Electron microscope specimen supports

Abstract: A specimen support for use in an electron microscope comprises a deposited diamond film. The film is deposited on a substrate using a plasma assisted chemical vapour deposition process and then machined to a desired configuration using a laser machining process. Molybdenum, tungsten or silicon are used as substrates.

Description: This invention relates to specimen supports for use in electron microscopes. In operation of electron microscopes, more especially transmission electron microscopes, the specimens being examined are often very thin, e.g. less than 100nm thick, and therefore need to be mounted on a support to restrain them physically and to aid handling during preparatory treatments. Commonly, supports in the form of copper grids are used for this purpose, a variety of mesh sizes being used, and in some cases a support with very few holes or slots, or even one hole or slot only, may be used. Supports made of other materials have also been used to suit various special applications, for example, supports made of beryllium have been used where low x-ray background is desirable. It is known from US 4 250127 to make specimen supports for electron microscopy out of copper, beryllium, woven nylon, or carbon which has been sputtered and then pyrolyzed. However, each of these materials presents its own problems in being used. Copper supports generate noise over a considerable range of the energy spectrum. Beryllium supports are toxic, difficult to produce and expensive. Woven nylon supports are non-conductive and so degrade image quality. Furthermore, they are not sufficiently rigid or thermally stable for this use. Sputtered and pyrolyzed carbon is extremely delicate and unable to withstand normal handling. As a solution to the lack of a suitable material for specimen supports, this document proposes polymer composites. It is an object of the present invention to provide a specimen support for use in an electron microscope which exhibits significant advantages in various applications. According to the present invention as disclosed in claim 1, there is provided a specimen support for use in an electron microscope comprising a deposited diamond film. Suitably the film is a film formed by chemical vapour deposition. The invention as disclosed in claim 5 also provides a method of fabricating a specimen support for use in an electron microscope comprising depositing a film of diamond on a substrate using a plasma assisted chemical vapour deposition process and machining the film to a desired configuration using a laser machining process. Various specimen supports in accordance with the invention and their method of fabrication will now be described, by way of example. The supports are of planar circular form with an outside diameter of 3.05mm so as to fit into the holders normally provided by electron microscope manufacturers. The supports have formed through them one or more apertures. Typically a regular pattern of circular or rectangular apertures is formed. Alternatively, a single circular central aperture of desired diameter is formed. The supports typically have a thickness of between 50µm and 75µm although thinner supports and supports of thickness up to 1.5mm can be fabricated. The supports are formed by microwave plasma chemical vapour deposition of diamond films on a substrate, followed by laser machining to form the required apertures and define the outer periphery. In a preferred fabrication process deposition takes place at 1000°C onto a molydenum substrate and the gas in the plasma consists of a mixture of hydrogen (H 2 ) at a flow rate of 532 sccm (standard cubic centimetres per minute), methane (CH 4 ) at a flow rate of 60 sccm and oxygen (O 2 ) at a flow rate of 9 sccm, at a pressure of 18665 Pa (140 torr). Under these conditions the growth rate is about 14.5µm per hour. After deposition the film is easily removed from the molydenum substrate and the free-standing diamond film machined using a Nd/YAG laser operated at a wavelength of 1064 nm. Instead of a Na/YAG laser a copper vapour laser may be used. Tungsten may suitably be used for the substrate instead of molybdenum. Where a very thin support is required a silicon substrate can be used and removed by chemical etching after laser machining of the support. One advantage of a specimen support according to the invention arises from the high thermal conductivity of diamond, which is five times that of copper. This makes a support according to the invention ideal for use as a support for a cross-section transmission electron microscope specimen of thermally sensitive material, which may be subject to thermal damage during ion beam milling when being prepared for examination. Furthermore, heat generated during electron optical observations in the microscope is conducted away rapidly by a support according to the invention. Another advantage of a support according to the invention is its low sputter rate, e.g. during ion beam milling of the specimen. This leads to cleaner specimens because of the low contamination due to sputtered material from the support. This also has the effect that a specimen will be etched faster than its support. The possibility of the support being etched away and the specimen falling into the ion beam milling apparatus is therefore avoided. The lower sputter rate of supports according to the invention also allows supports of finer grid form to be used. A further advantage of a support according to the invention is that, being formed of material of low atomic number, i.e. Z=6, it produces a low energy background signal when used to support a specimen for energy dispersive x-ray (EDX) analysis. Beryllium supports have been used for this purpose, but beryllium is toxic. Graphitised fibre supports have also been used but are too brittle to be made to precise dimensions. A further advantage of a support according to the invention is its chemical inertness. As a consequence a specimen can be cleaned by chemical etching whilst mounted on the support. Moreover, a support can often be re-used after being chemically cleaned. Finally a support according to the invention is hard and rigid and mechanically very stable, properties not found in materials conventionally used for electron microscope specimen support.

Claims: A specimen support for use in an electron microscope comprising a deposited diamond film, for support of the specimen. A support according to Claim 1 characterised in that the film is formed by chemical vapour deposition. A support according to Claim 1 or Claim 2 characterised in that the film is machined after deposition. A support according to Claim 3 characterised in that the film is machined using a laser. A method of fabricating a specimen support for use in an electron microscope comprising depositing a film of diamond on a substrate using a plasma assisted chemical vapour deposition process and machining the film to a desired configuration using a laser machining process. A method according to Claim 5 characterised in that the deposition process uses a gas in the plasma comprising a mixture of hydrogen, methane and oxygen. A method according to Claim 6 characterised in that the hydrogen, methane and oxygen have flow rates which are substantially 532, 60 and 9 sccm respectively. A method according to any of Claims 5, 6 or 7 characterised in that the deposition process occurs at a temperature of substantially 1000 °C. A method according to any of Claims 5 to 8 characterised in that the film is removed from the substrate before the laser machining process. A method according to any of Claims 5 to 8 characterised in that the film is removed from the substrate by chemical etching after the laser machining process.

Inventors: AHMED MUHAMMED MASOOD, AUGUSTUS PETER DAVID, AHMED, MUHAMMED MASOOD, AUGUSTUS, PETER DAVID
Applicants: MARCONI ELECTRONIC SYST LTD, MARCONI ELECTRONIC SYSTEMS LIMITED
Application year: 1996
Main classification: H01J37
IPC codes: H01J37