Chuck assembly, planarization process, apparatus and method of manufacturing an article

1. A chuck assembly for holding a plate, comprising:

a member configured to hold the plate, the member including:

a flexible portion configured to have a central opening; and

a first cavity formed by the flexible portion, wherein the plate is held by the flexible portion by reducing pressure in the first cavity;

a light-transmitting member covering the central opening of the member; and

a fluid path in communication with a second cavity defined by the flexible portion, the plate held by the member and the light-transmitting member for pressurizing the second cavity,

wherein the flexible portion is configured to be bent by a pressure in the second cavity.

2. The chuck assembly of claim 1 , wherein the member is configured such that, when the plate is held to the flexible portion of the member via the first cavity thereby closing the second cavity, pressurizing the second cavity via the fluid path causes the plate and the flexible portion of the member to bow.

3. The chuck assembly of claim 1 , wherein the member includes an inflexible portion.

4. The chuck assembly of claim 3 , wherein the member is configured such that, when the plate is held to the flexible portion of the member via the first cavity thereby closing the second cavity, pressurizing the second cavity via the fluid path causes the plate and the flexible portion of the member to bow, while the inflexible portion does not bow.

5. The chuck assembly of claim 1 , further comprising a support ring coupled with the member.

6. The chuck assembly of claim 5 , wherein the second cavity is further defined by the support ring.

7. The chuck assembly of claim 5 , wherein the support ring comprises a step supporting the light-transmitting member.

8. The chuck assembly of claim 5 , wherein the support ring comprises one or more annular cavities.

9. The chuck assembly of claim 8 , wherein the one or more annular cavities face the member.

10. The chuck assembly of claim 8 ,

wherein the one or more annular cavities comprise a plurality of annular cavities, and

wherein the plurality of annular cavities are concentrically disposed within the support ring.

11. The chuck assembly of claim 8 , wherein the one or more annular cavities are in communication with a vacuum source.

12. The chuck assembly of claim 11 , wherein the one or more annular cavities are configured such that imparting a vacuum suction to the one or more annular cavities via the vacuum source couples the member to the support ring.

13. The chuck assembly of claim 11 ,

wherein the member includes an inflexible portion, and

wherein the one or more annular cavities are configured such that imparting a vacuum suction to the one or more annular cavities via the vacuum source increases a size of the inflexible portion while decreasing a size of the flexible portion.

14. The chuck assembly of claim 1 , wherein the member is composed of a material having a flexural rigidity of 0.01 to 5 Pa·m 3 .

15. The chuck assembly of claim 1 ,

wherein a ratio of a thickness of the flexible portion to a length of the flexible portion is 1:2 to 1:1000.

16. The chuck assembly of claim 1 , wherein the member includes an inflexible support portion.

17. The chuck assembly of claim 16 , wherein the second cavity is further defined by the inflexible support portion of the member.

18. The chuck assembly of claim 16 , wherein the support portion of the member comprises a step supporting the light-transmitting member.

19. A planarization system, comprising:

a chuck assembly configured to hold a plate, the chuck assembly comprising:

a member configured to hold the plate, the member including:

a flexible portion configured to have a central opening; and

a first cavity formed by the flexible portion, wherein the plate is held by the flexible portion by reducing pressure in the first cavity;

a light-transmitting member covering the central opening of the member; and

a fluid path in communication with a second cavity defined by the flexible portion, the plate held by the member and the light-transmitting member for pressurizing the second cavity,

wherein the flexible portion is configured to be bent by a pressure in the second cavity;

a substrate chuck configured to hold a substrate;

a fluid dispenser configured to dispense formable material on the substrate;

a positioning system configured to contact the formable material with the plate; and

a curing system configured to cure the formable material under the plate so as to form cured formable material on the substrate.

20. A method of manufacturing an article, comprising:

dispensing a formable material on a substrate;

retaining a plate with a plate chuck assembly, the plate chuck assembly comprising:

a member configured to hold the plate, the member including:

a flexible portion configured to have a central opening; and

a first cavity formed by the flexible portion, wherein the plate is held by the flexible portion by reducing pressure in the first cavity;

a light-transmitting member covering the central opening of the member; and

a fluid path in communication with a second cavity defined by the flexible portion, the plate held by the member and the light-transmitting member for pressurizing the second cavity,

wherein the flexible portion is configured to be bent by a pressure in the second cavity;

contacting the plate with the formable material dispensed on the substrate;

curing the formable material with a curing source;

separating the plate from the cured formable material; and

processing the cured formable material to make the article.