Soft Mold Fabrication via Selective Curing and Threshold Prevention
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Solution Overview
Problem
Existing methods for fabricating soft molds face challenges when the master mold is smaller than the substrate, leading to threshold formation and poor attachment, resulting in incomplete or distorted fine patterns during in-plane printing.
Innovation Solution
A method involving the use of thermal or UV curing of pre-polymer layers on a jig with selective curing and removal of uncured portions, combined with coupling agent treatment and nucleic acid solution dipping, to ensure precise alignment and attachment of the soft mold to the substrate without threshold formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the master mold is made smaller than the substrate to be patterned, then the alignment flexibility is improved, but threshold formation occurs at the corner of the mold causing poor attachment and incomplete pattern formation
Solution Approach 1:
The patent divides the mold structure into two distinct parts: a master mold containing the fine pattern and a separate threshold prevention structure (raised portion or protrusion) that extends beyond the master mold boundaries. This segmentation allows the master mold to remain smaller than the substrate while the threshold prevention structure ensures complete contact between the soft mold and substrate, eliminating threshold formation and enabling high-quality pattern transfer.
2Ease of operation
If the master mold size is reduced for better alignment, then positioning ease is improved, but the mold becomes spaced apart from the substrate due to threshold formation
Solution Approach 1:
The patent introduces a threshold prevention structure (raised portion or protrusion) as an intermediary element between the master mold and the substrate. This intermediary structure extends beyond the master mold boundaries and ensures continuous contact with the substrate, acting as a mediator that maintains reliable mold-substrate attachment while allowing the master mold itself to remain smaller for easier alignment and positioning.
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 allows for the successful formation of fine patterns even when the master mold is smaller than the substrate, preventing threshold formation and ensuring proper mold alignment, thereby enhancing the accuracy and quality of pattern formation.
Implementation Method 1
selectively thermal-curing the pre-polymer layer in the microwave oven to selectively form a polymer layer
Implementation Method 2
selectively UV-curing the pre-polymer layer using a mask having a light-transmitting portion and a light-shielding portion to selectively form a polymer layer
Data Source
AI summary
A method for fabricating a soft mold is disclosed, in which process matching is high regardless of a size of a master mold for forming the soft mold. The method for fabricating a soft mold includes arranging a master mold on a jig, forming a pre-polymer layer in the jig, attaching a back-plane substrate onto the pre-polymer layer, selectively curing the pre-polymer layer to selectively form a polymer layer, stripping the polymer layer and the pre-polymer layer from the jig and the master mold, and removing the pre-polymer layer that is not cured.