Optical element for the beam guidance of imaging light in projection lithography
11029606 · 2021-06-08
Assignee
Inventors
Cpc classification
G03F7/70141
PHYSICS
G03F7/70316
PHYSICS
G03F7/70258
PHYSICS
International classification
Abstract
An optical element is configured to guide imaging light in projection lithography. The optical element has a main body and at least one optical surface carried by the main body. At least one compensation weight element, which is attached to the main body, serves for a weight compensation of a figure deformation of the optical surface caused by gravity. This results in an optical element with a small figure deformation at the use location.
Claims
1. An optical element, comprising: a main body; an optical surface supported by the main body; a compensation weight element supported by the main body, the compensation weight element comprising a compensation weight; and a lever connecting the compensation weight to the main body in a connection region so that a direction of a gravitational force of the compensation weight, proceeding from a center of mass thereof, extends a distance from the connection region, wherein: the lever has an adjustable length, and/or the lever has an adjustable direction; and the compensation weight element is configured to compensate a figure deformation of the optical surface caused by gravity.
2. The optical element of claim 1, wherein the optical element comprises a mirror, and the compensation weight element is supported by a side of the main body that faces away from the optical surface.
3. The optical element of claim 2, wherein the compensation weight element is supported by an edge of the main body.
4. The optical element of claim 1, wherein the optical element comprises a mirror, and the compensation weight element is supported by an edge of the main body.
5. The optical element of claim 1, wherein the compensation weight element is supported by the main body in a region of a center-of-mass axis of the optical element.
6. The optical element of claim 1, further comprising a plurality of bearing sites configured so that the optical element is bearable in a bearing receptacle via the plurality of bearing sites, wherein the compensation weight element is between two bearing sites that are adjacent each other in a circumferential direction of the optical element.
7. The optical element of claim 6, further comprising a plurality of compensation weight elements, wherein respectively one compensation weight element is arranged between all bearing sites that are adjacent to one another in the circumferential direction.
8. The optical element of claim 1, wherein the compensation weight element is supported by the main body in an interlocking manner.
9. The optical element of claim 1, wherein the compensation weight element is supported by the main body in an integrally bonded manner.
10. The optical element of claim 1, wherein the lever has an adjustable length.
11. The optical element of claim 1, further comprising an additional element connecting the compensation weight element to the main body.
12. The optical element of claim 1, further comprising a plurality of compensation weight elements, wherein each compensation weight element is configured compensate a figure deformation of the optical surface caused by gravity.
13. The optical element of claim 12, wherein: the optical element comprises a mirror; and at least one of the following holds: at least one of the plurality of compensation weight elements is supported by a side of the main body that faces away from the optical surface; and at least one of the plurality of compensation weight elements is supported by an edge of the main body.
14. The optical element of claim 12, wherein at least one of the compensation weight elements is supported by the main body in a region of a center-of-mass axis of the optical element.
15. An imaging optical unit, comprising: an optical element according to claim 1, wherein the imaging optical unit is configured to image an object field into an image field.
16. An optical system, comprising: an illumination optical unit configured to illuminate an object field; and an imaging optical unit configured to image an object field into an image field, wherein the imaging optical unit comprises an optical element according to claim 1.
17. A projection exposure apparatus, comprising: a light source configured to produce illumination light; an illumination optical unit configured to illuminate an object field with the illumination light; and an imaging optical unit configured to image an object field into an image field, wherein the imaging optical unit comprises an optical element according to claim 1.
18. A method of using a projection exposure apparatus comprising an illumination optical unit and an imaging optical unit, the method comprising: using the illumination optical unit configured to illuminate an object in an object field; and using the imaging optical unit configured to image an object field into an image field, wherein the imaging optical unit comprises an optical element according to claim 1.
19. The optical element of claim 1, wherein the lever has an adjustable direction.
20. A method, comprising: producing a blank of an optical element taking account of a negative deformation allowance so that the optical element has a desired figure only under a gravitational force of at least one compensation weight; transporting the blank to a use location of an apparatus for projection lithography; and attaching the at least one compensation weight element to a main body of the optical element taking account of a gravitational acceleration at the use location for weight compensation of a figure deformation of an optical surface of the optical element caused by gravity, wherein attaching the at least one compensation weight element to the main body of the optical element comprises: a) attaching at least one raw compensation weight element to the main body of the optical element, the at least one raw compensation weight element being designed to overcompensate an expected effect of gravity on the figure deformation of the optical surface of the optical element and b) after a), removing part of the at least one raw compensation weight element to reduce its weight to achieve a desired figure deformation of the optical surface of the optical element.
21. The method of claim 20, wherein the method results in the optical surface of the optical element having a deformation from a theoretical best fit which is less than 350 pm.
22. The method of claim 20, wherein the method results in the optical surface of the optical element having a deformation from a theoretical best fit which is approximately 13 pm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Exemplary embodiments of the disclosure is explained in greater detail below with reference to the drawings, in which:
(2)
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EXEMPLARY EMBODIMENTS OF THE DISCLOSURE
(18) A microlithographic projection exposure apparatus 1 has a light source 2 for illumination light or imaging light 3. The light source 2 is an EUV light source, which produces light in a wavelength range of e.g. between 5 nm and 30 nm, in particular between 5 nm and 15 nm. The light source 2 can be a plasma-based light source (laser-produced plasma (LPP), gas-discharge produced plasma (GDP)) or else a synchrotron-based light source, for example a free electron laser (FEL). In particular, the light source 2 may be a light source with a wavelength of 13.5 nm or a light source with a wavelength of 6.9 nm. Other EUV wavelengths are also possible. In general, even arbitrary wavelengths are possible for the illumination light 3 guided in the projection exposure apparatus 1, for example visible wavelengths or else other wavelengths which may find use in microlithography (for example, DUV, deep ultraviolet) and for which suitable laser light sources and/or LED light sources are available (e.g. 365 nm, 248 nm, 193 nm, 157 nm, 129 nm, 109 nm). A beam path of the illumination light 3 is depicted very schematically in
(19) An illumination optical unit 6 serves to guide the illumination light 3 from the light source 2 to an object field 4 in an object plane 5. Using a projection optical unit or imaging optical unit 7, the object field 4 is imaged into an image field 8 in an image plane 9 with a predetermined reduction scale.
(20) In order to facilitate the description of the projection exposure apparatus 1 and the various embodiments of the projection optical unit 7, a Cartesian xyz-coordinate system is indicated in the drawing, from which system the respective positional relationship of the components illustrated in the figures is evident. In
(21) In the projection optical unit 7, the object field 4 and the image field 8 have a bent or curved embodiment and, in particular, an embodiment shaped like a partial ring. A radius of curvature of this field curvature can be 81 mm on the image side. A corresponding ring field radius of the image field is defined in WO 2009/053023 A2. A basic form of a boundary contour of the object field 4 or of the image field 8 has a corresponding bend. Alternatively, it is possible to embody the object field 4 and the image field 8 with a rectangular shape. The object field 4 and the image field 8 have an x/y-aspect ratio of greater than 1. Therefore, the object field 4 has a longer object field dimension in the x-direction and a shorter object field dimension in the y-direction. These object field dimensions extend along the field coordinates x and y.
(22) In an exemplary embodiment of the projection optical unit 7, an x-dimension of the image field of 26 mm and a y-dimension of the image field 8 of 1.2 mm are present.
(23) Accordingly, the object field 4 is spanned by the first Cartesian object field coordinate x and the second Cartesian object field coordinate y. The third Cartesian coordinate z, which is perpendicular to these two object field coordinates x and y, is also referred to as normal coordinate below.
(24) The exemplary embodiment depicted in
(25) In the embodiment of the projection optical unit 7 according to
(26) The imaging by way of the projection optical unit 7 is implemented on the surface of a substrate 11 in the form of a wafer, which is carried by a substrate holder 12. The substrate holder 12 is displaced by a wafer or substrate displacement drive 12a.
(27)
(28) The projection exposure apparatus 1 is of the scanner type. Both the reticle 10 and the substrate 11 are scanned in the y-direction during the operation of the projection exposure apparatus 1. A stepper type of the projection exposure apparatus 1, in which a stepwise displacement of the reticle 10 and of the substrate 11 in the y-direction is effected between individual exposures of the substrate 11, is also possible. These displacements are effected synchronously to one another by an appropriate actuation of the displacement drives 10b and 12a.
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(31) The object plane 5 lies parallel to the image plane 9.
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(34) The mirrors M1 to M10 are embodied as free-form surfaces which cannot be described by a rotationally symmetric function. Other embodiments of the projection optical unit 7, in which at least one of the mirrors M1 to M10 is embodied as a rotationally symmetric asphere, are also possible. An asphere equation for such a rotationally symmetric asphere is known from DE 10 2010 029 050 A1. It is also possible for all mirrors M1 to M10 to be embodied as such aspheres.
(35) A free-form surface can be described by the following free-form surface equation (equation 1):
(36)
(37) The following applies to the parameters of this equation (1):
(38) Z is the sag of the free-form surface at the point x, y, where x.sup.2+y.sup.2=r.sup.2. Here, r is the distance from the reference axis of the free-form equation
(x=0; y=0).
(39) In the free-form surface equation (1), C.sub.1, C.sub.2, C.sub.3, . . . denote the coefficients of the free-form surface series expansion in powers of x and y.
(40) In the case of a conical base area, c.sub.x, c.sub.y is a constant corresponding to the vertex curvature of a corresponding asphere. Thus, c.sub.x=1/R.sub.x and c.sub.y=1/R.sub.y y applies. Here, k.sub.x and k.sub.y each correspond to a conical constant of a corresponding asphere. Thus, equation (1) describes a biconical free-form surface.
(41) An alternative possible free-form surface can be generated from a rotationally symmetric reference surface. Such free-form surfaces for reflection surfaces of the mirrors of projection optical units of microlithographic projection exposure apparatuses are known from US 2007-0058269 A1.
(42) Alternatively, free-form surfaces can also be described with the aid of two-dimensional spline surfaces. Examples for this are Bezier curves or non-uniform rational basis splines (NURBS). By way of example, two-dimensional spline surfaces can be described by a grid of points in an xy-plane and associated z-values, or by these points and gradients associated therewith. Depending on the respective type of the spline surface, the complete surface is obtained by interpolation between the grid points using for example polynomials or functions which have specific properties in respect of the continuity and the differentiability thereof. Examples for this are analytical functions.
(43) The used reflection surfaces of the mirrors M1 to M10 are carried by main bodies.
(44) The main body 18 can be manufactured from glass, from ceramics or from glass ceramics. The material of the main body 18 can be matched in such a way that its coefficient of thermal expansion at the selected operating temperature of the mirror M lies very close to the value of 0 and ideally is exactly 0. Zerodur® is an example of such a material.
(45)
(46) The mirror M shown in
(47) A compensation weight element 20 is attached to the main body 18 in the embodiment of the mirror M according to
(48) The compensation weight element 20 is attached to the rear side 21 of the main body 18. The compensation weight element 20 is attached to the main body 18 in the region of a center-of-mass axis SP of the mirror M that is indicated schematically in
(49) The compensation weight element 20 is connected to the main body 18 in interlocking fashion by way of an undercut catch that is not illustrated in any more detail. To this end, the main body 18 has a recess with an undercut, into which a section of the compensation weight element 20 that is complementary to the recess is latched or clipped, engaging behind this undercut. Alternatively, the compensation weight element 20 can also be connected to the main body 18 in an integrally bonded manner and/or by way of a screwed connection.
(50) Any further embodiment that is not illustrated here, the compensation weight element 20 also can be connected to the main body 18 by way of an interposed interface plate. The interface plate, in turn, can be connected firstly to the compensation weight element 20 and secondly to the main body 18 in an interlocking or integrally bonded manner, as already explained above in conjunction with the connection of the compensation weight element 20 to the main body 18.
(51) The main body 18 has a plurality of bearing sites 22. These are three bearing sites 22 in the illustrated exemplary embodiment. By way of these bearing sites 22, the main body 18 is borne in a bearing receptacle of the holding frame, not illustrated here, of the mirror M.
(52) The following procedure is adopted when producing an adjusted optical element in the style of the mirror M according to
(53) First, a blank of the mirror M is produced, taking into account a negative deformation allowance at a production location. Here, the optical surface 19 is preformed in such a way that it only has the desired figure under the force of at least one compensation weight element in the style of the compensation weight element 20. Subsequently, the blank that is pre-manufactured in this way is moved to the use location of the projection exposure apparatus. There, at least one compensation weight element in the style of the compensation weight element 20 is attached to the main body 18 of the mirror M, taking account of the gravitational acceleration at the use location, for the purposes of compensating the weight of a figure deformation of the optical surface 19 caused by gravity. Provided that the gravitational acceleration at the use location is sufficiently well known, it is possible to interchange the two last steps of “moving the blank to the use location” and “attaching the at least one compensation weight element”. Subsequently, the mirror is adjusted at its use location in the projection exposure apparatus.
(54) In a variant of the mirror production method, a raw compensation weight element can be attached immediately to the main body of the optical element during the production of the blank of the optical element, the raw compensation weight element overcompensating the expected effect of the figure deformation of the optical surface caused by gravity. For the purposes of producing the adjusted optical element, the compensation weight element then can be made lighter in respect of its weight effect on the optical surface by removing part of the compensation weight element, for example by ablation, until the desired weight compensation effect for achieving the desired compensation of the figure deformation is achieved. This variant of the production method avoids subsequently attaching a discharge element to the already completed optical surface, which could lead to an unwanted figure deformation in its own right.
(55) In an embodiment of the mirror M as an asymmetric mirror made of ceramics with a mass of 500 kg, a diameter of 90 cm and a thickness of 20cm, a theoretical fit deformation, caused by a gravitational acceleration variation of 0.1%, is approximately 350 pm. As a result of the weight compensation described above via a compensation weight element, this effect is reducible to approximately 13 pm. Thus, after compensation, less than 4% of the original figure deformation remain.
(56) In general, it is possible to achieve a compensation of the figure deformation caused by gravity to a value of less than 10% of the original figure deformation caused by gravity.
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(58) In addition to the central compensation weight element 20 in the region of the center-of-mass axis SP, the main body 18 of the mirror M according to
(59) In a further, not illustrated embodiment of an arrangement of compensation weight elements that otherwise corresponds to the embodiment according to
(60)
(61) In the arrangement according to
(62) Other ratios B/A in the range of between 1.1 and 10 are also possible. The radial compensation weight elements 26 can all have the same distance A from the central compensation weight element 20. Alternatively, it is possible to provide different distances A.sub.1, A.sub.2, . . . between the radial compensation weight elements 26 and the central compensation weight element 20.
(63) Overall, three radial compensation weight elements 26 and six circumferential compensation weight elements 23 are present in arrangement of the compensation weight elements according to
(64) While, in principle, having the same arrangement of the compensation weight elements as in
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(66) When the mirror M is oriented in such a way that the rear side thereof points upwards, a direction of the gravitational force G of the compensation weight 28 of the torque compensation weight element 27 extends, proceeding from the center of mass of the compensation weight 28, at a distance from a connection region via which the connecting lever 29 is connected to the main body 18, i.e., at a distance from the additional element (interface) 30. This results in a torque which the torque compensation weight element 27 introduces into the main body 18 of the mirror M. The introduction of torque can be used for a targeted change of the figure of the opposite optical surface 19 of the mirror that is used for reflection purposes.
(67) In the torque compensation weight element 27, it is possible to predetermine both the magnitude of the introduced torque and also the direction thereof in an adjustable manner. In order to predetermine the magnitude of the introduced torque, the compensation weight 28 can be displaced along the connecting lever 29 relative to the latter, as indicated in
(68) An effective length of the connecting lever 29 and hence the absolute value of the introduced torque is set by way of the displacement of the compensation weight 28 along the connecting lever 29. This adjustment of the compensation weight 28 along the connecting lever 29 can be brought about continuously. By way of example, the compensation weight 28 can be affixed magnetically to the connecting lever 29.
(69) A direction of the torque introduced into the main body 18 via the torque compensation weight element 27 can be predetermined by way of a pivot setting of the connecting lever 29 about a pivot axis SA, as indicated in
(70) Below, a further embodiment of such torque compensation weight element 31 is described on the basis of
(71) Instead of an elongate connecting lever 29 as in the embodiment from
(72)
(73) The main body 18 of the mirror M according to
(74)
(75) The interface unit 37 has a pin 38, the base plate portion 38a of which is connected to an interface lateral section 39 of the main body 18. In the embodiment according to
(76) The pin 38 represents a holding component for the compensation weight element 36.
(77) The pin 38 carries at least one magnet 40. Here, as illustrated, once again, in an axial section in
(78) In the circumferential direction about the interface lateral wall portion 39, at least one decoupling recess 41 is provided in the lateral wall 35 of the main body 18, wherein the decoupling recess can be a decoupling groove and, in particular, a decoupling annular groove. The decoupling recess 41 serves to prevent unwanted tension-induced surface deformations of the optical element M.
(79) The compensation weight element 36 is embodied as a ring which is plugged onto a free end of the pin 38 via its ring opening 42. In order to simplify this plugging process, the free end of the pin 38 can taper, as illustrated in
(80) The compensation weight element 36 has a thickness D and a diameter DM.
(81) The compensation weight element 36 can be a constituent part of a set of various compensation weight elements. Compensation weight elements of this set can differ in terms of diameter DM, but all have the same thickness D. The compensation weight elements of the set all have the same, homogeneous density.
(82)
(83) The compensation weight element 43 carries a magnet 45, which interacts with a counter component of the interface unit 44, namely the base plate portion 38a, for fixing the compensation weight element 43 to the interface unit 44. In the case of the interface unit 44, the base plate portion 38a is made of magnetic material, Invar® in the present example embodiment.
(84) The magnet 45 of the compensation weight element 43 can be a magnet portion that is introduced into the compensation weight element 43, which is otherwise embodied as a ring again. The magnet 45 can be adhesively bonded to the other compensation weight element 43 and/or connected to the latter by way of a press fit.
(85)
(86) Like the other compensation weight elements described above, too, the compensation weight element 43 also can be a constituent part of a set of different compensation weight elements. Once again, the compensation weight elements of such set only differ in terms of their diameter. An axial extent of the magnets 45 is just as large as the axial extent, i.e., the thickness, of the ring-shaped main body of the compensation weight element 43.
(87) In an illustration similar to
(88) In the compensation weight element 46, the magnet 45 has a two-part embodiment with magnetic portions 45a, 45b. The two magnetic portions 45a, 45b are arranged on both sides of the main body of the compensation weight element 46. The magnetic portions 45a, 45b are arranged with mirror symmetry in relation to a mid ring plane 47 of the main body of the compensation weight element 46. A ring axis 48 is perpendicular to the mid ring plane 47. The point of intersection between the ring axis 48 and the mid ring plane 47 simultaneously is the center of mass SP of the compensation weight element 46.
(89) In the arrangement variants of the magnets 45 according to
(90) The main body 18 of the optical element, i.e., for example of the mirror M, can be manufactured from ULE®.
(91) In order to produce a microstructured or nanostructured component, the projection exposure apparatus 1 is used as follows: First, the reflection mask 10 or the reticle and the substrate or the wafer 11 are provided. Subsequently, a structure on the reticle 10 is projected onto a light-sensitive layer of the wafer 11 with the aid of the projection exposure apparatus 1. Then, a microstructure or nanostructure on the wafer 11, and hence the microstructured component, is produced by developing the light-sensitive layer.