Patent ID: 7033238

Claim:
A method for forming and associating a lower section of a large-area field emission device (“FED”) which is sealed under a predetermined level of vacuum pressure with an upper section of a large-area FED, with an upper section of the FED including a faceplate, a first conductive layer disposed on a surface of the faceplate, a matrix member disposed on a surface of the first conductive layer, and cathodoluminescent material disposed on the first conductive layer in areas not covered by the matrix member, comprising: forming a substrate of a predetermined size; forming an emitter electrode structure on the substrate; forming a plurality of micropoints in a predetermined height range on the emitter electrode structure, including forming the plurality of micropoints in groups on the emitter electrode structure; coating the plurality of micropoints with a low-work function material; depositing an insulating layer over the coated plurality of micropoints; depositing a first conductive layer over the insulating layer such that the first conductive layer and the insulating layer have a combined height at least as high as a tallest coated micropoint of the plurality of micropoints; controlled polishing of a first surface of the first conductive layer to achieve a substantially smooth, flat first surface, the insulating layer and the first conductive layer having a combined thickness that is substantially uniform across the FED; etching openings through the first conductive layer and the insulating layer to expose the coated plurality of micropoints, including forming walls of the openings spaced away from the coated plurality of micropoints; disposing a plurality of spacers between the upper section and the lower section of the FED to provide a predetermined separation between the upper section and the lower section, wherein the plurality of spacers have heights commensurate with stresses exerted on the plurality of spacers.