Field Emission Lamps Prepared with Dip-Coated and Nickel Electroless Plated Carbon Nanotube Cathodes

Fabrication and efficiency enhancement of tubal field emission lamps (FELs) using multi-walled carbon nanotubes (MWNTs) as the cathode field emitters were studied. The cathode filaments were prepared by eletrolessly plating a nickel (Ni) film on the cathode made of a 304 stainless steel wire dip-coated with MWNTs. The 304 wire was dip-coated with MWNTs and nano-sized Pd catalyst in a solution, and then eletrolessly plated with Ni to form an MWNT-embedded composite film. The MWNTs embedded in Ni not only had better adhesion but also exhibited a higher FE threshold voltage, which is beneficial to our FEL system and can increase the luminous efficiency of the anode phosphor. Our results show that the FE cathode prepared by dipping three times in a solution containing 400 ppm Pd nano-catalysts and 0.2 wt.% MWNTs and then eletrolessly plating a Ni film at a deposition temperature of 60 °C, pH value of 5, and deposition time of 7 min has the best FE uniformity and efficiency. Its emission current can stay as low as 2.5 mA at a high applied voltage of 7 kV, which conforms to the high-voltage-and-low-current requirement of the P22 phosphor and can therefore maximize the luminous efficiency of our FEL. We found that the MWNT cathodes prepared by this approach are suitable for making high-efficiency FELs.