Patent ID: 7462088

Claim:
A method of forming and associating a lower section of a large-area field emission device (“FED”) with an upper section of the large-area FED, the method comprising: forming a plurality of micropoints in a predetermined height range on an 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; and 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.