Planar Field Emission Light Source with ZnO Nanorods
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Solution Overview
Problem
Existing field emission light sources, such as those described in EP1709665 and EP1246263, face challenges in manufacturing complexity and cost, particularly in achieving uniformity and energy efficiency, and are not suitable for general-purpose lighting applications beyond short illumination cycles.
Innovation Solution
A two-dimensional planar manufacturing process for field emission light sources using nanostructured cathodes and anodes, with a spacer structure to control the distance between the cathode and anode, and the use of wavelength converting materials and reflective features to optimize light emission and energy efficiency, allowing for modular manufacturing and improved uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bulb-shaped three-dimensional field emission light source structure is used, then omnidirectional light emission is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention transitions from a three-dimensional bulb-shaped structure to a two-dimensional planar structure. The field emission cathode and anode are arranged in a planar configuration rather than a spherical geometry, simplifying manufacturing while maintaining light emission capabilities through modular assembly of multiple planar units
2Adaptability or versatility
If a bulb-shaped three-dimensional field emission light source structure is used, then omnidirectional light emission is achieved, but manufacturing uniformity deteriorates
Solution Approach 1:
The planar geometry provides a flat substrate that facilitates uniform deposition of functional layers and consistent electrical field distribution across the emission area, enabling better control over light uniformity compared to curved bulb surfaces
Solution Approach 2:
The invention uses a modular planar design where the field emission device can be divided into separate functional layers (cathode, anode, spacer structures) that can be manufactured and assembled independently, allowing for better quality control and uniformity in each segment
3Illumination intensity
If traditional bulb structure manufacturing is used, then light emission is achieved, but manufacturing cost increases
Solution Approach 1:
The planar structure enables fabrication using standard semiconductor and thin-film deposition techniques on flat substrates, which are more cost-effective and scalable than glass bulb manufacturing processes, reducing overall production costs
Solution Approach 2:
The planar field emission device can be integrated with other planar components and manufactured using universal thin-film deposition techniques applicable to multiple device types, enabling economies of scale and reduced manufacturing costs
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 cost-effective, efficient, and uniform light emission over a wide range, suitable for general-purpose lighting, with enhanced manufacturing efficiency and reduced complexity compared to traditional bulb structures.
Implementation Method 1
Field emission is a phenomenon which occurs when a very high electric field is applied to the surface of a conducting material. This field will give electrons enough energy such that the electrons are emitted (into vacuum) from the material.
Implementation Method 2
As the electrons strike the light emitting layer, typically comprising a light powder such as a phosphor material, the light powder will emit photons. This process is referred to as cathodoluminescence.
Data Source
Figure 1~2a
Figure 2b~3
Figure 4a~4d
AI summary
The present invention relates to a field emission light source die configured to emit UV light and a method for forming such a field emission light source. The field emission light source comprises a field emission cathode (106) comprising a plurality of ZnO nanorods (104) formed on a wafer, an electrically conductive anode structure (108) comprising a wavelength converting material (118) arranged to cover at least a portion of the anode structure, and a circular or elliptical spacer structure (110) for forming an hermetically sealed and evacuated cavity (306) between the substrate of the field emission cathode and the anode structure.