Method for creating gated filament structures for field emission displays

1. A method of creating gated filament structures for a field emission display, comprising:

providing a multi-layer structure including a substrate, an insulating layer and a metal gate layer positioned on at least a portion of a top surface of the insulating layer;

providing a plurality of gates in the gate layer and a plurality of apertures in the gates on the top surface of the insulating layer, each aperture having an associated edge;

forming a plurality of spacers in the apertures at their edges on the top surface of the insulating layer;

etching the insulating layer and forming a plurality of pores in the insulating layer; and

plating the plurality of pores in the insulating layer with a filament material that extends from the pores into the gate apertures and creates a plurality of filaments.

2. The method of claim 1 , wherein the multi-layer structure further comprises,

a conductivity layer on at least a portion of a substrate top surface, between the substrate and the insulating layer.

3. The method of claim 1 , further comprising:

removing the spacers after plating the plurality of pores.

4. The method of claim 1 , wherein the multi-layer structure further comprises:

a metal row electrode positioned on a substrate top surface; and

a resistive layer at least partially positioned on a metal row electrode top surface, with the insulating layer positioned on a resistive layer top surface.

5. The method of claim 4 , wherein the multi-layer structure further comprises:

a tracking resist layer positioned on a metal gate layer top surface.

6. The method of claim 5 , further comprising:

irradiating the multi-layer structure with charged energy particles to produce a plurality of tracks in the tracking resist layer.

7. The method of claim 1 , further comprising:

removing a portion of the insulating layer adjacent to the filaments.

8. The method of claim 5 , further comprising:

irradiating the multi-layer structure with charged energetic particles to produce a plurality of tracks in the tracking resist layer;

etching the plurality of tracks to form a plurality of apertures in the tracking resist layer; and

etching the metal gate layer to form a plurality of gates defining a plurality of apertures on an insulating layer top.

9. The method of claim 3 , wherein forming the plurality of spacers comprises:

applying a conformal layer on a gate top surface and into the apertures; and

removing the conformal layer while leaving spacer material in the apertures, at edges of the gates, on an insulating layer top surface, to form a plurality of spacers.

10. The method of claim 5 , wherein the tracking resist layer is made of polycarbonate.

11. The method of claim 5 , further comprising:

irradiating the multi-layer structure with energetic charged Xe.

12. The method of claim 6 , wherein the plurality of tracks are etched to form the plurality of apertures in the tracking resist layer with an aperture size at the metal gate layer of about 0.05 to 2.0 microns.

13. The method of claim 1 , wherein the metal gate layer is etched with a reactive ion etching which does not extend substantially into the insulating layer.

14. The method of claim 1 , wherein the metal gate layer is etched with a reactive ion etching which etches the insulating layer at a slower rate than the metal gate layer.

15. The method of claim 9 , wherein the conformal layer is made of a material selected from silicon nitride, amorphous and small grained polycrystalline Si, or SiO 2 .

16. The method of claim 1 , wherein the metal gate layer has a thickness of about 500 to 2,000 Å.

17. The method of claim 9 , wherein the thickness of the conformal layer is about 50 nm.

18. The method of claim 1 , wherein an anisotropic reactive ion etch is provided to create the plurality of pores in the insulating layer.

19. The method of claim 1 , wherein undercutting of the insulating layer is minimized.

20. The method of claim 4 , wherein etching the insulating layer to form the plurality of insulating layer pores does not extend substantially into the resistive layer.

21. The method of claim 4 , wherein voltages applied on the resistive layer and on the metal gate layer are controlled to minimize plating filament material on the metal gate layer.

22. The method of claim 1 , further comprising:

treating the filaments to form a desired filament tip geometry.

23. A method of creating a plurality of pores in an insulating layer of a field emission display, comprising:

providing a multi-layer structure including a substrate, an insulating layer and a metal gate layer positioned on at least a portion of an insulating layer top surface;

providing a plurality of gates formed in the metal gate layer defining a plurality of apertures on the insulating layer top surface;

forming a plurality of spacers in the apertures at an edges of the gates on the insulating layer top surface; and

etching the insulating layer and forming a plurality of pores in the insulating layer.

24. The method of claim 23 , wherein the multi-layer structure further comprises:

a conductivity layer on at least a portion of a substrate top surface between the substrate and the insulating layer.