EUV Reticle Inspection Spectral Purity Filter

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Solution Overview

Problem

Current metrology and inspection systems for Extreme Ultraviolet (EUV) lithography are inadequate due to low transmission rates of conventional beam splitter materials at EUV wavelengths, leading to thermal damage and image flare issues, and lack effective spectral purification methods to filter out unwanted wavelengths.

Innovation Solution

An EUV actinic mask inspection system incorporating a spectral purity filter with multilayer interference-type elements disposed non-normally to the optical axis, which separates EUV light into a desired portion for illumination and an off-axis portion for reference detection, using materials like Zirconium and Silicon with specific layer thicknesses for high reflectivity and transmission efficiency, and a grazing incidence mirror array for efficient light handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional beam splitter materials (fused silica, magnesium fluoride, calcium fluoride) are used in EUV inspection systems, then the system structure can be simple and easy to manufacture, but the transmission rate at EUV wavelengths is low causing thermal damage and image flare

Engineering Contradiction:
Improveease of manufactureVSAvoidthermal damage and image flare
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters by selecting specific materials (Zirconium and Silicon) with appropriate layer thicknesses (e.g., 5-10 nm Zr and 15-20 nm Si layers) to achieve high EUV transmission. This parameter optimization resolves the contradiction by finding material compositions that simultaneously provide ease of manufacture and high transmission rates that prevent thermal damage and image flare.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs composite multilayer structures combining Zirconium and Silicon layers, where each material contributes different properties. The Zr layers provide high EUV reflectivity while Si layers provide transmission, creating a composite beam splitter that achieves both high transmission and structural integrity, preventing thermal damage and image flare while remaining manufacturable.

Inventive Principle:
Principle #40Composite materials

2Object-affected harmful factors

If spectral purity filters are added to filter out unwanted wavelengths, then thermal damage and image flare are reduced, but the device complexity increases

Engineering Contradiction:
Improvethermal damage and image flareVSAvoiddevice complexity
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the spectral filtering function with the beam splitter function into a single integrated component. The multilayer Zr-Si structure simultaneously performs beam splitting and spectral purification by reflecting unwanted wavelengths while transmitting EUV light, eliminating the need for separate filter components and reducing overall device complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The beam splitter component is designed to perform multiple functions: it splits the EUV beam, filters unwanted wavelengths, and prevents thermal damage and image flare. This multi-functional design resolves the contradiction by incorporating spectral purification capabilities directly into the beam splitter, avoiding additional device complexity while maintaining all necessary functions.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Reliability

If multilayer interference-type spectral purity filters with specific layer thicknesses are used, then transmission efficiency and signal-to-noise ratio are improved, but the manufacturing precision requirements increase

Engineering Contradiction:
Improvetransmission efficiency and signal-to-noise ratioVSAvoidmanufacturing precision
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent optimizes layer thickness parameters to ranges (e.g., Zr: 5-10 nm, Si: 15-20 nm) that provide high transmission efficiency and signal-to-noise ratio while being manufacturable with standard precision capabilities. These parameter selections resolve the contradiction by finding optimal values that achieve high reliability without requiring extreme manufacturing precision.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies different layer thicknesses and material properties at different positions in the multilayer structure to optimize local performance. By varying the thickness and composition of individual layers (e.g., alternating Zr and Si layers with specific thicknesses), the system achieves high overall transmission efficiency and signal-to-noise ratio while maintaining manufacturability through localized quality variations rather than uniform high precision requirements throughout.

Inventive Principle:
Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively purifies EUV light, reducing thermal damage and image flare, while providing accurate reference detection for spatial and temporal variations, with high transmission efficiency and suitable signal-to-noise ratio, suitable for EUV lithography applications.

Implementation Method 1

a spectral purity filter, wherein the spectral purity filter comprises a two-dimensional array of channels... each channel comprising a mirror surface... and a spectral filter... the spectral filter disposed to cover each channel at a proximal end

Methodology Applied
Scientific EffectInterference: Interference

Implementation Method 2

each channel comprising a mirror surface extending over said side and attached thereto... the mirror surface disposed at an angle theta relative to said one of said upper side, lower side, right side and left side

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentEP2954374B1Extreme ultraviolet (EUV) reticle inspection system and method of inspecting a reticle
Publication Date: 2022.12.21 KLA CORP
  • EP2954374B1 patent drawingFigure 1
  • EP2954374B1 patent drawingFigure 2
  • EP2954374B1 patent drawingFigure 3A~3C

AI summary

An extreme ultraviolet (EUM) mask inspection system, comprising a light source to project EUV light along an optical axis, an illumination system to receive the EUV light from the source, the illumination system comprising a spectral purity filter (SPF), the SPF transmits a first portion of the EUV light along the optical axis toward a mask and the SPF comprising a plurality of at least partially reflective elements, said elements reflects a second portion of the EUV light off the optical axis, a projection system adapted to receive the first portion of the EUV light after it has illuminated the mask, a first detector array adapted to receive the image, and a second detector array to receive the second portion of the EUV light. The SPF may comprise one or more multilayer interference-type filters. Alternatively, the SPF comprises a thin film filter disposed on a grazing incidence mirror array.