Microtransfer Molding of Gelcasting Suspensions to Fabricate Barrier Ribs for Plasma Display Panel

We have developed a new fabrication technique for the barrier ribs of a plasma display panel (PDP). The rib structure was formed on a glass plate by microtransfer molding a gelcasting suspension with a flexible soft mold. A well-dispersed gelcasting suspension of the glass frit was placed on the photolithographically patterned mold, followed by gelation and drying while pressed with a top glass plate. The rib structure replicated by micromolding was significantly influenced by the gelation kinetics, the green strength of the gelled body, and the mold release process. It was demonstrated that the box-type array of 1176 wells in the patterned area of 6.5 cm × 6.5 cm could be produced using the current method.