This U.S. non-provisional patent application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2010-0122869, filed on Dec. 3, 2010, in the Korean Intellectual Property Office, the entire contents of which are hereby incorporated by reference.
Embodiments of the inventive concepts relate to methods of and apparatuses for forming a metal pattern using a printing technique.
Traditionally, printing means a process for reproducing text, drawing and image with ink on paper. As high resolution and high accuracy printing technologies develop, there are a variety of attempts to apply the recently developed printing technologies to an electronic device fabrication. The printing is a green or environmental technology in that efficiency in using materials and process throughput can be improved using an additive process and the printing process can be performed at atmospheric pressure allowing energy saving. In addition, the printing has an advantage applicable to a large-area object using, for instance, a roll-to-roll method.
Embodiments of the inventive concepts provide metal-pattern-forming methods capable of improving electrical reliability and increasing a throughput.
Other embodiments of the inventive concepts provide metal-pattern-forming apparatuses capable of improving electrical reliability and increasing a throughput.
According to example embodiments of the inventive concepts, a method of forming a metal pattern may include forming bonding agent patterns on a substrate, providing an initiator solution on the substrate to form an initiator combined with the bonding agent pattern, providing a metal precursor solution on the substrate and performing a plating process to form a metal pattern combined with the initiator, and performing a cleaning process to remove the initiator solution and the metal precursor solution between the bonding agent patterns.
In some embodiments, the forming of the bonding agent patterns may be performed using at least one of reverse offset printing, nano-imprinting, gravure offset printing, micro-contact printing, and inkjet printing methods.
According to other example embodiments of the inventive concepts, an apparatus for forming a metal pattern may include a bonding agent solution supplying nozzle, a blanket roll configured to be three-dimensionally and pivotably movable, the bonding agent solution supplying nozzle being configured to supply a bonding agent solution onto an outer circumferential edge of the blanket roll, a conveyor belt, a substrate disposed on the conveyor belt and configured to be movable along the conveyor belt, an initiator solution supplying nozzle disposed over the conveyor belt, a metal precursor solution supplying nozzle disposed over the conveyor belt, and a cleaning solution supplying nozzle disposed over the conveyor belt.
In some embodiments, the apparatus may further include a printing substrate with projecting portions and recessed portions. The blanket roll may be configured to be able to press the printing substrate. In other embodiments, the blanket roll may include a blanket serving as the outer circumferential edge thereof and defining projecting portions and recessed portions.
Example embodiments will be more clearly understood from the following brief description taken in conjunction with the accompanying drawings.
It should be noted that these figures are intended to illustrate the general characteristics of methods, structure and/or materials utilized in certain example embodiments and to supplement the written description provided below. These drawings are not, however, to scale and may not precisely reflect the precise structural or performance characteristics of any given embodiment, and should not be interpreted as defining or limiting the range of values or properties encompassed by example embodiments. For example, the relative thicknesses and positioning of molecules, layers, regions and/or structural elements may be reduced or exaggerated for clarity. The use of similar or identical reference numbers in the various drawings is intended to indicate the presence of a similar or identical element or feature.
Example embodiments of the inventive concepts will now be described more fully with reference to the accompanying drawings, in which example embodiments are shown. Example embodiments of the inventive concepts may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those of ordinary skill in the art. In the drawings, the thicknesses of layers and regions are exaggerated for clarity. Like reference numerals in the drawings denote like elements, and thus their description will be omitted.
It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Like numbers indicate like elements throughout. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items. Other words used to describe the relationship between elements or layers should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” “on” versus “directly on”).
It will be understood that, although the terms “first”, “second”, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of example embodiments.
Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” if used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
Example embodiments of the inventive concepts are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments of the inventive concepts should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of example embodiments.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments of the inventive concepts belong. It will be further understood that terms, such as those defined in commonly-used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Referring to
The formation of the bonding agent pattern, in S10, may be performed using at least one of reverse offset printing, nano-imprinting, gravure offset printing, micro-contact printing, and inkjet printing methods. But, example embodiments of the inventive concepts may not be limited thereto, and the bonding agent pattern may be formed using one of various methods. Hereinafter, the formation of the bonding agent pattern on the substrate will be described in more detail with reference to the accompanying drawings.
Referring to
The bonding agent solution 12 may include at least one selected from a group of 2-trimethoxysilyl ethyl-2-pyridine, aminoethylaminomethyl-phenethyltrimethoxysilane, N-2-aminoethyl-3-amino propyltrimethoxysilane, phenethyltrichlorosilane, 4-chloromethylphenylsiloxane, and 3-aminopropyltriethoxysilane (APTS).
The formation of the bonding agent pattern 12b may further include rolling and pressing the blanket roll 14 onto a printing substrate 20 provided with projecting portions 22 to remain the bonding agent patterns 12b on the blanket roll 14 (in S12). The remainder 12c of the bonding agent layer 12a may remain on the projecting portions 22, as shown in
The formation of the bonding agent pattern 12b may further include rolling the blanket roll 14 with the bonding agent patterns 12b on a target substrate 30 to transfer the bonding agent patterns 12b onto the substrate 30 (in S13). Then, the bonding agent patterns 12b may be combined with a surface of the substrate 30 by a chemical reaction therebetween. The substrate 30 may be, for example, a silicon substrate, a plastic substrate, a flexible film or a glass. In the case that the bonding agent solution 12 contains 3-aminopropyltriethoxysilane (APTS), a chemical reaction on the substrate 30 may be represented by the following reaction formula.
In some embodiments, an additional step of volatilizing a solvent in the bonding agent pattern 12b may be performed after the transcription of the bonding agent pattern 12b onto the substrate 30.
Referring to
In other embodiments, the initiator solution may include nano particles, which may be formed of at least one selected from a group of boron (B), phosphorus (P), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt Co, nickel (Ni), copper (Cu), zinc (Zn), gallium (Ga), germanium (Ge), arsenic (As), selenium (Se), molybdenum (Mo),technetium (Tc), rhodium (Rh), silver (Ag), cadmium (Cd), indium (In), tin (Sn), antimony (Sb), tellurium (Te), tungsten (W), rhenium (Re), platinum (Pt), gold (Au), thallium (Tl), lead (Pb), or bismuth (Bi). The initiator solution may be a suspension of the nano particles in dispersion media. In some embodiments, the dispersion media may be water or alcohol.
In some embodiments, the bonding agent solution 12 contains 3-aminopropyltriethoxysilane (APTS), and the initiator solution is a suspension of lead (Pd) nano particles, a chemical reaction on the substrate 30 may be represented by the following reaction formula.
In some embodiments, an additional step of volatilizing a solvent in the initiator solution 40 may be performed, after waiting until the initiator is completely or sufficiently combined with the bonding agent pattern 12b.
Thereafter, referring to
In the case that the bonding agent solution 12 contains 3-aminopropyltriethoxysilane (APTS) and the initiator solution and the metal precursor solution are a suspension of lead (Pd) nano particles and aqueous diamminesilver(I) complex, respectively, a chemical reaction on the substrate 30 may be represented by the following reaction formula.
Thereafter, referring to
The methods of forming a metal pattern according to some embodiments of the inventive concepts may be automatically performed using an apparatus shown in
Referring to
In other embodiments, the metal pattern forming apparatus may include at least one rotating means for rotating the substrate 30. In these embodiments, the initiator solution 40, the metal precursor solution 50, and the cleaning solution 60 may be formed on the substrate 30 using a spin-coating method. In still other embodiments, the metal pattern forming apparatus may include containers for containing the initiator solution 40, the metal precursor solution 50, and the cleaning solution 60. In these embodiments, the initiator solution 40, the metal precursor solution 50, and the cleaning solution 60 may be formed on the substrate 30 using a dipping method.
Referring to
According to the present embodiments, a metal pattern forming apparatus 101 may include the blanket roll 14a with a blanket 16a of silicone, and an outer circumferential edge of the blanket 16a may be formed to have projecting portions 22 and the recessed portions 23. In some embodiments, the apparatus 101 may be configured not to include the printing substrate 20 of
In some embodiments, the afore-mentioned metal-pattern-forming methods may be applied to form electrodes and interconnection lines for a display backplane. In other embodiments, the afore-mentioned metal-pattern-forming methods may be applied to form a RFID or a sensor. But example embodiments of the inventive concepts may not be limited thereto.
According to example embodiments of the inventive concepts, the initiator and the metal pattern are sequentially combined on the previously-formed bonding agent pattern, and this enables to improve adhesion and/or junction properties between the substrate and the metal. Accordingly, the metal pattern can be minutely formed without undesirable pattern loss and metal interconnection lines and electrodes can be formed with improved electronic and/or electric reliability, as compared with the case that the initiator and the metal pattern are directly formed on the substrate without the bonding agent pattern. In some embodiments, the bonding agent pattern may be formed using a printing technique for a consecutive process, such as a reverse offset printing method, which leads to increasing a throughput. In some embodiments, the metal pattern may be formed using an electroless electrochemical plating method, and thus, it is possible to reduce the metal layer from being oxidized and to improve an electric property of the metal interconnection line. Furthermore, even at the final step, the metal pattern can be formed with improved uniformity in thickness and planar area.
Number | Date | Country | Kind |
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10-2010-0122869 | Dec 2010 | KR | national |