Patterning by energetically-stimulated local removal of solid-condensed-gas layers and solid state chemical reactions produced with such layers
The invention provides a method for forming a patterned material layer on a structure, by condensing a vapor to a solid condensate layer on a surface of the structure and then localized removal of selected regions of the condensate layer by directing a beam of energy at the selected regions. The structure can then be processed, with at least a portion of the patterned solid condensate layer on the structure surface, and then the solid condensate layer removed. Further there can be stimulated localized reaction between the solid condensate layer and the structure by directing a beam of energy at at least one selected region of the condensate layer.
1. A method for forming a nano-patterned material layer on a structure, comprising:
condensing a vapor to an amorphous solid water condensate layer on a surface of the structure; and
localized removal of at least one selected nanometric region of the condensate layer by directing a focused electron beam at the selected region.
2. The method of claim 1 further comprising:
processing the structure with at least a portion of the solid condensate layer on the structure surface; and
removing the solid condensate layer.
3. The method of claim 2 wherein processing the structure comprises selective masking of the structure surface, with a patterned solid condensate layer, from conditions of the structure processing.
4. The method of claim 2 wherein processing of the structure comprises selective etching of the structure.
5. The method of claim 4 wherein selective etching of the structure comprises formation of at least one trench in the structure.
6. The method of claim 4 wherein selective etching of the structure comprises formation of at least one aperture in the structure.
7. The method of claim 2 wherein processing of the structure comprises localized and stimulated chemical surface reaction between the solid condensate layer and the structure surface.
8. The method of claim 2 wherein processing of the structure comprises selective formation of a process material layer on the structure surface.
9. The method of claim 2 wherein processing of the structure comprises selective electrical doping of the structure.
10. The method of claim 2 wherein processing of the structure comprises exposing the structure to a beam of ions.
11. The method of claim 2 wherein processing of the structure comprises exposing the structure to a beam of electrons.
12. The method of claim 2 wherein processing of the structure comprises mechanically supporting the structure with the solid condensate layer during the structure processing.
13. The method of claim 12 wherein processing of the structure comprises selective removal of a portion of the structure.
14. The method of claim 2 wherein removal of the solid condensate layer comprises conversion of the solid condensate layer to a vapor.
15. The method of claim 14 wherein conversion of the solid condensate layer to a vapor comprises heating the structure to convert the solid condensate layer to a vapor.
16. The method of claim 14 wherein conversion of the solid condensate layer to a vapor comprises sublimation of the condensate layer.
17. The method of claim 2 wherein the structure comprises a planar structure.
18. The method of claim 2 wherein the structure comprises a nonplanar structure.
19. The method of claim 2 wherein the structure comprises a cylindrical structure.
20. The method of claim 19 wherein the structure comprises a nanowire.
21. The method of claim 19 wherein the structure comprises a nanotube.
22. The method of claim 21 wherein processing the nanotube comprises removal of a portion of the nanotube.
23. The method of claim 22 wherein removal of a portion of the nanotube comprises cutting the nanotube with an ion beam.
24. The method of claim 22 wherein the localized removal of at least one selected region of the condensate layer comprises directing a beam of energy at a location of the solid condensate layer corresponding to the nanotube portion to be removed.
25. The method of claim 24 wherein the localized removal of at least one selected region of the condensate layer comprises directing a beam of energy at a location of the solid condensate layer corresponding to a point along nanotube length at which the nanotube portion is to be removed.
26. The method of claim 1 wherein the vapor to be condensed to a solid condensate layer is supplied from a vapor source.
27. The method of claim 1 wherein the vapor to be condensed to a solid condensate layer is supplied from a liquid source.
28. The method of claim 1 wherein the vapor to be condensed to a solid condensate layer is supplied from a solid source.
29. The method of claim 1 wherein the vapor to be condensed to a solid condensate layer comprises water vapor.
30. The method of claim 29 wherein the solid condensate layer comprises ice.
31. The method of claim 1 further comprising controlling temperature and pressure conditions local to the structure surface to cause condensation of the vapor to the solid condensate layer.
32. The method of claim 31 wherein controlling temperature and pressure conditions local to the structure surface comprises providing the structure on a structure holder that is configured to control temperature of the structure.
33. The method of claim 31 wherein the controlled pressure condition local to the structure surface is characterized as a vacuum condition.
34. The method of claim 31 wherein the vapor to be condensed to a solid condensate layer comprises water vapor and the pressure local to the structure is controlled to be less than about 10 −4 T.
35. The method of claim 31 wherein the vapor to be condensed to a solid condensate layer comprises water vapor and the temperature local to the structure is controlled to be less than about 180 K.
36. The method of claim 31 wherein the vapor to be condensed to a solid condensate layer comprises water vapor and the temperature local to the structure is controlled to be less than about 130 K.
37. The method of claim 1 wherein the vapor to be condensed to a solid condensate layer is injected as a vapor into a process chamber in which the structure is provided.
38. The method of claim 1 wherein the solid condensate layer includes an additive selected to optimize absorption of the beam of energy by the solid condensate layer.
39. The method of claim 1 wherein the localized removal of at least one selected region of the condensate layer comprises localized conversion of the solid condensate to a vapor at the selected region.
40. The method of claim 39 wherein the localized conversion of the solid condensate to a vapor comprises localized sublimation of the solid condensate layer at the selected region.
41. The method of claim 1 wherein the localized removal of at least one selected region of the condensate layer comprises scanning of the electron beam on the solid condensate layer along a path corresponding to a desired pattern.
42. The method of claim 1 wherein the structure comprises a planar structure.
43. The method of claim 41 wherein the structure comprises a silicon substrate.
44. The method of claim 1 wherein the structure comprises a nonplanar structure.
45. The method of claim 1 wherein the structure comprises a cylindrical structure.
46. The method of claim 44 wherein the structure comprises a nanowire.
47. The method of claim 44 wherein the structure comprises a nanotube.
48. The method of claim 1 wherein directing a focused electron beam at the selected region comprises scanning the electron beam along the selected region.
49. The method of claim 1 wherein the focused electron beam is characterized by a beam energy of between about 1 KeV and about 30 KeV.
50. The method of claim 49 wherein the focused electron beam is characterized by a beam energy of about 5 KeV.
51. The method of claim 1 wherein the focused electron beam is characterized by a beam diameter of about 5 nm.
52. The method of claim 1 further comprising draining electron beam charge from the structure, during localized region removal, by electrically grounding the structure during localized region removal.
53. A method for forming a nano-patterned material layer on a structure, comprising:
condensing a vapor to an amorphous solid water condensate layer on a surface of the structure at a condensation rate of less than about 25 nm/sec; and
localized removal of at least one selected nanometric region of the condensate layer by directing a beam of energy at the selected region.
54. A method for forming a nano-patterned material layer on a structure, comprising:
condensing a vapor to an amorphous solid water condensate layer on a surface of the structure at a local pressure of less than about 10 −6 T and a local temperature of less than about 130 K; and
localized removal of at least one selected nanometric region of the condensate layer by directing a beam of energy at the selected region.
55. The method of claim 54 wherein the local pressure is less than about 10 −4 T and the local temperature is about 128 K.
56. A method for forming a nano-patterned material layer on a structure, comprising:
condensing a vapor to an amorphous solid condensate layer on a surface of the structure; and
localized removal of at least one selected nanometric region of the condensate layer by directing a focused electron beam, characterized by a beam energy of between about 1 KeV and about 30 KeV, at the selected region.
57. A method for forming a nano-patterned material layer on a structure, comprising:
condensing a vapor to an amorphous solid condensate layer on a surface of the structure; and
localized removal of at least one selected nanometric region of the condensate layer by directing a focused electron beam, characterized by a beam diameter of about 5 nm, at the selected region.
58. The method of claim 21 wherein processing the nanotube comprises doping of the nanotube.
59. The method of claim 21 wherein processing the nanotube comprises vapor deposition of material on the nanotube.
60. The method of claim 24 wherein removal of a portion of the nanotube comprises cutting the nanotube with an electron beam.
61. The method of claim 56 wherein the vapor to be condensed to a solid condensate layer comprises an inert gas.