Imprint System Substrate Mark Optical Contrast Alignment

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Solution Overview

Problem

In nano-imprinting technologies, aligning a mold with a substrate is challenging due to the difficulty in detecting substrate-side marks, especially when the substrate material has optical properties similar to the imprint material, leading to increased costs and complexity in the alignment process.

Innovation Solution

An imprint system that forms substrate-side marks using a material with distinct optical properties from the imprint material, allowing for improved alignment by detecting these marks and enabling precise positioning with the mold-side marks, thereby simplifying the alignment process and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If substrate material with optical properties similar to imprint material is used, then manufacturing versatility is improved, but measurement precision of substrate-side mark deteriorates

Engineering Contradiction:
Improvesubstrate material selectionVSAvoidsubstrate-side mark detection
Core Design Contradiction:
Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent introduces a substrate-side mark made of a material that serves as an intermediary between the substrate and the detection system. This mark material has optical properties that differ from both the substrate and the imprint material, allowing it to act as a mediator that enables detection. The mark provides a detectable optical signal that bridges the gap between the substrate and the detection apparatus, solving the problem of detecting marks on substrates with optical properties similar to the imprint material.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies local quality by making only the substrate-side mark region different in optical properties from the surrounding substrate area. The mark is formed with a specific material or structure that creates local optical contrast, while the rest of the substrate maintains its original properties. This localized differentiation allows detection without requiring the entire substrate to have different optical characteristics from the imprint material.

Inventive Principle:
Principle #3Local quality

2Measurement precision

If substrate-side mark is formed with material having distinct optical properties, then measurement precision is improved, but manufacturing cost increases

Engineering Contradiction:
Improvesubstrate-side mark detectionVSAvoidsubstrate-side mark formation
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by forming the substrate-side mark before the imprinting process. The mark is created in advance on the substrate, allowing it to be used for alignment and detection during subsequent processing steps. This preliminary formation enables the mark to be established with materials and methods optimized for detection, without adding complexity to the main imprinting process.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating a simplified representation of the alignment features on the substrate-side mark. Rather than requiring complex or expensive materials, the mark copies the essential function of alignment and detection using simpler, more cost-effective materials that still provide the necessary optical contrast for measurement.

Inventive Principle:
Principle #26Copying

3Device complexity

If alignment process is simplified, then device complexity is reduced, but manufacturing precision may deteriorate

Engineering Contradiction:
Improvealignment processVSAvoidmold-substrate alignment
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies the principle of color changes by utilizing differences in optical properties (analogous to color or light interaction) between the substrate-side mark material and both the substrate and imprint material. The mark is designed to exhibit distinct optical characteristics that enable easy detection and alignment. This optical differentiation allows for simplified alignment processes using standard detection methods while maintaining high manufacturing precision through reliable mark detection.

Inventive Principle:
Principle #32Color changes

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

The system achieves high-accuracy alignment and reliable product manufacturing by enhancing the detectability of substrate-side marks, improving the overall efficiency and cost-effectiveness of the nano-imprinting process.

Implementation Method 1

a detection unit configured to detect the substrate-side mark and the mold-side mark

Methodology Applied
Scientific EffectLight reflection: Reflection

Implementation Method 2

causing the mold substrate to transmit light from above and simultaneously observing the positioning mark provided on the mold substrate

Methodology Applied
Scientific EffectLight transmission: Light

Implementation Method 3

a photo-curing imprint material layer is formed on a substrate... a resin is cured by applying ultraviolet light thereto

Methodology Applied
Scientific EffectPhoto-curing: Photopolymerisation

Data Source

PatentUS20230415403A1Imprint system, substrate, imprint method, replica mold manufacturing method, and article manufacturing method
Publication Date: 2023.12.28 CANON KK
  • US20230415403A1 patent drawing
  • US20230415403A1 patent drawing
  • US20230415403A1 patent drawing

AI summary

An imprint system transfers a pattern formed on a mold to an imprint material supplied onto a substrate and includes: a formation unit configured to form a desired substrate-side mark including a predetermined material by applying the predetermined material onto the surface of the substrate and then transferring the substrate-side mark on the predetermined material and processing the substrate-side mark, wherein a difference in a predetermined optical property between the predetermined material and the imprint material is larger than a difference in the predetermined optical property between the imprint material and the substrate; and an alignment unit configured to align the substrate-side mark including the predetermined material and a mold-side mark provided on the mold.