METHOD FOR MOUNTING AN OPTICAL SYSTEM
20220283503 · 2022-09-08
Inventors
- Johann Dorn (Neu-Ulm, DE)
- Steffen Fritzsche (Aalen, DE)
- Wolfgang Grimm (Aalen, DE)
- Peter Nieland (Aalen, DE)
Cpc classification
G03F7/705
PHYSICS
G03F7/70975
PHYSICS
G03F7/70833
PHYSICS
G02B27/62
PHYSICS
G03F7/70141
PHYSICS
G02B27/0012
PHYSICS
G03F7/70258
PHYSICS
International classification
G02B27/00
PHYSICS
G02B27/62
PHYSICS
Abstract
A method includes: a) measuring individual parts K1-KN of an optical system to provide measurement data, N being greater than one; b) using the measurement data to virtualize the individual parts K1-KN and using the virtualized individual parts K1-KN to generate an actual assembly model by geometrically stringing together a plurality of the virtualized individual parts K1-KN, the actual assembly model comprising virtual actual positions of the virtualized individual parts K1-KN in a virtually assembled state; c) using the actual assembly model and a target assembly model to determine a correction measure, the target assembly model comprising virtual target positions of one or more of the virtualized individual parts K1-KN in the virtually assembled state; and d) using the correction measure, assembling the individual parts K1-KN to form the optical system.
Claims
1. A method, comprising: a) measuring individual parts K1-KN of an optical system to provide measurement data, N being greater than one; b) using the measurement data to virtualize the individual parts K1-KN and using the virtualized individual parts K1-KN to generate an actual assembly model by geometrically stringing together a plurality of the virtualized individual parts K1-KN, the actual assembly model comprising virtual actual positions of the virtualized individual parts K1-KN in a virtually assembled state; c) using the actual assembly model and a target assembly model to determine a correction measure, the target assembly model comprising virtual target positions of one or more of the virtualized individual parts K1-KN in the virtually assembled state; and d) using the correction measure, assembling the individual parts K1-KN to form the optical system.
2. The method of claim 1, further comprising: geometrically stringing together the virtualized individual parts K1-KN to generate the actual assembly model; and comparing the virtual actual position of a virtualized individual part KN and the virtual target position of the virtualized individual part KN to determine the correction measure.
3. The method of claim 1, further comprising: fixing the virtualized individual parts K1 and KN at their target positions from the target assembly model to generate the actual assembly model; geometrically stringing together the virtualized individual parts K2-KN-1 with K1 and/or KN; and determining the correction measure based on virtual actual positions of at least two virtualized individual parts K2-KN-1.
4. The method of claim 1, wherein d comprises applying the correction measure to the individual part KN-1 or to a region between the individual parts KN-1 and KN.
5. The method of claim 1, wherein d) comprises applying the correction measure to the individual part KN-1 or to a gap between the individual parts KN-1 and KN.
6. The method of claim 1, wherein at least one of the following holds: the individual part KN comprises an optical element; and the individual part KN-1 comprises a member selected from the group consisting of a mechanical component, a mechatronic component and a bearing.
7. The method of claim 1, wherein at least one of the following holds: the individual part KN comprises a member selected from the group consisting of a mirror, a lens element, an optical grating, a waveplate, a stop and a sensor; and the individual part KN-1 comprises a member selected from the group consisting of a mechanical component, a mechatronic component and a bearing.
8. The method of claim 1, wherein determining the correction measure comprises: inserting a spacer between two of the individual parts K1-KN; and adjusting a play of a fastening mechanism which fastens two of the individual parts K1-KN to one another, and/or adjusting an operating point of a mechatronic component as constituent part of one of the individual parts K1-KN.
9. The method of claim 8, wherein the mechatronic component comprises an actuator, and determining the correction measure is determined based on an available actuator travel of the actuator.
10. The method of claim 1, wherein N>5 or 10.
11. The method of claim 1, wherein c) comprises determining a gap between two of the individual parts K1-KN, and d) comprises inserting a spacer into the gap.
12. The method of claim 1, wherein the correction measure relates to at least a first degree of freedom and a second degree of freedom which is different from the first degree of freedom.
13. The method of claim 12, wherein d) comprises applying the correction measure to: to a first individual part K1-KN; between a first pair of individual parts K1-KN for the first degree of freedom and a second of the individual parts K1-KN; or between a second pair of individual parts K1-KN for the second degree of freedom.
14. The method of claim 1, further comprising: measuring the assembled optical system to provide assembly measurement data; comparing the assembly measurement data and the target assembly model to determine a further correction measure; and based on the further correction measure, aligning one or more of the individual parts K1-KN.
15. The method of claim 1, further comprising, after assembling the optical system, operating the optical system.
16. The method of claim 15, wherein the optical system comprises a lithography apparatus.
17. The method of claim 1, wherein the optical system comprises a lithography apparatus.
18. The method of claim 17, further comprising: geometrically stringing together the virtualized individual parts K1-KN to generate the actual assembly model; and comparing the virtual actual position of the virtualized individual part KN and the virtual target position of the virtualized individual part KN to determine the correction measure.
19. One or more machine-readable hardware storage devices comprising instructions that are executable by one or more processing devices to perform operations comprising the method of claim 1.
20. A system, comprising: one or more processing devices; and one or more machine-readable hardware storage devices comprising instructions that are executable by the one or more processing devices to perform operations comprising the method of claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0080] In the text that follows, the disclosure will be explained in more detail on the basis of embodiments with reference to the accompanying figures, in which:
[0081]
[0082]
[0083]
[0084]
[0085]
[0086]
[0087]
[0088]
DETAILED DESCRIPTION
[0089] Unless indicated to the contrary, elements that are the same or functionally the same have been provided with the same reference signs in the figures. It should also be noted that the illustrations in the figures are not necessarily true to scale.
[0090]
[0091] The EUV lithography apparatus 100A has an EUV light source 106A. A plasma source (or a synchrotron), which emits radiation 108A in the EUV range (extreme ultraviolet range), that is to say for example in the wavelength range of 5 nm to 20 nm, can for example be provided as the EUV light source 106A. In the beam-shaping and illumination system 102, the EUV radiation 108A is focused and the desired operating wavelength is filtered out from the EUV radiation 108A. The EUV radiation 108A generated by the EUV light source 106A has a relatively low transmissivity through air, for which reason the beam-guiding spaces in the beam-shaping and illumination system 102 and in the projection system 104 are evacuated.
[0092] The beam-shaping and illumination system 102 illustrated in
[0093] The projection system 104 (also referred to as a projection lens) has six mirrors M1 to M6 for imaging the photomask 120 onto the wafer 124. In this case, individual mirrors M1 to M6 of the projection system 104 may be arranged symmetrically in relation to an optical axis 126 of the projection system 104. It should be noted that the number of mirrors M1 to M6 of the EUV lithography apparatus 100A is not restricted to the number shown. A greater or lesser number of mirrors M1 to M6 may also be provided. Furthermore, the mirrors M1 to M6 are generally curved on their front sides for beam shaping.
[0094]
[0095] The DUV lithography apparatus 100B has a DUV light source 106B. By way of example, an ArF excimer laser that emits radiation 108B in the DUV range at 193 nm, for example, can be provided as the DUV light source 106B.
[0096] The beam-shaping and illumination system 102 illustrated in
[0097] The projection system 104 has a plurality of lens elements 128 and/or mirrors 130 for imaging the photomask 120 onto the wafer 124. In this case, individual lens elements 128 and/or mirrors 130 of the projection system 104 may be arranged symmetrically in relation to an optical axis 126 of the projection system 104. It should be noted that the number of lens elements 128 and mirrors 130 of the DUV lithography apparatus 100B is not restricted to the number shown. A greater or lesser number of lens elements 128 and/or mirrors 130 can also be provided. Furthermore, the mirrors 130 are generally curved on their front sides for beam shaping.
[0098] An air gap between the last lens element 128 and the wafer 124 can be replaced by a liquid medium 132 having a refractive index>1. The liquid medium 132 may be for example high-purity water. Such a structure is also referred to as immersion lithography and has an increased photolithographic resolution. The medium 132 can also be referred to as an immersion liquid.
[0099]
[0100] The data processing apparatus 200 is for example in the form of a computer device including a microprocessor and associated memory, for instance RAM, ROM, etc. The data processing apparatus 200 comprises a virtualization unit 202 and a determination unit 204. The units 202, 204 can be implemented in terms of hardware and/or software, i.e., in the form of program code.
[0101] Mechanical measurement data MEM and optional optical measurement data OEM are provided for the virtualization unit 202. Additionally, it may also be provided with further measurement data, for instance thermal measurement data.
[0102] The mechanical measurement data describe at least the geometry of a respective individual part K1 to KN. The individual parts K1 to KN are shown in exemplary fashion in a not yet assembled state in
[0103] The optical measurement data OEM describe optical properties of one or more of the individual parts K1 to KN. The following should be mentioned here as examples: a relative position of the optical axis or optical face, an (optionally spatially resolved) reflectivity, an (optionally also spatially resolved) transmission.
[0104] The mechanical measurement data MEM may have been acquired (S700 in
[0105] The virtualization unit 202 generates virtualized individual parts K1-KN (S704 in
[0106] Furthermore, construction data ABD are provided for the virtualization unit 202. The construction data ABD describe at least geometric and possibly mechanical connections, interfaces and contact faces between the virtualized individual parts K1 to KN in the yet to be created virtual actual assembly model IMM. In this case, the geometric connections or geometric interfaces reproduce real connections or interfaces, for example a fastening mechanism between the individual parts K1-KN to be assembled.
[0107] The construction data ABD may be provided from a CAD (computer aided design) program and/or from an optics design program (S706 in
[0108] The virtualization unit 202 generates a (virtual) actual assembly model IMM (S708 in
[0109] The actual assembly model IMM can be generated in different ways, with the subsequently determined correction measure KOM then being geared to the corresponding model. As a matter of principle, the correction measure KOM is determined from the actual assembly model IMM and a target assembly model SMM, for example by a comparison of the two models IMM, SMM.
[0110] The target assembly model SMM describes virtual target positions of one or more of the virtualized individual parts K1-KN in the virtually assembled state. In this case, the target assembly model SMM assumes idealized individual parts K1-KN, that is to say those which for example exactly correspond to the CAD model. In this case, the idealized individual parts K1 to KN are linked, for example geometrically linked, to one another via the construction data ABD. The target assembly model SMM can likewise be provided from the CAD (computer aided design) program and/or from an optics design program, that is to say, for example, with the aid of the computer device 210. The correction measures KOM may be provided in the form of data for example to a CNC (computer numerical controlled) milling device 212. Depending on the correction measure or the appropriate data, the CNC milling device 212 mills suitable spacers 304 (see the explanations below) or other compensation elements in automated fashion.
[0111] Below, a contact assembly model is initially explained in conjunction with
[0112] According to the contact assembly model, the virtualized individual parts K1 to KN are geometrically strung together, stacked on one another in the exemplary embodiment. In this case, a base 300 is chosen, for example for the individual part K1. The following individual parts K2 to KN are stacked on one another while taking account of the construction data ABD, that is to say K2 is placed on K1, K3 is placed on K2, . . . , KN is placed on KN-1.
[0113] By way of example, the individual part KN is chosen in such a way that it is such a component that has what is known as a functional face. This means faces critical to the function of the lithography apparatus, for example optical faces or end stops, that is to say stops that limit the maximum movement of optical elements. Therefore, the individual part KN is for example an optical element, for example a mirror, a lens element, an optical grating or a waveplate. In the exemplary embodiment, the individual part KN is a mirror with an optically effective face 302 (optical footprint).
[0114] What now arises by way of stacking the individual parts K1 to KN on one another is that the individual part KN or its functional face (optically effective face 302) is arranged at an actual position P.sub.actual. In
[0115] The determination unit 204 (see
[0116] The spacers 304 can be inserted between the individual part KN and the underlying individual part KN-1. In this case, N can be greater than 5 or greater than 10. Further alternatively, the correction measure can be carried out on the individual part KN itself, for example by way of appropriate material ablation therefrom.
[0117] Further optionally, the individual part KN-1 is a mechatronic component, for example an actuator, and/or a bearing. Actuators for example can be set in such a way that they provide the correction measure. By way of example, in the case of the exemplary embodiment of
[0118] By way of example, the same also applies to a bearing KN-1. By way of example, bearings may include a screwing mechanism, with the aid of which they are easily adjustable. A corresponding procedure may also be implemented in the case of a fastening mechanism, for instance a screwed connection. By way of example, a screw is tightened with less torque in order to compensate the offset or gap V. Further alternatively, a sensor can monitor or verify the correction measure.
[0119] The above-described, determined correction measures can optionally be verified in the virtual actual assembly model IMM. To this end, the actual assembly model IMM is generated again—with application of the determined correction measure—and step S710 is repeated.
[0120] Subsequently, the projection lens 104 is assembled from the individual parts K1 to KN (S712 in
[0121] Furthermore,
[0122] The aforementioned target point assembly model is explained below on the basis of
[0123] Otherwise, the features described in
[0124] In the exemplary embodiments according to
[0125] Thus,
[0126] The above-described actual assembly models IMM can be determined with the aid of homogenous coordinates and/or Euler angles, as illustrated below in
[0127] The components K1, K2 (corresponds to KN-1) and K3 (corresponds to KN-1) are arranged in a manner deviating from respective target positions (also referred to as “design” or “target pose” below) on account of manufacturing tolerances.
[0128] Hence, the problem arising is that of determining the thicknesses that the positioning elements Sp1, Sp2 and Sp3 (corresponding to the spacers 304 for example) should have so that the functional face CS_F_actual is at the target position CS_F_target in relation to the base CS_B, and to be precise more accurately than the summation of the manufacturing tolerances, usually even more accurately than any individual manufacturing tolerance.
[0129] The coordinate system CS_K represents the body K (virtualization) and is defined by: CS.orig=origin, CS.ex=X-axis, CS.ey=Y-axis and CS.ez=Z-axis, where (CS_K){circumflex over ( )}B refers to the coordinates of CS_K in CS_B.
[0130] The following calculation example should illustrate this:
[0131] Target positions given in CS_B:
TABLE-US-00001 (CS_F_target){circumflex over ( )}B = [95, 200, 305] mm, Ry = −14° CS_F_target = name: ‘CS_F’ base: ‘CS_Base’ orig: [95 200 305] ex: [ 0.9703 0 0.2419] ey: [ 0 1 0 ] ez: [−0.2419 0 0.9703]
[0132] 3 Spacer-reference points and effective directions:
TABLE-US-00002 Sp1 = name: ‘Spc1’ Sp2 = name: ‘Spc2’ Sp3 = name: ‘Spc3’ base: ‘CS_Base’ base: ‘CS_Base’ base: ‘CS_Base’ orig: [150 300 190] orig: [340 300 250] orig: [410 300 320] ez: [−1 0 2]/sqrt(5) ez: [−1 0 2]/sqrt(5) ez: [−1 0 0]
[0133] Let CS_K3 be measured in CS_B:
TABLE-US-00003 (CS_K3_actual){circumflex over ( )}B = [103 210 167], Ry = −17°, Rz = 182° CS_K3_actual = name: ‘CS_K3’ base: ‘CS_Base’ orig: [103 210 167] ex: [−0.9557 −0.0298 −0.2928] ey: [ 0.0334 −0.9994 −0.0072] ez: [−0.2924 −0.0167 0.9562]
[0134] Let CS_F be measured in CS_K3_actual:
TABLE-US-00004 (CS_F_actual){circumflex over ( )}K3 = [−25 0 126] mm, Ry = −5°, Rz = 179° CS_F_actual_K3 = name: ‘CS_F’ base: ‘CS_K3’ orig: [−25 0 126] ex: [−0.9960 0.0175 −0.0871] ey: [−0.0174 −0.9998 −0.0015] ez: [−0.0872 0 0.9962]
[0135] Calculation of the actual pose or actual position of CS_F in CS_B by way of a coordinate transformation from CS_K3 to CS_B, e.g., in homogenous coordinates:
TABLE-US-00005 (CS_F_actual){circumflex over ( )}B = K3_2_B * (CS_F_actual){circumflex over ( )}K3 K3_2_B = −0.9557 0.0334 −0.2924 103.0000 −0.0298 −0.9994 −0.0167 210.0000 −0.2928 −0.0072 0.9562 167.0000 0 0 0 1.0000
[0136] with the 4×4 transformation matrix K3_2_B
TABLE-US-00006 CS_F_actual = name: ‘CS_F’ base: ‘CS_Base’ orig: [90.0542 208.6420 294.7950] ex: [ 0.9780 0.0137 0.2082] ey: [−0.0163 0.9998 0.0109] ez: [−0.2080 −0.0140 0.9780]
[0137] Offset CS_F_actual from CS_F target in CS_B coordinates (IS_abs) and CS_F target coordinates (IS_rel), and assessment of the actual pose or actual position (comparison with the specification Tol_rel):
TABLE-US-00007 Pose CS_F wrt CS_Base: [mm, mrad] Tx Ty Tz Rx Ry Rz Target: 95.000 200.000 305.000 −0.000 −244.34 −0.000 Actual: 90.054 208.642 294.795 14.344 −209.491 16.674 I-S_abs: −4.946 8.642 −10.205 14.344 34.855 16.674 I-S_rel: −7.268 8.642 −8.705 14.039 34.830 13.202 Tol_rel: 2.000 2.000 1.000 5.000 5.000 2.000
[0138] Actuator travel calculation in CS_B, where Sp.ez is the unit vector in the effective direction of the positioning element (for example, the effective direction is the thickness in which it should bring about the displacement of K3 into the target position), Sp.orig is the target position of K3 at the reference point (K3-side rest of the positioning element), and sp_actual is the actual position of K3 at the reference point:
TABLE-US-00008 sp_delta = dot(sp_is, Sp.ez) where sp_is = Sp.orig − sp_actual = spacer point displacement from the actual to the target Change [mm] Sp1 5.04 Sp2 11.83 Sp3 −6.29
[0139] Although the present disclosure has been described on the basis of exemplary embodiments, it can be modified in various ways.
LIST OF REFERENCE SIGNS
[0140] 100A EUV lithography apparatus [0141] 100B DUV lithography apparatus [0142] 104 Beam-shaping and illumination system [0143] 104 Projection system [0144] 106A EUV light source [0145] 106B DUV light source [0146] 108A EUV radiation [0147] 108B DUV radiation [0148] 110 Mirror [0149] 112 Mirror [0150] 114 Mirror [0151] 116 Mirror [0152] 118 Mirror [0153] 120 Photomask [0154] 122 Mirror [0155] 124 Wafer [0156] 126 Optical axis [0157] 128 Lens element [0158] 130 Mirror [0159] 132 Medium [0160] 200 Data processing apparatus [0161] 202 Virtualization unit [0162] 204 Determination unit [0163] 206 Measuring device [0164] 208 Measuring device [0165] 210 Computer device [0166] 212 CNC milling device [0167] 300 Base [0168] 302 Optically effective face [0169] 304 Spacer [0170] 306 Force frame [0171] 308 Optical element [0172] ABD Construction data [0173] IMM Actual assembly model [0174] KOM Correction measure [0175] K1-KN Individual parts [0176] P.sub.target Target position [0177] P.sub.actualActual position [0178] P.sub.actual_KN-1 Actual position [0179] P.sub.actual_K2 Actual position [0180] MEM Mechanical measurement data [0181] M1 Mirror [0182] M2 Mirror [0183] M3 Mirror [0184] M4 Mirror [0185] M5 Mirror [0186] M6 Mirror [0187] OEM Optical measurement data [0188] SMM Target assembly model [0189] S700-S716 Method steps [0190] V Gap