Curable Composition with Pressure-Activated Gas Agent for Nanoimprint
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Solution Overview
Problem
In photo-nanoimprint methods, a large mold-releasing force is required to separate the mold and cured resin, which can lead to defects such as cracking and reduced alignment accuracy, and existing gas-generation methods either introduce bubbles or require complex pressure chambers.
Innovation Solution
A curable composition comprising a polymerizable monomer, a polymerization initiator, and a gas-generating agent that generates gas upon pressure application, allowing for a small mold-releasing force and reducing defects by sequential gas generation during a short pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a large mold-releasing force is applied to separate the mold and cured resin, then the mold can be released from the cured product, but defects such as cracking in the pattern and reduced alignment accuracy occur
Solution Approach 1:
A gas-generating agent is introduced as an intermediary substance between the mold and the cured resin. When pressure is applied, this agent generates gas that accumulates at the interface, creating a cushioning effect that reduces the adhesion force between the mold and cured product, enabling release with minimal force and preventing pattern damage
Solution Approach 2:
The physical state of the gas-generating agent changes from solid/liquid to gas when pressure is applied. This parameter change (phase transition) creates volume expansion and pressure at the mold-resin interface, reducing adhesion forces and enabling easy mold release without damaging the cured pattern
2Force
If a gas-generating agent generates gas by light or heat during curing, then the mold-releasing force is reduced, but bubbles are generated during curing leading to transfer defects
Solution Approach 1:
The gas-generating agent is designed to remain dormant during the curing process and only generates gas after curing is complete, when pressure is applied for mold release. This preliminary action timing ensures that gas generation occurs only when needed for release, not during curing when it would cause bubbles and defects
Solution Approach 2:
The gas generation is separated into distinct phases: no gas generation during curing, then gas generation upon pressure application for release. This periodic action pattern prevents bubbles during curing while still achieving mold release, solving the contradiction between reducing release force and maintaining pattern quality
3Force
If a pressure chamber system is used to generate gas for mold release, then the mold-releasing force is reduced, but the process becomes complex and time-consuming
Solution Approach 1:
The gas-generating agent is a self-contained component mixed into the curable composition itself. It autonomously generates gas when pressure is applied, eliminating the need for external pressure chambers or complex gas delivery systems. The system serves itself by incorporating the gas generation function directly into the material
Solution Approach 2:
The complex pressure chamber system is extracted and replaced by a simple pressure application mechanism. The gas generation function is separated from the equipment and embedded in the material itself, simplifying the overall system while maintaining the benefit of reduced mold-releasing force
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the mold to be released quickly with a small force after curing, minimizing defects like bubbles and improving pattern accuracy, while simplifying the process by distinguishing mold-releasing from photo-curing steps.
Implementation Method 1
a gas-generating agent that generates a gas by pressure application
Implementation Method 2
The polymerization initiator initiates polymerization of the polymerizable monomer, and the curable composition cures by polymerization of the polymerizable monomer
Data Source
AI summary
A curable composition that can be released from a mold simply within a short period of time after photo-curing by a small mold-releasing force is provided. The curable composition contains a gas-generating agent that generates a gas by pressure application. A method of forming a pattern is also provided. In the method, the mold can be released with a small force.