Nanostructured Transfer Tape for High-Yield Patterning
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Solution Overview
Problem
Current methods for patterning nanostructures and microstructures on large glass substrates are costly and inefficient, making it difficult to achieve high yields for applications like digital displays and photovoltaic devices.
Innovation Solution
A method involving the creation of a structured transfer film using a backfill material within a template, which is then laminated onto a receptor substrate, allowing for the removal of the template while maintaining the structured surface, using materials like silsesquioxane and adhesion promotion layers to enhance adhesion and pattern precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lamination transfer methods with sacrificial template layers are used, then nanostructures can be formed on glass substrates, but the process becomes complex and costly due to the need to remove the template layer while maintaining structure integrity
Solution Approach 1:
The patent extracts the sacrificial template layer removal step by using a release layer that allows the template to be peeled away cleanly after backfill material is deposited. The template layer is removed from the backfill layer while leaving the structured surface of the backfill layer substantially intact, eliminating the need for complex etching or dissolution processes.
Solution Approach 2:
The patent introduces a release layer as an intermediary between the template layer and the backfill material. This release layer facilitates easy separation of the template from the backfilled structure, simplifying the removal process and reducing overall process complexity while maintaining manufacturing precision.
2Manufacturing precision
If conventional patterning methods are used on large glass substrates, then structures can be formed, but the cost-effectiveness and yield are reduced
Solution Approach 1:
The patent performs preliminary action by creating the structured template layer with embedded release layer and filling it with backfill material before transferring to the final substrate. This pre-assembly approach allows for easier handling, quality control, and transfer to large substrates, improving both yield and cost-effectiveness while maintaining pattern accuracy.
Solution Approach 2:
The patent uses the structured template layer as a master copy that can be replicated onto multiple substrates. The template layer with its embedded release layer serves as a reusable master that can be transferred repeatedly, increasing productivity and reducing costs associated with direct patterning on each large substrate individually.
3Manufacturing precision
If the template layer is removed using dry etching or thermal decomposition, then the template can be eliminated, but the process becomes more complex and potentially damages the structured surface
Solution Approach 1:
The patent extracts the template layer removal from complex etching or thermal decomposition processes by using a release layer that enables simple mechanical peeling. The template layer is removed from the backfill layer through controlled adhesion differences, leaving the structured surface of the backfill layer substantially intact without requiring damaging removal processes.
Solution Approach 2:
The patent treats the template layer as a disposable sacrificial element that is easily removed after serving its purpose of defining the nanostructure. The release layer enables this temporary structure to be discarded through simple peeling rather than complex removal processes, reducing both process complexity and risk of damage to the final structured surface.
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 enables cost-effective and high-yield fabrication of nanostructures and microstructures on large areas, improving the efficiency of transferring patterns onto glass substrates and other receptor materials.
Implementation Method 1
The receptor substrate comprises a patterned adhesion promotion layer
Implementation Method 2
Typically the sample is cured photochemically
Data Source
AI summary
A method of making patterned structured solid surfaces is disclosed that includes filling a structured template with backfill material to produce a structured transfer film, patternwise curing the backfill material to produce cured areas and uncured areas in the structured transfer film, and laminating the structured transfer film to a receptor substrate. The structured template is capable of being removed to form structured and unstructured backfill layers. The structured and unstructured backfill layers may then be blanket cured. The backfill layer can include at least two different materials, one of which can be an adhesion promotion layer. In some embodiments the backfill layer includes a silsesquioxane such as polyvinyl silsesquioxane. The structured transfer film is a stable intermediate that can be covered temporarily with a release liner for storage and handling.