Method of forming microstructures on a substrate and a microstructured assembly used for same

Abstract

A method of forming microstructures on a substrate is disclosed. A microstructured assembly that may be used in the method for forming microstructures on a substrate is also disclosed. The methods and assemblies of the present disclosure can reduce the amount of air entrapped in barrier ribs formed on substrates used in Plasma Display devices.

1 . A flexible mold suitable for molding a lattice pattern, wherein the lattice pattern comprises a first set of ribs aligned in the first direction and a second set of ribs aligned in a second direction substantially orthogonal to the first direction, wherein the first set of ribs comprises a pitch of less than 500 μm, the ribs of each set have an average width, and the average width of the second set of ribs to the average width of the first set of ribs has a ratio of at least 1.5. 
     
     
         2 . The flexible mold of  claim 1 , wherein the pitch of the first set of ribs is less than 300 μm. 
     
     
         3 . The flexible mold of  claim 1  wherein the first and second set of ribs have an average width ranging from 20 μm to 50 μm. 
     
     
         4 . The flexible mold of  claim 1  wherein the first and second set of ribs have heights of about 120 μm to 140 μm. 
     
     
         5 . The flexible mold of  claim 1  wherein the first and second set of ribs have widths of about 20 μm to 75 μm. 
     
     
         6 . The flexible mold of  claim 1  wherein the mold is a transparent plastic mold. 
     
     
         7 . The flexible mold of  claim 1  wherein the mold is a flexible polymer sheet having a smooth surface and an opposing microstructured surface. 
     
     
         8 . A plasma display panel comprising barrier ribs having a lattice pattern, wherein the lattice pattern comprises a first set of ribs aligned in the first direction and a second set of ribs aligned in a second direction substantially orthogonal to the first direction, wherein the first set of ribs comprises a pitch of less than 500 μm, the ribs of each set have an average width, and the average width of the second set of ribs to the average width of the first set of ribs has a ratio of at least 1.5. 
     
     
         9 . The plasma display panel of  claim 8 , wherein the pitch of the first set of ribs is less than 300 μm. 
     
     
         10 . The plasma display panel of  claim 8  wherein the first and second set of ribs have an average width ranging from 20 μm to 50 μm. 
     
     
         11 . The plasma display panel of  claim 8  wherein the first and second set of ribs have heights of about 120 μm to 140 μm. 
     
     
         12 . The plasma display panel of  claim 8  wherein the first and second set of ribs have widths of about 20 μm to 75 μm. 
     
     
         13 . The plasma display panel of  claim 8 , wherein a plurality of ribs of the first set of ribs are connected by intervening land regions, and further wherein the intervening land regions comprise a substantially uniform center thickness. 
     
     
         14 . The plasma display panel of  claim 8 , wherein a plurality of ribs of the second set of ribs are connected by intervening land regions, and further wherein the intervening land regions comprise a substantially uniform center thickness. 
     
     
         15 . The plasma display panel of  claim 8 , wherein the ribs comprises a cured and fired ceramic material.