Abstract: An anode plate 50 for use in a field emission flat panel display device comprises a transparent planar substrate 58 having a plurality of electrically conductive, parallel stripes 52 comprising the anode electrode of the device, which are covered by phosphors 54.sub.R, 54.sub.G and 54.sub.B. A substantially opaque, electrically insulating material 56 is affixed to substrate 58 in the spaces between conductors 52, acting as a barrier to the passage of ambient light into and out of the device. The electrical insulating quality of opaque material 56 increases the electrical isolation of conductive stripes 52 from one another, reducing the risk of breakdown due to increased leakage current. Opaque material 56 preferably comprises glass having impurities dispersed therein, wherein the impurities may include one or more organic dyes, selected to provide relatively uniform opacity over the visible range of the electromagnetic spectrum.

Abstract: A porous dielectric material such as silica-based aerogel is used as the dielectric layer 48 between the gate and the cathode on the emitter plate 12 of a field emission device. Aerogel, which can have a relative dielectric constant as low as 1.03, is deposited over the resistive layer 44 of the emitter plate 12. Metal layer 49, functioning as the gate electrode, is subsequently deposited over the aerogel layer 48. The use of aerogel as a gate dielectric reduces power consumption. In a disclosed embodiment, aerogel layer 48 is comprised of sublayers 48a, 48b, and 48c of aerogels of differing densities, thereby providing better adhesion of the aerogel gate dielectric to both the resistive layer 44 and metal layer 49. Methods of fabricating the aerogel gate dielectric are disclosed.

Abstract: The emitter plate 60 of a field emission flat panel display device includes a layer 68 of a resistive material and a mesh-like structure 62 of an electrically conductive material. A conductive plate 78 is also formed on top of resistive coating 68 within the spacing defined by the meshes of conductor 62. Microtip emitters 70, illustratively in the shape of cones, are formed on the upper surface of conductive plate 78. With this configuration, all of the microtip emitters 70 will be at an equal potential by virtue of their electrical connection to conductive plate 78. In one embodiment, a single conductive plate 82 is positioned within each mesh spacing of conductor 80; in another embodiment, four conductive plates 92 are symmetrically positioned within each mesh spacing of conductor 90.

Abstract: An anode plate 40 for use in a field emission flat panel display device comprises a transparent planar substrate 42 having a plurality of electrically conductive, parallel stripes 46 comprising the anode electrode of the device, which are covered by phosphors 48.sub.R, 48.sub.G and 48.sub.B, and a gettering material 52 in the interstices of the stripes 46. The gettering material 52 is preferably selected from among zirconium-vanadium-iron and barium. The getter 52 may be thermally reactivated by passing a current through it at selected times, or by electron bombardment from microtips on the emitter substrate. The getter 52 may be formed on a substantially opaque, electrically insulating material 50 affixed to substrate 42 in the spaces formed between conductors 46, which acts as a barrier to the passage of ambient light into and out of the device. Methods of fabricating the getter stripes 52 on the anode plate 40 are disclosed.

Abstract: The emitter plate 60 of a field emission flat panel display device includes a layer 68 of a resistive material and a mesh-like structure 62 of an electrically conductive material. A conductive plate 78 is also formed on top of resistive coating 68 within the spacing defined by the meshes of conductor 62. Microtip emitters 70, illustratively in the shape of cones, are formed on the upper surface of conductive plate 78. With this configuration, all of the microtip emitters 70 will be at an equal potential by virtue of their electrical connection to conductive plate 78. In one embodiment, a single conductive plate 82 is positioned within each mesh spacing of conductor 80; in another embodiment, four conductive plates 92 are symmetrically positioned within each mesh spacing of conductor 90.

Abstract: An improved method of affixing spheres 4 to a foil matrix 2 is described herein. First, a cell sandwich 32 is prepared. This cell sandwich 32 includes spheres 4 mounted on a foil matrix 2 which are disposed between upper and lower pressure pads 34 and 36. The cell sandwich 32 is then heated (e.g., to about 530.degree. C.). The spheres 4 are then affixed to the foil matrix 2 by directing the cell sandwich 32 through a roll press 48 which compresses the heated cell sandwich 32.

Abstract: A grooved anode plate 40 for use in a field emission flat panel display device comprises a transparent planar substrate 42 having a plurality of electrically conductive, parallel stripes 46 comprising the anode electrode of the device, which are covered by phosphors 48.sub.R, 48.sub.G and 48.sub.B. In one embodiment, grooves 50, having generally straight sidewalls, are formed in the upper surface of planar substrate 42 at the interstices of conductors 46. In a second embodiment, grooves 50', which provide a substantial undercutting of the material of substrate 42' adjacent the edges of conductors 46', are formed in the upper surface of planar substrate 42' at the interstices of conductors 46'. A substantially opaque, electrically insulating material 52 is affixed to substrate 42 in the grooves 50 formed between conductors 46, acting as a barrier to the passage of ambient light into and out of the device.

Abstract: An improved method of affixing spheres 4 to a conductive foil sheet 28 is described herein. A cell matrix is provided. The cell matrix includes a conductive foil matrix 2 with spheres 4 mounted therein. Each of the spheres 4 has an insulating layer 20 disposed on it. A portion of this insulating layer 20 is removed from each of the spheres 4 to expose a portion 22 of the spheres 4. A cell sandwich 32 is then formed between an upper pressure pad 34 and a lower pressure pad 36. The cell sandwich 32 includes the cell matrix 2/4 and a conductive foil 28. The cell sandwich 32 is then heated (preferably to between about 350.degree. and 450.degree. C.). The spheres 4 are then affixed to the conductive foil 28 by compressing the cell sandwich 32. In one embodiment, the compression takes place in a roll press 48.

Abstract: An anode plate 40 for use in a field emission flat panel display device comprises a transparent planar substrate 42 having a plurality of electrically conductive, parallel stripes 46 comprising the anode electrode of the device, which are covered by phosphors 48.sub.R, 48.sub.G and 48.sub.B, and a gettering material 52 in the interstices of the stripes 46. The gettering material 52 is preferably selected from among zirconium-vanadium-iron and barium. The getter 52 may be thermally reactivated by passing a current through it at selected times, or by electron bombardment from microtips on the emitter substrate. The getter 52 may be formed on a substantially opaque, electrically insulating material 50 affixed to substrate 42 in the spaces formed between conductors 46, which acts as a barrier to the passage of ambient light into and out of the device. Methods of fabricating the getter stripes 52 on the anode plate 40 are disclosed.

Abstract: A spacer 40 for use in a field emission device includes a comb-like structure having a plurality of elongated filaments 42 joined to a support member 44. The filaments 42, which may be glass, are positioned longitudinally in a single layer between the facing surfaces of the anode structure 10 and the electron emitting: structure 12. Support member 44 is positioned entirely outside the active regions of anode structure 10 and emitting structure 12. Spacer 40 provides voltage isolation between the anode structure 10 and the cathode structure 12, and also provides standoff of the mechanical forces of vacuum within the assembly. In a second embodiment, spacer 50 includes elongated filaments 52 joined at each end to a support member 54 a and 54b, the additional support facilitating handling, fabrication and assembly.

Abstract: A cover (14) for an array (12) of foil matrix-mounted (18), spaced photovoltaic members (16) protects the array (12) from the environment and increases its efficiency. Upper portions (31) of the members (16) extend above the free reflective surface (20T) of the foil matrix (18). The cover (14)includes an environment-excluding coating (60) which is emplaced on the array (12) to conform to the upper portions (31). The coating is configured as cusps (68) which overlie the free surface (20T) of the matrix (18) centrally between adjacent members (16). The nadirs (72) of the cusps (68) are closely spaced from the free surface (20T). Accordingly, each member (16) effectively supports a conformal lens (70) which directs thereat much of the otherwise "wasted" light that would fall on the free foil surface (20T) between adjacent members (16) and would not fall on the members (16).

Abstract: Solar cells are formed of semi-conductor spheres of P-type interior having an N-type skin are pressed between a pair of aluminum foil members forming the electrical contacts to the P-type and N-type regions. The aluminum foils, which comprise 1.0% silicon by weight, are flexible and electrically insulated from one another. The spheres are patterned in a foil matrix forming a cell. Multiple cells can be interconnected to form a module of solar cell elements for converting sun light into electricity.

Abstract: A method of making single crystal semiconductor grade silicon spheres for solar cells and the like from metallurgical grade silicon. The process comprises sizing metallurgical grade silicon particles to a desired range and oxidizing the outer surfaces of the particles to form a silicon dioxide skin thereon. The particles are then heated to melt the silicon within the skin to cause impurities to travel into the skin. This is made possible because single crystals are formed. The skin and impurities therein are then etched off and the remaining particles are again treated to form a skin with subsequent melt of the interior silicon and removal of the skin, the cycle being repeated until the desired degree of silicon purity is obtained. An intermediate shotting step can yield spheres of substantially uniform diameter for use as the feed for the repeat cycle.

Abstract: A method and apparatus for forming silicon spheres (40) from irregular-shaped particles (38) for use in solar cells are disclosed. The apparatus (10) generally comprises a vertically aligned cylindrical chamber (12) having an abrasive lining (32) integrally formed therein. The abrasive lining (32) is preferably a silicon carbide material. A gas source (36) is tangentially injected into the chamber (12) to create an gas vortex inside the chamber (12). This vortex induces the repeated collision of the particles (38) against the abrasive lining (32) to eventually form the silicon spheres (40) and simultaneously sizing the silicon spheres (40).

Abstract: The disclosure relates to a solar array with interconnects wherein an array is formed by providing a pair of spaced flexible aluminum foil sheets which are electrically insulated from each other and wherein semiconductor spheres extend through one of the sheets and are electrically coupled to both sheets. A plurality of such arrays are formed in a strip and the individual arrays are separated by placing shims at the scribe locations and scribing thereover so that one of the sheets has an edge extending outwardly for connection to a sheet of another array. In this manner, large solar panels can be formed from a plurality of interconnected arrays in a reel-to-reel embodiment.

Abstract: The disclosures relates to a method of forming an array of small apertures in an aluminum foil for receiving semiconductor spheres in said aperature. The apertures are formed by embossing the foil at the locations of the apertures to provide worked metal regions of reduced thickness at said locations. The foil is then etched in toto, etching taking place more rapidly at the worked metal region. Also, due to the reduced thickness of the foil at the embossed regions, such regions are etched away to provide apertures before the remainder of the foil undergoes material metal loss to provide the desired aperture array.

Abstract: The disclosure relates to a method of forming adherent contacts to oxide coated semiconductor material wherein the oxide coating and a portion of the semiconductor material are mechanically removed, such as by abrading, to provide a roughened surface on the semiconductor material. The contact material is then applied over the mechanically roughened surface and bonded at elevated temperatures to provide the adherent contact.

Abstract: The disclosure relates to a method of bonding semiconductor material to aluminum foil to provide electrical connection therebetween wherein the foil and/or the semiconductor material may have an oxide coating thereon. The method comprises heating the foil to a temperature in the range of from about 500.degree. C. to about 577.degree. C. and then moving the semiconductor into said foil under impact to expose elemental aluminum and semiconductor material at the point of impact and form a bond therebetween at the point of impact.

Abstract: The disclosure relates to a method of making solar cell arrays and modules and the arrays and modules wherein the arrays are formed of semiconductor spheres of P-type interior having an N-type skin housed in a pair of aluminum foil members which form the contacts to the P-type and N-type regions. The foils are electrically insulated from each other and are flexible. Multiple arrays can be interconnected to form a module of solar cell elements for converting light energy into electrical energy.

Abstract: The disclosure relates to a method of making solar cell arrays and modules and the arrays and modules wherein the arrays are formed of semiconductor spheres of P-type interior having an N-type skin housed in a pair of aluminum foil members which form the contacts to the P-type and N-type regions. The foils are electrically insulated from each other and are flexible. Multiple arrays can be interconnected to form a module of solar cell elements for converting light energy into electrical energy.