Patent Number: 
Section: description

Certain embodiments of X-ray sources according to the invention generate X-rays from a plasma produced by focusing pulsed laser light on a target material inside a reduced-pressure chamber. Other embodiments generate X-rays from a plasma produced by converting a target material into a plasma using an electrical discharge. An X-ray optical element is used to receive the X-rays from the plasma and guide the X-rays to a downstream X-ray optical system. First Representative Embodiment This embodiment is depicted in FIG. 1. The X-ray source is an LPX source. X-rays are produced from a plasma 603 generated by discharging a target gas from a nozzle 600 at ultrasonic velocity while irradiating the discharged target gas with a pulsed laser light 602. Discharge of target gas through the nozzle 600 is controlled by a pulse valve 601. The generated X-rays have a nearly uniform intensity distribution within a plane parallel to the laser-incidence plane (a horizontal plane in the figure). A paraboloidal mirror 604 having a focal point in the middle of the plasma is situated as shown in the figure. The paraboloidal mirror 604 reflects the X-rays emitted from the plasma 603 and produces a collimated X-ray light flux 611 having an axially symmetric intensity distribution. The paraboloidal mirror 604 also directs the X-ray light flux 611 toward a downstream optical system. The paraboloidal mirror 604 is coated with multiple thin-film layers so as to be reflective to X-rays having a specified wavelength. The multi-layer period varies in a controlled manner across the reflective surface of the mirror 604 so as to maximize the reflectivity of the mirror at various locations on the mirror surface. The axis of rotational symmetry of the paraboloid is oriented so as to pass through the center of the plasma 603. Thus, the rotational axis of the paraboloidal mirror 604 is coincident with the optical axis of X-rays reflected from the mirror 604 (this optical axis is the axis of symmetry of the X-ray source). A rotational actuator 605 is situated relative to the paraboloidal mirror 604 and is configured to rotate the mirror 604 about its axis of rotational symmetry. The rotational actuator 605 is mounted via linear stages 608, 609, 610 on tilt stages 606, 607. The tilt stages 606, 607 are oriented perpendicularly to one another. The linear stages 608, 609, 610 also are oriented perpendicularly to one another in three dimensions. The combination of the tilt stages 606, 607 and linear stages 608-610 are a representative example of various mechanisms that can be utilized for accurately positioning and rotating the mirror 604. Contact-type displacement sensors 612, 613 are mounted, with respective orientations that are perpendicular to each other, on the side and rear surfaces (in the figure) of the paraboloidal mirror 604. (The direction orthogonal to the plane of the page is not depicted.) The particular configuration of the depicted displacement sensor 612 is exemplary only. Any of various types of displacement sensors can be employed. To facilitate displacement sensing, the side and rear surfaces (in the figure) of the paraboloidal mirror 604 extend very accurately parallel and perpendicular, respectively, to the axis of rotational symmetry of the mirror 604. The output of each displacement sensor 612, 613 is routed to a computer or other processor (not shown but well understood in the art) as a representative controller. During rotation of the mirror 604, any change in the rotational axis of the mirror 604 is detected by the displacement sensors 612, 613 as a corresponding shift in mirror position. Data from the displacement sensors 612, 613 are processed by the computer. If the computer determines that the magnitude of shift exceeds applicable specifications, then the computer initiates actuation of the tilt stages 606, 607 and/or the linear stages 608, 609 to return the mirror position to within specification. Thus, by providing in this embodiment respective devices for detecting mirror position, for controlling mirror position, and for actuating a drive mechanism to restore proper mirror position, displacement of the optical axis of X-rays reflected by the rotating mirror 604 is maintained within specification so as to ensure that any flying debris deposited on downstream optical components is distributed uniformly about the axis. If the accuracy of the mirror-rotation mechanism is sufficiently high for maintaining axial displacement of the rotating mirror within the maximal angular spread of the X-ray light flux accommodated by the downstream optical system, then the devices for detecting mirror position, controlling mirror position, and actuating drive mechanisms to restore mirror position can be omitted. Second Representative Embodiment An X-ray source (LPX source) according to this embodiment is shown in FIG. 2. X-rays are generated by a plasma produced by irradiation of laser light on a gaseous target material. The X-ray source is contained within a chamber 100 defining an interior space evacuated by a vacuum pump (not shown but well understood in the art). The pressure of the interior space is reduced to a level at which X-rays radiating from the plasma are not absorbed or excessively attenuated en route. The target-gas-delivery device in this embodiment is a gas nozzle 101 (desirably made of an inert metal such as stainless steel) from which the target gas (e.g., krypton) is discharged. Discharge from the gas nozzle 101 is controlled by a pulse valve 113. Target gas discharged from the nozzle 101 that is not converted into the plasma is evacuated to the external environment through an evacuation port 104 located axially opposite the nozzle 101 and connected to the vacuum pump. Any other target gas circulating in the vacuum chamber 100 is evacuated through the vacuum port 104 by the vacuum pump discussed above. The laser is incident along an optical axis, passing through the center of the plasma 102, extending perpendicularly to the plane of the page of FIG. 2. I.e., the laser pulses are incident at the plasma 102 from below the plane of the page along an axis perpendicular to the plane of the page. Pulsed laser light emitted from the laser device (not shown but well understood in the art) is focused by a condenser lens (not shown) at a position 0.5 mm from the tip of the nozzle 101, along the axis of the nozzle, to produce the plasma 102. The shape of the plasma 102 is filamentous, with a length of approximately 300 xcexcm along the optical axis of the laser and approximately 100 xcexcm perpendicular to the optical axis of the laser. The plasma 102 is produced approximately 500 xcexcm toward the condenser lens from directly in front of the nozzle 101. A paraboloidal mirror 103 and the nozzle 101 are situated such that the plasma 102 is formed substantially at the focal point of the mirror 103. Regarding the X-rays emitted from the plasma 102, only those X-rays of a specified wavelength (e.g., 13 nm) are reflected by the mirror 103. To such end, the paraboloidal mirror 103 is coated with multiple thin-film layers. X-rays reflected from the mirror 103 are collimated and pass through a filter 110 that is opaque to visible light but transmissive to X-rays. By way of example, the filter 110 comprises a thin film of zirconium (Zr), 150 nm thick, formed on a mesh of nickel (Ni). The mesh is supported by a holder 111. The X-rays passing through the filter 110 propagate to a downstream X-ray optical system (not shown). The mirror 103 is supported by a stage assembly, comprising an annular ultrasonic motor 105 situated and configured to rotate the paraboloidal mirror 103 around its axis of rotational symmetry. The stage assembly also comprises three axially orthogonal stages 106, 107, 108 for determining and controlling the position of the mirror 103, and a tilting stage 109 for controlling the inclination of the mirror 103. The stages 108, 109 are mounted behind the mirror 103, and the stages 106, 107 are displaced laterally from the stages 108, 109. The stages 106-109 can be driven by respective motors or other actuators from outside the vacuum chamber 100. In this embodiment, a set of multiple (desirably three) semiconductor lasers and respective photodiodes is used for detecting the position and inclination of the paraboloidal mirror 103. The semiconductor lasers and photodiodes are disposed adjacent the paraboloidal mirror 103 at positions that do not block X-rays reflected by the mirror 103. The semiconductor lasers are positioned at 120xc2x0 relative to each other. The respective photodiodes also are positioned at 120xc2x0 from each other, but angularly between the lasers. This scheme is depicted in FIG. 3(A) so as to be understood readily, wherein FIG. 3(A) represents a view, from a location on the mirror axis but downstream of the mirror 103, toward the mirror 103. A laser beam from the semiconductor laser 201 strikes a point on the surface of the paraboloidal mirror 103 and is reflected toward a respective photodiode 204. Respective laser beams from the other two semiconductor lasers 202, 203 are likewise reflected by the surface of the mirror 103 toward respective photodiodes 205, 206. Hence, the points on the surface of the mirror 103 irradiated by the laser beams are at 120xc2x0 relative to each another. Each photodiode 204, 205, 206 has a respective light-reception surface 208 that is partitioned into four portions 208a-208d, as shown in FIG. 3(B). Each portion produces a respective electrical signal from respective incident light of the reflected laser beam. These electrical signals are routed to the computer (discussed above). In a situation in which the nozzle 101, the paraboloidal mirror 103, and the downstream optical system are all aligned with each other, the respective signals output from the photodiodes 204-206 (3 photodiodesxc3x974 portions each=12 signals) are received by, stored in, and processed by the computer. This situation represents an xe2x80x9cinitial statexe2x80x9d of the system. Upon starting up this X-ray source, rotation of the paraboloidal mirror 103 commences, as effected by the ultrasonic motor 105. The rotational velocity of the mirror is a function of the rate at which flying debris from the plasma adhere to and accumulate on neighboring structures. If the rate of production of flying debris by the plasma is low, then a low rotational velocity is permissible. Conversely, higher-velocity rotation is necessary if the rate of particle adhesion is high. By way of example, the LPX of this embodiment tends to emit low quantities of flying debris, so the rotational velocity of the mirror 103 can be one revolution per hour. In any event, if alignment of the mirror 103 shifts during rotation, then the positions at which the respective reflected laser beams from the semiconductor lasers 201-203 reach the respective photodiodes 204-206 change accordingly. These changes produce corresponding changes in the magnitudes of respective signals produced by the portions 208a-208d of the light-reception surface 208 in each photodiode 204-206. If the differences in electrical outputs from the portions 208a-208d of the light-reception surfaces in the photodiodes 204-206, relative to the initial conditions, exceeds predetermined thresholds, then the computer will detect an excessive misalignment of the mirror 103 and will cause the inclination stage 109 and the linear stages 106-108 to apply corrective positioning of the mirror 103 to return the electrical signals to within specifications. In addition, the direction of mirror shift can be ascertained from the signal changes in the four portions 208a-208d of the respective light-reception surface 208 of each photodiode 204-206, allowing the stages 106-109 to be actuated appropriately to correct the shift. Hence, changes in the optical axis of the X-rays reflected from the mirror 103 are maintained within specifications so as not to have any adverse effect on downstream optical systems, even while rotating the mirror 103. In addition, there is no loss in the axial symmetry of the X-rays reflecting from the mirror 103, even if the angular distribution of the flying debris is asymmetrical. In this embodiment, the X-ray filter 110 is located in the chamber 100. As a result, flying debris from the plasma also can accumulate on the filter 110. If the angular distribution of the flying debris is asymmetric, then the debris will accumulate asymmetrically on the filter 110. As a result, the flux of X-rays transmitted by the filter 110 will become asymmetric. Therefore, in this embodiment, an annular ultrasonic motor 112 (or analogous actuator) is installed on the perimeter of the holder 111 on which the X-ray filter 110 is mounted, so as to rotate the filter 110 around the center axis of the X-ray flux. The filter rotation prevents degradation of the symmetry of the transmitted X-ray flux, by ensuring that the quantity of flying debris accumulating on the filter 110 is axially symmetric relative to the X-ray optical axis. In this embodiment, since the rate of change in the transmissivity of the filter 110 is miniscule, even if some shift occurs in the rotational axis of the filter 110, a filter-position sensor is not normally necessary (and hence is not shown). By rotating the filter 110 as described above, variations in the transmission of X-rays through the filter 110 can be ameliorated (e.g., variances arising by variances in the thickness of the filter material and/or of the mesh support members). This is especially effective whenever the X-ray source of this embodiment is used for performing microlithographic exposures, as in soft X-ray (EUV) microlithography apparatus and methods. The respective rotational velocities of the mirror 103 and filter 110 may be equal, or they may be different according to the operating status of the X-ray source. In addition, the respective directions of rotation of the mirror and filter may be the same or different. Although a paraboloidal mirror 103 is used in this embodiment, it will be understood that the mirror alternatively can be a spherical mirror or an ellipsoidal mirror. The mirror also may be a rotationally symmetrical a spherical mirror. The mirror surface (whether spherical, paraboloidal, ellipsoidal, and/or a spherical) can be formed on a single substrate, or alternatively on a substrate divided into multiple segments conjoined into a single unit or situated adjacent one another. In this embodiment, the light-receiving surface 208 of each photodiode 204-206 was divided into four portions 208a-208d. However, the number of portions is not limited to four. Alternatively, each light-receiving surface 208 can be divided into two, three, or more portions, or not divided at all. The photodiodes 204-206 can be one-dimensional (as in photodiode arrays), or two-dimensional (as in CCDs). Although semiconductor lasers were used in this embodiment to measure displacements of the mirror 103, other measuring devices alternatively can be used such as contact-needle displacement gauges (see FIG. 1), over-current sensors, ultrasonic sensors, electrostatic capacity sensors, etc. The mirror can be disposed in any orientation relative to the plasma. FIG. 4 shows an example configuration employing a discharge-plasma X-ray source (dense-plasma focus, or DPF source). In FIG. 4, only the electrodes (anode 300, cathode 301) of the DPF source are shown, and the power supply is not shown. A multilayered paraboloidal mirror 305 is situated laterally adjacent the electrode. Also not shown are a mirror-drive mechanism and a device for detecting mirror position. If the mirror is planar it can be rotated using the direction of a normal ray as an axis. FIG. 5 shows a situation in which a multilayer planar mirror 404 is used, together with a gas-jet LPX used to generate X-rays from a plasma 402. The multilayer planar mirror 404 is rotated about the normal-ray axis AA. Not shown are a mirror-drive mechanism and a device for detecting mirror position. A laser beam 403 is focused at the location of the plasma 402. Whereas a multilayer mirror is used in the embodiments described above, a grazing-incidence mirror alternatively can be used for achieving full reflection of incident X-rays. An example configuration employing a grazing-incidence paraboloidal mirror 502 is shown in FIG. 6, used in conjunction with a DPF for generating the X-rays. In this figure, only the electrodes (anode 500, cathode 501) of the DPF source are shown; the power supply is not shown. The DPF source produces a plasma 504 at the location shown, relative to the mirror 502. In FIG. 6, the mirror 502 is rotated about its axis of symmetry (axis Bxe2x80x94B), which is the propagation axis of X-rays reflected from the mirror 502. (The mirror-drive mechanism and device for detecting mirror position are not shown.) Although the mirror 502 has a paraboloidal reflective surface, the mirror 502 alternatively can have an ellipsoidal reflective surface or a reflective surface having a combination of these profiles (e.g., a Walter mirror). Item 503 is an axial beam stop useful for producing a collimated beam. Although LPXs were used in several of the embodiments described above in which gas jets were used, LPXs employing mechanisms in which the target material is discharged in clusters, a liquid jet, liquid droplets, microdroplets, or microparticles alternatively can be used. The target material used for LPXs or discharge-plasma X-ray sources is not limited to krypton. Alternatively, the target material can be, e.g., xenon (Xe), carbon dioxide (CO2), or lithium (Li), or a mixture or compound of any of these substances. As an alternative to using a DPF source for generating X-rays, other configurations of discharge-plasma X-ray sources alternatively can be used. For example, a Z-pinch plasma source or a capillary-discharge plasma source can be used. By employing a rotating reflective optical element (onto which X-rays generated from the plasma are initially incident), or other rotating optical element in the vicinity of the plasma, flying debris will accumulate in an axially symmetrical fashion on the optical element, even if the flying debris is emitted from the plasma in a spatially irregular distribution. As a result, the axial symmetry of the X-ray flux reflected or transmitted by the optical element is maintained. Consequently, there is no decrease in the performance of a downstream optical system requiring an axially symmetrical X-ray flux, even if the X-ray source is operated for a long period of time. Whereas the invention has been described in connection with multiple representative embodiments, it will be understood that the invention is not limited to those embodiments. On the contrary, the invention is intended to encompass all modifications, alternatives, and equivalents as may be included within the spirit and scope of the invention, as defined by the appended claims.