CONTROLLED DEPOSITION OF A FUNCTIONAL MATERIAL ONTO A TARGET SURFACE
20230136483 · 2023-05-04
Inventors
Cpc classification
C23C28/00
CHEMISTRY; METALLURGY
C23C26/00
CHEMISTRY; METALLURGY
C03C2217/734
CHEMISTRY; METALLURGY
C23C28/04
CHEMISTRY; METALLURGY
International classification
C03C17/34
CHEMISTRY; METALLURGY
Abstract
A plate including functional material to be deposited onto a target surface using monochromatic radiation having a wavelength is described. The plate further includes a substrate with a first surface directed towards the target surface and with a second surface to receive the monochromatic radiation. The first surface is patterned with recessed areas that have a dielectric coating and that are filled with the functional material. The dielectric coating includes a sequence of dielectric coating layers alternating in refractive index. The dielectric coating therewith has a relatively high reflectivity for said monochromatic radiation incident perpendicular to the dielectric coating in comparison to a reflectivity for said monochromatic radiation incident at an angle of 45 degrees to the dielectric coating. As such shear forces are mitigated without requiring a high alignment accuracy. The present application further describes a deposition device including the plate and a method involving the plate.
Claims
1. A method for controlled deposition of a functional material onto a target surface using monochromatic radiation having a wavelength, the method comprising: providing a transparent carrier plate having a substrate with a first surface and a second surface opposite to the first surface, therewith providing the first surface with one or more recessed areas; depositing a dielectric coating comprising a sequence of dielectric coating layers alternating in refractive index on the first surface, the dielectric coating having a relatively high reflectivity for the monochromatic radiation incident perpendicular to the dielectric coating in comparison to a reflectivity for the monochromatic radiation incident at an angle of 45 degrees to the dielectric coating; filling the one or more recessed areas with the functional material; positioning the transparent carrier plate between the monochromatic radiation source and the target surface, with the first surface facing the target surface; directing the monochromatic radiation towards the second surface of the plate, the monochromatic radiation having an intensity and a duration that causes a transfer of functional material from the one or more recessed areas to the target surface.
2. The method according to claim 1, wherein the dielectric coating layers have a thickness in a range of 0.05 to 0.15 times the wavelength of the monochromatic radiation.
3. The method according to claim 1, further comprising, before providing the first surface with one or more recessed areas, depositing a reflective coating at the first surface that substantially reflects the monochromatic radiation incident thereto.
4. The method according to claim 1, wherein a scanning laser is used to generate the monochromatic radiation.
5. The method according to claim 4, wherein the monochromatic radiation is directed via a telecentric lens to the second surface of the plate to ensure that the angle of incidence is equal over the area covered by the monochromatic radiation.
6. The method according to claim 4, wherein an excimer laser is used to generate the monochromatic radiation.
7. The method according to claim 1, further comprising the step of depositing a photon radiation absorbing layer subsequent to the depositing the dielectric coating, and preceding the filling the one or more recessed areas with the functional material.
8. A plate comprising: a functional material to be deposited onto a target surface using monochromatic radiation having a wavelength; and a substrate with a first surface to be directed towards the target surface and with a second surface to receive the monochromatic radiation, wherein the first surface is patterned with one or more recessed areas having a dielectric coating and being filled with said-the functional material, and wherein the dielectric coating comprises a sequence of dielectric coating layers alternating in refractive index, the dielectric coating having a relatively high reflectivity for the monochromatic radiation incident perpendicular to the dielectric coating in comparison to a reflectivity for the monochromatic radiation incident at an angle of 45 degrees to the dielectric coating.
9. The plate according to claim 8, wherein the dielectric coating layers have a thickness in a range of 0.05 to 0.15 times the wavelength of the monochromatic radiation.
10. The plate according to claim 8, wherein the dielectric coating covers the first surface in a blanketwise manner.
11. The plate according to claim 8, wherein the dielectric coating is covered with a protective layer.
12. The plate according to claim 8, wherein non-recessed portions of the first surface are provided with a reflective coating that substantially reflects the monochromatic radiation.
13. The plate according to claim 8, comprising at least in the one or more recessed areas a photon radiation absorbing layer between the dielectric coating and the functional material.
14. The plate according to claim 8, being provided at its second surface with a gray-scale mask to control a heat flux of the monochromatic radiation to cooperate with the dielectric coating to provide for an at least substantially homogeneous transmitted heat flux at the inner surface of the one or more recessed areas and/or to suppress transmission of the radiation outside these areas.
15. A deposition device comprising: a plate comprising: a functional material to be deposited onto a target surface using monochromatic radiation having a wavelength; and a substrate with a first surface to be directed towards the target surface and with a second surface to receive the monochromatic radiation, wherein the first surface is patterned with one or more recessed areas having a dielectric coating and being filled with the functional material, and wherein the dielectric coating comprises a sequence of dielectric coating layers alternating in refractive index, the dielectric coating having a relatively high reflectivity for the monochromatic radiation incident perpendicular to the dielectric coating in comparison to a reflectivity for the monochromatic radiation incident at an angle of 45 degrees to the dielectric coating; a holder configured to hold a target with a target surface facing the first surface of the plate; a monochromatic radiation source configured to render the monochromatic radiation to be directed towards the second surface of the plate; a controller configured to cause the monochromatic radiation source to render the monochromatic radiation with an intensity and a duration that causes a transfer of functional material from the one or more recessed areas to the target surface.
16. The deposition device according to claim 15, wherein the dielectric coating layers have a thickness in the range of 0.05 to 0.15 times the wavelength of the monochromatic radiation.
17. The deposition device according to claim 15, wherein the dielectric coating covers the first surface in a blanketwise manner.
18. The deposition device according to claim 15, wherein the dielectric coating is covered with a protective layer.
19. The deposition device according to claim 15, wherein non-recessed portions of the first surface are provided with a reflective coating that substantially reflects the monochromatic radiation.
20. The deposition device according to claim 15, wherein the plate comprises at least in the one or more recessed areas a photon radiation absorbing layer between the dielectric coating and the functional material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] These and other aspects are described in more detail with reference to the drawings. Therein
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
DETAILED DESCRPTION OF EMBODIMENTS
[0039]
[0040] As schematically shown in
[0041] In operation of the deposition device the controller 8 causes the monochromatic radiation source 3 to render monochromatic photon radiation R3 with an intensity and a duration that causes a transfer of functional material 2 from the one or more recessed areas 111 to the target surface 51. The monochromatic radiation source 3 directs the monochromatic radiation R3 towards the second surface 12 of the carrier plate 1. To that end the monochromatic radiation source 3 may include a laser, e.g. an excimer laser or a scanning laser and optional further optical components, such as a telecentric lens.
[0042] As shown schematically in
[0043] A first example is shown in more detail in
[0044] It is noted that in dielectric mirrors the thickness of the layers multiplied with their refractive index is typically a quarter of the wavelength of the radiation to be reflected, so that the high refractive index layers are thinner than the layers with a lower refractive index. In the present application it is not necessary that the dielectric coating reflects all radiation, but it is sufficient that the radiation directed towards the bottom of the recessed portions is attenuated to a sufficient extent to achieve a substantially homogeneous distribution of the transmitted heat flux over the inner surface of the recessed areas. Suitable coatings that meet this requirement can selected without undue effort using a simulation. For example starting from the following input, a wavelength XR.sub.3 of the monochromatic radiation used, a slanting angle of the walls of the recessed elements a number of dielectric layers in the dielectric coating and a selection of the mutually different dielectric materials for these layers, the thickness can be varied in the simulation to determine for which thickness the required attenuation is achieved. It can be presumed in the simulation that the thickness of the layers is equal, or that the layer thicknesses for high- and low refractive index layers mutually have a fixed thickness ratio. Therewith only one parameter needs to be varied in the simulation. https://www.filmetrics.com/reflectance-calculator provides a simulator suitable for this purpose.
[0045] At each interface 10-41, 41-42, 42-43 and 43-45 and 45, a reflection occurs and these reflections reinforce or cancel each other depending on the path length difference. The path length through each layer is the product of the layer thickness (d) and its refractive index (n).
[0046] The strength of the reflection at the interface of mutually subsequent layers depends on their refractive indices (n.sub.o, n.sub.s) according to the following relationship.
[0047] The extent to which reflections mutually cancel each other depends on their phase difference.
[0048] In an example, the wavelength λ.sub.R3 of the monochromatic radiation source used is 532 nm. Therewith for the layers 41, 42, 43, 45 the bidirectional optic path length (*λ.sub.R3) for radiation incident in the direction of the surface normal expressed as a fraction of the wavelength is as follows:
TABLE-US-00001 Layer Material n.d *λ.sub.R3 41, 43 TiO2 (n = 2.4) 96 0.36 42 SiO2 (n = 1.45) 58 0.22 45 Al2O3 (n = 1.75) 70 0.26
[0049] In the center of the recessed area, the incident angle of the light is transverse to the plane of the layers. The various partial reflections are out of phase but are not fully in counter phase, so that part of the radiation R3B is reflected, and does not arrive at the bottom 111B of the recessed area 111.
[0050] In the case of
[0051]
[0052] In another example, the wavelength λ.sub.R3 of the monochromatic radiation source used is 308 nm and the dielectric coating 4 is provided with a first high refractive index (n=2.1) layer 41 of HfO2 with a thickness of 38 nm, a first low refractive index (n=1.45) layer 42 of SiO2 with a thickness of 38 nm, and a second high refractive index layer 43 of HfO2 with a thickness of 38 nm. Also a protective coating layer 45 of Al2O3 with a thickness of 25 nm is provided. The latter has a refractive index n=1.75.
TABLE-US-00002 Layer Material n.d *λ.sub.R3 41, 43 HfO2 (n = 2.1) 55 0.36 42 SiO2 (n = 1.45) 80 0.51 45 Al2O3 (n = 1.75) 44 0.28
[0053]
[0054]
[0055] Therewith it is avoided that any functional material 2″ present in these areas is transferred to the target surface 51, even if the monochromatic radiation R3 is directed thereto. It is not necessary that a reflective coating 6 fully reflects the radiation R3. It is sufficient if the monochromatic radiation R3 is sufficiently reduced in strength to avoid the transfer.
[0056] In the embodiment shown in
[0057]
[0058] In the embodiment of
[0059] In step S2 of the method, a dielectric coating is deposited Step S2 comprises a sequence of sub-steps wherein in each subsequent sub-step a dielectric coating layer is deposited having a refractive index different from that of the dielectric coating layer deposited in the preceding sub-step. It is sufficient that the dielectric coating obtained therewith extends within the portions of the first surface defined by the one or more recessed areas, but alternatively the dielectric coating may also extend beyond the one or more recessed areas. Typically the dielectric coating is deposited over the entire surface of the plate, therewith obviating masking and aligning issues.
[0060] The dielectric coating has a reflectivity for the monochromatic radiation incident perpendicular thereto that is relatively high in comparison to a reflectivity for said monochromatic radiation incident at an angle of 45 degrees to the dielectric coating.
[0061] In a subsequent step S3 the one or more recessed areas are filled with the functional material, e.g. copper, aluminum, tungsten, chromium, polysilicon to be deposited. Other materials than metal are also suitable for use as a functional material. The functional material may for example be provided as an ink wherein conductive particles are suspended. Rheological properties of the functional material may be modified by additives or solvent, for example to obtain a shear-thickening, a shear-thinning, a thixotropic, a rheopectic or a Bingham plastic behavior. In particular donor materials with a shear-thinning behavior are favorable. Donor materials with this behavior have a viscosity that decreases with the rate of shear strain. Shear-thinning donor materials remain as a stable layer on the donor substrate, but are relatively easily morphed at the time of deposition. By way of example, the functional material is a viscous silver nanoparticle ink with a high metal load.
[0062] It is noted further process steps may take place before the one or more recessed areas are filled with the functional material. For example a photon radiation absorbing layer may be deposited subsequent to the step of depositing the dielectric coating, and preceding the step of filling the one or more recessed areas with said functional material. As noted above this improves the conversion of the monochromatic radiation into heat. Alternatively or additionally a vaporizable material may be deposited the one or more recessed areas before filling with the functional material.
[0063] After the one or more recessed areas are filled in step S3 with the functional material, the transparent carrier plate is ready for use in a deposition device, for example as shown in
[0064] Therewith the transparent carrier plate 1 is positioned between the monochromatic radiation source 3 and the target surface 51 of a target, with the first surface 11 facing the target surface 51, as shown in
[0065] In operation the monochromatic radiation R3 of the monochromatic radiation source 3 is directed in step S4 towards the second surface 12 of the plate 1. Therewith the monochromatic radiation R3 has an intensity and a duration that causes a transfer S5 of functional material 2 from the one or more recessed areas 111 to the target surface 51. Optimal values for intensity and duration can be determined by routine tests for a selected functional material and the transmissivity of the coating layers. The duration of the heat irradiation is typically short, e.g. in terms of microseconds, usually even shorter, nano-seconds. In practice good results with modest technical requirements may be obtained with a pulse duration in the order of a few to a few tens of ns. Nevertheless, in some cases an even shorter pulse duration may be applied, e.g. in the range of 10-500 ps. In a test phase the intensity can be varied from a relatively low value (e.g. corresponding to an exposure (fluence) of about 0.1 J/cm.sup.2) to a relatively high value (e.g. corresponding to an exposure (fluence) of about 1 J/cm.sup.2) to determine for which value or value range the transfer of the functional material 2 is optimal in terms of deposition accuracy.
[0066] According to one approach, the entire second surface 12 of the plate 1 is irradiated with a beam of homogeneous power density. In that case a homogeneous exposure is achieved having an exposure value equal to the product of the power density and the exposure time.
[0067] According to another approach, as illustrated in
[0068] In this case, the exposure E(x,y) can be determined as:
E(x,y)=∫.sub.t=−∞.sup.+∞P(x,v,t)Q(t)dt
Wherein P( . , . ) specifies the spatial distribution of the beam R3 and Q( ) specifies how the total beam power varies in time t.
[0069]
[0070] This may be achieved with a highly uniform beam. Alternatively, as shown in
[0071] As noted with reference to
[0072] Returning to
[0073]
[0074] In the example shown in
[0075] In the example shown in
[0076] In the example shown in