Soluble Mold Imprint with Dissociable Tape for Defect-Free Patterns
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Solution Overview
Problem
The existing imprint methods using soluble molds face challenges with mold release, leading to mold damage and defective fine structures due to strong adherence, and deformation of the formed structures from uneven distribution and expansion of the mold material.
Innovation Solution
The method involves creating a soluble mold with a dissociable tape and a ring frame for easy separation from the master mold, aligning it accurately on a polymer layer using alignment marks, applying high temperature and pressure for imprint pattern formation, and dissolving the mold with a solvent to obtain a defect-free imprint workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a soluble mold is used to form fine structures through imprint, then the mold can be removed from the master mold, but strong adherence between the mold and transfer article causes mold damage and defective fine structures
Solution Approach 1:
A dissociable tape is introduced as an intermediary layer between the soluble mold and the master mold. The tape is adhered to the soluble mold before imprinting, allowing easy separation from the master mold while preventing direct contact between the mold and the transfer article, thus avoiding mold damage and ensuring defect-free fine structures.
Solution Approach 2:
The mold removal process is segmented into distinct stages: first separating the soluble mold from the master mold using the dissociable tape, then performing the imprinting process. This segmentation allows independent optimization of each step, ensuring complete mold removal without compromising the integrity of the transfer article.
2Strength
If the soluble material concentration and thickness are increased to improve mold strength, then the curing time increases, requiring operator expertise to determine the optimal curing level
Solution Approach 1:
The dissociable tape is adhered to the soluble mold immediately after molding, before the curing process is complete. This preliminary action allows the mold to be prepared for separation while still in a manageable state, eliminating the need for extended curing times and operator judgment about optimal curing levels.
3Manufacturing precision
If the soluble mold material is evenly distributed on the article using a roller, then the imprint process can proceed, but the structure spaces expand causing deformation of the formed fine structures
Solution Approach 1:
The dissociable tape serves as a mediator that prevents direct contact between the soluble mold and the transfer article. This intermediary layer eliminates the need for roller application of soluble material, preventing structure space expansion and maintaining the geometric accuracy of the formed fine structures.
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 enhances the ease of mold removal, ensures accurate alignment and pattern formation, and prevents structural defects, resulting in high-quality optical elements with improved optical properties.
Implementation Method 1
solidifying the soluble material to form a soluble mold having a mold pattern
Implementation Method 2
applying a high temperature and a pressure to the soluble mold to allow the polymer layer having an imprint pattern corresponding to the mold pattern and solidification, and to dissociate the tape
Implementation Method 3
applying a high temperature and a pressure to the soluble mold to allow the polymer layer having an imprint pattern corresponding to the mold pattern
Implementation Method 4
providing a solvent to dissolve the soluble mold to obtain an imprint workpiece having the imprint pattern
Data Source
AI summary
An imprint method provided herein includes the steps of: adding a soluble material to a master mold; solidifying the soluble material to form a soluble mold having a mold pattern; adhering a dissociable tape to the soluble mold to separate the soluble mold from the master mold; placing the soluble mold onto a polymer layer of a workpiece for imprint; applying a high temperature and a pressure to the soluble mold to allow the polymer layer having an imprint pattern corresponding to the mold pattern and solidification, and to dissociate the tape; and providing a solvent to dissolve the soluble mold to obtain an imprint workpiece having the imprint pattern.