Spacer assembly for flat panel display apparatus, method of manufacturing spacer assembly, method of manufacturing flat panel display apparatus, flat panel display apparatus, and mold used in manufacture of spacer assembly

A method of manufacturing a spacer assembly having a substrate and a plurality of columnar spacers formed on the substrate and used for a flat panel display apparatus, comprising:

• preparing a substrate and a mold having a number of through holes;
• filling the through holes of the mold with a spacer forming material and arranging the mold on a surface of the substrate to be in tight contact therewith;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the surface of the substrate to be higher than that of the spacer forming material with respect to the mold;
• calcining the spacer forming material with the mold being in tight contact with the substrate, thereby forming spacers on the substrate;
• and
• after cooling, releasing the mold from the substrate.

A method of manufacturing a spacer assembly having a substrate and a plurality of columnar spacers formed on the substrate and used for a flat panel display apparatus, comprising:

• preparing a substrate having opposing first and second surfaces and a plurality of through holes, and first and second molds each having a plurality of through holes;
• arranging the first and second molds on the first and second surfaces of the substrate to be in tight contact therewith such that the holes of the substrate and the through holes of the first and second molds are aligned with each other, and thereafter filling the holes of the substrate and the through holes of the first and second mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the substrate to be higher than that of the spacer forming material with respect to the first and second molds;
• calcining the spacer forming material with the first and second molds being in tight contact with the substrate, thereby forming spacers on the first and second surfaces of the substrate;
• and
• after cooling, releasing the first and second molds from the substrate.

A method of manufacturing a spacer assembly having a substrate and a plurality of columnar spacers formed on the substrate and used for a flat panel display apparatus, comprising:

• preparing a substrate having opposing first and second surfaces, and first and second molds each having a plurality of through holes;
• arranging the first mold on the first surface of the substrate to be in tight contact therewith, and thereafter filling the through holes of the first mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the first surface of the substrate to be higher than that of the spacer forming material with respect to the first mold;
• arranging the second mold on the second surface of the substrate to be in tight contact therewith, and filling the through holes of the second mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the second surface of the substrate to be higher than that of the spacer forming material with respect to the second mold;
• after irradiation with the radiation, calcining the spacer forming material with the first and second molds being in tight contact with the substrate, thereby forming spacers on the first and second surfaces of the substrate;
• and
• after cooling, releasing the first and second molds from the substrate.

A method of manufacturing a flat panel display apparatus having a first substrate with an inner surface with a phosphor layer formed thereon, a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer, a frame-like side wall that joins peripheries of the first and second substrates, a plate-like grid arranged between the first and second substrates to oppose the substrates and having a number of holes located to correspond to the phosphor exciting sources, a number of columnar first spacers arranged between the first substrate and the grid, and a number of columnar second spacers arranged between the second substrate and the grid, the method comprising:

• preparing a grid and a mold having a number of through holes;
• arranging the mold on a surface of the grid to be in tight contact therewith and filling the through holes of the mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the surface of the grid to be higher than that of the spacer forming material with respect to the mold;
• calcining the spacer forming material with the mold being in tight contact with the substrate, thereby forming the large number of first spacers on the grid;
• and
• after cooling, releasing the mold from the grid.

A method of manufacturing a flat panel display apparatus having a first substrate with an inner surface with a phosphor layer formed thereon, a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer, a frame-like side wall that joins peripheries of the first and second substrates, a plate-like grid arranged between the first and second substrates to oppose the substrates and having a number of apertures located to correspond to the phosphor exciting sources, a number of columnar first spacers arranged between the first substrate and the grid, and a number of columnar second spacers arranged between the second substrate and the grid, the method comprising:

• preparing a grid having opposing first and second surfaces and a plurality of spacer holes, and first and second molds each having a plurality of through holes;
• arranging the first and second molds on the first and second surfaces of the substrate to be in tight contact therewith such that the spacer holes of the grid and the through holes of the first and second molds are aligned with each other, and thereafter filling the through holes of the first and second molds with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the first and second surfaces of the substrate to be higher than that of the spacer forming material with respect to the first and second molds;
• calcining the spacer forming material with the first and second molds being in tight contact with the grid, thereby forming first and second spacers on the first and second surfaces of the grid;
• and
• after cooling, releasing the first and second molds from the substrate.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• a plate-like grid arranged between the first and second substrates to oppose the substrates and having a number of apertures located to correspond to the phosphor exciting sources;
• a plurality of columnar first spacers arranged between the grid and the first substrate, a diameter of that end of each of the first spacers which abuts against the first substrate being smaller than that of a grid-side end thereof;
• and
• a plurality of columnar second spacers arranged between the grid and the second substrate, a diameter of that end of each of the second spacers which abuts against the second substrate is smaller than that of a grid-side end thereof, wherein
• a height of each of the first spacers is larger than that of each of the second spacers.

A spacer assembly used for a flat panel display apparatus, comprising:

• a substrate;
• and
• a plurality of columnar spacers standing on the substrate to be integral therewith, wherein
• each of the spacers integrally has a plurality of steps stacked from the substrate toward an extending end and with diameters that decrease gradually, each of the steps being formed in a tapered shape to be thinner from the substrate toward the extending end.

A spacer assembly used for a flat panel display apparatus, comprising:

• a plate-like grid having first and second opposing surfaces and a plurality of apertures;
• a plurality of columnar first spacers standing on the first surface of the grid to be integral therewith;
• and
• a plurality of columnar second spacers standing on the second surface of the grid to be integral therewith, wherein
• each of the first and second spacers integrally including a plurality of steps stacked from the grid toward an extending end and with diameters that decrease gradually, and each of the steps being formed in a tapered shape to be thinner toward an extending end.

A method of manufacturing a spacer assembly having a plate-like grid with a number of apertures and a plurality of columnar spacers formed on the grid and used in a flat panel display apparatus, the method comprising:

• preparing a plate-like grid having first and second surfaces;
• preparing plate-like first and second molds having a number of stepped tapered through holes each having a diameter that decreases gradually from one end toward the other end thereof;
• arranging the first mold on the first surface of the grid to be in tight contact with such that large-diameter sides of the through holes are located on a grid side, and filling the through holes of the first mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the first surface of the grid to be higher than that of the spacer forming material with respect to the first mold;
• arranging the second mold on the second surface of the grid to be in tight contact therewith such that large-diameter sides of the through holes are located on a grid side, and filling the through holes of the second mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the second surface of the grid to be higher than that of the spacer forming material with respect to the second mold;
• after irradiation with the radiation, calcining the spacer forming material with the first and second molds being in tight contact with the grid, thereby forming spacers on the first and second surfaces of the grid;
• and
• after cooling, releasing the first and second molds from the substrate.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• and
• a spacer assembly arranged between the first and second substrates, wherein
• the spacer assembly includes a plate-like grid having a number of apertures opposing the phosphor exciting sources, and a plurality of columnar spacers standing on the grid to be integral therewith, and
• each of the first and second spacers integrally has a plurality of steps stacked from the grid toward an extending end and with diameters that decrease gradually, and each of the steps is formed in a tapered shape to be thinner toward the extending end.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• and
• a spacer assembly arranged between the first and second substrates, wherein
• the spacer assembly includes
• a plate-like grid having first and second surfaces and a plurality of apertures opposing the phosphor exciting sources,
• a plurality of columnar first spacers standing on the first surface of the grid to be integral therewith and in contact with the first substrate, and
• a plurality of columnar second spacers standing on the second surface of the grid to be integral therewith and in contact with the second substrate, and
• each of the first and second spacers integrally has a plurality of steps stacked from the grid toward an extending end and with diameters that decrease gradually, and each of the steps is formed in a tapered shape to be thinner toward the extending end.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• a spacer assembly including a plate-like grid which has first and second surfaces and a number of apertures opposing the phosphor exciting sources and which is arranged between the first and second substrates, and a plurality of columnar first spacers standing on the first surface of the grid to be integral therewith and in contact with the first substrate;
• and
• a plurality of columnar second spacers standing on the second substrate to be integral therewith and in contact with the second surface of the grid, wherein
• each of the first and second spacers integrally has a plurality of steps stacked toward an extending end and with diameters that decrease gradually, and each of the steps is formed in a tapered shape to be thinner toward the extending end.

A method of manufacturing a spacer assembly having a substrate and a plurality of columnar spacers formed on the substrate and used in a flat panel display apparatus, the method comprising:

• preparing a substrate and a plate-like mold having a plurality of stepped tapered through holes each with a diameter that decreases gradually from one end toward the other end thereof;
• arranging the mold on a surface of the substrate to be in tight contact therewith such that large-diameter sides of the through holes are located on a substrate side and filling the through holes of the mold with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the surface of the substrate to be higher than that of the spacer forming material with respect to the mold;
• calcining the spacer forming material with the mold being in tight contact with the substrate, thereby integrally forming spacers on the substrate;
• and
• after cooling, releasing the mold from the substrate.

A method of manufacturing a spacer assembly having a plate-like grid with a number of apertures and a plurality of columnar spacers formed on the grid and used in a flat panel display apparatus, the method comprising:

• preparing a plate-like grid with first and second surfaces and a plurality of spacer holes located between the apertures;
• preparing plate-like first and second molds having a plurality of stepped tapered through holes each having a diameter that decreases gradually from one end toward the other end thereof;
• bringing the first and second molds into tight contact with the first and second surfaces of the grid such that large-diameter sides of the through holes are located on a grid side and arranging the first and second molds such that the spacer holes of the grid and the through holes of the first and second molds are aligned, and filling the through holes of the first and second molds with a spacer forming material;
• curing the spacer forming material by irradiation with radiation, thereby increasing adhesion of the spacer forming material with respect to the grid to be higher than that of the spacer forming material with respect to the first and second molds;
• calcining the spacer forming material with the first and second molds being in tight contact with the grid, thereby forming spacers on the first and second surfaces of the grid;
• and
• after cooling, releasing the first and second molds from the grid.

A flat panel display apparatus comprising:

• a face plate and a rear plate arranged to oppose each other at a predetermined gap;
• and
• a spacer assembly arranged between the face plate and the rear plate, wherein
• the spacer assembly includes
• an electrode plate having opposing first and second surfaces and a plurality of spacer holes and arranged between the face plate and the rear plate to oppose the face plate and the rear plate,
• a plurality of first spacers formed on the first surface of the electrode plate,
• a plurality of second spacers formed on the second surface of the electrode plate, and
• connecting portions connecting one of the second spacers to a plurality of the first spacers to each other through corresponding spacer holes formed in the electrode plate.

A flat panel display apparatus comprising:

• a face plate having an inner surface formed with a phosphor layer;
• a rear plate arranged to oppose the face plate at a predetermined gap and provided with a plurality of electron-emitting portions for exciting the phosphor layer;
• a frame-like side wall that joins peripheries of the face plate and the rear plate;
• and
• a spacer assembly arranged between the face plate and the rear plate, wherein
• the spacer assembly includes
• an electrode plate having opposing first and second surfaces and a plurality of spacer holes and arranged between the face plate and the rear plate to oppose the face plate and the rear plate,
• a plurality of first spacers formed on the first surface of the electrode plate and in contact with the face plate, and
• a plurality of second spacers formed on the second surface of the electrode plate and in contact with the rear plate, and
• a plurality of the first spacers are connected to one of the second spacers, by connecting portions, through corresponding spacer holes formed in the electrode plate.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• a plate-like grid arranged between the first and second substrates to oppose the substrates and having a first surface opposing the first substrate, a second surface opposing the second substrate, and a number of apertures located to correspond to the phosphor exciting sources;
• a plurality of columnar first spacers arranged between the grid and the first substrate and standing on the first surface of the grid to be integral therewith;
• and
• a plurality of columnar second spacers arranged between the grid and the second substrate and standing on the second surface of the grid to be integral therewith, wherein
• a height of each of the first spacers is larger than that of each of the second spacers.

A flat panel display apparatus comprising:

• a first substrate having an inner surface with a phosphor layer formed thereon;
• a second substrate arranged to oppose the first substrate at a predetermined gap and provided with phosphor exciting sources configured to excite the phosphor layer;
• a frame-like side wall that joins peripheries of the first and second substrates;
• a plate-like grid arranged between the first and second substrates to oppose the substrates and having a number of apertures located to correspond to the phosphor exciting sources;
• a plurality of columnar first spacers arranged between the grid and the first substrate and standing on the first surface of the grid to be integral therewith;
• and
• a plurality of columnar second spacers arranged between the grid and the second substrate and standing on the second substrate of the grid to be integral therewith, wherein
• a height of each of the first spacers is larger than that of each of the second spacers.