Patent ID: 6287487
Filing Date: 2001-09-11
Classification: C03B,G02B,H01J,Y10T

Abstract:
A method of forming a microchannel plate in a field emission display having a planar substrate and a planar faceplate adapted to be positioned in parallel relationship, the method comprising:providing a plurality of single fibers each having an inner core and an outer cladding, the outer cladding being formed from different materials in which the outer cladding is selectively removable from the inner core;placing a plurality of the single fibers into a mold base of a first mold, the mold base having an upwardly facing lower cavity defined by a bottom surface and a pair of side walls, the bottom surface and side walls together defining one-half of a hexagon;placing a unitary mold cover over the mold base, the unitary mold cover having a downwardly facing upper cavity defined by an integrally formed top surface and a pair of side walls, the top surface and side walls together defining one-half of a hexagon, the mold base and mold cover interfitting so that the one-half-hexagon formed by the mold base and the one-half-hexagon formed by the mold cover together form a hexagonal mold cavity, the single fibers being molded in the mold cavity into a hexagonal multiple fiber preform;removing the hexagonal multiple fiber preform from the mold cavity;drawing the hexagonal multiple fleer preform to reduce its cross-sectional area and increase its length thereby forming a hexagonal multiple fiber;dividing the hexagonal multiple fiber into a plurality of pieces;placing the pieces of hexagonal multiple fiber into a mold cavity of a second mold, the mold cavity being defined by a bottom surface and a pair of side walls;placing a mold cover over the mold cavity of the second mold so that it intersects the side walls of the mold base, the pieces of hexagonal multiple fiber being molded in the mold cavity into a fiber block;dividing the fiber block into a plurality of slices having parallel end surfaces;mounting a slice of the fiber block within a space formed between the substrate and the faceplate of the field emission display; andselectively removing the inner core from the outer cladding, thereby leaving a sheet formed by a plurality of outer claddings positioned between the substrate and the faceplate of the field emission display.