Flat panel display with focus mesh

A method for making a flat panel display having a baseplate with field emission microtips, and a faceplate with focus mesh, comprising the steps of:

• providing a glass substrate to act as the base for said faceplate;
• forming a first conductive layer over said glass substrate;
• forming a first dielectric layer over said first conductive layer;
• forming a second conductive layer over said first dielectric layer;
• patterning said second conductive layer and said first dielectric layer to form intersecting perpendicular lines to create said focus mesh;
• forming phosphor elements within and separated from said pattern of intersecting lines, and over said first conductive layer;
• mounting said faceplate with focus mesh opposite to and parallel to said baseplate, which has a plurality of field emission microtips that extend up from a substrate through openings formed in a sandwich structure of a second insulating layer and a third conductive layer.

A method of making a field emission display having a baseplate with field emission microtips, and a faceplate with focus mesh, using a single mask, comprising the steps of:

• providing a glass substrate to act as the base for said faceplate;
• forming a first conductive layer over said glass substrate;
• patterning said first conductive layer, using said single mask, to create three separate conductive structures, comprising a first combed structure, a second combed structure interlocking with said first combed structure, and an interweaving structure located between said first and second combed structures;
• forming a first dielectric layer over said first and second combed structure and said interweaving structure;
• forming a second conductive layer over said first dielectric layer;
• patterning said second conductive layer and said first dielectric layer to form intersecting perpendicular lines to create said focus mesh;
• forming a layer of first phosphorescent material over said first combed structure;
• forming a layer of second phosphorescent material over said second combed structure;
• forming a layer of third phosphorescent material over said interweaving structure;
• mounting said faceplate with focus mesh opposite to and parallel to said baseplate which has a plurality of field emission microtips extending up from a substrate through openings formed in a sandwich structure of a second insulating layer and a third conductive layer.

A field emission display, having a baseplate with field emission microtips, and a faceplate with focus mesh, comprising:

• a glass substrate acting as a face for said faceplate;
• a first combed conductive structure, a second combed conductive structure interlocking with said first combed conductive structure, and an interweaving conductive structure located between said first and second combed conductive structures, all formed over said glass substrate;
• a focus mesh dielectric, formed over said first, second, and interweaving conductive structures, comprising a pattern of intersecting lines formed perpendicularly to one another;
• a focus mesh conductor, over said focus mesh dielectric;
• a first layer of phosphorescent material over said first combed conductive structure;
• a second layer of phosphorescent material over said second combed conductive structure;
• a third layer of phosphorescent material over said interweaving conductive structure;
• a means to provide a first voltage to said first, second, and interweaving conductive structures;
• and
• a means to provide a second voltage to said focus mesh conductor, whereby during operation of said flat panel display said first and second voltages create an electric field to focus electrons emitted from said field emission microtips on to said layers of phosphorescent material.