Electrically conducting paths were formed at the interface between a soda-lime glass substrate and a lead-glass overglaze in a gas discharge display panel under an electric field of 7 kV/cm. This resulted in the panel malfunctioning after 4000-h operation. The current leakage paths consisted of Pb atoms, produced by the reduction of PbO by Na ions. The rate of path formation was strongly sensitive to the electric field, substrate temperature, and also to the presence of ionized gases in the vicinity of the interface. Methods of avoiding insulation failure include using a Pb-free dielectric overglaze, sandwiching the electrodes between lead glasses, and reducing the intensity of the electric field.
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