Method for adusting a first element of a lithography apparatus towards a second element of a lithography apparatus by a tunable spacer
11460780 · 2022-10-04
Assignee
Inventors
Cpc classification
G02B7/198
PHYSICS
G03F7/70833
PHYSICS
G03F7/70258
PHYSICS
International classification
Abstract
A method adjusts a first element of a lithography apparatus toward a second element of the lithography apparatus via a tunable spacer which is arranged between the first element and the second element. The method includes: determining an actual location of the first element; determining a nominal location of the first element; unloading the tunable spacer; adjusting a height of the tunable spacer to bring the first element from the actual location to the nominal location; and loading the tunable spacer.
Claims
1. A method of adjusting a first element of a lithography apparatus relative to a second element of the lithography apparatus via a tunable spacer arranged between the first and second elements, the method comprising: a) removing at least a portion of a weight of the first element from the tunable spacer; b) while the weight of the first element is at least partially removed from the tunable spacer, adjusting a height of the tunable spacer so that the tunable spacer has an adjusted height; and c) while the tunable spacer has the adjusted height, putting the weight of the first element on the tunable spacer to adjust the first element relative to the second element, wherein: before a) while the weight of the first element is on the tunable spacer, the first element has a first location; after c) while the weight of the first element is on the tunable spacer, the first element has a second location; and the second location of the first element is different from the first location of the first element.
2. The method of claim 1, further comprising, before a): determining the first location of the first element; and determining the second location of the first element.
3. The method of claim 2, wherein determining the first location of the first element comprises measuring the first location of the first element or calculating the first location of the first element.
4. The method of claim 2, wherein determining the second location of the first element comprises calculating the second location of the first element.
5. The method of claim 2, wherein determining the first location of the first element comprises determining the first location of the first element relative to the second element.
6. The method of claim 1, wherein b) comprises steplessly adjusting the height of the tunable spacer.
7. The method of claim 1, wherein a) comprises lifting the first element from the tunable spacer to at least partially remove the weight of the first element from the tunable spacer.
8. The method of claim 1, wherein c) comprises settling the first element on the tunable spacer to put the weight of the first element on the tunable spacer.
9. The method of claim 1, wherein b) comprises using a gear mechanism to adjust the height of the tunable spacer, wherein the gear mechanism comprises a part of the tunable spacer.
10. The method of claim 9, wherein b) comprises adjusting the height of the tunable spacer via a linear movement of a displacement element of the tunable spacer relatively toward a housing element of the tunable spacer along a first spatial direction.
11. The method of claim 10, wherein, during b), the gear mechanism transfers the linear movement of the displacement element along the first spatial direction into a linear movement of the displacement element along a second spatial direction different from the first spatial direction.
12. The method of claim 10, further comprising, during the linear movement of the displacement element relatively toward the housing element, gliding an inclined gliding surface of the displacement element on an inclined gliding surface of the housing element.
13. The method of claim 10, further comprising using an adjustment element to move the displacement element relatively toward the housing element along the first spatial direction.
14. The method of claim 1, wherein b) comprises bringing the tunable spacer from a non-deflected status into a deflected status, and a height of the tunable spacer in the deflected status is greater than a height of the tunable spacer the non-deflected status.
15. The method of claim 1, comprising keeping the tunable spacer between the first and second elements throughout a) to c).
16. The method of claim 1, wherein, during c), the tunable spacer is force-free.
17. The method of claim 1, wherein: a) comprises lifting the first element from the tunable spacer to at least partially remove the weight of the first element from the tunable spacer; and b) comprises steplessly adjusting the height of the tunable spacer.
18. The method of claim 17, wherein c) comprises settling the first element on the tunable spacer to put the weight of the first element on the tunable spacer.
19. The method of claim 18, further comprising, before a): determining the first location of the first element; and determining the second location of the first element.
20. The method of claim 1, wherein: a) comprises lifting the first element from the tunable spacer to at least partially remove the weight of the first element from the tunable spacer; b) comprises using a gear mechanism to adjust the height of the tunable spacer; and the gear mechanism comprises a part of the tunable spacer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the text that follows, the disclosure is explained in more detail on the basis of illustrative embodiments and with reference to the accompanying figures.
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DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(13) Identical elements or elements having an identical function have been provided with the same reference signs in the figures, unless indicated to the contrary. It should also be noted that the illustrations in the figures are not necessarily true to scale.
(14)
(15) The EUV lithography apparatus 100A includes 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.
(16) The beam shaping and illumination system 102 illustrated in
(17) The projection system 104 (also referred to as 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 can 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 represented. A greater or lesser number of mirrors M1 to M6 can also be provided. Furthermore, the mirrors M1 to M6 are generally curved on their front face for beam shaping.
(18)
(19) 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.
(20) The beam shaping and illumination system 102 illustrated in
(21) 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 can 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 represented. 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 face for beam shaping.
(22) An air gap between the last lens element 128 and the wafer 124 can be replaced by a liquid medium 132 which has a refractive index of >1. The liquid medium 132 can be high-purity water, for example. Such a construction 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.
(23)
(24) The optical system 200 includes a first element 202. The first element 202 can be, for example, an optical element, such as one of the mirrors 110, 112, 114, 116, 118, 122, 130, M1 to M6, one of the lens elements 128 or a stop. However, the first element 202 can also be a force frame, an adjusting element or actuator for aligning an optical element, an end stop of an optical element, part of an active vibration isolation system (AVIS), such as for suspension of a sensor frame, or similar.
(25) The optical system 200 moreover includes a second element 204. The second element 204 can be a base of the optical system 200. The base can also be designated as a fixed world of the optical system 200. For example, the second element 204 can also be an aforementioned force frame of the optical system 200 or of the EUV lithography apparatus 100A. In this case, the first element 202 can be, for example, an optical element as explained above, which is carried or supported by the second element 204.
(26) The first element 202 has in particular six degrees of freedom with respect to the second element 204, namely three translational degrees of freedom along an x direction x, a y direction y and a z direction z, respectively, and three rotational degrees of freedom about the x direction x, the y direction y and the z direction z, respectively. In other words, a position and an orientation of the first element 202 can be determined or described with the aid of the six degrees of freedom. The directions x, y, z can also be designated as spatial directions.
(27) The “position” of the first element 202 is to be understood in particular as its coordinates or the coordinates of a measurement point provided on the first element 202 with respect to the x direction x, the y direction y and the z direction z. The “orientation” of the first element 202 is to be understood in particular as its tilt with respect to the three spatial directions x, y, z. In other words, the first element 202 can be tilted about the x direction x, the y direction y and/or the z direction z. This gives the six degrees of freedom for the position and/or orientation of the first element 202. A “location” of the first element 202 includes both its position and its orientation.
(28) An interface 206 is provided between the first element 202 and the second element 204. The first element 202 is coupled to the second element 204 at the interface 206. A surface 208 of the first element 202 and a surface 210 of the second element 204 are assigned to the interface 206. The surfaces 208, 210 face towards each other.
(29) Before the optical system 200 is started up, for example before exposure operation, it is desirable to adapt the position and/or orientation of the first element 202. For this purpose, for example, the first element 202 can be adjusted or oriented in a coordinate system defined by the spatial directions x, y, z, or the first element 202 is adjusted or oriented relative to the second element 204.
(30) In the present case, “adjusting” can be understood as bringing the first element 202 from an actual position IL (shown in
(31) The adjustment of the first element 202 can be effected, for example, with the aid of spacers. For this purpose, desired thicknesses or heights of such spacer elements are first of all determined, for example with the aid of a virtual assembly model or with the aid of short-circuit measurements. A “short-circuit measurement” is to be understood in the present case as meaning that the optical system 200 is assembled completely with standard or nominal spacers and then measured.
(32) In order to avoid long processing times, for example on account of the grinding of the spacers, a modular system of spacers of very different heights or thicknesses is made available. The spacers are ground here with a precision of ±2 μm, in order to achieve the desired process tolerances. A plurality of spacers can be combined to form a spacer stack. On account of the small increments of 10 μm and the usual desire for a large adjustment range of up to 0.5 mm, it is desirable to make available a large number of spacers. For example, over 1000 spacers have to be kept in stock for a projection system 104 of the kind explained above. The complicated handling and the logistics of the spacers drive up the costs. Moreover, long processing times have to be expected. The production and cleaning of high-precision spacers is also very complex.
(33) In order to make adjustment easier in relation to known spacers, a tunable spacer 300 is provided at the interface 206. With the spacer 300 shown in
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(35) The first housing element 302 includes a first gliding plane or first gliding surface 308, which is inclined at a first angle of inclination α1 relative to an outer face 310 of the first housing element 302. The angle of inclination α1 is can be smaller than 10°, for example 5° to 8°. Accordingly, the second housing element 304 has a second gliding plane or second gliding surface 312, which is inclined at a second angle of inclination α2 relative to an outer face 314 of the second housing element 304. The angles of inclination α1, α2 can be of the same size. Alternatively, the angles of inclination α1, α2 can also be of different size. The outer faces 310, 314 bear on the surfaces 208, 210 of the elements 202, 204. The angles of inclination α1, α2 can also be designated as wedge angles.
(36) The spacer 300 moreover includes a displacement element 316 arranged between the housing elements 302, 304 and linearly displaceable relative to the latter. The displacement element 316 is wedge-shaped. Therefore, the displacement element 316 can also be designated as a wedge element. The displacement element 316 can be configured with mirror symmetry in relation to the plane of symmetry 306.
(37) The displacement element 316 includes a first gliding plane or first gliding surface 318, which bears and can slide on the first gliding surface 308 of the first housing element 302. The displacement element 316 moreover includes a second gliding plane or second gliding surface 320, which bears and can slide on the second gliding surface 312 of the second housing element 304. The gliding surfaces 318, 320 are positioned with mirror symmetry in relation to the plane of symmetry 306.
(38) The first gliding surface 318 is inclined relative to the plane of symmetry 306 at a first angle of inclination β1, which can be equal to the first angle of inclination α1. The second gliding surface 320 is inclined relative to the plane of symmetry 306 at a second angle of inclination β2, which can be equal to the second angle of inclination α2. In the case where the angles of inclination α1, α2 are of different sizes, the angles of inclination β1, β2 are also of different sizes, although the first angles of inclination α1, β1 and the second angles of inclination α2, β2 are in each case of the same size. For example, the first angles of inclination α1, β1 or the second angles of inclination α2, β2 can also be equal to 0°, such that the corresponding gliding surfaces 308, 318 or 312, 320 are positioned parallel to the plane of symmetry 306. The angles of inclination β1, β2 can also be designated as wedge angles.
(39) The gliding surfaces 308, 312, 318, 320 are part of a gear mechanism 322 of the spacer 300. The gear mechanism 322 is designed to convert a linear movement of the displacement element 316 in a spatial direction, for example in the x direction x, into a linear movement of at least one of the housing elements 302, 304 in a spatial direction differing from the spatial direction in which the displacement element 316 is shifted, for example the z direction z. That is to say, in the orientation in
(40) The spacer 300 can moreover include an optional spring element 326. The spring element 326 can be a cylindrical spring, such as a compression spring. The spring element 326 is positioned between the displacement element 316 and a fixed bearing 328. For example, the spring element 326 couples the displacement element 316 to the fixed bearing 328. The fixed bearing 328 can be, for example, part of the housing elements 302, 304 of the spacer 300.
(41) The spacer 300 can be brought from a non-deflected state Z1, shown in
(42) As the spacer 300 is brought from the non-deflected state Z1 to the deflected state Z2, the spring element 326 is brought reversibly from an uncompressed or untensioned state Z10 to a compressed or tensioned state Z20. In the tensioned state Z20, the spring element 326 exerts a spring force F, such as a compressive force, on the displacement element 316, such that the displacement element 316 is pretensioned in the direction of the non-deflected state Z1.
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(44) In the geometry shown in
(45) The shallow angle of inclination α1, α2, β1, β2 also increases the static friction between the displacement element 316 and the housing elements 302, 304. The spacer 300 is therefore self-locking. That is to say, the spacer 300 cannot be brought from the deflected state Z2 to the non-deflected state Z1 by application of forces to the outer faces 310, 314 of the housing elements 302, 304. Therefore, compared to a non-adjustable spacer, the spacer 300 is no less stiff and, moreover, has no lesser stability.
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(47) The spacer 300 includes two adjustment elements 332, 334. The adjustment elements 332, 334 could be screws, such as cap screws. A first adjustment element 332 and a second adjustment element 334 are provided. The adjustment elements 332, 334 can be part of the gear mechanism 322. With the aid of the adjustment elements 332, 334, the displacement element 316 can be moved linearly along the displacement path Δx counter to the spring force F of the spring element 326, in order to bring the spacer 300 from the non-deflected state Z1 to the deflected state Z2. The adjustment elements 332, 334 can be actuated alternately.
(48) To bring the spacer 300 from the deflected state Z2 to the non-deflected state Z1, the adjustment elements 332, 334 are released again, as a result of which the spring element 326 again brings the spacer 300 automatically from the deflected state Z2 to the non-deflected state Z1.
(49) In the case where the spacer 300 has no spring element 326, the spacer 300 can also be brought from the deflected state Z2 to the non-deflected state Z1 by a striking action against the loosened adjustment elements 332, 334. Moreover, the spacer 300 can also alternatively include only one adjustment element 332, 334.
(50) The first housing element 302 shown in a schematic perspective view in
(51) The first housing element 302 moreover includes a rear wall 344 with a perforation 346 through which the second adjustment element 334 is guided. The aforementioned fixed bearing 328 of the spring element 326 can be part of the rear wall 344. The first housing element 302 has a first guide rail 348, and a second guide rail 350 arranged parallel to and at a distance from the first guide rail 348. The guide rails 348, 350 can also be designated as guide surfaces or guide walls. As
(52) The displacement element 316 shown in a schematic perspective view in
(53) Each receiving portion 354, 356 has a threaded bore (not shown) into which the respective adjustment element 332, 334 can be screwed. A receiving region 358, which is formed as a perforation, serves to receive the spring element 326. The displacement element 316 can be produced from a metal material, for example from a steel alloy or an aluminium alloy.
(54) The spacer 300 has many advantages over known spacers. The accuracy of the adjustment of the height h is not achieved through high-precision and therefore costly production, but with the aid on a non-sensitive adjustment mechanism in the form of the gear mechanism 322. It is not necessary to exchange the spacer 300 in order to adjust the height h. Rather, lateral access to the adjustment elements 332, 334 is sufficient to adjust the height h. With the spacer 300, it is possible to achieve at least the same adjustment accuracy, that is to say the graduation of the height h, as is possible with the aforementioned modular concept. The spacer 300 provides stiffness and stability that are no poorer than those of a known spacer stack.
(55)
(56) In a step S1, the actual location IL of the first element is determined. After that, the nominal location SL of the first element 202 is determined in a step S2. In a step S3, the spacer 300 is unloaded. This can be done by lifting the first element 202 from the spacer 300. Consequently, the height h of the spacer 300 is adjusted in a step S4 in order to bring the first element 20 from the actual location IL into the nominal location SL. This can be done while leaving the spacer 300 sandwiched between the two elements 202, 204. Finally, the spacer 300 is loaded again in a step S5. For example, the spacer 300 is loaded with the weight G of the first element 202.
(57) Although the present disclosure has been described on the basis of illustrative embodiments, it is modifiable in diverse ways.
LIST OF REFERENCE SIGNS
(58) 100A EUV lithography apparatus 100B DUV lithography apparatus 102 beam shaping and illumination system 104 projection system 106A EUV light source 106B DUV light source 108A EUV radiation 108B DUV radiation 110 mirror 112 mirror 114 mirror 116 mirror 118 mirror 120 photomask 122 mirror 124 wafer 126 optical axis 128 lens element 130 mirror 132 medium 200 optical system 202 element 202′ element 204 element 206 interface 208 surface 210 surface 212 fastening element 300 spacer 302 housing element 304 housing element 306 plane of symmetry 308 gliding surface 310 outer face 312 gliding surface 314 outer face 316 displacement element 318 gliding surface 320 gliding surface 322 gear mechanism 324 arrow 326 spring element 328 fixed bearing 330 perforation 332 adjustment element 334 adjustment element 336 perforation 338 groove 340 groove 342 receiving region 344 rear wall 346 perforation 348 guide rail 350 guide rail 352 perforation 354 receiving portion 356 receiving portion 358 receiving region F spring force G weight h height h′ height IL actual position M1 mirror M2 mirror M3 mirror M4 mirror M5 mirror M6 mirror SL nominal position S1 step S2 step S3 step S4 step S5 step x spatial direction y spatial direction z spatial direction Z1 state Z2 state Z10 state Z20 state α1 angle of inclination α2 angle of inclination β1 angle of inclination β2 angle of inclination Δh height change Δx displacement path