Mold for forming spacers for flat panel displays
OwnerJames Hofmann, Brian Vaartstra +2inventors
InventorsJames Hofmann, Brian Vaartstra, Brenda Kraus, Donald Westmoreland
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Abstract
The present invention describes thick film photolithographic molds, methods of making thick film photolithographic molds, and methods of using thick film photolithographic molds to form spacers on a substrate. The thick film photolithographic molds preferably comprise an epoxy bisphenol A novolac resin. The present invention also describes sol gel spacers comprising sodium silicates and potassium silicates. The thick film photolithographic molds and sol gel spacers of the present invention can be used in flat panel displays, such as field emission displays and plasma displays.
Claims48
A method for adjusting the adhesion between a support and a photolithographic material comprising:
- providing a support;
- applying a priming agent to the support;
- preparing a composition comprising a photolithographic material;
- and
- applying the composition on the support.
A method for forming a negative mold for forming spacers on a flat panel display comprising:
- providing a positive mold comprising at least one post and a photolithographic material;
- covering the positive mold with a composition;
- allowing the composition to harden;
- and
- removing the positive mold to reveal the negative mold comprising the hardened composition.
A mold for forming spacers on a flat panel display prepared by the process comprising:
- adding a dry photolithographic material to a mixture comprising a solvent and a photoinitiator;
- applying the mixture to a support;
- heating the mixture until the mixture forms a flowable composition on the support;
- applying a photomask over the composition;
- curing exposed portions of the composition;
- and
- removing un-cured portions of the composition to reveal the mold.
A method for forming a mold comprising:
- providing a support;
- placing alignment marks on the support;
- applying a thick film photolithographic material on the support, wherein the thick film photolithographic material is positioned within the alignment marks on the support;
- and
- curing the thick film photolithographic material to form the mold.
A method for forming a mold comprising:
- providing a support;
- placing alignment marks on the support;
- applying a transparent photolithographic material over the support;
- placing a photomask on the photolithographic material, wherein the photomask is positioned within the alignment marks on the support;
- curing the photolithographic material;
- and
- removing the un-cured photolithographic material to reveal the mold.
A method of forming at least one spacer on a substrate comprising:
- applying a negative mold on a substrate, wherein the negative mold comprises a photolithographic material, and at least one hole;
- applying a spacer material to the negative mold, wherein the spacer material fills the at least one hole;
- hardening and bonding the spacer material to the substrate;
- and
- removing the negative mold from the substrate, wherein the hardened spacer material remains bonded to the substrate.
A method of forming a spacer on a substrate comprising:
- preparing a mold comprising at least one hole;
- filling the at least one hole in the mold with a spacer material;
- contacting the mold with a substrate;
- allowing the spacer material to harden and bond to the substrate;
- and
- removing the mold from the substrate, wherein the hardened spacer material remains bonded to the substrate.
A spacer for a flat panel display comprising sodium silicate and potassium silicate.
A method for preparing a spacer for a flat panel display comprising:
- preparing a composition comprising formamide, potassium silicate and sodium silicate;
- allowing the composition to form a gel;
- and
- firing the gel to produce the spacer.
A flat panel display comprising:
- a faceplate;
- a baseplate;
- and
- at least one spacer between the faceplate and the baseplate, wherein the spacer comprises a sodium silicate and a potassium silicate.
A method of forming spacers on a display comprising:
- providing a resilient negative mold, the negative mold comprising a first layer and a second layer, the first layer being characterized by a first durometer, the second layer being characterized by a second durometer, the second durometer being higher than the first durometer, the first layer defining a plurality of apertures and a plurality of vacuum pump-out channels;
- placing the negative mold in contact with a substrate;
- using the vacuum pump-out channels to remove gas from between the substrate and the negative mold;
- filling the apertures with a spacer material;
- allowing some of the spacer material to cure and to become attached to the substrate;
- and
- separating the substrate from the negative mold.
Dependencies are inferred from the claim text.