Photoimageable Silver-CNT Composite for FED Cathodes
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Solution Overview
Problem
Current field emission device (FED) manufacturing processes are complex and involve multiple steps to achieve fine conductor lines and carbon nanotube (CNT) emitters, necessitating a need for a more efficient method to minimize process steps and improve processing conditions.
Innovation Solution
A co-processing method using a photoimageable silver composition and a CNT composition, where the CNTs are less than 9 wt% of the total weight, combined with a silver composition that can be photo-imaged and developed to form FED cathode electrodes and emitters, reducing the number of manufacturing steps and improving emitter uniformity and emission properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate imaging, development and firing steps are used for conductor electrodes and CNT emitters, then manufacturing precision can be maintained, but device complexity and processing time increase significantly
Solution Approach 1:
The patent combines the imaging, development, and firing steps for conductor electrodes and CNT emitters into a single integrated process. A photoimageable silver paste containing CNTs is applied, imaged, developed, and fired in one sequence, eliminating the need for separate processing of electrodes and emitters while maintaining manufacturing precision through the photoimageable nature of the composite paste
Solution Approach 2:
The silver paste serves multiple functions simultaneously: it acts as both the conductor electrode material and the CNT emitter precursor. The composite paste contains both silver particles for conductivity and CNTs for emission, allowing a single material layer to fulfill both electrode and emitter roles after processing
2Reliability
If multiple separate processing steps are used for electrodes and emitters, then material properties can be optimized, but productivity decreases due to increased processing time
Solution Approach 1:
The patent merges the processing of electrodes and emitters into a single integrated flow where the photoimageable silver paste containing CNTs is processed through imaging, development, and firing in one sequence, significantly reducing manufacturing time while maintaining emitter uniformity through controlled photoimaging and uniform firing conditions
Solution Approach 2:
The CNTs are pre-dispersed and uniformly distributed within the silver paste matrix before imaging, ensuring homogeneous emitter formation throughout the processed area. This preliminary uniform distribution prevents variability that would otherwise require multiple processing steps to correct
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 co-processing method simplifies the FED manufacturing process, achieving excellent emitter uniformity and emission properties while facilitating the production of large-area electron field emitters for flat panel displays, such as those greater than 30 inches in size, with reduced processing complexity.
Implementation Method 1
The silver composition can be photo-imaged and developed by basic aqueous solutions to form fine lines
Implementation Method 2
Field emission electron sources, often referred to as field emission materials or field emitters, can be used in a variety of electronic applications
Data Source
AI summary
Described herein are methods of manufacturing an electrode and emitter in a field emission device, and devices formed from the methods. Compositions useful for the manufacture of an electrode and emitter in a field emission device are also described.