Patent Description:
Cutting-edge optical systems, such as microlithography system for making semiconductor chips, use electromagnetic radiation in the extreme-ultraviolet ("EUV") and X-ray regions. Such regions have small wavelengths in the range of <NUM>-<NUM>, which can enable the design of optical systems that can reproduce patterns with extremely fine resolution. The optical components for such systems involve reflective elements because of the strong absorption of EUV and X-ray radiation in most materials. Accordingly, such reflective elements need to have reflective surfaces of extremely high-quality, including surfaces that conform to precisely optimized curvatures and forms and that are also extremely smooth.

Techniques exist for figuring, polishing, and otherwise finishing such surfaces, including, e.g., ion-beam figuring ("IBF"), magneto-rheological finishing ("MRF"), chemical mechanical polishing ("CMP"), and computer controlled optical surfacing ("CCOS"). However, such techniques are generally expensive and time-consuming for the tolerances required for EUV and X-ray optics. Moreover, the constraints on such techniques are exacerbating by the requirement to process the non-planar surface required for the design of the reflective optical elements currently proposed for cutting-edge EUV lithography systems, including not only aspheric elements, but also non-rotationally symmetric elements such as free-form grazing incidence mirrors.

A measure commonly used to characterize the degree to which an optic surface is sufficiently "smooth" is surface roughness. Surface roughness is the repetitive and/or random deviation from the nominal surface that forms the three-dimensional topology of the surface. Especially relevant for EUV and X-ray optics is high-spatial frequency roughness ("HSFR") corresponding to deviations on the micrometer to nanometer size scale (e.g., spatial periods from about <NUM> microns to <NUM> nanometers) because such roughness causes scattering loses that lowers the transmission throughput of EUV and X-ray optical system implementing such optics. Lower spatial frequency deviations such as waviness can generally be corrected during the figuring process (at least, for example, for spatial periods greater than about <NUM>-<NUM>). Waviness can be caused by workpiece deflections, vibrations, chatters, heat treatment, or warping strains. HSFR, on the other hand, is typically an intrinsic consequence of the polishing process (e.g., randomized effects of polishing grit). HSFR includes hills (aspherities) (local maxima) and valleys (local minima) of varying amplitudes and spacings that are large compared to molecular dimensions.

Roughness R is usually characterized by one of the two statistical height descriptors advocated by the American National Standards Institute (ANSI) and the International Standardization Organization (ISO) (Anonymous, <NUM>, <NUM>) (see, e.g., ISO <NUM>-<NUM>). These are (<NUM>) Ra, CLA (center-line average), or AA (arithmetic average) and (<NUM>) the standard deviation or variance (σ), Rq or root mean square (RMS). While not critical to the present invention, for the present application, HSFR be will defined according to the root mean square of the vertical deviation of the three-dimensional surface topography from the nominal three-dimension surface topography corresponding to the design surface for the optic with respect to high spatial frequencies (e.g., spatial periods below <NUM> microns). For example, for a sampling region extending along a line of length L extending along an x-axis of a surface having an actual surface topography z(x) relative to a nominal surface topography z'(x) for scale lengths L up to <NUM> microns, the high spatial frequency roughness R is: <MAT> HSFR can be measured with an atomic force microscope ("AFM") or an optical interferometer. To make timely measurements of HSFR with nanometer-scale lateral resolutions and because HSFR is understood to result from intrinsic properties of the polishing, HSFR measurements are typically made over areas no larger than <NUM> microns by <NUM> microns, and more typically on the order <NUM> microns by <NUM> microns.

For normal incidence EUV mirrors, the required tolerances for HSFR can be less than a few Angstroms (e.g., R < <NUM>) to avoid scattering losses. Although still very strict, the tolerances can be increased somewhat for grazing incidence mirrors because scattering decreases at increased incident angles (e.g., R < <NUM>). For example, in the publication "<NPL>), HSFR was reduced from <NUM> rms to <NUM> by spin-coating a thin layer of glass over a substrate figured for use as a grazing-incidence, cylindrical fly-eye for an EUV optical system. An AFM was used over a <NUM>-micron by <NUM>-micron region of the substrate to determine the HSFR.

<CIT> describes a method for producing EUV lithography mirrors by fabricating the optic substrate with standard or high-precision machining techniques and by depositing a smoothening overcoat layer onto the substrate to obtain a required surface smoothness.

<CIT> describes fabrication and use of a reticle or mask in an EUV lithography process. To achieve a desired surface flatness of a substrate, a planarizing layer is formed on the substrate.

<CIT> describes a method for producing an X-ray mirror by providing a substrate, forming on said substrate an intermediate layer of a high molecular weight material, and forming a thin film on said intermediate layer.

The inventor has recognized that the tolerances for reflective EUV optics require not only very small HSFR, but also very few surface defects, and that spin-coating techniques can also be used to reduce the number of defects. Any area on the surface of a material that is discontinuous and discreet that does not follow the natural texture of the surface or its roughness is classified as a defect (or equivalently a "flaw"). For example, defects include scratches, pits, and digs. The size of a defect along its shortest lateral dimension is typically less than <NUM>, or more typically less than <NUM>; but larger than the size scale for HSFR that gives rise to diffuse scatter. Unfortunately, such defects can be easily overlooked when preparing super-polished substrates for EUV optics. First, such optics are typically characterized for HSFR and the inspection area for a HSFR measurement (e.g., <NUM>-microns by <NUM>-microns) is much smaller than the usable area of the optic (e.g.. , an area on the order of at least a few square millimeters), so the HSFR measurement will not observe defects outside the inspection area. Second, even if a defect were observed in the HSFR inspection area, it is commonly disregarded as an anomaly and excluded from the HSFR calculation because it would otherwise skew the HSFR result. Third, there is a failure to appreciate the necessary defect tolerances for EUV optics. For example, certain optics require fewer than <NUM> defect per <NUM> square millimeter area over the entire usual area of the optic, e.g., <NUM> to <NUM>,<NUM> square millimeters in area or even larger.

In general, in one aspect, a method of making a mirror for use with extreme ultraviolet (EUV) or X-ray radiation is disclosed. The method includes: a) providing an optical element having a curved mirror surface, wherein the curved mirror surface comprises localized defects that degrade performance of the curved mirror surface; b) spin-coating the curved mirror surface with a material to cover at least some of the defects; and c) curing the spin-coated material on the curved mirror surface to reduce the number of defects and improve the performance of the curved mirror surface. The mirror surface has a high spatial frequency surface roughness, HSFR, less than <NUM> before the spin-coating.

Embodiments of the method may include any of the following features.

The mirror surface has a high spatial frequency surface roughness HSFR of less than <NUM>, or even less than <NUM>, before the spin-coating.

The method may further include characterizing the number of defects on the mirror surface before the spin-coating, characterizing the number of defects on the mirror surface after the spin-coating, or characterizing the number of defects on the mirror surface before and after the spin-coating. For example, the characterizing may include inspecting the mirror surface with an optical microscope, such as a confocal microscope, over an area greater than <NUM><NUM>.

The optical element may include a substrate made of any of: silicon, fused silica, quartz silicon, titanium-doped silica, glass ceramic, and polishable ceramic. The mirror may be for use in a wavelength range between <NUM> and <NUM>. The curved mirror surface may be an aspheric mirror surface.

The defects may include any of scratches, pits, and digs having at least one lateral dimension smaller than <NUM>.

The spin-coating may include: a) depositing the material onto the curved mirror surface in the vicinity of a spin-coating rotation axis for the curved surface; and b) rotating the curved surface of the optical element about the rotation axis so that the glass-like material flows radially outward to cover the curved mirror surface and form a thin film. For example, the rotating may include rotating the optical element at between <NUM> to <NUM> rotations per minute. For example, the thin film may be between <NUM> and <NUM> thick, or more narrowly between <NUM> and <NUM> thick. The spin-coating may further include rotating the curved surface after the deposition of the material to spin-off and evaporate excess material as the thin film is formed. The spin coating may further include heating the curved mirror surface to help evaporate any solvents for the material.

The curing may include heating the spin-coated substrate in an oven in the presence of at least one of ozone and UV radiation. For example, the oven may be heated to a temperature between <NUM> degrees Celsius and <NUM> degrees Celsius.

The spin-coating material may be a glass-like material, such as hydrogen silsesquioxane or methylsiloxane.

After the curing, the number of defects may be reduced to less than <NUM> defect per <NUM> square millimeter over the usable area of the curved mirror surface.

The method may further include coating the cured, spin-coated mirror surface with multiple optical layers to provide a reflective mirror surface for the EUV or X-ray radiation. For example, the multiple layers may include layers of molybdenum and silicon.

A mirror for use with extreme ultraviolet (EUV) or X-ray radiation can be made according to the methods described above. The mirror includes: a) an optical element having a curved mirror surface, wherein the curved mirror surface comprises localized defects that degrade performance of the curved mirror surface; and b) a thin film formed on the curved mirror surface by: i) spin-coating the curved mirror surface with a material to cover at least some of the defects; and ii) curing the spin-coated material on the curved mirror surface to reduce the number of defects and improve the performance of the curved mirror surface.

The mirror may include any of the following features.

The mirror may further include multiple optical layers coated onto the cured, spin-coated mirror surface to provide a reflective mirror surface for the EUV or X-ray radiation. For example, the multiple layers may include layers of molybdenum and silicon.

<FIG> is a flow chart describing embodiments for making a curved reflective element (i.e., a curved mirror) for use with extreme ultraviolet (EUV) or X-ray radiation.

In step <NUM>, a substrate is provided. The substrate can be made of material typically used in EUV and X-ray optical systems. Preferably the material is compatible with the subsequent deposition of alternating multiple thin layers such as molybdenum and silicon to provide Bragg reflectivity for the final mirror. For example, the substrate material can be silicon, fused silica, titanium-oxide doped silica, and ULE®-glass from Corning. Furthermore, the substrate material can be a glass ceramic or another polishable ceramic. The substrate has a surface topology corresponding to a desired curvature for the final mirror. For example, the curvature can be spherical or aspherical, but rotationally symmetric. Furthermore, the curvature can be a free-form curvature that is not rotationally symmetric. A desired rotationally symmetric curvature can be achieved by using conventional diamond turning machines. Further refinements, including localized and/or free-form deviations from rotational symmetry can be achieved by ion-beam figuring ("IBF"). To distinguish from substrates intended to be nominally planar, for example, the substrate curvature can have an absolute sagittal dimension greater than at least <NUM> microns, or even greater than <NUM> microns.

In step <NUM>, the high spatial frequency roughness ("HSFR") of the substrate is measured and if it is too high, the substrate can be smoothed using polishing techniques such as MRF and CMP. According to the invention, the HSFR is reduced to less than <NUM>, or less than <NUM>, or even less than <NUM>. For example, an AFM can be used over a <NUM>-micron by <NUM>-micron region of the substrate to determine the HSFR. Alternatively, optical interferometric microscopes for measuring topology can be used for measuring the HSFR. As noted above, HSFR can be measured according to ISO <NUM>-<NUM>. <FIG> is a schematic figure from Chapter <NUM>, Section <NUM> of the Modem Tribology Handbook by B. Bhushan that depicts roughness R, including low and high spatial frequency roughness, on a substrate surface.

In step <NUM>, the substrate is inspected to identify and quantify defects. As noted above, any area on the surface of a material that is discontinuous and discreet that does not follow the natural texture of the surface or its roughness is classified as a defect (or equivalently a "flaw"). For example, defects include scratches, pits, and digs. In this step, the substrate is inspected over a larger area than that used to measure roughness to ensure defects are not overlooked. For example, the substrate can be inspected over the usable area of the optic (e.g., an area on the order of at least a few square millimeters). The inspection of the substrate for defects can be done with optical microscope, such as a confocal microscope. The defects can be characterized according to standards such as Military Specification MIL-<NUM>-<NUM> or International Standards Organization ISO <NUM>-<NUM>. Assuming at least some defects are observed, the method of <FIG> continues with the subsequent steps. For the EUV and X-ray optics that are of particular interest here, the defects can include, for example, any of scratches, pits, and digs having at least one lateral dimension smaller than, for example, <NUM>, or even smaller than <NUM>. Depending on the required tolerances of the mirror, the subsequent steps will continue even if the number of defects observed are fewer than <NUM> defects per <NUM> square millimeter over the entire usual area of the optic, or, in some embodiments, even fewer than <NUM> defects per <NUM> square millimeter area over the entire usual area of the optic, or, in some further embodiments, even fewer than <NUM> defects per <NUM> square millimeter over the entire usual area of the optic.

In step <NUM>, the substrate is prepared for spin-coating to reduce the number of defects observed in step <NUM>. The preparation can include, for example, one or more of: i) cleaning the substrate surface with a detergent; ii) flushing the substrate surface with de-ionized water; iii) further cleaning the substrate surface with a solvent; and iv) drying the substrate surface with an inert gas such as nitrogen with a nitrogen gun.

In step <NUM>, the prepared substrate is mounted in a spin-coating machine and spin-coated. For example, the substrate can be mounted by vacuum on a turn-table, and an automated dispense unit deposits a known amount of spin-coat material onto the substrate surface in the vicinity of the rotation axis for the turn-table. The turn-table is then rotationally accelerated up to a final spinning rate to cause the spin-coat material flow to the edges of the substrate and evenly coat substrate surface with a thin film of the spin-coat material.

One embodiment of the process is depicted schematically in <FIG>, which shows: <NUM>) the deposition of the spin coat material onto the substrate; <NUM>) rotation of the substrate at angular frequency ω to form the thin film; <NUM>) continued spinning to ensure evenness of the thin film; and <NUM>) evaporation of any solvent in the spin-coat material in preparation for subsequent curing. Suitable materials for the spin-coat material include glass-like materials such as hydrogen silsesquioxane (HSQ") and methylsiloxane, as well as spin-coat polymers such as polyimides.

The thickness of the thin film formed on the substrate during the spin-coat process will depend on the angular frequency of the spinning and the viscosity of the spin-coat material. For example, the final spinning rate can be in the range of <NUM> to <NUM> rotations per minute ("rpm") and the desired film thickness can be between <NUM> and <NUM>, for example, between <NUM> and <NUM>. <FIG> is a graph showing an exemplary relationship between spinning rate vr and thin film thickness t. The thin film formed on the substrate surface can smoothly bridge over defects up to a critical dimension that depends on the thickness of the film and the spin-coat material. The critical dimension will typically be at least <NUM>, or even at least <NUM>. Otherwise the thin film conforms to and retains the tailored curvature of the underlying substrate, including its low roughness. This "bridging" over defects is schematically depicted in <FIG>. Although the bridging schematically depicted in <FIG> illustrate no filling of the underlying defects, this is only one embodiment. In other embodiments, the film provides a smooth surface that bridges over the defect, but will also partially or totally fill in the underlying defect.

In step <NUM>, the spin-coated substrate is removed from the spin-coating machine and cured to harden the thin-film formed on the substrate. For example, the spin-coated substrate can be placed in a curing oven and heated to temperatures of, e.g., <NUM> to <NUM>, optionally in presence of ozone and/or together with exposure to ultraviolet light. For the case of HSQ as the spin-coat material, such curing steps drive of solvent and cross-link HSQ molecules to form a hard silicon oxide layer.

In step <NUM>, the hardened, spin-coated substrate is again inspected for defects as in step <NUM> to determine whether the spin-coating has reduced the number of defects to an acceptable level. If not, the spin-coating and curing steps are optionally repeated.

In step <NUM>, the hardened, spin-coated substrate is inspected for topology using an optical interferometer to ensure that the surface figure error remains within specification after the spin-coating. If not, a surface figure error map determined from the inspection in step <NUM> is then used in step <NUM> to guide surface figure correction using, for example, IBF.

In step <NUM>, the figure-corrected substrate, including the hardened and spin-coated, thin film, is again inspected for defects to ensure that the no additional defects were introduced during the surface figure correction. If so, than the spin-coating and subsequent steps are optionally repeated.

In step <NUM>, after it is has been established that the figure-corrected substrate including the hardened and spin-coated, thin film is within desired tolerances with respect to surface figure error, roughness, and number of defects, the substrate surface is optionally coated with multiple optical layers, such as alternating thin layers such of molybdenum and silicon to provide Bragg reflectivity for the substrate and form the final mirror for the EUV and/or X-ray optical system. Techniques for forming such multi-layer stacks are well-known in the art.

Further embodiments of the invention include, for example, the mirror formed by the method of the flow chart of <FIG>.

It must be noted that as used herein and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise, e.g., when the word "single" is used.

As used herein, the terms "adapted" and "configured" mean that the element, component or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms "adapted" and "configured" should not be construed to mean that a given element, component, or other subject matter is simply "capable of" performing a given function.

As used herein, the phrases "at least one of" and "one or more of," in reference to a list of more than one entity, means any one or more of the entity in the list of entity, and is not limited to at least one of each and every entity specifically listed within the list of entity. For example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and/or B") may refer to A alone, B alone, or the combination of A and B.

As used herein, the term "and/or" placed between a first entity and a second entity means one of (<NUM>) the first entity, (<NUM>) the second entity, and (<NUM>) the first entity and the second entity. Multiple entity listed with "and/or" should be construed in the same manner, i.e., "one or more" of the entity so conjoined. Other entity may optionally be present other than the entity specifically identified by the "and/or" clause, whether related or unrelated to those entities specifically identified.

Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In certain implementations, multitasking and parallel processing may be advantageous.

Claim 1:
A method (<NUM>) of making a mirror for use with extreme ultraviolet EUV, or X-ray radiation, the method comprising:
a. providing (<NUM>) an optical element having a curved mirror surface, wherein the curved mirror surface comprises localized defects that degrade performance of the curved mirror surface;
b. spin-coating (<NUM>) the curved mirror surface with a material to cover at least some of the defects; and
c. curing (<NUM>) the spin-coated material on the curved mirror surface to reduce the number of defects and improve the performance of the curved mirror surface, the method being characterized in that the mirror surface has a high spatial frequency surface roughness, HSFR, less than <NUM> before the spin-coating.