REPLICATION TOOL
The present invention relates to a replication tool for replicating an element from a replication material, the replication tool comprising a replication side, a plurality of cavities on the replication side, each defining the shape of one element or a group of elements, the replication tool further comprising at least one bump portion, protruding, on the replication side, from the cavities, and further comprising means for confining the replication material to a predetermined area of the tool, when the tool is pressed against a substrate, which predetermined area exceeds the desired volume of the element in at least one direction along the surface of the substrate.
1 . A replication tool for replicating an element from a replication material, the replication tool comprising a replication side, a plurality of cavities on the replication side, each defining the shape of one element or a group of elements, the replication tool further comprising at least one bump portion, protruding, on the replication side, from the cavities, and further comprising means for confining the replication material to a predetermined area of the tool, when the tool is pressed against a substrate, which predetermined area exceeds the desired volume of the element in at least one direction along the surface of the substrate, characterized in that said at least one bump defines a curved surface transition zone having a fillet radius R in a range of 50 micron-500 micron.
2 . The replication tool of claim 1 , wherein said at least one bump defines a curved surface transition zone having a fillet radius R in a range of 100 micron to 120 micron.
3 . The replication tool according to claim 1 , wherein each cavity being limited by said curved surface transition zone serving as the bump portion, an inner edge between the cavity and the transition zone, an overflow volume and an outer edge between the transition zone and the overflow volume.
4 . The replication tool according to claim 3 , wherein said outer edge defines a peripheral resin run out zone with an inclination angle e in a range of 1-35 deg.
5 . The replication tool according to claim 4 , wherein the length of said peripheral resin run out zone is at least 20 micron, preferably at least 50 micron, preferably in a range of 60-80 micron.
6 . The replication tool according to claim 2 , wherein the distance between said curved surface transition zone and said substrate, when the tool is pressed against a substrate, is less than 60 micron, preferably in a range of 20-40 micron, said distance being measured at the highest point of said curved surface transition zone.
7 . A method of manufacturing an element by means of a replication tool, comprising the steps of:
providing a replication tool that defines the shape of the element;
providing a substrate;
pressing the replication tool against the substrate, with a replication material in a liquid or viscous or plastically deformable state located between the tool and the substrate;
confining the replication material to a predetermined area of the substrate, which predetermined area exceeds the desired area of the element on the substrate, in at least one direction along the surface of the substrate by less than a predetermined distance;
hardening the replication material to form the element, wherein said replication tool is a replication tool according to anyone or more of the preceding claims.