STAMPER MANUFACTURING METHOD
According to one embodiment, a three dimensional structure of a stamper is subject to etch by supplying a pulsed electric currentelectric current to the surface of the stamper.
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This application is based upon and claims the benefit of priority from Japanese Patent Applications No. 2009-141430, filed Jun. 12, 2009; and No. 2010-116927, filed May 21, 2010; the entire contents of which are incorporated herein by reference.
FIELDEmbodiments described herein relate generally to a method of manufacturing a stamper for use in producing a large quantity of data recording media by transferring patterns by means of injection molding, imprinting, or the like.
BACKGROUNDRecently, the recording capacity of data recording apparatuses has been increased by increasing the recording density of a magnetic recording medium. As a magnetic recording medium for achieving a high recording density, a discrete-type magnetic recoding (discrete track recording [DTR]) medium having patterns including a magnetic portion and nonmagnetic portion on a plurality of, e.g., concentrically formed data recording tracks is known.
A method of manufacturing this magnetic recording medium adopts nanoimprinting, injection molding, or the like using a nickel (Ni) stamper as disclosed in, e.g., Patent Reference 1 as a metal mold.
As the recording density of the discrete-type magnetic recording medium increases, the stamper for use in the manufacture of the medium is beginning to require micropatterning that forms three-dimensional patterns at a track pitch of 100 nm or less as disclosed in, e.g., Jpn. Pat. Appln. KOKAI Publication No. 2008-12705.
When the density increases as the track pitch of the three-dimensional patterns decreases as described above, however, sufficiently wide projecting portions are necessary to maintain the performance of write/read to the medium projecting portions with respect to the narrow pitch. Accordingly, finer recess patterns must be written by an electron beam. Unfortunately, the limitation of an electron-beam lithography apparatus makes it difficult to write grooves of a few nanometers. This makes it impossible to obtain a high-density master in the future.
A general architecture that implements the various feature of the embodiments will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate the embodiments and not to limit the scope of the invention.
Various embodiments will be described hereinafter with reference to the accompanying drawings.
In general, according to one embodiment, a stamper processing method according to the embodiment etches a three-dimensional structure of a stamper by supplying a pulsed electric current to the surface of the stamper.
According to one embodiment, a stamper manufacturing method forms first, second, and third stampers by transferring three-dimensional patterns of a master.
In forming the third stamper, the stamper processing method described above can be used to process the three-dimensional patterns.
First, a first conductive layer is formed on the surface of a master having three-dimensional patterns, a first electroformed layer is formed on the first conductive layer, and the first electroformed layer and first conductive layer are separated from the master, thereby forming a first stamper onto which the three-dimensional structure of the master is transferred.
Subsequently, a first release layer is formed on the surface of the first stamper, a second conductive layer is formed on the first release layer, a second electroformed layer is formed on the second conductive layer, and the second electroformed layer and second conductive layer are separated from the first stamper, thereby forming a second stamper onto which the three-dimensional structure of the first stamper is transferred.
Furthermore, a second release layer is formed on the second stamper, a third conductive layer is formed on the second release layer, a third electroformed layer is formed on the third conductive layer, and the third electroformed layer and third conductive layer are separated from the second stamper, thereby forming a third stamper onto which the three-dimensional structure of the second stamper is transferred.
The stamper manufacturing method according to the embodiment is characterized by etching the three-dimensional structure of the third stamper by supplying a pulsed electric current to the surface of the third stamper.
In the one embodiment, plating metal deposition caused by a positive pulsed electric current and plating metal etching caused by a reverse pulsed electric current occur repetitively. When a pulsed electric current is supplied to the three-dimensional structure of nano-patterns, plating metal etching occurs with priority on plating metal deposition. Consequently, smooth etching can be performed.
When using the embodiment, the third stamper is etched by supplying a pulsed electric current. Since three-dimensional nano-patterns can be etched, projecting portions of the three-dimensional structure can be made narrower so that the line edge roughness is decreased. This prevents the formation of a rough three-dimensional surface, and the formation of, e.g., rough spiral or concentric three-dimensional patterns. Also, dust particles are removed by the repetition of plating metal deposition and etching. In addition, the stamper and transferred patterns are roughened and damaged less. Since this increases the durability of the stamper, the number of duplication cycles is greatly increased.
Furthermore, the three-dimensional structure can have periodic patterns having a track pitch of 100 nm or less, e.g., 75 to 90 nm.
The etching is performed in a plating solution.
Ni sulfamate can be used as the plating solution. It is also possible to use, e.g., an Ni sulfate-Ni chloride solution mixture (Watts bath).
A pulsed electric current can be supplied at a frequency of 100 Hz or more, e.g., 500 to 5,000 Hz and an accumulated current of 0.1 to 5.0 μA·min/mm2 by alternately supplying a positive electric current and reverse electric current.
One embodiment will be explained in more detail below with reference to the accompanying drawing.
FIRST EMBODIMENTFirst, as shown in
Then, as shown in
Subsequently, as shown in
Then, as shown in
Subsequently, as shown in
The surface of the son stamper 21 thus obtained is dipped in an Ni sulfamate bath, and a pulsed electric current is supplied under the following conditions, thereby etching the three-dimensional surface patterns. The electroforming apparatus is used in this etching.
The three-dimensional pattern structure of the son stamper used had a pitch of 85 nm, a height of 50 nm, and a width of 30 nm.
Frequency: 500 Hz
On-Time: 1 ms
Off-Time: 1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 1.0 μA·min/mm2
The three-dimensional pattern structure of a pulse etching son stamper 22 obtained as described above had a height of 50 nm and a width of 18 nm as shown in
After that, a protective film was formed on the three-dimensional pattern surface by spin coating and dried. A stamper for mass-transfer of media as a final form is completed through steps such as lower-surface polishing and punching as needed.
As the thin conductive film 13 described above, it is possible to use a material mainly containing Ni because the material has high physical strength, high mechanical strength, high resistances against corrosion and wear, and high adhesion to Ni as the electroforming material. Also, Ni or a material containing Ni and one of Co, S, B, and P can be used as the electroformed layer 14, 17, and 20.
For example, when forming an electroformed layer on a master, father stamper, or mother stamper (referred to as a matrix 150 hereinafter) having three-dimensional patterns as shown in
When using this electroforming apparatus in the etching using a pulsed electric current according to the embodiment, a DC power supply capable of generating a pulse waveform can be used instead of the rectifier.
SECOND EMBODIMENTAfter a son stamper 21 was manufactured following the same procedures as in First Embodiment, the surface of the son stamper was dipped in the above-mentioned Ni sulfamate bath, and a pulsed electric current was supplied under the following conditions, thereby etching the three-dimensional surface patterns.
The three-dimensional pattern structure of the son stamper used had a pitch of 85 nm, a height of 50 nm, and a width of 30 nm.
Frequency: 500 Hz
On-Time: 1 ms
Off-Time: 1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 0.2 μA·min/mm2
The three-dimensional pattern structure of a pulse etching son stamper obtained as described above had a height of 50 nm and a width of 25 nm, i.e., the three-dimensional pattern structure was etched by 5 nm compared with that before the pulsed electric current was supplied. The LER after the etching had decreased by 0.91 nm compared with that before the etching.
THIRD EMBODIMENTAfter a son stamper 21 was manufactured following the same procedures as in First Embodiment, the steps shown in
The three-dimensional pattern structure of the grandson stamper used had a pitch of 85 nm, a height of 47 nm, and a width of 27 nm.
Frequency: 500 Hz
On-Time: 1 ms
Off-Time: 1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 1.6 μA·min/mm2
The three-dimensional pattern structure of a pulse etching grandson stamper obtained as described above had a height of 40 nm and a width of 8 nm, i.e., the three-dimensional pattern structure was etched by 19 nm compared with that before the pulsed electric current was supplied. The LER after the etching had decreased by 1.30 nm compared with that before the etching.
FOURTH EMBODIMENTAfter a son stamper 21 was manufactured following the same procedures as in First Embodiment, the steps shown in
The three-dimensional pattern structure of the grandson stamper used had a pitch of 85 nm, a height of 47 nm, and a width of 27 nm.
Frequency: 5,000 Hz
On-Time: 0.1 ms
Off-Time: 0.1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 4.8 ∥A·min/mm2
The three-dimensional pattern structure of a pulse etching grandson stamper obtained as described above had a height of 35 nm and a width of 10 nm, i.e., the three-dimensional pattern structure was etched by 17 nm compared with that before the pulsed electric current was supplied. The LER after the etching had decreased by 0.03 nm compared with that before the etching.
FIFTH EMBODIMENTAfter a son stamper 21 was manufactured following the same procedures as in First Embodiment, the steps shown in
The three-dimensional pattern structure of the grandson stamper used had a pitch of 85 nm, a height of 47 nm, and a width of 27 nm.
Frequency: 5,000 Hz
On-Time: 0.1 ms
Off-Time: 0.1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 6.0 ∥A·min/mm2
The three-dimensional pattern structure of a pulse etching grandson stamper obtained as described above had a height of 20 nm and a width of 15 nm, i.e., the three-dimensional pattern structure was etched by 12 nm compared with that before the pulsed electric current was supplied. The LER after the etching increased by 0.56 nm compared with that before the etching.
SIXTH EMBODIMENTAfter a son stamper 21 was manufactured following the same procedures as in First Embodiment, the surface of the son stamper was dipped in the above-mentioned Ni sulfamate bath, and a pulsed electric current was supplied under the following conditions, thereby etching the three-dimensional surface patterns.
The three-dimensional pattern structure of the son stamper was formed by a lithography apparatus to a dot shape having a pitch of 90 nm, a height of 37 nm, and a diameter of 50 nm.
Frequency: 500 Hz
On-Time: 1 ms
Off-Time: 1 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 0.2 μA·min/mm2
The three-dimensional pattern structure of a pulse etching son stamper obtained as described above had a height of 35 nm and a diameter of 40 nm, i.e., the three-dimensional pattern structure was etched by 10 nm in diameter compared with that before the pulsed electric current was supplied. The three-dimensional pattern structure of the dot shape having a regular prism form was changed into a cylindrical form and the edge of the dot shape was decreased after the etching compared with that before the etching.
Since the stamper manufactured by this embodiment Exhibited decreased LER and the edge of the dot shape pattern was decreased, the number of duplication cycles is greatly increased. In stamper duplication, the transfer efficiency is generally less than 100%. When repeating duplication, therefore, the patterns of the stamper wear and increase the roughness, and this exerts an adverse effect on a later imprinting process. When using the embodiment, however, the roughness of the manufactured stamper is decreased. This makes it possible to greatly increase the number of duplication cycles; more specifically, the number of duplication cycles is twice that of a conventional stamper.
Also, the number of dust particles adhering to the patterns of the stamper manufactured by this embodiment was counted by an optical reflection microdefect testing apparatus, e.g., Micro Max manufactured by Vision Psytec. As a result, 115 dust particles were found in the conventional duplicating method, whereas 18 dust particles were found in the etching method of this proposal. That is, the embodiment achieves the effect of removing dust particles by etching using a pulsed electric current.
COMPARATIVE EXAMPLE 1After a son stamper 21 was manufactured following the same procedures as in First Embodiment, the surface of the obtained son stamper 21 was dipped in the above-mentioned Ni sulfamate bath, and a pulsed electric current was supplied under the following conditions, thereby etching the three-dimensional surface patterns.
The three-dimensional pattern structure of the son stamper used had a pitch of 85 nm, a height of 50 nm, and a width of 30 nm.
Frequency: 50 Hz
On-Time: 100 ms
Off-Time: 100 ms
Positive (deposition-side) electric current: 1.00 A
Reverse (dissolution-side) electric current: 0.99 A
Accumulated current: 1.0 μA·min/mm2
The three-dimensional pattern structure of a pulse etching grandson stamper obtained as described above had a height of 10 nm and a width of 10 nm, i.e., the patterns disappeared.
An example of a DTR medium manufacturing method will briefly be explained below with reference to
DTR media were manufactured by the method shown in
A magnetic layer 51 is deposited on a substrate 50, and coated with a resist 52 (
Then, a stamper 30 having three-dimensional patterns is prepared, the pattern surface of the stamper 30 is opposed to the resist 52, and the patterns of the stamper 30 are transferred onto the resist 52 by imprinting (
A magnetic recording apparatus (hard disk drive) as shown in
The spindle motor 72 rotates the magnetic recording medium 71. The head slider 76 incorporates the magnetic head including a write head and read head. The actuator arm 74 is pivotally attached to a pivot 73. The suspension 75 is attached to one end of the actuator arm 74. The head slider 76 is elastically supported via a gimbal formed on the suspension 75. The VCM 77 is formed at the other end of the actuator arm 74. The VCM 77 generates rotating torque around the pivot 73 of the actuator arm 74, thereby positioning the magnetic head in a floated state on an arbitrary radial position of the magnetic recording medium 71.
Note that the embodiment is not limited to the above embodiments, and can variously be modified when practiced without changing the spirit and scope of the invention. Note also that the above-mentioned embodiments have portions in which shapes, numerical values, and the like are different from actual ones, but these factors can appropriately be changed in consideration of known techniques.
Furthermore, the above embodiments include inventions in various stages, so various inventions can be extracted by properly combining a plurality of disclosed constituent elements. For example, even when some of all the constituent elements disclosed in the embodiments are deleted, an arrangement from which these constituent elements are deleted can be extracted as an invention, provided that the problems described in the section of the problems to be solved by the invention can be solved, and the effects described in the section of the effects of the invention can be obtained.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The various modules of the systems described herein can be implemented as software applications, hardware and/or software modules, or components on one or more computers, such as servers. While the various modules are illustrated separately, they may share some or all of the same underlying logic or code. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Claims
1. A stamper manufacturing method comprising:
- forming a first conductive layer on a surface of a master having a three-dimensional structure;
- forming a first electroformed layer on the first conductive layer;
- separating the first electroformed layer and the first conductive layer from the master to form a first stamper onto which the three-dimensional structure of the master is transferred;
- forming a first release layer on a surface of the first stamper;
- forming a second conductive layer on the first release layer;
- forming a second electroformed layer on the second conductive layer;
- separating the second electroformed layer and the second conductive layer from the first stamper to form a second stamper onto which the three-dimensional structure of the first stamper is transferred;
- forming a second release layer on a surface of the second stamper;
- forming a third conductive layer on the second release layer;
- forming a third electroformed layer on the third conductive layer;
- separating the third electroformed layer and the third conductive layer from the second stamper to form a third stamper onto which the three-dimensional structure of the second stamper is transferred; and
- etching the three-dimensional structure of the third stamper by supplying a pulsed electric current to a surface of the third stamper.
2. The method of claim 1, wherein the three-dimensional structure has a periodical pattern having a track pitch of not more than 100 nm, and the etching is performed in an Ni sulfamate solution, and the pulsed electric current is supplied at a frequency of not less than 100 Hz and an accumulated current of about 0.1 to 5.0 μA·min/mm2 by alternately supplying a positive electric current and a reverse electric current.
3. A stamper processing method of etching a three-dimensional structure of a stamper by supplying a pulsed electric current to a three-dimensional surface of the stamper.
4. The method of claim 3, wherein the etching is performed in an Ni sulfamate solution, and the pulsed electric current is supplied at a frequency of not less than 100 Hz and an accumulated current of about 0.1 to 5.0 μA·min/mm2 by alternately supplying a positive electric current and a reverse electric current.
Type: Application
Filed: Jun 11, 2010
Publication Date: Dec 16, 2010
Applicant: KABUSHIKI KAISHA TOSHIBA (Tokyo)
Inventors: Takuya SHIMADA (Kawasaki-shi), Shinobu SUGIMURA (Yokohama-shi), Yoshiyuki KAMATA (Tokyo), Masatoshi SAKURAI (Tokyo)
Application Number: 12/814,415
International Classification: C25D 1/10 (20060101);