since the fluidity is relatively high, it may flow down along the side surface of the partition wall from the top of the partition wall. is there.

[0022]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below with reference to the drawings. In the following description, the dimensional ratio of each part in the drawings is not always accurate.

FIG. 3 shows a reflection type DC color plasma display panel (hereinafter referred to as a color PDP) manufactured by a method for manufacturing a gas discharge panel according to an embodiment of the present invention.
It is a figure which shows the structure of 34 typically. In the figure, the color PDP 34 is made of, for example, a glass flat plate and has a translucent front plate 36, a rear plate 38 also made of a glass flat plate, and a matrix arrangement between the front plate 36 and the back plate 38. And a grid-shaped partition wall 42 forming a plurality of discharge spaces 40. The partition wall 42 is made of, for example, a low softening point glass containing a filler such as alumina, and the rectangular discharge space 40 formed by the partition wall 42 has a width of 0.2 to 2 in each direction.
The height is about 1 mm and the height is about 0.1 to 0.3 mm. In this embodiment, the back plate 38 corresponds to the substrate.

On the inner surface of the front plate 36, which is located on the rear plate 38 side, a plurality of cathode electrodes 44 are arranged at substantially equal intervals along one of the long wall portions forming the partition wall 42, and a discharge space is formed. It is provided so as to be located at a substantially central portion of 40. The cathode electrode 44 has a width of 0.05 to 0.5 mm, for example.
With a thickness of 0.5 to 50 μm, Ni (nickel), Al (aluminum), LaB ₆ (lanthanum hexaboride)
Electrode materials such as the above are formed by a thick film screen printing method or the like, and the distance between the plurality of cathode electrodes 44 (that is, the center-to-center distance) is, for example, about 0.2 to 2.0 mm. A method of patterning by a photolithography method or a sandblasting method after forming the thick film base layer, a thermal spraying method, a lift-off method in which a groove is formed in the substrate (front plate 36) by a sandblasting method, and an electrode material is embedded in the groove, a resist After forming the negative pattern with, the cathode electrode 44 may be formed by a photo casting method or the like which is embedded in a portion corresponding to the positive pattern. Also,
The exposed area of the cathode electrode 44 in the discharge space 40 influences the discharge state. The exposed area may be limited by coating with a dielectric.

The inner surface of the back plate 38 on the side of the front plate 36 covers the entire surface thereof, for example, a trigger electrode 46 having a thickness of about 1 to 10 μm, and the entire surface of the trigger electrode 46, for example, 20 to 60 μm. A dielectric layer 48 of some degree is provided. This trigger electrode 46 is made of, for example, Ag (silver) or Au.
(Gold), metal electrode materials such as Al, ITO (indium tin oxide), ATO (antimony
It is made of a transparent electrode type electrode material such as tin oxide) and is formed by a thick film method such as screen printing or spraying, or a thin film method such as CVD. Also,
The dielectric layer 48 is formed, for example, by thick-screen printing a low softening point glass to which a filler such as alumina, zirconia, lead titanate, or barium titanate is added.

On the above-mentioned dielectric layer 48, along the other of the longitudinal walls which form the partition wall 42, that is, the front plate 36.
A plurality of anode electrode buses 50 are provided at substantially equal intervals along a direction orthogonal to the cathode electrode 44 provided on the inner surface of the discharge electrode 40 so as to be located at a substantially central portion of the discharge space 40. That is, the cathode electrode 44 and the anode electrode bus 5
0s are arranged orthogonally to each other in a matrix, and the discharge spaces 40 centered on the intersections thereof form a color cell. RGB (red, green, blue) in each color cell
One color is assigned to each, but different colors are assigned to form one pixel with three cells arranged in one direction, and one color is assigned to two cells and the other two colors are assigned to one cell. 1 in 4 cells arranged in a rectangle
Pixels may be formed in some cases. One pixel is, for example, 0.3-2.
The cell pitch, which is about 0 mm square and is equal to the distance between the anode electrode bus bars 50, is 1/3 or 1/2 thereof.
The anode bus 50 is, for example, about 0.1 to 0.5 mm wide,
A conductive material such as Al, Ag, and Ni is formed to a thickness of about 0.5 to 50 μm by using a thick film screen printing method or a photolithography method.

Further, one surface 52 of the dielectric layer 48 on the rear plate 38 on the front plate 36 side (more precisely, the one surface 52 and the upper surface of the anode electrode bus 50) and the side surface 54 of the partition wall 42 have, for example, a thickness of 10 A phosphor layer 56 whose thickness is controlled for each color within the range of about 50 μm is provided. The phosphor layer 56 is provided on one surface 52 of the dielectric layer 48, but since the dielectric layer 48 is provided on one surface side of the back plate 38 on which the partition wall 42 is erected, the phosphor layer 56 is substantially provided. The phosphor layer 56 is provided on one surface of the back plate 38. The phosphor layer 56
Is not provided in the center of the bottom surface of each discharge space 40 (that is, immediately below the cathode electrode 44), and the pad portion 57 of the anode electrode bus 50 is partially exposed.
In this embodiment, the pad portion 57 substantially functions as an anode electrode for discharging between the pad portion 57 and the cathode electrode 44.

The above-mentioned phosphor layer 56 is made to emit R (red), G by the ultraviolet ray excitation generated by the discharge between the paired cathode electrode 44 and pad 57 (anode electrode).
Phosphors corresponding to emission colors such as (green) and B (blue) are provided for each discharge space 40, and for example, as shown in FIG.
As shown in (h) to (h), it is provided by so-called drop printing using thick film screen printing.
In FIGS. 4 to 6 below, the anode electrode bus 50 and the pad portion 57 are omitted.

That is, first, the one surface 52 of the dielectric layer 48.
A thick film insulating paste containing a predetermined amount of low softening point glass and a suitable filler (such as alumina and zirconia) is repeatedly printed and laminated using a predetermined partition pattern,
By firing at a predetermined temperature, as shown in FIG. 4A, grid-shaped barrier ribs 42 for partitioning and forming a plurality of discharge spaces 40 are formed on one surface 52 thereof. The partition wall 42 is formed, for example, by forming a paste layer or a glass layer from the above-mentioned thick film insulating paste on one surface 52 of the dielectric layer 48, and then removing unnecessary portions by sandblasting, photolithography, a lift-off method, or the like. You may form by doing. In this embodiment, the process shown in FIG. 4A corresponds to the partition wall forming process.

Next, for example, PVA (polyvinyl alcohol) having a relatively small molecular weight and easily dissolved in water,
For example, a PVA paste is prepared by mixing a predetermined amount of at least one selected from the group consisting of Aerosil having an average particle size of several tens of nm, fine alumina particles of submicron, and alumina powder having a particle size of several μm, and dissolving the mixture in water. The PVA paste is applied to the top 58 of the partition wall 42 by a transfer method, a roll coating method, a screen printing method or the like as shown in FIGS. ), A top coat layer 60 having a thickness of, for example, about 0.1 to 20 μm is formed.

In the transfer method shown in FIG. 5 (a), the PVA paste 64 is applied to the entire surface of the transfer sheet 62, and the PVA paste 64 is placed on the partition wall 42 and peeled off.
8 is transferred to the PVA paste. In addition, in the roll coating method of FIG.
By applying a PVA paste 64 to the entire surface of the roll and rotating the same in a direction perpendicular to the longitudinal direction of the partition wall 42 while rotating the same, or by rotating the same while supplying the PVA paste 64 to the surface of the roll 66, PVA at 58
Paste is applied. Further, in the screen printing method of FIG. 5 (c), the PVA paste 6 is applied on the screen 68.
When the squeegee 20 is slid with the 4 placed thereon, the PVA paste 64 is applied only to the top 58 in contact with the screen 68.

After the top coat layer 60 is formed on the entire surface of the top portion 58 of the partition wall 42 as described above, the same PVA paste 64 or a PVA paste in which the addition ratio of the filler component is further increased on a part of the top portion 58. By coating and drying, as shown in Fig. 4 (c), for example, 5 ~ 50μ
A projection 69 having a thickness of about m is formed. This projection 69
As shown in FIG. 6, a top portion 58 located on the opposite side of each discharge space 40 with respect to the entire discharge space 40.
For example, the length is about 0.1 to 0.3 mm and the width is the same as the partition wall 42 at intervals of about 0.2 to 0.5 mm corresponding to the cell pitch. The convex portions 69 are formed on the surface of the transfer sheet 62 or the roll 66, for example, by the PV pattern having
The top coat layer 60 is formed by applying the A paste 64 or the like, or by using the screen 68 on which the above convex pattern is formed, using the same method as in the above-described FIGS. 5 (a) to 5 (c). Can be formed.

The fine alumina powder is mixed with the PVA paste 64 or the like because the PVA paste 64 has relatively high fluidity and low shape retention unless it is mixed with the fine alumina powder. The side surface 5 of the partition wall 42 when
This is because it will flow down to No. 4 and cover the side surface 54. Further, in FIGS. 4 to 6 and FIGS. 7 and 8 described later, the thicknesses of the top coat layer 60 and the protrusions 69 are exaggeratedly drawn. In this embodiment, the process shown in FIG. 4C corresponds to the convex portion forming process.

After that, a predetermined phosphor constituting the phosphor layer 56 is dissolved in a vehicle prepared by dissolving an ethyl cellulose or acrylic resin in an oil solvent such as butyl carbitol acetate, carbitol acetate or terpineol. By dispersing, a phosphor paste 70 is prepared and is applied from the top 58 side of the partition wall 42 by screen printing using a mask 72 having a predetermined phosphor pattern formed thereon, as shown in FIG. 4 (d). To do. A different pattern is used for the mask 72 according to the phosphor paste 70 so that the phosphor layer 56 arranges three types of phosphors in a predetermined pattern.

When the squeegee 20 is slid on the mask 72 when the phosphor paste 70 is applied as described above, the phosphor paste 70 is applied to the partition wall 42 side as shown in FIG. 4 (d). The extruded phosphor paste 70 has a mask 72 on the top 5 of the partition wall 42.
8 (accurately, the top coat layer 60 or the convex portion 69), as shown in FIG.
The mask 72 adheres to the upper part of the side surface 54 of the partition wall 42 corresponding to the periphery of the non-emulsion part 74 and is peeled off from the mask 72. When the amount of the phosphor paste 70 attached to the upper portion of the side surface 54 becomes sufficiently large, the phosphor paste 70 shown in FIG.
As shown in the figure, the fluidity quickly flows down to one surface 52 of the dielectric layer 48 due to its own fluidity, and the one surface 5
2 and the side surface 54, and a paste layer having a desired thickness is formed on the one surface 52 and the side surface 54 integrally with the one surface 52, as shown in FIG.

At this time, when the squeegee 20 is slid as described above, the mask 72 is pressed against the partition wall 42 and brought into contact with the top 58 of the partition wall 42. Since the convex portion 69 having a length of about 50 μm and a length of about 0.1 to 0.3 mm is provided, the mask 72 cannot be brought into close contact with the top portion 58. Therefore, as shown in FIG. 7 as a cross section parallel to the sliding direction of the squeegee 20, a gap 76 is formed before and after the convex portion 69 in the sliding direction, and the phosphor paste 70 is separated from the side surface of the partition wall 42 after the plate separation. Even when it adheres to the upper portion 54, a gap 78 corresponding to the gap 76 is formed between the phosphor paste 70 and the side surface 54, as shown in FIG. 8, and the discharge space 40 is not blocked. Therefore, as shown by the broken line in FIG. 4 (f), even when the phosphor paste 70 flows down toward the one surface 52 of the dielectric layer 48 while being continuously formed between the partition walls 42, 42, Air escapes from the gap 78, and no air pocket is formed between the phosphor paste 70 and the one surface 52.

When the partition wall 42 and the mask 72 are misaligned, the phosphor paste 70 can be printed on the top coat layer 60 and the convex portion 69. However, while the top coat layer 60 and the protrusions 69 are made of PVA which is easily dissolved in water and have hydrophilicity, the phosphor paste 70 has a solvent such as butyl carbitol acetate, carbitol acetate or terpineol. Since the oily paste has a low mutual affinity (or affinity), and the lyophilicity of the top coat layer 60 and the protrusions 69 to the phosphor paste 70 is low, the phosphor paste 70 is the top coat layer 60. And the convex portion 6
It is difficult for the phosphor paste 70 to adhere to the partition wall 4 of the
It is difficult to continue on the top 58 of 2. Therefore, even when the phosphor paste 70 is applied to the top portion 58 due to a positional shift or the like, the discharge space 40 is not closed, and the occurrence of air pockets is suppressed.

When the amount of the phosphor paste 70 adhering to the partition walls 42 is insufficient, the side surface 5 as described above is used.
4 does not flow down, or even if it flows down, its thickness is insufficient or it cannot cover the whole one surface 52 of the dielectric layer 48, but the amount necessary to form a paste layer of a desired thickness. By repeatedly sliding the squeegee 20 until the phosphor paste 70 of FIG. 4 is supplied to the side surface 54, a paste layer having a desired thickness is formed on the side surface 54 and the one surface 52 as shown in FIG. 4 (g). To be done.

After carrying out the operations shown in FIGS. 4 (d) to 4 (g) for each of the three types of phosphors so as to obtain a predetermined arrangement of the phosphors, for example, a predetermined temperature of about 400 to 500 ° C. Firing at the firing temperature of, as shown in Fig. 4 (h),
By removing the resin component of the phosphor paste 70 and at the same time disassembling and removing the top coat layer 60 and the protrusions 69, the phosphor layer 56 is obtained. At this time, since no air pocket is formed below the phosphor paste 70 as described above, the phosphor layer 56 is the one surface 52 of the dielectric layer 48.
And the volume of the discharge space 40 does not vary,
In addition, a sufficient adhesion area can be obtained. In this embodiment, the steps shown in FIGS. 4 (d) to 4 (h) above are the phosphor layer forming step, and the step shown in FIG. 4 (h) is the heat treatment step, that is, the convex portion removing step. Corresponds to each.

Further, although the fine alumina powder contained in the top coat layer 60 and the convex portion 69 is not decomposed at the above firing (binder removal) temperature, it is a small amount and is a fine powder, so that the powders are bonded to each other. Since PVA is decomposed and loses its binding force, it scatters and disappears due to the gas (air or the like) supplied at the time of firing, or can be easily removed by pressure air or the like after firing, and the phosphor layer 56 is temporarily used.
Even if it adheres to the inside, it does not cause a big problem in light emission characteristics. When the content of the fine alumina powder is relatively large and the characteristics of the phosphor layer 56 or the like may be hindered after the firing treatment, the top coat layer 60 and the protrusions 69 may be removed by washing with water before firing. Good. Since the top coat layer 60 and the protrusions 69 are made of water-soluble PVA, they can be easily removed by washing with water and the phosphor paste 7 can be removed.
Since 0 has water repellency, problems such as partial removal and permeation of eluted substances do not occur even after washing with water. In that case, the washing process corresponds to the protrusion removal process.

The pad portion 57 shown in FIG.
For example, when the phosphor paste 70 is applied as described above, the above-mentioned PVA paste 64 for forming the top coat layer 60 and the protrusion 69 is applied to the anode electrode bus 50.
It is formed by applying it to a portion corresponding to the pad portion 57, and making the portion corresponding to the pad portion 57 hydrophilic so that the phosphor paste 70 does not adhere.

After forming the phosphor layer 56 as described above,
The front plate 36 on which the cathode electrode 44 is formed is placed on the partition wall 40, and the front plate 36 and the rear plate 38 are joined to each other at a peripheral portion (not shown) by frit glass or the like to make the inside airtight. The discharge space 40 is once evacuated, and a discharge gas such as He, Ne, Xe or the like is sealed at a pressure of about 200 to 500 Torr, thereby producing the color PDP 34 shown in FIG. Although the front plate 36 and the partition 42 are not joined to each other, a gap between the front plate 36 and the partition 42 due to a change in the undulation or the like of the front plate 36 due to a change in pressure in the panel in the above-described vacuum / enclosing step. Occurs, for example, the partition 42
A glass paste or the like that melts and bonds to the front plate 36 at the time of joining the peripheral portion may be applied to the top portion 58.

Color PDP 34 constructed as described above
First, for example, first, a predetermined negative voltage is momentarily applied to the trigger electrode 46, and at the same time, a predetermined voltage pulse is applied to all the anode electrode buses 50, so that the pad portion 57 of the anode electrode bus 50 and the trigger electrode 46. Auxiliary discharge is performed between and to accumulate positive wall charges or aerial charges in the discharge space 40. After that, a predetermined negative voltage is sequentially applied to the cathode electrode 44, and at the same time, a predetermined positive voltage is applied to a predetermined anode electrode bus 50 in synchronization with the scanning timing, whereby both electrodes 44, 50 to which the voltage is applied. A main discharge for causing light emission is generated in a predetermined discharge space 40 located at the intersection point of. Ultraviolet light generated by the main discharge excites the phosphor layer 56 provided in the discharge space 40 to generate visible light of a predetermined color, and an image of a desired character, symbol, figure, or the like is displayed. It is.
Note that the driving method of the color PDP 34 is not necessarily required for understanding the present embodiment, and thus a detailed description is omitted.

Here, according to this embodiment, the dielectric layer 48
The partition wall 4 on one surface 52 (that is, one surface of the back plate 38).
2 is provided upright, the projecting portion 69 is formed on a part of the top 58 of the partition wall 42, and the partitioning step is performed after the projecting portion forming step. The dielectric layer 48 is formed by applying the phosphor paste 70 from the top 58 side of 42.
The phosphor layer 56 is formed on the one surface 52 and the side surface 54 of the partition wall 42.
The color PDP 34 is manufactured by a process including the phosphor layer forming process of FIGS. Therefore, in the phosphor layer forming step, a gap 78 is formed between the convex portion 69 and the partition wall 42 at the peripheral portion position based on the height difference between the convex portion 69 and the top 58 of the partition wall 42. As described above, the phosphor paste 70 is applied.

As described above, during the application of the phosphor paste 70, the discharge space 4 is formed by the phosphor paste 70.
Since 0 is suppressed from being blocked, when the phosphor paste 70 flows down along the side surface 54 of the partition wall 42, the air in the discharge space 40 is discharged from the gap 78 to the upper side of the phosphor paste 70. , The bottom, that is, between the phosphor paste 70 and the one surface 52 of the dielectric layer 48 does not remain. Therefore, no air pocket is formed below the phosphor layer 56. For this reason, variation in the volume of the discharge space 40 and variation in the thickness of the phosphor layer 56 are suppressed, and a sufficient adhesion area of the phosphor layer 56 can be secured to obtain sufficient adhesion strength. .

Further, according to this embodiment, the convex portion 69
Are provided on a part of the tops 58 of the partition walls 42 forming the discharge spaces 40 in all the discharge spaces 40 separated from each other. By doing so, the convex portions 69 are provided for all of the individual discharge spaces 40 separated from each other.
Is provided, it is possible to suppress the occurrence of air pockets below the phosphor layer 56 in all the discharge spaces 40.

Further, according to this embodiment, the color PDP 3
In the manufacturing method of No. 4, the plurality of convex portions 69 are formed on the phosphor paste 7
It further includes the step of removing the convex portion of FIG. 4 (h), which is to remove after 0 is applied. By doing so, the protrusion 69 is removed after the application of the phosphor paste 70 is finished, so that the height difference between the protrusion 69 and the top 58 of the partition wall 42 becomes relatively large. If formed,
In order to form the airtight discharge space 40, the top portion 5 of the partition wall 42 is
Since a large gap is not formed between the front plate 36 and the front plate 36 provided on the eight side, problems such as crosstalk caused by the fact that the individual discharge spaces 40 are not completely separated do not occur.

Moreover, according to the present embodiment, in the above-mentioned convex portion removing step, in order to form the phosphor layer 56 from the phosphor paste 70 in the phosphor layer forming step, for example,
By heating at a predetermined temperature of about 500 ° C., the resin component of the phosphor paste 70 (that is, ethylcellulose-based or acrylic-based resin, etc.) is removed, and at the same time, the convex portion 69 is decomposed and removed. Is. That is, the heat treatment process for forming the phosphor layer 56 also serves as the protrusion removal process. By doing so, since the convex portion 69 is simultaneously decomposed and removed by the heat treatment for forming the phosphor layer 56 from the phosphor paste 70,
It is not necessary to separately provide a step of removing the convex portion 69.

Further, according to the present embodiment, the convex portion 69 has a surface texture that is less lyophilic to the phosphor paste 70 than the partition wall 42. In this way, the phosphor paste 70 is unlikely to adhere to the surface of the convex portion 69, so that the gap 78 between the phosphor paste 70 and the partition 42 is formed more reliably.

Further, according to this embodiment, the color PDP 3
The manufacturing method of 4 further includes a top coating step of FIG. 4B, in which a top coating layer 60 having a surface property that is less lyophilic to the phosphor paste 70 than the partition 42 is formed on the top 58 of the partition 42. The convex portion 69 is provided on the top coat layer 60. By doing so, the lyophilicity of the entire top portion 58 of the partition wall 42 is lowered and the phosphor paste 70 is less likely to adhere to the partition wall 42.
The phosphor paste 70 applied from the side of the top 58 of the above will quickly flow down along the side surface 54 thereof, and the discharge space 40 will be further suppressed from being blocked during the application.

Moreover, even when the phosphor paste 70 is applied on the top portion 58 due to plate misalignment or the like, the partition wall side surface 5
4, the phosphor paste 70 attached to 4 becomes excessive,
Since the formation of the phosphor layer 56 on the top 58 is suppressed, the thickness of the phosphor layer 56 becomes non-uniform due to them, or the phosphor layer 56 formed on the top 58.
Thus, a gap is prevented from being formed between the partition plate 42 and the front plate 36, and a stable phosphor layer 56 can be formed when the color PDP 34 is manufactured.

Further, in this embodiment, the convex portion 69 contains a small amount of fine alumina powder as a shape-retaining material.
In this way, the shape retention of the convex portion 69 is enhanced, and thus the PVA paste 64 is suppressed from spreading to the side surface 54 of the partition wall 42 when the convex portion 69 is formed. Accordingly, the partition walls 42 formed of the low softening point glass and having sufficiently high lyophilicity (that is, adhesive force at the interface) with the phosphor paste 70 maintain the original characteristics, and are similar to the case where the convex portions 69 are not formed. A phosphor layer 56 is formed on the side surface 54 to a sufficient thickness. The convex portion 69 is formed by directly printing, transferring,
Alternatively, it can be formed by a roll coating method or the like, but when the shape-retaining material is not included, since the fluidity is relatively high immediately after being formed on the top portion 58, the top portion 5 is formed.
8 may run down along side 54,
Lamination is necessary to form a sufficient thickness, which complicates the process.

In this embodiment, since the amount of the phosphor paste 70 flowing down the side surface 54 is small in the portion where the gap 78 is formed, the thickness of the phosphor layer 56 is thinned in that portion. obtain. However, the color PDP 34 requires a wide viewing angle mainly in the left-right direction when the display surface (that is, the front plate 36) is arranged in the vertical direction. The position of the portion where the thickness of the layer 56 becomes thin,
That is, if the position of the convex portion 69 is provided in a direction in which a wide viewing angle is not required, that is, in the up-down direction, the required viewing angle in the left-right direction is ensured, and no trouble occurs. Note that the projection 69 may be provided at any position with respect to the discharge space 40 as long as the phosphor layer 56 has a sufficient thickness.

Although one embodiment of the present invention has been described in detail with reference to the drawings, the present invention can be implemented in still another mode.

For example, in the above-described embodiment, the present invention is a reflection type DC color PDP 3 having partition walls 42 in a grid pattern.
4 has been described, the side surface 54 of the partition wall 42 and one surface on the rear plate 38 side (for example, the dielectric layer 48).
The present invention is similarly applied to a DC color PDP or an AC color PDP having a long partition 42 as long as it is a gas discharge panel having a phosphor layer 56 on one surface 52). In addition, when the partition wall 42 is formed in a longitudinal shape, the air in the discharge space 40 escapes along the longitudinal direction, so that the problem that the discharge space 40 is blocked by the phosphor paste 70 is unlikely to occur. By providing the convex portion 69, the air also escapes to the side of the top portion 58, so that the occurrence of the air trap can be suppressed more reliably.

Further, in the embodiment, the convex portion 69 is formed by PV.
A formed from aqueous solution, for example, methyl cellulose,
An aqueous solution such as hydroxymethylcellulose or hydroxypropylcellulose may be used.

Further, in the embodiment, since the phosphor paste 70 is dissolved by the oil-based vehicle, the convex portion 69 is made hydrophilic. For example, the phosphor paste 70 is dissolved by the aqueous vehicle. In this case, the convex portion 69
Is preferably lipophilic.

Further, in the embodiment, the convex portion 69 contains fine alumina powder as a shape-retaining material, but the shape-retaining material does not necessarily have to be included. However, in this case, it is preferable that the PVA paste 64 is laminated little by little so that the PVA paste 64 does not spread to the side surface 54 of the partition wall 42 when the projection 69 is formed.

Further, in the embodiment, the top coat layer 60 is formed on the entire surface of the top 58 of the partition wall 42, and then the protrusion 69 is formed on a part of the top coat layer 60.
Even if 9 is directly provided on the top portion 58, the occurrence of air accumulation can be suppressed, and thus the top coating layer 60 does not necessarily have to be provided.

Further, in the embodiment, the convex portion 69 is formed by PV.
The projection 69 is decomposed and removed in the heat treatment step (firing step) for forming the phosphor layer 56 from the phosphor paste 70 by forming the phosphor layer from the aqueous solution A, but the projection 69 may not necessarily be removed. That is, when the height of the convex portion 69 is sufficiently low, the airtightness of the discharge space 40 cannot be reduced to such a degree as to cause crosstalk or the like, and thus does not need to be removed. If you do not remove in this way,
The protrusion 69 may be formed of, for example, glass or the like.

Further, in the embodiment, the convex portion 69 is configured to be less lyophilic with the phosphor paste 70 than the partition wall 42. However, since the convex portion 69 is provided, the phosphor is Since the gap 78 is formed between the paste 70 and the partition wall 42, the lyophilicity of the convex portion 69 with the phosphor paste 70 may be made relatively high.

Further, in the embodiment, the trigger electrode 46 is used.
The case where the present invention is applied to the DC type PDP 34 provided with is explained, but the trigger electrode 46 is provided for stabilizing the display discharge, and instead of providing this, the trigger electrode 46 is provided in the discharge space 40 (display cell). Auxiliary cells may be formed adjacent to each other. In the embodiment, the trigger electrode 46
Is provided in the vicinity of the anode electrode bus 50 and the pad portion 5
Auxiliary discharge was generated between the cathode electrode 4 and
4 may be provided in the vicinity of the cathode electrode 4 and an auxiliary discharge may be generated with the cathode electrode 44. Further, the trigger electrode 46 may be provided in a stripe shape on the same surface as the anode electrode bus 50.

Although not illustrated one by one, the present invention can be variously modified without departing from the spirit thereof.

[Brief description of drawings]

FIGS. 1A to 1E are diagrams for explaining a conventional method for forming a phosphor layer.

2 (a) to (c) are diagrams for explaining problems that may occur when a phosphor layer is formed by the method of FIG.

FIG. 3 is a diagram schematically showing a structure of a color PDP manufactured by a manufacturing method according to an embodiment of the present invention.

4 (a) to (h) are the same as those in the color PDP of FIG.
It is a figure explaining the process of forming a phosphor layer.

5A to 5C are diagrams illustrating a method of forming a convex portion in the manufacturing process of FIG.

FIG. 6 is a diagram schematically showing a partition wall in which a convex portion is formed in the step of FIG. 4 (b).

FIG. 7 is a diagram illustrating a contact state between a mask and a partition wall when applying a phosphor paste.

FIG. 8 is a diagram illustrating a gap formed between a phosphor paste and a partition.

[Explanation of symbols]

 34: Color PDP (gas discharge panel) 38: Back plate (substrate) 42: Partition wall 52: One face 54: Side face 56: Phosphor layer 58: Top part 69: Convex part 70: Phosphor paste

Claims (6)

[Claims] 1. A partition wall forming step of standingly forming partition walls for forming a plurality of discharge spaces on one surface of a substrate, and a convex portion forming step of forming a plurality of convex portions on a part of a top portion of the partition wall. And a phosphor layer forming step of forming a phosphor layer on one surface of the substrate and on the side surfaces of the partition wall by applying a phosphor paste from the top side of the partition wall after the projecting portion forming step. A characteristic gas discharge panel manufacturing method. 2. The gas according to claim 1, wherein the plurality of convex portions are provided on a part of a top portion of the partition wall forming the discharge space in all the discharge spaces separated from each other. Discharge panel manufacturing method. 3. The method of manufacturing a gas discharge panel according to claim 1, further comprising a convex portion removing step of removing the plurality of convex portions after the phosphor paste is applied in the phosphor layer forming step. 4. The convex portion removing step is a heating treatment at a predetermined temperature for forming a phosphor layer from the phosphor paste in the phosphor layer forming step, whereby the plurality of convex portions are decomposed and removed at the same time. The method for manufacturing a gas discharge panel according to claim 3, which is a heat treatment step of: 5. The method of manufacturing a gas discharge panel according to claim 1, wherein the convex portion has a surface texture that is less lyophilic to the phosphor paste than the partition wall. 6. The method further includes a top coating step of forming a top coating layer on the top of the partition wall, the top coating layer having a surface property that is less lyophilic to the phosphor paste than the partition wall, and the convex portion includes the top coating layer. The method for manufacturing a gas discharge panel according to claim 1, which is provided on the top.