Patterned Resin Layer via Master Template Transfer
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Solution Overview
Problem
Current methods for producing fine patterns in electronic circuits and displays, such as photolithography, are costly and complex, and existing techniques for creating patterns with different surface free energies are either inefficient or require complicated processes.
Innovation Solution
A production method involving a resin composition with a first compound of low surface free energy and a second compound of higher surface free energy, combined with a photopolymerization initiator, is applied to a base and cured in contact with a master having surface free energy differences to transfer a pattern, allowing for the formation of a cured resin layer with varying surface energies without the need for lithography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to produce fine patterns for electronic circuits, then manufacturing precision is improved, but production cost increases and productivity decreases
Solution Approach 1:
The patent uses a master template with pre-formed patterns to transfer surface free energy patterns directly to the resin composition, eliminating the need for photolithography. The master serves as a reusable copy tool that imprints the desired pattern structure onto the material surface through contact, significantly reducing manufacturing complexity and cost while maintaining fine pattern precision
Solution Approach 2:
The patent replaces the complex chemical and optical systems of photolithography with a simple mechanical contact process. By bringing the resin composition into direct contact with the master template, the pattern transfer occurs through physical contact and surface energy differential, eliminating the need for photoresists, aligners, and chemical development processes
2Manufacturing precision
If intaglio transfer technique is used to transfer patterns, then manufacturing precision is improved, but device complexity increases due to repeated material segregation
Solution Approach 1:
The patent performs preliminary action by pre-forming the surface free energy pattern on the master template before the transfer process. The master is prepared in advance with the desired pattern structure, and this pre-formed pattern is then transferred to the resin composition in a single contact step, eliminating the need for repeated material segregation and complex in-process adjustments
3Manufacturing precision
If surface modification with mask pattern is used to create surface free energy differences, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent uses the master template as a copying tool that transfers its pre-formed surface free energy pattern directly to the resin composition. This copying approach eliminates the need for mask-based surface modification processes, as the pattern is imprinted through contact rather than being created through complex mask alignment and surface treatment steps
4Manufacturing precision
If traditional lithography methods are used, then manufacturing precision is maintained, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces complex lithography equipment and chemical processes with a simple mechanical contact transfer system. The master template is brought into direct contact with the resin composition, and the pattern transfers through surface energy differential, eliminating the need for expensive lithography equipment, photoresists, and chemical development processes while maintaining pattern accuracy
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 method enables the easy attainment of patterns with different surface free energies, offering fine pitches and excellent size stability, reducing production costs and simplifying the process compared to traditional methods.
Implementation Method 1
curing the resin composition with bringing the resin composition into contact with a master, to which a pattern has been formed with surface free energy differences
Data Source
AI summary
To provide a production method of a pattern-formed body, which can simply provide a pattern with surface free energy differences. A cured resin layer, to which a pattern of a master (20) has been transferred, is formed on a base (11), by applying a resin composition (12) containing a first compound exhibiting low surface free energy, and a second compound exhibiting surface free energy higher than the surface free energy of the first compound, on the base (11), and curing the resin composition (12) with bringing the resin composition into contact with a master (20), to which a pattern has been formed with surface free energy differences.