Double-Layered Barrier Rib Slurry for Plasma Display Panels
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Solution Overview
Problem
Conventional methods for forming barrier ribs in plasma display panels are complex, time-consuming, and costly, with difficulties in achieving a desired shape and structural stability.
Innovation Solution
A slurry composition and green sheet comprising a base film with a first and second film-forming layer, each containing glass powder, filler, solvent, dispersing agent, plasticizer, and binder, applied to form a double-layered structure with different etching rates to create barrier ribs, allowing for easier and more stable formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the Sand Blasting method is used to form barrier ribs, then the barrier ribs can be formed with desired shape, but the equipment cost is high and the process is complex
Solution Approach 1:
The barrier rib formation process is segmented into multiple screen-printing steps, where each step deposits a portion of the glass paste to build up the final rib structure. This divides the complex single-step process into manageable sequential operations that achieve the desired shape through layering rather than direct machining.
Solution Approach 2:
The invention replaces the mechanical Sand Blasting system with a chemical/thermal system based on screen printing and sintering. Instead of using high-speed sand particles to erode and shape the material, the process uses controlled deposition of glass paste followed by thermal sintering to form the barrier ribs, eliminating the need for complex blasting equipment.
2Ease of manufacture
If the Screen Printing method is used to form barrier ribs, then the process can be simplified, but multiple printing steps are required to achieve desired thickness
Solution Approach 1:
The barrier rib formation employs periodic screen-printing actions where the screen is repeatedly positioned, printed, and dried in cycles. Each periodic cycle deposits a layer of glass paste, and through multiple such periodic actions, the desired thickness is achieved while maintaining process control and simplicity.
Solution Approach 2:
The screen printing process performs preliminary deposition of glass paste layers before the final sintering step. By pre-forming the rib structure through multiple printing cycles and then consolidating it in a single sintering operation, the process achieves the desired thickness efficiently without requiring complex real-time adjustments during sintering.
3Stability of the object's composition
If glass paste is applied and sintered to form barrier ribs, then the ribs provide structural stability, but cracks may be caused during sintering due to high physical impact
Solution Approach 1:
The screen-printing process applies glass paste in multiple thin layers rather than a single thick layer, which cushions the thermal stress during sintering. Each layer is relatively thin and flexible, allowing the structure to accommodate thermal expansion and contraction more evenly, thereby preventing crack formation while still achieving the desired final thickness and structural stability.
Solution Approach 2:
The invention changes the physical parameters of the glass paste application by controlling the thickness and composition of each deposited layer. By adjusting the paste formulation and deposition parameters to create optimal layer characteristics, the material achieves both the structural stability needed for barrier ribs and the crack resistance required during high-temperature sintering.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the formation of barrier ribs with a desired shape and structural stability, reducing the risk of damage from side-etching and simplifying the manufacturing process, thereby reducing costs and improving efficiency.
Implementation Method 1
followed by a sintering step
Implementation Method 2
the barrier ribs are shaped by etching the exposed portions through openings of the mask with an etching agent
Implementation Method 3
fine sand particles are sprayed thereon at high speed through the mask pattern, thereby forming the barrier ribs
Data Source
AI summary
A slurry composition for forming a double-layered barrier rib of a plasma display panel is provided. The slurry composition for barrier ribs comprises about 100 parts by weight of a mixture comprising a glass powder and a filler; about 20 to 50 parts by weight of a solvent; about 0.01 to 2 parts by weight of a dispersing agent; about 1 to 10 parts by weight of a plasticizer; and about 10 to 20 parts by weight of a binder. A green sheet employing such a slurry compositions is disclosed as is methods of manufacturing a double layered barrier rib using such slurry compositions to form a green sheet.