Abstract:
This invention is an improved processing method and structure for the packaging technique of a large size field emission display. A large size field emission display includes an indium-tin oxides (ITO) conducting glass substrate, which is covered by the first screen mask and the second screen mask defined to a BM layer area, a multi-phosphor layer area and a hollow area. Each area was coated to form an Al layer, which was formed an AlO x  layer through a phosphor sintering process. The spacer was fixed in a hollow area of an AlO x  layer through an anodic assembling technique. The next plate was fixed on the spacer to accomplish an aligner process.

Description:
This is a CIP application of Ser. No. 09/767,918, filed on Jan. 24, 2001, entitled AN IMPROVED PACKAGING TECHNIQUE OF A LARGE SIZE FED, now abandoned) 

   BACKGROUND OF THE INVENTION 
   This invention is to provide an improved processing method and structure for the packaging technique of a large size field emission display. The spacer was efficiently fixed on the upper plate through an anodic assembling technique to save the processing and its thickness. 
   The screen of various electrical equipments such as computer, television, and cellular phone is the best communication bridge between person and electrical equipment. The cathode ray tube (CRT) has been the principal device in the past years since it demonstrates rich color, high resolution, brightness, high contrast, wide viewing angles, rapid speed, and cheapness. But the requirements of today&#39;s screen are not only for high-resolution, natural color, light thin volume, low radiation, and low electricity consumption; but also the more important requirement is to satisfy the mobile demand such as cellular phone and automobile display. Thus, the development of CRT screen was limited very much. 
   Replacements of CRT screen are like liquid crystal display (LCD), electro luminescent display (ELD), plasma display panel (PDP), vacuum fluorescent display (VFD) etc. Most of them are very expensive and are not very efficient except LCD. But LCD still has the following limitations:
     1. Point distance is too long, picture is not soft;   2. Reaction is too slow, ghost shadow is easily formed;   3. Brightness is not enough, not suitable for the outdoors use.   

   Hence, it needs not only to have all advantages of LCD, but also to overcome all limitations described above to satisfy all requirements of screen. 
   Field emission display (FED) has not only soft picture, rapid reaction, and clear brightness like CRT, but also possesses characteristics of lightness of flat display and low performance consumption. 
   An upper plate called anode plate and a lower plate called cathode plate assemble FED. Having processed the upper plate and the lower plate, then assembling these two plates, the formation of the space between the upper plate and the lower plate was vacuumed to 10 −5 ˜10 −7  torr and readily for the next process. 
   The size of FED increases resulting the center of glass flat of the vacuumed space between the upper plate and lower plate becomes very hard and fragile due to the atmosphere pressure. In order to solve this problem we put multiple spacers at the suitable positions between the upper plate and the lower plate to increase the tolerance of glass flat for the atmosphere pressure, also to decrease the fragile possibility of the glass flat. 
     FIG. 1  show a conventional FED device, after the processing of the upper plate  1  the spacers  2  were fixed on the upper plate  1 , then proceeding the aligner process of the upper plate  1  and lower plate  3 . There are two methods for the fixing of spacers  2  on the upper plate  1  as follows:
     1. As shown in  FIG. 2 , after the processing of the upper plate  1 , the binding layer  12  was put on the upper plate  1 , then, the spacers  2  were bonded on the binding layer  12 .   2. As shown in  FIG. 3 , after the processing of the upper plate  1  increasing one more process in which the formation of the slots  13  was on the upper plat  1  and the spacers  2  were bound on the slots  13 .   
   Methods described above show the fixing of the spacers  2  on the upper plate  1 , but the limitations are as follows:
     1. Both of methods need to increase the process and the cost.   2. The fixing of the binding layer  12  on the spacers  2  will increase the thickness of FED due to the binding layer  12 .   3. In the method of the fixing of the spacers  2  using the slots  13 , the spacers  2  were only bonded on the upper plate  1 ; the spacers  2  will drop off during the aligner process of the upper plate and the lower plate due to vibration of the moving process and the other unpredictable strength.   

   SUMMARY OF THE INVENTION 
   Hence, the object of this invention is to provide the improved structure of the packaging technique for a large FED. It is very sufficient that the spacers were fixed on the upper plate and were not dropped off before the proceeding of the aligner process. 
   The another object of this invention is to provide the improved methods of the packaging technique for a large FED. It does not need increase any process before the process of the fixing of the spacers on the upper plate. 
   The further object of this invention is to provide the improved structure of the packaging technique for a large FED. It is very sufficient that the spacers were bonded on the upper plate and the thickness of FED could not increase. 
   In order to achieve the objects described above, a large size FED includes an ITO conducting glass substrate, which is covered by the first screen mask and the second screen mask defined to a BM layer area, a multi-phosphor layer area and a hollow area. Each area was coated to form an Al layer, which was formed an AlO x  layer through a phosphor sintering process. The spacer was fixed in a hollow area of an AlO x  layer through an anodic assembling technique. The next plate was fixed on the spacer to accomplish an aligner process. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates the flow chart of the process of a known technique; 
       FIG. 2  illustrates the cross-sectional view of binding layer fixing on the spacers of a known technique; 
       FIG. 3  illustrates the bottom view of the slots fixing on the spacers of a known technique; 
       FIG. 4  illustrates the flow chart of the processing of this invention; 
       FIG. 5A ,  FIG. 5B ,  FIG. 5C ,  FIG. 5D , and  FIG. 5E  illustrate the cross-sectional view of the processes of this invention; 
       FIG. 6  shows the positions of the spacers, AlO x  layer, phosphor layer, and BM layer of this invention; 
       FIG. 7  illustrates the data of the binding process of the upper plate and the spacers; 
       FIG. 8  illustrates the curve of electrical current vs. time during an anodic bonding process of this invention; 
       FIG. 9  illustrates the projection of the accomplishment of the aligner process of the upper plate and the lower plate. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIGS. 1–3  show the flow chart of the process of a known technique, the cross-sectional view of binding layer fixing on the spacers of a known technique, the bottom view of the slots fixing on the spacers of a known technique, and the flow chart of the processing of this invention, respectively. As shown in  FIGS. 1–4  after processing the upper plate  1  according to the flow chart of the processing of a known technique, it needs the process of coating the binding layer  12  as shown in  FIG. 2  or the process of digging slots  13  as shown in  FIG. 3 . And then it carries out the process of the fixing spacer  2 , in which the binding layer  12  is frit to fix the spacer on the upper plate through the binding method. Slots  13  are bound with the spacer  2  on the upper plate readily for the aligner process of the upper plate  1  and the lower plate  3 . The flow chart of the processing of this invention as shown in  FIG. 4 , after processing the upper plate it carries out the fixing process of the spacer  2 ; it omits the process of coating with the binding layer  12  as shown in  FIG. 2  or the process of digging slots  13  as shown in  FIG. 3 . 
     FIGS. 5A–5E  show the cross-sectional views of the process of the three-dimensional structure of the upper plate  1  for FED of this invention. First, a substrate glass  111  assembles with an ITO layer  112  to form an ITO conducting glass substrate  11 , which is covered by the first screen mask (not shown in FIG.) and the second screen mask (not shown in FIG.) defined to a BM layer area  14 , a multi-phosphor layer area  15  and a hollow area  16 . The inside of a hollow area  16  was coated with a thin Cr/CrO x  layer area  20  of the BM layer. Each area was coated to form an Al layer  17 , which was formed an AlO x  layer  18  due to the sintering process of phosphor area  15 . X is the equivalence ratio of oxygen component in the aluminum and chromium oxide and its range is from 0.2 to 2.0. The spacers  2  were fixed in a hollow area  16  of an AlO x  layer  18 . 
   ITO conducting glass  11  is a typical industrial available. The first screen mask and the second screen mask on the ITO conducting glass  11  was defined to a BM layer area  14 , a multi-phosphor layer area  15 , and a hollow area  16 . The inside of a hollow area  16  was coated with a Cr/CrO x  layer area  20  of the BM layer. All of these processes are typical known technique and are not described here. Once the defined areas on the ITO conducting glass  11  as described above, which were coated to form an Al layer  17 . An Al layer  17  is usually formed through the vacuum evaporation or electron beam evaporation. The thickness of an Al layer  17  is about 1000–3000 angstroms. Then a multi-phosphor layer area  15  was carried out a sintering process at the temperatures of 500–560° C. During the sintering process the surface of an Al layer  17  was forming an AlO x  layer  18 , in which the thickness is about 50–200 angstroms. The sintering process described was carried out in a furnace. 
   A spacer  2 , a cross column structure, the height is about 1.1 mm, was fixed in the hollow area  16  of an AlO x  layer  18 . Multiple bonding areas are between the spacers  2  and an AlO x  layer. The technique for fixing the spacers  2  on an AlO x  layer  18  is an anodic bonding technique, in which the positive voltage and the negative voltage was connected to the spacer  2  and an Al layer  17 , respectively. The intensity of an electric field is around 1.00–1.50 V/μm. The substrate glass was heated on a hot plate  19  at the temperatures of 200–300° C. about 5–10 minutes. 
     FIG. 6  shows the top view of the positions for the spacer  2 , an AlO x  layer  18 , a multiple phosphor areas  15 , and a BM layer area  14 . As shown in the figure, the spacer  2  possesses the cross-sectional view of a cross column structure and is positioned in the hollow area  16  (as shown in  FIG. 5D ) of the phosphor layer  15  and the BM layer area  14 . Multiple bonding areas are between the spacers  2  and an AlO x  layer  18 , and the number of bonding areas is changed according to the difference of the shapes of the cross-sectional view of the spacer  2 . 
   An ITO conducting glass  11  of the upper plate  1 , 470 mm in length, 370 mm in width, and 1.1 mm in thickness, is manufacture by Asahi Japan. The thickness of both BM layer  14  and phosphor layer  15  is 10 μm. The thickness of Cr/CrO x  layer  20  is about 3000 angstroms. The thickness of an Al layer  17  is 3000 angstroms. The thickness of an AlO x  layer  18  is 200 angstroms. The depth of the hollow area  16  is about 7000 angstroms. The spacer  2  is a glass material possessing the cross-sectional view of a cross column structure, in which the height is 1.1 mm, the thickness is 80 μm, and the length of each arm of the cross is 1.0 mm. This kind of the upper plate  1  and the spacer  2  were carrying out an anodic bonding experiment. 
     FIG. 7  shows the data collected from an anodic bonding process of the upper plate  1  and the spacer  2  of this invention. The upper plate  1  described before and the spacer  2  was carried out an anodic bonding experiment at 300° C. with 1.23 V/μm, and 0.91 V/μm, at 250° C. with 1.23 V/μm and 0.91 V/μm, and at 200° C. with 1.23 V/μm. It was recording an electric current every 20 seconds. 
     FIG. 8  shows the curve diagram of electric current (mA) vs. time (second) during an anodic bonding process. Plotting the diagram of electric current vs. time in accordance with data of  FIG. 7 , at 300° C. with 1.23 V/μm, and 0.91 V/μm, at 250° C. with 1.23 V/μm and 0.91 V/μm, and at 200° C. with 1.23 V/μm, every curve has the tendency of rising up firstly then dropping down. The highest point of the curve represents the beginning of the breakage of bond between atom and atom, in which the broken bond atoms start moving freely between the spacer  2  and an AlO x  layer  18  at such a temperature and voltage during an anodic bonding process. The bond between atom and atom is broken down sufficiently at the highest point of the curve; at this moment the movement of atoms between the spacer  2  and an AlO x  layer  18  reaches the highest peak, hence, the electric current is the largest. As shown in  FIG. 8 , the free moving atoms are decreased gradually since the bonding surface is accomplished between an AlO x  layer  18  and the spacer  2 ; hence, the electric current is dropped down. 
   When it was carrying out an anodic bonding process at the same temperature such as 300° C. or 250° C. using different voltages such as 1.23 V/μm, and 0.91 V/μm, respectively, the producing electric current at higher voltage is larger than that of at lower voltage. Under the condition of the same voltage 1.23 V/μm or 0.91 V/μm at the different temperatures such as 300° C. and 250° C. using hot plate  19 , the producing electric current at higher temperature is larger than that of at lower temperature. Basically, the larger the density of electric current is, the more the efficiency of bonding is. 
   As shown in  FIG. 8  no matter the voltage using 1.23 V/μm or 0.91 V/μm at 300° C. or 250° C. using hot plate  19 , it produces the largest electric current in the curve about 60 seconds; however, there is no such as this matter in the curve at 200° C. using hot plate  19  since the energy is still not enough to break down the bonding between atoms each other, hence, atoms between the spacer  2  and an AlO x  layer  18  can not move freely, and the efficiency of an anodic bonding is decreased. 
     FIG. 9  shows the cross-sectional view of the accomplishment of aligner process of the upper plate  1  and the lower plate  3  of this invention, in which the upper plate  1  and the spacer  2  were fixing to each other according to the processing methods and structure of this invention, and readily for the next process. 
   This invention specially discloses and describes selected the best examples. It is to be understood, however, that this invention is not limited to the specific features shown and described. The invention is claimed in any forms or modifications within the spirit and the scope of the appended claims.