Method for high-precision multi-layered thin film deposition for deep and extreme ultraviolet mirrors
First Claim
1. A method for fabricating high-precision thin film coatings for multi-layered mirrors in a deposition chamber for use with a light source at a desired wavelength of operation, comprising the steps of:
- selecting a first target material and a second target material to be deposited on at least one optical substrate, each of the first and second target materials having a suitable refractive index N at the desired wavelength of operation, the refractive index N being defined by N=n+ik, where n is a real component, i is the square root of negative one, and k is an imaginary component;
calibrating the thickness deposition profiles for the first target material and the second target material;
modeling a desired thickness deposition profile for the first target material and the second target material; and
depositing a plurality of layers of a first thin film layer of the first target material and a second thin film layer of the second target material on the at least one optical substrate to produce at least one multi-layered mirror, the plurality of layers of the first thin film layer and the second thin film layer being deposited at a predetermined pressure, the plurality of layers of the first thin film layer and the second thin film layer having a predetermined number, thickness, and thickness gradient, wherein the predetermined thickness gradient is determined using a thin film coating design program that optimizes reflectance by maintaining a constant optical phase shift for each of the first thin film layer and the second thin film layer, wherein the optical phase shift is determined by δ
=(4π
dN cosθ
)/(λ
)±
π
, where θ
is the optical phase shift, d is the thickness of each of the first thin film layer and the second thin film layer, N is the refractive index of each of the first thin film layer and the second thin film layer, λ
is the desired wavelength of operation, and θ
is the angle of incidence of incoming light from the light source relative to the normal.
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Abstract
A method for coating (flat or non-flat) optical substrates with high-reflectivity multi-layer coatings for use at Deep Ultra-Violet ("DUV") and Extreme Ultra-Violet ("EUV") wavelengths. The method results in a product with minimum feature sizes of less than 0.10-μm for the shortest wavelength (13.4-nm). The present invention employs a computer-based modeling and deposition method to enable lateral and vertical thickness control by scanning the position of the substrate with respect to the sputter target during deposition. The thickness profile of the sputter targets is modeled before deposition and then an appropriate scanning algorithm is implemented to produce any desired, radially-symmetric thickness profile. The present invention offers the ability to predict and achieve a wide range of thickness profiles on flat or figured substrates, i.e., account for 1/R2 factor in a model, and the ability to predict and accommodate changes in deposition rate as a result of plasma geometry, i.e., over figured substrates.
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Citations
28 Claims
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1. A method for fabricating high-precision thin film coatings for multi-layered mirrors in a deposition chamber for use with a light source at a desired wavelength of operation, comprising the steps of:
-
selecting a first target material and a second target material to be deposited on at least one optical substrate, each of the first and second target materials having a suitable refractive index N at the desired wavelength of operation, the refractive index N being defined by N=n+ik, where n is a real component, i is the square root of negative one, and k is an imaginary component; calibrating the thickness deposition profiles for the first target material and the second target material; modeling a desired thickness deposition profile for the first target material and the second target material; and depositing a plurality of layers of a first thin film layer of the first target material and a second thin film layer of the second target material on the at least one optical substrate to produce at least one multi-layered mirror, the plurality of layers of the first thin film layer and the second thin film layer being deposited at a predetermined pressure, the plurality of layers of the first thin film layer and the second thin film layer having a predetermined number, thickness, and thickness gradient, wherein the predetermined thickness gradient is determined using a thin film coating design program that optimizes reflectance by maintaining a constant optical phase shift for each of the first thin film layer and the second thin film layer, wherein the optical phase shift is determined by δ
=(4π
dN cosθ
)/(λ
)±
π
, where θ
is the optical phase shift, d is the thickness of each of the first thin film layer and the second thin film layer, N is the refractive index of each of the first thin film layer and the second thin film layer, λ
is the desired wavelength of operation, and θ
is the angle of incidence of incoming light from the light source relative to the normal. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification