This invention relates to field emission materials and devices, and is concerned particularly but not exclusively with methods of manufacturing addressable field electron emission cathode arrays. Preferred embodiments of the present invention aim to provide improved designs with improved uniformity and reliability.
It has become clear to those skilled in the art that the key to practical field emission devices, particularly displays, lies in arrangements that permit the control of the emitted current with low voltages. Until recently, the majority of the art in this field related to tip-based emitters—that is, structures that utilise atomically sharp micro-tips as the field emitting source.
There is considerable prior art relating to tip-based emitters. The main objective of workers in that art has been to place an electrode with an aperture (the gate) less than 1 micron away from each single emitting tip, so that the required high fields can by achieved using applied potentials of 100V or less—these emitters are termed gated arrays. The first practical realisation of this was described by C A Spindt, working at Stanford Research Institute in California (J. Appl. Phys. 39, 7, pp 3504-3505, (1968)). Spindt's arrays used molybdenum emitting tips which were produced, using a self masking technique, by vacuum evaporation of metal into cylindrical depressions in a SiO2 layer on a Si substrate. Many variants and improvements on the basic Spindt technology are described in the scientific and patent literature.
In about 1985, it was discovered that thin films of diamond could be grown on heated substrates from a hydrogen-methane atmosphere, to provide broad-area field emitters. Much later (1995) Tuck, Taylor and Latham (GB 2 304 989) described an improved broad-area emitter. Work in this area, which includes carbon and other nanotube layers, is now very fashionable and there is a building body of art in both the patent and scientific literature.
The best examples of such broad-area emitters can produce usable electric currents at fields less than 10 V/micron. In the context of this specification, a broad-area field emitter is any material including carbon and other nanotube layers that by virtue of its composition, micro-structure, work function or other property emits useable electronic currents at macroscopic electrical fields that might be reasonably generated at a planar or near-planar surface—that is, without the use of atomically sharp micro-tips as emitting sites.
A problem with broad-area emitters is that the exact location of the emitter or emitters within the emitter cell formed by the aperture in the gate electrode, the gate insulating layer, the cathode track and the coating of emitter, is unpredictable. This in contrast to tip-based emitters, which will typically be close to the centre. The extraction field is highest near the perimeter of the cell and, as a result, the electrons rarely originate from the centre of the cell so that their kinetic energies have a large radial component. It is rare for the combined effect of the modest number of sources from the multiple cells in a pixel to be a symmetrical, which results in each pixel exciting a different shaped region on the phosphor coated anode. Even with the same current per pixel, the visual effect of this is very visible fixed pattern noise.
The high radial component of kinetic energy also reduces the effectiveness of conventional electron optical focusing schemes, which in turn limits pixel and sub-pixel sizes—the problem is particularly serious with colour displays where electron cross-talk between sub-pixels affects colour purity.
Recently, Van der Vaart et al (WO 03/041039 A2) described a field emission display which has a perforated insulating plate with an upper conducting layer (the hop-electrode) set to a positive voltage placed between the cathode plane and the anode. Within this so-called Hop-Plate, secondary electron hopping transport is used to homogenise the electrons and re-emit them as secondary electrons with energies around 5 eV. The hop-plate is normally made of glass having a coefficient of expansion matched to the rest of the display. The channels are usually formed by powder blasting. This electron hopping transport was first described by Van Gorkorn in U.S. Pat. No. 5,270,611 together with devices using the technique. A display based upon this principle called Zeus was well described in Philips Journal of Research Vol 50, Nos. 3/4 (1996).
Because the hopping is a chaotic process, there is no correlation between the location at which an electron leaves the pixel, the direction it travels within the channel and the position of re-emission of the low energy secondary electron. As a result, there are effectively as many emitting sites per pixel as there are electrons in the pulse, leading to excellent intra-pixel uniformity. Provided the correct voltage is applied to the hop-electrode, the channel has a transmission factor of unity—i.e. as many electrons leave the exit as arrive at the entrance.
It is in this area of Hop-FED displays and other devices using the technology that preferred embodiments of the present invention make a contribution to the art.
According to one aspect of the present invention, there is provided a Hop-ED structure comprising:
Preferably, said surface is formed with projections that space the remainder of the hop-plate from said substrate and emitter areas.
Preferably, said projections are formed as pillars or ribs.
Said electrically conductive layer may be provided on said projections.
Said electrically conductive layer may not be provided on said projections.
Said electrically conductive layer may be of a material of high electrical resistivity.
Said material may have a surface resistivity in the range 107 to 1011 ohms per square.
Said material may have a surface resistivity in the range 108 to 1010 ohms per square.
Said material may have a surface resistivity of substantially 109 ohms per square.
Said material may be selected from the group comprising amorphous silicon and silver doped silica.
Said electrically conductive layer may extend partially within the channels of the hop-plate.
Said electrically conductive layer may be connected to means for holding said layer at a predetermined potential.
In another aspect, the invention provides a Hop-FED structure comprising:
Preferably, said spacer means comprises projections provided on one or both faces of said hop-plate.
Such a Hop-FED structure may further comprise a flue-plate between said hop-plate and anode.
Said spacer means may comprise projections provided on one or both faces of said flue-plate.
Preferably, said spacer means are formed as pillars or ribs on said hop-plate and/or flue-plate.
Preferably, said gettering material forms a distributed getter.
Said gettering material may comprise a non-evaporated getter.
Said gettering material may comprise an alloy containing at least one Group IV metal.
Preferably, the structure is sealed by a glass-frit seal that is spaced from said gettering material, and the structure further comprises a conductive member that is compatible with said glass-frit and extends from outside the structure, through said glass-frit seal and to said gettering material, to which it is electrically connected.
In another aspect, the invention provides a method of manufacturing a hop-plate for a Hop-FED structure, the method comprising the steps of,
Such a Hop-FED structure Preferably, in accordance with any of the preceding aspects of the invention.
Said sacrificial layer may comprise vacuum-evaporated or sputter-coated aluminium.
Said protective layer may comprise a photoresist material.
Preferably, said erosion step is carried out by powder blasting.
Said blasting may utilise alumina abrasive media.
Said secondary emission layer may comprise alumina.
A method as above may further comprise the step of applying a hop-electrode to said main body.
In another aspect, the invention provides a method of manufacturing a Hop-FED structure with a gettering material as above, the method comprising the steps of:
b. eroding portions of said main body through said apertures, said protective layer otherwise protecting said main body from erosion; and
c. removing said protective layer to define at locations under said protective layer projections to serve as said spacer means.
Preferably, said protective layer comprises a photoresist material.
Preferably, said erosion step is carried out by powder blasting.
Said blasting may utilise alumina abrasive media.
Said erosion step may be carried out by etching.
In another aspect, the invention provides a method of manufacturing a Hop-FED structure with a gettering material as above, the method comprising the steps of applying a metal film in a pattern to a main body of a hop-plate or flue-plate and electroplating said metal film to define projections that serve as said spacer means.
Preferably, said metal film is applied by sputter coating.
In another aspect, the invention provides a method of manufacturing a Hop-FED structure with a gettering material as above, the method comprising the steps of applying multiple layers of glass frit to a main body of a hop-plate or flue-plate to define projections that serve as said spacer means.
Preferably, said layers of glass frit are applied by a printing process.
Preferably, said main body is of glass.
For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, in which:
a shows fuller details of a Hop-FED;
b shows a Monte Carlo electron trajectory simulation of a Hop-FED;
a and 3b show a Hop-Fed with pillars or ribs, and charging problems that can occur;
a and 4b are views similar to
c is a view similar to
a and 5b are graphs to demonstrate the effectiveness of the embodiments of
a to 7e show an exemplary process flow to create the structure of
In the figures, like reference numerals denote like or corresponding parts.
In the context of this specification, a “Hop-FED structure” comprises an insulating plate (the hop-plate) that is perforated to define channels through which electrons pass, is placed between cathode and anode, and has a conducting layer (the hop-electrode) on the anode side.
In this embodiment, a hop-plate 205 sits directly upon the FED cathode plane with hop-electrode 207. The flue-plate 209 sits upon the hop-plate 205 and anode plate 210 completes the sandwich structure. The electrons are now confined to channel 206 where, in the hop-plate portion, they undergo homogenisation by hopping 208 and in the flue-plate channel they are accelerated to high voltage. Both the hop-plate and the flue-plate have various functional coatings applied to them.
Whilst the concept of the Hop-FED is attractive, some very real problems appear when one tries to build and operate one. The first of these are illustrated in
One potential solution to this problem is illustrated in
a (wherein like elements are numbered as in previous figures) shows a solution to this problem. A conducting layer 401 is applied to the underside of the hop-plate 303 and pillars 307. To prevent the conducting layer short-circuiting all gate tracks together, a highly resistive layer is used. This is sufficiently conductive to dissipate any charge build-up but sufficiently resistive that it does not draw excessive current from the gate driver electronics. A surface resistivity of 109 ohms per square may be suitable. Suitable films are sputtered amorphous silicon and a printed silver doped silica layer as described in our co-pending application GB 03 22360.9.
b (wherein like elements are numbered as in previous figures) shows an alternative approach where the pillars 307 are left uncoated, and hence are insulating, and a conductive film 402 is applied to the underside of the hop-plate 303 only. It is now less import that the film be resistive and its potential may be set by connection to an external power supply 403.
c shows yet another approach where the hop-plate 303 does not have insulating pillars but sits directly on the surface of the gates. In this case, film 410 has a high surface resistivity of ˜109 ohms per square but the high field region, which would be at the entrance to the hop-channel, is moved away from the gate surface by allowing film 410 to enter the channel by typically 100 microns 411. Suitable films are sputtered amorphous silicon where the penetration is controlled by choice of sputtering pressure or printed silver doped silica layer that has been allowed to flow into the channel by controlling printing conditions.
Although two examples of resistive films have been given, others may be substituted by those skilled in the art.
a and 5b demonstrate the effectiveness of the embodiments of
It can be seen clearly in
In order to achieve long-term operation, it is normal to coat the inner region of the hop-channel with a material that has both a high secondary emission yield and is stable under electron bombardment. Suitable materials are MgO or Al2O3 but others may be used. These layers are typically sputtered or electron beam evaporated. For a simple spaced hop-plate, the final structure required is that in
a to 7e show an exemplary process flow to create a desired structure; those skilled in the art may create others without departing from the teachings of this document. Note that, whilst in the case illustrated, the hop-electrode layer 601 is applied later, it could equally be applied before powder blasting is commenced and protected either by jigging or a resist layer.
a shows a preliminary stage in which we have glass 600, resistive layer 604 deposited as previously described and a sacrificial layer 605, such as vacuum-evaporated or sputter-coated aluminium. A photoresist layer 606 has been applied, exposed and patterned to define the entrance apertures of the hop-channels.
Moving now to
c shows the completed structure with resist stripped off and the secondary emission layer 603—say alumina—coated inside the hop-channels and unavoidably over the whole lower side of the plate.
Moving now to
In
We now move to another improvement to the Hop-FED art—this concerns vacuum design. Returning to
NEGs are typically introduced into vacuum devices in the form of pellets or metal tape with the powdered gettering material swaged into the surface. However, recently work has been reported on directly applying these materials onto device surfaces by, for example, sputter coating—e.g. Prodromides describes a sputtered Ti:Zr:V ternary alloy (Thèse No. 2652, 2002, Ecole Polytechnique Fédérale de Lausanne) This document can be conveniently be downloaded from the CERN Document Server at:
In the context of this specification, a “distributed” getter is a getter that is distributed over a predetermined region, in contrast to a getter that is applied indiscriminately over an available area.
Whilst the simple conceptual Hop-FED of
The fabrication of the ribs can be by a variety of methods.
Returning now to
However, no known NEG materials are compatible with frit seals, so a separate lead-out material is likely to be required.
In this specification, the verb “comprise” has its normal dictionary meaning, to denote non-exclusive inclusion. That is, use of the word “comprise” (or any of its derivatives) to include one feature or more, does not exclude the possibility of also including further features.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
The reader's attention is directed to all and any priority documents identified in connection with this application and to all and any papers and documents that are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
Number | Date | Country | Kind |
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0323942.3 | Oct 2003 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP04/52509 | 10/12/2004 | WO | 4/12/2006 |