Source: http://www.google.com/patents/US7997890?dq=6,205,432
Timestamp: 2014-07-13 01:51:02
Document Index: 494897972

Matched Legal Cases: ['art.\n8', 'art.\n10', 'Application No. 04445057', 'Application No. 60', 'art 101', 'art 102', 'art 101', 'art 102', 'art 102', 'arts 101', 'arts 101', 'art 102', 'Application No. 2005', 'Application No. 04']

Patent US7997890 - Device and method for lithography - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsApparatus and method for transferring a pattern from a template (10) having a structured surface to a substrate (12) carrying a surface layer of a radiation polymerisable fluid (14). The apparatus comprises a first main part (101) and a second main part (102) having opposing surfaces (104;105), means...http://www.google.com/patents/US7997890?utm_source=gb-gplus-sharePatent US7997890 - Device and method for lithographyAdvanced Patent SearchPublication numberUS7997890 B2Publication typeGrantApplication numberUS 11/905,036Publication dateAug 16, 2011Filing dateSep 27, 2007Priority dateMay 7, 2004Also published asCN1700100A, CN101073034A, CN101073034B, EP1594001A1, EP1743217A2, EP1743217B1, US7972553, US20050274693, US20070164487, US20080030700, WO2005109095A2, WO2005109095A3Publication number11905036, 905036, US 7997890 B2, US 7997890B2, US-B2-7997890, US7997890 B2, US7997890B2InventorsBabak Heidari, Marc BeckOriginal AssigneeObducat AbExport CitationBiBTeX, EndNote, RefManPatent Citations (40), Non-Patent Citations (18), Referenced by (2), Classifications (34) External Links: USPTO, USPTO Assignment, EspacenetDevice and method for lithographyUS 7997890 B2Abstract Apparatus and method for transferring a pattern from a template (10) having a structured surface to a substrate (12) carrying a surface layer of a radiation polymerisable fluid (14). The apparatus comprises a first main part (101) and a second main part (102) having opposing surfaces (104;105), means for adjusting a spacing (115) between said main parts, support means (106) for supporting said template and substrate in mutual parallel engagement in said spacing with said structured surface facing said surface layer, a radiation source (110) devised to emit radiation into said spacing. A cavity (115) has a first wall comprising a flexible membrane (113) devised to engage said template or substrate, and means (114;116) are provided for applying an adjustable overpressure to a medium present in said cavity, whereby an even distribution of force is obtained over the whole of the contact surface between the substrate and the template. The apparatus further includes a heater device having a surface facing said spacing, for heating either fluid layer (14).
1. Apparatus for transferring a pattern from a template having a structured surface to a substrate carrying a surface layer of a radiation polymerisable fluid, said apparatus comprising:
a first main part and a second main part having opposing surfaces,
means for adjusting a spacing between said main parts,
support means for supporting said template and substrate in mutual parallel engagement in said spacing with said structured surface facing said surface layer,
a radiation source wherein said radiation source is positioned in said first main part, devised to emit radiation usable for solidifying a selected polymerisable fluid into said spacing from a first direction,
a cavity having a first wall comprising a flexible membrane devised to engage said template or substrate, means for applying an adjustable overpressure to a medium present in said cavity, said cavity being defined by a part of the surface of said first main part, a flexible seal member arranged in and protruding from said first main part surface and said membrane which engages said seal member, said membrane being transparent to a wavelength range of said radiation, said radiation source being positioned behind said membrane, and
a heater device having a surface facing said spacing, wherein said heater device is positioned in said second main part, having said surface of the heater device facing said spacing from a second direction, opposite said first direction.
2. The apparatus as recited in claim 1, wherein said heater device comprises a heating element, connected to an energy source.
3. The apparatus as recited in claim 2, wherein said heater device comprises a cooling element, connected to a cooling source.
4. The apparatus as recited in claim 1, wherein said medium comprises a gas.
5. The apparatus as recited in claim 4, wherein said medium comprises air.
6. The apparatus as recited in claim 1, wherein said means for applying an adjustable overpressure is arranged to adjust the pressure to 1-500 bar.
7. The apparatus as recited in claim 1, wherein said membrane is disconnectable from said seal member, and devised to engage said seal member by application of pressure from said second main part.
8. The apparatus as recited in claim 1, wherein said membrane is transparent to a wavelength range of said radiation, said radiation source being positioned behind said membrane.
9. The apparatus as recited in claim 1, wherein said membrane and at least a portion of said surface of said first main part is transparent to a wavelength range of said radiation, said radiation source being positioned behind said portion of said surface of said first main part.
10. The apparatus as recited in claim 1, wherein said portion of said surface of said first main part is made from quartz, calcium fluoride or any other pressure stable material being transparent to said radiation.
11. The apparatus as recited in claim 1, wherein said radiation source is devised to emit radiation at least in a wavelength range of 100-500 nm.
12. The apparatus as recited in claim 8, wherein said radiation source is devised to emit pulsating radiation with a pulse duration of 0.5-10 μs and a pulse rate of 1-10 pulses per second.
13. The apparatus as recited in claim 1, wherein said membrane is made from a polymer material.
14. The apparatus as recited in claim 1, wherein said membrane has a diameter or width of 50-1000 mm.
15. The apparatus as recited in claim 1, where said substrate acts as said membrane.
CROSS REFERENCE TO RELATED APPLICATIONS This application is a divisional of application Ser. No. 11/123,087 filed May 6, 2005, which claims the priority of European Patent Application No. 04445057.5, filed May 7, 2004; and the benefit of U.S. Provisional Application No. 60/521,562, filed May 25, 2004, the contents of all of which are incorporated herein by reference.
FIELD OF THE INVENTION The invention relates to a device in connection with the lithography of structures on a micro or nanometer scale. In particular, the invention relates to imprint lithography on substrates or objects.
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide methods and means for improving fabrication of structures comprising three-dimensional features on a micro or nanometer scale. In particular, it is an object to provide improved methods and means for transferring a pattern of such structures to substrates having widths of more than one inch, and even for 8 inch diameters, 12 inch diameters, and larger. An aspect of this object is to provide an apparatus and an associated process which is more cost effective and more versatile.
According to a first aspect, this object is fulfilled by an apparatus for transferring a pattern from a template having a structured surface to a substrate carrying a surface layer of a radiation polymerisable fluid, said apparatus comprising a first main part and a second main part having opposing surfaces, means for adjusting a spacing between said main parts, support means for supporting said template and substrate in mutual parallel engagement in said spacing with said structured surface facing said surface layer, a radiation source devised to emit radiation into said spacing, a cavity having a first wall comprising a flexible membrane devised to engage said template or substrate, means for applying an adjustable overpressure to a medium present in said cavity, and a heater device having a surface facing said spacing. Due to the flexible membrane, an absolutely even distribution of force is obtained over the whole of the contact surface between the substrate and the template, whereby patterning of large area substrates in a single imprint step is made possible.
Preferably, said radiation source is positioned in said first main part, devised to emit radiation into said spacing from a first direction, and said heater device is positioned in said second main part, having said surface of the heater device facing said spacing from a second direction, opposite said first direction.
In one embodiment, said heater device comprises a heating element, connected to an energy source.
In one embodiment, said heater device comprises a cooling element, connected to a cooling source.
arranging said template and substrate mutually parallel in an imprint apparatus, with said structured surface facing said surface layer, between a stop member and a first side of a flexible membrane; heating said surface layer by means of a heater device in said imprint apparatus; applying an overpressure to a medium present on a second side of the membrane, opposite to said first side, for imprinting said pattern into said layer; and exposing said layer to radiation for solidifying said layer. In a preferred embodiment, the method further comprises the step of:
baking said layer by providing heat from said heater device after said step of exposing said layer to radiation. Preferably, said medium comprises a gas or a liquid.
clamping said membrane at a peripheral portion thereof between said stop member and a seal member, thereby defining a peripheral wall for a cavity for said medium. Preferably, the method comprises the steps of:
emitting radiation to said layer through said template, which template is transparent to a wavelength range of a radiation usable for polymerising said fluid; and heating said substrate by direct contact with said heater device. Alternatively, the method may comprise the steps of:
emitting radiation to said layer through said substrate, which substrate is transparent to a wavelength range of a radiation usable for polymerising said fluid; and heating said template by direct contact with said heater device. In a preferred embodiment, the method comprises the step of:
applying a vacuum between said template and said substrate in order to extract air inclusions from said surface layer prior to exposing said layer to radiation. According to a third aspect, the object of the present invention is fulfilled by a method for transferring a pattern from a template having a structured surface to a substrate carrying a surface layer of a radiation polymerisable fluid, wherein said template includes protrusions defining a pattern, which protrusions have non-transparent layers at outer ends, comprising the steps of:
arranging said template and substrate mutually parallel in an imprint apparatus, with said structured surface facing said surface layer, between a stop member and a first side of a flexible membrane; heating said surface layer by means of a heater device in said imprint apparatus; applying an overpressure to a medium present on a second side of the membrane, opposite to said first side, for imprinting said pattern into said layer; and exposing said layer to radiation for solidifying said layer at portions between said protrusions. In a preferred embodiment, the method further comprises the step of:
baking said layer by providing heat from said heater device after said step of exposing said layer to radiation. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in greater detail below with reference to the accompanying drawings, on which:
FIG. 7 schematically illustrates an embodiment of an apparatus according to the invention, for performing the process as generally described in FIG. 1-3 or 4-6;
FIGS. 10-12 illustrates an alternative embodiment of an imprint process according to the present invention.
Substrate 12 is positioned on a heater device 20. Heater device 20 preferably comprises a heater body 21 of metal, e.g. aluminium. A heater element 22 is connected to or included in heater body 21, for transferring thermal energy to heater body 21. In one embodiment, heater element 22 is an electrical immersion heater inserted in a socket in heater body 21. In another embodiment, an electrical heating coil is provided inside heater body 21, or attached to a lower surface of heater body 21. In yet another embodiment, heating element 22 is a formed channel in heater body 21, for passing a heating fluid through said channel. Heater element 22 is further provided with connectors 23 for connection to an external energy source (not shown). In the case of electrical heating, connectors 23 are preferably galvanic contacts for connection to a current source. For an embodiment with formed channels for passing a heating fluid, said connectors 23 are preferably conduits for attachment to a heated fluid source. The heating fluid may e.g. be water, or an oil.
Heater body 21 is preferably a piece of cast metal, such as aluminium, stainless steel, or other metal. Furthermore, a body 21 of a certain mass and thickness is preferably used such that an even distribution of heat at an upper side of heater device 20 is achieved, which upper side is connected to substrate 12 for transferring heat from body 21 through substrate 12 to heat layer 14. For an imprint process used to imprint 2.5″ substrates, a heater body 21 of at least 2.5″ diameter, and preferably 3″ or more, is used, with a thickness of at least 1 cm, preferably at least 2 or 3 cm. For an imprint process used to imprint 6″ substrates, a heater body. 21 of at least 6″ diameter, and preferably 7″ or more, is used, with a thickness of at least 2 cm, preferably at least 3 or 4 cm. Heater device 20 is preferably capable of heating heater body 21 to a temperature of 200-300� C., though lower temperatures will be sufficient for most processes.
For the purpose of providing controlled cooling of layer 14, heater device 20 is further provided with a cooling element 24 connected to or included in heater body 21, for transferring thermal energy from heater body 21. In a preferred embodiment, cooling element 24 comprises a formed channel or channels in heater body 21, for passing a cooling fluid through said channel or channels. Cooling element 24 is further provided with connectors 25 for connection to an external cooling source (not shown). Preferably, said connectors 25 are conduits for attachment to a cooling fluid source. Said cooling fluid is preferably water, but may alternatively be an oil, e.g. an insulating oil, or any other suitable coolant.
The arrows of FIG. 1 illustrate that the template surface 11 is pressed into surface 16 of the polymerisable fluid layer 14. At this step, heater device 20 is preferably used to control the temperature of layer 14, for obtaining a suitable viscosity in the material of layer 14.
FIG. 2 illustrates how the structures of template surface 11 has made an imprint in the fluid layer 14, at which the fluid has been forced to fill the recesses in template surface 11. In the illustrated embodiment, the highest protrusions in template surface 11 do not penetrate all the way down to substrate surface 17. This may be beneficial for protecting the substrate surface 17, and particularly the template surface 11, from damage. However, in alternative embodiments, such as one including a transfer layer, imprint may be performed all the way down to transfer layer surface 17. In the embodiment illustrated in FIGS. 1-3, the template is made from a material which is transparent to radiation 19 of a predetermined wavelength or wavelength range, which is usable for solidifying a selected polymerisable fluid. Such materials may e.g. be quartz or various forms of polymers, dependent on the radiation wavelength. Radiation 19 is typically applied when template 10 has been pressed into fluid layer 14 with a suitable alignment between template 10 and substrate 12. When exposed to this radiation 19, solidification of the polymerisable fluid is initiated, for solidification to a solid body 14′ taking the shape determined by the template 10. However, heater device 20 is preferably used to provide heat to layer 14′, for baking layer 14′ to a solid body before separation of template 10 and substrate 12.
FIGS. 4-6 schematically present the basic process steps of the actual pattern transfer steps, or imprint steps, of an alternative embodiment of the invention. The only real difference from the embodiment of FIGS. 1-3 is that in this embodiment the radiation 19 is applied through substrate 12 instead of through template 10, while the same reference marks have been used. Furthermore, heater device 20 is instead connected to template 10, for heating layer 14 through template 10. Heater device 20 of FIGS. 4-6 otherwise comprises the same features as the heater device of FIGS. 1-3, wherefore the same reference markings have been used. No further explanation of the features of FIGS. 4-6 will therefore be made.
In operation, apparatus 100 is further provided with a flexible membrane 113, which is substantially flat and engages seal member 108. In a preferred embodiment, seal member 113 is a separate member from seal member 108, and is only engaged with seal member 108 by applying a counter pressure from surface 105 of plate 106, as will be explained. However, in an alternative embodiment, membrane 113 is attached to seal member 108, e.g. by means of a cement, or by being an integral part of seal member 108. Furthermore, in such an alternative embodiment, membrane 113 may be firmly attached to main part 101, whereas seal 108 is disposed outwardly of membrane 113. For an embodiment such as the one illustrated, also membrane 113 is formed in a material which is transparent to radiation of a certain wavelength or wavelength range of radiation source 110. This way, radiation emitted from radiation source 110 is transmitted into spacing 103 through said cavity 115 and its boundary walls 104 and 113. Examples of usable materials for membrane 113, for the embodiment of FIGS. 7-9, include polycarbonate, polypropylene, polyethylene. The thickness of membrane 113 may typically be 10-500 μm.
FIG. 8 illustrates the apparatus embodiment of FIG. 7, when being loaded with a substrate and a template for a lithographic process. For better understanding of this drawing, reference is also made to FIGS. 1-3. Second main part 102 has been displaced downwards from first main part 101, for opening up spacing 103. As indicated in FIGS. 1-6, either the template or the substrate are transparent to radiation of a certain wavelength or wavelength range of radiation source 110. The illustrated embodiment of FIG. 8 shows an apparatus loaded with a transparent template 10 on top of a substrate 12. Substrate 12 is placed with a backside thereof on surface 105 of heater body 21, placed on or in the second main part 102. Thereby, substrate 12 has its substrate surface 17 with the layer 14 of polymerisable fluid facing upwards. For the sake of simplicity, all features of heater device 20, as seen in FIGS. 1-6 are not shown in FIG. 8. Template 10 is placed on or adjacent to substrate 12, with its structured surface 11 facing substrate 12. Means for aligning template 10 with substrate 12 may be provided, but are not illustrated in this schematic drawing. Membrane 113 is then placed on top of template 10. For an embodiment where membrane 113 is attached to the first main part, the step of actually placing membrane 113 on the template is, of course, dispensed with. In FIG. 8 template 10, substrate 12 and membrane 113 are shown completely separated for the sake of clarity only, whereas in a real situation they would be stacked on surface 105.
FIG. 9 illustrates an operative position of apparatus 100. Second main part 102 has been raised to a position where membrane 113 is clamped between seal member 108 and surface 105. In reality, both template 10 and substrate 12 are very thin, typically only parts of a millimeter, and the actual bending of membrane 113 as illustrated is minimal. Still, surface 105 may optionally be devised with a raised peripheral portion at the point where it contacts seal member 108 through membrane 113, for compensating for the combined thickness of template 10 and substrate 12.
Once main parts 101 and 102 are engaged to clamp membrane 113, cavity 115 is sealed. Pressure source 116 is then devised to apply an overpressure to a fluid medium in cavity 115. The pressure in cavity 115 is transferred by membrane 113 to template 10, which is pressed towards substrate 12 for imprinting the template pattern in the polymerisable fluid layer 14, cf. FIG. 2. For a polymer material of layer 14 having sufficient viscosity at the operating temperature, typically room temperature between 20 and 25� C., imprint may be made directly. However, certain types of polymers need pre-heating to overcome its glass transition temperature TG, which may be about 60� C. An example of such a polymer is MRL 6000 by Micro Resist Technology. When using such polymers, the apparatus 100, having combined radiation and heating capabilities, is particularly useful. Heater device 20 is activated to heat polymer layer 14 through substrate 12, by means of heater body 21, until TG has been over come. The pressure of the medium in cavity 115 is then increased to 5-500 bar, advantageously to 5-200 bar, and preferably to 5-100 bar. Template 10 and substrate 12 are thereby being pressed together with a corresponding pressure. Thanks to flexible membrane 113, an absolutely even distribution of force is obtained over the whole of the contact surface between the substrate and the template. The template and the substrate are thereby made to arrange themselves absolutely parallel in relation to one another and, the influence of any irregularities in the surface of the substrate or template being eliminated.
When template 10 and substrate 12 have been brought together by means of the applied fluid medium pressure, radiation source is triggered to emit radiation 19. The radiation is transmitted through surface portion 112, which acts as a window, through cavity 115, membrane 113, and template 10. The radiation is partly or completely absorbed in the layer 14 of polymerisable fluid, which thereby is solidified in the perfectly parallel arrangement between template 10 and substrate 12, provided by the pressure and membrane assisted compression. Radiation exposure time is dependent on the type and amount of fluid in layer 14, the radiation wavelength combined with the type of fluid, and of the radiation power. The feature of solidifying such a polymerisable fluid is well known as such, and the relevant combinations of the mentioned parameters are likewise known to the skilled person. Once the fluid has solidified to form a layer 14′, further exposure has no major effect. However, dependent on the type of polymerisable fluid, post-baking at an elevated temperature of 150-160� C. may be necessitated for a time period of 0.5-1 hour. With the apparatus 100 according to the present invention, post-baking may be performed in the imprint machine 100, which means that it is not necessary to bring the substrate out of the apparatus and into a separate oven. This saves one process step, which makes both time and cost savings possible in the imprint process. For the example of MRL 6000, post-baking is typically performed at 100-120� C. for about 10 minutes. By performing the post-baking step while the template 10 is still held with the selected pressure towards substrate 10, higher accuracy in the resulting structure pattern in layer 14 may also be achieved, which makes it possible to produce finer structures. Following an exposure time and possibly post-baking under compression, depending on the choice of material and radiation, and dimensions of the polymerisable layer; the pressure in cavity 115 is reduced and the two main parts 101 and 102 are separated from one another. In one embodiment, cooling element 24 of heater device 20 may first be used to cool down the substrate 12 and template 10 before separation. Substrate 12 and template 10 are thereafter separated from one another. After this, the substrate is subjected to further treatment according to what is previously known for imprint lithography.
FIGS. 10-12 illustrates an alternative method of using apparatus 100, in accordance with an embodiment of the invention. The same reference markings are used for like features as in FIGS. 1-3. However, in the process of FIGS. 10-12, a transparent template 200 is used, preferably made from glass or quartz. Template 200 has a structured surface facing substrate 12, with projecting pattern-defining protrusions 201 having opaque layers 202 covering the outer end surfaces of protrusions 201. Preferably, layers 202 are metal layers. In a preferred embodiment, template 200 is manufactured by means of first applying a metal mask 202 on selected areas of the template surface, where after an etching process is used for defining grooves between the masked portions. Instead of removing the mask after the etching step, the mask 202 is kept on the template to define the non-transparent outer end surfaces of the template protrusions 201. By manufacturing template 200 by means of this process, it is also ensured that a near completely even common plane for the outer end surfaces of protrusions 201 is achieved, since the template manufacturing process starts from a flat template body with a plane surface. It should be noted that dimensions illustrated in FIGS. 1-12 are exaggerated for the sake of easy understanding. For instance, layers 202 may be only a few atomic monolayers thick.
In FIG. 10, template 200 is pressed into layer 214 on substrate 12, preferably by using an apparatus as described with reference to FIGS. 7-9. Layer 214 is in this case a UV-curable negative resist polymer, which may be of any known type. An even pressure is achieved over the entire engaging surfaces of template 200 and substrate 12, thanks to the imprint technique using a membrane and gas pressure as described above. Preferably, the template 200 is pressed into layer 214 such that the outer ends of protrusions 201 come extremely close to substrate layer 17, preferably only a few nanometers. In one embodiment, heater device 20 is used for pre-heating layer 214 trough substrate 12, in order for the polymer of layer 214 to overcome the glass transition temperature.
In FIG. 11, radiation 19 is applied through template 200, towards substrate 12. Radiation which hits layers 202 is stopped and reflected, and does not reach layer portions 214′. Radiation which radiates between protrusions 201, however, will hit layer 214 and start a curing or solidification process in layer portions 214″. Preferably, baking process is then performed using heater device 20 for completing the curing process.
In the step illustrated in FIG. 12, template 200 is separated and removed from template 12, leaving layer 214 as imprinted. In this shape, substrate 12 is exposed to a negative resist developer fluid. The exact type of fluid may be of any known kind, although the skilled person realises that developer type has to be selected dependent on the resist polymer used. The developer will only remove portions 214′ which were not exposed to radiation, and which remain only as very thin layers at the bottom of the recesses in the polymer layer formed by protrusions 201. Compared to prior art processes, where an ashing or etching process has to be applied to remove the remaining polymer portions 214′ in the recesses, which is then also cured, this process is considerably easier and faster. Furthermore, ashing or etching of the patterned polymer layer 14 will remove material from all parts of layer 214, both portions 214′ and 214″, whereas the proposed method only takes away the portions 214′ which were not exposed to radiation.
One embodiment of the system according to the invention further comprises mechanical clamping means, for clamping together substrate 12 and template 10. This is particularly preferred in an embodiment with an external alignment system for aligning substrate and template prior to pattern transfer; where the aligned stack comprising the template and the substrate has to be transferred into the imprint apparatus. The system may also contain means for applying a vacuum between template and substrate in order to extract air inclusions from the polymerisable layer of the stacked sandwich prior to hardening of the polymerisable fluid through UV irradiation.
After compression by means of membrane 113 with a pressure of 5-100 bar for about 30 seconds, radiation source 110 is turned on. Radiation source 110 is typically devised to emit at least in the ultraviolet region below 400 nm. In a preferred embodiment, an air-cooled xenon lamp with an emission spectrum ranging from 200-1000 nm is employed as the radiation source 110. The preferred xenon type radiation source 110 provides a radiation of 1-10 W/cm2, and is devised to flash 1-5 μs pulses, with a pulse rate of 1-5 pulses per second. In an alternative embodiment, a continuous mode UV source is used. A window 112 of quartz is formed in surface 104 for passing through radiation. Exposure time is preferably between 1-30 seconds, for polymerising fluid layer 14 into a solid layer 14′. After successful exposure, second main part 102 is lowered to a position similar to that of FIG. 8, following which template 10 and substrate 12 are removed from the apparatus for separation and further processing of the substrate.
The disclosed apparatus and method is particularly advantageous for large area imprint in a single step, and has as such huge benefits over the previously known step and flash method. Thanks to the membrane-transferred fluid pressure, the present invention can be used for one step imprint of substrates of 8 inch, 12 inch, and even larger discs. Even full flat panel displays with sizes of about 400�600 mm and larger can be patterned with a single imprint and exposure step with the present invention. The present invention therefore provides a technique which may for the first time make radiation-assisted polymerisation imprint attractive to large scale production. The invention is usable for forming patterns in a substrate for production of e.g. printed wire boards or circuit boards, electronic circuits, miniaturised mechanical or electromechanical structures, magnetic and optical storage media etc. The apparatus according to the invention may of course also be used only with the radiation source, or instead only with the heater device.
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