TW201509254A - Manufacturing method of substrate and manufacturing device of substrate - Google Patents
Manufacturing method of substrate and manufacturing device of substrate Download PDFInfo
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- TW201509254A TW201509254A TW103123630A TW103123630A TW201509254A TW 201509254 A TW201509254 A TW 201509254A TW 103123630 A TW103123630 A TW 103123630A TW 103123630 A TW103123630 A TW 103123630A TW 201509254 A TW201509254 A TW 201509254A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
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Description
本發明係有關一種在支撐基板的表面形成寬度不同之複數個線狀圖案之基板製造方法及基板製造裝置。 The present invention relates to a substrate manufacturing method and a substrate manufacturing apparatus for forming a plurality of linear patterns having different widths on a surface of a support substrate.
已知有藉由在支撐基板的表面形成遮罩圖案,並且在未形成遮罩圖案且暴露之區域鍍上金屬來製作印刷基板之技術(專利文獻1)。遮罩圖案例如藉由將感光性乾膜曝光及顯影來形成。若被鍍金屬之高度超過遮罩圖案的高度,則被鍍金屬超過預先用遮罩圖案設定之線寬而導致橫向擴散。藉由使遮罩圖案厚於被鍍金屬,從而能夠防止橫向擴散。 A technique of forming a mask pattern on the surface of a support substrate and plating a metal on a region where the mask pattern is not formed and exposed is known (Patent Document 1). The mask pattern is formed, for example, by exposing and developing a photosensitive dry film. If the height of the metal to be plated exceeds the height of the mask pattern, the metallized metal exceeds the line width previously set by the mask pattern to cause lateral diffusion. By making the mask pattern thicker than the metal to be plated, lateral diffusion can be prevented.
專利文獻1:日本特開2011-228605號專利公報 Patent Document 1: Japanese Patent Laid-Open Publication No. 2011-228605
在形成100μm以上厚度的厚金屬圖案例如厚銅圖案時,必須使遮罩圖案厚於100μm。然而,很難藉由曝光及顯影來形成該種厚遮罩圖案。本發明的目的在於提供一種在支撐基板上形成用於形成厚金屬圖案之遮罩圖案之方法。本發明的另一目的在於提供一種能夠適用於形成該遮罩圖案之方法的基板製造裝置。 When a thick metal pattern having a thickness of 100 μm or more, for example, a thick copper pattern is formed, it is necessary to make the mask pattern thicker than 100 μm. However, it is difficult to form such a thick mask pattern by exposure and development. It is an object of the present invention to provide a method of forming a mask pattern for forming a thick metal pattern on a support substrate. Another object of the present invention is to provide a substrate manufacturing apparatus which can be applied to a method of forming the mask pattern.
依本發明的其中一觀點提供一種基板製造方法,其具有:準備應形成第1線狀圖案、及比前述第1線狀圖案粗的第2線狀圖案之支撐基板之製程;及在前述支撐基板之應形成前述第1線狀圖案及前述第2線狀圖案的區域,多次重複進行使薄膜材料液滴化後彈著,並使彈著之前述薄膜材料硬化的步驟之製程,用以形成前述第1線狀圖案之前述步驟的重複次數多於用以形成前述第2線狀圖案之前述步驟的重複次數。並且,提供一種基板製造裝置,其具有:載物台,保持應形成第1線狀圖案、及比前述第1線狀圖案粗的第2線狀圖案之支撐基板;噴嘴頭,具有朝向保持在前述載物臺上之支撐基板吐出光硬化性液狀薄膜材料的複數個噴嘴孔;移動機構,使前述支撐基板及前述噴嘴頭的其中一方相對於另一方移動; 光源,向附著於保持在前述載物臺上之支撐基板之液狀的前述薄膜材料照射硬化用光;及控制裝置,控制前述噴嘴頭、前述光源、及前述移動機構;前述第1線狀圖案的高度的目標值與前述第2線狀圖案的高度的目標值相等;前述控制裝置控制前述噴嘴頭、前述光源、及前述移動機構,並且多次重複進行第1步驟,前述第1步驟係一邊使前述噴嘴頭及前述基板的其中一方相對於另一方移動,一邊從前述噴嘴頭吐出液狀薄膜材料,並使液狀薄膜材料附著在前述基板之表面中應形成第1線狀圖案及第2線狀圖案之區域,並且從前述光源向附著在前述基板之液狀的前述薄膜材料照射硬化用光而使前述薄膜材料硬化,進一步至少執行1次第2步驟,前述第2步驟一邊使前述噴嘴頭及前述基板的其中一方相對於另一方移動,一邊從前述噴嘴頭吐出液狀薄膜材料,並使液狀薄膜材料附著在前述基板之表面中應形成前述第1線狀圖案之區域,並且從前述光源向附著在前述基板之液狀的前述薄膜材料照射硬化用光而使前述薄膜材料硬化,並且不使液狀薄膜材料附著在應形成前述第2線狀圖案之區域。 According to still another aspect of the present invention, a substrate manufacturing method includes: a process of preparing a support substrate in which a first linear pattern and a second linear pattern thicker than the first linear pattern are to be formed; and the support a region in which the first linear pattern and the second linear pattern are to be formed on the substrate, and a process of performing a step of causing the thin film material to be dropletized and then bucking and curing the stretched film material is repeated for a plurality of times The number of repetitions of the above-described steps of forming the first linear pattern is larger than the number of repetitions of the above-described steps for forming the second linear pattern. Further, there is provided a substrate manufacturing apparatus comprising: a carrier, a support substrate that holds a first linear pattern and a second linear pattern that is thicker than the first linear pattern; and the nozzle head has an orientation a plurality of nozzle holes for discharging a photocurable liquid film material on the support substrate on the stage; and a moving mechanism for moving one of the support substrate and the nozzle head relative to the other; a light source that irradiates the liquid film material adhered to the support substrate held on the stage to the curing light; and a control device that controls the nozzle head, the light source, and the moving mechanism; and the first linear pattern The target value of the height is equal to the target value of the height of the second linear pattern; the control device controls the nozzle head, the light source, and the moving mechanism, and repeats the first step a plurality of times, the first step is one side When one of the nozzle head and the substrate is moved relative to the other, a liquid film material is discharged from the nozzle head, and a liquid film material is adhered to the surface of the substrate to form a first linear pattern and a second pattern. In the region of the linear pattern, the film material is irradiated with light from the light source to the liquid material adhering to the substrate to cure the film material, and the second step is performed at least once, and the nozzle head is made in the second step. And moving one of the substrates to the other, and discharging the liquid film material from the nozzle head to form a liquid The film material adheres to a region of the surface of the substrate to form the first linear pattern, and the film material is cured from the light source to the liquid film material adhering to the substrate to cure the film material, and the film material is not cured. The liquid film material adheres to a region where the second linear pattern is to be formed.
用於形成第1線狀圖案之步驟的重複次數多於用於形 成第2線狀圖案之前述步驟的重複次數。若步驟的重複次數相同,則導致相對較細的第1線狀圖案變得低於第2線狀圖案。藉由使用於形成第1線狀圖案之步驟的重複次數多於用於形成第2線狀圖案之前述步驟的重複次數,從而能夠對齊第1線狀圖案與第2線狀圖案的高度。 The number of repetitions of the steps for forming the first linear pattern is more than that for the shape The number of repetitions of the aforementioned steps in the second linear pattern. If the number of repetitions of the steps is the same, the relatively thin first line pattern becomes lower than the second line pattern. The height of the first linear pattern and the second linear pattern can be aligned by the number of repetitions of the step of forming the first linear pattern being larger than the number of repetitions of the above-described steps for forming the second linear pattern.
10‧‧‧支撐基板 10‧‧‧Support substrate
11‧‧‧應形成第1線狀圖案之區域 11‧‧‧The area where the first linear pattern should be formed
12‧‧‧應形成第2線狀圖案之區域 12‧‧‧The area where the second line pattern should be formed
13‧‧‧應形成第3線狀圖案之區域 13‧‧‧The area of the third linear pattern should be formed
15‧‧‧應形成遮罩圖案之區域 15‧‧‧ areas where mask patterns should be formed
20‧‧‧薄膜材料 20‧‧‧ Film material
31‧‧‧第1層 31‧‧‧1st floor
32‧‧‧第2層 32‧‧‧2nd floor
33‧‧‧第3層 33‧‧‧3rd floor
41‧‧‧第1線狀圖案 41‧‧‧1st line pattern
42‧‧‧第2線狀圖案 42‧‧‧2nd line pattern
43‧‧‧第3線狀圖案 43‧‧‧3rd linear pattern
45‧‧‧金屬圖案 45‧‧‧Metal pattern
50‧‧‧平臺 50‧‧‧ platform
51‧‧‧移動機構 51‧‧‧Mobile agencies
52‧‧‧載物台 52‧‧‧stage
53‧‧‧噴嘴單元 53‧‧‧Nozzle unit
54‧‧‧攝像機 54‧‧‧Camera
60‧‧‧控制裝置 60‧‧‧Control device
70‧‧‧支撐板 70‧‧‧support board
71‧‧‧噴嘴頭 71‧‧‧Nozzle head
72‧‧‧硬化用光源 72‧‧‧ Hardening light source
73‧‧‧噴嘴孔 73‧‧‧Nozzle hole
80‧‧‧搬入站 80‧‧‧ moving into the station
81‧‧‧臨時定位站 81‧‧‧ Temporary positioning station
82‧‧‧塗布站 82‧‧‧ coating station
83‧‧‧硬化站 83‧‧‧ hardening station
84‧‧‧搬送裝置 84‧‧‧Transporting device
85‧‧‧第1搬送輥 85‧‧‧1st conveying roller
86‧‧‧第2搬送輥 86‧‧‧2nd conveying roller
87‧‧‧擋塊 87‧‧‧block
88‧‧‧硬化用光源 88‧‧‧ Hardening light source
90‧‧‧導件 90‧‧‧ Guides
91、92‧‧‧提升器 91, 92‧‧‧ Lifter
第1圖係在根據實施例之基板製造方法中使用之支撐基板的俯視圖。 Fig. 1 is a plan view of a support substrate used in a substrate manufacturing method according to an embodiment.
第2圖A~第2圖D係藉由根據實施例之基板製造方法製造之基板的,製造中途階段的剖面圖。 FIGS. 2A to 2D are cross-sectional views showing the intermediate stage of manufacture of the substrate manufactured by the substrate manufacturing method according to the embodiment.
第2圖E係藉由根據實施例之基板製造方法製造之基板的,製造中途階段的剖面圖,第2圖F係藉由根據實施例之基板製造方法製造出之基板的剖面圖。 Fig. 2E is a cross-sectional view showing a substrate manufactured by the substrate manufacturing method according to the embodiment, in the middle of the manufacturing process, and Fig. 2F is a cross-sectional view of the substrate manufactured by the substrate manufacturing method according to the embodiment.
第3圖係用於對用於形成各線狀圖案之步驟的,較佳重複次數進行說明之線狀圖案的概要圖。 Fig. 3 is a schematic view showing a linear pattern for explaining the number of repetitions of the steps for forming the respective line patterns.
第4圖係表示線狀圖案的寬度和高度、及與步驟的重複次數n的關係的一例之曲線圖。 Fig. 4 is a graph showing an example of the relationship between the width and height of the linear pattern and the number of repetitions n of the step.
第5圖係根據實施例之基板製造裝置的塗布站的概要圖。 Fig. 5 is a schematic view of a coating station of a substrate manufacturing apparatus according to an embodiment.
第6圖A係噴嘴單元的立體圖,第6圖B係噴嘴單元的仰視圖。 Fig. 6A is a perspective view of the nozzle unit, and Fig. 6B is a bottom view of the nozzle unit.
第7圖係根據實施例之基板製造裝置的載物台及噴嘴單元的俯視圖。 Fig. 7 is a plan view of a stage and a nozzle unit of the substrate manufacturing apparatus according to the embodiment.
第8圖係根據實施例之基板製造裝置的整體概要圖。 Fig. 8 is a schematic overall view of a substrate manufacturing apparatus according to an embodiment.
參閱第1圖、第2圖A~第2圖F,對根據實施例之基板製造方法進行說明。首先,準備成為應形成圖案之基底的支撐基板。 Referring to Fig. 1 and Fig. 2A to Fig. 2F, a method of manufacturing a substrate according to the embodiment will be described. First, a support substrate to be a substrate to be patterned is prepared.
第1圖表示出在根據實施例之基板製造方法中使用之支撐基板10的俯視圖。在支撐基板10的表面劃定有應形成遮罩圖案之區域15。應形成之遮罩圖案具有寬度不同之複數個線狀圖案。例如,應形成遮罩圖案之區域15包括應形成第1線狀圖案之區域11(以下稱為第1區域。)、應形成第2線狀圖案之區域12(以下稱為第2區域。)、及應形成第3線狀圖案之區域13(以下稱為第3區域。)。第1區域11的寬度最細,第3區域13的寬度最粗。第1線狀圖案、第2線狀圖案、及第3線狀圖案的高度的目標值全部相等。 The first graph shows a plan view of the support substrate 10 used in the substrate manufacturing method according to the embodiment. A region 15 where a mask pattern should be formed is defined on the surface of the support substrate 10. The mask pattern to be formed has a plurality of line patterns having different widths. For example, the region 15 in which the mask pattern is to be formed includes a region 11 (hereinafter referred to as a first region) in which the first linear pattern is to be formed, and a region 12 in which the second linear pattern is to be formed (hereinafter referred to as a second region). And a region 13 (hereinafter referred to as a third region) in which a third linear pattern is to be formed. The width of the first region 11 is the smallest, and the width of the third region 13 is the thickest. The target values of the heights of the first linear pattern, the second linear pattern, and the third linear pattern are all equal.
第2圖A~第2圖F表示出藉由根據實施例之基板製造方法製造之基板的,製造中途階段的剖面圖。第2圖A~第2圖F相當於第1圖的單點鏈線2-2的剖面。 2A to 2F are cross-sectional views showing the stage of manufacture in the substrate manufactured by the substrate manufacturing method according to the embodiment. Fig. 2A to Fig. 2F correspond to the cross section of the single-dot chain line 2-2 of Fig. 1.
如第2圖A所示,在支撐基板10的表面劃定有第1區域11、第2區域12、及第3區域13。使薄膜材料20液滴化後塗布於第1區域11、第2區域12、及第3區域13。之後,使塗布在支撐基板10之薄膜材料20硬化。 As shown in FIG. 2A, the first region 11, the second region 12, and the third region 13 are defined on the surface of the support substrate 10. The film material 20 is dropletized and applied to the first region 11, the second region 12, and the third region 13. Thereafter, the film material 20 coated on the support substrate 10 is cured.
液滴彈著點的分佈密度在第1區域11、第2區域 12、及第3區域13內全部相同。例如可使用光硬化性樹脂作為液狀薄膜材料20。藉由向塗布在支撐基板10之薄膜材料20照射硬化用光,例如紫外線來使薄膜材料20硬化。藉此,在第1區域11形成構成第1線狀圖案的一部份之第1層31。同樣地,在第2區域12、及第3區域13分別形成構成第2線狀圖案的一部份之第2層32及構成第3線狀圖案的一部份之第3層33。在該階段硬化度無需一定為大致100%。得到如下程度的硬化度即可:薄膜材料20不向面內方向流動,且能夠在已硬化之薄膜材料20之上再塗布液狀薄膜材料20。 The distribution density of the droplet impact point is in the first region 11 and the second region 12. All of the same in the third area 13 are the same. For example, a photocurable resin can be used as the liquid film material 20. The film material 20 is cured by irradiating the film material 20 coated on the support substrate 10 with light for curing, for example, ultraviolet rays. Thereby, the first layer 31 constituting a part of the first linear pattern is formed in the first region 11. Similarly, in the second region 12 and the third region 13, a second layer 32 constituting a part of the second linear pattern and a third layer 33 constituting a part of the third linear pattern are formed. The degree of hardening at this stage need not necessarily be approximately 100%. The degree of hardening can be obtained as follows: the film material 20 does not flow in the in-plane direction, and the liquid film material 20 can be further coated on the hardened film material 20.
如第2圖B所示,使薄膜材料20液滴化後塗布於支撐基板10的第1區域11、第2區域12、及第3區域13,並使其硬化,藉此在第1層31、第2層32、及第3層33上分別形成第2層的第1層31、第2層32、及第3層33。 As shown in FIG. 2B, the film material 20 is dropletized and applied to the first region 11, the second region 12, and the third region 13 of the support substrate 10, and is cured, whereby the first layer 31 is formed. The first layer 31, the second layer 32, and the third layer 33 of the second layer are formed on the second layer 32 and the third layer 33, respectively.
如第2圖C所示,重複進行使薄膜材料20液滴化後塗布於支撐基板10的第1區域11、第2區域12、及第3區域13,並使其硬化之步驟。藉此,在第1區域11形成由多層第1層31構成之第1線狀圖案41。同樣地,在第2區域12及第3區域13分別形成由多層第2層32構成之第2線狀圖案42及由多層第3層33構成之第3線狀圖案43。在該階段,第1層31的層積數、第2層32的層積數、及第3層33的層積數全部相等。 As shown in FIG. 2C, the step of applying the droplets of the film material 20 to the first region 11, the second region 12, and the third region 13 of the support substrate 10 and then hardening them is repeated. Thereby, the first linear pattern 41 composed of the plurality of first layers 31 is formed in the first region 11. Similarly, in the second region 12 and the third region 13, a second linear pattern 42 composed of a plurality of second layers 32 and a third linear pattern 43 composed of a plurality of third layers 33 are formed. At this stage, the number of layers of the first layer 31, the number of layers of the second layer 32, and the number of layers of the third layer 33 are all equal.
塗布於第1層31之上的薄膜材料20在到完全硬化為 止的期間橫向擴散。因此,第1線狀圖案41的側面傾斜,其剖面成為接近直立梯形之形狀。第2線狀圖案42及第3線狀圖案43的側面也同樣地傾斜,其剖面成為接近直立梯形之形狀。 The film material 20 coated on the first layer 31 is completely hardened to The period of the period spreads laterally. Therefore, the side surface of the first linear pattern 41 is inclined, and the cross section thereof has a shape close to an upright trapezoid. The side faces of the second linear pattern 42 and the third linear pattern 43 are also inclined in the same manner, and the cross section thereof has a shape close to an upright trapezoid.
側面傾斜之部份的寬度幾乎不依存於線狀圖案的寬度。因此,第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43的側面傾斜之部份的寬度大致相等。在構成線狀圖案之薄膜材料中,線寬越細使用於側面傾斜之部份的薄膜材料的比例就越大。在第2圖C所示之階段中,最細的第1線狀圖案41的高度最低,最粗的第3線狀圖案43的高度最高。第2圖C示出第3線狀圖案43的高度達到目標高度之時點的剖面圖。 The width of the side inclined portion hardly depends on the width of the line pattern. Therefore, the widths of the portions of the first linear pattern 41, the second linear pattern 42, and the side surface of the third linear pattern 43 which are inclined are substantially equal. In the film material constituting the linear pattern, the finer the line width, the larger the ratio of the film material used for the side inclined portion. In the stage shown in FIG. 2C, the thinnest first linear pattern 41 has the lowest height, and the thickest third linear pattern 43 has the highest height. Fig. 2C is a cross-sectional view showing the point at which the height of the third linear pattern 43 reaches the target height.
如第2圖D所示,使薄膜材料20液滴化後塗布於第1線狀圖案41的上表面及第2線狀圖案42的上表面,並使其硬化。在第3線狀圖案43的上表面不塗布薄膜材料20。藉此,第1線狀圖案41及第2線狀圖案42的高度增加。在第2線狀圖案42的高度與第3線狀圖案43的高度變得幾乎相等之時點,結束向第2線狀圖案42的上表面塗布薄膜材料20。在該時點,第1線狀圖案41低於第2線狀圖案42及第3線狀圖案43。 As shown in FIG. 2D, the film material 20 is dropped and applied to the upper surface of the first linear pattern 41 and the upper surface of the second linear pattern 42 to be cured. The film material 20 is not applied to the upper surface of the third linear pattern 43. Thereby, the heights of the first linear pattern 41 and the second linear pattern 42 increase. When the height of the second linear pattern 42 and the height of the third linear pattern 43 become almost equal, the application of the film material 20 to the upper surface of the second linear pattern 42 is completed. At this time, the first linear pattern 41 is lower than the second linear pattern 42 and the third linear pattern 43.
如第2圖E所示,使薄膜材料20液滴化後塗布於第1線狀圖案41的上表面並使其硬化。在第2線狀圖案42及第3線狀圖案43的上表面不塗布薄膜材料20。藉此,第1線狀圖案41的高度增加。第1線狀圖案41的高度與 第2線狀圖案42及第3線狀圖案43的高度變得幾乎相等時,結束向第1線狀圖案41的上表面附著薄膜材料20。 As shown in FIG. 2E, the film material 20 is dropped and applied to the upper surface of the first linear pattern 41 to be cured. The film material 20 is not applied to the upper surfaces of the second linear patterns 42 and the third linear patterns 43. Thereby, the height of the first linear pattern 41 is increased. The height of the first linear pattern 41 and When the heights of the second linear pattern 42 and the third linear pattern 43 are almost equal, the film material 20 is attached to the upper surface of the first linear pattern 41.
如第2圖F所示,在支撐基板10的表面中未形成第1線狀圖案41、前述第2線狀圖案42、及第3線狀圖案43,且在支撐基板10的表面暴露之區域堆積金屬。藉此,形成金屬圖案45。金屬圖案45使用例如銅。 As shown in FIG. 2F, the first linear pattern 41, the second linear pattern 42, and the third linear pattern 43 are not formed on the surface of the support substrate 10, and the exposed surface of the support substrate 10 is exposed. Stacking metal. Thereby, the metal pattern 45 is formed. The metal pattern 45 uses, for example, copper.
在根據實施例之方法中,使薄膜材料20液滴化後塗布於支撐基板10的應形成線狀圖案之區域,並使已塗布之薄膜材料20硬化。藉由多次重複進行該塗布及硬化的步驟(以下簡稱為“步驟”。)來形成第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43。著眼於第1線狀圖案41及第2線狀圖案42,用於形成相對較細的第1線狀圖案41之步驟的重複次數多於用於形成相對較粗的第2線狀圖案42之步驟的重複次數。著眼於第2線狀圖案42及第3線狀圖案43,用於形成相對較細的第2線狀圖案42之步驟的重複次數多於用於形成相對較粗的第3線狀圖案43之步驟的重複次數。 In the method according to the embodiment, the film material 20 is dropletized and applied to a region of the support substrate 10 where the linear pattern is to be formed, and the coated film material 20 is cured. The first linear pattern 41, the second linear pattern 42, and the third linear pattern 43 are formed by repeating the coating and curing step (hereinafter simply referred to as "step"). Focusing on the first linear pattern 41 and the second linear pattern 42, the number of repetitions of the step for forming the relatively thin first linear pattern 41 is larger than that for forming the relatively thick second linear pattern 42. The number of repetitions of the step. Focusing on the second linear pattern 42 and the third linear pattern 43, the number of repetitions of the step for forming the relatively thin second linear pattern 42 is larger than that for forming the relatively thick third linear pattern 43. The number of repetitions of the step.
如此,藉由設定步驟的重複次數,從而能夠對齊粗細不同之複數個線狀圖案的高度。即使加高線狀圖案也能夠對齊寬度不同之複數個線狀圖案的高度,因此上述基板製造方法尤其能夠適用於具有100μm以上厚度的厚銅圖案之基板的製造。 Thus, by setting the number of repetitions of the steps, it is possible to align the heights of the plurality of line patterns having different thicknesses. Even if the line pattern is raised, the heights of the plurality of line patterns having different widths can be aligned. Therefore, the above substrate manufacturing method can be suitably applied to the production of a substrate having a thick copper pattern having a thickness of 100 μm or more.
參閱第3圖對用於形成各線狀圖案之步驟的較佳重複次數進行說明。 The preferred number of repetitions of the steps for forming the respective line patterns will be described with reference to FIG.
以n表示用於形成第1線狀圖案41之步驟的重複次數時,以滿足以下條件之方式設定重複次數n為較佳。步驟的重複次數為n-1時的第1線狀圖案41的高度H10低於第3線狀圖案43的高度H3(亦即目標高度)。而且,若將步驟的重複次數設為n+1次,則第1線狀圖案41的高度H11變得高於第3線狀圖案43的高度H3。若以滿足該條件之方式設定重複次數n,則能夠使第1線狀圖案41的高度H1與第3線狀圖案43的高度H3之間的差變小。 When n is the number of repetitions of the step for forming the first linear pattern 41, it is preferable to set the number of repetitions n so as to satisfy the following conditions. The height H10 of the first linear pattern 41 when the number of repetitions of the step is n-1 is lower than the height H3 of the third linear pattern 43 (that is, the target height). When the number of repetitions of the step is n+1, the height H11 of the first linear pattern 41 becomes higher than the height H3 of the third linear pattern 43. When the number of repetitions n is set so as to satisfy the condition, the difference between the height H1 of the first linear pattern 41 and the height H3 of the third linear pattern 43 can be made small.
用於形成第2線狀圖案42之步驟的較佳重複次數也能夠以與用於形成第1線狀圖案41之步驟的較佳重複次數n相同的方法進行設定。藉此,能夠使第2線狀圖案42的高度H2與第3線狀圖案43的高度H3之間的差變小。 The preferred number of repetitions of the step for forming the second linear pattern 42 can also be set in the same manner as the preferred number of repetitions n of the step for forming the first linear pattern 41. Thereby, the difference between the height H2 of the second linear pattern 42 and the height H3 of the third linear pattern 43 can be made small.
滿足上述條件之重複次數n的解通常有2個。此時,將步驟的重複次數n設定為所形成之線狀圖案的高度更接近目標高度的一方的重複次數為較佳。 There are usually two solutions for the number of repetitions n satisfying the above conditions. At this time, it is preferable to set the number of repetitions n of the steps to the number of repetitions of the height of the formed linear pattern closer to the target height.
第4圖示出線狀圖案的寬度和高度、及與步驟的重複次數n的關係的一例。橫軸表示線狀圖案的寬度,縱軸表示線狀圖案的高度。賦予第4圖的各實線之數值n表示步驟的重複次數。固定步驟的重複次數n時,隨著線狀圖案的寬度變窄而線狀圖案的高度變低。如第2圖C所示,這是因為用於側面傾斜之部份之薄膜材料的比例變高。 Fig. 4 shows an example of the relationship between the width and height of the linear pattern and the number of repetitions n of the step. The horizontal axis represents the width of the linear pattern, and the vertical axis represents the height of the linear pattern. The numerical value n assigned to each solid line in Fig. 4 indicates the number of repetitions of the step. When the number of repetitions n of the fixing step is n, the height of the linear pattern becomes lower as the width of the linear pattern becomes narrower. As shown in Fig. 2C, this is because the proportion of the film material for the side inclined portion becomes high.
將第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43(第2圖E)的高度的目標值設為Ht。在第4圖 所示之例子中,形成寬度W1的第1線狀圖案41之步驟之重複次數為14時,其高度變得與目標高度Ht最接近。形成寬度W2的第2線狀圖案42之步驟的重複次數為13時,其高度變得與目標高度Ht最接近。形成寬度W3的第3線狀圖案43之步驟的重複次數為12時,其高度變得與目標高度Ht最接近。如此,以線狀圖案的高度變得與目標高度Ht最接近之方式設定步驟的重複次數n,藉此能夠對齊線狀圖案的高度。 The target value of the height of the first linear pattern 41, the second linear pattern 42, and the third linear pattern 43 (second image E) is Ht. In Figure 4 In the example shown, when the number of repetitions of the step of forming the first linear pattern 41 of the width W1 is 14, the height becomes the closest to the target height Ht. When the number of repetitions of the step of forming the second linear pattern 42 having the width W2 is 13, the height becomes closest to the target height Ht. When the number of repetitions of the step of forming the third linear pattern 43 having the width W3 is 12, the height thereof becomes closest to the target height Ht. In this manner, the number of repetitions n of the steps is set such that the height of the linear pattern becomes closest to the target height Ht, whereby the height of the linear pattern can be aligned.
第5圖表示出根據實施例之基板製造裝置的塗布站的概要圖。在平臺50上經由移動機構51支撐載物台52。載物台52保持作為形成薄膜的對象之支撐基板10。定義將與支撐基板10的表面平行的面設為xy面,將支撐基板10的表面的法線方向設為z方向之xyz直角座標系統。在載物台52的上方支撐有噴嘴單元53及攝像機54。移動機構51使支撐基板10及噴嘴單元53的其中一方相對於另一方,向x方向及y方向移動。在第5圖中表示出使噴嘴單元53相對於平臺50靜止,使支撐基板10移動之結構,相反,也可設為使支撐基板10靜止,使噴嘴單元53移動之結構。 The fifth graph shows a schematic view of a coating station of the substrate manufacturing apparatus according to the embodiment. The stage 52 is supported on the platform 50 via a moving mechanism 51. The stage 52 holds the support substrate 10 as a target for forming a film. A surface in which the surface parallel to the surface of the support substrate 10 is defined as an xy plane, and a normal direction of the surface of the support substrate 10 is defined as an xyz rectangular coordinate system in the z direction. A nozzle unit 53 and a camera 54 are supported above the stage 52. The moving mechanism 51 moves one of the support substrate 10 and the nozzle unit 53 in the x direction and the y direction with respect to the other. In the fifth diagram, the configuration in which the nozzle unit 53 is stationary with respect to the stage 50 to move the support substrate 10 is shown. Conversely, the support unit 10 may be stationary and the nozzle unit 53 may be moved.
噴嘴單元53具有與支撐基板10對置之噴嘴頭。光硬化性液狀薄膜材料從形成於噴嘴頭之複數個噴嘴孔朝向支撐基板10被液滴化後吐出。從噴嘴孔吐出薄膜材料之時機由控制裝置60控制。攝像機54拍攝形成於支撐基板10之對準標誌並將圖像資料發送到控制裝置60。 The nozzle unit 53 has a nozzle head opposed to the support substrate 10. The photocurable liquid film material is discharged from a plurality of nozzle holes formed in the nozzle head toward the support substrate 10, and then discharged. The timing of discharging the film material from the nozzle holes is controlled by the control device 60. The camera 54 captures an alignment mark formed on the support substrate 10 and transmits the image data to the control device 60.
第6圖A表示出噴嘴單元53的側視圖,第6圖B示出噴嘴單元53的仰視圖。在支撐板70上組裝有2個噴嘴頭71及3個光硬化用光源72。在y方向並排配置2個噴嘴頭71。在2個噴嘴頭71之間、及比噴嘴頭71更靠外側分別配置有硬化用光源72。著眼於1個噴嘴頭71,在噴嘴頭71的y方向的正側及負側分別配置有硬化用光源72。 Fig. 6A shows a side view of the nozzle unit 53, and Fig. 6B shows a bottom view of the nozzle unit 53. Two nozzle heads 71 and three light-curing light sources 72 are assembled to the support plate 70. Two nozzle heads 71 are arranged side by side in the y direction. A curing light source 72 is disposed between the two nozzle heads 71 and outside the nozzle head 71. Focusing on one nozzle head 71, a curing light source 72 is disposed on each of the positive side and the negative side of the nozzle head 71 in the y direction.
在各噴嘴頭71上形成有在x方向上等間隔配列的複數個噴嘴孔73。第6圖A及第6圖B中表示出各噴嘴頭71的複數個噴嘴孔73配列成2列之例子。2個噴嘴頭71在x方向上相互錯開而固定。在2個噴嘴頭71上形成之共計4列的噴嘴孔73整體上在x方向上等間隔分佈。 A plurality of nozzle holes 73 arranged at equal intervals in the x direction are formed in each nozzle head 71. In FIGS. 6A and 6B, an example in which a plurality of nozzle holes 73 of the nozzle heads 71 are arranged in two rows is shown. The two nozzle heads 71 are shifted from each other in the x direction and fixed. The nozzle holes 73 formed in a total of four rows formed on the two nozzle heads 71 are distributed at equal intervals in the x direction as a whole.
硬化用光源72向塗布於支撐基板10(第5圖)之液狀薄膜材料照射硬化用光。例如,若一邊使支撐基板10(第5圖)沿y方向移動,一邊從噴嘴頭71吐出薄膜材料,則塗布於支撐基板10的薄膜材料藉由來自比吐出薄膜材料之噴嘴頭71更靠下游側配置之硬化用光源72的光被硬化。 The curing light source 72 irradiates the liquid thin film material applied to the support substrate 10 (Fig. 5) with light for curing. For example, when the film material is discharged from the nozzle head 71 while moving the support substrate 10 (Fig. 5) in the y direction, the film material applied to the support substrate 10 is further downstream from the nozzle head 71 than the film material. The light of the hardening light source 72 disposed on the side is hardened.
第6圖A及第6圖B中,噴嘴頭71的搭載數為2個,但是,噴嘴頭71的搭載數可為1個,也可為3個以上。硬化用光源72可配置在噴嘴頭71各自的下游側。一邊使支撐基板10沿y方向移動,一邊塗布薄膜材料時,硬化用光源72配置於噴嘴頭71的各兩側。若使噴嘴頭71的搭載數增加,則在x方向上等間隔分佈之噴嘴孔73 的間距變小。藉此,能夠提高應形成線狀圖案之解析度。 In FIG. 6 and FIG. 6B, the number of the nozzle heads 71 is two. However, the number of the nozzle heads 71 to be mounted may be one or three or more. The hardening light source 72 can be disposed on the downstream side of each of the nozzle heads 71. When the film material is applied while moving the support substrate 10 in the y direction, the curing light source 72 is disposed on each side of the nozzle head 71. When the number of the nozzle heads 71 is increased, the nozzle holes 73 are equally spaced in the x direction. The pitch becomes smaller. Thereby, the resolution of the linear pattern to be formed can be improved.
第7圖中示出根據實施例之基板製造裝置的載物台52及噴嘴單元53的俯視圖。在載物台52上保持有支撐基板10。在支撐基板10的表面劃定有應形成遮罩圖案之區域15。 Fig. 7 is a plan view showing the stage 52 and the nozzle unit 53 of the substrate manufacturing apparatus according to the embodiment. The support substrate 10 is held on the stage 52. A region 15 where a mask pattern should be formed is defined on the surface of the support substrate 10.
在支撐基板10的上方配置有噴嘴單元53。噴嘴單元53包括噴嘴頭71及硬化用光源72。一邊藉由移動機構51使支撐基板10沿y方向移動,一邊使薄膜材料從噴嘴頭71吐出,藉此能夠向支撐基板10塗布薄膜材料。控制裝置60控制依據移動機構51之支撐基板10的移動、及來自噴嘴頭71的薄膜材料的吐出時刻。藉此,能夠在應形成遮罩圖案之區域15塗布薄膜材料。應形成遮罩圖案之區域15的圖案資訊預先記憶於控制裝置60。 A nozzle unit 53 is disposed above the support substrate 10. The nozzle unit 53 includes a nozzle head 71 and a curing light source 72. The film material is discharged from the nozzle head 71 while the support substrate 10 is moved in the y direction by the moving mechanism 51, whereby the film material can be applied to the support substrate 10. The control device 60 controls the movement of the support substrate 10 according to the moving mechanism 51 and the discharge timing of the film material from the nozzle head 71. Thereby, the film material can be applied in the region 15 where the mask pattern should be formed. The pattern information of the area 15 where the mask pattern is to be formed is previously stored in the control device 60.
將支撐基板10在x方向錯開而重複進行相同的處理,藉此能夠在支撐基板10的表面的任意區域塗布薄膜材料。 The support substrate 10 is shifted in the x direction, and the same process is repeated, whereby the film material can be applied to any region of the surface of the support substrate 10.
第8圖示出根據實施例之基板製造裝置的整體的概要圖。根據實施例之基板製造裝置包括搬入站80、臨時定位站81、塗布站82、硬化站83及搬送裝置84。定義將水平面設為xy面,將鉛垂方向設為z軸的正方向之xyz直角座標系統。朝向x軸的正方向依次配置搬入站80、臨時定位站81、塗布站82及硬化站83。控制裝置60控制搬入站80、臨時定位站81、塗布站82、硬化站83內的各裝置及搬送裝置84。 Fig. 8 is a schematic view showing the entirety of a substrate manufacturing apparatus according to an embodiment. The substrate manufacturing apparatus according to the embodiment includes a loading station 80, a temporary positioning station 81, a coating station 82, a hardening station 83, and a conveying device 84. Define the xyz rectangular coordinate system with the horizontal plane set to the xy plane and the vertical direction to the positive direction of the z-axis. The loading station 80, the temporary positioning station 81, the coating station 82, and the hardening station 83 are disposed in this order in the positive direction of the x-axis. The control device 60 controls the loading station 80, the temporary positioning station 81, the coating station 82, and the respective devices in the curing station 83 and the conveying device 84.
第1搬送輥85向x軸的正方向將處理對象的支撐基板10從搬入站80搬送至臨時定位站81。藉由第1搬送輥85搬送之支撐基板10的前端接觸到擋塊87,藉此與搬送方向相關地進行支撐基板10的粗定位。 The first transport roller 85 transports the support substrate 10 to be processed from the loading station 80 to the temporary positioning station 81 in the positive direction of the x-axis. The front end of the support substrate 10 conveyed by the first transfer roller 85 comes into contact with the stopper 87, whereby the support substrate 10 is roughly positioned in relation to the conveyance direction.
搬送裝置84將支撐基板10從臨時定位站81搬送至塗布站82、及從塗布站82搬送至硬化站83。搬送裝置84包括導件90及2台提升器91、92。提升器91、92由導件90導引並沿x方向移動。提升器91、92具有例如與支撐基板10的底面接觸並支撐支撐基板10之L字狀的支撐臂。其中一方的提升器91將支撐基板10從臨時定位站81搬送至塗布站82,另一方的提升器92將支撐基板10從塗布站82搬送至硬化站83。 The transport device 84 transports the support substrate 10 from the temporary positioning station 81 to the coating station 82 and from the coating station 82 to the curing station 83. The conveying device 84 includes a guide 90 and two lifters 91, 92. The lifters 91, 92 are guided by the guide 90 and moved in the x direction. The lifters 91, 92 have, for example, L-shaped support arms that are in contact with the bottom surface of the support substrate 10 and support the support substrate 10. One of the lifters 91 transports the support substrate 10 from the temporary positioning station 81 to the coating station 82, and the other lifter 92 transports the support substrate 10 from the coating station 82 to the hardening station 83.
如第5圖所示,塗布站82包括平臺50、移動機構51及載物台52。第8圖中未示出噴嘴單元53(第5圖)等。 As shown in FIG. 5, the coating station 82 includes a stage 50, a moving mechanism 51, and a stage 52. The nozzle unit 53 (Fig. 5) and the like are not shown in Fig. 8.
在硬化站83配置有第2搬送輥86。在塗布站82處理之支撐基板10藉由搬送裝置84搬送至硬化站83,並搭載於第2搬送輥86上。第2搬送輥86沿x軸的正方向搬送支撐基板10。在支撐基板10的搬送路徑的上方配置有硬化用光源88。硬化用光源88向藉由第2搬送輥86搬送之支撐基板10照射包括使薄膜材料硬化之長波成份的光。 The second transfer roller 86 is disposed in the hardening station 83. The support substrate 10 processed by the coating station 82 is transported to the curing station 83 by the transfer device 84, and is mounted on the second transfer roller 86. The second transport roller 86 transports the support substrate 10 in the positive direction of the x-axis. A curing light source 88 is disposed above the transport path of the support substrate 10. The curing light source 88 irradiates the support substrate 10 conveyed by the second transfer roller 86 with light including a long-wave component that hardens the film material.
在塗布站82形成如第2圖E所示之第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43。在由來自塗 布站82的硬化光源72的光進行的硬化處理中,有時硬化度不夠充份。在塗布站82形成之第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43在硬化站83進一步被硬化。藉此,可以得到充份的硬化度。 The first linear pattern 41, the second linear pattern 42, and the third linear pattern 43 as shown in FIG. 2E are formed in the coating station 82. Painted by In the hardening treatment by the light of the hardened light source 72 of the cloth station 82, the degree of hardening may not be sufficient. The first linear pattern 41, the second linear pattern 42, and the third linear pattern 43 formed at the coating station 82 are further cured at the curing station 83. Thereby, a sufficient degree of hardening can be obtained.
在控制裝置60中記憶有用於由線狀圖案的寬度和高度求出步驟的重複次數之對應關係資訊(第4圖)。控制裝置60依據線狀圖案的高度的目標值(第4圖的高度Ht)、第1線狀圖案41的寬度的目標值(第4圖的寬度W1)、第2線狀圖案的寬度的目標值(第4圖的寬度W2)、第3線狀圖案43的寬度的目標值(第4圖的寬度W3)、及對應關係資訊(第4圖),求出形成第1線狀圖案41、第2線狀圖案42、及第3線狀圖案43之步驟的重複次數n。 Correspondence information (Fig. 4) for determining the number of repetitions of the step by the width and height of the line pattern is stored in the control device 60. The control device 60 is based on the target value of the height of the linear pattern (the height Ht in FIG. 4), the target value of the width of the first linear pattern 41 (the width W1 in FIG. 4), and the target of the width of the second linear pattern. The value (the width W2 in FIG. 4), the target value of the width of the third linear pattern 43 (the width W3 in FIG. 4), and the correspondence relationship information (fourth image), and the formation of the first linear pattern 41, The number of repetitions n of the steps of the second linear pattern 42 and the third linear pattern 43.
第2圖A到第2圖C為止的步驟的重複次數與形成第3線狀圖案43之步驟的重複次數相等。第2圖A到第2圖D為止的步驟的重複次數與形成第2線狀圖案42之步驟的重複次數相等。第2圖A到第2圖E為止的步驟的重複次數與形成第1線狀圖案41之步驟的重複次數相等。 The number of repetitions of the steps from the second drawing A to the second drawing C is equal to the number of repetitions of the step of forming the third linear pattern 43. The number of repetitions of the steps from the second drawing A to the second drawing D is equal to the number of repetitions of the step of forming the second linear pattern 42. The number of repetitions of the steps from the second drawing A to the second drawing E is equal to the number of repetitions of the step of forming the first linear pattern 41.
控制裝置60依據形成各線狀圖案之步驟的重複次數n、及圖案資訊,控制噴嘴頭71及移動機構51。如此,依據線狀圖案的寬度適當決定步驟的重複次數,藉此能夠形成高度對齊之線狀圖案。 The control device 60 controls the nozzle head 71 and the moving mechanism 51 in accordance with the number of repetitions n of the steps of forming the respective line patterns and the pattern information. Thus, the number of repetitions of the steps is appropriately determined depending on the width of the line pattern, whereby a highly aligned line pattern can be formed.
按照以上實施例對本發明進行了說明,但本發明並不 限定於此者。例如,可進行各種變更、改良、組合等對於本領域的技術人員來說是顯而易見的。 The invention has been described in accordance with the above embodiments, but the invention is not Limited to this. For example, various changes, modifications, combinations and the like can be made apparent to those skilled in the art.
10‧‧‧支撐基板 10‧‧‧Support substrate
11‧‧‧應形成第1線狀圖案之區域 11‧‧‧The area where the first linear pattern should be formed
12‧‧‧應形成第2線狀圖案之區域 12‧‧‧The area where the second line pattern should be formed
13‧‧‧應形成第3線狀圖案之區域 13‧‧‧The area of the third linear pattern should be formed
20‧‧‧薄膜材料 20‧‧‧ Film material
31‧‧‧第1層 31‧‧‧1st floor
32‧‧‧第2層 32‧‧‧2nd floor
33‧‧‧第3層 33‧‧‧3rd floor
41‧‧‧第1線狀圖案 41‧‧‧1st line pattern
42‧‧‧第2線狀圖案 42‧‧‧2nd line pattern
43‧‧‧第3線狀圖案 43‧‧‧3rd linear pattern
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