Method of fabricating an ultra-high resolution three-color screen

Abstract

Phosphor color screens with triad pitches of 150 .mu.m and less are fabricated by a combination of modified microelectronic processing techniques and electrophoretic coating of the phosphors and black screen. Indeed, triad pitches based on 15 .mu.m color line width and 5 .mu.m black matrix between colors are achievable. The method of the invention for fabricating a three-color screen comprises (a) forming a conductive coating on a major surface of the substrate; (b) forming multiple masking layers on the conductive coating; (c) patterning the masking layers in a prescribed pattern to form a first plurality of openings therein to expose first portions of the conductive coating; (d) electrophoretically depositing a first phosphor on the exposed first portions of the conductive coating; and (e) repeating steps (b) through (d) three times (1) to deposit a second phosphor on second portions of the conductive coating, (2) to deposit a third phosphor on third portions of the conductive coating, and (3) to deposit a black layer around all three color portions, to thereby define a plurality of triads of said first, second, and third colors in spaced relationship, separated by the black layer.