Methods for fabricating microstructures by imaging a radiation sensitive layer sandwiched between outer layers
First Claim
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1. A method of fabricating microstructures comprising:
- imaging a microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer, the pair of outer layers comprising a first outer layer adjacent the imaging platform and a second outer layer remote from the imaging platform;
removing the second outer layer from the radiation sensitive layer;
developing the microstructures that were defined in the radiation sensitive layer; and
creating a second-generation stamper from the microstructures that were developed in the radiation sensitive layer by contacting the microstructures to a stamper blank.
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Abstract
Microstructures are fabricated by imaging a microstructure master blank that includes a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer. At least one of the outer layers is then removed. The microstructures that were defined in the radiation sensitive layer are developed. The radiation sensitive layer sandwiched between the pair of outer layers may be fabricated as webs, to provide microstructure master blanks.
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Citations
34 Claims
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1. A method of fabricating microstructures comprising:
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imaging a microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer, the pair of outer layers comprising a first outer layer adjacent the imaging platform and a second outer layer remote from the imaging platform; removing the second outer layer from the radiation sensitive layer; developing the microstructures that were defined in the radiation sensitive layer; and creating a second-generation stamper from the microstructures that were developed in the radiation sensitive layer by contacting the microstructures to a stamper blank. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of fabricating microstructures comprising:
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imaging a microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer, the pair of outer layers comprising a first outer layer adjacent the imaging platform and a second outer layer remote from the imaging platform; separating the first outer layer from the imaging platform; and separating the first or second outer layer from the radiation sensitive layer; developing the microstructures that were defined in the radiation sensitive layer; and creating a second-generation stamper from the microstructures that were developed in the radiation sensitive layer by contacting the microstructures to a stamper blank. - View Dependent Claims (16, 17, 18)
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19. A method of fabricating microstructures comprising:
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imaging a first microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer, removing at least one of the outer layers; creating a second generation stamper by developing the microstructures in the first microstructure master blank and contacting the microstructures to a stamper blank; and imaging a second microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on the imaging platform, to define second microstructures in the radiation sensitive layer; wherein imaging a second microstructure master blank and creating a second-generation stamper at least partially overlap in time. - View Dependent Claims (20)
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21. A method of fabricating microstructures comprising:
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imaging a first microstructure master blank that comprises a radiation sensitive layer sandwiched between a pair of outer layers, on an imaging platform, to define the microstructures in the radiation sensitive layer, removing at least one of the outer layers; developing the microstructures that were defined in the radiation sensitive layer to provide a microstructure master; forming a plurality of second generation stampers directly from the master; and forming a plurality of third generation microstructure end products directly from a stamper. - View Dependent Claims (22)
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23. A method of fabricating a microstructure master comprising:
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placing on a cylindrical platform, a microstructure master blank that comprises a first outer layer, a negative photoresist layer on the first outer layer and a second outer layer on the negative photoresist layer, such that the first outer layer is adjacent the cylindrical platform and the second outer layer is remote from the cylindrical platform; impinging a laser beam through the second outer layer into the negative photoresist layer while simultaneously rotating the cylindrical platform about an axis thereof and while simultaneously axially rastering the laser beam across at least a portion of the negative photoresist layer to image the microstructures in the negative photoresist layer; separating the first outer layer from the cylindrical platform; separating the first outer layer from the negative photoresist layer; developing the microstructures that were imaged in the negative photoresist layer; and creating a second-generation stamper from the microstructures that were developed in the negative photoresist layer by contacting the microstructures to a stamper blank. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30)
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31. A method of fabricating a microstructure master comprising:
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placing on a cylindrical platform, a first microstructure master blank that comprises a first outer layer, a negative photoresist layer on the first outer layer and a second outer layer on the negative photoresist layer, such that the first outer layer is adjacent the cylindrical platform and the second outer layer is remote from the cylindrical platform; impinging a laser beam through the second outer layer into the negative photoresist layer while simultaneously rotating the cylindrical platform about an axis thereof and while simultaneously axially rastering the laser beam across at least a portion of the negative photoresist layer to image the microstructures in the negative photoresist layer; separating the first outer layer from the cylindrical platform; separating the first outer layer from the negative photoresist layer; and developing the microstructures that were imaged in the negative photoresist layer; wherein separating the first outer layer from the cylindrical platform is followed by; creating a second generation stamper from the microstructures that were developed in the negative photoresist layer of the first microstructure master blank by contacting the microstructures to a stamper blank; placing on the cylindrical platform, a second microstructure master blank that comprises a first outer layer, a negative photoresist layer on the first outer layer and a second outer layer on the negative photoresist layer, such that the first outer layer is adjacent the cylindrical platform and the second outer layer is remote from the cylindrical platform; impinging the laser beam through the second outer layer of the second microstructure master blank into the negative photoresist layer of the second microstructure master blank while simultaneously rotating the cylindrical platform about an axis thereof and while simultaneously axially rastering the laser beam across at least a portion of the negative photoresist layer of the second microstructure master blank to image the microstructures in the negative photoresist layer of the second microstructure master blank; wherein creating a second generation stamper and impinging the laser beam through the second outer layer of the second microstructure master blank at least partially overlap in time. - View Dependent Claims (32)
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33. A method of fabricating a microstructure master comprising:
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placing on a cylindrical platform, a microstructure master blank that comprises a first outer layer, a negative photoresist layer on the first outer layer and a second outer layer on the negative photoresist layer, such that the first outer layer is adjacent the cylindrical platform and the second outer layer is remote from the cylindrical platform; impinging a laser beam through the second outer layer into the negative photoresist layer while simultaneously rotating the cylindrical platform about an axis thereof and while simultaneously axially rastering the laser beam across at least a portion of the negative photoresist layer to image the microstructures in the negative photoresist layer; separating the first outer layer from the cylindrical platform; separating the first outer layer from the negative photoresist layer; developing the microstructures that were imaged in the negative photoresist layer; creating a second-generation stamper from the microstructures that were developed in the negative photoresist layer by contacting the microstructures to a stamper blank; and forming a plurality of third generation microstructure end products directly from a stamper. - View Dependent Claims (34)
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Specification