Fiber containing carbon, substrate and electron emission device using fiber containing carbon, electron source using the electron emission device, display panel using the electron source, and information displaying/playing apparatus using the display panel, and a method of manufacturing thereof

• US 20050134161A1
• Filed: 12/06/2004
• Published: 06/23/2005
• Est. Priority Date: 12/18/2003
• Status: Active Grant

• Current Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Original Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Inventors: Tsukamoto, Takeo, Kitamura, Shin
• Granted Patent: US 7,528,538 B2
• Time in Patent Office: Days
• US Class Current: 313/309
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: D01F 9/127 by thermal decomposition of hydrocarbon gases or vapours or other carbon-containing compounds in the form of gas or vapour, e.g. carbon monoxide, alcohols
• CPC Class Codes: D01F 9/1271 Alkanes or cycloalkanes
• CPC Class Codes: D01F 9/1273 Alkenes, alkynes
• CPC Class Codes: D01F 9/1275 Acetylene
• CPC Class Codes: D01F 9/1278 Carbon monoxide
• CPC Class Codes: D01F 9/133 Apparatus therefor
• CPC Class Codes: H01J 1/3042 microengineered, e.g. Spindt-type
• CPC Class Codes: H01J 9/025 of field emission cathodes

Abstract

The invention provides a fiber containing carbon which is less deteriorated in terms of electron emission characteristic, is excellent in terms of reproducibility, and can in addition be formed at a low cost, a substrate and electron emission device using the fiber containing carbon, an electron source using the electron emission device, a display panel using the electron source, and an information displaying/playing apparatus using the display panel, and a method of manufacturing these. The manufacturing method comprises a first step of preparing a substrate (substrate 1) equipped with a catalyst (catalyst layer 3) on its surface; and a second step of causing the fiber containing carbon (carbon fiber 4) to grow using the catalyst, whereby the second step comprises, in order to decrease, from a midway point of time in this step, the growth rate at which the fiber containing carbon grows, a sub-step of controlling the growth conditions for the fiber containing carbon.

Claims

1. A method of manufacturing a fiber containing carbon, the method comprising:

a first step of preparing a substrate having a catalyst on its surface; and

a second step of growing a fiber containing carbon using the catalyst,

wherein the second step comprises a sub-step of controlling the growth condition of the fiber, in order to decrease a growth rate of the fiber.

15. A method of manufacturing an electron emission device having a fiber containing carbon, wherein

the fiber containing carbon is manufactured using the method of manufacturing as set forth in claim 1.

19. A method of manufacturing an electron source having multiple electron emission devices, wherein

the electron emission device is manufactured using the method of manufacturing as set forth in claim 15.

23. A method of manufacturing an image display apparatus having an electron source and a light-emitting member capable of emitting a light by the electrons emitted from the electron source, wherein

the electron source is manufactured using the method of manufacturing as set forth in claim 19.

27. A method of manufacturing an information displaying/playing apparatus comprising at least a receiver unit that outputs at least one of image information, character information, and sound information contained in a broadcasting signal that has been received, and an image display apparatus connected to the receiver unit, wherein

the image display apparatus is manufactured using the method of manufacturing as set forth in claim 23.

2. A method of manufacturing a fiber containing carbon, the method comprising:

a first step of preparing a substrate having a catalyst on its surface; and

a second step of growing a fiber containing carbon by heating the substrate in a carbon-containing atmosphere,

wherein the second step includes a sub-step for decreasing a growth rate of the fiber.

3. A method of manufacturing a fiber containing carbon according to claim 2, wherein

the sub-step comprises a first sub-step of heating the substrate in a carbon-containing atmosphere in which a partial pressure of a carbon-containing gas in the atmosphere is first partial pressure;

and

a second sub-step of heating the substrate, after the first sub-step, in a carbon-containing atmosphere in which a partial pressure of a carbon-containing gas in the atmosphere is second partial pressure, which is lower than the first partial pressure.

4. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the partial pressure of the carbon-containing gas is phased out from the first partial pressure to the second partial pressure.

5. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the partial pressure of the carbon-containing gas is continuously decreased from the first partial pressure to the second partial pressure.

6. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the second partial pressure is 20 Pa or less.

7. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the temperature for heating the substrate in the second sub-step is the same as the temperature for heating the substrate in the first sub-step.

8. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the temperature for heating the substrate in the second sub-step is ±

10% or less in terms of its temperature fluctuation as measured from the temperature for heating the substrate in the first sub-step.

9. A method of manufacturing a fiber containing carbon according to claim 2, wherein

between the first step and the second step, a step of heating the substrate in a reducing atmosphere is further comprised.

10. A method of manufacturing a fiber containing carbon according to claim 3, wherein

the second sub-step is the one wherein, in a state where the substrate is kept heated, the partial pressure of the carbon-containing gas is decreased from the same partial pressure as the first partial pressure or a partial pressure lower than that first partial pressure to a partial pressure under which the fiber is substantially not grown.

11. A method of manufacturing a fiber containing carbon according to claim 10, wherein

the partial pressure under which the fiber is substantially not grown is 0.0001 Pa or less.

16. A method of manufacturing an electron emission device having a fiber containing carbon, wherein

the fiber containing carbon is manufactured using the method of manufacturing as set forth in claim 2.

20. A method of manufacturing an electron source having multiple electron emission devices, wherein

the electron emission device is manufactured using the method of manufacturing as set forth in claim 16.

24. A method of manufacturing an image display apparatus having an electron source and a light-emitting member capable of emitting a light by the electrons emitted from the electron source, wherein

the electron source is manufactured using the method of manufacturing as set forth in claim 20.

28. A method of manufacturing an information displaying/playing apparatus comprising at least a receiver unit that outputs at least one of image information contained in a broadcasting signal that has been received, character information, and sound information, and an image display apparatus connected to the receiver unit, wherein

the image display apparatus is manufactured using the method of manufacturing as set forth in claim 24.

12. A method of manufacturing a fiber containing carbon, the method comprising:

(A) disposing within a chamber a substrate having multiple catalyst particles thereon;

(B) introducing a reducing gas within the chamber up to a desired partial pressure;

(C) commencing heating of the substrate and heating the substrate at a desired fixed value of temperature; and

(D) growing a fiber containing carbon to on the substrate, by introducing carbon-containing gas into the chamber while the temperature of the substrate is maintained at the desired temperature.

13. A method of manufacturing a fiber containing carbon according to claim 12, which further comprises:

(E) evacuating the carbon-containg gas from the chamber up to a partial pressure under which the fiber containing carbon is substantially not grown; and

(F) commencing lowering the temperature of the substrate, while a state where the partial pressure for the carbon-containg gas within the chamber is kept a partial pressure under which the fiber containing carbon is substantially not grown is maintained.

17. A method of manufacturing an electron emission device having a fiber containing carbon, wherein

the fiber containing carbon is manufactured using the method of manufacturing as set forth in claim 12.

21. A method of manufacturing an electron source having multiple electron emission devices, wherein

the electron emission device is manufactured using the method of manufacturing as set forth in claim 17.

25. A method of manufacturing an image display apparatus having an electron source and a light-emitting member capable of emitting a light by the electrons emitted from the electron source, wherein

the electron source is manufactured using the method of manufacturing as set forth in claim 21.

29. A method of manufacturing an information displaying/playing apparatus comprising at least a receiver unit that outputs at least one of image information contained in a broadcasting signal that has been received, character information, and sound information, and an image display apparatus connected to the receiver unit, wherein

the image display apparatus is manufactured using the method of manufacturing as set forth in claim 25.

14. A method of manufacturing a fiber containing carbon, the method comprising:

(A) disposing within a chamber a substrate having multiple catalyst particles thereon;

(B) growing a fiber containing carbon to on the substrate, by introducing carbon-containing gas into the chamber and heating the substrate up to a desired temperature;

(C) evacuating the carbon-containing gas from the chamber down to a partial pressure under which the fiber is substantially not grown, while the temperature of the substrate is maintained at the desired temperature; and

(D) commencing lowering the temperature of the substrate, while a state where the partial pressure for the carbon-containing gas within the chamber is kept a partial pressure under which the fiber is substantially not grown is maintained.

18. A method of manufacturing an electron emission device having a fiber containing carbon, wherein

the fiber containing carbon is manufactured using the method of manufacturing as set forth in claim 14.

22. A method of manufacturing an electron source having multiple electron emission devices, wherein

the electron emission device is manufactured using the method of manufacturing as set forth in claim 18.

26. A method of manufacturing an image display apparatus having an electron source and a light-emitting member capable of emitting a light by the electrons emitted from the electron source, wherein

the electron source is manufactured using the method of manufacturing as set forth in claim 22.

30. A method of manufacturing an information displaying/playing apparatus comprising at least a receiver unit that outputs at least one of image information contained in a broadcasting signal that has been received, character information, and sound information, and an image display apparatus connected to the receiver unit, wherein

the image display apparatus is manufactured using the method of manufacturing as set forth in claim 26.

31. A fiber containing carbon having both ends in its longitudinal direction, wherein the degree of crystallinity at one of the both ends is higher than a degree of crystallinity at the other portions.

32. A fiber containing carbon according to claim 31, wherein, when in the Raman spectrum at the one end h1₁ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₁ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, while when in the Raman spectrum at the other portions h1₂ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₂ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, there is established the relationship;

(h1₁−

h1₂)/h1₁×

100≧

20 and/or
(h2₁−

h2₂)/h2₁×

100≧

20

33. A fiber containing carbon according to claim 31, wherein, when in the Raman spectrum at the one end, h3₁ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser and in the Raman spectrum at the other portions h3₂ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser, there is established the relationship;

(h3₂−

h3₁)/h3₂×

100≧

20

34. A substrate having thereon multiple fibers containing carbon, wherein

each of the fibers has both ends in its longitudinal direction;

and one of the both ends is not fixed to the substrate while the other end is fixed to the substrate,

wherein a degree of crystallinity at the one of the both ends is higher than a degree of crystallinity at other portions.

35. A substrate according to claim 34, wherein, when in the Raman spectrum at the one end h1₁ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₁ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, while when in the Raman spectrum at the other portions h1₂ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₂ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, there is established the relationship;

(h1₁−

h1₂)/h1₁×

100≧

20 and/or
(h2₁−

h2₂)/h2₁×

100≧

20

36. A substrate according to claim 34, wherein, when in the Raman spectrum at the one end, h3₁ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser and in the Raman spectrum at the other portions h3₂ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser, there is established the relationship;

(h3₂−

h3₁)/h3₂×

100≧

20

37. An electron emission device comprising:

electron emission device including a fiber containing carbon having both ends in its longitudinal direction;

a cathode electrode; and

a control electrode that is located at a position spaced away from the cathode electrode,

wherein

one end of said fiber is not fixed to the cathode electrode, and

a degree of crystallinity of the one end of the fiber containing carbon is higher than that of other portions of the fiber.

38. An electron emission device according to claim 37, wherein, when in the Raman spectrum at the one end h1₁ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₁ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, while when in the Raman spectrum at the other portions h1₂ represents the maximum value of the Raman scattered light intensity in a range of 1355±

10 kayser and h2₂ represents the maximum value of the Raman scattered light intensity in a range of 1580±

10 kayser, there is established the relationship;

(h1₁−

h1₂)/h1₁×

100≧

20 and/or
(h2₁−

h2₂)/h2₁×

100≧

20

39. An electron emission device according to claim 38, wherein, when in the Raman spectrum at the one end, h3₁ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser and in the Raman spectrum at the other portions h3₂ represents a local maximum value of the Raman scattered light intensity between the range of 1355±

10 kayser and the range of 1580±

10 kayser, there is established the relationship;

(h3₂−

h3₁)/h3₂×

100≧

20

40. An electron source, the electron source including a plurality of electron emission devices, wherein

each of the plurality of electron emission devices is the one as set forth in claim 37.

41. A display panel, the display panel having an electron source and a screen constructed of a light-emitting member which emits light by irradiation of electrons emitted from an electron source, wherein the electron source is the one as set forth in claim 40.

42. An information displaying/playing apparatus comprising at least a display panel having a screen, a receiver unit that outputs at least one of image information, character information, and sound information contained in a broadcasting signal that has been received, and a drive circuit for displaying on the screen of the display panel the information that has been output from the receiver unit, wherein the display panel is the one as set forth in claim 41.