Patent ID: 7785907

Claim:
A method for manufacturing a cathode assembly of a field emission display, comprising the steps of: providing a substrate; forming a cathode on the substrate; forming an electrically insulating layer on the cathode; forming a gate electrode layer on the electrically insulating layer; forming a photoresist layer on the gate electrode layer; defining at least one opening in the photoresist layer using a photolithographic process; etching the gate electrode layer through the at least one opening in the photoresist layer so as to form at least one gate electrode opening in the gate electrode layer; etching the electrically insulating layer to define at least one cavity in the electrically insulating layer; pressing the photoresist layer in a manner such that a thickness of the photoresist layer is decreased and an area of the photoresist layer is increased such that a size of the at least one opening in the photoresist layer is smaller than a size of the at least one gate electrode opening, wherein the photoresist layer is softened by heating before it is pressed; depositing a catalyst layer on the substrate in the at least one cavity through the at least one opening; and growing carbon nanotubes on the catalyst layer.