WO2014047750A1 - 一种用于高亮度led图形化的纳米压印装置和方法 - Google Patents
一种用于高亮度led图形化的纳米压印装置和方法 Download PDFInfo
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- WO2014047750A1 WO2014047750A1 PCT/CN2012/001430 CN2012001430W WO2014047750A1 WO 2014047750 A1 WO2014047750 A1 WO 2014047750A1 CN 2012001430 W CN2012001430 W CN 2012001430W WO 2014047750 A1 WO2014047750 A1 WO 2014047750A1
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- mold
- substrate
- pressure
- vacuum
- embossing
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- 238000000034 method Methods 0.000 title claims abstract description 113
- 238000000059 patterning Methods 0.000 title claims abstract description 34
- 239000000758 substrate Substances 0.000 claims abstract description 90
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 4
- 238000004049 embossing Methods 0.000 claims description 75
- 230000007246 mechanism Effects 0.000 claims description 58
- 238000001723 curing Methods 0.000 claims description 25
- 239000007788 liquid Substances 0.000 claims description 21
- 239000000463 material Substances 0.000 claims description 18
- 230000007547 defect Effects 0.000 claims description 12
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 8
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 8
- 238000007639 printing Methods 0.000 claims description 7
- 230000000750 progressive effect Effects 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 6
- 229920000642 polymer Polymers 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 238000012546 transfer Methods 0.000 claims description 5
- 239000007864 aqueous solution Substances 0.000 claims description 4
- 229920003169 water-soluble polymer Polymers 0.000 claims description 4
- 150000001875 compounds Chemical class 0.000 claims description 3
- 238000006073 displacement reaction Methods 0.000 claims description 3
- 238000001312 dry etching Methods 0.000 claims description 3
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- 238000000926 separation method Methods 0.000 claims description 2
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- 238000000016 photochemical curing Methods 0.000 claims 1
- 239000004584 polyacrylic acid Substances 0.000 claims 1
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- 238000004519 manufacturing process Methods 0.000 abstract description 36
- 230000003287 optical effect Effects 0.000 abstract description 4
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- 238000011031 large-scale manufacturing process Methods 0.000 abstract 2
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- 238000001127 nanoimprint lithography Methods 0.000 description 5
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- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/0002—Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0095—Post-treatment of devices, e.g. annealing, recrystallisation or short-circuit elimination
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y10/00—Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0083—Periodic patterns for optical field-shaping in or on the semiconductor body or semiconductor body package, e.g. photonic bandgap structures
Definitions
- the invention belongs to the technical field of micro-nano manufacturing and optoelectronic device manufacturing, and in particular relates to a nano-imprinting device and method for high-brightness LED patterning.
- LED patterning (sapphire substrate patterning and LED epitaxial patterning) has been considered by academics and industry to improve light generation efficiency and light extraction efficiency and to improve light source quality (controlling light emission direction and far field pattern uniformity).
- NPSS Nano-Patterned Sapphire Substrate
- LED epitaxial wafer patterning technology Photonic Crystal LED, Photonic Crystal LED; Nanorod LED, Nanorod LED; Nanowire LED, Nanowire LED
- sapphire substrates and LED epitaxial wafers have the following characteristics: uneven surface, warpage and bending deformation, large thickness variation, and sharp surface of several micrometers. Protrusions, as well as the presence of more pronounced surface defects and particulate contaminants, and exhibit fragile properties. Therefore, it is extremely difficult to manufacture a large-area, high-aspect-ratio micro-nano structure on a non-flat LED epitaxial wafer or a sapphire substrate surface with high efficiency, low cost, and large scale by using various existing micro-nano manufacturing methods. The need for graphical industrial applications.
- the conventional optical lithography focal depth ratio cannot meet the requirements of exposure; the fabrication of large-area nanostructures by electron beam lithography is costly and low in productivity. It is difficult to achieve large-scale, large-scale manufacturing.
- the existing contact or proximity lithography equipment cannot meet the requirements of nano-pattern manufacturing precision.
- Stepper projection lithography can realize NPSS manufacturing, but the Stepper used in the semiconductor industry appears in the LED industry. Too expensive, greatly increasing the manufacturing cost of LEDs. LEDs are very cost sensitive.
- some companies currently use the second-hand refurbished Stepper but there are problems in terms of product yield and equipment reliability.
- Interferometric lithography has great advantages in the fabrication of large-area periodic micro/nano structures, but the method is not enough: the depth of focus is small, the selectivity of nanostructured patterns is poor, and the production environment is demanding (and LED production process) Poor compatibility), especially at present, there is hardly a commercial company that provides a mature lithography machine (manufacturing of large-size wafer nano-patterns).
- nanofabrication methods such as nanosphere lithography, anodized aluminum stencil (AAO), natural lithography, block copolymer self-assembly, etc. have also been tried to be applied to LED patterning, there are some deficiencies, such as Cost, productivity, consistency, yield and scale manufacturing. Unable to meet the high-efficiency, low-cost, consistent industrial-grade production requirements for LED graphics.
- Nanoimprint Lithography is a new micro-nano patterning method, which is a technique for patterning through the deformation of a resist by using a mold.
- NIL has High resolution, ultra-low cost (NIL is at least an order of magnitude lower than traditional optical projection lithography by international authorities), and its most significant advantage is its large-area, complex three-dimensional micro-nano structure.
- the ability to manufacture, especially for soft UV nanoimprinting has the potential to achieve round-scale nanoimprinting on non-flat (bending, warping or step), fragile substrates, and the unique features of the roll-press process Continuous large-area embossing capability.
- Nanoimprint lithography has been identified by academics and industry as the most ideal technical solution for LED graphics.
- the existing nanoimprint process is applied to LED patterning, and there are still many shortcomings in mold life, productivity, yield and reliability, especially facing some challenging technical problems, such as difficulty in large-area demoulding and soft mold deformation. , damage to the mold due to particulate dirt and sharp protrusion defects, consistency and repeatability of the imprinted pattern, and the like.
- materials such as sapphire and GaN are difficult to etch, and it is usually necessary to deposit a hard mask layer first, in order to reduce the production cost, shorten the process route, and directly emboss the large on the resist.
- the aspect ratio feature structure eliminates the need for a hard mask layer process, simplifies the production process and reduces production costs. Therefore, LED patterning has a very urgent need for new imprinting techniques that produce large-area, high-aspect-ratio micro-nano structures efficiently and at low cost on non-flat surfaces or curved or fragile substrates.
- the object of the present invention is to solve the above problems, and to provide a nanoimprinting device and method for high-brightness LED patterning, which adopts a low-cost water-soluble, film-like elastic composite soft mold combined with large-area nano-pressure Printing process and gas-assisted progressive sequential pressure application and uncovering release method for high-efficiency, low-cost manufacturing of large areas, high depth and width on non-flat surfaces (bending, warping, steps or protrusions) or curved or fragile substrates Than the micro-nano structure.
- the present invention adopts the following technical solution - a nanoimprinting device for high-brightness LED patterning, which comprises: a film stage, a vacuum chuck, a substrate (wafer or epitaxial wafer), ultraviolet curing Type nanoimprint resist, mold, gas valve plate, embossing mechanism, ultraviolet light source, mold feeding mechanism, vacuum line, pressure line; wherein, the vacuum chuck is fixed directly above the wafer table, and the vacuum chuck is positive
- the substrate is adsorbed on the upper surface, and the liquid ultraviolet curing type nanoimprint resist is coated on the substrate;
- the mold is attached to the mold feeding mechanism, the roller for placing the film mold, the two auxiliary supporting rollers and the embossing mold On the outside of the recovered roller, the mold is placed above the substrate coated with the liquid UV-curable nanoimprint resist and below the valve plate through the auxiliary support roller, and the gas plate is fixed under the embossing mechanism.
- the ultraviolet light source is fixed above the imprinting mechanism; the vacuum line and
- the mold is a water-soluble, film-like, elastic composite transparent soft mold comprising a pattern layer and a support layer, wherein the pattern layer has the following characteristics: water solubility, high elastic modulus, high transparency, thermal stability and good mechanics Characteristics, choose Poly B A water-soluble polymer compound such as polyvinyl alcohol (PVA) or poly(acrylic acid, PAA).
- the support layer is a transparent high elastic film-like PET material.
- the graphics layer contains the micro-nano feature structure (graphics) to be copied, and the support layer is located above the graphics layer.
- the thickness of the patterned layer is 10-50 microns and the thickness of the support layer PET is 100-200 microns.
- the mold is manufactured by a roll printing process, a printed electronic technique or a nanoimprint technique.
- the mold feeding mechanism comprises: a roller for placing a film-shaped mold, a roller for recovering the mold after pressing, an auxiliary supporting roller, a guiding and an anti-torsion mechanism, and the mold feeding mechanism is divided into two axes On the side, one side is a roller for placing a film-shaped mold and an auxiliary support roller, the roller for placing the film-shaped mold is closer to the central axis of the mold feeding mechanism than the auxiliary support roller, and the other side is for recycling the mold after imprinting.
- the roller and the other auxiliary support roller, the roller recovered by the die after embossing is symmetric with the roller on which the film-shaped mold is placed with respect to the central axis of the die feeding mechanism, and the auxiliary support roller and the other auxiliary support roller are opposite to The center axis of the mold feeding mechanism is symmetrical.
- the wafer stage is an x-y precision workbench, which realizes the substrate replacement station and the positioning and position adjustment of the substrate and the mold during the imprint process.
- the embossing mechanism includes a one-dimensional displacement platform and an ultraviolet light source connecting bracket that move up and down in the z-axis direction, and a plurality of buffer gaskets are mounted under the connecting bracket.
- the ultraviolet light source is an ultraviolet LED lamp array.
- the working range of the pressure line is: 0-2 bar; the working pressure during the imprinting process is 10-100 mbar.
- the working range of the vacuum line is: -O.lbar ⁇ -0.4bar, the working pressure during the embossing process is -300Pa ⁇ - 5kPa; the closed area I under the mold and the vacuum suction cup during the embossing work is low pressure In the vacuum environment, the closed area II surrounded by the mold and the embossing mechanism is a pressure environment.
- the working method adopted by the above nanoimprinting device for high-brightness LED patterning includes the following steps: Step (1): Pretreatment process;
- Step (2) The imprint process
- Step (3) curing process
- Step (4) demolding process
- Step (5) post-processing
- Step (6) Transfer of the imprinted graphic.
- the working process of the step (1) is to spin-coat a liquid ultraviolet curing type nanoimprint resist on the substrate, place the substrate on the vacuum chuck above the film stage, and apply vacuum suction
- the substrate coated with the ultraviolet curable nanoimprint resist is adsorbed and fixed on the vacuum chuck; the wafer stage is moved from the initial station to the imprint station, and the imprint station is the center position directly under the mold.
- the working process of the step (2) is:
- the embossing mechanism drives the gas valve plate and the ultraviolet light source to move from the initial station to the substrate until the buffer seal of the embossing mechanism and the upper surface support layer of the mold, the pattern layer on the lower surface of the mold and the vacuum chuck
- the cushioning gasket is completely in close contact; the sealing area I formed under the mold and the vacuum chuck, the upper part of the mold and the embossing mechanism enclose a closed area II, and the sealing area I and II should be sealed during the embossing and demolding work. Not leaking;
- the vacuum suction cup opens the vacuum pipeline, and a low-pressure vacuum environment is formed in the sealed region I to remove the bubble defect trapped in the imprint process.
- the film-shaped mold is completely conformally contacted with the liquid ultraviolet-curable nanoimprint resist on the substrate; at the same time, the pressure of all the pressure lines of the gas-ceiling plate is kept uniform and uniform, and the upper and the pressure of the mold are increased.
- the closed area II enclosed by the printing mechanism forms a low pressure pressure environment, and a uniform embossing force is applied on the film-shaped mold to realize complete filling of the ultraviolet curing type nanoimprint resist in the mold micro-nano structure cavity, and reduce Thin to a predetermined residual layer thickness; or the direct initial film thickness is the same as the height of the embossed feature structure, so that no film embossing is achieved. Since it is a disposable mold, there is no need to worry about the mold being damaged by the direct contact of the mold with the substrate.
- the working process of the step (3) is:
- the ultraviolet light source is turned on, and the ultraviolet light is exposed to the ultraviolet curable nanoimprint resist through the mold to fully cure the ultraviolet curable nanoimprint resist; the curing time is 10-30 s.
- step (4) The working process of the step (4) is:
- step (5) The working process of the step (5) is:
- the imprinting mechanism moves up and returns to the initial station; at the same time, the carrier moves to the substrate changing station, and the vacuum is turned off.
- the vacuum line on the suction cup remove the embossed substrate, replace the new substrate, and open the vacuum line on the vacuum suction cup to fix the new substrate on the vacuum suction cup;
- step (6) The working process of the step (6) is:
- the feature structure is transferred to the substrate by an etching process using a cured UV-cured nanoimprint resist as a mask; or by a "Lift-off" process,
- the feature structure is transferred to other functional structural materials, including dry etching or wet etching.
- the working principle of the invention is:
- the embossing process uses "compressed gas and low-pressure vacuum to assist the pressure" and adopts a progressive sequential micro-contact embossing method from the center of the mold to the two outer directions. Based on the film-like elastic mold structure, gas assist on the mold The embossing force and the vacuum suction force of the lower part of the mold, as well as the capillary force, achieve uniform distribution of the embossing force on the non-flat substrate (protrusion, wave shape, curved surface, etc.), and realize the mold under the condition of small embossing force.
- the demolding process uses a mold to continuously "uncover" the mold release from the sides of the substrate to the center. Under the combined action of the vacuum suction above the mold and the release force of the compressed air under the mold, a slight release force is applied. Large area demoulding can be achieved.
- the mold and the UV-curable nanoimprint resist solve the problem of removing bubbles in the large-area imprinting process and ensuring complete contact between the mold and the substrate to improve the imprinting in a low-pressure vacuum environment. Graphic consistency.
- the innovations and benefits of the present invention are: (1) 'The mold used in the present invention is a disposable low-cost mold.
- the water-soluble material is easy to remove; its film shape and high elastic property ensure good conformal contact with the non-flat substrate; in addition, it can effectively reduce the defects caused by particles in the production environment during nanoimprinting. .
- the imprinting and demolding processes are based on sequential and micro-contact modes, which reduce the deformation and release force of the mold, and the bubbles trapped during the imprinting process can be Discharge in time.
- the mold pattern layer material is a water-soluble material.
- the mold pattern layer material is a water-soluble material.
- the embossing process is under the condition of low pressure vacuum, and combined with the progressive micro-contact embossing method from the center position of the mold to the two outer directions, solving the technical problem of trapping bubbles in the large-area embossing process and ensuring small embossing. Good conformal contact under force conditions.
- the embossing force release process is used to fully release the deformation of the mold, effectively improving the quality and precision of the soft mold embossing pattern.
- the film-shaped mold adopts a continuous rolling embossing process and the like, and the embossing material has low cost, and the mold manufacturing has the advantages of high efficiency and low cost manufacturing. Meet the requirements of batch industrial applications.
- the embossing process and the demolding process of the present invention take the center of the mold as a symmetry axis, the mold is uniformly and symmetrically stressed, and both sides of the embossing and demoulding processes are simultaneously performed, and the production efficiency is high.
- the mold is disposable.
- the water-soluble mold solves the problem that the sharp protrusion, the defect, the particulate matter and the like are damaged to the mold, and the technical problem that the high aspect ratio structure release mold is easily damaged, and the mold life is low.
- the present invention simplifies the structure of the apparatus without relying on the balance, the uniform hook applied by the precision machine, and the embossing force perpendicular to the surface. Uniform pressure application during large-area imprinting is achieved by gas-assisted pressure (combination of positive and negative pressure).
- the present invention combines the advantages of both plate embossing and roll embossing, and realizes efficient and low-cost manufacturing of large-area micro-nano structures. Provides an industrial grade solution for commercial applications of large area micro/nanostructures.
- the most significant advantages of the present invention are: to achieve a large area of high efficiency and low cost in various soft and hard substrates, including non-flat (bending, warping, step or protrusion) or curved substrate or fragile substrate surface.
- high aspect ratio micro-nano structure for large area micro-nano structure manufacturing, or large-area nano-patterning of non-flat substrate, or large-area nano-patterning of curved surface, or high-aspect ratio large-area micro-nano structure manufacturing Industrial grade application solutions.
- the invention is suitable for high-density magnetic disks (HDD), micro-optical devices (such as optical lenses, diffractive optical elements, etc.), various coatings (anti-reflection, self-cleaning, frost resistance, etc.), three-dimensional miniature batteries, and butterfly solar concentrating Manufacture of device, compound eye sensor, microfluidic device, biosensor, MEMS device, photovoltaic device, etc., especially suitable for LED nano-patterning (photonic crystal LED manufacturing nano-patterned sapphire substrate, etc.) and wafer level micro Industrial grade production of optics.
- HDD high-density magnetic disks
- micro-optical devices such as optical lenses, diffractive optical elements, etc.
- various coatings anti-reflection, self-cleaning, frost resistance, etc.
- three-dimensional miniature batteries three-dimensional miniature batteries
- butterfly solar concentrating Manufacture of device compound eye sensor, microfluidic device, biosensor, MEMS device, photovoltaic device, etc., especially suitable for LED nano-patterning
- FIG. 1 is a schematic structural view of a nanoimprinting apparatus for high-brightness LED patterning according to the present invention
- FIG. 2 is a schematic view showing the structure of a water-soluble, film-like elastic composite soft mold used in the present invention
- Figure 3 is a schematic structural view of the internal piping arrangement of the gas valve plate of the present invention.
- Figure 4a is a plan view showing the structure of the vacuum chuck of the present invention.
- Figure 4b is a side cross-sectional view showing the structure of the internal piping arrangement of the vacuum chuck of the present invention.
- Figure 5 is a schematic structural view of the embossing mechanism of the present invention.
- Figure 6 is a schematic structural view of the mold feeding mechanism of the present invention.
- FIG. 7 is a flow chart showing the working process of the imprint method for high-brightness LED patterning of the present invention.
- the invention adopts a nano-patterned 4 inch sapphire substrate as an embodiment, the substrate 3 is a 4-inch sapphire, and the patterned layer 501 of the film-like composite elastic soft mold selects a water-soluble polymer polyvinyl alcohol (PVA), a support layer. 502 Uses a highly transparent and elastic film-like PET material.
- PVA polymer polyvinyl alcohol
- FIG. 1 is a schematic structural view of a nanoimprinting apparatus for high-brightness LED patterning according to the present invention, which includes: a wafer stage 1. Vacuum chuck 2, substrate 3, ultraviolet curing type nanoimprint resist 4, mold 5, gas valve plate 6, imprint mechanism 7, ultraviolet light source 8, mold feeding mechanism 9, vacuum line 10, pressure tube
- the substrate 3 coated with the ultraviolet curable nanoimprint resist 4 is adsorbed on the vacuum chuck 2, and the vacuum chuck 2 is fixed on the wafer stage 1; the gas valve plate 6 is fixed at the pressure
- the bottom surface 706 of the printing mechanism 7 is fixed to the top surface 705 of the imprinting mechanism 7;
- the mold 5 is attached to the roller 901 of the mold feeding mechanism 9 where the film-like mold is placed, the two auxiliary supporting rollers 902 and the pressing
- the mold 5 is placed above the substrate 3 coated with the liquid ultraviolet-curable nanoimprint resist 4 and below the gas slab 6 through the auxiliary support roller 902, the vacuum line 10 and the pressure line 11 are connected
- the template 5 is a two-layer film-like elastic transparent soft mold comprising a pattern layer 501 and a support layer 502.
- the graphic layer 501 comprises a micro/nano feature 50101 to be replicated, the thickness of the graphic layer 501 is 40 microns, and the thickness of the support layer 502 PET is 150 microns.
- the support layer 502 is located above the graphic layer 501.
- the graphic layer 501 is made of a water-soluble polymer polyvinyl alcohol (PVA) ; the support layer 502 is made of a highly transparent and elastic film-like PET material.
- PVA water-soluble polymer polyvinyl alcohol
- Figure 3 is a schematic view showing the structure of the gas valve panel 6 of the present invention and its internal piping arrangement.
- One of the sides is provided with an air inlet 601, the bottom surface is formed with a groove surface 602, and one side of the groove surface 602 is communicated with the air inlet 601.
- the intake port 601 is connected to the vacuum line 10 and the pressure line 11.
- FIG. 4a is a plan view showing the structure of the vacuum chuck 2 of the present invention
- FIG. 4b is a side cross-sectional view showing the structure of the internal piping of the vacuum chuck 2 of the present invention, which comprises: a first buffer gasket 201 (freely movable up and down), and a first buffer gasket is placed.
- connection bracket 701 is configured to connect and fix the ultraviolet light source 8, the gas valve plate 6, the second buffer gasket 702, and the motion actuator 709 for moving the stamping mechanism 7 up and down in the z-axis direction. (such as one-dimensional displacement platform, etc.).
- the sealing area II is formed by the second cushioning gasket 702, the mold 5 and the first cushioning gasket 201 on the vacuum chuck 2 cooperating.
- the top surface 705 of the connecting bracket 701 of the embossing mechanism 7 is connected to the ultraviolet light source 8.
- the bottom surface 706 of the connecting bracket 701 of the embossing mechanism 7 is connected to the gas valve panel 6, and the top surface 705 of the connecting bracket 701 of the embossing mechanism 7 is The motion actuators 709 are connected.
- Fig. 6 is a schematic view showing the structure of the mold feeding mechanism 9 of the present invention, which comprises a roller 901 for placing a film-shaped mold, an auxiliary supporting roller 902, and a roller 903 for recovering the mold after imprinting.
- the roller 901 in which the film-shaped mold is placed is used for placing (loading) the film-shaped mold 5 (the film-shaped elastic mold 5 manufactured by the roll-pressing process), and the roller 903 recovered by the mold after the embossing is used for recovering the mold-removed
- the mold 5, the auxiliary support roller 902 functions to assist the support, guide and anti-torsion, and can be placed at different positions (two in this embodiment).
- the roller 903 recovered by the die after the embossing is the active rotating wheel, and the roller 901 for placing the film-shaped mold is a passive rotating wheel. After the embossing is performed once, the roller 903 recovered by the embossing is actively rotated after the embossing, the new mold 5 The feed is moved to the imprinting station, and the working process cycle of the next imprint is started.
- Figure 7 is a flow chart showing the operation of the embossing method for high-brightness LED patterning of the present invention, which comprises the following steps:
- a 200 nm liquid UV-curable nanoimprint resist 4 was spin-coated on a 4-inch sapphire substrate 3, placed on a vacuum chuck 2 above the wafer stage 1, and coated with ultraviolet light by vacuum suction.
- the sapphire substrate 3 of the photocurable nanoimprint resist 4 is adsorbed and fixed on the vacuum chuck 2.
- the stage 1 is moved from the initial station to the imprint station (center position directly below the mold 5).
- the embossing mechanism 7 drives the gas valve plate 6 and the ultraviolet light source 8 to move from the initial station to the sapphire substrate 3 until the second buffer gasket 702 of the embossing mechanism 7 and the mold 5, the mold 5 and the vacuum chuck 2
- the first cushion seal 201 is in full contact.
- the lower portion of the mold 5 and the closed region I formed by the vacuum chuck 2, the upper portion of the mold 5 and the imprint mechanism 7 enclose a closed region II, and it is ensured that the sealed regions I and II are sealed and airtight during the imprinting and demolding work.
- the pressure line 11 is opened one by one in the two outer directions, and the ultraviolet curing type on the film-like mold 5 and the sapphire substrate 3 is performed under the uniform pressure exerted by the compressed air.
- the nanoimprint resist 4 is gradually conformally contacted; 3 after the film-like mold 5 is completely conformally and uniformly contacted with the ultraviolet curable nanoimprint resist 4, the vacuum chuck 2 opens the vacuum line 10 and is formed in the sealed region I.
- the liquid ultraviolet curable nanoimprint resist 4 gradually releases the pressure applied to the mold 5 before curing, and finally maintains the imprint force of 5 mbar to make the mold The deformation of 5 is completely restored; 2 Subsequently, the ultraviolet light source 8 is turned on, and the ultraviolet light is exposed to the liquid ultraviolet curing type nanoimprint resist 4 through the mold 5 to fully cure the liquid ultraviolet curing type nanoimprint resist. Agent 4.
- the curing time is 20s.
- the pressure line 11 of the gas valve plate 6 and the vacuum line 10 of the vacuum suction cup 2 are closed; 2 from the outermost sides of the gas valve plate 6 simultaneously start the vacuum line 10 one by one toward the center of the mold 5, and the closed area II forms a low pressure vacuum At the same time, the pressure line 11 is opened on the vacuum chuck 2, and the sealed area I forms a low pressure pressure environment.
- the mold 5 is continuously "uncovered" from the outer side to the center of the sapphire substrate 3; finally, the center position of the mold 5 is separated from the solidified polymer on the sapphire substrate 3, and the mold 5 and the imprinted micro-nano are realized.
- the complete separation of the feature structure 50101 completes the demolding. 3
- the vacuum line 10 in the gas valve plate 6, the pressure line 11 of the vacuum chuck 2, and the horizontal pressure line 202 of the pressure line 11 of the first buffer seal 201 on the vacuum chuck 2 are closed (first buffer seal) Pad 201 is reset).
- the imprinting mechanism 7 moves up and returns to the initial station.
- the stage 1 is moved to the substrate 3 replacement station, the horizontal vacuum line 204 on the vacuum chuck 2 is closed, the embossed sapphire substrate 3 is removed, the new sapphire substrate 3 is replaced, and the vacuum chuck 2 is opened at the same time.
- the horizontal vacuum line 204 secures the new sapphire substrate 3 to the vacuum chuck 2. 2
- the roller 903 recovered by the die is rotated, and the film-shaped mold 5 is advanced to the movement, and the size of the feed movement is 300 mm. Begin a new round of embossing work cycle.
- the remaining mold 5 material in the structure of the cured UV-curable nanoimprint resist 4 after curing is removed.
- the micro/nano feature 50101 of the mold 5 may have some micro-nano feature 50101 residual of the mold 5 due to the adhesion of the polymer to the mold release or the mold release force is not uniform or the mechanical strength of the mold 5 is low after the mold release process.
- the mold 5 material remaining in the imprinted special structure forms an embossing defect), resulting in Mold 5 failure and generation of embossing defects.
- the present invention provides an ideal solution using a water soluble disposable mold 5.
- the material of the mold 5 remaining in the embossed structure is a water-soluble material. Therefore, the substrate 3 and the embossed features thereon were placed in an 80 ⁇ aqueous solution for 10 minutes to remove the mold 5 remaining in the characteristic structure. 2 with Thereafter, the residual layer is removed by a reactive ion etching process, and the embossed organic polymer is used as a mask to transfer the features to the sapphire substrate 3 by an ICP dry etching process.
- the working range of the pressure line 11 in this embodiment is: 0-2 bar ; the working pressure in the embossing process is 30 mbar. The pressure is released to 5 mbar and the embossing force of 5 mbar is maintained during the curing process.
- the mold 5 is manufactured by a roll-to-roll nanoimprint process, and the manufacturing process thereof: (1) manufacturing a silicon mold (mother mold) by laser interference lithography; (2) using a silicon mold as a master mold, using an electroforming process, A nickel mold of a sheet structure is fabricated and coated on a cylindrical roller to form a working die for roll printing; G) a nickel mold of a roller type is used as a working mold, and a PET is used as a backing (support layer 502)
- the water-soluble PVA is an imprint material, and the mold 5 required for the present embodiment is produced by roll-to-roll or roll-to-plane nanoimprint process (heat curing).
- the working range of the vacuum line 10 is: ⁇ -0.2 bar, and the working pressure during the imprinting process is -600 Pa ;
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US14/362,464 US9563119B2 (en) | 2012-09-29 | 2012-10-25 | Large-area nanopatterning apparatus and method |
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US20140305904A1 (en) | 2014-10-16 |
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