Projection exposure method and projection exposure apparatus for microlithography
11181826 · 2021-11-23
Assignee
Inventors
Cpc classification
G03F7/70266
PHYSICS
G03F7/702
PHYSICS
G03F7/70308
PHYSICS
International classification
Abstract
A projection exposure method and apparatus are disclosed for exposing a radiation-sensitive substrate with at least one image of a pattern of a mask under the control of an operating control system of a projection exposure apparatus, part of the pattern lying in an illumination region is imaged onto the image field on the substrate with the aid of a projection lens, wherein all rays of the projection radiation contributing to the image generation in the image field form a projection beam path.
Claims
1. A projection lens, comprising: a multiplicity of reflective optical elements with optical surfaces are arranged in a projection beam path between an object plane and an image plane so that a pattern in the object plane is imageable in the image plane via the reflective optical elements; and a wavefront manipulation system configured to dynamically influence a wavefront of projection radiation travelling from the object plane to the image plane, wherein: the projection lens comprises a dedicated telecentricity manipulator; the dedicated telecentricity manipulator comprises a first manipulator element and a second manipulator element separate from the first manipulator element; the first manipulator element is in the projection beam path in or optically near a first field plane; the second manipulator element is arranged in the projection beam path in or optically near a second field plane optically conjugate to the first field plane; the projection lens comprises an actuating device assigned to the first and second manipulator elements; and the actuating device is configured to bring about a relative change of the first and second manipulator elements with respect to one another so that the first manipulator element brings about a change in telecentricity, distortion and defocus and the second manipulator element partly or completely compensates for the change in distortion and defocus caused by the first manipulator element.
2. The projection lens of claim 1, wherein the first manipulator element comprises a deformable mirror surface.
3. The projection lens of claim 2, wherein the second manipulator element comprises a deformable mirror surface.
4. The projection lens of claim 1, wherein the second manipulator element comprises a deformable mirror surface.
5. An apparatus, comprising: the projection lens of claim 1, wherein the apparatus is a projection exposure apparatus.
6. The apparatus of claim 5, further comprising an illumination system configured to illuminate an object plan of the projection lens, wherein the projection lens is configured to image an object in the object plane into an image plane of the projection lens.
7. A method of using a projection exposure apparatus comprising an illumination system and a projection lens, the method comprising: using the illumination system to illuminate a mask comprising a pattern; and using the projection lens to project at least a portion of the illuminated pattern of the mask onto an object plane, wherein the projection lens is a projection lens according to claim 1.
8. A projection lens, comprising: a first objective part configured to image an object plane of the projection lens into a first intermediate image plane of the projection lens; a second objective part configured to image the first intermediate image plane of the projection lens into a second intermediate image plane of the projection lens; and a third objective part configured to image the second intermediate image plane of the projection lens into an image plane of the projection lens, wherein: the projection lens comprises a dedicated telecentricity manipulator; the dedicated telecentricity manipulator comprises a first manipulator element and a second manipulator element separate from the first manipulator element; the first manipulator element is in the projection beam path in or optically near a first field plane; the second manipulator element is arranged in the projection beam path in or optically near a second field plane optically conjugate to the first field plane; the projection lens comprises an actuating device assigned to the first and second manipulator elements; and the actuating device is configured to bring about a relative change of the first and second manipulator elements with respect to one another so that the first manipulator element brings about a change in telecentricity, distortion and defocus and the second manipulator element partly or completely compensates for the change in distortion and defocus caused by the first manipulator element.
9. The projection lens of claim 8, wherein the first objective part comprises a first multiplicity of refractive optical elements, and the third objective part comprises a second multiplicity of refractive optical elements.
10. The projection lens of claim 9, wherein the second objective part comprises at least one mirror.
11. The projection lens of claim 10, wherein the second objective part comprises at least one refractive optical element.
12. The projection lens of claim 8, wherein the first manipulator element comprises a deformable mirror surface.
13. The projection lens of claim 12, wherein the second manipulator element comprises a deformable mirror surface.
14. The projection lens of claim 8, wherein the second manipulator element comprises a deformable mirror surface.
15. The projection lens of claim 8, wherein the projection lens is a DUV projection lens.
16. An apparatus, comprising: the projection lens of claim 8, wherein the apparatus is a projection exposure apparatus.
17. The apparatus of claim 16, further comprising an illumination system configured to illuminate an object plan of the projection lens, wherein the projection lens is configured to image an object in the object plane into an image plane of the projection lens.
18. A method of using a projection exposure apparatus comprising an illumination system and a projection lens, the method comprising: using the illumination system to illuminate a mask comprising a pattern; and using the projection lens to project at least a portion of the illuminated pattern of the mask onto an object plane, wherein the projection lens is a projection lens according to claim 8.
19. A projection lens, comprising: a first objective part configured to image an object plane of the projection lens into a first intermediate image plane of the projection lens; a second objective part configured to image the first intermediate image plane of the projection lens into a second intermediate image plane of the projection lens; and a third objective part configured to image the second intermediate image plane of the projection lens into an image plane of the projection lens, wherein: the first objective part is dioptric; the second objective part comprises a reflective optical element; the third objective part is dioptric; the projection lens comprises a dedicated telecentricity manipulator; the dedicated telecentricity manipulator comprises a first manipulator element and a second manipulator element separate from the first manipulator element; the first manipulator element is in the projection beam path in or optically near a first field plane; the second manipulator element is arranged in the projection beam path in or optically near a second field plane optically conjugate to the first field plane; the projection lens comprises an actuating device assigned to the first and second manipulator elements; the actuating device is configured to bring about a relative change of the first and second manipulator elements with respect to one another so that the first manipulator element brings about a change in telecentricity, distortion and defocus and the second manipulator element partly or completely compensates for the change in distortion and defocus caused by the first manipulator element; and the projection lens is a DUV projection lens.
20. The projection lens of claim 19, wherein the first manipulator element comprises a deformable mirror surface.
21. The projection lens of claim 20, wherein the second manipulator element comprises a deformable mirror surface.
22. The projection lens of claim 19, wherein the second manipulator element comprises a deformable mirror surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Further advantages and aspects of the disclosure are evident from the claims and from the following description of preferred exemplary embodiments of the disclosure, which are explained below with reference to the figures.
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DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
(14) In order to provide a more detailed explanation of the background of aspects of the claimed disclosure, firstly an explanation is given below of relationships between telecentricity properties of an optical imaging system and alternative modes of description, such as the field profile of the Zernike coefficient Z1 or the OPL function.
(15) The textbook “An Introduction to Hamiltonian Optics” by H. A. Buchdahl, Cambridge University Press (1970) shows that an optical system can be completely characterized by a scalar function with the designation “characteristic”. The mixed characteristic W.sub.1 is particularly suitable for an imaging system. This function corresponds to the sum of the optical path lengths OPL indicated in the direction cosines in the object plane and the spatial coordinates in the image plane with the weighted scalar product of the start locations and start directions,
W.sub.1(k.sub.x,k.sub.y;X,Y):=OPL(k.sub.x,k.sub.y;X,Y)+n.sub.o(k.sub.xx+k.sub.yy)
wherein the convention was chosen that the coordinates in the object space are described as lowercase letters and the coordinates in the image space are described as uppercase letters.
(16) The combination of the characteristics to form the ray data follows from Fermat's principle. Specifically, the derivatives of W.sub.1 with respect to the direction cosines in the object plane yield the intersection points of the rays at this plane scaled with the refractive index n.sub.o
(17)
and the derivatives with respect to the locations in the image plane yield the direction cosines in the corresponding plane scaled with the refractive index N.sub.B
(18)
(19) The ideal, aberration-free characteristic of an optical system with the imaging scale can be written as
(20)
(21) This follows from the differential equations (∂W/∂k.sub.x) and (∂W/∂k.sub.y) if the imaging conditions
X=βx and Y=βy
are taken into account. The aberrations of an optical system are described as the deviations of the W.sub.1 characteristic from the ideal characteristic where
W.sub.Aberration=W.sub.1−W.sub.ideal
(22) That is the wavefront aberration that is obtained as a result in optical design programmes such as e.g. OSLO®, CODEV® or ZEMAX®. All these programmes can only calculate an approximation of the wavefront aberration.
(23) Considerations with regard to telecentricity will now follow. In previously examined texts concerning the wavefront aberration, the term R(X, Y) in the equation for (W.sub.ideal) is argued away since it does not contribute to the imaging quality. This term becomes important, however, if statements concerning the telecentricity of an optical system are intended to be made. Specifically, if the ideal characteristic is inserted into the equations (∂W/∂k.sub.x) and (∂W/∂k.sub.y), then the following is obtained:
(24)
(25) These equations correspond to the sine condition. They state that the variation of the ray direction in the image space is proportional to the variation of the ray direction in the object space. The proportionality constant is the inverse of the imaging scale β.
(26) For a doubly telecentric optical unit, the rays that start perpendicularly in the object (k.sub.x=0, k.sub.y=0), arrive perpendicularly in the image concomitantly (K.sub.x=0, K.sub.y=0). These conditions are met if R(X, Y) is constant. This shows that the telecentricity of an optical system is described by the term R(X, Y).
(27) Moreover, the ideal characteristic for doubly telecentric lenses have the following form:
(28)
wherein c represents an arbitrary constant.
(29) Projection lenses for microlithography via EUV radiation (EUV optical units) cannot be doubly telecentric because the masks are reflective. The beams in such systems start at the object plane at a fixed chief ray angle α, which is generally a few degrees (e.g. between 3° and 10°, e.g. approximately 6°). The EUV optical units are telecentric, however, in the image plane (only image-side telecentricity). For the ideal characteristic this corresponds to the properties
(30)
(31) The solution to these equations reads
(32)
wherein c is an arbitrary constant. Using similar arguments, the properties for the ideal profile of the function R(X, Y) can easily also be derived for systems which are not telecentric on both sides.
(33) The combination for Zernike expansion can be understood as follows. The wavefront aberrations (W.sub.aberration) are typically expanded into Zernike polynomials Z.sub.n(k.sub.x, k.sub.y) where
(34)
this expansion has an attractive interpretation since the Zernike polynomials can be interpreted as known image aberrations. By way of example, Z.sub.2 and Z.sub.3 correspond to the distortion and Z.sub.4 corresponds to the defocus of an optical unit.
(35) The Zernike polynomial Z.sub.1 corresponds to a constant and the field profile of the Zernike coefficient c.sub.1(X, Y) thus corresponds to the profile of the telecentricity.
(36) The Z1 term is disregarded in all of the optical design programmes (OSLO®, ZEMAX® and CODEV®) tested by the inventor. It is assumed that this is owing to historical development in optical design, inter alia. Traditionally a design is assessed point by point. The global phase corresponding to the Z1 is unimportant at a fixed point (X, Y). Therefore, in the programmes mentioned above, the global phase at a point is chosen such that the wavefront aberration in the centre of the pupil vanishes. This makes it impossible to calculate the Z1 field profile.
(37) A visual representation of the results is presented below with reference to
(38) A representation in which the incidence location (X, Y) is fixed is usually chosen. This corresponds to the procedure supported by all optical design programmes. In this case, field points (fixed incidence locations) are defined, at which the wavefront aberrations are then controlled. In this case, the ideal characteristic (equation for (W.sub.ideal)), as is depicted schematically in
(39) For fixed incidence locations (X,Y), the ideal characteristic reduces to a linear function W.sub.ideal=c.sub.1k.sub.x+c.sub.2 k.sub.y+c.sub.0 in the direction cosines k.sub.x and k.sub.y and represents a spherical wave. If the ideal characteristic is considered only at a point, then the doubly telecentric lenses (
(40) However, if consideration is given to the unusual case, not taken into account hitherto, in which the directions (k.sub.x, k.sub.y) are fixed, then the desired property that plane surfaces of the constant OPL in the object space are imaged onto plane surfaces in the image space is obtained from the formula for the ideal characteristic of a doubly telecentric system (equation for (W.sub.ideal-doublyTel)). This relationship is depicted schematically in
(41)
can be written as a linear function in the incidence locations (X,Y), which corresponds to a plane.
(42) The schematic depictions in
(43)
the surface of the constant OPL in the image space corresponds to the function R(X,Y).
(44) In
(45) The dashed lines in both figures show the profile of the surface having constant OPL for (k.sub.x=0,k.sub.y=0). In the doubly telecentric case (
(46) An explanation is given below of quantitative aspects concerning sensitivities of Z1 for the design of an operating control and for the design of manipulators for influencing the telecentricity on the basis of practical examples.
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(48) Pupil surfaces or pupil planes P1, P2, P3 of the imaging system respectively lie between the object plane and the first intermediate image, between the first and the second intermediate image and between the second intermediate image and the image plane, respectively where the chief ray CR of the optical imaging intersects the optical axis OA. The aperture stop AS of the system can be attached in the region of the pupil surface P3 of the third lens part OP3. The pupil surface P2 within the catadioptric second lens part OP2 lies in direct proximity to a concave mirror CM.
(49) With regard to its optical construction, the exemplary embodiment shown in
(50) The catadioptric second lens part OP2 contains the sole concave mirror CM of the projection lens. A negative group NG having two negative lens elements is situated directly upstream of the concave mirror. In this arrangement, which is occasionally referred to as a Schupmann achromate, the Petzval correction, i.e. the correction of the image field curvature, is achieved as a result of the curvature of the concave mirror and the negative lens elements in the vicinity thereof, the chromatic correction as a result of the refractive power of the negative lens elements upstream of the concave mirror and also the stop position with respect to the concave mirror.
(51) A reflective deflection device serves to separate the beam passing from the object plane OS to the concave mirror CM or the corresponding partial beam path from that beam or partial beam path which, after reflection at the concave mirror, passes between the latter and the image plane IS. For this purpose, the deflection device has a plane first deflection mirror FM1 having a first mirror surface (surface 26) for reflecting the radiation coming from the object plane to the concave mirror CM and a plane second deflection mirror FM2 aligned at right angles to the first deflection mirror FM1 and having a second mirror surface (surface 36), wherein the second deflection mirror deflects the radiation reflected from the concave mirror in the direction of the image plane IS. Since the optical axis is folded at the deflection mirrors, in this application the deflection mirrors are also referred to as folding mirrors. The deflection mirrors are tilted relative to the optical axis OA of the projection lens about tilt axes extending perpendicularly to the optical axis and parallel to a first direction (x-direction), e.g. by 45°. For this purpose, the deflection device is realized by a prism whose externally reflectively coated cathetus surfaces aligned perpendicularly to one another serve as deflection mirrors.
(52) The intermediate images IMI1, IMI2 each lie in optical proximity to the deflection mirrors FM1 and FM2, respectively, closest to them, but can be at a minimum optical distance from them, such that possible defects on the mirror surfaces are not sharply imaged into the image plane, and the plane deflection mirrors (plane mirrors) FM1, FM2 lie in the region of moderate radiation energy density.
(53) The positions of the (paraxial) intermediate images define field planes of the system which are optically conjugate to the object plane and to the image plane, respectively. The deflection mirrors thus lie in optical proximity to field planes of the system, which is also referred to as “near-field” in the context of this application. In this case, the first deflection mirror is arranged in optical proximity to a first field plane, belonging to the first intermediate image IMI1, and the second deflection mirror is arranged in optical proximity to a second field plane, optically conjugate to the first field plane and belonging to the second intermediate image IMI2.
(54) The optical proximity or the optical distance of an optical surface with respect to a reference plane (e.g. a field plane or a pupil plane) is described by the so-called subaperture ratio SAR in this application. For the purposes of this application, the subaperture ratio SAR of an optical surface is defined as follows:
SAR=sign h(|r|/(|h|+|r|))
where r denotes the marginal ray height, h denotes the chief ray height and the signum function sign x denotes the sign of x, with sign 0=1 according to convention. The chief ray height is understood to mean the ray height of the chief ray of a field point of the object field with a maximum field height in terms of magnitude. The ray height should be understood to be signed. The marginal ray height is understood to mean the ray height of a ray with a maximum aperture proceeding from the point of intersection between the optical axis and the object plane. This field point need not contribute to transferring the pattern arranged in the object plane—in particular in the case of off-axis image fields.
(55) The subaperture ratio is a signed variable which is a measure of the field or pupil proximity of a plane in the beam path. By definition, the subaperture ratio is normalized to values between −1 and +1, wherein the subaperture ratio is zero in each field plane and wherein the subaperture ratio jumps from −1 to +1, or vice versa, in a pupil plane. Therefore, a subaperture ratio with an absolute value of 1 determines a pupil plane.
(56) An optical surface or a plane is then designated as “(optically) near” to an optical reference surface if the subaperture ratios of these two surfaces are comparable in terms of numerical value. In particular, an optical surface or a plane is designated “(optically) near-field” if it has a subaperture ratio that is close to 0. An optical surface or a plane is designated as “(optically) near-pupil” if it has a subaperture ratio that is close to 1 in terms of absolute value.
(57) For both deflection mirrors it holds true that no optical element is arranged between the deflection mirror and the closest intermediate image (direct proximity) and that the subaperture ratio SAR, in terms of absolute value, is less than 0.3, in particular less than 0.2.
(58) The projection lens PO has an image-side numerical aperture NA=1.35. The size of the effective image field is 26 mm×22 mm. The telecentricity deviation from perfect image-side telecentricity is less than 1 mrad.
(59)
(60) In order to determine to what extent changes at individual optical surfaces of the optical system affect the telecentricity, that is to say in order to determine the sensitivities of individual optical surfaces to the Z1 profile in the projection lens, there was added to each optical surface a parabolic profile of the form x.sup.2+y.sup.2 with a maximum amplitude of 2 μm in the optically free region of the respective optical surface. The difference between the new Z1 profile and the profile of the reference design was then determined in each case. The diagram in
(61) If it is taken into account that typical manipulated value changes or travels of manipulators can be of the order of magnitude of 1 or 2 μm, then it is directly evident from
(62) In some wavefront manipulation systems, a change in the operating wavelength is also used as a manipulator. By way of example, the wavelength in the case of great changes in air pressure in the vicinity of a projection exposure apparatus and the resultant changes in refraction time can be used as a manipulator. Experience shows that typical values for the wavelength changes can be in the range of ±50 μm.
(63) The comprehensive analyses by the inventor, which are explained here only on the basis of a few examples, led to the following insights, inter alia: (i) the typical manipulated value changes that are used in many systems to highlight or compensate for external disturbances (for example on account of pressure variations) may be sufficient to significantly disturb the telecentricity. (ii) The Z1 profile can be controlled or set particularly effectively at near-field optical surfaces since the sensitivity for Z1 is particularly high here. (iii) The sensitivity for Z1 is all the greater, the smaller the numerical aperture at the optical surface respectively considered.
(64) Taking account of the Z1 sensitivity (or other relationships suitable as telecentricity sensitivities) in the actuation of manipulators of an operating control system of a projection exposure apparatus is currently regarded as a good possibility for addressing this issue. It appears to be expedient to limit the Z1 to the smallest possible values, for example to the value 0, which would correspond to the ideal state. What can be achieved thereby is that the telecentricity is not adjusted to an arbitrarily great extent during operation, rather possible changes in the telecentricity properties are limited to relatively noncritical values.
(65) The quantitative analyses show that typical orders of magnitude of the Z1 sensitivity are in the micrometres range. In comparison therewith, typical units of many other Zernike coefficients (which are normally in the nm range) are smaller by three orders of magnitude. It therefore appears to be expedient to provide the telecentricity or Z1 in the definition of the target function of a control with significantly smaller weights than those of other Zernike coefficients.
(66) Considerations regarding criteria for the design of a dedicated telecentricity manipulator are explained below. The term “dedicated telecentricity manipulator” here means that this is a manipulator which can cause a targeted variation of the telecentricity of the projection lens in reaction to control signals of an operating control system, wherein the influence on telecentricity predominates in comparison with likewise possible influences on other aberrations, such as distortion and defocus, for example. In other words: A dedicated telecentricity manipulator allows a targeted variation of the telecentricity, wherein the level of other aberrations that are possibly likewise induced, in particular distortion and defocus, is low by comparison with the level of the variation of the telecentricity.
(67) In some applications it may be advantageous for the manipulator to have, with respect to the telecentricity (quantified by Z1), a sensitivity that is greater than the sensitivity for Z2/Z3 by at least three orders of magnitude (at least a factor of 1000). There are also applications which deliberately do not use the projection lens in the best focus position, e.g. focus drilling. A difference in sensitivity by the factor of 10 or 100 may also be sufficient in those cases, inter alia.
(68) In order to elucidate the considerations,
(69) The reference sign MS denotes a manipulator surface of a manipulator element of the dedicated telecentricity manipulator. Let the manipulator surface lie initially, in a first operating position of the manipulator, in the field plane FE1, such that the chief ray and the coma ray intersect at the manipulator surface. The refractive indices n.sub.1 on the left-hand side (light entrance side) of the manipulator surface and n.sub.2 on the right-hand side (light exit side) of the manipulator surface are different. By way of example, gas or vacuum where n.sub.1≈n.sub.1 may prevail on the light entrance side (left), while the manipulator surface MS is an optical surface of a transparent optical element whose material has a refractive index n.sub.2>n.sub.1. However, n.sub.2<n.sub.1 could also hold true.
(70) If the manipulator surface MS is then displaced by a displacement distance dx parallel to the optical axis or to the chief ray into the position MS' illustrated by a dashed line, then the chief ray CR experiences a phase change or a change in the optical path length in accordance with:
OPD.sub.chief=dx(n.sub.1−n.sub.2)=dxδn
(71) The abbreviation δn stands for the difference in refractive index between n.sub.1 and n.sub.2. The coma ray COR, by contrast, experiences a different phase change, which can be represented as follows:
(72)
(73) In this case, the parameter α represents the aperture angle of the coma ray COR relative to the chief ray. The optical path length difference OPD.sub.chief indicated above corresponds to the global phase of a beam, which can be described with the Zernike coefficient Z1. The difference
(74)
between the optical path length difference of the chief ray CR and the optical path length difference of the coma ray COR corresponds to the Zernike coefficients Z2, Z3 and Z4 or the aberrations of distortion (Z2 and Z3) and defocus (Z4) that can be described thereby. All higher Zernike coefficients vanish in this idealized case in which the manipulator surface in one of the operating positions is situated directly in a field plane FE1. These considerations show that in the region of a single field plane the telecentricity cannot be varied or manipulated independently of the distortion (Z2/Z3) and the defocus (Z4). To put it another way, a sought or desired change in the telecentricity also induces undesired (parasitic) aberrations, in particular distortion and defocus.
(75) These considerations also show that a manipulator surface in the region of an intermediate image with a relatively small aperture angle principally influences the telecentricity, the influence on distortion and/or defocus being smaller by comparison therewith.
(76) For the field of projection lenses for microlithography, where the image-side numerical aperture should be relatively high for achieving high resolutions, it can be difficult, with the aid of a single manipulator element in or optically near a field plane, to vary principally the telecentricity to a desired extent, without at the same time likewise noticeably varying defocus and distortion.
(77) By contrast, according to the inventor's insights it is possible to provide a dedicated telecentricity manipulator for a projection lens for microlithography if the projection lens includes two field planes which are accessible for attaching a manipulator element and which are optically conjugate to one another and in which the aperture angles of the coma rays relative to the chief ray (or the numerical apertures) have different magnitudes. Under these preconditions, ideally the manipulator elements can be altered relative to one another such that the sum of the phase changes of the coma rays vanishes, such that all that is left as the remaining induced aberration is the telecentricity or a telecentricity change. The condition for the sum of the phases of the coma rays to vanish can be formulated as follows:
(78)
(79) In this case, the following relationship results for the variation of the Z1 coefficient or for the variation of the telecentricity that can be described thereby:
(80)
(81) This shows that it is possible, in principle, with two manipulator elements positioned in different field planes, to realise a pure telecentricity manipulator or a dedicated telecentricity manipulator having an ideal effect. It is immediately evident from the last equation that the effect of the dedicated telecentricity manipulator becomes particularly great if the aperture angles α.sub.1 and α.sub.2 at the field planes optically conjugate to one another differ greatly.
(82) These insights can be used to configure a dedicated telecentricity manipulator for a projection lens that really exists. This shall be explained on the basis of the example of the projection lens PO from
(83) A dedicated telecentricity manipulator can include a first manipulator element, the manipulator surface of which is as close as possible to the object plane OS, for example in the region of a subaperture ratio SAR of 0.1 or less. A second manipulator element adapted thereto can be arranged in direct optical proximity to the image plane IS, for example in the form of a manipulator surface formed at the entrance side or exit side of the last optical element on the image side (plane plate PP).
(84) A possible practical implementation of the concept in a projection lens PO is described with reference to
(85) The dedicated telecentricity manipulator is embodied in the manner of an Alvarez manipulator including two transparent plate-type manipulator elements ME1, ME2, in the case of which respectively one of the plate surfaces is plane and the other plate surface (first manipulator surface) has an aspherical shape that deviates significantly from a plane surface. The combination of both manipulator elements can be referred to as an Alvarez manipulator. The first manipulator element ME1 is arranged directly downstream of the object plane OS optically near this field plane in such a way that the plane entrance surface and the aspherical exit surface both lie in a region in which the subaperture ratio SAR is less than 0.3 or less than 0.2 or even less than 0.1. The first manipulator element ME1 can be moved in a plane perpendicular to the optical axis OA with the aid of a first actuating device DR1.
(86) The first manipulator element is assigned a second manipulator element ME2, which is part of the Alvarez manipulator and has an asphere similar to that of the first manipulator element ME1.
(87) The second manipulator element ME2 is the last optical element, closest to the image plane IS, of the projection lens and lies in a region in which for both surfaces the subaperture ratio is less than 0.2 or less than 0.1. The second manipulator element ME2 is likewise manipulatable and is actuated upon the displacement of the first manipulator element in such a way that the parasitic effect thereof on distortion and defocus is partly or completely compensated for or minimized, such that substantially only the desired influence on the telecentricity results.
(88) The two manipulator surfaces MS1 and MS2 assigned to one another are designed with regard to their surface shape such that the surfaces each correspond to the form of the antiderivative of a telecentricity error to be corrected. They are shaped complementarily to one another (taking account of the reducing imaging scale). In the first operating position (zero position) illustrated, the first manipulator element ME1 is positioned with respect to the second manipulator element ME2 such that the overall effect of the two manipulator elements on the rays or wavefronts travelling from the object plane to the image plane compensate for one another, such that the two manipulator elements overall do not produce any significant wavefront deformation.
(89) In order to achieve a targeted variation of the telecentricity of the projection lens, the first manipulator element ME1 can be displaced perpendicularly to the optical axis into the dashed second operating position ME1′ illustrated, for example, with the aid of the first actuating device DR1. For the chief ray CR discernible in
(90) The surface shapes of the manipulator surfaces are then adapted to one another, taking account of the reduced imaging scale applicable between object plane and image plane, such that the effect of the displacement of the first manipulator element ME1 on the distortion (Z2/Z3) and the defocus (Z4) is compensated for to the greatest possible extent by the second manipulator element ME2, while the variation of the telecentricity or of the global phase that is produced as a result of the displacement is substantially not compensated for, such that a variation of the telecentricity in the image plane IS remains as the resulting variation.
(91) In the case of the variant in
(92) Numerous variants are possible. By way of example, the first manipulator element ME2 can alternatively also be positioned in the region of a first intermediate image plane at the first intermediate image IMI1 or in a second intermediate image plane at the second intermediate image IMI2, provided that the third lens part, which images the second intermediate image IMI2 into the image plane IS, has a sufficiently greatly reducing imaging scale. If a reduced imaging is effected overall between the object plane and an intermediate image plane, the second manipulator element could also be arranged in the region of the corresponding intermediate image plane.
(93) One variant of the embodiment shown in
(94) Suitable manipulator elements are not restricted to transmissive refractive elements or refractive elements through which radiation can be transmitted. It is also possible to design one manipulator element or both manipulator elements of a dedicated telecentricity manipulator as a manipulatable mirror, for example having a deformable mirror surface, which can function as a manipulator surface. A reflective manipulator element having a specularly reflective manipulator surface (for example a bendable mirror) may be expedient for a number of reasons. Firstly, for a mirror or a reflective manipulator surface it holds true that the difference in refractive index is n.sub.1−n.sub.2=2, such that in this respect a higher sensitivity is provided and even small deformations can have great effects on the telecentricity. Secondly, in the case of the projection lens in
(95) Exemplary embodiments of projection exposure apparatuses in which the insights are implemented via hardware and software are described below.
(96)
(97) At its exit surface ES, an illumination system ILL disposed downstream of the light source LS generates a large, sharply delimited and substantially homogeneously illuminated illumination field, which is adapted to the desired properties of telecentricity of the projection lens PO arranged downstream thereof in the light path. The illumination system ILL has devices for setting different illumination modes (illumination settings) and it can be switched for example between conventional on-axis illumination with different degrees of coherence σ and off-axis illumination. By way of example, the off-axis illumination modes include an annular illumination or a dipole illumination or a quadrupole illumination or any other multi-polar illumination. The design of suitable illumination systems is known per se and therefore not explained in any more detail here. The patent application US 2007/0165202 A1 (corresponding to WO 2005/026843 A2) shows examples of illumination systems which can be used within the scope of various embodiments. In this respect, the disclosure content of the patent application is incorporated by reference in the content of this description.
(98) Those optical components which receive the light from the light source LS and shape illumination radiation from this light, which illumination radiation is directed to the illumination field lying in the exit plane ES or to the reticle M, are part of the illumination system ILL of the projection exposure apparatus.
(99) Arranged downstream of the illumination system is a device RS for holding and manipulating the mask M (reticle) in such a way that the pattern PAT arranged at the reticle lies in the region of the object plane OS of the projection lens PO, which coincides with the exit plane ES of the illumination system and which is also referred to here as reticle plane OS. For the purposes of scanner operation, the mask is movable parallel to this plane in a scanning direction (y-direction) perpendicular to the optical axis OA (z-direction) with the aid of a scanning drive.
(100) The device RS includes an integrated lifting device for linearly displacing the mask in relation to the object plane in the z-direction, i.e. perpendicular to the object plane, and an integrated tilting device for tilting the mask about a tilt axis extending in the x-direction.
(101) Following downstream of the reticle plane OS is the projection lens PO, which acts as a reduction lens and images an image of the pattern arranged at the mask M with a reduced scale, for example with the scale of 1:4 (|β|=0.25) or 1:5 (|β|=0.20), onto a substrate W coated with a photoresist layer, the light-sensitive substrate surface SS of which lies in the region of the image plane IS of the projection lens PO. The projection lens is nominally doubly telecentric, that is to say has no or only very small deviations from perfect telecentricity on the object side and on the image side.
(102) The substrate to be exposed, which is a semiconductor wafer W in the exemplary case, is held by a device WS which includes a scanner drive in order to move the wafer synchronously with the reticle M perpendicular to the optical axis OA in a scanning direction (y-direction). The device WS furthermore includes a lifting device for linearly displacing the substrate in relation to the image plane in the z-direction and a tilting device for tilting the substrate about a tilt axis extending in the x-direction.
(103) The device WS, which is also referred to as “wafer stage”, and the device RS, which is also referred to as “reticle stage”, are constituents of a scanner device which is controlled by way of a scan control device which, in the embodiment, is integrated in the central control device CU of the projection exposure apparatus.
(104) The illumination field produced by the illumination system ILL defines the effective object field OF used during the projection exposure. In the exemplary case, the latter is rectangular, it has a height A* measured parallel to the scanning direction (y-direction) and it has a width B*>A* measured perpendicular thereto (in the x-direction). In general, the aspect ratio AR=B*/A* lies between 2 and 10, in particular between 3 and 6. The effective object field lies at a distance next to the optical axis in the y-direction (off-axis field). The effective image field in the image surface IS, which is optically conjugate to the effective object field, likewise is an off-axis field and it has the same shape and the same aspect ratio between the height B and width A as the effective object field, but the absolute field dimension is reduced by the imaging scale β of the projection lens, i.e. A=|β| A* and B=|β|B*.
(105) If the projection lens is designed and operated as an immersion lens, then radiation is transmitted through a thin layer of an immersion liquid during the operation of the projection lens, which thin layer is situated between the exit surface of the projection lens and the image plane IS. Image-side numerical apertures NA>1 are possible during the immersion operation. A configuration as a dry lens is also possible; in this case, the image-side numerical aperture is restricted to values NA<1.
(106) The projection exposure apparatus WSC has an operating control system which is configured to undertake a near-instantaneous fine optimization of imaging-relevant properties of the projection exposure apparatus as a reaction to environmental influences and other disturbances and/or on the basis of stored control data. To this end, the operating control system has a multiplicity of manipulators which permit a targeted intervention into the projection behaviour of the projection exposure apparatus. An actively actuatable manipulator contains one or more actuating members (or one or more actuators), the current manipulated value of which can be modified on the basis of control signals of the operating control system by virtue of defined manipulated value changes being undertaken.
(107) The projection lens or the projection exposure apparatus is equipped with, inter alia, a wavefront manipulation system WFM, which is configured to modify the wavefront of the projection radiation travelling from the object plane OS to the image plane IS in a controllable manner within the meaning of the optical effect of the wavefront manipulation system being able to be variably adjusted by way of control signals of an operating control system.
(108) The wavefront manipulation system in the exemplary embodiment has a multiplicity of mutually independently driveable manipulators MAN1, MAN2 etc., each having at least one manipulator element ME1, ME2 etc., which is arranged in the projection beam path of the projection lens and has a (at least one) manipulator surface MS1, MS2 which is arranged in the projection beam path and whose position (location) and/or orientation and/or surface shape and/or refractive index distribution can be varied reversibly with the aid of an actuating device DR1, DR2 etc. A manipulator can be designed e.g. for a decentration or displacement of an optical element parallel or perpendicular to a reference axis, a tilting of an optical element, a local or global heating or cooling of an optical element and/or a deformation of an optical element. The term “manipulator” also encompasses devices which, on the basis of corresponding control signals of an operating control system, act on the mask or on the substrate in order for example to displace, to tilt and/or to deform the mask or the substrate.
(109) In a memory SP of the operating control system, sensitivities S(Z1), S(Z2), . . . , S(Zn) of the manipulators are stored for numerous aberrations, which are symbolized here in each case by the associated Zernike coefficients Z1 (for telecentricity), Z2 (for the tilt of a wavefront in the x-direction) etc. A dedicated set of sensitivities can be stored for each manipulator. What is important is that telecentricity sensitivities S(Z1) of manipulators for varying the telecentricity are also stored here in addition to the sensitivities also stored in some conventional systems. A telecentricity sensitivity quantitatively describes a relationship between a defined manipulated value change at a manipulator and the effect achieved thereby on the telecentricity in the image field. The operation of the projection exposure apparatus can thus also be controlled taking account of the telecentricity sensitivities, e.g. in such a way that manipulated value changes of a manipulator are limited to magnitudes below a manipulated value limit value taking account of the telecentricity sensitivities.
(110) When determining manipulated value changes of the manipulators, the operating control system uses a target function that describes the quality of the exposure process as a weighted sum of a multiplicity of “lithographic aberrations”. In this case, the term “lithographic aberration” is intended to encompass all defects relevant to lithography during the imaging. The lithographic aberrations include, inter alia, aberrations such as distortion (non-uniform displacement of image points in the image field), deviations of the lateral image position (uniform displacement of image points in the image field), image rotation, asymmetrical imaging scale, deformations of the focus position (non-uniform image point displacement perpendicular to the image plane), etc., but also variations of the critical dimensions over the image field (CD variations), differences in the critical dimensions in mutually orthogonal directions (HV aberrations), etc. In general, these aberrations are not uniform over the image field, but rather vary within the image field. Distortion and deformations of the focal plane can lead to overlay aberrations (e.g. overlay aberrations between different patterns (mask structures) and focus aberrations. The lithographic aberrations are influenced by various properties of the projection exposure apparatus or of the projection exposure process, including the substrate, the radiation-sensitive layer on the substrate, the projection ray provided by the light source, the mask and the projection system.
(111) In the case of the projection exposure apparatus WSC, the target function to be optimized by the control programme for each of the manipulators includes a telecentricity sensitivity S(Z1) describing a relationship between a defined manipulated value change at the manipulator and an effect achievable thereby on the telecentricity of the projection radiation in the image field. The optimization of the target function generally involves simulating many manipulated value changes of manipulators and calculating the effects thereof on the target function. Since telecentricity sensitivities are also taken into account, the effects of manipulated value changes at manipulators on the telecentricity can be taken into account in the optimization of the target function. What can thereby be achieved, for example, is that an end customer (user of the projection exposure apparatus), without telecentricity measurement, is afforded a possibility of documenting the deviation of the telecentricity from the telecentricity of the delivery state and a subsequent adjustment by manipulators, and of ensuring that the telecentricity remains in the range of a predefined specification. A predefined specification may be such that image-side telecentricity is to be maintained in a range of less than 20 mrad (millirad), with preferred values of image-side telecentricity in the range of less than 10 mrad, the latter limit particularly applicable for DUV systems.
(112) The projection lens can be assigned a dedicated telecentricity manipulator of the type described in this application in order to make targeted interventions in the telecentricity properties of the projection lens. However, this is not mandatory.
(113) In principle, the lithography optical units in the EUV range cannot be doubly telecentric since no transmissive reticles exist in that wavelength range. These optical systems are therefore simply telecentric (at the wafer) in their design. The insights and concepts described here can also be used in projection exposure apparatus for microlithography with EUV radiation.