Patent Number: 047013915
Section: description

A mask comprising a magnesium diaphragm can be manufactured by various methods, which are represented in detail in Methods A to E. All the methods have in common that the magnesium diaphragm is first deposited in the form of a thin layer on an auxiliary carrier, which is then removed or is retained if a suitable material is used for the auxiliary carrier. Method A An auxiliary carrier 1 of a synthetic material, for example, a polyimide foil, which is adhered to a supporting ring 3 and is stretched on it, has applied to it a magnesium layer 5 by cathode sputtering with the following parameters: ______________________________________ HF generator 13.6 MHz Electrode diameter 200 mm Electrode gap 45 mm Working pressure of the 25 .mu.bar gas atmosphere (Ar) Potential at the cathode 600 V. ______________________________________ Magnesium layers 1 to 2 .mu.m thickness are maufactured. The thickness of the layer depends upon the duration of the cathode sputtering process and can be adjusted correspondingly. The composite diaphragm of magnesium-polyimide thus manufactured has a very high breaking strength and retains its accuracy to size even under conditions which would have adversely affected a diaphragm consisting solely of polyimide. Diaphragms having a diameter of up to 60 mm were manufactured; however, with this value the limit of the possibilities is not yet reached. In the FIGURE, an absorber pattern 7 is present on the magnesium layer 5 constituting the diaphragm. The auxiliary support may be retained as a component of the mask (this case is shown in the FIGURE), but it may alternatively be removed (as described in the method B to E) so that self-supporting diaphragms consisting only of the magnesium layer 5 are then obtained. Method B A self-supporting magnesium diaphragm can be manufactured in such a manner that a magnesium layer, as described for the method A, is first deposited on a polyimide foil and that the polyimide foil is removed from the magnesium layer in a subsequent etching process. The polyimide foil can be removed either by a plasma etching process in an oxygen plasma or by reactive ion etching, for example with the following parameters: ______________________________________ HF generator 27.25 MHz Electrode diameter 200 mm Potential at the cathode 100 V Working pressure of the 150 .mu.bar. gas atmosphere (O.sub.2) ______________________________________ The etching process works selectively so that the magnesium layer is substantially not attacked because of the defined MgO layer to be formed on it. The self-supporting Mg diaphragm is already stabilized by a surface layer of MgO having a thickness of a few tens of nm. In the manner described, Mg diaphragms having a diameter of 1.5 cm and a thickness of 1.0 .mu.m were manufactured; These values do not represent the upper limit either. Method C Instead of a polyimide foil, as described for method A, a polycarbonate foil may be used as an auxiliary carrier for the deposition of the magnesium layer. If a self-supporting Mg diaphragm is to be formed from the deposited magnesium layer, the polycarbonate foil can be removed in a swelling process. As a swelling and detaching agent use may be made of dichloromethane. Method D A self supporting Mg diaphragm can alternatively be manufactured by the following processing steps: A gold layer having a thickness of 50 nm is applied by cathode sputtering to an auxiliary carrier in the form of a glass plate whose surface has a low roughness in the range of both short-wave and long-wave radiation. The working pressure of the gas atmosphere of argon is efficaciously 12 .mu.bar with a power of 125 W. A TiO.sub.2 layer is applied by cathode sputtering to this gold layer at a working pressure of the gas atmosphere of O.sub.2 of 12 .mu.bar and with a power of 125 W. This TiO.sub.2 layer acts as a diffusion barrier. Subsequently, a layer of Mg is applied by cathode sputtering to the layer of TiO.sub.2, as described for method A. The gold layer poorly adhering to the glass plate permits of pulling the Au/TiO.sub.2 /Mg layer off the glass plate; for this purpose, an auxiliary frame is adhered to the layer to be pulled off. In order to promote the detaching process, the coated glass plate can be immersed in a bath of, for example, glycerine or a glycol. The detached Mg diaphragm can then be stretched and adhered to a frame of, for example, glass in the desired manner. Thus, diaphragms were obtained having a diameter of 90 mm; this value does not represent an upper limit, however. The thickness of the diaphragms thus manufactured was in the range of from 1.8 to 2.2 nm, which does not represent the lower limit attainable, however. Method E In order to render the detaching process described for method D more effective, that is to say in order to increase the output of usable diaphragms, the Mg layer may be additionally made more stable by means of a lacquer layer having a thickness of about 2 .mu.m and consisting of, for example, a commercially available photolacquer. The photolacquer layer is then removed by an etching step, for example by etching by means of cathode sputtering in an oxygen plasma. Diaphragms of magnesium are opaque to visible light. In order to permit carrying out direct adjustment processes by means of laser beams, it is therefore efficacious to provide the diaphragm with adjustment windows which consist of a material transparent to visible light, for example, of polyimide. Subsequently, the absorber pattern is formed on the diaphragm manufactured by means of the method A to E. For this purpose, multilayer absorber layers, for example of tungsten and molybdenum, have proved particularly suitable. To this end, the procedure can be as follows: Both the tungsten layer and the molybdenum layer are applied by cathode sputtering. The tungsten layer is manufactured efficaciously with the following parameters: ______________________________________ HF generator 13.6 MHz; Electrode diameter 200 mm; Electrode gap 42 mm; Working pressure of the 2 Pa; gas atmosphere (Ar) Potential at the electrode 800 V; Potential at the mask 40 V. carrier ______________________________________ The molybdenum can be applied by cathode sputtering under the following conditions: ______________________________________ HF generator 13.6 MHz; Electrode diameter 200 mm; Electrode gap 42 mm; Working pressure of the 2 Pa; gas atmosphere (Ar) Potential at the electrode 700 V; Potential at the mask 95 V. carrier. ______________________________________ This absorber layer can be structured in accordance with the desired mask pattern by means of known techniques, for example, by means of electron beam lithography.