CNT Field Emitter with Glassified Matrix for Mass Production
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Solution Overview
Problem
Conventional methods for creating large-size carbon nano-tube (CNT) field emitting light sources are expensive and limited, making them unsuitable for mass production and small-size applications.
Innovation Solution
A light source design featuring a cathode with a conductive layer and an emitter layer composed of CNTs, low-melting-point glass, and conductive particles, where the mixture is sintered to form a glassified emitter layer, allowing for uniform distribution and firm fixation of CNTs, enabling efficient electron emission and fluorescence production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods (catalyst layer coating or direct implantation) are used to distribute CNTs on the cathode, then CNT distribution is achieved, but the manufacturing cost is high and scalability to large sizes is limited
Solution Approach 1:
The invention changes the physical and chemical parameters of the glass material by selecting specific low-melting-point glass compositions (such as lead glass, borosilicate glass) and controlling sintering temperature and time parameters. This allows the glass to transition from a powder state through melting and bonding to a solidified matrix that firmly fixes CNTs, achieving both large-area scalability and cost-effective manufacturing
Solution Approach 2:
The invention creates a composite emitter layer structure consisting of CNTs embedded in a glass matrix with conductive particles dispersed throughout. This composite structure combines the electron emission properties of CNTs with the binding and structural properties of glass, and the conductive properties of metal particles, achieving both firm fixation and electrical functionality across large cathode areas
2Productivity
If conventional CNT distribution methods are used, then CNTs can be grown or implanted, but the process is expensive and not suitable for mass production
Solution Approach 1:
The invention replaces complex mechanical and chemical growth processes (catalyst layer coating, controlled CNT growth, precise implantation) with a simpler powder mixing and sintering process. The CNTs, glass powder, and conductive particles are uniformly mixed and then sintered together, eliminating the need for expensive catalyst materials, controlled growth environments, and precise implantation equipment, thereby enabling mass production at lower costs
Solution Approach 2:
By controlling the sintering temperature (typically 400-600°C) and time parameters, the glass powder transitions from a loose powder state to a bonded matrix that firmly fixes CNTs. This parameter-controlled transformation simplifies the manufacturing process and enables scalable production while maintaining CNT functionality
3Reliability
If CNTs are distributed using conventional methods, then emission function is achieved, but CNTs are not firmly fixed and may break off during operation, reducing lifetime
Solution Approach 1:
The invention creates a composite structure where CNTs are embedded in a solidified glass matrix. The glass acts as a binding medium that mechanically anchors CNTs to the cathode substrate and to each other, preventing CNT detachment and breakage during operation. The conductive particles embedded in the glass matrix provide additional structural support and electrical pathways, enhancing both fixation strength and emission reliability
Solution Approach 2:
The glass material undergoes a phase transition from powder to melted state during sintering, then solidifies into a rigid matrix that firmly fixes CNTs. This phase transition creates strong mechanical bonds between glass particles and CNT surfaces, ensuring CNTs remain firmly fixed during thermal and mechanical stress in operation, thereby extending device lifetime
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of large-size CNT field emitting light sources at a lower cost, suitable for mass production, with improved durability and longer operational lifetime due to firmly fixed CNTs, and flexibility in size scalability.
Implementation Method 1
sintering the mixture and obtaining a glassified emitter layer configured on the cathode
Implementation Method 2
sintering the mixture and obtaining a glassified emitter layer
Implementation Method 3
the CNTs emit electrodes bombarding the fluorescent layer to produce fluorescence thereby
Data Source
AI summary
A CNT field emitting light source (20) is provided. The light source includes an anode (202), an anode substrate (201), a cathode (214), a cathode substrate (208), a fluorescent layer (203) and a sealing means (205). The anode is configured on the anode substrate, and the cathode is configured on the cathode substrate. The anode and the cathode are oppositely configured to produce a spatial electrical field when a voltage is applied therebetween. The cathode includes an emitter layer (206), capable of emitting electrodes bombarding the cathode and matters attached thereupon when activated and controlled by the spatial electric field, and a conductive layer (207), sandwiched between the cathode substrate and the emitter layer for providing an electrically connection therebetween. The fluorescent layer is configured on a surface of the anode oppositely facing the emitter layer, so as to produce fluorescence when bombarded by electrodes emitted from the emitter layer.