JP2008117764A - Device for injecting liquid containing metal particulates, and line pattern manufactured by device for injecting liquid containing metal particulates - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a novel manufacturing device capable of stably manufacturing a line pattern without being clogged when forming the line pattern on a substrate by connecting a plurality of dots so as to be superimposed on each other. <P>SOLUTION: Liquid droplets of a liquid containing a metal particle material are injected and given between a pair of electrodes on the substrate 14 by a liquid droplet injection head 11 of a discharge port diameter of Φ10 μm to Φ25 μm, and the plurality of the dots are connected so as to be superimposed on each other, thereby forming the line pattern. The liquid (droplet) containing a material in order to form the line pattern is a liquid obtained by dispersing the metal particulates into the liquid. When the size of the metal particulate is made Dp, and the discharge port diameter is made Do, the upper limit value is determined as Dp/Do≤0.01, and the lower limit value is made to be 0.002 μm. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a metal fine particle-containing liquid ejecting apparatus, more specifically, the liquid discharge port is not clogged, the metal fine particles can be dispersed in a liquid in a stable state, and moreover reliable on the substrate. The present invention relates to a metal fine particle-containing liquid ejecting apparatus capable of forming a good electron-emitting device, and a line pattern of dots formed on a substrate by such a metal fine particle-containing liquid ejecting apparatus.

  Conventionally, two types of electron-emitting devices are known: a thermionic source and a cold cathode electron source. Cold cathode electron sources include field emission type (hereinafter referred to as FE type), metal / insulating layer / metal type (hereinafter referred to as MIM type), surface conduction type electron-emitting devices, and the like. Examples of the FE type are “WPDyke & WWDolan,“ Field emission ”, Advance in Electron Physics, 8 89 (1956)” (Non-Patent Document 1) or “CASpindt,“ Physical Properties of thin-film fieldemission cathodes with molybdenium “J. Appl. Phys., 475248 (1976)” (Non-Patent Document 2) and the like are known. As an example of the MIM type, “C. A. Mead,“ The Tunnel-emission amplifier ”, J. Appl. Phys., 32 646 (1961)” (Non-Patent Document 3) and the like are known.

Examples of the surface conduction electron-emitting device type include “MIElinson, Radio Eng. Electron Phys., 1290 (1965)” (Non-Patent Document 4). The surface conduction electron-emitting device utilizes a phenomenon in which electron emission occurs when a current flows through a small-area thin film formed on a substrate in parallel to the film surface. As this surface conduction electron-emitting device, one using an SnO ₂ thin film by Elinson et al. Or one using an Au thin film (“G. Dittmer:“ Thin SolidFilms ”, 9 317 (1972)) (Non-patent Document 5)) , In ₂ O ₃ / SnO ₂ thin film (“M. Hartwell and CGFonstad:“ IEEETrans.ED Conf. ”, 519 (1975)) (non-patent document 6)), carbon thin film (“ Hiroshi Araki et al .: Vacuum, Vol. 26, No. 1, page 22 (1983) (Non-patent Document 7)) and the like have been reported.

  As a typical device configuration of these surface conduction electron-emitting devices, the above-described M.I. The Hartwell device configuration is shown in FIG. In FIG. 29, 1 is a substrate, 2 and 3 are element electrodes, 4 is a conductive thin film, and the conductive thin film 4 is made of a metal oxide thin film formed by sputtering in an H-shaped pattern, which will be described later. The electron emission portion 5 is formed by an energization process called energization forming. In the figure, the distance L1 between the device electrodes 2 and 3 is set to 0.5 to 1 mm, and W1 is set to 0.1 mm.

  Conventionally, in these surface conduction electron-emitting devices, it is common to form the electron-emitting portion 5 by applying an energization process called energization forming to the conductive thin film 4 in advance before performing electron emission. . In the energization forming, a DC voltage or a very slow rising voltage, for example, about 1 V / min is applied to both ends of the conductive thin film 4, and the conductive thin film 4 is locally broken, deformed, or altered, and electrically high. It is to form the electron emission portion 5 in a resistance state. In the electron emission portion 5, a crack is generated in a part of the conductive thin film 4, and the electron is emitted from the vicinity of the crack. The surface conduction electron-emitting device subjected to the energization forming process emits electrons from the electron-emitting portion 5 by applying a voltage to the conductive thin film 4 and passing a current through the device.

  Since the surface conduction electron-emitting device as described above has a simple structure and is easy to manufacture, there is an advantage that a large number of devices can be formed over a large area. Therefore, applied researches on charged beam sources, display devices, etc. that take advantage of this feature have been made. As an example in which a large number of surface-conduction electron-emitting devices are arrayed, as will be described later, surface-conduction electron-emitting devices are arrayed in parallel, called a trapezoidal arrangement, and both ends of each element are wired (also called common wiring) ), An electron source in which a number of connected lines are arranged (see, for example, Patent Documents 1-3).

  In particular, in an image forming apparatus such as a display device, in recent years, flat panel display devices using liquid crystals have been used in place of CRTs, but problems such as having a backlight because they are not self-luminous. Therefore, development of a self-luminous display device has been desired. Examples of the self-luminous display device include an image forming apparatus that is a display device in which an electron source in which a large number of surface-conduction emission elements are arranged and a phosphor that emits visible light by electrons emitted from the electron source. (For example, refer to Patent Document 4).

  However, the manufacturing method according to the above-described conventional example of the surface conduction electron-emitting device uses a lot of vacuum film formation and the photolithography etching method in the semiconductor process, and there are many steps to form the device over a large area. There is a disadvantage that the production cost of the electron source substrate is high.

  In response to the problems as described above, the present inventor, in forming the conductive thin film of the element portion of the surface conduction electron-emitting device as described above, describes US Pat. No. 3,060,429 (Patent Document 5), No. 3,298,030. No. (Patent Literature 6), No. 3596275 (Patent Literature 7), No. 3416153 (Patent Literature 8), No. 3747120 (Patent Literature 9), No. 5729257 (Patent Literature 10), etc. It was thought that the above-mentioned conductive thin film could be formed stably and with good yield and at low cost by the droplet applying means, regardless of the vacuum film forming method and the photolithography / etching method. Japanese Patent Laid-Open No. 2001-319567 (Patent Document 11) discloses the results of extensive studies on the specific production method.

  However, unlike ink-jet recording in which so-called ink is ejected toward paper and recording is performed, there are still many unresolved elements for stably flying a solution containing an element that becomes a conductive thin film and applying it onto a substrate. Exists. For example, such an element is generally a metal element, and there are still many unknown techniques for stably injecting a solution containing metal fine particles over a long period of time. In particular, the clogging problem must be solved in order to make the jet performance over a long period constant.

Conventionally, in the field of ink jet recording using a recording liquid in which a water-soluble dye is dissolved, the ejection port (nozzle) of the head used is conventionally from Φ33 μm to Φ34 μm (about 900 μm ^{2 in} terms of area) to Φ50 μm. Those having a diameter of ˜51 μm (about 2000 μm ² in terms of area) are generally used, and since the dye is also dissolved in the liquid medium, the problem of anti-clogging has been addressed. However, as in the present invention, a technique for stably injecting a solution containing metal fine particles from an unprecedented fine discharge port of, for example, Φ25 μm or less (less than 500 μm ² in terms of area) for a long time has been established. Absent.
Japanese Patent Application Laid-Open No. 64-31332 Japanese Patent Laid-Open No. 1-283749 JP-A-2-257552 US Pat. No. 5,066,883 U.S. Pat. No. 3,060,429 US Pat. No. 3,298,030 US Pat. No. 3,596,275 U.S. Pat. No. 3,416,153 U.S. Pat. No. 3,747,120 US Pat. No. 5,729,257 JP 2001-319567 A WPDyke & WWDolan, “Field emission”, Advance in Electron Physics, 8 89 (1956) CASpindt, “Physical Properties of thin-film fieldemission cathodes with molybdenium” J. Appl. Phys., 475248 (1976) CAMead, “The Tunnel-emission amplifier”, J. Appl. Phys., 32 646 (1961) MIElinson, Radio Eng.Electron Phys., 1290 (1965) G. Dittmer: “Thin SolidFilms”, 9 317 (1972) M. Hartwell and CGFonstad: “IEEETrans.ED Conf.”, 519 (1975) Hisashi Araki et al .: Vacuum, Vol. 26, No. 1, p. 22 (1983)

The present invention relates to a metal fine particle-containing liquid ejecting apparatus as described above, and a line pattern with dots produced by such a metal fine particle-containing liquid ejecting apparatus,
The first object is to produce a liquid containing metal fine particles on a substrate by jetting, so that the liquid discharge port is not clogged during jetting, and the metal fine particles can be dispersed in a stable state. An object of the present invention is to provide a metal fine particle-containing liquid ejecting apparatus capable of producing a line pattern with good dots on a substrate.

  The second object is to make the dot line pattern produced on the substrate by such a metal fine particle-containing liquid ejecting apparatus more reliable and more favorable.

In order to achieve the above object, the present invention provides
In the invention of claim 1, a liquid droplet containing a metal fine particle material is jetted from a discharge port between a pair of electrodes on a substrate, a plurality of dots are connected so as to overlap, and a line pattern is formed, In the metal fine particle-containing liquid ejecting apparatus that volatilizes the volatile components in the line pattern by the dots of the liquid droplets after application and causes the solid content to remain on the substrate to make electrical connection between the electrodes, the metal in the liquid The fine particles have a size equal to or less than the surface roughness of the surface on which the line pattern by the dots is formed, and when the size of the metal fine particles is Dp and the diameter of the discharge port is Do, the discharge port diameter Do is Φ10 μm to In the case of Φ25 μm, the upper limit of the size Dp of the metal fine particles is defined as Dp / Do ≦ 0.01 so that the discharge port is not clogged, and the metal fine particles are With a 0.002μm lower limit value of the size Dp of the fine metal particles in order to disperse in a constant state, and the thickness of the line pattern by the dot so as to have a thickness equal to or greater than the surface roughness.

  In the invention of claim 2, a liquid containing metal fine particles is ejected and applied between a pair of electrodes on the substrate by a liquid ejecting apparatus, a plurality of dots are connected so as to overlap, and a line pattern is formed. In the line pattern by dots produced by the liquid ejecting apparatus containing metal fine particles, which volatilizes the volatile components in the line pattern by the dots by liquid and leaves the solid content on the substrate to make electrical connection between the electrodes, The metal fine particles had a size equal to or less than the surface roughness of the surface on which the line pattern thin film formed of the dots was formed, and the thickness of the line pattern thin film formed of the dots was equal to or greater than the surface roughness.

Effect corresponding to the invention of claim 1 A liquid droplet containing a metal fine particle material is sprayed and applied from a discharge port between a pair of electrodes on a substrate, and a plurality of dots are overlapped to form a line pattern. In the liquid ejecting apparatus containing fine metal particles, the volatile components in the line pattern due to the dots of the applied droplets are volatilized and the solid content remains on the substrate to make electrical connection between the electrodes. The metal fine particles have a size equal to or less than the surface roughness of the surface on which the line pattern by the dots is formed, and when the size of the metal fine particles is Dp and the diameter of the discharge port is Do, the discharge port diameter Do is Φ10 μm. In the case of .about..PHI.25 .mu.m, the upper limit of the metal fine particle size Dp is defined by Dp / Do.ltoreq.0.01 so that the discharge port is not clogged. There is no clogging of the mouth.
In order to disperse the metal fine particles in a stable state, the lower limit value of the size Dp of the metal fine particles is set to 0.002 μm, so that the metal fine particles can be dispersed in a stable state.
Since the thickness of the line pattern of the dots is equal to or greater than the surface roughness, it is possible to provide a reliable line pattern of dots.

Effect corresponding to the invention of claim 2 A liquid containing metal fine particles is ejected and applied between the pair of electrodes on the substrate by the liquid ejecting apparatus, a plurality of dots are connected so as to overlap, and a line pattern is formed and applied The line pattern of dots produced by a metal fine particle-containing liquid jet production apparatus that volatilizes volatile components in the line pattern of dots by a later liquid and causes the solid content to remain on the substrate to make electrical connection between the electrodes. The metal fine particles have a size equal to or smaller than the surface roughness of the surface on which the line pattern thin film formed by the dots is formed, and the thickness of the line pattern thin film formed from the dots is equal to or greater than the surface roughness. Therefore, it is possible to provide a reliable and good line pattern with dots.

  FIG. 1 is a schematic view showing an example of an electron source substrate that constitutes a planar surface conduction electron-emitting device according to an embodiment of the present invention. FIG. 1 (A) is a plan view thereof, and FIG. FIG. 1B is a cross-sectional view taken along line BB in FIG. 1A, where 1 is a substrate, 2 is a device electrode, 4 is a conductive thin film, and 5 is an electron emission portion. The basic configuration of the surface conduction electron-emitting device of the present invention is a planar type, and here, the configuration of one planar surface conduction electron-emitting device is schematically shown in a simplified manner. As will be described later, such a planar surface conduction electron-emitting device is configured as an element group in a matrix arrangement.

As the substrate 1, quartz glass, glass with a reduced impurity content such as Na, blue plate glass, a glass substrate on which SiO ₂ is deposited, a ceramic substrate such as alumina, and the like can be used. As the material for the device electrodes 2 and 3, a general conductive material can be used, for example, a metal or alloy such as Ni, Cr, Au, Mo, W, Pt, Ti, Al, Cu, Pd, Pd, From printed conductors composed of metals such as As, Ag, Au, RuO ₂ , Pd—Ag or metal oxides and glass, transparent conductors such as In ₂ O ₃ —SnO ₂ , semiconductor materials such as polysilicon, etc. It is selected appropriately.

  The distance L between the device electrodes 2 and 3 is preferably in the range of several thousand to several hundred μm, and more preferably in the range of 1 to 100 μm in consideration of the voltage applied between the device electrodes 2 and 3. is there. The length W of the device electrodes 2 and 3 is several μm to several hundred μm in consideration of the resistance value and electron emission characteristics of the electrodes, and the film thickness d of the device electrodes 2 and 3 is 100 μm to 1 μm. It is a range.

  2 is a diagram for explaining a method of manufacturing the planar surface conduction electron-emitting device shown in FIG. 1, FIG. 2A is a diagram in which device electrodes 2 and 3 are formed on the substrate 1, and FIG. FIG. 2B is a diagram in which the conductive thin film 4 is formed on the device electrodes 2 and 3, and FIG. 2C is a diagram in which the electron emission portion 5 is formed on the conductive thin film 4. In order to obtain good electron emission characteristics, the conductive thin film 4 is particularly preferably a fine particle film composed of fine particles. The film thickness is step coverage to the device electrodes 2 and 3 and the resistance between the device electrodes 2 and 3. Although it is appropriately set depending on the value, energization forming conditions described later, etc., it is preferably several to thousands, and particularly preferably 10 to 500. Further, the resistance value is a value of Rs of 10 2 to 10 7. Rs is a value that appears when the resistance R of a thin film having a thickness of t, a width of w, and a length of l is set as R = Rs (1 / w). If the resistivity of the thin film material is ρ, Rs = Ρ / t. Here, the energization process will be described as an example of the forming process, but the forming process is not limited to this, and any method may be used as long as it forms a high resistance state by causing a crack in the film. Also good.

  As a material constituting the conductive thin film 4, metals such as Pd, Pt, Ru, Ag, Zn, Sn, W, and Pb can perform good electron emission as the surface conduction electron-emitting device of the present invention. As a material. However, as described later, it is necessary to consider compatibility with the droplet ejecting head used in the manufacturing apparatus of the present invention, and not all of these materials can be suitably used.

The fine particle film described here is a film in which a plurality of fine particles are aggregated, and the fine structure is not only in a state where the fine particles are individually dispersed and arranged, but also in a state where the fine particles are adjacent to each other or overlap (some fine particles are aggregated). And the case where an island is formed as a whole). The particle diameter of the fine particles is several to 1 μm, preferably 10 to 200 μm.
The present invention is not limited to the configuration shown in FIG. 1, and the device electrodes 2 and 3 may be formed on the conductive thin film 4 on the substrate 1.

An apparatus for manufacturing an electron source substrate on which a surface conduction electron-emitting device according to an embodiment of the present invention is formed will be described below. FIG. 3 is a view showing an example of an electron source substrate manufacturing apparatus according to the present invention, in which 11 is an ejection head unit (jet head), 12 is a carriage, 13 is a substrate holder, and 14 is a planar surface conduction device. 15 is a substrate for forming a group of electron-emitting devices, 15 is a solution supply tube containing a conductive thin film material, 16 is a signal supply cable, 17 is an ejection head control box, 18 is an X-direction scan motor for the carriage 12, and 19 is Y-direction scanning motor of the carriage 12, 20 is a computer, 21 control _{box, 22 (22X 1, 22Y 1} , 22X 2, 22Y 2) is a substrate positioning / holding means.

  The configuration shown in FIG. 3 shows an example in which the ejection head 11 moves by carriage scanning on the front surface of the substrate 14 placed on the substrate holder 13 and ejects a solution containing a conductive thin film material. The ejection head 11 may have any mechanism as long as it can discharge a given amount of liquid droplets in particular, and in particular, an ink jet type mechanism capable of forming a liquid droplet of about several tens to several picoliters or a smaller volume of liquid droplets. desirable. As the ink jet method, any of a piezo jet method using a piezoelectric element, a bubble jet (registered trademark) method that generates bubbles using the thermal energy of a heater, or a charge control method (continuous flow method) may be used. Absent.

  FIG. 4 is a schematic diagram for explaining an example of a configuration of a droplet applying apparatus to which the method of manufacturing an electron source substrate of the present invention can be applied. FIG. 5 is a diagram of an ejection head unit of the droplet applying apparatus of FIG. It is a principal part schematic block diagram. The configuration of FIG. 4 is different from the configuration of FIG. 3 in that the electron-emitting device group is formed on the substrate by moving the substrate side. 4 and 5, 2 and 3 are element electrodes, 14 is a substrate, 30 is an ejection head unit (corresponding to the ejection head 11 in FIG. 3), 31 is a head alignment control mechanism, 32 is a detection optical system, and 33 is an inkjet. Head, 34 is a head alignment fine movement mechanism, 35 is a control computer, 36 is an image identification mechanism, 37 is an XY direction scanning mechanism, 38 is a position detection mechanism, 39 is a position correction control mechanism, 40 is an inkjet head drive / control mechanism, 41 Is an optical axis, 42 is a droplet, and 43 is a droplet landing position.

  As in the case of FIG. 3, the droplet applying device (inkjet head 33) of the ejection head unit 30 is preferably an inkjet mechanism, a piezojet method using a piezoelectric element, and bubbles using the thermal energy of a heater. Any method such as a bubble jet (registered trademark) system for generating the charge or a charge control system (continuous flow system) may be used.

  Below, the structure of the apparatus which moves the board | substrate 14 side shown in FIG. 4 is demonstrated. First, in FIG. 4, the substrate 14 is placed on the XY direction scanning mechanism 37. The surface conduction electron-emitting device on the substrate 14 has the same configuration as that shown in FIG. 1, and the single device is the same as that shown in FIG. 1, and the substrate 1, the device electrodes 2, 3 and the conductive thin film (fine particle film). It is made up of four. An ejection head unit 30 for applying droplets is positioned above the substrate 14. In the present embodiment, the discharge head unit 30 is fixed, and the substrate 14 is moved to an arbitrary position by the XY direction scanning mechanism 37, whereby the relative movement between the discharge head unit 30 and the substrate 14 is realized.

  Next, the configuration of the ejection head unit 30 will be described with reference to FIG. The detection optical system 32 captures image information on the substrate 14, is close to the inkjet head 33 that ejects the droplet 42, the optical axis 41 and the focal position of the detection optical system 32, and the droplet 42 by the inkjet head 33. The landing positions 43 are arranged so as to coincide with each other. In this case, the positional relationship between the detection optical system 32 and the inkjet head 33 can be precisely adjusted by the head alignment fine movement mechanism 34 and the head alignment control mechanism 31. The detection optical system 32 uses a CCD camera and a lens.

  Returning again to FIG. The image identification mechanism 36 identifies the image information captured by the previous detection optical system 32, and has a function of binarizing the contrast of the image and calculating the centroid position of the binarized specific contrast portion. It is. Specifically, a high-precision image recognition device manufactured by Keyence Corporation; VX-4210 can be used. A means for giving position information on the substrate 14 to the image information obtained thereby is a position detection mechanism 38. For this purpose, a length measuring device such as a linear encoder provided in the XY direction scanning mechanism 37 can be used. The position correction control mechanism 39 corrects the position based on the image information and the position information on the substrate 14, and this mechanism corrects the movement of the XY direction scanning mechanism 37. Further, the inkjet head 33 is driven by the inkjet head drive / control mechanism 40, and droplets are applied onto the substrate 14. Each control mechanism described so far is centrally controlled by the control computer 35.

  In the above description, the ejection head unit 30 is fixed, and the substrate 14 is moved to an arbitrary position by the XY direction scanning mechanism 37 to realize relative movement between the ejection head unit 30 and the substrate 14. As shown in FIG. 3, it is needless to say that the substrate 14 may be fixed and the ejection head unit 30 may scan in the XY directions. In particular, when the present invention is applied to the production of an image forming apparatus having a medium screen of about 200 mm × 200 mm to a large screen of 2000 mm × 2000 mm or more, the substrate 14 is fixed and the discharge head unit 30 is orthogonal as in the latter case. It is preferable that the scanning is performed in two directions of X and Y, and the droplets of the solution are sequentially applied in such two orthogonal directions.

  As another example, when the substrate size is, for example, about 400 mm or less in the lateral direction, the discharge head unit for applying droplets is a large array multi-nozzle type that can cover the range of 400 mm, and discharge Relative movement of the head unit and the substrate can be performed in only one direction (longitudinal direction) (for example, only in the X direction) without performing relative movement in two orthogonal directions (X direction and Y direction). In the case where the short direction of the substrate size is longer than 400 mm, it is technically necessary to manufacture a large array multi-nozzle type discharge head unit capable of covering such a longer range than 400 mm. It is difficult to realize in terms of cost, and as in the present invention, the ejection head unit 30 scans in two directions of X and Y that are orthogonal to each other. The application of drops is better where the structure to perform sequentially in such two orthogonal directions.

  As the material of the droplets 42, an aqueous solution, an organic solvent, or the like containing the element or compound that becomes the conductive thin film described above can be used. For example, when the element or compound used as the conductive thin film is palladium, examples thereof include palladium acetate-ethanolamine complex (PA-ME), palladium acetate-diethanol complex (PA-DE), palladium acetate-triethanolamine. An aqueous solution containing an ethanolamine complex such as a complex (PA-TE), palladium acetate-butylethanolamine complex (PA-BE), palladium acetate-dimethylethanolamine complex (PA-DME), or a palladium-glycine complex ( Pd-Gly), palladium-β-alanine complex (Pd-β-Ala), an aqueous solution containing an amine acid complex such as palladium-DL-alanine complex (Pd-DL-Ala), and further palladium acetate-bis- Examples thereof include a butyl acetate solution of a di-propylamine complex.

  More specifically, for example, in the case of a palladium acetate-triethanolamine aqueous solution, it is produced as follows. That is, 50 g of palladium acetate is suspended in 500 cc of isopropyl alcohol, 100 g of triethanolamine is further added, and the mixture is stirred at 35 ° C. for 12 hours. After completion of the reaction, isopropyl alcohol is removed by evaporation, ethyl alcohol is added to the solid to dissolve and filter, and palladium acetate-triethanolamine is recrystallized from the filtrate. 10 g of the palladium acetate-triethanolamine thus obtained can be dissolved in 190 g of pure water to obtain a jetting solution.

  As another example, palladium fine particles are ozone-treated with an ozone generator having a voltage of 60 V, a frequency of 50 Hz, and an oxygen flow rate of 40 ml / min, and 7 g of the treated palladium fine particles are converted into a solution of 5 g of ethylene glycol, 8 g of ethanol, and 80 g of pure water. It can be dispersed into a jetting solution.

  As is clear from the above description, the electron source substrate of the present invention is manufactured by flying a solution containing an element or compound to be a conductive thin film in the air on the principle of ink jet and applying it as droplets on the substrate. However, in order to stably form a high-quality surface conduction electron-emitting device over a long period of time, the manufacturing apparatus must stably maintain a certain performance. Here, the most important point is the long-term performance stability of the ejection head. As described above, in the present invention, the solution containing the material for forming the conductive thin film is a solution in which metal fine particles are dispersed in a liquid.

  However, the metal fine particles are present like abrasive grains dispersed in the solution. When a large amount of this solution is used, there is a problem that the passage of the solution in the ejection head is damaged or worn. Among the passages, scratches and wear of the discharge port (nozzle) are particularly problematic because they affect the droplet ejection performance of the solution.

  By the way, the scratches and wear are caused when two objects collide with each other or rub against each other. Therefore, it is considered that they can be solved by appropriately selecting the hardness of each other. In addition, it is true that scratches affect the droplet jetting performance of the jet head, but how much the scratches are affected is considered to be determined by the size of the scratch and the size of the solution passage. For example, even if a water discharge hose having an inner diameter of Φ15 mm to Φ20 mm has scratches on the order of nanometers, the water discharge flow rate cannot be greatly affected.

In the present invention, considering these points, the hardness of the material of the discharge port portion, the hardness of the material of the metal fine particles, and the size of the discharge port portion are intensively studied.
Specifically, by using an ejection head having a multi-nozzle plate attached to the surface of the rectangular nozzle portion 58 with the ejection head as shown in FIG. It was investigated whether or not the nozzle hole) was flawed, and whether or not the element shape to be formed (the shape of the dot pattern was good) and the element performance were deteriorated due to the deterioration of the solution droplet discharge performance. Multi-nozzle plates were prepared with different materials and nozzle diameters (here rounded). The device performance was examined after performing a forming process described later.

  The ejecting head used is a thermal ink jet system that uses thermal energy. As described above, the ejecting head of FIG. 6 is equipped with a nozzle plate (nozzle plate is not shown). What is shown shows only four outlets for ease of explanation. Actually, the number of discharge ports is 64, and the arrangement density is 400 dpi. In FIG. 6, 50 is an ejection head, 51 is a heating element substrate, 52 is a lid substrate, 53 is a silicon substrate, 54 is an individual electrode, 55 is a common electrode, 56 is a heating element, 57 is a solution inlet, and 58 is 6A is a perspective view of the ejection head, FIG. 6B is an exploded view of the heating element substrate 51 and the lid substrate 52, and FIG. 6C. FIG. 5 is a perspective view of the lid substrate 52 as seen from the back side.

The size of the heating element was 22 μm × 90 μm, the resistance value was 111Ω, the driving voltage for droplet ejection was 24 V, the driving pulse width was 6.5 μs, and the driving frequency was 12 kHz.
The injection was performed continuously for 100 hours, and the discharge port portion after injection was observed with an SEM to examine the presence or absence of scratches.

  The discharge port diameters of Φ25 μm (H1), Φ16 μm (H2), and Φ10 μm (H3) were prepared. As a comparative reference example, one having a discharge port diameter of Φ36 μm (reference head) was also prepared. In this case, the number of discharge ports is 48 and the arrangement density is 240 dpi. The size of the heating element was 35 μm × 150 μm, the resistance value was 120Ω, the driving voltage for ink ejection was 30 V, the driving pulse width was 7 μs, and the driving frequency was 3.8 kHz. The thickness of the nozzle plate was 30 μm for H1 and H2, 20 μm for H3, and 40 μm for the reference head. The speed of the droplet during ejection was about 8 m / s in any ejection head.

  The nozzle plate was made of Ni and austenitic stainless steel SUS304. A Ni nozzle made of a multi-nozzle plate by an electroforming method, and a nozzle made of SUS304 made of stainless steel foil was formed with nozzle holes by electric discharge machining. When the hardness was measured with a Vickers hardness meter, the Vickers hardness Hv was 58 to 63 in the case of Ni material, and the Vickers hardness Hv was 170 to 190 in the case of SUS304 material.

  The liquids used were S1 to S7 shown in Table 1, and the element names of the contained metal particles and the Vickers hardness Hv in the bulk state were shown, respectively. In addition, this Vickers hardness Hv published the value of the metal data book (The Metallurgy Society of Japan edition, revised 3rd edition, publication: Maruzen). The metal fine particle content in each solution was about 7%, and the fine particle diameter was 150 to 200 mm.

  The results of evaluation using these sample solutions and the ejection head are shown in Table 2 to Table 5. In the table, scratches ○ indicate that no conspicuous scratches could be confirmed after 100 hours of injection, and × indicates that a number of scratches that affect the nozzle shape or dimensions exist. The element shape ○ indicates that the dot pattern was formed in a good round shape at the target position (between a pair of electrodes) when the element was manufactured after jetting for 100 hours, and × the position was slightly aimed It is out of place, the shape is irregular, or microdroplets are scattered around. XX of the device performance is good (◯) or not (×) of electron emission after performing a forming process described later.

  From the above results, it can be seen that when the hardness of the contained metal fine particles is greater than the material of the discharge port (S3, S6), the discharge port is damaged. It can also be seen that the shape of the element formed thereby is poor and the element performance is also poor. Therefore, it can be seen that when such a surface conduction electron-emitting device is formed by a manufacturing apparatus such as the present invention, it is necessary to select a material for the metal fine particles that is softer than the member constituting the discharge port.

Some of the scratches do not deteriorate the element shape due to the size of the discharge port. As in the case of the reference head, when the discharge port diameter is as large as 36 μm (= the area is about 1000 μm ² ), since the discharge port diameter is large even if it is scratched, it is not a scratch that would cause the jetting performance to deteriorate, A sufficiently usable element shape is obtained. On the other hand, when the discharge port diameter is Φ25 μm or less (= the area is less than about 500 μm ² ), when the area comparison is less than half of the reference head, even if there is a scratch, it is compared with the discharge port diameter. It can be seen that there is a great influence on the film, and that a good element shape and element performance cannot be obtained.

  In other words, if the surface conduction electron-emitting device is not formed so fine, the problem of scratches does not affect the device performance, so there is no concern. However, as in the present invention, a liquid having a discharge port diameter of Φ25 μm or less. In the case where a solution containing 10 μm to 200 μm of metal fine particles is sprayed and applied by a droplet ejecting head to form a surface conduction electron-emitting device group using a conductive thin film, a flaw in the discharge port is a factor in device performance. Since it is fatal, it is necessary to select a combination of a solution and a discharge port member that does not cause scratches. In other words, the metal fine particles need to be made of a material that is softer than the member constituting the discharge port.

In the experiment, a round Φ25 μm nozzle (area is about 490 μm ² ), Φ16 μm nozzle (area is about 200 μm ² ), and Φ10 μm nozzle (area is about 80 μm ² ) were used. When using (for example, a rectangle), the area may be compared. For example, a 22 μm × 22 μm nozzle is equivalent to the round Φ25 μm nozzle of the present invention. In other words, the present invention is applied to a case where a surface conduction electron-emitting device group is formed by ejecting such a solution with an ejection head using a nozzle having an area of less than 500 μm ² .

  Next, other features of the present invention will be described. As described above, in the present invention, the solution containing the material for forming the conductive thin film is a solution in which metal fine particles are dispersed in a liquid. And it is related with the technique which forms the electroconductive thin film on a board | substrate by injecting the solution from a fine discharge port by the technique equivalent to what is called an inkjet injection principle. However, in the ink used in the conventional ink jet recording field, the dye is dissolved in the solution, whereas in the solution used in the present invention, since the metal fine particles are only dispersed in the solution, clogging is caused. It is easy to happen.

Further, according to the present invention, from a required device (electron-emitting device) application, a fine discharge port diameter that has not been conventionally used, for example, the discharge port diameter is Φ25 μm or less (in terms of area, less than 500 μm ² ). An ejection head must be used, and this clogging is a very serious problem.

  By the way, clogging is derived from the principle itself that a solution is ejected from a fine discharge port. That is, it occurs because the discharge port is fine. Therefore, there is a close relationship between the size of the discharge port and the size of the metal fine particles, which can be called foreign matter in the solution.

  In view of this point, the present invention pays attention to the size of the discharge port and the size of the metal fine particles, and has found out the relationship between the difficulty of clogging and their relationship. Specifically, a solution in which the metal fine particle diameter is changed is prepared, and an ejection head with a known discharge port size is used. The discharge port was checked for clogging. In that case, not only a complete blockage of the outlet, but also a partial clogging and a prior indication (a slight clogging) were considered as clogging and tested.

  The used ejection head is equivalent to the thermal ink jet method using thermal energy, and as described above, the ejection head of FIG. 6 is mounted with a nozzle plate (nozzle plate is not shown). FIG. 6 shows only four discharge ports for simplicity of explanation. In actual use, the number of discharge ports is 128 and the arrangement density is 600 dpi. The size of the heating element was 20 μm × 85 μm, the resistance value was 105Ω, the driving voltage for droplet ejection was 22 V, the driving pulse width was 6 μs, and the driving frequency was 14 kHz. The recording heads were prepared from H1 to H4 (respective ejection port diameters were H1 = Φ25 μm, H2 = Φ20 μm, H3 = Φ15 μm, H4 = Φ10 μm). The nozzle plate was formed by Ni electroforming, and the thickness of the discharge port portion was all 30 μm.

  The solution used was ozone-treated with fine particles of palladium in an ozone generator with a voltage of 60 V, a frequency of 50 Hz, and an oxygen flow rate of 40 ml / min. 7 g of the treated palladium fine particles were dispersed in a solution of 5 g of ethylene glycol, 8 g of ethanol, and 80 g of pure water. A solution for injection was prepared by changing the palladium fine particle diameter from 0.0003 to 0.5 μm and tested in combination with H1 to H4 having different discharge port diameters. Further, the condition for leaving after droplet ejection for a certain time (10 minutes) is to stand for 10 hours in an atmosphere of a temperature of 40 ° C. and a humidity of 30%.

  Tables 6 to 9 show the results of examining the occurrence of clogging by combining the solutions with the palladium fine particle diameter changed and the heads H1 to H4 with the discharge port diameter changed.

  Table 6 shows head H1 (discharge port diameter Do = Φ25 μm), Table 7 shows head H2 (discharge port diameter Do = Φ20 μm), Table 8 shows head H3 (discharge port diameter Do = Φ15 μm), and Table 9 shows head H4. The case of (discharge port diameter Do = Φ10 μm) is shown. Judgment ○ indicates that it can be used practically well, Δ indicates that it can be used but is not very preferable, and X indicates that it is not practical at all. When the palladium fine particle diameter was 0.001 μm or less, it could not be stably dispersed and could not be evaluated.

  From the above results, when an ejection head having a discharge port diameter of Φ10 μm to Φ25 μm is used, there is no clogging if the palladium fine particle diameter Dp and the discharge port diameter Do satisfy the relationship of Dp / Do ≦ 0.01. It can be seen that stable droplet ejection can be obtained. Incidentally, although it is the lower limit value of Dp / Do, it is difficult for the palladium fine particle diameter Dp to be 0.001 μm or less considering that such fine metal fine particles are stably dispersed in the solution. Further, in order to stably eject droplets to all ejection heads having an ejection orifice diameter of Φ25 μm or less, the lower limit value may be set to 0.0002 with a margin. That is, if the relationship between the metal fine particle diameter Dp and the discharge port diameter Do satisfies the relationship of 0.0002 ≦ Dp / Do ≦ 0.01, the conductivity by droplet ejection using an ejection head having an ejection port diameter of Φ25 μm or less. It can be seen that a stable dispersion capable of forming a conductive thin film can be produced, and clogging can be prevented.

In this experiment, a round discharge port (nozzle) was used. However, as described above, in the case of other shapes, the area may be compared. For example, in the case of a 22 μm × 22 μm rectangular discharge port Is equivalent to the round Φ25 μm nozzle of the present invention. In other words, the present invention is applied to a jet head using a nozzle having an area of less than 500 μm ² and jetting such a solution to form a surface conduction electron-emitting device group.

  In the experiment, a thermal jet (bubble jet (registered trademark)) type jet head was used. However, the jet head used in the manufacturing apparatus of the present invention was not limited to this, and a piezoelectric element was used. Any of a piezo jet method, a method using an electrostatic force, or a charge control method (continuous flow method) may be used.

  For example, in the case of a piezo jet method using a piezoelectric element, by always keeping the input voltage to the piezo element constant, round uniform droplets can be obtained when the droplets fly, and good round dots can be obtained on the substrate. Further, since heat is not used unlike the thermal jet method, there is an advantage that the solution to be used is not thermally deteriorated and there are few restrictions on the solution to be used.

  On the other hand, in the case of the thermal jet method, it flies with small satellite droplets when the solution flies, but the velocity at the time of flight is high (for example, 6 m / s to 18 m / s), and stable jet flight can be obtained. There are benefits. As a result, minute satellite droplets also fly at a high speed (6 m / s to 18 m / s), adhere to the same location on the substrate, and obtain a dot that secures a highly accurate landing position. In other words, in the case of the thermal jet method, the total amount of solution for forming one dot can be obtained if the input energy to the heating element is always constant even if the satellite droplets fly as if they were scattered. Are the same (because they adhere to the same location), and as in the case of the piezo jet method, a good round dot is obtained, a high-quality / high-quality electron-emitting device is obtained, and the position accuracy is also high. It is done.

  FIG. 7 shows the shape of the solution at the time of jetting and flight in the case of the thermal jet method in which the metal fine particle material-containing solution is jetted from the micro discharge port by utilizing the growth action force of the film boiling bubble preferably used in the present invention. It is shown. FIG. 8 and FIG. 9 show the shape of the solution at the time of jetting and flying in the case of the piezo jet method in which the piezo element is used as a driving force for droplet discharge and jetted by mechanical action force.

  The difference between FIG. 7 and FIG. 8 and FIG. 9 is that in the case of FIG. 7, a part of the solution is instantaneously heated (for several μs) to 300 to 400 ° C. to generate film boiling bubbles, In order to inject the solution by using the growth (for several μs) and the pressure increase (acting force), the piezoelectric element shown in FIGS. The injection pressure is higher and the injection speed is faster than in the case of the piezo jet method. As a result, as shown in FIG. 7, when flying, the flying shape of the solution has a characteristic of flying at high speed with a droplet 42 extending in the shape of an elongated column in the flying direction and a plurality of 42 minute droplets behind. Yes. For example, the shape at the time of flying the solution is such that when a stable film boiling bubble is generated, the elongated columnar length l extending in the flying direction is more than 5 times the diameter d, and The speed is about 6 m / s to 18 m / s.

  As a result, there is an advantage that the jetting is stable and the landing accuracy of the jetted solution on the substrate is high, but on the other hand, if the relative moving speed of the jet head and the substrate is not properly selected, the solution is elongated in the flight direction. The solution at the rear portion extending to the columnar droplets 42 and a plurality of minute droplets (satellite minute droplets) connected to the rear side may hinder the formation of a good round dot.

  In the present invention, as a result of intensive studies on this point, it is found that it is necessary to optimize the relationship between the spray speed and the relative movement speed when spraying the solution containing the metal fine particle material. It was.

  By the way, when the discharge head unit 11 is moved relative to the substrate 14 in the X and Y directions while maintaining a certain distance, the metal fine particle material-containing solution is ejected to form the electron-emitting device pattern. In this case, the solution is deposited and formed on the substrate 14 at the speed of the combined vector of the relative speed and the spray speed. With respect to the positional accuracy, the solution is attached to the target position by appropriately selecting the ejection timing in consideration of the distance between the substrate 14 and the solution ejection port surface of the ejection head unit 11 and the speed of the combined vector. be able to.

  However, even if the target can be attached to the target position, if the relative speed is too high, the attached solution flows on the substrate 14 due to the relative speed, and a good round dot shape is obtained. In other words, a good electron-emitting device pattern cannot be formed. In addition, a number of minute droplets (satellite minute droplets) that are connected to the back adhere randomly and scattered at a position outside the position where they should originally adhere, hindering the formation of a good round dot, and electron-emitting device performance May cause a decrease in The present invention has been examined in this regard.

  An example of the examination results is shown below. In this example, the apparatus as shown in FIG. 3 is used, and the X direction moving speed of the carriage 12 and the ejection speed of the ejection head unit 11 are changed, so that good solution adhesion can be made on the substrate 14 and good electron emission is achieved. It was investigated whether an element pattern could be formed.

  FIG. 10 shows an example of the pattern used for the test. Here, a palladium fine particle-containing solution is sprayed to form an electron-emitting device pattern in which two rows of adjacent device electrodes 2 and 3 (between the ITO transparent electrodes) are connected to the dot pattern 42 by the solution. It evaluates the formation status. Evaluation evaluated the pattern after formation under the microscope, and judged good / bad ((circle) / x). FIG. 10A is good (◯), and each dot pattern does not have a good round shape as shown in FIG. 10B, becomes an oval shape, and the landing position on the substrate is the original aim. Anything that deviates from the position of and touches the adjacent dot pattern is defective (x). Furthermore, the thing in which the micro droplet resulting from the dot pattern 42 was scattered was also set as the defect (x).

  In addition to the evaluation of the shape, the resistance value between the upper and lower ITO transparent electrodes was measured to evaluate the resistance value fluctuation due to disconnection due to poor dot position accuracy or contact with adjacent (left and right) dots (○: Resistance value as intended, x: resistance value outside the target).

  Details of the experimental conditions are shown below. The substrate used was a glass substrate with an ITO transparent electrode, and the above-mentioned solution containing palladium fine particles (here, a fine particle diameter of 0.01 μm was used) shown in FIG. 6 (provided with an opening of Φ15 μm) In addition, a pattern was formed so that a pair of ITO transparent electrodes 2 and 3 as shown in FIG. 10 were filled with 4 dots in combination with a multi-nozzle plate formed by Ni electroforming. In addition, a similar pattern connecting adjacent ITO transparent electrodes and ITO transparent electrodes is formed by setting the center-to-center distance w to 25 μm.

  The used ejection head is the above-described ejection head (FIG. 6 shows four simplified nozzles), but the number of nozzles (discharge ports) is 64. The arrangement density is 400 dpi. The heating element size is 10 μm × 40 μm, and its resistance value is 102Ω. The head drive voltage was 12 V, the pulse width was 3 μs, and the drive frequency was 14 kHz. The volume of the ejected droplet is approximately 3 pl.

  Under such conditions, the above-mentioned pattern (FIG. 10) is formed on the glass substrate, and after the formation, pattern evaluation is performed. Under the same conditions, a separate injection experiment is performed, and a solution 3 mm ahead from the discharge port. The injection situation of was observed. This is because the test pattern of FIG. 10 was manufactured with a distance between the substrate and the discharge port of 3 mm. As shown in FIG. 7, the flight form was a columnar shape (1 = 5d to 20d) 42 that was elongated very long in the flight direction. Moreover, it was in the state with a plurality of minute droplets 42 behind the flying droplets. The examination results are shown below.

  From the above results, it can be seen that when the moving speed of the carriage in the X direction exceeds 1/3 of the ejection speed, a good element cannot be formed. Although this example is an example in which the ejection head is scanned by carriage, it is also applied to the case where the ejection head is fixed and the substrate is moved as shown in FIG. That is, when the thermal jet method is used for jetting, the relative moving speed of the jet head and the substrate must be 1/3 or less of the speed of the jetted solution.

  Next, still another feature of the present invention will be described. The electron source substrate manufactured according to the present invention is a liquid containing a metal fine particle material in which countless fine metal fine particles and metal nano fine particles are dispersed in a solution, flying in the air according to the principle of ink jet, and being applied as droplets on the substrate. However, in order to produce an electron source substrate with high accuracy and high quality, a fine dot pattern can be formed by spraying and applying a solution containing a metal fine particle material onto the substrate. It is necessary to optimize the surface roughness of the substrate and the size of the metal fine particles during the process.

  For example, the surface roughness of the substrate is the unevenness of the surface, but as shown in FIG. 11, the particles 6 having a size that protrudes from the unevenness of the surface 1 ′ of the substrate 1 are the surface 1 ′ of the substrate 1. If it adheres, a good dot pattern will not be obtained. On the other hand, as shown in FIG. 12, if the particle size is 7 or less, the dot pattern will be good. In the present invention, in view of this point, the dot pattern 42 is formed on the substrate 1 whose surface roughness is known in advance by a solution containing metal fine particles having different sizes, and the quality of the formed pattern is evaluated. .

  In the experiment, Pyrex (registered trademark) glass was polished to have a surface roughness of 0.01 s to 0.02 s, and the above-described palladium fine particle-containing solution (here, the fine particle diameter was adjusted) on the polished substrate. A thermal jet method (bubble jet (registration)) using a film boiling bubble growth force that instantaneously generates the motive force of droplet ejection in a solution as shown in FIG. 6 is used (0.002 μm to 0.2 μm). (Trademark) method) is ejected in combination with a liquid ejecting head to form a pattern in which dots are connected, the smoothness of the pattern is observed under a microscope, and sensory evaluation is performed. X) was judged.

  Here, an ejection head having a structure in which a nozzle plate in which nozzle holes are separately drilled is provided on the surface of the nozzle 58 is used instead of the type in which the flow path becomes the nozzle 58 as shown in FIG. The nozzle is a round nozzle formed by Ni electroforming, the size is Φ15 μm, and the opening thickness is 13 μm.

  The number of nozzles is 64 and the arrangement density is 400 dpi. The heating element size is 10 μm × 40 μm, and its resistance value is 100Ω. The head drive voltage was 12 V, the pulse width was 3 μs, and the drive frequency was 14 kHz. The amount of one droplet ejected under this condition is about 3 pl.

  As shown in FIG. 10, the formed pattern is formed in a vertical line between ITO transparent electrodes 2 and 3 formed on a Pyrex (registered trademark) glass at intervals of 20 μm vertically, and dots of about Φ18 μm are approximately formed. Four of them were driven at an 8 μm pitch.

  In order to obtain a dot pitch of 8 μm, the ejection head and the substrate are moved relative to each other (here, the substrate is fixed and the ejection head is scanned with the carriage), the position is controlled in μ order, and the ejection timing is controlled. As described above, dots were deposited at a pitch of about 8 μm. In addition, a similar pattern connecting adjacent ITO transparent electrodes 2 and 3 and ITO transparent electrodes 2 and 3 is formed with a center-to-center distance of 25 μm.

  Under such conditions, the above-mentioned pattern (FIG. 10) is formed on the glass substrate, and after the formation, pattern evaluation is performed. Under the same conditions, a separate injection experiment is performed, and a solution 3 mm ahead from the discharge port. The injection situation of was observed. This is because the test pattern of FIG. 10 was manufactured with a distance between the substrate and the discharge port of 3 mm. As shown in FIG. 7, the flight form was a columnar shape (l = 5d to 20d) that was very elongated in the flight direction. Moreover, it was in a state with a plurality of minute droplets behind the flying droplets.

  As described above, palladium fine particle-containing solutions having different particle diameters ranging from 0.002 μm to 0.2 μm were prepared and used (solution No. is common), but the particle diameter was 0.02 μm or more. In this case, nozzle clogging started to occur, and therefore, evaluation was performed by selecting only those patterns that were not clogged and that were well formed, among the formed patterns. The results are shown below.

  From the above results, the metal fine particles contained in the solution can form a smooth, good and highly accurate dot pattern by making the size of the surface roughness of the surface on which the pattern of the substrate is formed, and good electrons. It can be seen that an emission element can be formed. On the other hand, when the size of the fine particles is larger than that, the smoothness of the dot pattern shape is impaired, and it can be seen that a good electron-emitting device cannot be obtained.

In other words, in order to perform smooth and good pattern formation and obtain a good electron-emitting device, the surface roughness of the surface on which the substrate pattern is formed should be made rougher than the size of the metal fine particles contained in the solution. Although it is good, although the metal fine particles used in the present invention are very fine nano-particles, the surface roughness of the substrate is visually specular, and the substrate is highly accurate. Need to be polished. Alternatively, when a substrate having a thin film such as SiO ₂ formed on the surface of the substrate is used, a smooth SiO ₂ surface can be obtained even when the thin film is formed (eg, formed by sputtering). It is necessary to perform film formation carefully over time. That is, the substrate manufacturing cost is high.

  By the way, considering that the electron source substrate of the present invention has a structure in which a pattern is formed on one surface of the substrate, it can be understood that only a substrate on which a pattern is formed needs to be a smooth surface. . That is, it is sufficient that only the surface of the substrate (surface on which the pattern is formed) has the surface roughness as described above and the back surface is rougher than that.

  In other words, in the present invention, an electron source substrate on which a high-precision electron-emitting device is formed can be obtained by using a substrate whose surface roughness on the back surface is rougher than the surface on which the pattern of the substrate is formed. This means that the substrate manufacturing cost can be reduced. For example, the back surface roughness is made an order of magnitude larger than the front surface (surface on which the pattern is formed) (for example, when the front surface is set to 0.01 s to 0.02 s, the back surface is set to 0.1 s to 0.2 s. The cost of manufacturing the board is greatly reduced. Furthermore, if the surface is roughened more than that, the cost will be practically sufficient to make the front surface almost good, and the manufacturing cost can be reduced to nearly half that of a substrate polished on both sides. However, although it is the upper limit of the back surface roughness, it does not mean that it can be any amount, and it is necessary to maintain a certain level of quality as an industrial product.

  Next, still another feature of the present invention will be described. As described above, in the present invention, a metal fine particle material-containing solution in which metal fine particles are dispersed in a solution is made to fly in the air on the principle of ink jet and applied onto a substrate to form a pattern, thereby producing an electron-emitting device. However, the thickness of the pattern of the electron emission part formed by the solid content remaining after the volatile components in the droplet pattern formed by solution jetting, application of droplets or solution after volatilization remains high quality. It is important to obtain a simple electron-emitting device. For example, the substrate on which the electron-emitting device is formed has a certain surface roughness, but in order to obtain a good electron-emitting device, the relationship between the thickness of the pattern and the surface roughness, that is, the unevenness of the surface is determined. It is necessary to choose appropriately. The examination results are shown below.

  In the experiment, a Pyrex (registered trademark) glass substrate having a different surface roughness was prepared, and a solution containing palladium fine particles was combined with the above-described H3 jet head (nozzle diameter Φ15 μm) on a pair of device electrodes formed thereon. To form a pattern in which dots are joined together, and a device is formed by performing a forming process to be described later, and whether or not it actually functions well (good electron emission can be obtained ... Not obtained ... x) was evaluated.

  In addition, in order to change the pattern film thickness, the solution has the above-mentioned No. No. 6 solution (palladium fine particle diameter Dp = 0.006 μm) was diluted 2 to 50 times with pure water and used. As a result, it was possible to form electron-emitting devices having different pattern film thicknesses after a pattern was formed by spraying and application, and after drying and solid content remained.

Details of the experimental conditions are shown below. The pattern is one row in the vertical direction, and four dots of about Φ18 μm are implanted at a pitch of about 8 μm.
The ejection head and the substrate move relative to each other (here, the substrate is fixed and the ejection head is scanned by carriage), the control is controlled in μ order, and the timing of ejection is controlled. Went.
The nozzle size of the used ejection head is Φ15 μm, the plate thickness of the opening is 13 μm, the number of nozzles is 64, and the arrangement density is 400 dpi. The heating element size is 10 μm × 40 μm, and its resistance value is 100Ω. The head drive voltage was 12 V, the pulse width was 3 μs, and the drive frequency was 14 kHz. The amount of one droplet ejected under this condition is about 3 pl. The results are shown below.

  From the above results, the electron-emitting device formed according to the principle of the present invention has a good electron-emitting device by making the thickness of the pattern of the electron-emitting portion more than the surface roughness of the substrate. It can be seen that

  By the way, when an electron-emitting device is formed by combining such round dot patterns, in order to function as a good electron-emitting device, not only a good round dot pattern but also a pattern formed by combining them has its shape. Need to be good.

  This will be described with reference to FIG. FIG. 13 shows a case where a solution in which metal fine particles are dispersed is sprayed between two ITO transparent electrodes 2 and 3 formed on a substrate to form a round dot pattern 42, It is a schematic diagram in the case of forming. In the figure, Ld is a dot diameter when a dot is formed alone on the substrate, and Pd is a center-to-center distance (dot pitch) between adjacent dots.

  FIG. 13A shows a case where three dots 42 are formed between the two ITO transparent electrodes 2 and 3, but the formation (driving) density is too high, and the two ITO transparent electrodes 2 and 3 are electrically connected. (Pd> Ld). In this case, of course, it does not function as a good element. FIG. 13B shows an example in which each dot 42 is barely electrically connected at the periphery (Pd = Ld). FIG. 13C is an example in which the dots overlap each other and are electrically connected to each other in the peripheral portion (Pd <Ld), compared to the case of FIG. 13B. FIGS. 13D and 13E show a case where the overlapping region is large.

  Here, from the viewpoint of whether or not electrical connection can be obtained, FIG. 13A is out of the question, and in the case of FIG. 13B to FIG. However, in the case of FIGS. 13B and 13C, when viewed as one line pattern formed by combining round dots in a horizontal row, the line pattern width between adjacent dots (the area where dots overlap) (Vertical width in the figure) is narrowed, and the risk of disconnection is very high. For example, as shown in FIG. 13B, when each dot is barely connected at the peripheral portion, it is connected for the time being, but it is disconnected at the same time as the electric signal is input and is not usable at all. In the case of FIG. 13C, for the same reason, even if it can be used at the beginning of use, it cannot withstand long-term use.

  In the present invention, in order to solve this, one or more dots are surely overlapped between such adjacent dots. Even in the case where each dot 42 is barely connected at the periphery as in the case of FIG. 13B, if one dot is formed in the center between adjacent dots, the dot is When there is no line, one dot is overlapped on the area where the line pattern width is the minimum value, so the line pattern width of that area is the maximum value, that is, the width (Ld) for one dot.

  In this way, the condition for forming one dot overlapped at the center between adjacent dots is expressed in another way. If the dot diameter is Ld when the dot is formed alone, it is driven at a density of Ld / 2 or less. It is to form with.

  In addition, in this way, not only can a line pattern excellent in long-term reliability with no disconnection be formed, but also the contour of the line pattern becomes smooth with little unevenness. This is because, as shown in FIGS. 13B and 13C, only round dots are driven at a density at which electrical connection can be obtained, and there are no dots to fill between adjacent dots. 13 (D) and (E), in addition to the density at which electrical connection has already been obtained, it is obvious when comparing the case where one or more dots for filling the gap between adjacent dots are provided. is there. In the latter case, the outline of the line pattern is smoother with less unevenness, and an excellent electron-emitting device with less variation can be obtained.

As shown in FIG. 13, the present invention is applied to a case where the final line pattern of the electron-emitting device is formed by arranging droplet dots in one row.
For example, a line pattern as shown in FIG. 14 is also formed by the manufacturing apparatus of the present invention. In this case, a relatively thick line width is obtained by arranging three dots arranged in a line in the horizontal direction. In this example, a thick line pattern is obtained by arranging three lines in the arrangement example of FIG. That is, this is an example in which disconnection occurs with only one.

  However, since there are three (two may be provided) in this way, it functions well without disconnection. Therefore, in the case where a plurality of dots (three in this example) are arranged in this way, the dots for filling the space between the adjacent dots are merely formed by round dots having a density at which electrical connection can be obtained. Even if there is no, there is no risk of disconnection because a plurality of lines are arranged in the vertical direction (line pattern width direction).

  That is, as in the present invention, the condition that one or more dots for filling the space between adjacent dots are provided in an overlapping manner is that droplets or solution dots are arranged in one row in order to form a finer electron-emitting device. This is a condition that must be applied when forming an array.

  In addition, although two electrodes are experimented and demonstrated in the example of an ITO transparent electrode, it is not necessarily limited to ITO, Materials, such as Al, Au, Cu, can also be used conveniently.

  Next, still another feature of the present invention will be described. The present invention is a technique for manufacturing an electron-emitting device. In the electron-emitting device portion to be formed, a solution containing a metal fine particle material is usually sprayed onto a pair of electrode patterns previously formed on a substrate. A round dot pattern is formed to form an electron-emitting device. What is important here is the quality when the metal fine particle material-containing solution is newly sprayed on the previously formed pattern and the pattern is electrically connected to the previous electrode pattern. This will be described with reference to FIG.

  FIG. 15 is a diagram illustrating a method of injecting a metal fine particle material-containing solution between two ITO transparent electrodes 2 and 3 formed on a substrate to form a round dot pattern 42 to form an electron-emitting device. It is a schematic diagram in the case. In the figure, Ld is the dot diameter when dots are formed independently on the substrate.

  FIG. 15A shows a case where a dot pattern is formed by spraying a metal fine particle material-containing solution between two ITO transparent electrodes, but between the two ITO transparent electrodes 2 and 3 at the left and right ends of the dot pattern. This is an example of being barely electrically connected. FIG. 15B is an example in which the dots overlap each other and are electrically connected to each other in the peripheral portion, as compared with the case of FIG. 15A, and the length of the overlapping region is represented by Lc. FIGS. 15C and 15D show a case where the overlapping region Lc is large.

  Here, from the point of view of whether or not electrical connection can be obtained, all of the cases shown in FIGS. 15A to 15D are connected. However, in the case of FIGS. 15A and 15B, although they are connected, they are disconnected simultaneously with the input of the electric signal. Or even if it does not break immediately, the contact resistance of the connection part is too high and abnormal heat is generated, and there is a long-term reliability due to it, and there is a problem that it will eventually break, and it demonstrates its original performance Can not.

  In order to solve this problem in the present invention, when a dot pattern is formed by ejecting the metal fine particle material-containing solution later on the pattern previously formed on the substrate in such a connection region. As shown in 15 (C) and 15 (D), the dot at the end is driven and formed so as to cover half or more of one dot on the previously formed pattern. In other words, when the dot diameter when the dot 42 is formed independently is Ld, the size of the injection port is such that the relationship between Ld and Lc is satisfied so that Ld / 2 ≦ Lc. (Solution injection amount) and driving method.

  Another example will be described. In the example of FIGS. 16 and 17, the pair of electrodes 2 and 3 and the electron emission portions between these electrodes 2 and 3 are not arranged in a straight line as shown in FIG. Although the example of the pattern arrangement is orthogonal, it is not necessarily limited to such a pattern arrangement, and needless to say, the configuration shown in FIG. 15 may be used.

  FIG. 16 shows two ITO transparent electrode patterns formed on the substrate. This pattern was formed by a so-called photolithography technique called sputtering and etching. As shown in FIG. 17, a dot pattern is formed by using a jetting head in which a palladium fine particle-containing solution can obtain a dot diameter of about Φ12 μm, and shifting the center-to-center distance (dot pitch) by about 3 μm. 42 was formed. In this case, the distance of the overlapping region with the ITO transparent electrode pattern was set to about 13 μm (Lcx) and 8 μm (Lcy), and the connection was made by overlapping more than half of one dot diameter. As a result, a stable pattern is obtained without disconnection over a long period of time.

  FIG. 18 shows another example. In this case, the previously formed element electrode patterns 2 and 3 are also formed by the dot pattern 42 by the metal fine particle material-containing solution injection of the present invention. In this case, Ag was used as the metal fine particles. Also in this case, as shown in FIG. 19, overlapping regions (Lcx, Lcy) of dot patterns to be formed later are connected so as to overlap more than half the dot diameter of the dots.

  Although this example shows an example in which the previous dot pattern 42 and the subsequent dot pattern 42 have the same dot diameter, these patterns may have different dot diameters as necessary. In particular, when forming a pattern with a large area ahead due to the device configuration rather than a thin wiring line, it is more efficient to obtain a large dot diameter by an ejection head having a large nozzle diameter.

  Here, the two element electrodes have been experimentally described with an example of an ITO transparent electrode, but are not necessarily limited to ITO, and materials such as Al, Au, and Cu can also be suitably used. Then, an element electrode pattern may be formed by thin film formation, etching, or the like using these materials. As shown in the above example 1, a metal fine particle material-containing solution in which fine particles of these metals are dispersed is sprayed. A device electrode pattern may be formed.

  Next, still another feature of the present invention will be described with reference to FIGS. FIG. 20 is an enlarged view of FIG. 2B described above. FIG. 21 shows each region of the pattern of the conductive thin film 4 in order to explain the characteristics of the present invention.

  In the present invention, the conductive thin film 4 is formed by injecting a metal fine particle material-containing solution between the device electrodes 2 and 3 to form a dot pattern and then drying it. At that time, the problem is the step coverage of the conductive thin film 4 at the edge portion of the pattern of the element electrodes 2 and 3 formed previously.

  As shown in FIG. 21A, since there is a step in the pattern of the element electrode 3 formed in the part A, a solution in which metal fine particles are dispersed is sprayed later to form a conductive thin film. When 4 is formed, there is a problem that a good coating cannot be obtained at the edge portion. For this reason, disconnection may occur in the portion, impairing the durability of the electron-emitting device, resulting in low reliability and difficulty in practical use.

  In the present invention, in view of this point, the conductive thin film 4 formed by spraying a solution in which metal fine particles are dispersed in this region, that is, the pattern edge portion of the element electrode previously formed on the substrate. The ejection head is subjected to ejection control so that the thickness is formed to be thicker than other regions (B portion in FIG. 21B) that are not edge portions.

  Specifically, in the case where the solution is ejected to the area A, in the ejection head applied to the present invention, the input energy to the piezo element or the heating element is increased and the area B is ejected. By increasing the size of the droplet or the mass of the flying liquid, the film thickness formed there (region A) can be increased.

  More specifically, the thickness of the element electrode pattern is set to, for example, 300 mm, the metal fine particle material-containing solution is sprayed to form the conductive thin film 4, the volatile components in the solution are dried, and after drying in the region B If the final thickness of the nozzle is 200 mm, the step A has good step coverage by controlling the ejection head so that the thickness of the area A is 300 mm to 500 mm. Therefore, a highly reliable electron-emitting device can be obtained.

  Other solutions include, for example, a case where dots are formed by spraying a solution to the region A and a case where dots are formed by spraying a solution to the region B to form dots. Change the number of times. That is, after the electron-emitting device of the present invention is formed as shown in FIG. 15D, the dots are once again or twice or three times in the region B where step coverage is a problem. Good. In other words, the ejection control may be performed so that the device electrode is electrically connected to the device electrode previously formed on the substrate, and the dots are driven multiple times (two times or more) at the edge portion of the device electrode in the connection region.

  Here are some more specific examples. The prototype is the pattern shown in FIG. The thickness of the ITO element electrode pattern is 250 mm. Using a jet head in which a dot diameter of about φ12 μm is obtained from a solution containing palladium fine particles, a dot pattern is formed with an array pitch of 8 μm, and the edge portion of the device electrode in the connection region (refer to FIG. 21B) The same dot pattern was overprinted only once for part B). After drying, the thickness of the portion A in FIG. 21A is 300 mm, the thickness of B in FIG. 21B is 200 mm, and the edge of the device electrode in the connection region is thick. Thus, good tip coverage was obtained, and there was no disconnection or the like even after long-term use, and a highly reliable electron-emitting device could be obtained.

  As is apparent from the above description, the present invention is a technique for manufacturing an electron-emitting device, but a very fine pattern of several tens of μm to several μm is not formed by a conventional photolithography technique, but conventionally. The electron-emitting device group is directly manufactured by a simple apparatus in which a metal fine particle material-containing solution is directly applied to a substrate by an injection head having no minute discharge port. Therefore, there is an advantage that an expensive manufacturing apparatus used in a so-called semiconductor manufacturing process is not required, and the manufacturing can be stably performed at a low cost.

  In this way, after forming a pattern of a surface conduction electron-emitting device group having a good shape, in the present invention, the electron-emitting portion 5 is formed by a forming process as described below (FIGS. 1 and 2). reference).

  The electron emission portion 5 is constituted by a high-resistance crack formed in a part of the conductive thin film 4, and depends on the film thickness, film quality, material, etc. of the conductive thin film 4, or forming process conditions. The inside of the electron emission part 5 may contain conductive fine particles having a particle size of 100 mm or less.

  As an example of the forming treatment method applied to the conductive thin film 4, a method by energization treatment will be described. When energization is performed between the device electrodes 2 and 3 using a power source (not shown), an electron emission portion 5 having a changed structure is formed in a portion of the conductive thin film 4. That is, according to the energization forming, a region having a structural change such as local destruction, deformation, or alteration is formed in the conductive thin film 4, and this site becomes the electron emission portion 5.

  FIG. 22 is a diagram showing an example of voltage waveforms of the energization forming process as described above applied to the present invention. The voltage waveform is particularly preferably a pulse waveform. When a voltage pulse having a constant pulse peak value is applied continuously (FIG. 22A), or when a voltage pulse is applied while increasing the pulse peak value (FIG. 22). (B)). First, the case where the pulse peak value is a constant voltage (FIG. 22A) will be described.

  In FIG. 22A, T1 and T2 are the pulse width and pulse interval of the voltage waveform, respectively, T1 is 1 μs to 10 ms, T2 is 10 μs to 100 ms, and the peak value of the triangular wave (peak voltage during energization forming) is surface conduction. It selects suitably according to the form of a type | mold electron-emitting element. Under such conditions, for example, a voltage is applied for several seconds to several tens of minutes. The pulse waveform is not limited to a triangular wave, and a desired waveform such as a rectangular wave may be used.

  T1 and T2 in FIG. 22 (B) indicate the pulse width and pulse interval of the voltage waveform, respectively, as shown in FIG. 22 (A), and the peak value of the triangular wave (peak voltage during energization forming) is, for example, It can be increased by about 0.1V step.

  The end of the energization forming process can be detected by applying a voltage that does not cause local destruction or deformation of the conductive thin film 4 during the pulse interval T2, and measuring the current. For example, the element current that flows when a voltage of about 0.1 V is applied is measured, the resistance value is obtained, and the energization forming is terminated when a resistance of 1 MΩ or more is indicated.

  It is desirable to perform a process called an activation process on the element that has completed energization forming. By applying the activation process, the device current If and the emission current Ie change remarkably. The activation step can be performed, for example, by repeating the application of pulses in the same manner as the energization forming in an atmosphere containing an organic substance gas. The above atmosphere can be formed using, for example, an organic gas remaining in the atmosphere when the inside of the vacuum container is discarded using an oil diffusion pump, a rotary pump, etc. It can also be obtained by introducing an appropriate organic substance gas into the evacuated vacuum. A preferable gas pressure of the organic material at this time is appropriately set according to the case because it varies depending on the application form, the shape of the vacuum container, the kind of the organic material, and the like.

Examples of the organic substances include alkanes, alkenes, alkyne aliphatic hydrocarbons, aromatic hydrocarbons, alcohols, aldehydes, ketones, amines, organic acids such as phenol, carboxylic acid, and sulfonic acid. Specific examples include saturated hydrocarbons represented by CnH ₂ n + 2 such as methane, ethane, and propane, unsaturated hydrocarbons represented by a composition formula such as CnH ₂ n such as ethylene and propylene, benzene, and toluene. Methanol, formaldehyde, acetaldehyde, acetone, methyl ethyl ketone, methylamine, ethylamine, phenol, formic acid, acetic acid, propionic acid and the like can be used. By this treatment, carbon or a carbon compound is deposited on the element from an organic substance present in the atmosphere, and the element current If and the emission current Ie change remarkably. The end of the activation process is determined while measuring the device current If and the emission current Ie. The pulse width, pulse interval, pulse peak value, etc. are set as appropriate.

  Carbon or a carbon compound is graphite (refers to both single crystal and polycrystal) and amorphous carbon (amorphous carbon and carbon including a mixture of amorphous carbon and microcrystalline graphite). The film thickness is preferably 500 mm or less, more preferably 300 mm or less.

As described above, the prepared electron-emitting device is preferably subjected to stabilization treatment. This treatment is preferably performed at a partial pressure of the organic substance in the vacuum vessel of 1 × 10 ⁻⁸ Torr or less, preferably 1 × 10 ⁻¹⁰ Torr or less. The pressure in the vacuum vessel is preferably 10 ⁻⁶ to 10 ⁻⁷ Torr or less, and particularly preferably 1 × 10 ⁻⁸ Torr or less. As the vacuum exhaust device for exhausting the vacuum vessel, it is preferable to use a device that does not use oil so that the oil generated from the device does not affect the characteristics of the element. Specifically, a vacuum exhaust apparatus such as a sorption pump or an ion pump can be used. Furthermore, when evacuating the inside of the vacuum vessel, it is preferable to overheat the entire vacuum vessel so that organic substance molecules adsorbed on the inner wall of the vacuum vessel and the electron-emitting device can be easily evacuated. The evacuation condition in the heated state at this time is preferably 80 to 200 ° C. for 5 hours or longer, but is not particularly limited to this condition, and various conditions such as the size and shape of the vacuum vessel and the configuration of the electron-emitting device. It depends on.

  The partial pressure of the organic substance is determined by measuring partial pressures of organic molecules mainly composed of carbon and hydrogen having a mass number of 10 to 200 using a mass spectrometer and integrating the partial pressures. After the stabilization process, the driving atmosphere is preferably maintained at the end of the stabilization process, but is not limited to this, and the degree of vacuum itself is sufficient if the organic substance is sufficiently removed. Sufficiently stable characteristics can be maintained even with a slight decrease. By adopting such a vacuum atmosphere, deposition of new carbon or a carbon compound can be suppressed, and as a result, the device current If and the emission current Ie are stabilized.

  As described above, the electron-emitting device of the present invention is manufactured and formed, and then used as an image forming apparatus (display) as described later. However, there is one problem here.

  This is a problem during the above forming process or when used as a display, but is an abnormal discharge in the element electrode portion.

  This will be described with reference to FIG. In the present invention, as shown in FIG. 23, an electron emitting portion is formed by a dot pattern 42 of a metal fine particle material-containing solution between a plurality (two in this example) of device electrodes 2 and 3. The electrodes 2 and 3 are configured by a rectangular pattern or a combination of rectangular patterns. This is a rectangular shape depending on the shape of the photomask when such an element electrode pattern is formed by a photolithography technique (the rectangle is most easily manufactured in terms of cost). As shown in (A), the corner portions 2 'and 3' of the two opposing device electrodes are sharp, and electric field concentration occurs at those portions.

  As a result, it is applied between both electrodes by the forming process, or even when used as a display, but it is applied between both electrodes. There is a problem that the image quality of the display is deteriorated because the processing cannot be performed or abnormal electron emission occurs.

  In view of this point, in the present invention, for example, as shown in FIG. 23B, the corner portions of the plurality of element electrodes facing each other are chamfered shapes 2 ″ and 3 ″. In this example, c-shaped chamfering when displayed in a mechanical drawing is used, but it goes without saying that it may be r-shaped chamfering.

  Such a shape may be such that when the device electrode pattern is formed by photolithography, the shape of the photomask does not have such a sharp corner portion. Alternatively, as described with reference to FIG. 18, if the element electrode is formed by the dot pattern formed by the metal fine particle material-containing solution injection of the present invention, the outer shape of the dot pattern itself is round and there is no pointed portion. Therefore, it can be automatically chamfered.

  The size of the chamfered portion is about 1/2 to 1/5 of the diameter of the dot pattern forming the electron emitting portion, that is, c2 μm to c5 μm, or r2 μm to r5 μm. It can be set as a simple element electrode.

  In the present invention, by eliminating the sharp portion of the element electrode and eliminating the electric field concentration, there is no abnormal discharge even during forming processing or when used as a display as described later, Even when used for a long period of time, stable and good electron emission can be obtained, and furthermore, a high-quality image display can be realized.

  Next, another means for solving this problem will be described with reference to FIG. This is an example in which pattern formation control is performed so that corner portions of a plurality of element electrodes facing each other are covered with a dot pattern of a metal fine particle material-containing solution.

  FIG. 24A shows an example in which the dot pattern row is two vertically, and FIG. 24B shows an example in which one row is used, but it goes without saying. In short, if the sharp portions 2 'and 3' of the device electrode pattern are covered with the dot pattern of the metal fine particle material-containing solution and the portions are not exposed to the surface, abnormal discharge due to electric field concentration can be prevented, forming Even when used as a display as described later, there is no abnormal discharge, stable electron emission can be obtained even when used for a long time, and a display with high quality image quality. You will be able to do it.

  Next, still another feature of the present invention will be described with reference to FIG. As described above (FIGS. 3 and 4), in the present invention, the ejection head is ejected with the metal fine particle material-containing solution while moving relative to the substrate 14 to form an electron-emitting device group. FIG. 25 shows the device electrodes 2 and 3 formed on the electron source substrate 14 and the electron emission device 10 group formed by applying four solution dot patterns in the vertical direction (sub-scanning direction) between the device electrodes 2 and 3. Show.

  Here, the horizontal direction is defined as the main scanning direction, and the vertical direction is defined as the sub-scanning direction. Each electron-emitting device has a center-to-center distance (arrangement pitch) of each element, that is, an arrangement pitch in the main scanning direction and an arrangement pitch in the sub-scanning direction, respectively, when the electron source substrate of the present invention is used as a display as described later. It is an important factor that affects image quality.

  In the display using the electron-emitting device of the present invention, the phosphor is caused to emit light by electrons emitted from a crack portion formed somewhere between the device electrodes by the forming process as described above. Here, the crack portion can be formed somewhere between the device electrodes, but it cannot always be formed at a certain place. That is, the display to which the present invention is applied is a display having the character that the accuracy of the light-emitting pixel (picture element) varies at the maximum by the distance between the element electrodes (variation between elements). Therefore, for example, as shown in FIG. 26, it is also possible to arrange the elements between the elements more than in the case of FIG. 25 and to arrange both the arrangement pitch in the main scanning direction and the arrangement pitch in the sub scanning direction to be double that in FIG. However, since there is a variation of the light emitting portion (positional accuracy is maximum, and the distance between the element electrodes varies), this is not meaningful.

  That is, in the present invention, it does not make sense to set the distance between the centers (arrangement pitch) of each element to be equal to or less than the distance between the element electrodes. In other words, in the present invention, when the distance between the electrodes of each element is made smaller than the arrangement pitch of the electron-emitting devices, it is possible to obtain an effective and efficient display for the first time.

  As an example, for example, the distance between the electrodes (here, the distance between the electrodes is the distance s of the closest side of the opposing electrodes as shown in FIG. 25) is 15 μm, and the arrangement pitch Xp in the main scanning direction, The arrangement pitch Yp in the sub scanning direction is 30 μm. At this time, the electron emission portion is formed by three dot patterns (pattern diameter of about Φ15 μm). As the ejection head for forming such a pattern, the above-mentioned head H4 (ejection port diameter Do = Φ10 μm) can be used, and the ejection control is performed with a solution ejection drive voltage of 15 V and a drive pulse width of 2.5 μs. can get. As the solution to be used, the palladium fine particle-containing solution as described above is used. In addition, in order to perform element formation with high accuracy in such an arrangement pitch in the main scanning direction and an arrangement pitch in the sub-scanning direction, a highly accurate relative movement between the ejection head and the substrate is performed by the manufacturing apparatus shown in FIG. Can be realized.

  In another example, for example, the distance between the electrodes is 30 μm, and the arrangement pitch in the main scanning direction and the arrangement pitch in the sub-scanning direction are both 50 μm. At this time, the electron emission portion is formed by five dot patterns (pattern diameter of about Φ20 μm). As the ejection head for forming such a pattern, the above-described head H3 (ejection port diameter Do = Φ15 μm) can be used, and the ejection control is performed with the drive voltage for solution ejection being 13.5 V and the drive pulse width being 3 μs. can get. As the solution to be used, the palladium fine particle-containing solution as described above is used. In addition, in order to perform element formation with high accuracy in such an arrangement pitch in the main scanning direction and an arrangement pitch in the sub-scanning direction, a highly accurate relative movement between the ejection head and the substrate is performed by the manufacturing apparatus shown in FIG. Can be realized.

  The above example is an example of a thermal jet (Bubble Jet (registered trademark)) type jet head, but a piezoelectric jet type using a piezoelectric element, a type using an electrostatic force, a charge control type (continuous flow type), etc. It goes without saying that can be used.

  Next, the image forming apparatus of the present invention will be described. Various arrangements of the electron-emitting devices of the electron source substrate used in the image forming apparatus can be adopted. First, each of a large number of electron-emitting devices arranged in parallel is connected at both ends, and a plurality of rows of electron-emitting devices are arranged (referred to as the row direction), and electrons are perpendicular to the wiring (referred to as the column direction). There is a ladder-type arrangement in which electrons from the electron-emitting device are controlled and driven by a control electrode (also referred to as a grid) arranged above the emitting device. Separately, a plurality of electron-emitting devices are arranged in a matrix in the X and Y directions, and one of the electrodes of the plurality of electron-emitting devices arranged in the same row is connected in common to the wiring in the X direction, Examples include one in which the other of the electrodes of the plurality of electron-emitting devices arranged in the same column is commonly connected to the Y-direction wiring. Such is a so-called simple matrix arrangement.

  Next, an image forming apparatus using an electron source having a simple matrix arrangement will be described. FIG. 27 is a diagram for explaining an example of the basic configuration of the display panel of the image forming apparatus. In FIG. 27, reference numeral 71 denotes an electron source substrate in which the electron-emitting device 74 is formed on the substrate, and 81 denotes the electron source substrate 71 fixed. A rear plate 82 is a support frame, and 86 is a face plate 86 in which a fluorescent film 84 and a metal back 85 are formed on the inner surface of a glass substrate 83. Frit glass or the like is applied to the rear plate 81, the support frame 82, and the face plate 86. The envelope 88 is sealed by baking at 400 to 500 degrees in air or nitrogen for 10 minutes or more.

Although the envelope 88 is constituted by the face plate 86, the support frame 82, and the rear plate 81 as described above, the rear plate 81 is provided mainly for the purpose of reinforcing the strength of the electron source substrate 71. If the substrate itself has sufficient strength, the separate rear plate 81 is not necessary, and the support frame 82 is sealed directly on the electron source substrate 71, and the face plate 86, the support frame 82, and the electron source substrate 71 are attached outside. The envelope 88 may be configured. Furthermore, by providing an atmospheric pressure-resistant support member called a spacer between the face plate 86 and the rear plate 81, an envelope 88 having sufficient strength against atmospheric pressure can be configured.
In any case, such a face plate is laminated and integrated with the electron source substrate to constitute an image forming apparatus (image display apparatus), and therefore has substantially the same shape and size as the electron source substrate.

  28 is a schematic diagram showing a configuration example of the fluorescent film 84 used in the image forming apparatus of FIG. 27. FIG. 28A shows a black stripe type fluorescent film, and FIG. 28B shows a black matrix type fluorescent film. ). In FIG. 28, 91 is a black conductive material, and 92 is a phosphor.

  In the case of a monochrome film, the fluorescent film 84 is composed of only a phosphor. In the case of a color fluorescent film, the phosphor film 84 is composed of a black conductive material 91 called a black stripe or a black matrix and a phosphor 92 depending on the arrangement of the phosphors. . The purpose of providing the black stripe and the black matrix is to make the mixed colors and the like inconspicuous by making the coloration portions between the phosphors 92 of the necessary three primary color phosphors black in the case of color display, It is to suppress a decrease in contrast due to light reflection. The material of the black stripe is not limited to the material that is not only a material mainly composed of graphite, which is usually used well, but also a material that is conductive and has little light transmission and reflection.

  In the present invention, the stripe direction of the matrix-formed phosphor 92 as described above, or the two directions orthogonal to each other of the matrix and the two directions orthogonal to each other of the electron-emitting device 74 are parallel to each other. In addition, the electron-emitting devices 74 are positioned and laminated so that the phosphors 92 coincide with each other to constitute an image display device. Since the image display apparatus having such a configuration matches the directions and positions of the matrixes, a very high-quality image display apparatus can be realized.

  As a method of applying the phosphor on the glass substrate 83, a precipitation method or a printing method is used regardless of monochrome or color. A metal back 85 is usually provided on the inner surface side of the fluorescent film 84 (FIG. 27). The metal back 85 improves the luminance by specularly reflecting the light emitted from the phosphor toward the inner surface to the face plate 86 side, acts as an electrode for applying an electron beam acceleration voltage, It has a role of protecting the phosphor from damage caused by collision of negative ions generated in the vessel. The metal back 85 can be manufactured by preparing the fluorescent film 84, performing a smoothing process (usually called filming) on the inner surface of the fluorescent film 84, and then depositing Al by vacuum evaporation or the like. Further, the face plate 86 may be provided with a transparent electrode (not shown) on the outer surface side of the fluorescent film 84 in order to further increase the conductivity of the fluorescent film 84.

  When sealing for producing the envelope 88 described above, in the case of color, each color phosphor 92 and the electron-emitting device 74 must correspond to each other, and sufficient alignment is required. In order to perform this sufficient alignment, in the present invention, as described above, the phosphor 92 is disposed at a position facing the electron-emitting device 74 and the matrixes of the electron-emitting device 74 and the phosphor 92 are orthogonal to each other. The two directions are parallel to each other. In order to obtain a highly accurate image display device having such a configuration, it is desirable that the phosphor substrate also adopts the same positioning method as the electron source substrate of the present invention.

Specifically, the image forming apparatus shown in FIG. 27 is manufactured as follows. The envelope 88 is exhausted through an exhaust pipe (not shown) by an exhaust device that does not use oil, such as an ion pump or a sorption pump, while being appropriately heated, as in the stabilization step described above, and a vacuum degree of about 10 ⁻⁷ Torr. After the atmosphere is sufficiently reduced, it is sealed. In some cases, a getter process is performed to maintain the degree of vacuum after the envelope 88 is sealed. This is because vapor deposition is performed by heating a getter disposed at a predetermined position (not shown) in the envelope 88 by a heating method such as resistance heating or high-frequency heating immediately before or after sealing the envelope 88. This is a process for forming a film. The getter usually has Ba or the like as a main component, and maintains a vacuum degree of, for example, 1 × 10 ⁻⁵ Torr to 1 × 10 ⁻⁷ Torr by the adsorption action of the deposited film.

1 is a schematic diagram showing a configuration of a planar surface conduction electron-emitting device according to an embodiment of the present invention. It is a schematic diagram for demonstrating the manufacturing method of the surface conduction electron-emitting device shown in FIG. It is a block diagram which shows an example of the manufacturing apparatus of the electron source board | substrate which concerns on this invention. It is a figure for demonstrating an example of a structure of the droplet application apparatus which can apply this invention. FIG. 5 is a schematic configuration diagram of a main part of a discharge head unit of the droplet applying device of FIG. 4. It is a figure which shows one example of the ejection head used for the manufacturing apparatus of the surface conduction type electron-emitting device according to the present invention. It is a figure for demonstrating the example of the solution flight shape in the case of the thermal jet system sprayed with the action force by a film | membrane boiling bubble with the injection head used for the electron source substrate manufacturing apparatus of this invention. It is a figure for demonstrating the example of the droplet flying shape in the case of the piezo jet system which ejects with the action force by mechanical displacement with the ejection head used for the electron source substrate manufacturing apparatus of this invention. It is a figure for demonstrating the example of the other droplet flight shape in the case of the piezo jet system which ejects with the action force by mechanical displacement with the ejection head used for the electron source substrate manufacturing apparatus of this invention. It is a figure which shows the example of the test pattern used in order to find the conditions which perform favorable pattern formation with the electron source substrate manufacturing apparatus of this invention. It is the figure which showed typically the relationship between a metal microparticle and surface roughness at the time of forming a dot pattern with the solution containing the metal microparticle larger than the surface roughness of a board | substrate. It is the figure which showed typically the relationship between a metal microparticle and surface roughness at the time of forming a dot pattern with the solution containing the metal microparticle of the magnitude | size below the surface roughness of a board | substrate. It is a figure for demonstrating the example which arranges the dot of a droplet or a solution in 1 row, and forms a fine electron emission element pattern. It is a figure for demonstrating the example which forms the thick electron-emitting element pattern by arranging the dot row of a droplet or a solution in multiple rows. It is a figure for demonstrating the connection method in the case of forming the electron-emitting device pattern by arranging the dot of a droplet. It is a figure which shows the two ITO transparent electrode patterns currently formed on the board | substrate. It is a figure for demonstrating the specific example which arranges the dot of a droplet and forms an electron-emitting device pattern. It is a figure which shows the dot pattern formed previously on the board | substrate. It is a figure for demonstrating the specific example which forms the electron emission element pattern by arranging the dot of a droplet in the dot pattern formed previously on the board | substrate. 1 is a cross-sectional view showing a configuration of a planar surface conduction electron-emitting device according to an embodiment of the present invention. It is sectional drawing for demonstrating changing the film thickness of the electron emission element pattern in an electron emission part and an electrode element part. It is a figure which shows the example of the voltage waveform in the energization forming process employable for manufacture of the surface conduction electron-emitting device by this invention. It is a figure explaining the example which applied the present invention and eliminated electric field concentration. It is a figure explaining the other example which applied this invention and eliminated electric field concentration. It is a figure explaining the definition of the main scanning direction of a carriage at the time of droplet ejection at the time of forming a plane type surface conduction type electron-emitting device group concerning one embodiment of the present invention, a sub-scanning direction, and each size. It is a figure explaining that even if it arranges a planar type surface conduction type electron-emitting device group in higher density, it will be wasted. It is a figure for demonstrating an example of the basic composition of the display panel of the image forming apparatus by the matrix arrangement | positioning type electron source board | substrate which can apply this invention. It is a schematic diagram which shows the structural example of the fluorescent film used for the image forming apparatus which can apply this invention. It is a figure which shows an example of the conventional electron emission element.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Board | substrate, 2, 3 ... Element electrode, 4 ... Conductive thin film, 5 ... Electron emission part, 6 ... Metal particle (large), 7 ... Metal particle (small), 10 ... Electron emission element, 11 ... Discharge head unit (Jet head), 12 ... carriage, 13 ... substrate holder, 14 ... substrate, 15 ... supply tube, 16 ... signal supply cable, 17 ... jet head control box, 18 ... X-direction scan motor of carriage 12, 19 ... carriage 12 Y-direction scan motors, 20... Computer, 21... Control box, 22 (22X ₁ , 22Y ₁ , 22X ₂ , 22Y ₂ ) ... Substrate positioning / holding means, 30 ... Discharge head unit, 31 ... Head alignment control mechanism, 32 ... Detection optical system, 33 ... Inkjet head, 34 ... Head alignment fine movement mechanism, 35 ... Control computer, 36 Image identification mechanism, 37 ... XY direction scanning mechanism, 38 ... position detection mechanism, 39 ... position correction control mechanism, 40 ... inkjet head drive / control mechanism, 41 ... optical axis, 42 ... droplet, 43 ... droplet landing position, 44 ... dots, 50 ... jetting head (inkjet head), 51 ... heating element substrate, 52 ... lid substrate, 53 ... silicon substrate used for producing the heating element substrate, 54 ... individual electrode, 55 ... common electrode, 56 ... heating element 57 ... Solution inlet, 58 ... Nozzle, 59 ... Groove, 60 ... Recessed region, 71 ... Electron source substrate, 74 ... Electron emitter, 81 ... Rear plate, 82 ... Support frame, 83 ... Glass substrate, 84 ... Fluorescence Membrane, 85 ... metal back, 86 ... face plate, 88 ... envelope, 91 ... black conductive material, 92 ... phosphor.

Claims (2)

  A liquid droplet containing a metal fine particle material is jetted and applied between a pair of electrodes on a substrate from a discharge port, a plurality of dots are connected so as to overlap, and a line pattern is formed. In the liquid ejecting apparatus containing fine metal particles, the volatile components in the line pattern are volatilized and the solid content remains on the substrate to make electrical connection between the electrodes. The fine metal particles in the liquid have a line pattern formed by the dots. In the case where the size of the surface to be formed is equal to or less than the surface roughness, the size of the metal fine particles is Dp, and the diameter of the discharge port is Do, the discharge port diameter Do is Φ10 μm to Φ25 μm. The upper limit of the size Dp of the metal fine particles is defined as Dp / Do ≦ 0.01 so that the discharge port is not clogged, and the metal fine particles are dispersed in a stable state. In addition, the lower limit value of the size Dp of the metal fine particles is set to 0.002 μm, and the injection control is performed so that the thickness of the line pattern by the dots is greater than the surface roughness. Liquid injection device.   A liquid containing metal fine particles is sprayed and applied between a pair of electrodes on the substrate by a liquid jetting device, a plurality of dots are connected so as to overlap, and a line pattern is formed. In the line pattern of dots produced by a metal fine particle-containing liquid ejecting apparatus that volatilizes volatile components and leaves solids on the substrate to make electrical connection between the electrodes, the metal fine particles are line patterns of the dots. A line pattern with dots having a size equal to or smaller than the surface roughness of the surface on which the thin film is formed, and a thickness of the thin film of the line pattern with the dots being equal to or greater than the surface roughness.