JPH11296106A - Manufacture of barrier rib - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a barrier rib highly accurate in shape and also at low cost. SOLUTION: Groove 11 formed in a metallic die 21 are filled with barrier rib material 2. Next, a substrate 1 is mounted on the die 21 in a state that it comes into contact with the filled barrier rib material 2. An ultraviolet hardening device 26 is mounted on the substrate 1 and the material 2 is irradiated with ultraviolet rays 19 through the substrate 1 while the substrate 1 is pressed uniformly by air pressure 30. Then the material 2 is hardened from the substrate 1 side and the barrier rib 7 is formed on the substrate 1. And, the substrate 1 is pulled up.

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 barrier rib which is a partition of a plasma chamber used for a large-sized thin display device such as a plasma display panel and a plasma addressing LCD.

[0002]

2. Description of the Related Art Various conventional methods for manufacturing barrier ribs will be described with reference to FIGS.

FIG. 2 shows a method called a sand blast method. In this method, as shown in FIG.
Then, a barrier rib material film 2 is formed, and a photosensitive film 3 is further formed thereon. Next, as shown in FIG. 2B, the photosensitive film 3 is irradiated with ultraviolet rays 4 to form stripes of an ultraviolet cured part 3a and a part 3b not exposed to ultraviolet rays.

When the portion 3b to which the ultraviolet light is not applied is removed by a chemical, as shown in FIG.
Stripes remain. In this state, as shown in FIG. 2D, when a sand blast 5 that is a process of irradiating a powder made of fine particles such as glass and ceramics is applied, the groove 6 is processed.

When the ultraviolet cured portion 3a is removed with a chemical,
As shown in FIG. 2E, a barrier rib 7 is formed on the substrate 1.

FIG. 3 shows a method called a printing method. In this method, the steps of printing and drying the barrier rib material 2 little by little on the substrate 1 are repeated as shown in (a), (b), (c), and (d), and finally, as shown in FIG. In this method, the barrier ribs 7 are formed on the substrate 1 as shown.

FIG. 4 shows a method called embossing. In this method, as shown in FIG. 4A, a film of a barrier rib material 2 is formed on a substrate 1 and, as shown in FIG. The material 2 is dried.

Thereafter, as shown in FIG.
Is pressed from the direction of arrow a by a hot plate (not shown). After that, when you die-cut,
As shown in FIG. 4D, a barrier rib 7 is formed on the substrate 1.

Next, a conventional manufacturing method shown in FIG. 5 will be described. In this method, as shown in FIG.
As shown in FIG. 5B, a mold release agent 15 is vapor-deposited on the mold 14 having a mold release agent to form a film 16 of the mold release agent.

Next, as shown in FIG. 5C, the groove 11 is filled with the barrier rib material 2. The barrier rib material 2 is obtained by mixing a ceramic powder and a glass powder with an ultraviolet curable resin as a binder resin.

Next, as shown in FIG.
The substrate 1 is placed on 7, and the mold 14 filled with the barrier rib material 2 is overlaid. An ultraviolet lamp 18 is arranged on the back of the quartz table 17, and ultraviolet rays 19 are irradiated to the barrier rib material 2 via the quartz table 17 and the substrate 1.

When the mold 14 is removed after the barrier rib material 2 is sufficiently cured by ultraviolet light, the barrier ribs 7 are formed on the substrate 1 as shown in FIG.

Next, a conventional manufacturing method shown in FIG. 6 will be described. In this method, as shown in FIG.
Is formed of a material having a good ultraviolet transmittance, such as quartz or Vycor, and as shown in FIG. 6B, a release agent 15 is deposited to form a coating 16 of the release agent.

Then, as shown in FIG.
Is filled with the barrier rib material 2. The barrier rib material 2 is kneaded with an ultraviolet curable resin as a binder resin.

Next, as shown in FIG. 6D, a mold 20 filled with the barrier rib material 2 is overlaid on the substrate 1, and ultraviolet rays 19 are irradiated from above the mold 20 by an ultraviolet lamp 18 to form the barrier rib material 2. To cure. When the mold 20 is removed after curing,
As shown in FIG. 6E, a barrier rib 7 is formed on the substrate 1.

[0016]

The above prior arts have the following problems.

In the prior art shown in FIG. 2, an expensive photosensitive film 3 is used.
This is a method of manufacturing in which the yield of materials is extremely low because the material is consumed or most of the barrier rib material 2 is consumed by sandblasting, and cannot meet the demand for reducing the manufacturing cost of the plasma display or the plasma addressing LCD. Further, in the sand blast method, there is a problem that it is difficult to secure the shape of the groove 6 with sufficient accuracy.

The conventional method shown in FIG. 3 has disadvantages in that the printing process is complicated and costly, and that it is difficult to secure the shape accuracy of the barrier rib 7.

In the conventional method shown in FIG. 4, although the shape accuracy of the barrier rib 7 is good, there is a problem in that a large-scale hot press is required, and the barrier rib material remains in the middle 12 of the barrier rib 7. It is not applicable to plasma addressing LCDs. Because, in the plasma addressing LCD, the brightness of the screen is obtained using the backlight from the direction of arrow b on the back side of the substrate 1,
This is because if the barrier rib material remains in the middle 12 of the barrier rib 7, the backlight is shut off.

In the conventional method shown in FIG. 5, there is a problem in that an expensive quartz table 17 having a good ultraviolet transmittance must be used.
There is a problem that a part of the barrier rib material 2 remains in the mold 14 when the mold is removed because no attempt is made to improve the adhesion to the mold 4.

In the prior art shown in FIG. 6, since the ultraviolet rays 19 are radiated from the mold 20 side, the barrier rib material 2 is cured from the mold 20 side. Therefore, even if the coating 16 of the release agent is formed, the bonding of the barrier rib material 2 to the groove 11 becomes strong,
There was a problem that a part of the barrier rib material 2 remained on the mold 20 side even after the mold was removed.

In view of the above prior art, an object of the present invention is to provide a method for producing a barrier rib which can contribute to cost reduction and quality improvement of the production of the rib.

[0023]

In order to solve the above-mentioned problems, the present invention provides a structure in which a mold having a groove corresponding to the shape of a barrier rib is formed of metal, and the groove is filled with a UV-curable barrier rib material. Place the substrate on the mold in a state where the barrier rib material is in contact with the mold, seal the four sides of the substrate, uniformly pressurize the back surface of the substrate with air pressure, and irradiate ultraviolet rays from the back side of the substrate to irradiate the substrate. The barrier rib material is cured by allowing the light to pass through and reach the barrier rib material in the groove to form a barrier rib on the substrate, and after curing, the substrate is removed from the mold.

Further, in the constitution of the present invention, as an essential component of the ultraviolet-curable barrier rib material, a curing reaction occurs by irradiation of energy rays, and then the curing reaction is continuously performed in a chain reaction with the heat of reaction during curing and cations. And using a resin composition that enables curing regardless of the presence or absence of a thick and energy ray shielding filler and an attenuating filler.

[0025]

Embodiments of the present invention will be described below in detail with reference to the drawings.

In the embodiment of the present invention, the step of filling the barrier rib material into the mold shown in FIG. 1A, the step of curing the barrier rib material with ultraviolet light shown in FIG. 1B, and the step shown in FIG. It is a punching process.

In FIG. 1A, the mold 21 is made of metal and has a plurality of grooves 11 formed therein. A screen 25 is laid on the surface of the mold 21. The screen 25 is made up of the fiber sheet 24 and the mask 2.
The mask 22 has a plurality of elongated holes 23 formed in the mask 22, and the elongated holes 23 face the grooves 11.

The barrier rib material 2 supplied on the screen 25 is filled in the groove 11 as the squeegee 13 moves in the direction of arrow c. The barrier rib material 2 is obtained by kneading ceramic powder, glass powder, an ultraviolet curable resin, and a solvent. In this case, as the ultraviolet curing resin, UV
The curing reaction occurs by irradiation of energy rays such as, and then the curing reaction is continuously performed in a chain reaction with the reaction heat and cation during curing, and the presence of thick and energy ray shielding fillers and attenuating fillers Regardless, it is preferable to use a resin composition that enables curing.

After filling the groove 11 with the barrier rib material 2, the screen 25 is removed, and the solvent in the barrier rib material 2 is sufficiently evaporated.

The volume of the barrier rib material 2 filling the groove 11 is larger than that of the groove 11 by the thickness of the mask 22.
This allows for a reduction in volume due to evaporation of the solvent and a reduction in volume due to compression in a subsequent step.

After the solvent of the filled barrier rib material 2 is sufficiently evaporated, as shown in FIG.
7, the substrate 1 is placed on the mold 21 with the filled barrier rib material 2 in contact with the substrate 1.

Next, the ultraviolet curing device 26 is placed on the substrate 1. The ultraviolet curing device 26 seals four sides of the substrate 1 by being in contact with the substrate 1 via an elastic seal 28, and incorporates the ultraviolet lamp 18. Further, compressed air is supplied from the direction of the arrow e through the pipe 29, and a uniform air pressure 30 is applied to the back surface of the substrate 1 (the upper surface of the substrate 1 in the figure).

The ultraviolet light 19 emitted from the ultraviolet lamp 18 while the air pressure 30 is applied passes through the inside of the substrate 1 from the back surface of the substrate 1 and irradiates the filled barrier rib material 2. To cure.

Next, as shown in FIG. 1C, after the ultraviolet curing device 26 is removed, the stamping device 31 is brought into contact with the back surface of the substrate 1. The punching device 3 includes a suction pad 3.
2 and a suction hole 33 are provided, and the back surface of the substrate 1 is sucked by evacuating in a direction indicated by an arrow f by a vacuum exhaust device (not shown).

Similarly, the support base 27 is also provided with a suction pad and a suction hole.
Adsorb the back surface of.

With the substrate 1 being sucked by the die-cutting device 31 and the back surface of the die 21 being sucked by the support 27, the die-cutting device 31 is pulled up in the direction of the arrow h, so that the substrate 1 and the die 1 are removed. 21 is performed to form the barrier ribs 7 on the substrate 1.

In this embodiment, since the ultraviolet curing of the barrier rib material 2 is performed from the substrate 1 side, the curing / adhesion of the barrier rib material 2 starts from the substrate 1 side, and the barrier rib material 7 adheres to the substrate 1.
Is good, and the releasability from the mold 21 is improved.

In general, the substrate 1 may be made of a material having a low ultraviolet transmittance. However, as an ultraviolet curable resin kneaded into the barrier rib material 2, a curing reaction occurs by irradiation of energy rays such as UV, and then curing is performed. When the curing reaction is performed continuously in a chain reaction with the reaction heat and cation at the time, using a resin composition that enables curing regardless of the presence or absence of thick and energy ray shielding fillers and attenuating fillers Since the curing reaction is continuously generated by the self-curing reaction heat and the cation, the barrier rib material 2 can be sufficiently cured even with the substrate 1 having a low ultraviolet transmittance.

In the present embodiment, the barrier rib material 2 is cured by ultraviolet rays while pressing the substrate 1 against the mold 21 with a uniform pressure. Therefore, the denseness of the cured barrier rib material 2 (barrier rib 7) can be ensured. 1 and the barrier rib 7 can be increased in bonding force.

By setting the thickness of the mask 22 to an appropriate value when filling the barrier rib material 2, the shrinkage due to drying of the solvent and the volume of the barrier rib material 2 that is pressure-shrinked when the substrate 1 is pressed against the mold 21 are taken into consideration. By setting the volume of the barrier rib material 2 to be filled to be larger than the volume of the groove 11 of the mold 21, the barrier rib material 2 is cured by ultraviolet rays while uniformly pressing the substrate 1. The nature increases.

In this embodiment, a metal is selected as the material of the mold 21, but this also contributes to the improvement of the releasability between the cured barrier rib material 2 (barrier rib 7) and the mold 21. . Even in the case of an ultraviolet curable resin, the next curing is promoted by the curing reaction heat, and when the temperature is low, a chain reaction of curing is suppressed. From this point of view, the mold 21 made of metal has high thermal conductivity, and the substrate 1 made of glass has low thermal conductivity. A thermal gradient is generated between the mold 21 and the temperature of the substrate 1 becomes higher than that of the mold 21. Therefore, the ultraviolet curing reaction starts from the barrier rib material 2 on the substrate 1 side, and the curing of the barrier rib material 2 in contact with the mold 21 is delayed. Further, by selecting an ultraviolet curable resin having a curing shrinkage property, the mold releasability between the mold 21 and the barrier rib material 2 (barrier rib 7) is enhanced.

[0042]

As described above in detail with the embodiments, in the present invention, a mold having a groove corresponding to the shape of a barrier rib is made of metal, and the groove is filled with an ultraviolet-curable barrier rib material. Place the substrate on the mold in a state where the filled barrier rib material is in contact, seal the four sides of the substrate, uniformly pressurize the back surface of the substrate with air pressure, and irradiate ultraviolet rays from the back side of the substrate. The barrier rib material was cured by passing through the substrate and reaching the barrier rib material in the groove to form a barrier rib on the substrate, and after curing, the substrate was removed from the mold.

In the present invention, as an essential component of the ultraviolet-curable barrier rib material, a curing reaction occurs by irradiation with energy rays, and thereafter, the curing reaction is continuously performed in a chain reaction by reaction heat and cations at the time of curing. In this case, a resin composition capable of being cured regardless of the presence or absence of the thick and energy ray shielding filler and the attenuating filler is used.

Since the above method is employed, the method for manufacturing a barrier rib according to the present invention has the following effects (1) to (9), and contributes to a reduction in barrier rib manufacturing cost and an improvement in quality.

(1) Since only the necessary barrier rib material is used by filling the grooves of the mold, the material yield of the barrier rib material is high. (2) Since no photosensitive film is used, there is no expenditure for the consumption of the photosensitive film. (3) Since a sandblast is not used, it is easy to maintain a clean environment.

(4) Since a large-scale hot press is not required, manufacturing equipment costs are small. (5) Since the manufacturing process is simple, the tact time can be reduced as compared with the printing method and the sand blast method. (6) Since the shape accuracy of the barrier rib is ensured by the mold, the shape accuracy of the barrier rib is better than that of the printing method or the sand blast method.

(7) Since there is no barrier rib material layer remaining and hardened between adjacent barrier ribs, it can be used as a barrier rib for a plasma addressed LCD. (8) Since ultraviolet curing is performed while applying uniform pressure, dense barrier ribs can be ensured. (9) Since a metal mold is used and cured by irradiating ultraviolet rays from the back side of the substrate, the cured barrier rib has good bonding properties to the substrate and releasability from the mold, and the barrier rib is not easily chipped. (10) As an ultraviolet-curing resin, a curing reaction occurs by irradiation with energy rays such as UV, and then the curing reaction is continuously performed in a chain reaction with the heat of reaction and cations during curing, thereby blocking the thick and energy rays. By using a resin composition capable of being cured regardless of the presence or absence of a filler and an attenuating filler, it becomes possible to cure even a substrate made of a material having a low ultraviolet transmittance.

[Brief description of the drawings]

FIG. 1 is a process chart showing a method for manufacturing a barrier rib according to an embodiment of the present invention.

FIG. 2 is a process chart showing an example of a method for manufacturing a barrier rib according to a conventional technique.

FIG. 3 is a process chart showing an example of a method for manufacturing a barrier rib according to a conventional technique.

FIG. 4 is a process chart showing an example of a method for manufacturing a barrier rib according to a conventional technique.

FIG. 5 is a process chart showing an example of a method for manufacturing a barrier rib according to a conventional technique.

FIG. 6 is a process chart showing an example of a method for manufacturing a barrier rib according to a conventional technique.

[Explanation of symbols]

 Reference Signs List 1 substrate 2 barrier rib material 3 photosensitive film 4 ultraviolet ray 5 sandblast 6 groove 7 barrier rib 8 lamp 9 radiant heat 10 type 11 groove 12 intermediate 14 type 15 release agent 16 coating 17 quartz table 18 ultraviolet lamp 19 ultraviolet ray 20 type 21 type 22 mask 23 opening Slot 24 fiber sheet 25 screen 26 ultraviolet curing device 27 support base 28 elastic seal 29 piping 30 pneumatic

 ──────────────────────────────────────────────────の Continuing on the front page (72) Inventor Nobuya Hayashi No. 1, Takamichi, Iwazuka-cho, Nakamura-ku, Nagoya-shi, Aichi Nagoya Research Laboratory, Mitsubishi Heavy Industries, Ltd.

Claims (2)

[Claims] 1. A mold having a groove corresponding to the shape of a barrier rib is made of metal, and the groove is filled with a UV-curable barrier rib material, and the substrate is placed on the mold with the filled barrier rib material in contact therewith. The four sides of the substrate are sealed, the back side of the substrate is uniformly pressurized by air pressure, and ultraviolet rays are irradiated from the back side of the substrate to transmit the substrate and reach the barrier rib material in the groove, thereby forming a barrier rib. Forming a barrier rib on the substrate by curing a material; and removing the substrate from the mold after curing. 2. A curing reaction occurs by irradiation with energy rays as an essential component of the ultraviolet-curable barrier rib material,
After that, the curing reaction is continuously performed in a chain reaction with the reaction heat and cation during curing, and a resin composition that enables curing regardless of the presence of thick and energy ray shielding fillers and attenuating fillers is used. 2. The method according to claim 1, wherein
Barrier rib manufacturing method.