3-dimensional imprint tool
First Claim
1. A method for fabricating an imprint tool master, comprising:
- providing a metallic substrate;
forming a first photoresist layer onto said substrate;
aligning an image pattern mask onto said photoresist layer, wherein said pattern mask has portions that block exposure light and portions which transmit exposure light;
exposing said photoresist layer with a first exposure of exposure light;
removing said first pattern mask;
developing said first photoresist layer to produce a master mandrel;
forming a conductive film onto said master mandrel; and
forming a tool master on said conductive film.
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Abstract
The invention is a method for the fabrication of an imprint tool master. The process begins with a metallic substrate. A layer of photoresist is placed onto the metallic substrate and a image pattern mask is then aligned to the mask. The mask pattern has opaque portions that block exposure light and “open” or transparent portions which transmit exposure light. The photoresist layer is then exposed to light transmitted through the “open” portions of the first image pattern mask and the mask is then removed. A second layer of photoresist then can be placed onto the first photoresist layer and a second image pattern mask may be placed on the second layer of photoresist. The second layer of photoresist is exposed to light, as before, and the second mask removed. The photoresist layers are developed simultaneously to produce a multi-level master mandrel upon which a conductive film is formed. A tool master can now be formed onto the conductive film. An imprint tool is then produced from the tool master. In one embodiment, nickel is electroplated onto the tool master to produce a three-dimensional imprint tool.
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Citations
38 Claims
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1. A method for fabricating an imprint tool master, comprising:
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providing a metallic substrate;
forming a first photoresist layer onto said substrate;
aligning an image pattern mask onto said photoresist layer, wherein said pattern mask has portions that block exposure light and portions which transmit exposure light;
exposing said photoresist layer with a first exposure of exposure light;
removing said first pattern mask;
developing said first photoresist layer to produce a master mandrel;
forming a conductive film onto said master mandrel; and
forming a tool master on said conductive film. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 36, 37)
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16. A method for fabricating an imprint tool master, comprising:
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providing a metallic substrate;
forming a first photoresist layer onto said substrate;
aligning an image pattern mask onto said photoresist layer, wherein said pattern mask has first portions that block exposure light and first portions which transmit exposure light;
exposing said photoresist layer with a first exposure of exposure light;
removing said first pattern mask;
forming a second photoresist layer onto said first photoresist layer;
aligning a second pattern mask of a second desired pattern onto said second photoresist layer, wherein said second pattern mask has second portions that block exposure light and second portions which transmit exposure light;
exposing said second photoresist layer with a second exposure of said exposure light transmitted through said second portions;
removing said second pattern mask;
developing both said first photoresist layer and said second photoresist layer to produce a master mandrel;
forming a conductive film onto said master mandrel; and
forming a tool master on said conductive film.
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35. A 3 dimensional embossing tool, comprising:
an electroformed metal sheet having a print positive electroformed image of an embossing pattern, said pattern including a plurality of structures having variable geometries and minimum feature dimensions as small as about 0.0005 inches.
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38. A tool master for forming a 3 dimensional embossing tool, comprising:
an electroformed metal sheet having a print negative image of an embossing structure formed into said electroformed sheet, said sheet formed by electroplating a thickness of a metal over a print positive image comprising a metallic coated photoresist.
Specification