Line selected F2 two chamber laser system
First Claim
1. A very narrow band two chamber high repetition rate F2 gas discharge laser system comprising:
- A) a first laser unit comprising;
1) a first discharge chamber containing;
a) a first laser gas b) a first pair of elongated spaced apart electrodes defining a first discharge region, 2) a first fan for producing sufficient gas velocities of said first laser gas in said first discharge region to clear from said first discharge region, following each pulse, substantially all discharge produced ions prior to a next pulse when operating at a repetition rate in the range of 4,000 pulses per second or greater, 3) a first heat exchanger system capable of removing at least 16 kw of heat energy from said first laser gas, B) a line selection unit for minimizing energy outside of a single selected line spectrum, C) a second laser unit comprising;
1) a second discharge chamber containing;
a) a second laser gas, b) a second pair of elongated spaced apart electrodes defining a second discharge region 2) a second fan for producing sufficient gas velocities of said second laser gas in said second discharge region to clear from said second discharge region, following each pulse, substantially all discharge produced ions prior to a next pulse when operating at a repetition rate in the range of 4,000 pulses per second or greater, 3) a second heat exchanger system capable of removing at least 16 kw of heat energy from said second laser gas, D) a pulse power system configured to provide electrical pulses to said first pair of electrodes and to said second pair of electrodes sufficient to produce laser pulses at rates of about 4,000 pulses per second with precisely controlled pulse energies in excess of about 5 mJ, E) a laser beam measurement and control system for measuring pulse energy of laser output pulses produced by said two chamber laser system and controlling said laser output pulses in a feedback control arrangement, and wherein output laser beams from said first laser unit are utilized as a seed beam for seeding said second laser unit.
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Accused Products
Abstract
An injection seeded modular gas discharge laser system capable of producing high quality pulsed laser beams at pulse rates of about 4,000 Hz or greater and at pulse energies of about 5 mJ or greater. Two separate discharge chambers are provided, one of which is a part of a master oscillator producing a very narrow band seed beam which is amplified in the second discharge chamber. The chambers can be controlled separately permitting separate optimization of wavelength parameters in the master oscillator and optimization of pulse energy parameters in the amplifying chamber. A preferred embodiment in a F2 laser system configured as a MOPA and specifically designed for use as a light source for integrated circuit lithography. In the preferred MOPA embodiment, each chamber comprises a single tangential fan providing sufficient gas flow to permit operation at pulse rates of 4000 Hz or greater by clearing debris from the discharge region in less time than the approximately 0.25 milliseconds between pulses. The master oscillator is equipped with a line selection package for selecting the strongest F2 spectral line.
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Citations
77 Claims
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1. A very narrow band two chamber high repetition rate F2 gas discharge laser system comprising:
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A) a first laser unit comprising;
1) a first discharge chamber containing;
a) a first laser gas b) a first pair of elongated spaced apart electrodes defining a first discharge region, 2) a first fan for producing sufficient gas velocities of said first laser gas in said first discharge region to clear from said first discharge region, following each pulse, substantially all discharge produced ions prior to a next pulse when operating at a repetition rate in the range of 4,000 pulses per second or greater, 3) a first heat exchanger system capable of removing at least 16 kw of heat energy from said first laser gas, B) a line selection unit for minimizing energy outside of a single selected line spectrum, C) a second laser unit comprising;
1) a second discharge chamber containing;
a) a second laser gas, b) a second pair of elongated spaced apart electrodes defining a second discharge region 2) a second fan for producing sufficient gas velocities of said second laser gas in said second discharge region to clear from said second discharge region, following each pulse, substantially all discharge produced ions prior to a next pulse when operating at a repetition rate in the range of 4,000 pulses per second or greater, 3) a second heat exchanger system capable of removing at least 16 kw of heat energy from said second laser gas, D) a pulse power system configured to provide electrical pulses to said first pair of electrodes and to said second pair of electrodes sufficient to produce laser pulses at rates of about 4,000 pulses per second with precisely controlled pulse energies in excess of about 5 mJ, E) a laser beam measurement and control system for measuring pulse energy of laser output pulses produced by said two chamber laser system and controlling said laser output pulses in a feedback control arrangement, and wherein output laser beams from said first laser unit are utilized as a seed beam for seeding said second laser unit. - 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, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77)
A) a first temperature monitor for monitoring gas temperature in said first discharge chamber, B) a first gas temperature control system where gas temperature control system comprises a control algorithm for adjusting gas temperature to avoid adverse acoustic effects resulting from reflected acoustic waves.
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50. A laser as in claim 1 and further comprising:
- A) a second temperature monitor for monitoring gas temperature in said second discharge chamber, B) a second gas temperature control system where gas temperature control system comprises a control algorithm for adjusting gas temperature to avoid adverse acoustic effects resulting from reflected acoustic waves.
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51. A laser as in claim 1 and further comprising a nitrogen filter.
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52. A laser as in claim 1 and further comprising a nitrogen purge system comprising a purge module comprising flow monitors said laser also comprising purge exhaust tubes for transporting exhaust purge gas from said laser.
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53. A laser as in claim 1 and further comprising a shutter unit comprising an electrically operated shutter and a power meter which can be positioned in a laser output beam path with a command signal.
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54. A laser as in claim 1 and further comprising a beam enclosure system comprising:
- A) at least one beam seal said beam seals comprising a metal bellows, and B) a purge means for purging said beam enclosure with a purge gas.
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55. A laser as in claim 54 wherein said beam enclosure means comprise a flow directing means for producing purge flow transverse to laser beams produced in said second laser unit.
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56. A laser as in claim 54 wherein said at least one beam seal is configured to permit easy replacement of said laser chamber.
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57. A laser as in claim 54 wherein said at least one beam seal contains no elastomer, provides vibration isolation from said chamber, provides beam train isolation from atmospheric gases and permits unrestricted replacement of said laser chamber without disturbance of said line selection unit.
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58. A laser as in claim 54 wherein said at least one beam seal is vacuum compatible.
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59. A laser as in claim 58 wherein said at least one beam seal is a plurality of beam seals and said plurality of said seals are easy sealing bellows seals configured for easy removal by hand.
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60. A laser as in claim 1 wherein said measurement and control system comprises a primary beam splitter for splitting off a small percentage of each laser output pulse from said second laser unit and an optical means for directing a portion of said small percentage to a pulse energy detector and an isolation means for isolating a volume bounded at least in part by said primary beam splitter and a window of said pulse energy detector from other portions of said measurement and control system to define an isolated region.
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61. A laser as in claim 60 and further comprising a purge means for purging said isolated region with a purge gas.
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62. A laser system as in claim 1 wherein said system is configured to operate either of a KrF laser system, an ArF laser system or an F2 laser system with minor modifications.
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63. A laser system as in claim 1 wherein substantially all components are contained in a laser enclosure but said system comprises an AC/DC module physically separate from the enclosure.
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64. A laser system as in claim 1 wherein said pulse power system comprises a master oscillator charging capacitor bank and a power amplifier charging capacitor bank and a resonant charger configured to charge both charging capacitor banks in parallel.
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65. A laser as in claim 64 wherein said pulse power system comprises a power supply configured to furnish at least 2000V supply to said resonant charger.
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66. A laser as in claim 1 and further comprising a gas control system for controlling F2 concentrations in said first laser gas to control master oscillator beam parameters.
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67. A laser as in claim 1 and further comprising a gas control system for controlling laser gas pressure in said first laser gas to control master oscillator beam parameters.
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68. A laser as in claim 1 and further comprising a pulse multiplier unit for increasing duration of output pulses from said laser.
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69. A laser as in claim 68 wherein said pulse multiplier unit is arranged to receive said laser output pulses and to multiply the number of laser pulses per second by at least a factor of two so as to produce a single multiplied laser output pulse beam comprised of a larger number of pulses with substantially reduced intensity values as compared with the laser output pulses, and pulse multiplier unit comprising:
- (1) a first beam splitter arranged to separate a portion of said laser output pulse beam, the separated portion defining a delayed portion, and the laser output pulse beam defining a beam size and angular spread at said first beam splitter;
(2) a first delay path originating and terminating at said first beam splitter said first delay path comprising at least two focusing mirrors, said mirrors being arranged to focus said delayed portion at a focal point within said first delay path and to return said delayed portion to said first beam splitter with a beam size and angular spread equal to or approximately equal to the beam size and angular spread of the output beam at said first beam splitter.
- (1) a first beam splitter arranged to separate a portion of said laser output pulse beam, the separated portion defining a delayed portion, and the laser output pulse beam defining a beam size and angular spread at said first beam splitter;
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70. A laser system as in claim 69 wherein said at least two focusing mirrors are spherical mirrors.
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71. A laser system as in claim 69 and further comprising a second delay path comprising at least two spherical mirrors.
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72. A laser system as in claim 69 wherein said first delay path comprises four focusing mirrors.
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73. A laser system as in claim 72 and further comprising said second delay path created by a second beam splitter located in said first delay path.
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74. A laser as in claim 69 wherein said first delay path comprises a second beam splitter and further comprising a second delay path comprising at least two focusing mirrors, said mirrors being arranged to focus said delayed portion at a focal point within said first delay path and to return said delayed portion to said first beam splitter with a beam size and angular spread equal to or approximately equal to the beam size and angular spread of the laser output pulse beam at said first beam splitter.
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75. A laser as in claim 69 wherein said first beam splitter is configured to direct a laser beam in at least two directions utilizing optical property of frustrated internal reflection.
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76. A laser as in claim 69 wherein said first beam splitter is comprised of two transparent optical elements each element having a flat surface, said optical elements being positioned with said flat surfaces parallel to each other and separated by less than 200 nm.
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77. A laser as in claim 69 wherein said first beam splitter is an uncoated optical element oriented at an angle with said laser output pulse beam so as to achieve a desired reflection-transmission ratio.
Specification