PATTERN FORMATION METHOD AND PATTERN FORMATION APPARATUS

According to one embodiment, a pattern formation method includes preparing a mold including a first pattern, preparing a substrate including a second pattern, coating a photosensitive resin onto the substrate, bringing the mold into contact with the photosensitive resin, determining whether or not the photosensitive resin is filled between the first pattern and the second pattern, performing an alignment of the first pattern and the second pattern according to a first reference in the case where the photosensitive resin is filled between the first pattern and the second pattern, and performing the alignment of the first pattern and the second pattern according to a second reference different from the first reference in the case where the photosensitive resin is not filled between the first pattern and the second pattern, curing the photosensitive resin, and releasing the mold from the photosensitive resin.

DETAILED DESCRIPTION

In general, according to one embodiment, a pattern formation method includes preparing a mold including a first pattern, preparing a substrate including a second pattern, coating a photosensitive resin onto the substrate, bringing the mold into contact with the photosensitive resin, determining whether or not the photosensitive resin is filled between the first pattern and the second pattern, performing an alignment of the first pattern and the second pattern according to a first reference in the case where the photosensitive resin is filled between the first pattern and the second pattern, and performing the alignment of the first pattern and the second pattern according to a second reference different from the first reference in the case where the photosensitive resin is not filled between the first pattern and the second pattern, curing the photosensitive resin, and releasing the mold from the photosensitive resin.

Various embodiments will be described hereinafter with reference to the accompanying the drawings. In the description hereinbelow, similar members are marked with like reference numerals, and a description is omitted as appropriate for members once described.

First Embodiment

FIG. 1is a flowchart showing a pattern formation method according to a first embodiment.

FIGS. 2A to 2Dare schematic cross-sectional views showing a pattern formation method using a mold.

As shown inFIG. 1, the pattern formation method according to the first embodiment includes a process (step S101) of preparing a substrate, a process (step S102) of preparing a mold, a process (step S103) of coating a photosensitive resin, a process (step S104) of bringing the mold into contact, a process (step S105) of determining whether or not the photosensitive resin is filled, processes (steps S106and S110) of performing an alignment using the first reference or the second reference, a process (step S107) of determining the alignment, a process (step S108) of performing an exposure, and a process (step S109) of releasing the mold.

The pattern formation method according to the embodiment is a pattern formation method by imprinting using a mold (a master) including a concave-convex pattern. In the pattern formation method according to the embodiment, the alignment of the mold and the substrate is performed without waiting for the completion of the filling of the photosensitive resin by switching the reference of the alignment of the mold and the substrate according to the state of the filling of the photosensitive resin. Thereby, the throughput of the pattern formation is increased by reducing the time that is necessary from the contact of the mold with the photosensitive resin to the completion of the alignment.

An example of a pattern formation method using a mold will now be described with reference toFIGS. 2A to 2D.

First, as shown inFIG. 2A, a photosensitive resin70is coated onto a substrate250. The photosensitive resin70includes, for example, acrylic ester. The photosensitive resin70is coated onto the substrate250by, for example, inkjet from a nozzle N. The size of the liquid droplets of the photosensitive resin70is, for example, about several picoliters (pL). The spacing of the liquid droplets of the photosensitive resin70is, for example, not less than 10 micrometers (μm) and not more than 100 μm. The photosensitive resin70may be coated with a uniform thickness onto the substrate250by spin coating, etc.

Then, as shown inFIG. 2B, a mold110is prepared. The mold110includes a pattern portion P in which a concave-convex pattern is formed. Continuing, the pattern portion P of the mold110is brought into contact with the photosensitive resin70. The photosensitive resin70enters the interior of a concave pattern P1due to capillary action. The photosensitive resin70is filled into the concave pattern P1.

The pattern portion P of the mold110is brought into contact with the photosensitive resin70; and the alignment of the mold110and the substrate250is performed.

Then, light C is irradiated from a base member10side of the mold110in the state in which the alignment of the mold110and the substrate250is complete. The light C is, for example, ultraviolet light. The light C is irradiated onto the photosensitive resin70by passing through the base member10and the pattern portion P. The photosensitive resin70is cured by being irradiated with the light C.

Continuing as shown inFIG. 2C, the mold110is released from the photosensitive resin70. Thereby, a transfer pattern70a, onto which the uneven configuration of the pattern portion P of the mold110is transferred, is formed on the substrate250. When the mold110is brought into contact with the photosensitive resin70, a slight gap is provided between the mold110and the substrate250. The photosensitive resin70that enters the gap remains as a residual film70bafter the curing.

Then, processing is performed to remove the residual film70b. For example, etch-back of the transfer pattern70aand the residual film70bis performed by RIE (Reactive Ion Etching). Thereby, as shown inFIG. 2D, only the transfer pattern70aremains on the substrate250.

A specific example of the pattern formation method according to the embodiment will now be described.

FIGS. 3A and 3Bare schematic views showing the mold.

FIG. 3Ais a schematic plan view of the mold110.FIG. 3Bis a schematic cross-sectional view of line A-A shown inFIG. 3A. The mold110shown inFIGS. 3A and 3Bis an example of the mold that is prepared in step S101ofFIG. 1.

As shown inFIGS. 3A and 3B, the mold110includes the base member10, a pedestal portion20, and the pattern portion P. The base member10includes, for example, a material that is light-transmissive. The material of the base member10is, for example, silicon oxide (SiO2) or quartz. The outline of the base member10is, for example, a rectangle. The size of the outline of the base member10is, for example, 150 millimeters (mm) long by 150 mm wide.

The pedestal portion20is provided to protrude from the central portion of the base member10. The outline of the pedestal portion20is, for example, a rectangle. The size of the outline of the pedestal portion20is, for example, 33 mm long by 26 mm wide. The height of the pedestal portion20is, for example, 3 μm.

The pattern portion P includes the concave pattern P1and a protrusion pattern P2(a concave-convex pattern) provided in the pedestal portion20. The concave pattern P1is a pattern having a trench configuration that recedes from the surface of the pedestal portion20. In the case where multiple concave patterns P1are provided, the protrusion pattern P2is between two mutually-adjacent concave patterns P1.

As shown inFIG. 3A, a first alignment pattern (a first pattern) AP1is provided in the pedestal portion20. The first alignment pattern AP1is provided, for example, in the vicinity of the circumferential edge of the pedestal portion20. The first alignment pattern AP1may be provided inside the pattern portion P.

The first alignment pattern AP1includes a concave-convex pattern having a prescribed configuration. The first alignment pattern AP1is used to sense the positional shift between the mold110and the substrate250when overlaying the first alignment pattern AP1onto an alignment pattern on the substrate side described below. As an example in the embodiment, the case is described where a line-and-space concave-convex pattern is included in the first alignment pattern AP1.

FIG. 4is a schematic plan view showing a substrate.

The substrate250shown inFIG. 4is, for example, a semiconductor wafer. The substrate250shown inFIG. 4is an example of the substrate prepared in step S102ofFIG. 1. The substrate250may be any substrate such as an insulative substrate (a glass substrate, etc.), an SOI (Silicon On Insulator) substrate, etc. The substrate250includes a shot region R. The shot region R is the region where the pattern is transferred by one imprint by the mold110. The shot region R is, for example, a region corresponding to one chip, a region corresponding to multiple chips, or a region corresponding to a portion inside one chip.

The substrate250includes the second alignment pattern (a second pattern) AP2. The second alignment pattern AP2is provided inside the shot region R. In the case where multiple shot regions R are provided, the second alignment pattern AP2is provided in each of the shot regions R.

The second alignment pattern AP2includes a concave-convex pattern having a prescribed configuration. The second alignment pattern AP2is used to sense the positional shift between the mold110and the substrate250when overlaying the second alignment pattern AP2onto the first alignment pattern AP1of the mold110. As an example in the embodiment, the case is described where a line-and-space concave-convex pattern is included in the second alignment pattern AP2.

In the case where the pattern is formed by imprinting as shown inFIG. 4, the mold110is disposed on the shot region R of the substrate250. Then, an alignment of the mold110and the substrate250is performed according to the overlap state between the first alignment pattern AP1of the mold110and the second alignment pattern AP2of the substrate250.

For example, light (an alignment light) for the alignment is irradiated onto the first alignment pattern AP1and the second alignment pattern AP2in the state in which the mold110is disposed on the substrate250. The alignment light includes light of a wavelength that does not cure the photosensitive resin70.

The reflected light of the alignment light is received by a light receiving part (an alignment sensor); and the alignment is performed based on the waveform of the signal obtained by the light receiving part. For example, the alignment is performed using coherent light in the embodiment.

In the embodiment, the pitch in the first direction of the concave-convex pattern included in the first alignment pattern AP1is different from the pitch in the first direction of the concave-convex pattern included in the second alignment pattern AP2. The first alignment pattern AP1has a first spacing in a first direction. The second alignment pattern AP2has a second spacing in the first direction. The second spacing is not an integer multiple of the first spacing and not the first spacing divided by an integer.

The first alignment pattern AP1and the second alignment pattern AP2have diffraction gratings. In other words, moiré (interference fringes) due to the reflected light (the diffracted light) of the alignment light occurs when the alignment light is irradiated in the state in which the first alignment pattern AP1and the second alignment pattern AP2overlap each other. The alignment is performed by sensing the shading of the moiré and determining the shift amount between the first alignment pattern AP1and the second alignment pattern AP2from the waveform based on the shading.

FIG. 5Ashows the state in which the first alignment pattern AP1and the second alignment pattern AP2overlap each other,FIG. 5Bshows a waveform W1of the shading of the moiré occurring in the overlap state ofFIG. 5A. InFIG. 5B, the horizontal axis is the position; and the vertical axis is the light intensity.

In the example shown inFIG. 5A, the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2. In other words, air is interposed between the first alignment pattern AP1and the second alignment pattern AP2.

To perform the alignment of the mold110and the substrate250, for example, the positions of the peaks of the waveform W1of the shading of the moiré such as that shown inFIG. 5Bare sensed. The optical characteristics of the mold110are different from the optical characteristics of air. Accordingly, the waveform W1has a large amplitude. Then, the positional relationship between the mold110and the substrate250is adjusted to cause the positions of the peaks that are sensed to be positioned at a prescribed position.

FIG. 5Cshows the state in which the first alignment pattern AP1and the second alignment pattern AP2overlap each other.FIG. 5Dshows a waveform W2of the shading of the moiré occurring in the overlap state ofFIG. 5C. InFIG. 5D, the horizontal axis is the position; and the vertical axis is the light intensity.

In the example shown inFIG. 5C, the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. Here, in the case where the optical characteristics (e.g., the refractive index and the extinction coefficient at the wavelength of the alignment light) of the photosensitive resin70are substantially the same as the optical characteristics of the mold110, the amplitude of the waveform W2of the shading of the moiré becomes extremely small.

FIG. 6Ashows the state in which the first alignment pattern AP1and the second alignment pattern AP2overlap each other. A light-shielding film SH, which is made of a material (e.g., chrome (Cr)) that has different optical characteristics than those of the mold110and the photosensitive resin70, is provided in the concave pattern of the first alignment pattern AP1of the mold110shown inFIG. 6A.FIG. 6Bshows a waveform W10of the shading of the moiré occurring in the overlap state ofFIG. 6A. InFIG. 6B, the horizontal axis is the position; and the vertical axis is the light intensity.

In the example shown inFIG. 6A, the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2. In other words, air is interposed between the first alignment pattern AP1and the second alignment pattern AP2. Generally, the optical constants (e.g., the extinction coefficient and the refractive index) of air are different from the optical constants of the photosensitive resin70and the optical constants of the mold110. Therefore, in the case where the mold110including the light-shielding film SH is used, the waveform W10of the shading of the moiré has an amplitude that is substantially equivalent to that of the waveform W1shown inFIG. 5B.

FIG. 6Cshows the state in which the first alignment pattern AP1and the second alignment pattern AP2overlap each other. Similarly to the mold110shown inFIG. 6A, the mold110shown inFIG. 6Cincludes the light-shielding film SH.FIG. 6Dshows a waveform W20of the shading of the moiré occurring in the overlap state ofFIG. 6C. InFIG. 6D, the horizontal axis is the position; and the vertical axis is the light intensity.

In the example shown inFIG. 6C, the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. In the case where the light-shielding film SH is provided in the concave pattern of the first alignment pattern AP1of the mold110, the amplitude of the waveform W20of the shading of the moiré is less than the amplitude of the waveform W10shown inFIG. 6B. However, the amplitude of the waveform W20is greater than the amplitude of the waveform W2shown inFIG. 5D.

For example, even in the case where the optical characteristics of the photosensitive resin70are substantially the same as the optical characteristics of the mold110, the amplitude of the waveform W20is obtained when using the mold110including the light-shielding film SH.

In the pattern formation method according to the embodiment, to perform an alignment such as that recited above, a determination of whether or not the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2is performed (step S105ofFIG. 1). Then, in the case where it is determined that the photosensitive resin70is filled between the first alignment pattern API and the second alignment pattern AP2, the alignment using the first reference is performed (step S106ofFIG. 1); and in the case where it is determined that the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2, the alignment using the second reference which is different from the first reference is performed (step S110ofFIG. 1).

Here, the determination of whether or not the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2is performed according to, for example, the change of the waveforms W1, W2, W10, and W20such as those shown inFIG. 5B,FIG. 5D,FIG. 6B, andFIG. 6D.

For example, in the case where the light-shielding film SH is not provided in the mold110as shown inFIGS. 5A to 5D, the waveform W1is obtained when the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2; and the waveform W2is obtained when the photosensitive resin70is filled. Accordingly, the information of whether or not the photosensitive resin70is filled is obtained from the waveforms (the waveform W1and the waveform W2) of the signal of the reflected light of the alignment light obtained by the light receiving part.

Similarly, in the case where the light-shielding film SH is provided in the mold110as shown inFIGS. 6A to 6D, the information of whether or not the photosensitive resin70is filled is obtained from the waveforms (the waveform W10and the waveform W20) of the signal obtained by the light receiving part.

Although the determination of whether or not the photosensitive resin70is filled is performed using the first alignment pattern AP1and the second alignment pattern AP2in the example recited above, another pattern may be used. For example, a third pattern (a pattern that is different from the first alignment pattern AP1and the second alignment pattern AP2) may be provided in the mold110; and the third pattern may be used to determine whether or not the photosensitive resin70is filled. Even in the case where the third pattern is used, it is sufficient to perform the determination according to the change of the waveform, intensity, phase, or the like of the reflected light of the alignment light that is caused by whether or not the photosensitive resin70is filled. It is desirable for the third pattern to be provided in the vicinity of the first alignment pattern AP1.

In the embodiment, the alignment of the mold110and the substrate250is performed using the first reference (step S106ofFIG. 1) in the case where it is determined that the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2in step S105shown inFIG. 1.

Here, the first reference includes a first range to sense the shading of the moiré in the case where the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. For example, in the case where the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2as shown inFIG. 6C, a first range RG1having the amplitude of the waveform W20shown inFIG. 6Dis set as the detection range of the waveform W20.

On the other hand, the alignment of the mold110and the substrate250is performed using the second reference (step S110ofFIG. 1) in the case where it is determined that the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2in step S105shown inFIG. 1.

The second reference includes a second range to sense the shading of the moiré in the case where the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2. For example, in the case where the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2as shown inFIG. 6A, a second range RG2having the amplitude of the waveform W10shown inFIG. 6Bis set as the detection range of the waveform W10. For example, the second range RG2is wider than the first range RG1.

Thus, in the embodiment, the optimal detection range of the waveforms W10and W20when performing the alignment is set based on whether or not the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. Accordingly, in the embodiment, the waveforms W10and W20are sensed using the optimal detection range in both the case where the photosensitive resin70is filled between the first alignment pattern API and the second alignment pattern AP2and the case where the photosensitive resin70is not filled between the first alignment pattern AP1and the second alignment pattern AP2.

Generally, in a pattern formation method by imprinting, the alignment of the mold110and the substrate250is performed after bringing the mold110into contact with the photosensitive resin70and waiting until the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2.

Conversely, in the embodiment, the alignment of the mold110and the substrate250is started after bringing the mold110into contact with the photosensitive resin70without waiting until the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. In other words, in the embodiment, the alignment is started directly after bringing the mold110into contact with the photosensitive resin70.

Also, the waveforms (e.g., the waveforms W20and W10) are sensed using the optimal detection ranges (e.g., the first range RG1and the second range RG2) based on the existence and absence, respectively, of the photosensitive resin70between the first alignment pattern AP1and the second alignment pattern AP2. Accordingly, the wait time to fill the photosensitive resin70between the first alignment pattern API and the second alignment pattern AP2after bringing the mold110into contact with the photosensitive resin70becomes unnecessary. That is, the throughput of the pattern formation increases.

Further, because the waveforms W10and W20are sensed using the optimal detection ranges based on the existence and absence, respectively, of the photosensitive resin70between the first alignment pattern AP1and the second alignment pattern AP2in the embodiment, the waveforms W10and W20are sensed with high precision regardless of the existence or absence of the photosensitive resin70.

FIG. 7Ashows moiré M1in the state in which the photosensitive resin70is not filled.FIG. 7Ashows the first alignment pattern AP1and the second alignment pattern AP2. A portion of the first alignment pattern AP1overlaps a portion of the second alignment pattern AP2. The moiré M1occurs in the overlapping portion.

FIG. 7Bshows a waveform W11of the moiré M1. The waveform W11has an amplitude AMP1. In such a case, the alignment is performed by sensing the waveform W11using the second range RG2included in the second reference as the detection range.

FIG. 8Ashows moiré M2in the state in which the photosensitive resin70is filled,FIG. 8Ashows the first alignment pattern AP1and the second alignment pattern AP2. A portion of the first alignment pattern API overlaps a portion of the second alignment pattern AP2. The moiré M2occurs in the overlapping portion.

FIG. 8Bshows a waveform W21of the moiré M2. The waveform W21has an amplitude AMP2. The amplitude AMP2is less than the amplitude AMP1. In such a case, the alignment is performed by sensing the waveform W21using the first range RG1included in the first reference as the detection range.

FIG. 9is a schematic plan view showing a group of alignment patterns.

FIG. 9shows an example of a group G of alignment patterns provided in the mold110. Alignment patterns that correspond to the alignment patterns of the mold110are provided in the substrate250.

As shown inFIG. 9, the group G of alignment patterns includes a pattern AP51for performing a rough alignment and a pattern AP52for performing a precise alignment. A plurality of the patterns AP51and a plurality of the patterns AP52may be provided. The pattern AP52for performing the precise alignment includes, for example, the first alignment pattern AP1.

The pattern AP51for performing the rough alignment may include a third pattern AP53to determine whether or not the photosensitive resin70is filled.

After the alignment of the mold110and the substrate250is completed, the light from the light emitting part is irradiated onto the photosensitive resin70. The photosensitive resin70is cured by the irradiation of the light. After the photosensitive resin70is cured, the mold110is released from the photosensitive resin70. Thereby, a pattern, onto which the configuration of the concave-convex pattern of the mold110is transferred, is formed on the substrate250.

In the pattern formation method according to the embodiment, the alignment is performed after bringing the mold110into contact with the photosensitive resin70without waiting until the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. Accordingly, the throughput of the pattern formation increases. The alignment is performed for each of the shot regions R on the substrate250. Accordingly, the effect of increasing the throughput is obtained more markedly as the number of shot regions R provided on the substrate250is increased.

Second Embodiment

FIG. 10is a schematic view showing the configuration of a pattern formation apparatus according to a second embodiment.

As shown inFIG. 10, the pattern formation apparatus200includes a mold holder (a first holder)2, a substrate holder (a second holder)5, a driver8, a coating part14, a light emitting part12, and a controller21. The pattern formation apparatus200further includes an alignment sensor7, an alignment part9, and a pressing part15. The pattern formation apparatus200according to the embodiment is an imprint apparatus that transfers the configuration of the concave-convex pattern of the mold110onto the photosensitive resin70on the substrate250.

The substrate250is, for example, a semiconductor substrate or a glass substrate. A foundation pattern is formed in the substrate250. The substrate250may include a film formed on the foundation pattern. The film is at least one selected from an insulating film, a metal film (a conductive film), and a semiconductor film. A resin is coated onto the substrate250when transferring the pattern.

The substrate holder5is movably provided on a stage planar table13. The substrate holder5is provided to be movable along two axes along an upper surface13aof the stage planar table13. Herein, the two axes along the upper surface13aof the stage planar table13are taken as an X axis and a Y axis. The substrate holder5is provided to be movable also along a Z axis that is orthogonal to the X axis and the Y axis. It is desirable for the substrate holder5to be provided rotatably around the X axis, the Y axis, and the Z axis.

A reference mark table6is provided in the substrate holder5. A reference mark (not shown) that is used as the reference position of the apparatus is mounted on the reference mark table6. For example, the reference mark includes a diffraction grating. The reference mark is utilized to calibrate the alignment sensor7and align (control/adjust the orientation of) the mold110. The reference mark is used as an origin on the substrate holder5. The X, Y coordinates of the substrate250placed on the substrate holder5are coordinates having the reference mark table6as the origin.

The mold holder2fixes the mold110. The mold holder2holds the circumferential edge portion of the mold110by, for example, vacuum-attaching. Here, the mold110is formed of a material such as quartz, fluorite, etc., that transmits ultraviolet (UV light). The concave-convex pattern formed in the mold110may include a pattern corresponding to the device pattern and alignment patterns used in the alignment of the mold110and the substrate250. The mold holder2operates to align the mold110with the apparatus reference. The mold holder2is mounted to a base part11.

The alignment part9and the pressing part15(the actuator) are mounted to the base part11. The alignment part9includes an adjustment mechanism that finely adjusts the position (the orientation) of the mold110. The relative positions of the mold110and the substrate250are corrected by the alignment part9finely adjusting the position (the orientation) of the mold110. For example, the alignment part9performs the alignment of the substrate250and the mold110and the fine adjustment of the position of the mold110by receiving an instruction from the controller21.

The pressing part15causes the mold110to distort by applying stress to the side surfaces of the mold110. In the case of a rectangular mold110, the pressing part15presses the mold110toward the center from the four side surfaces of the mold110. Thereby, the alignment of the mold110is performed. Also, the pressing part15causes the mold110to deform by the balance of the pressing of the mold110. For example, the pressing part15presses the mold110with a prescribed stress by receiving an instruction from the controller21.

The alignment sensor7senses the first alignment pattern AP1provided in the mold110and the second alignment pattern AP2provided in the substrate250. The alignment sensor7includes, for example, an optical camera. The relative positional shift amount of the first alignment pattern AP1and the second alignment pattern AP2is determined from, for example, the signal (the waveform) of the image of the moiré that is acquired by the optical camera.

The alignment sensor7senses the positional shift of the mold110with respect to the reference mark on the reference mark table6and the positional shift of the mold110using the substrate250as a reference. For example, the signal (the waveform) of the image of the moiré that is sensed by the alignment sensor7is transmitted to the controller21. The alignment sensor7may be fixed or movable.

The controller21calculates the positional shift amount based on the positional information of the first alignment pattern AP1and the second alignment pattern AP2sensed by the alignment sensor7. The alignment part9performs the alignment adjustment between the substrate250and the mold110according to the signal transmitted from the controller21.

The controller21controls the light emitting part12. When forming the pattern by imprinting, after coating the photosensitive resin70onto the substrate250, light is irradiated onto the photosensitive resin70from the light emitting part12in the state of the concave-convex pattern of the mold110being in contact with the photosensitive resin70. The controller21controls the irradiation timing and/or the irradiation amount of the light.

The light emitting part12emits, for example, ultraviolet light. For example, the light emitting part12is mounted directly above the mold110. The position of the light emitting part12is not limited to being directly above the mold110. In the case where the light emitting part12is disposed at a position other than directly above the mold110, it is sufficient to use a configuration in which an optical path is set using an optical member such as a mirror, etc., and the light emitted from the light emitting part12is irradiated toward the mold110from directly above the mold110.

The coating part14coats the photosensitive resin70onto the substrate250. The coating part14includes a nozzle; and the photosensitive resin70is dropped onto the substrate250from the nozzle.

The driver8drives the mold holder2and the substrate holder5. The driver8changes the relative positional relationship between the mold110and the substrate250by driving at least one selected from the mold holder2and the substrate holder5.

After bringing the concave-convex pattern of the mold110into contact with the photosensitive resin70, the controller21of the pattern formation apparatus200performs a control to perform the alignment of the mold110and the substrate250and irradiate light toward the photosensitive resin70. The controller21executes the processing of step S101to step S110shown inFIG. 1. Here, the preparation of the mold shown in step S101includes the mold110being held by the mold holder2. The preparation of the substrate shown in step S102includes the substrate250being held by the substrate holder5.

According to such a pattern formation apparatus200, the alignment is performed after bringing the mold110into contact with the photosensitive resin70without waiting until the photosensitive resin70is filled between the first alignment pattern AP1and the second alignment pattern AP2. Accordingly, the throughput of the pattern formation increases.

Third Embodiment

The pattern formation method according to the first embodiment described above is realizable as a program (a pattern formation program) that is executed by a computer.

FIG. 11shows the hardware configuration of the computer.

A computer300includes a central processing unit301, an input unit302, an output unit303, and a memory304. The input unit302also functions to read information recorded in a recording medium M. The pattern formation program is executed by the central processing unit301.

The pattern formation program causes the computer300to execute the processing of step S101to step S110shown inFIG. 1.

Fourth Embodiment

The pattern formation program may be recorded in a computer-readable recording medium. The recording medium M stores the processing of step S101to step S110shown inFIG. 1in a format that is readable by the computer300. The recording medium M may be a memory device such as a server, etc., connected to a network. Also, the pattern formation program may be distributed via the network.

As described above, according to the pattern formation method and the pattern formation apparatus according to the embodiments, the throughput of the pattern formation can be increased.

Although the embodiments are described above, the invention is not limited to these examples. For example, the alignment of the first alignment pattern AP1and the second alignment pattern AP2is not limited to sensing the shading of the moiré; and any means for sensing the information of the positional shift is applicable. Additions, deletions, or design modifications of components or appropriate combinations of the features of the embodiments appropriately made by one skilled in the art in regard to the embodiments described above are within the scope of the invention to the extent that the spirit of the invention is included.