Field emission display cathode assembly

Abstract

Improved field emission display includes a buffer layer of copper, aluminum, silicon nitride or doped or undoped amorphous, poly, or microcrystalline silicon located between a chromium gate electrode and associated dielectric layer in a cathode assembly. The buffer layer substantially reduces or eliminates the occurrence of an adverse chemical reaction between the chromium gate electrode and dielectric layer.

Description

BACKGROUND OF THE INVENTION

[0003] The present invention relates to an improvement in field emission display (FED) technology and, in particular, to a FED cathode assembly that substantially reduces or eliminates the occurrence of an adverse chemical reaction between a chromium gate electrode and an insulating (i.e., dielectric) oxide layer.

[0004] FIG. 1 illustrates a typical FED structure 10, which includes a cathode assembly 9 and an anode assembly 8 separated from each other by spacers 25. Cathode assembly 9 has a substrate or baseplate 12 with a base conductive layer 14 formed thereon, a resistive layer 15 (e.g., amorphous silicon) deposited on top of layer 14, and a plurality of conical, cold cathode emitters 16 formed on layer 15. Also formed on layer 15 is an electrically insulating (i.e., dielectric) layer 18 having a conductive layer located thereon, which forms gate electrode 20. This electrode, which is typically formed from metal, functions as an extraction grid to control the emission of electrons from emitters 16.

[0005] Anode assembly 8 has a transparent faceplate 22, a transparent conductive layer 23 over faceplate 22 and a black matrix grille (not shown) formed over layer 23 to define pixel regions. A cathodoluminescent coating (i.e., phosphor) 24 is deposited on these defined regions. This assembly is positioned a predetermined distance from emitters 16 using spacers 25. Typically, a vacuum exists between emitters 16 and anode 8.

[0006] A power supply 26 is electrically coupled to conductive layer 23, electrode 20 and conductive layer 14 for providing an electric field that causes emitters 16 to emit electrons and accelerate the electrons toward conductive layer 23. A vacuum in the space between baseplate 12 and anode 22 provides a relatively clear path for electrons emitted from emitters 16. The emitted electrons strike cathodoluminescent coating 24, which emits light to form a video image on a display screen created by anode 8.

[0007] FIG. 2 is a schematic diagram of a portion of the FED structure 10 shown in FIG. 1. In operation, electrons flow from the conductive layer 14 to an emitter 16 through resistor 32, which is formed by the resistive layer 15. This resistive layer is current limiting. Even in the case of a short circuit between emitter 16 and electrode 20, resistive layer 15 limits the flow of current, and thus the flow of electrons, through the circuit branch formed by conductive layer 14, resistive layer 15, and emitter 16.

[0008] Referring again to FIG. 2, an electric potential placed on gate electrode 20 (which functions as an extraction grid) pulls an electron emission stream from emitter 16. A second potential placed on layer 23 attracts the freed electrons, which accelerate toward this layer until they strike cathodoluminescent coating 24. Specific examples of FEDs are disclosed in the following U.S. patents, each of which is hereby incorporated by reference in its entirety for all purposes: U.S. Pat. Nos. 3,671,798, 3,970,887, 4,940,916, 5,151,061, 5,162,704, 5,212,426, 5,283,500, and 5,359,256.

[0009] Successful FED operation depends upon, among other things, a dependable gate electrode that is capable of consistent and prolonged operation. The formation of conventional gate electrodes is well known and described, for example, in the following U.S. patents, each of which is hereby incorporated by reference in its entirety for all purposes: U.S. Pat. Nos. 5,186,670, 5,299,331, 5,259,799 and 5,372,973.

[0010] Chromium metal is considered an ideal gate electrode in field emission displays. Although the electrical conductivity of chromium (Cr) is less than aluminum and the noble metals, critical parameters such as chemical durability, adhesion to glass and nonreactivity with solutions such as “Piranha” (i.e., a 2:1 mixture of H2SO4 and H2O2, commonly used to remove organic contamination and strip photoresist) and hydrofluoric acid (an aqueous solution of HF commonly used to etch SiO2) make chromium an attractive candidate for gate electrodes. In a conventional FED structure, such as shown in FIG. 1, electrodes formed from Cr layers (e.g., base conductive layer 14 and the conductive layer forming gate electrode 20) are sputter deposited to a thickness of approximately 200 nm. An insulating layer of SiO2 located between these layers (e.g., dielectric layer 18) is deposited to a thickness of about 500 nm.

[0011] It has been observed that chromium used as a gate electrode (e.g., electrode 20) adversely reacts with deposited silicon dioxide (SiO2; e.g., dielectric layer 18) upon application of an electrical potential between the gate electrode and a base conductive layer (e.g., layer 14), both in ambient and under vacuum conditions. Under ambient atmospheric pressure, the reaction occurs rapidly and results in a brown, bubbling reaction product at the surface of the chrome electrode. This reaction coincides with a rapid reduction in the breakdown voltage of the dielectric layer. Under vacuum conditions typical of an FED operating environment (i.e., about 1×10−7 to 1×10−8 Torr; referred to herein as “FED vacuum conditions”), no bubbling is observed on the chrome electrode, however, a gradual chemical transformation occurs at a site on the electrode where electrical contact is made with a probe tip (i.e., a standard tungsten probe tip commonly used for contacting structures during electrical measurements). Again, this reaction coincides with a gradual deterioration of the dielectric breakdown voltage.

[0012] Deterioration of dielectric breakdown voltage of a FED cathode assembly under FED vacuum conditions could lead to shorting between the Cr gate electrode and an associated base conductive layer, degradation in emission current of emitters (e.g., cold cathode emitters 16), reduction in brightness of an associated FED display and eventual failure of the FED unit. Accordingly, the very reliability of a FED unit is jeopardized by this phenomena.

[0013] From the above, it is seen that a method and apparatus is desired for substantially reducing or eliminating the occurrence of an adverse chemical reaction between a chromium gate electrode and an insulating (i.e., dielectric) layer that coincides with a deterioration of dielectric breakdown voltage in a FED cathode assembly.

SUMMARY OF THE INVENTION

[0014] A FED cathode assembly and method for making same that substantially reduces or eliminates the occurrence of an adverse chemical reaction between a chromium gate electrode and an insulating (i.e., dielectric) layer is provided. In one embodiment, the invention provides a cathode assembly that includes a layer of insulating material, a buffer layer located over the insulating layer and a layer of chromium located over the buffer layer. In another embodiment, an FED is provided that includes a baseplate, a first layer of conductive material located over the baseplate, a layer of insulating material located over the first layer of conductive material, a buffer layer located over the insulating material and a second layer of conductive material located over the buffer layer. In both embodiments, the buffer layer may be formed from copper, aluminum, silicon nitride or silicon (e.g., amorphous, polycrystalline or microcrystalline).

[0015] In yet another embodiment, a method for forming a cathode assembly is provided that includes the steps of forming a layer of insulating material over a first layer of conductive material, forming a buffer layer over the insulating layer and forming a second layer of conductive material over the buffer layer.

[0016] A further understanding of the nature and advantages of the invention may be realized by reference to the remaining portions of the specification and the drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a schematic vertical section of a cold cathode field emission display (FED);

[0018] FIG. 2 is an electrical schematic diagram of a typical FED configuration;

[0019] FIG. 3 is an x-ray photoelectron spectroscopy (XPS) depth profile of a portion of a test structure shown in FIG. 12 before voltage is applied;

[0020] FIGS. 4 and 5 illustrate binding energy data of select elements of the test structure shown in FIG. 12 before voltage is applied;

[0021] FIG. 6 is an optical micrograph of a Cr surface with an underlying SiO2 layer after voltage is applied;

[0022] FIG. 7 is a depth profile of a portion of the test structure of FIG. 12 after voltage is applied;

[0023] FIG. 8 illustrates binding energy data of a select element of the test structure of FIG. 12 after voltage is applied;

[0024] FIG. 9 is a schematic vertical section of a cold cathode FED constructed according to the principles of the invention;

[0025] FIG. 10 a illustrates exemplary process parameters for plasma-enhanced chemical vapor deposition (PECVD);

[0026] FIG. 10 b illustrates exemplary process parameters for dc magnetron sputtering;

[0027] FIG. 11 is a flow chart of a method for constructing a cathode assembly of the cold cathode FED of FIG. 9 according to the principles of the invention; and

[0028] FIG. 12 is a schematic drawing of a portion of a test structure.

DESCRIPTION OF SPECIFIC EMBODIMENTS

[0029] For purposes of the following discussion, electrode 20 and dielectric layer 18 in FED structure 10 (FIG. 1) are considered to be formed from Cr and SiO2, respectively. In such a configuration, it has been determined that application of an electric potential (e.g., 20 to 200 V) under ambient conditions across layer 18 leads to vigorous bubbling at the surface of electrode 20 and subsequent formation of chromium oxides (predominantly Cr2O3, but also CrO3) throughout electrode 20. (Although 20 to 200 V is suggested, any voltage level will produce similar results over time.) Due to the formation of such chromium oxides, there is a rapid reduction in the breakdown voltage of dielectric layer 18.

[0030] FIGS. 3-8 illustrate the change in composition of a chromium layer (such as electrode 20) resulting from an applied voltage under ambient (i.e., atmosphere) conditions. FIGS. 3-5 relate to a pre-voltage state while FIGS. 6-8 relate to a post-voltage state. More specifically, FIG. 3 shows x-ray photoelectron spectroscopy (XPS) data of a depth profile of a test structure from the top of a Cr layer to a contiguous SiO2 layer. The test structure, a portion of which is shown in FIG. 12 (not drawn to scale), includes a first (i.e., bottom) layer of glass 1202, a second layer of B-doped amorphous silicon (ˆ 1aSiB) 1204 located atop the first layer, a third layer of SiO2 1206 located atop the second layer and a fourth (i.e., top) layer of Cr 1208 located atop the third layer. Cr layer 1208 is approximately 275 angstroms thick and contacts SiO2 layer 1206 at interface 1210.

[0031] The composition of Cr layer 1208 and a portion of SiO2 layer 1206 of the test structure is graphically illustrated in FIG. 3, which shows atomic concentration of constituent elements in relation to depth from the top (i.e., surface) of Cr layer 1208 (i.e., lines 100, 102, 104 and 106 represent atomic concentrations of Cr2O3, Cr, oxygen and silicon, respectively). The intersection of lines 102 and 104 at point 108 represents the interface 1210 between Cr layer 1208 and SiO2 layer 1206 of FIG. 12.

[0032] As shown by line 100 of FIG. 3, a native oxide is present to a depth of about 50 angstroms from the top of the Cr layer 1208. This oxide is identified as Cr2O3 (based upon measured binding energy, as shown at data point 150 in FIG. 4.) The bulk of the Cr layer 1208 is identified as pure chromium (based again upon measured binding energy, and shown by data point 152 of FIG. 4.) This pure chromium persists until reaching interface 1210 (FIG. 12) between the Cr and SiO2 layers. At this interface, 6% of the chromium detected is identified as chromium VI (CrO3) and chromium IV (CrO2) oxides (oxidation states +6 and +4, respectively), as shown at binding energy data points 202 and 204, respectively, in FIG. 5.

[0033] FIG. 6 shows an optical micrograph of the surface of a Cr layer (such as layer 1208) after a voltage of about 30-40 V is applied across an underlying SiO2 layer (such as layer 1206) for about 1-2 minutes and an adverse chemical reaction has occurred. As can be seen in the figure, liquid formation nucleates at different points until the entire area of chrome metal is enveloped. During the liquid formation, if a voltage is present across an underlying SiO2 layer, it gives rise to a bubbling effect and the near-total elimination of the chromium metal.

[0034] FIG. 7 is a depth profile of a portion of the test structure of FIG. 12 after voltage is applied. Referring to FIG. 7, line 704 represents oxygen that is bonded to chromium (represented by line 702) in at least layer 1208 of the test structure of FIG. 12. The chromium oxide formed by the constituent elements of lines 704 and 702 is identified through binding energy as chromium oxide (Cr2O3), as shown in FIG. 8. (Such oxide has a theoretical binding energy of 576.95 eV which, as shown in FIG. 8, is nearly identical to the measured value of approximately 576.8 eV.) Chromium oxide is present throughout Cr layer 1208 (indicated by lines 702 and 704); such presence coincides with the deterioration of dielectric breakdown voltage.

[0035] In contrast to operating under ambient conditions, when a potential of about 200 V is continuously applied under FED vacuum conditions (i.e., the operating environment of a FED) to Cr electrode 20 (FIG. 1) for about six to forty-eight hours, there is a gradual adverse chemical reaction at a probe site on electrode 20 (i.e., a location on electrode 20 where electrical contact is made with a standard tungsten probe tip) which results in a decrease in the breakdown voltage of dielectric layer 18. The reaction at the affected site on and just below the surface (about 30 angstroms) of electrode 20 is found to be associated with chromium oxides (Cr2O3 and CrO2), sodium and silicon dioxide (SiO2) rather than pure chromium. Although slower, the adverse chemical reaction observed in the Cr electrode under FED vacuum conditions produces essentially the same result as the reaction under ambient conditions: deterioration of dielectric breakdown voltage.

[0036] FIG. 9 is a cross-sectional view of a portion of a cold cathode FED structure 40 constructed to substantially reduce or eliminate altogether the foregoing adverse chemical reaction between a Cr electrode and SiO2 layer. Structure 40 includes a cathode assembly 60 and an anode assembly 62, which are separated from each other by spacers 55 (only one is shown for clarity). Cathode assembly 60 has a substrate or baseplate 42 constructed from, for example, soda-lime glass. (Other glasses may be used, such as Corning glass.) A conductive layer 44 is formed over baseplate 42, a resistive layer 46 is deposited over layer 44 and one or more cold cathode emitters 48 are formed on layer 46 (only one is shown for clarity). Also formed on resistive layer 46 is a dielectric layer 50. Cavities are formed in layer 50 to accommodate emitters 48.

[0037] According to the invention, a buffer layer 52 is formed on top of insulating dielectric layer 50 such that a chromium gate electrode 54 (forming an extraction grid) is not in direct contact with dielectric layer 50. Buffer layer 52 may be formed from copper, aluminum, silicon nitride (Si3N4) and doped or undoped amorphous, poly, or microcrystalline silicon.

[0038] Anode assembly 62 has a transparent faceplate 56, a transparent conductive layer 57 formed over faceplate 56 and a black matrix (not shown) formed over layer 57 to define pixel regions. A cathodoluminescent coating (i.e., phosphor) 58 is deposited on these defined regions (only one is shown for clarity). This assembly is spaced at a predetermined distance from emitters 48 via spacers 55 (only one is shown), and a vacuum exists between these emitters and anode 62. Exemplary materials for use in one embodiment of the invention are identified in Table 1.

TABLE 1
Element             Material
substrate 56        soda-lime glass
conductive layer 57 indium tin oxide (ITO)
coating 58          cathodoluminescent phosphors
black matrix        cobalt oxide
electrode 54        chromium
buffer 52           metal (copper, aluminum), silicon nitride or silicon
                    (amorphous, poly or microcrystalline)
insulating layer 50 silicon dioxide
emitter 48          amorphous silicon
resistive layer 46  amorphous silicon
conductive layer 44 metal (e.g., chromium)
substrate 42        glass

[0039] In an alternative embodiment, resistive layer 46 may be replaced with an external resistor (used for current limiting) located in series (electrically) between power supply 64 and conductive layer 44.

[0040] Referring again to FIG. 9, cathode assembly 60 of FED structure 40 may be constructed using conventional semiconductor fabrication processes, as described below. Fabrication steps are illustrated in chart 1100 of FIG. 11 and exemplary process parameters are provided in FIGS. 10a and 10b.

[0041] Initially, a conductive layer 44 (FIG. 9), for example, is formed on baseplate 42 pursuant to block 1102 of FIG. 11. This layer may be constructed from chromium and formed by dc magnetron sputtering (i.e., dc sputtering within an applied magnetic field, a process well known to those having ordinary skill in the art), as indicated in FIG. 10b. Resistive layer 46 is next formed, over layer 44, pursuant to block 1104 in FIG. 11, using plasma enhanced chemical vapor deposition (PECVD) as indicated in FIG. 10a. Emitters 48 are then formed in accordance with block 1106 of FIG. 11, by any known method, such as disclosed in U.S. Pat. No. 5,186,670. The emitter tip layer may be formed from amorphous silicon using PECVD, as indicated in FIG. 10a.

[0042] Pursuant to block 1108 in FIG. 11, insulating layer 50 is next formed on resistive layer 46 and emitters 48. This step may be carried out through PECVD of SiO2, as indicated in FIG. 10a. In block 1110, buffer layer 52 is formed on top of insulating layer 50. If made from metal (e.g., copper or aluminum), buffer layer 52 may be formed by dc magnetron sputtering pursuant to FIG. 10b. Alternatively, if made from silicon nitride or silicon (e.g., amorphous, poly or microcrystalline), this layer may be formed by PECVD pursuant to FIG. 10a. Finally, a conductive layer that creates electrode 54 is formed on buffer layer 52, pursuant to block 1112. This layer may be formed by dc magnetron sputtering in accordance with FIG. 10b.

[0043] The foregoing process steps (and process parameters provided in FIGS. 10a and 10b) are merely exemplary. One having ordinary skill in the art would recognize that many conventional semiconductor fabrication processes may be used to construct cathode assembly 60 in FIG. 9. For example, dc sputtering (i.e., without an applied magnetic field), diode sputtering, triode sputtering, electron beam evaporation and thermal evaporation may be used instead of dc magnetron sputtering. Similarly, chemical vapor deposition (CVD), hot-wire deposition and CVD hot-wire deposition may be used instead of PECVD. Preferably, layer 52 is constructed from silicon nitride using PECVD. Moreover, as is well known, the silicon-based layers identified in FIG. 10a (i.e., layers 46, 48, 50 and 52) will include a minority percentage of hydrogen (i.e., no more than about 25% for silicon nitride and about 20% for the remainder).

[0044] To compensate for the presence of buffer layer 52 (i.e., to maintain the same proximal relationship between gate electrode 54 and tips of emitters 48), the thickness of insulating layer 50 may be reduced by approximately the thickness of layer 52. Alternatively, the height of emitters 48 may be increased by the same amount to maintain the same emitter tip to extraction grid spacing. Preferred approximate layer thickness, approximate emitter height and material used to create FED structure 40 is provided in Table 2.

	TABLE 2
	Element	Thickness/Height	Material
	faceplate 56	0.5	mm	Corning 1734 glass
	conductive layer 57	1000	angstroms	ITO
	coating 58	5{circumflex over ( )}1	mm	phosphor
	black matrix	3-4{circumflex over ( )}1	mm	cobalt oxide
	electrode 54	2000	angstroms	chromium
	buffer 52	1000	angstroms	silicon nitride
	insulating layer 50	7000	angstroms	silicon dioxide
	emitter 48	10000	angstroms	{circumflex over ( )}1aSiP
	resistive layer 46	5000	angstroms	{circumflex over ( )}1aSiB
	conductive layer 44	2000	angstroms	chromium
	baseplate 42	3	mm	soda-lime glass

[0045] Referring to Table 2, ˆ 1aSiP and ˆ 1aSiB represent P-doped and B-doped amorphous silicon, respectively. When buffer layer 52 is formed from silicon nitride (Si3N4), thickness may range from about 500 to about 4000 angstroms, and the preferred thickness, as noted in Table 2, is about 1000 angstroms. In addition, when layer 52 is formed from silicon (e.g., microcrystalline, amorphous, or polycrystalline), thickness may range from about 1000 to about 5000 angstroms, and the preferred thickness is about 3000 angstroms (in which case, insulating layer 50 may be reduced to about 5000 angstroms thick if using the dimensions of Table 2). Finally, when layer 52 is formed from metal (e.g., copper or aluminum), thickness may range from about 500 to about 2000 angstroms, and the preferred thickness is about 1000 angstroms (in which case, the dimensions of Table 2 remain unchanged).

[0046] A power supply 64 is electrically coupled to conductive layer 44, electrode 54 and conductive layer 57 for providing an electric field that causes emitters 48 to emit electrons to regions 58. Typically, supply 64 grounds conductive layer 44 and applies a DC voltage of approximately 2000 to 6000 V to anode 62 and approximately 100 V to gate electrode 54. As a result, electrons flow from conductive layer 44, through resistive layer 46, and out from the tips of emitters 48. The emitted electrons strike cathodoluminescent coating regions 58, which generate visible light or luminance.

[0047] As noted above with respect to FED structure 10 in FIG. 1, applying a potential between substrate conductive layer 14 and Cr electrode 20 in cathode assembly 9 may cause failure of gate electrode 20 due to an adverse chemical reaction. However, in accordance with the invention, application of a potential between substrate conductive layer 44 and Cr electrode 54 in FIG. 9 will not cause failure of electrode 54 due to the presence of buffer layer 52. In this context, experimental tests conducted on Cr gate electrodes buffered by layers composed of aluminum, polysilicon or silicon nitride resulted in no measurable adverse chemical reaction at the surface or interface of the electrodes with applied voltages as high as approximately 300 V to 400 V.

[0048] The invention has now been described in terms of the foregoing embodiment with variations. Modifications and substitutions will now be apparent to persons of ordinary skill in the art. Accordingly, it is not intended that the invention be limited except as provided by the appended claims.

Claims

1. A field emission display comprising; a cathode assembly including: a baseplate, a first layer of conductive material over said baseplate, an emitter, over the first layer of conductive material, for emitting electrons, a layer of insulating material over said first layer of conductive material and around the emitter, a buffer layer made of metal and located on, and in direct contact with, the layer of insulating material, and a second layer of conductive material on, and in direct contact with, the buffer layer; and an anode assembly including a faceplate and a material responsive to electrons emitted from the emitter for emitting light.

2. The field emission display of claim 1, wherein said metal is selected from the group consisting of copper and aluminum.

3. The field emission display of claim 1, further comprising a layer of resistive material over the first layer of conductive material and under the layer of insulating material and the emitter.

4. The field emission display of claim 1, wherein the second layer of conductive material is made from chromium and the buffer layer is sufficiently thick to prevent the chromium layer from oxidizing.

5. The field emission display of claim 1, further comprising a voltage source for providing a voltage between the second conductive layer and the first conductive layer.

6. The field emission display of claim 5, wherein the anode assembly includes a transparent conductive layer, the voltage source being coupled to the transparent conductive layer.

7. The field emission display of claim 1, wherein the anode assembly and cathode assembly are separated with spacers.

8. The field emission display of claim 1, further comprising a plurality of electron emitters over the first layer of conductive material, each surrounded by the layer of insulating material.

9. The field emission display of claim 1, wherein the buffer layer has a thickness between 500 and 2000 Angstroms.

10. A field emission display comprising; a cathode assembly including: a baseplate, a first layer of conductive material over said baseplate, an emitter over the first layer of conductive material, for emitting electrons, a layer of insulating material including an oxide over said first layer of conductive material and around the emitter, a buffer layer located on, and in direct contact with, the layer of insulating material; and a layer of chromium on, and in direct contact with, the buffer layer, the buffer layer being sufficiently thick to substantially reduce the formation of chromium oxides in the chromium layer; and an anode assembly including a faceplate and a material responsive to electrons emitted from the emitter for emitting light.

11. The method of claim 10 wherein the metal layer comprises a material selected from the group consisting of copper and aluminum.

12. The field emission display of claim 10, further comprising a layer of resistive material over the first layer of conductive material and under the layer of insulating material and the emitter.

13. The field emission display of claim 10, further comprising a voltage source for providing a voltage between the chromium layer and the first conductive layer.

14. The field emission display of claim 13, wherein the anode assembly includes a transparent conductive layer, the voltage source being coupled to the transparent conductive layer.

15. The field emission display of claim 10, further comprising a plurality of electron emitters over the first layer of conductive material, each surrounded by the layer of insulating material.

16. A field emission display comprising: a plurality of electron emitters; an insulating layer around the electron emitters; a conductive gate layer made of chromium over the insulating layer; and means for substantially reducing the formation of chromium oxides in the conductive gate layer.