Nanoimprint Mold Segmentation Prevents Resin Clogging

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Solution Overview

Problem

The production of nanoimprint films faces issues with mold clogging and defective recess formation due to the hard coat layer, which affects the quality and durability of the films, and the adhesiveness between the base film and the imprint resin layer.

Innovation Solution

A mold design where the nanostructure is formed only on specific surfaces, with masked regions lacking nanostructures to prevent clogging and dust formation, and a method involving masking during the production process using tapes like Kapton to ensure efficient and reliable nanoimprint film production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hard coat layer is provided between the base film and the imprint resin layer, then the surface durability and adhesiveness are improved, but the mold irregularities become clogged with the hard coat resin causing production stoppages

Engineering Contradiction:

Improvesurface durabilityVSAvoidcontinuous production capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The mold surface is segmented into two distinct regions: a first surface with nanostructures for imprinting and a second surface without nanostructures positioned at the peripheral portion. This segmentation prevents the hard coat resin from clogging the nanostructures while maintaining the hard coat layer's protective function on the imprinting surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different surfaces of the mold are given different properties: the first surface has nanostructures for pattern transfer, while the second peripheral surface is made flat to prevent resin clogging. This local differentiation allows the hard coat layer to provide durability where needed without causing production stoppages.

Inventive Principle:

Principle #3Local quality

2Reliability

If a hard coat layer is provided between the base film and the imprint resin layer, then the adhesiveness is improved, but dust is generated from the hard coat resin rubbing against the mold, causing defective recesses

Engineering Contradiction:

ImproveadhesivenessVSAvoiddust generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The mold surface is divided into a first surface with nanostructures for imprinting and a second surface without nanostructures at the periphery. This prevents hard coat resin from rubbing against nanostructures and generating dust that would cause defective recesses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The potential harm of hard coat resin rubbing against the mold is converted into a benefit by designing a flat peripheral surface that prevents rubbing while still allowing the hard coat layer to provide adhesiveness on the imprinting surface.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If nanostructures are formed on the entire mold surface, then the imprinting quality is improved, but the hard coat resin clogs the nanostructures at the peripheral portion, stopping production

Engineering Contradiction:

Improveimprint qualityVSAvoidcontinuous production capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mold surface is segmented into a first surface with nanostructures for high-quality imprinting and a second surface without nanostructures at the periphery to prevent hard coat resin clogging, enabling continuous production.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Nanostructures are locally applied only to the first surface where imprinting occurs, while the second peripheral surface is kept flat to prevent resin accumulation and maintain continuous production capability.

Inventive Principle:

Principle #3Local quality

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

This approach prevents mold clogging and defective recess formation, ensuring continuous and high-quality nanoimprint film production with improved adhesiveness and surface durability.

Implementation Method 1

a mold having a nanostructure is pressed to the thin film

Methodology Applied

Scientific EffectMechanical Pressure: Pressure Increase

Implementation Method 2

the thin film is irradiated with ultraviolet rays to give a thin film (hereinafter, also referred to as a nanoimprint film) with a nanostructure

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS10155340B2Mold, method for producing mold, and method for producing nanoimprint film

Publication Date: 2018.12.18 SHARP KK

AI summary

A mold is disclosed, which is capable of producing a nanoimprint film without a problem of clogging of irregularities of the mold with a resin material. A method for producing the mold and a method for producing a nanoimprint film using the mold are further disclosed. In an embodiment, the mold includes: a first surface having a nanostructure including plural recesses spaced at an interval of less than 1 μm between bottom points of adjacent recesses; and at least two second surfaces substantially not having the nanostructure, wherein the first surface is coplanar with the at least two second surfaces and is positioned between two second surfaces.