Process for forming a color cathode ray tube screen structure having optical filter elements therein

Claim 2

In the viewing panel of a color cathode ray tube whereon a patterned screen structure formed of a plurality of pattern elements is disposed on the interior surface of said panel relative to a multiple apertured pattern mask member spatially positioned adjacent thereto, an improved process for forming a multi-windowed screen structure defined by a webbing of uniform opaque interstices disposed on an interior surface of said panel prior to the fabrication of the phosphor Screen thereon, said windows defining areas of transparent optical filter materials and evidencing peripheral shapings free of indentations similar to those of the respective formative apertures in said pattern mask, said improved process comprising the steps of: coating the interior of said panel with a uniform layer of a protective coating formed of a negative photosensitive resist material admixed with an inert substance; exposing said coated panel by directing actinic radiations emanating from at least two spaced-apart positions through the apertures in said pattern mask to light-polymerize those portions of said photosensitive coating mixture in said exposed areas; developing said light exposed areas of said panel coating to provide a plurality of polymerized filter pattern window elements on the bare glass of said panel; overcoating said patterned panel with a uniform liquid primary layer of a heat formable first optical filter material; heating said overcoated panel to thermally degrade said polymerized window elements formed of said resist mixture and to transform and adhere a substantially continuous and transparent primary layer of said optical filter material to the glass surface of said panel, said primary layer having a defined plurality of filter pattern window areas therein wherein the degraded materials resultant of said heat are loosely retained; removing said loosely retained materials from the filter pattern window areas in said primary layer; coating said panel with a uniform layer of said protective coating formed of said negative photoresist material admixed with said inert substance; exposing said coated panel to actinic radiations emanating from at least two spaced apart positions to light-polymerize a plurality of discrete portions of said photosensitive coating mixture; developing said light-exposed panel to provide a plurality of filter pattern elements definitively superimposed on the primary layer of said first optical filter material; overcoating said patterned panel with a uniform liquid secondary layer of a heat formable second optical filter material; heating said overcoated panel to thermally degrade said polymerized window elements formed of said resist mixture and to transform and adhere a substantially continuous and transparent secondary layer of said second optical filter material to selected portions of said primary filter layer, said secondary layer having a defined plurality of at least two filter pattern window elements therein wherein said degraded mixture and associated second filter materials are loosely retained; removing said loosely retained materials from the plurality of at least two open filter window areas in said secondary filter layer; coating said panel with a uniform layer of said protective coating formed of said negative photoresist material admixed with said inert substance; exposing said coated panel by directing actinic radiations emanating from at least two spaced apart positions to light-polymerize discrete portions of said photosensitive coating mixture; developing said light exposed panel coating to provide a plurality of at least two polymerized filter patterned elements disposed on selected portions of said secondary filter layer; overcoating said patterned panel with a uniform liquid tertiary layer of a heat formable third optical filter material; heating said overcoated panel to thermally degrade said polymerized window elements formed of said resist mixture and to transform and adhere a substantially continuous and transparent tertiary layer of said third optical filter material to selected portions of said secondary filter layer, said tertiary layer having a plurality of at least two defined filter pattern window areas therein wherein said degraded mixture and associated third filter material are loosely retained; and removing said loosely retained materials from the plurality of filter patterned window areas in said tertiAry layer to provide at least two open filter window areas therein, said superimposed patterned primary, secondary, and tertiary filter layers providing at least two window areas having specific filter materials disposed therein, and wherein said superposed filter layers provide in combination a substantially opaque and uniform interstitial webbing fully surrounding each of respective window areas in said screen structure whereof the uniform peripheral encompassment of each window area is free of indentations.

Claim 3

IN THE VIEWING PANEL OF A COLOR CATHODE RAY TUBE WHEREON A PATTERNED SCREEN STRUCTURE FORMED OF FIRST, SECOND AND THIRD PATTERN ELEMENTS IN DISPOSED ON THE INTERIOR SURFACE OF SAID PANEL RELATIVE TO A MULTIPLE APERTURED PATTERN MASK SPATIALLY POSITIONED ADJACENT THERETO, AN IMPROVED PROCESS FOR FORMING AN IMPROVED MULTI-WINDOWED SCREEN STRUCTURE DEFINED BY A WEBBING OF UNIFORM OPAQUE INTERSTICES DISPOSED ON THE INTERIOR SURFACE OF SAID PANEL PRIOR TO THE FABRICATION OF THE PHOSPHOR SCREEN THEREON, EACH OF SAID WINDOWS DEFINING AN AREA OF A SELECTED SUBSTANTIALLY TRANSPARENT OPTICAL FILTER MATERIAL AND EVIDENCING A PERIPHERAL SHAPING FREE OF INDENTATIONS SIMILAR TO THAT OF THE RESPECTIVE FORMATIVE APERTURE IN SAID PATTERN MASK, SAID IMPROVED PROCESS COMPRISING THE STEPS OF: COATING THE INTERIOR OF SID PANEL WITH A UNIFORM LAYER OF A PROTECTIVE COATING FORMED OF A NEGATIVE PHOTOSENSITIVE RESIST MATERIAL ADMIXED WITH AN INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES IN SAID PATTERN MASK TO LIGHT-POLYMERIZE THOSE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THE AREAS SUBSEQUENTLY OCCUPIED BY SAID SECOND AND THIRD FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE COATING MIXTURE THEREFROM TO PROVIDE SECOND AND THIRD POLYMERIZED FILTER PATTERN WINDOW ELEMENTS ON THE BARE GLASS OF SAID PANEL; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID PRIMARY LAYER OF A HEAT FORMABLE FIRST OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE SAID FIRST OPTICAL MATERIAL AND ADHERE A SUBSTANTIALLY CONTINUOUS AND TRANSPARENT PRIMARY LAYER OF SAID FIRST OPTICAL FILTER MATERIAL TO THE GLASS SURFACE OF SAID PANEL, SAID PRIMARY LAYER HAVING DEFINED SECOND AND THIRD FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED FIRST FILTER MATERIALS ARE LOOSELY RETAINED; TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID SECOND AND THIRD FILTER PATTERN WINDOW AREAS TO PROVIDE A PRIMARY LAYER OF SAID FIRST OPTICAL FILTER MATERIAL HAVING A SECOND AND THIRD PATTERN OPEN FILTER WINDOWS THEREIN; COATING SAID PANEL WITH A UNIFORM LAYER OF SAID PROTECTIVE COATING FORMED OF SAID NEGATIVE PHOROTESIST MATERIAL ADMIXED WITH SAID INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES OF SAID PATTERN MASK TO LIGHT-POLYMERIZE DISCRETE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THOSE AREAS SUBSEQUENTLY OCCUPIED BY SAID FIRST AND THIRD FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT-EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE MIXTURE THEREFROM TO PROVIDE A PLURALITY OF FIRST POLYMERIZED FILTER PATTERN ELEMENTS SUPERIMPOSED ON SAID FIRST OPTICAL FILTER MATERIAL IN A MANNER TO DEFINE THE FIRST FILTER PATTERN WINDOW AREAS, AND A PLURALITY OF THIRD POLYMERIZED FILTER PATTERN ELEMENTS DISPOSED IN THE OPEN THIRD PATTERN WINDOW AREAS OF SAID PRIMARY FILTER LAYER; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID SECONDARY LAYER OF A HEAT FORMABLE SECOND OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE AND ADHERE A SUBSTANTIALLY CONTINOUS AND TRANSPARENT SECONDARY LAYER OF SAID SECOND OPTICAL FILTER MATERIAL TO PORTIONS OF SAID PRIMARY FILTER LAYER INCLUDING DEPOSITION IN THE SECOND FILTER PATTERN WINDOWS THEREOF, SAID SECONDARY LAYER HAVING DEFINED FIRST AND THIRD FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED SECOND FILTER MATERIALS ARE LOOSELY RETAINED; TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID FIRST AND THIRD FILTER WINDOW AREAS WHEREUPON SAID PRIMARY FILTER LAYER IS COVERED WITH SAID SECONDARY LAYER OF THE SECOND OPTICAL FILTER MATERIAL HAVING FIRST AND THIRD PATTERN OPEN FILTER WINDOWS THEREIN; COATING SAID PANEL WITH A UNIFORM LAYER OF SAID PROTECTIVE COATING FORMED OF SAID NEGATIVE PHOSORESIST MATERIAL ADMIXED WITH SAID INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES IN SAID PATTERN MASK TO LIGHT POLYMERIZE DISCRETE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THOSE AREAS SUBSEQUENTLY OCCUPIED BY SAID FIRST AND SECOND FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE COATING MIXTURE THEREFROM TO PROVIDE A PLURALITY OF FIRST POLYMERIZED FILTER PATTERN ELEMENTS DEPOSED IN SAID OPEN FIRST PATTERN WINDOW AREAS OF SAID SECONDARY FILTER LAYER, AND A PLURALITY OF SECOND POLYMERIZED FILTER PATTERN ELEMENTS DISPOSED IN THE OPEN SECOND PATTERN WINDOW AREAS OF SAID SECONDARY FILTER LAYER; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID TERTIARY LAYER OF HEAT FORMABLE THIRD OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE AND ADHERE A SUBSTANTIALLY CONTINOUS AND TRANSPARENT TERTIARY LAYER OF SAID THIRD OPTICAL FILTER MATERIAL TO PORTIONS OF SAID SECONDARY FILTER LAYER INCLUDING DEPOSITION IN THE THIRD FILTER PATTERN WINDOWS THEREOF, SAID TERTIARY LAYER HAVING DEFINED FIRST AND SECOND FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED THIRD FILTER MATERIALS ARE LOOSELY RETAINED; AND TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID FIRST AND SECOND FILTER PATTERN WINDOW AREAS WHEREUPON THE SECONDARY FILTER LAYER IS RECOVERD WITH SAID TERTIARY LAYER OF A THIRD OPTICAL FILTER MATERIAL HAVING FIRST AND SECOND PATTERN OPEN FILTER WINDOWS THEREIN, THE COMBINATION OF SAID SUPERIMPOSED PRIMARY, SECONDARY AND TERTIARY FILTER LAYERS PROVIDES A SUBSTANTIALLY OPAQUE UNIFORMLY STRUCTURED INTERSTITIAL WEBBING FULLY SURROUNDING EACH OF THE RESPECTIVE OPTICAL FILTER WINDOWS IN SAID SCREEN STRUCTURE WHEREOF THE UNIFORM PERIPHERAL ENCOMPASSMENT OF EACH FILTER WINDOW IS FREE OF INDENTATIONS.

Claim 4

IN THE VIEWING PANEL OF A COLOR CATHODE RAY TUBE WHEREON A PATTERNED SCREEN STRUCTURE FORMED OF FIRST, SECOND AND THIRD PATTERN ELEMENTS IN DISPOSED ON THE INTERIOR SURFACE OF SAID PANEL RELATIVE TO A MULTIPLE APERTURED PATTERN MASK SPATIALLY POSITIONED ADJACENT THERETO, AN IMPROVED PROCESS FOR FORMING AN IMPROVED MULTI-WINDOWED SCREEN STRUCTURE DEFINED BY A WEBBING OF UNIFORM OPAQUE INTERSTICES DISPOSED ON THE INTERIOR SURFACE OF SAID PANEL PRIOR TO THE FABRICATION OF THE PHOSPHOR SCREEN THEREON, EACH OF SAID WINDOWS DEFINING AN AREA OF A SELECTED SUBSTANTIALLY TRANSPARENT OPTICAL FILTER MATERIAL AND EVIDENCING A PERIPHERAL SHAPING FREE OF INDENTATIONS SIMILAR TO THAT OF THE RESPECTIVE FORMATIVE APERTURE IN SAID PATTERN MASK, SAID IMPROVED PROCESS COMPRISING THE STEPS OF: COATING THE INTERIOR OF SID PANEL WITH A UNIFORM LAYER OF A PROTECTIVE COATING FORMED OF A NEGATIVE PHOTOSENSITIVE RESIST MATERIAL ADMIXED WITH AN INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES IN SAID PATTERN MASK TO LIGHT-POLYMERIZE THOSE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THE AREAS SUBSEQUENTLY OCCUPIED BY SAID SECOND AND THIRD FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE COATING MIXTURE THEREFROM TO PROVIDE SECOND AND THIRD POLYMERIZED FILTER PATTERN WINDOW ELEMENTS ON THE BARE GLASS OF SAID PANEL; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID PRIMARY LAYER OF A HEAT FORMABLE FIRST OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE SAID FIRST OPTICAL MATERIAL AND ADHERE A SUBSTANTIALLY CONTINUOUS AND TRANSPARENT PRIMARY LAYER OF SAID FIRST OPTICAL FILTER MATERIAL TO THE GLASS SURFACE OF SAID PANEL, SAID PRIMARY LAYER HAVING DEFINED SECOND AND THIRD FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED FIRST FILTER MATERIALS ARE LOOSELY RETAINED; TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID SECOND AND THIRD FILTER PATTERN WINDOW AREAS TO PROVIDE A PRIMARY LAYER OF SAID FIRST OPTICAL FILTER MATERIAL HAVING A SECOND AND THIRD PATTERN OPEN FILTER WINDOWS THEREIN; COATING SAID PANEL WITH A UNIFORM LAYER OF SAID PROTECTIVE COATING FORMED OF SAID NEGATIVE PHOROTESIST MATERIAL ADMIXED WITH SAID INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES OF SAID PATTERN MASK TO LIGHT-POLYMERIZE DISCRETE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THOSE AREAS SUBSEQUENTLY OCCUPIED BY SAID FIRST AND THIRD FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT-EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE MIXTURE THEREFROM TO PROVIDE A PLURALITY OF FIRST POLYMERIZED FILTER PATTERN ELEMENTS SUPERIMPOSED ON SAID FIRST OPTICAL FILTER MATERIAL IN A MANNER TO DEFINE THE FIRST FILTER PATTERN WINDOW AREAS, AND A PLURALITY OF THIRD POLYMERIZED FILTER PATTERN ELEMENTS DISPOSED IN THE OPEN THIRD PATTERN WINDOW AREAS OF SAID PRIMARY FILTER LAYER; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID SECONDARY LAYER OF A HEAT FORMABLE SECOND OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE AND ADHERE A SUBSTANTIALLY CONTINOUS AND TRANSPARENT SECONDARY LAYER OF SAID SECOND OPTICAL FILTER MATERIAL TO PORTIONS OF SAID PRIMARY FILTER LAYER INCLUDING DEPOSITION IN THE SECOND FILTER PATTERN WINDOWS THEREOF, SAID SECONDARY LAYER HAVING DEFINED FIRST AND THIRD FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED SECOND FILTER MATERIALS ARE LOOSELY RETAINED; TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID FIRST AND THIRD FILTER WINDOW AREAS WHEREUPON SAID PRIMARY FILTER LAYER IS COVERED WITH SAID SECONDARY LAYER OF THE SECOND OPTICAL FILTER MATERIAL HAVING FIRST AND THIRD PATTERN OPEN FILTER WINDOWS THEREIN; COATING SAID PANEL WITH A UNIFORM LAYER OF SAID PROTECTIVE COATING FORMED OF SAID NEGATIVE PHOSORESIST MATERIAL ADMIXED WITH SAID INERT SUBSTANCE; EXPOSING SAID COATED PANEL BY DIRECTING ACTINIC RADIATIONS EMANATING FROM TWO SPACED APART POSITIONS THROUGH THE APERTURES IN SAID PATTERN MASK TO LIGHT POLYMERIZE DISCRETE PORTIONS OF SAID PHOTOSENSITIVE COATING MIXTURE IN THOSE AREAS SUBSEQUENTLY OCCUPIED BY SAID FIRST AND SECOND FILTER PATTERN WINDOWS; DEVELOPING SAID LIGHT EXPOSED PANEL COATING BY REMOVING THE UNEXPOSED PHOTOSENSITIVE COATING MIXTURE THEREFROM TO PROVIDE A PLURALITY OF FIRST POLYMERIZED FILTER PATTERN ELEMENTS DEPOSED IN SAID OPEN FIRST PATTERN WINDOW AREAS OF SAID SECONDARY FILTER LAYER, AND A PLURALITY OF SECOND POLYMERIZED FILTER PATTERN ELEMENTS DISPOSED IN THE OPEN SECOND PATTERN WINDOW AREAS OF SAID SECONDARY FILTER LAYER; OVERCOATING SAID PATTERNED PANEL WITH A UNIFORM LIQUID TERTIARY LAYER OF HEAT FORMABLE THIRD OPTICAL FILTER MATERIAL; HEATING SAID OVERCOATED PANEL IN A CONTROLLED OXYGEN ATMOSPHERE TO THERMALLY DEGRADE SAID POLYMERIZED WINDOW ELEMENTS FORMED OF SAID RESIST MIXTURE AND OXIDIZE AND ADHERE A SUBSTANTIALLY CONTINOUS AND TRANSPARENT TERTIARY LAYER OF SAID THIRD OPTICAL FILTER MATERIAL TO PORTIONS OF SAID SECONDARY FILTER LAYER INCLUDING DEPOSITION IN THE THIRD FILTER PATTERN WINDOWS THEREOF, SAID TERTIARY LAYER HAVING DEFINED FIRST AND SECOND FILTER PATTERN WINDOW AREAS THEREIN WHEREIN SAID DEGRADED MIXTURE AND ASSOCIATED THIRD FILTER MATERIALS ARE LOOSELY RETAINED; AND TREATING SAID PANEL TO REMOVE SAID LOOSELY RETAINED MATERIALS FROM SAID FIRST AND SECOND FILTER PATTERN WINDOW AREAS WHEREUPON THE SECONDARY FILTER LAYER IS RECOVERD WITH SAID TERTIARY LAYER OF A THIRD OPTICAL FILTER MATERIAL HAVING FIRST AND SECOND PATTERN OPEN FILTER WINDOWS THEREIN, THE COMBINATION OF SAID SUPERIMPOSED PRIMARY, SECONDARY AND TERTIARY FILTER LAYERS PROVIDES A SUBSTANTIALLY OPAQUE UNIFORMLY STRUCTURED INTERSTITIAL WEBBING FULLY SURROUNDING EACH OF THE RESPECTIVE OPTICAL FILTER WINDOWS IN SAID SCREEN STRUCTURE WHEREOF THE UNIFORM PERIPHERAL ENCOMPASSMENT OF EACH FILTER WINDOW IS FREE OF INDENTATIONS.

Claim 5

The process for forming the improved multi-windowed screen structure according to claim 2 wherein the negative photosensitive resist material is a water-alcohol solution of polyvinyl alcohol sensitized with ammonium dichromate, and wherein said inert protective substance is a material that is thermally and chemically inactive to the temperatures and materials encountered in said process, and one that does not substantially alter the pH of the polyvinyl alcohol system.

Claim 6

The process for forming the improved multi-windowed screen structure according to claim 3 wherein said inert protective substance associated with said negative photosensitive resist material is at least one selected from the group comprising aluminum silicate, zinc oxide, calcium carbonate, and materials related thereto.

Claim 7

A process for forming the improved multi-windowed screen structure according to claim 2 wherein the heat formable optical filter materials are organometallic luster compositions.

Claim 8

A process for forming the improved multi-windowed screen structure according to claim 2 wherein said heating of the overcoated panel is within the range of suBstantially 450* to 500* Centigrade.

Claim 9

A process for forming the improved multi-windowed screen structure according to claim 2 wherein the treating of said panel to remove the loosely retained materials resultant from heating is in the form of lightly brushing the panel with a non-abrasive means.

Claim 10

A process for forming the improved multi-windowed screen structure according to claim 2 wherein the treating of said panel to remove the loosely retained materials resultant from heating involves immersing the screen area in an aqueous solution and subjecting the environment to ultrasonic vibrations.