US 12,437,955 B2
Method of forming field emission cathodes by co-electrodeposition
Cheng Qian, Cary, NC (US)
Assigned to NCX Corporation, Raleigh, NC (US)
Appl. No. 18/247,298
Filed by NCX Corporation, Raleigh, NC (US)
PCT Filed Sep. 29, 2021, PCT No. PCT/IB2021/058949
§ 371(c)(1), (2) Date Mar. 30, 2023,
PCT Pub. No. WO2022/070103, PCT Pub. Date Apr. 7, 2022.
Claims priority of provisional application 63/085,542, filed on Sep. 30, 2020.
Prior Publication US 2023/0411104 A1, Dec. 21, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. H01J 9/02 (2006.01); H01J 1/304 (2006.01); C01B 32/174 (2017.01); C25D 13/02 (2006.01)
CPC H01J 9/025 (2013.01) [H01J 1/3048 (2013.01); C01B 32/174 (2017.08); C25D 13/02 (2013.01); H01J 2201/30469 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A method of forming a field emission cathode, comprising:
forming a field emission material, comprising:
mixing a plurality of carbon nanotubes and a poly (3,4-ethylendioxythiophene)-poly (styrene sulfonic acid) (PEDOT: PSS) solution in water at a ratio to form a base mixture;
exposing the base mixture to an ultrasonic dispersion process at a power of greater than 1 W/cm2 and at a frequency of about 20-50 kHz;
introducing at least one matrix particle, at least one metal salt, at least one charger, or a combination thereof to the base mixture to form a field emission material precursor, the at least one metal salt being different from the at least one charger; and
exposing the field emission material precursor to an ultrasonic dispersion process at a power of less than 1 W/cm2 and at a frequency of greater than 50 kHz to form the field emission material comprising a stable suspension of the field emission material precursor;
depositing a layer of the field emission material on to at least a portion of a substrate via a co-electrodeposition process;
drying the layer and the substrate at a temperature of about 20° C. to about 150° C. at atmosphere or under a vacuum;
annealing the layer and the substrate at a temperature of about 300° C. to about 1000° C. under a vacuum; and
activating the layer of the field emission material to obtain the field emission cathode.