Patent ID: 6413136
Filing Date: 2002-07-02
Classification: H01J

Abstract:
A flat-panel evacuated display having a face plate assembly which includes a laminar face plate and an array of integral spacer support structures formed from material that is continuous with that from which the laminar face plate is formed, said face plate assembly fabricated via a process comprising the steps of:providing a generally laminar substrate; providing a laminar template having a pair of major planar faces and an array of mold holes perpendicular to the major planar faces, each mold hole corresponding to a desired location of a spacer support structure; providing a manifold block having at least one generally planar surface and an array of mating ports on said planar surface, each such port mating with an adjacent major surface of said laminar template and aligning with at least one mold hole in said template; forming a temporary structure by sealably sandwiching said laminar template between said laminar substrate and the planar surface of said manifold block; heating said laminar substrate to a state of plasticity at prevailing pressure conditions; creating a pressure differential between the ambient atmosphere surrounding the temporary structure and the pressure within the mold holes, the pressure within the mold holes being less than that of the ambient atmosphere, the pressure differential causing each of the mold holes to fill with material from the laminar substrate; and removing the face plate assembly from the laminar template.