Patent Grant
7422503
THIS APPLICATION IS A U.S. NATIONAL PHASE APPLICATION OF PCT INTERNATIONAL APPLICATION PCT/JP2004/007031.
The present invention relates to a plasma display panel used for a wall-mount TV and a large sized monitor, and also relates to a method of manufacturing the same.
In a plasma display panel (hereinafter referred to as a PDP) with an alternate current (AC) discharging type, AC surface discharge PDPs have been dominating. Such a PDP has a front plate and a back plate that are made of a glass substrate. Scan electrodes and sustain electrodes, which are responsible for surface discharge, are disposed on the front plate, and data electrodes are disposed on the back plate. The two plates are oppositely disposed so that the electrodes disposed on each plate forms a grid pattern, and sealed at the peripheries with a sealing material, such as glass frit. A sealed clearance formed between the two plates is a discharge space divided into discharge cells by barrier ribs. Each cell has a phosphor layer.
In a PDP structured above, gas discharge generates ultraviolet light, by which phosphors responsible for red (R), green (G), and blue (B) are excited to generate visible light of respective colors.
In driving operation of the PDP, one field is divided into a plurality of sub-fields. Combining the sub-fields to be lit provides the PDP with gradation display. Each sub-field has a reset period, an address period, and a sustain period. To display images on the screen, voltage having a different waveform according to each period is applied to the electrodes. In the reset period, for example, positive pulse voltage is applied to all the scan electrodes to form necessary wall charges on a protective film provided over a dielectric layer covering the scan electrodes and sustain electrodes, and on the phosphor layers. In the address period, the scan electrodes undergo scanning in which negative scanning pulses are sequentially applied to all the scan electrodes. To display images on the screen, positive data pulses are applied to the data electrodes during the scanning. This causes discharge between the scan electrodes and the data electrodes, thereby forming wall charges on the surface of the protective film on the scan electrodes.
In the sustain period following the address period, a voltage adequate for sustaining discharge for a predetermined period is applied between the scan electrodes and the sustain electrodes. The application of voltage generates discharge plasma between the scan electrodes and the sustain electrodes, by which an excited phosphor layer emits light for a period. On the other hand, in the discharge space to which no data pulse is applied during the address period, no discharge occurs and accordingly, neither excitation nor light emitting of the phosphor layers.
In the PDP above, a perceptible discharge delay generated in the address period invites an unstable addressing operation. Increasing the address time so that the addressing operation is satisfactorily carried out inevitably shortens the time for the sustain period, which results in a poor luminescence.
To address the problems above, there has been a suggestion in which a PDP and a driving method capable of minimizing the discharge delay. According to the suggestion, an auxiliary discharge electrode is disposed on the front plate to generate surface auxiliary discharge spreading in a plane near by the front plate. As a result, priming discharge occurs, contributing to minimized discharge delay.
The PDP introduced in the suggestion above, however, has several problems: insufficient reduction of the discharge delay in the address period; insufficient operation margin of the auxiliary discharge; unstable operations influenced by undesired false discharge. In addition, the auxiliary discharge occurs in the surface of the front plate, and therefore an amount of priming particles larger than necessary for priming is fed to an adjacent discharge cell, which has often caused crosstalk.
The PDP of the present invention contains a first electrode and a second electrode disposed on a first substrate so as to be parallel with each other; a third electrode disposed on a second substrate confronting the first substrate via a discharge space so as to be orthogonal to the first electrode and the second electrode; a fourth electrode disposed on the second substrate so as to be parallel with the first and second electrodes and to be positioned closer to the first and second electrodes than the third electrode; and a barrier rib disposed on the second substrate so as to separate a plurality of main discharge cells, which are formed of the first, second, and third electrodes, from a plurality of priming discharge cells, which are formed of the first electrode and the fourth electrode or formed of the second electrode and the fourth electrode. In the aforementioned PDP, at least the third electrodes are covered with a first dielectric layer and the fourth electrodes are disposed on the first dielectric layer. In addition, the fourth electrodes are made of material having a softening temperature lower than that of material forming the first dielectric layer.
The exemplary embodiments of the present invention are described hereinafter with reference to the accompanying drawings.
Here will be described a PDP and a manufacturing method of the first exemplary embodiment with reference to
As shown in
On back plate 2, as shown in
As shown in
Next will be described how an image data is shown on a PDP. According to the PDP in the embodiment, one field is divided into a plurality of sub-fields each of which has a weight of luminance in binary representation. Combining the sub-field to be lit provides the PDP with gradation display. Each sub-field has a reset period, an address period, and a sustain period.
In the priming discharge cell, when scan pulse SPn is applied to scan electrode Yn, priming discharge occurs between priming electrode Pr and the auxiliary electrode, providing the main discharge cell (corresponding to main discharge cell 12 in
In the structure in which priming electrode 15 is formed on first dielectric layer 17 in priming discharge cell 16, first dielectric layer 17 can provide dielectric voltage between data electrode 10 and priming electrode 15—as long as first dielectric layer 17 is properly formed, contributing to stable priming discharge and address discharge. Besides, in priming discharge cell 16 where priming electrode 15 is formed on first dielectric layer 17, the distance between priming electrode 15 and auxiliary electrode 9 becomes shorter than that between data electrode 10 and scan electrode 6 in main discharge cell 12. The structure above allows main discharge cell 12, which corresponds to scan electrode 6 connected to auxiliary electrode 9, to have priming discharge with reliability and stability prior to the address discharge. This contributes to minimized delay in discharge in main discharge cell 12.
In step 1, as shown in
In the next steps 6 and 7, priming electrode 15 is formed. In step 6, silver (Ag) paste is applied to first dielectric layer 17 in a manner almost the same as that for forming data electrode 10 in step 2. Of glass components forming priming electrode 15, at least one component has a softening temperature of 570° C. In step 7, the paste is baked at 575° C. to complete priming electrode 15. The baking temperature at this time (i.e., 575° C.) is lower than 580° C. that is the softening temperature of first dielectric layer 17, and is not less than 570° C. that is the softening temperature of the materials forming priming electrode 15. That is, deterioration or deformation in first dielectric layer 17 can be suppressed during the baking process of priming electrode 15.
Conventionally, the softening temperature of priming electrode 15 has not always determined to be lower than that of first dielectric layer 17. Therefore, the baking temperature of priming electrode 15 has often exceeded the softening temperature of first dielectric layer 17. In this case, when priming electrode 15 undergoes the baking process, underlying first dielectric layer 17 softens, and thermally deformed priming electrode 15 sinks into softened first dielectric layer 17. As a result, priming electrode 15 and data electrode 10 cannot have a proper insulation distance therebetween.
Steps 8 and 9 are for forming second dielectric layer 18. Second dielectric layer 18 is formed in the same manner as first dielectric layer 17 formed in steps 4 and 5. The composition of second dielectric layer 18 differs from that second dielectric layer 18 differs from that of first dielectric layer 17 in having approx. 5 wt %-increased PbO content. The softening temperature of second dielectric layer 18 is determined at 560° C., which is a 20° C.-lowered setting than the softening temperature of first dielectric layer 17. In step 8, the paste prepared for second dielectric layer 18 is applied on first dielectric layer 17 so as to cover priming electrode 15 by screen printing, or other methods described earlier. In step 9, the paste is baked at 565° C. to complete second dielectric layer 18. The baking temperature at this time (565° C.) is determined so as to be lower than the softening temperatures of the materials forming priming electrode 15 (570° C.); first dielectric layer 17 (580° C.); and data electrode 10 (590° C.), and so as to be higher than the softening temperature of the material forming second dielectric layer 18. Therefore the temperature setting can protect priming electrode 15, first dielectric layer 17, and data electrode 10 from deterioration or deformation during the baking process of second dielectric layer 18, eliminating a cause of dielectric breakdown on priming electrode 15.
Steps 10 and 11 are for forming barrier rib 11 and phosphor layers 14. In step 10, photosensitive paste including a glass component and a photosensitive organic component is applied on second dielectric layer 18 and then dried. Through a photo process, patterns of vertical wall 11a and horizontal wall 11b, which form the space between main discharge cells 12, the space between priming discharge cells 16, and gap 13, are formed. Besides, phosphor layers 14 for red (R), green (G), and blue (B) are formed by filling in main discharge cells 12. The softening temperatures of barrier rib 11 and phosphor layers 14 are 550° C. or lower. In step 11, barrier rib 11 and phosphor layers 14 are simultaneously baked at 555° C. to complete them. The baking temperature at that time is set to be lower than each softening temperature of underlying second dielectric layer 18, priming electrode 15, first dielectric layer 17, and data electrode 10. The temperature setting can protect the underlying components from deterioration or deformation during the baking process. As a further advantage, the underlying components make a foundation to support top-situated barrier rib 11. Minimizing the deformation in the underlying components can provide barrier rib 11 with consistent dimensional accuracy. As a result, a PDP with a high accuracy of dimension can be obtained.
Back substrate 2 is thus completed through the process above.
Next will be described the second exemplary embodiment of the present invention with reference to
In the first exemplary embodiment, data electrodes 10, first dielectric layer 17, priming electrodes 15, second dielectric layer 18, and barrier rib 11 are separately baked with the softening temperature of them determined in higher-to-lower order named, whereby all the components forming the back substrate are considerably protected against deterioration and deformation. Among the components above, deformation of first dielectric layer 17 seriously affects the dielectric breakdown. The following method, which focuses on protecting only first dielectric layer 17 from deformation, can simplify the manufacturing process. That is, the softening temperatures of first dielectric layer 17, priming electrode 15, second dielectric layer 18 are determined in higher-to-lower order named; the softening temperature of data electrode 10 is determined to be the same as that of first dielectric layer 17 and the two are baked at the same time; and each softening temperature of barrier rib 11 and phosphor layer 14 is determined to be the same as that of second dielectric layer 18 and the three are baked at the same time.
The second exemplary embodiment describes a manufacturing process in which data electrode 10 and first dielectric layer 17 undergo the simultaneous baking, while second dielectric layer 18, barrier rib 11, and phosphor layer 14 undergo the simultaneous baking.
In step 1, as shown in
Step 3 is for forming the precursor layer for first dielectric layer 17. As the materials of first dielectric layer 17, ZnO—B2O3—SiO2-based mixture, PbO—B2O3—SiO2-based mixture, PbO—B2O3—SiO2—Al2O3-based mixture, PbO—ZnO—B2O3—SiO2-based mixture, Bi2O3—B2O3—SiO2-based mixture, or the like, can be employed. First dielectric layer 17 of the embodiment of the present invention is a mixture of 65-70 wt % PbO; 5 wt % B2O3; and 25-30 wt % SiO2, having the same softening temperature as data electrode 10. The softening temperature can be flexibly determined by increasing or decreasing the PbO content. Mix the materials of first dielectric layer 17 into a paste and apply it over the precursor for data electrode 10. The applying method is not limited to a specific one; the paste can be applied or printed in a well know manner, such as roll coating, slit die coating, doctor blade method, screen printing, and off-set printing. In the second embodiment of the present invention, the applying thickness of the paste of first dielectric layer 17 should preferably range from 5 to 40 μm. Applying the paste with a thickness of 5 μm or more can lessen the unevenness of the surface of first dielectric layer 17—due to data electrodes 10 disposed thereunder—after the baking process. The applying thickness of first dielectric layer 17 depends on the mineral element content in the paste.
In step 4, the precursor for data electrode 10 and the precursor layer for first dielectric layer 17 are simultaneously baked at 585° C. Data electrode 10 and first dielectric layer 17 are thus completed.
In the next steps 5 and 6, priming electrode 15 is formed. In step 5, silver (Ag) paste is applied to first dielectric layer 17 in a manner almost the same as that for forming the precursor for data electrode 10 in step 2. Of glass components forming priming electrode 15, at least one component has a softening temperature of 570° C. In step 6, the paste is baked at 575° C. to complete priming electrode 15. The baking temperature at this time (i.e., 575° C.) is lower than the softening temperatures of the materials forming first dielectric layer 17 (580° C.) and data electrode 10 (580° C.); and is not less than the softening temperature of the materials forming priming electrode 15 (570° C.). The temperature setting can protect first dielectric layer 17 from deterioration or deformation during the baking process of priming electrode 15, eliminating a cause of dielectric breakdown on priming electrode 15. As a result, a PDP with high reliability in operation can be provided.
Step 7 is for forming the precursor layer for second dielectric layer 18. Second dielectric layer 18 is formed in the same manner as first dielectric layer 17 formed in steps 3. To form the precursor layer for second dielectric layer 18, paste is applied on first dielectric layer 17 so as to cover priming electrode 15 by screen printing, or other methods described earlier. The composition of second dielectric layer 18 differs from that of first dielectric layer 17 in having approx. 5 wt %-increased PbO content. The softening temperature of second dielectric layer 18 is determined at 560° C. or lower, which is a 20° C.-lowered setting than the softening temperature of first dielectric layer 17.
Step 8 is for forming barrier rib 11 and the precursor layer for phosphor layer 14. First, photosensitive paste including a glass component and a photosensitive organic component is applied on second dielectric layer 18 and then dried. Through a photo process, patterns of vertical wall 11a and horizontal wall 11b, which form the space between main discharge cells 12, the space between priming discharge cells 16, and gap 13, are formed. Besides, phosphor layers 14 for red (R), green (G), and blue (B) are formed by filling in main discharge cells 12. The softening temperatures of barrier rib 11 and phosphor layers 14 are determined to be the same as that of second dielectric layer 18.
In step 9, the precursor layer for second dielectric layer 18, barrier rib 11, and the precursor layer for phosphor layer 14 are simultaneously baked at 565° C. to complete them. Second dielectric layer 18, barrier rib 11, and phosphor layer 14 are thus completed. The baking temperature at that time (565° C.) is lower not only than the softening temperature of the materials forming priming electrode 15 (570° C.) but also than the lower softening temperature of the materials forming first dielectric layer 17 and data electrode 10, and is not less than the highest softening temperature of the materials for second dielectric layer 18, barrier rib 11, and phosphor layer 14. The temperature setting can protect priming electrode 15, first dielectric layer 17, and data electrode 10 from deterioration or deformation during the baking process. As a further advantage, the aforementioned components make a foundation to support top-situated barrier rib 11. Minimizing the deformation in the components can provide barrier rib 11 with consistent dimensional accuracy. As a result, a PDP with a high accuracy of dimension can be obtained.
As described above, data electrode 10 and first dielectric layer 17 are simultaneously baked; on the other hand, second dielectric layer 18, barrier rib 11, and phosphor layer 14 are simultaneously baked. Introducing the simultaneous baking can simplify the manufacturing steps of back plate 2.
Moreover, priming electrode 15, second dielectric layer 18, barrier rib 11, and phosphor layer 14 can be simultaneously baked. This can further simplify the manufacturing process.
Step 5 is for forming the precursor for priming electrode 15. Of glass components forming priming electrode 15, at least one component has a softening temperature of 560° C.
Step 6 is for forming the precursor layer for second dielectric layer 18. Here in the description, the softening temperature of second dielectric layer 18 is determined to be the same as that of priming electrode 15.
Step 7 is for forming barrier rib 11 and the precursor layer for phosphor layer 14. The softening temperature of barrier rib 11 and phosphor layer 14 are also determined to be the same as that of priming electrode 15.
Step 8 is for forming priming electrode 15, second dielectric layer 18, barrier rib 11, and phosphor layer 14. In this step, the precursor for priming electrode 15, the precursor layer for second dielectric layer 18, barrier rib 11, and the precursor layer for phosphor layer 14 are simultaneously baked at 565° C.
The baking temperature at that time (565° C.) is lower than the lower softening temperature (580° C.) of the materials forming data electrode 10 and first dielectric layer 17, and is not less than the highest softening temperature (560° C.) of the materials for priming electrode 15, second dielectric layer 18, barrier rib 11, and phosphor layer 14. The temperature setting can protect first dielectric layer 17 from deterioration or deformation during the baking process.
Baking priming electrode 15 together with second dielectric layer 18 and the components above can further simplify the manufacturing process. These components are baked at a temperature lower than the softening temperature of first dielectric layer 17. This protects first dielectric layer 17 from deterioration or deformation during the baking process, eliminating a cause of dielectric breakdown on priming electrode 15. As a result, a PDP with high reliability in operation can be provided.
Although lead (Pb)-based mixture is used for the material of first dielectric layer 17 and second dielectric layer 18 in the description, zinc (Zn)-, or bismuth (Bi)-based mixture can be employed for them. In this case, the softening temperature of the material can be flexibly determined by increasing or decreasing the Zn or Bi content.
The wording of the “same” softening temperature used through the description means substantially the same temperature. Therefore, a difference between the materials that are baked at the same time is negligible in the scope that the purpose of the present invention can be realized as is intended.
The PDP of the present invention contains, as described above, priming discharge cells responsible for priming discharge between the front plate and the back plate. The discharge distance of a priming discharge cell is smaller than that of a main discharge cell, allowing the priming discharge cell to have the priming discharge with reliability prior to main discharge (i.e., address discharge). As a further advantage, keeping a proper dielectric voltage between the data electrode and the priming electrode can improve reliable operations of a PDP.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-143042 | May 2003 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2004/007031 | 5/18/2004 | WO | 00 | 11/1/2005 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2004/105074 | 12/2/2004 | WO | A |
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|---|---|---|---|
| 6200182 | Nanto et al. | Mar 2001 | B1 |
| 6538381 | Ueoka et al. | Mar 2003 | B1 |
| 7116289 | Yamada | Oct 2006 | B2 |
| 20010020924 | Makino | Sep 2001 | A1 |
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| Number | Date | Country | |
|---|---|---|---|
| 20060279214 A1 | Dec 2006 | US |
