High power gas discharge laser with line narrowing unit

Details High power gas discharge laser with line narrowing unit High power gas discharge laser with line narrowing unit

1999-11-30

2004-05-11

Sanghavi, Hemang (Department: 2874)

Coherent light generators

Particular resonant cavity

Specified cavity component

C372S020000, C372S057000, C372S099000

Reexamination Certificate

active

06735236

ABSTRACT:

BACKGROUND OF THE INVENTION
Narrow Band Gas Discharge Lasers
Gas discharge ultraviolet lasers used a light source for integrated circuit lithography typically are line narrowed. A preferred line narrowing prior art technique is to use a grating based line narrowing unit along with an output coupler to form the laser resonance cavity. The gain medium within this cavity is produced by electrical discharges into a circulating laser gas such as krypton, fluorine and neon (for a KrF laser); argon, fluorine and neon (for an ArF laser); or fluorine and helium and/or neon (for an F
2
laser).
Prior Art Purge Technique
A sketch of such a prior art system is shown in
FIG. 1
which is extracted from Japan Patent No. 2,696,285. The system shown includes output coupler (or front mirror)
4
, laser chamber
3
, chamber windows
11
, and a grating based line narrowing unit
7
. The line narrowing unit
7
is typically provided on lithography laser system as an easily replaceable unit and is sometimes called a “line narrowing package” or “LNP” for short. This unit includes two beam expanding prisms
27
and
29
and a grating
16
disposed in a Litrow configuration. Gratings used in these systems are extremely sensitive optical devices and deteriorate rapidly under ultraviolet radiation in the presence of oxygen in standard air. For this reason, the optical components of line narrowing units for lithography lasers are typically purged continuously during operation with nitrogen.
For many years, designers for line narrowed lasers have believed that distortions of the laser beam could be caused by gas flow near the face of the grating. Therefore, laser designers in the past have made special efforts to keep the purge nitrogen from flowing directly on the face of the grating. Several examples of these efforts are described in the Japan Patent 2,696,285 referred to above. In the example shown in extracted
FIG. 1
, the purge flow is directed from N
2
gas bottle
44
toward the back side of grating
16
through port
46
.
Increased Repetition Rates
Line narrowed ultraviolet laser light sources currently in use in the integrated circuit industry typically produce about 10 mJ per pulse at repetition rates of about 1000 Hz and duty factors of about 20 percent. Increased integrated circuit production can be achieved at higher repetition rates and greater duty cycles. Applicants and their fellow workers have designed a 2000 Hz gas discharge lithography laser and several of these lasers have been sold for lithography use. Applicants are now experimenting with even higher repetition rates of up to 5000 Hz. Applicants have experienced difficulties maintaining consistent narrow bandwidths at these higher repetition rates and duty cycles.
A need exists for reliable line narrowing devices and techniques for high repetition rate, high duty cycle gas discharge lasers.
SUMMARY OF THE INVENTION
The present invention provides a grating based line narrowing device for line narrowing lasers producing high energy laser beams. Techniques are provided for minimizing adverse effects of hot gas layers present on the face of the grating.
In preferred embodiments a stream of gas is directed across the face of the grating. In other embodiments the effect of the hot gas layer is reduced with the use of helium as a purge gas and in other embodiments the purge gas pressure is reduced to reduce the optical effects of the hot gas layer.


REFERENCES:
patent: 3845409 (1974-10-01), Wada et al.
patent: 4977563 (1990-12-01), Nakatani et al.
patent: 5095492 (1992-03-01), Sandstrom
patent: 04-314374 (1992-11-01), None
patent: 05-167172 (1993-07-01), None
patent: 2696285 (1997-09-01), None
Press, William H. et al., “Numerical Recipes, The art of Scientific Computing”, Cambridge, University Press (1990), pp. 274-277, 289-293 and 312-321.

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