Microlithographic Mirror With Piezoelectric Actuation and Compaction Control

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Solution Overview

Problem

The compaction sensitivity of the smoothing layer in adaptive mirrors used in EUV microlithography systems, typically made from amorphous material, leads to uncontrollable deformation and spatial inhomogeneity, hindering effective correction of optical aberrations and surface smoothing.

Innovation Solution

Incorporating a compaction-sensitive layer of amorphous material with a thickness of at least 20 μm, optionally with a blocking layer, to protect the spatially inhomogeneous regions from electron beam radiation, allowing controlled structuring and smoothing without penetrating the electrode arrangement or piezoelectric layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a smoothing layer made from amorphous material is used in adaptive mirrors, then the mirror can be manufactured with suitable surface properties, but the smoothing layer exhibits compaction sensitivity leading to uncontrollable deformation and spatial inhomogeneity

Engineering Contradiction:
Improvemanufacturability of mirror surfaceVSAvoidsurface uniformity and deformation control
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent divides the smoothing layer into multiple sub-layers with different properties. The first sub-layer (closest to the reflective surface) has lower compaction sensitivity, while the second sub-layer has higher compaction sensitivity. This segmentation allows each layer to perform its specific function: the first layer provides a stable base that resists unwanted deformation, while the second layer can be selectively compacted to achieve desired surface profiles.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies different compaction sensitivities to different regions/layers of the smoothing layer. By making the first sub-layer less sensitive to compaction and the second sub-layer more sensitive, the patent creates local quality differences that enable controlled deformation in specific regions while maintaining stability in others. This allows precise control over which areas of the mirror surface deform and how.

Inventive Principle:
Principle #3Local quality

2Manufacturing precision

If electron beam radiation is applied to compact the smoothing layer for surface smoothing, then surface profiles can be improved, but spatial inhomogeneity and uncontrollable deformation occur

Engineering Contradiction:
Improvesurface profile qualityVSAvoidspatial homogeneity of the smoothing layer
Core Design Contradiction:
Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent segments the smoothing layer into sub-layers with differentiated compaction sensitivities. When electron beam radiation is applied, the first sub-layer (with lower compaction sensitivity) remains relatively stable and maintains spatial homogeneity, while the second sub-layer (with higher compaction sensitivity) can be selectively compacted to achieve desired surface profiles. This segmentation prevents the spatial inhomogeneity that would occur if the entire layer had uniform high sensitivity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent changes the compaction sensitivity parameter of the smoothing layer by creating sub-layers with different properties. The first sub-layer is designed with parameters that make it less sensitive to compaction (e.g., different material composition, density, or structure), while the second sub-layer has parameters that make it more sensitive. This parameter differentiation allows controlled response to electron beam radiation, achieving surface smoothing without the uncontrollable deformation that would occur in a uniformly sensitive layer.

Inventive Principle:
Principle #35Parameter changes

3Manufacturing precision

If the smoothing layer is made thinner to reduce compaction sensitivity effects, then deformation control improves, but the layer can no longer effectively smooth spatial inhomogeneities

Engineering Contradiction:
Improvedeformation controlVSAvoidsurface smoothing capability
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Instead of using a single thin layer, the patent segments the smoothing function across multiple sub-layers. The first sub-layer can be relatively thin to provide deformation control, while the second sub-layer can be thicker to provide the smoothing capability. Together, they achieve both functions that would be difficult to achieve with a single thin layer.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent creates a composite smoothing layer structure where the first and second sub-layers have different material properties or structures. The first sub-layer is designed with properties that provide deformation control (lower compaction sensitivity), while the second sub-layer has properties that provide smoothing capability (higher compaction sensitivity). This composite structure combines the advantages of both thin and thick layers.

Inventive Principle:
Principle #40Composite materials

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

Enables controlled actuation and structuring of adaptive mirrors, effectively correcting optical aberrations and achieving desired surface profiles while preventing unwanted compaction and inhomogeneity.

Implementation Method 1

an adaptive mirror with an actuator layer composed of a piezoelectric material, wherein an electric field having a locally varying strength is generated across this piezoelectric layer by an electrical voltage being applied to electrodes arranged on both sides with respect to the piezoelectric layer. In the case of a local deformation of the piezoelectric layer, the reflection layer stack of the adaptive mirror also deforms

Methodology Applied
Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

a layer of amorphous material which is compaction-sensitive on exposure to low-energy electron beam radiation and which is arranged on the side of piezoelectric layer facing the reflection layer system

Methodology Applied
Scientific EffectElectron beam compaction: Electron Beam

Data Source

PatentUS20250231399A1Mirror, in particular for a microlithographic projection exposure apparatus, and method of processing a mirror
Publication Date: 2025.07.17 CARL ZEISS SMT GMBH
  • US20250231399A1 patent drawing
  • US20250231399A1 patent drawing
  • US20250231399A1 patent drawing

AI summary

A microlithographic projection exposure mirror has an optical effective surface (11, 21, 31), a mirror substrate (12, 22, 32), a reflection layer system (17, 27, 37) reflecting electromagnetic radiation incident on the optical effective surface, and at least one piezoelectric layer (14, 24, 34) arranged between the substrate and the reflection layer system. An electric field for producing a locally variable deformation is applied by a first electrode arrangement (15, 25, 35) situated on the side of the piezoelectric layer facing the reflection layer system, and by a second electrode arrangement (13, 23, 33) situated on the side of the piezoelectric layer facing the mirror substrate. A layer (16, 26b, 36b) of amorphous material which is compaction-sensitive on exposure to low-energy electron beam radiation and which is arranged on the side of the piezoelectric layer facing the reflection layer system has a thickness of at least 20 μm.