METHOD FOR OPERATING AN EUV LITHOGRAPHTY APPARATUS, AND EUV LITHOGRAPHY APPARATUS
20230041588 · 2023-02-09
Inventors
Cpc classification
G03F7/70958
PHYSICS
G03F7/70925
PHYSICS
G03F7/70916
PHYSICS
International classification
Abstract
A method for operating an EUV lithography apparatus (1) with at least one vacuum housing (27) for at least one reflective optical element (12) includes operating the EUV lithography apparatus in an exposure operating mode (B), in which EUV radiation (5) is radiated into the vacuum housing, wherein a reducing plasma is generated at a surface (12a) of the reflective optical element in response to an interaction of the EUV radiation with a residual gas present in the vacuum housing. After an exposure pause, in which no EUV radiation is radiated into the vacuum housing, and before renewed operation of the EUV lithography apparatus in the exposure operating mode (B), the EUV lithography apparatus is operated in a recovery operating mode, in which oxidized contaminants at the surface of the reflective optical element are reduced in order to recover a transmission of the EUV lithography apparatus before the exposure pause.
Claims
1. Method for operating an extreme ultraviolet (EUV) lithography apparatus having at least one vacuum housing in which at least one reflective optical element is arranged, comprising: operating the EUV lithography apparatus in an exposure operating mode (B), in which EUV radiation is radiated into the vacuum housing, wherein a reducing plasma is generated at a surface of the reflective optical element in response to an interaction of the EUV radiation with a residual gas present in the vacuum housing, after an exposure pause (P), in which no EUV radiation is radiated into the vacuum housing, and before a renewed operation of the EUV lithography apparatus in the exposure operating mode (B), operating the EUV lithography apparatus in a recovery operating mode (R), in which oxidized contaminants at the surface of the reflective optical element are reduced, thereby recovering, at least in part, a transmission of the EUV lithography apparatus before the exposure pause (P).
2. Method according to claim 1, wherein at least one component which outgasses contaminants upon contact with the reducing plasma in the exposure operating mode (B) is arranged in the vacuum housing, wherein the contaminants accumulate at the surface of the reflective optical element and form oxidized contaminants during the exposure pause (P).
3. Method according to claim 1, further comprising, in the recovery operating mode (R), radiating EUV radiation generated by an EUV light source into the vacuum housing, thereby generating a reducing plasma in the vacuum housing.
4. Method according to claim 1, further comprising, in the recovery operating mode (R), radiating radiation at at least one wavelength outside the EUV wavelength range into the vacuum housing.
5. Method according to claim 4, wherein the radiation outside the EUV wavelength range is generated by an EUV light source of the EUV lithography apparatus.
6. Method according to claim 3, further comprising exchanging a mask used in the exposure operating mode (B) for a more highly reflective mask in the recovery operating mode (R).
7. Method according to claim 4, further comprising exchanging a mask used in the exposure operating mode (B) for a more highly reflective mask in the recovery operating mode (R).
8. Method according to claim 3, wherein a power of the EUV light source in the recovery operating mode (R) is increased relative to a power of the EUV light source in the exposure operating mode (B).
9. Method according to claim 4, wherein a power of the EUV light source in the recovery operating mode (R) is increased relative to a power of the EUV light source in the exposure operating mode (B).
10. Method according to claim 1, wherein, in the exposure pause (P) and/or in the recovery operating mode (R), at least one partial pressure of a gas constituent of the residual gas that forms the reducing plasma is increased.
11. Method according to claim 10, wherein, in the exposure pause (P) and/or in the recovery operating mode (R), the increased partial pressure is a partial pressure of molecular hydrogen.
12. Method according to claim 1, wherein, in the exposure pause (P) and/or in the recovery operating mode (R), at least one additional gas that forms a reducing plasma is fed to the residual gas.
13. Method according to claim 12, wherein the at least one additional gas that forms a reducing plasma is carbon monoxide.
14. Method according to claim 1, further comprising heating the at least one reflective optical element in the exposure pause (P) and/or in the recovery operating mode (R).
15. Method according to claim 1, further comprising, in the exposure pause (P) and/or in the recovery operating mode (R), activating at least one plasma generating device, thereby generating a reducing gas species.
16. Method according to claim 15, wherein, in the exposure pause (P) and/or in the recovery operating mode (R), the reducing gas species comprises hydrogen ions.
17. Method according to claim 1, further comprising, during the exposure pause (P) and/or during the recovery operating mode (R), activating at least one purge device, thereby reducing a partial pressure of oxidizing species in a region of the surface of the reflective optical element.
18. Method according to claim 1, further comprising, during the exposure pause (P) and/or during the recovery operating mode (R), activating at least one pump device, thereby reducing a concentration of oxidizing species in the vacuum housing.
19. Method according to claim 1, further comprising measuring the transmission of the EUV lithography apparatus during the exposure operating mode (B) and/or during the recovery operating mode (R).
20. Method according to claim 1, further comprising determining a time duration of the recovery operating mode (R) depending on a transmission loss of the EUV lithography apparatus during the exposure pause (P).
21. Extreme ultraviolet (EUV) lithography apparatus, comprising: at least one vacuum housing in which at least one reflective optical element is arranged, a control device configured to operate the EUV lithography apparatus in an exposure operating mode (B), in which EUV radiation is radiated into the vacuum housing, wherein a reducing plasma is generated at a surface of the reflective optical element in response to an interaction of the EUV radiation with a residual gas present in the vacuum housing, wherein the control device is configured, in accordance with computer-readable instructions, after an exposure pause (P), in which no EUV radiation is radiated into the vacuum housing, and before renewed operation of the EUV lithography apparatus in the exposure operating mode (B), to operate the EUV lithography apparatus in a recovery operating mode (R), in which oxidized contaminants at the surface of the reflective optical element are reduced, thereby recovering, at least in part, a transmission of the EUV lithography apparatus before the exposure pause (P).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Exemplary embodiments are illustrated in the schematic drawing and are explained in the following description. In the figures:
[0042]
[0043]
[0044]
[0045]
DETAILED DESCRIPTION
[0046] In the following description of the drawings, identical reference signs are used for identical or analogous, or functionally identical or analogous, component parts.
[0047]
[0048] The illumination beam path 7 serves to illuminate a structured object M with an illumination system 10, which in the present example has five reflective optical elements 12 to 16 (mirrors).
[0049] The structured object M can be for example a reflective photomask, which has reflective and non-reflective, or at least less reflective, regions for producing at least one structure on the object M. Alternatively, the structured object M can be a plurality of micro-mirrors, which are arranged in a one-dimensional or multi-dimensional arrangement and which are optionally movable about at least one axis, in order to set the angle of incidence of the EUV radiation on the respective mirror.
[0050] The structured object M reflects part of the illumination beam path 7 and shapes a projection beam path 9, which carries the information about the structure of the structured object M and is radiated into a projection lens 20, which generates a projected image of the structured object M or of a respective partial region thereof on a substrate W. The substrate W, for example a wafer, comprises a semiconductor material, for example silicon, and is disposed on a mounting, which is also referred to as a wafer stage WS.
[0051] In the present example, the projection lens 20 has six reflective optical elements 21 to 26 (mirrors) in order to generate an image of the structure that is present at the structured object M on the wafer W. The number of mirrors in a projection lens 20 is typically between four and eight; optionally, however, it is also possible to use only two mirrors or else ten mirrors.
[0052] The collector mirror 6, the reflective optical elements 12 to 16 of the illumination system 10 and the reflective optical elements 21 to 26 of the projection lens 20 are arranged in a vacuum environment. In this case, a respective optical element 6, 12 to 16, 21 to 26 is typically arranged in a dedicated vacuum housing, also referred to as “mini environment”.
[0053] By way of example,
[0054] The EUV lithography apparatus 1 shown in
[0055]
[0056] The optical element 12 likewise comprises a substrate 51 composed of titanium-doped quartz glass, to which is applied a reflective multilayer coating 52 optimized for the reflection of EUV radiation 5 at the operating wavelength λ.sub.B of 13.5 nm. The multilayer coating 52 comprises alternating layers 53a, 53b of molybdenum and silicon. At the operating wavelength λ.sub.B of 13.5 nm, the silicon layers 53b have a higher real part of the refractive index than the molybdenum layers 53a. Depending on the exact value of the operating wavelength λ.sub.B, other material combinations, such as e.g. molybdenum and beryllium, ruthenium and beryllium, or lanthanum and B.sub.4C, are likewise possible. In order to protect the multilayer coating 52, a protective layer 54 of ruthenium is applied to it.
[0057] During the exposure operating mode B, in which the structured object M or a respective partial region thereof is imaged onto the substrate W, a native SiO.sub.2 layer at the surface of the component 50 is reduced to Si upon contact with ionic hydrogen species H.sub.3.sup.+. The ionic hydrogen species H.sub.3.sup.+ are constituents of a reducing plasma 43 formed in the vacuum housing 27 as a result of the interaction of a residual gas 40 present in the vacuum housing 27, said residual gas being shown in
[0058] As a result of the attack of radical hydrogen species H from the plasma 43, gaseous silane (SiH.sub.4) forms from the silicon in accordance with the following reaction equation:
Si (s)+4H (g).fwdarw.SiH.sub.4 (g)
[0059] At the surface 12a of the reflective optical element 12, corresponding to the surface of the Ru protective layer, degradation occurs on account of the accumulation of silicon:
SiH.sub.4 (g)+Ru (s).fwdarw.Si—Ru (s)+2H.sub.2 (g).
[0060] During an exposure pause P (cf.
Si—Ru (s)+2O(g).fwdarw.SiO.sub.2(s)+Ru(s)
[0061] The presence of the oxidized contaminant in the form of silicon oxide (SiO.sub.2) at the surface 12a of the reflective optical element 12 results in a considerably greater reflectivity loss and thus a reduced transmission T.sub.P of the EUV lithography apparatus 1 after the exposure pause P. The reflectivity loss that arises as a result of the presence of the oxidized contaminant (SiO.sub.2) is significantly greater than the reflectivity loss that arises as a result of the presence of the non-oxidized contaminant in the form of silicon (Si) that is present at the surface 12a of the reflective optical element 12 in the exposure operating mode B before the operating pause P.
[0062] Accordingly, the transmission T.sub.B (cf.
[0063] The time duration until the—at least partial—recovery of the transmission T.sub.B in the renewed exposure operating mode B can be a number of days, however, particularly in the case of the reflective optical elements 21 to 26 of the projection system 20. In order to accelerate the recovery of the transmission T.sub.B, the EUV lithography apparatus 1 is operated in a recovery operating mode R, which is described in greater detail below with reference to
[0064] In order to accelerate the reduction of the oxidized contaminants, e.g. SiO.sub.2, various measures can be carried out individually or in combination, a number of which measures are described by way of example below.
[0065] In the example shown in
[0066] The additional radiation 5a intensifies the photoionization or the excitation of gas constituents present in the residual gas 40, and thus the effect of the reducing plasma 43. The additional radiation 5a can be generated by a dedicated (VUV) light source (not illustrated). In the example shown, the additional radiation 5a is generated by the EUV light source 2 itself: In the case of the EUV light source 2 embodied as a plasma light source as described here, a proportion of radiation 5a is generated at wavelengths outside the EUV wavelength range anyway. This proportion in the spectrum of the EUV light source 2 that is not in the EUV wavelength range can be amplified by suitably modifying the beam profile of the laser beam 4 used to generate the tin plasma.
[0067] Additionally or alternatively it is possible, in the recovery operating mode R, to operate the EUV light source 2 with a power p.sub.R that is greater than the power p.sub.B of the EUV light source 12 in the exposure operating mode B. As a result of the greater power p.sub.R, the reducing effect of the plasma 43 likewise increases.
[0068] In order to increase the reducing effect on the reflective optical elements 21 to 26 arranged in the projection system 20, the mask M used for the exposure operating mode B can be exchanged for a highly reflective mask RM in the recovery operating mode R (cf.
[0069] While specific constituents of the residual gas 40 are present in small amounts in the vacuum housing 27 anyway, other constituents serving as purge gases 42, in particular molecular hydrogen (H.sub.2), are fed to the vacuum housing 27 via a feed device 41 in the form of a tubular gas feed. By way of a controllable valve or the like, the feed device 41 can control the flow of the purge gas or the flow of the individual constituents of the purge gas 42 by open-loop control or optionally closed-loop control.
[0070] A further possibility for intensifying the effect of the reducing plasma 43 consists in increasing a partial pressure of at least one gas constituent of the residual gas 40 in the vacuum housing 27 in the recovery operating mode R relative to a partial pressure in the exposure operating mode B. By way of example, the partial pressure p(H.sub.2) of molecular hydrogen H.sub.2 in the vacuum housing 27 can be increased during the recovery operating mode R by driving the feed device 41 in a suitable manner. In the recovery operating mode R, additional reducing gases that are otherwise not present in the residual gas 40 in the vacuum housing 27 can also be admitted into the vacuum housing 27. The additional reducing gas can be CO, for example, as is indicated in
[0071] The measures described further above relating to the feed of the purge gas 42 can also be carried out during the operating pause P, particularly if the EUV lithography apparatus 1 is not ventilated during the operating pause P.
[0072] The measures described below in association with
[0073]
[0074] The optical element 22 is arranged in a vacuum housing 27a, into which purge gases 42 can be fed via a feed line 41. A residual gas 40 is situated in the vacuum housing 27a. A plasma generating device 44 is also arranged in the vacuum housing 27a, said plasma generating device being used to generate reducing gas species, here in the form of activated or atomic hydrogen H* or hydrogen radicals. In the example shown, the plasma generating device 44 forms a cleaning head embodied as described in WO 2008/034582 A2. In the example shown, the plasma generating device 44 can be moved within the vacuum housing 27a and in the process can be positioned over the surface 22a of the reflective optical element 22, as is illustrated in
[0075] In the example illustrated in
[0076] The plasma generating device 44 can remain activated during the entire time duration of the recovery operating mode R, but it is also possible for the plasma generating device 44 to be active only for one part of the time duration of the recovery operating mode R and for the EUV radiation 5 to be radiated into the vacuum housing 27a during another part of the time duration of the recovery operating mode R. If the plasma generating device 44 is positioned suitably relative to the optical element 22, radiating in the EUV radiation 5 and activating the plasma generating device 44 can also be effected simultaneously.
[0077] In order to increase the reactivity of the reduction reactions at the surface 22a of the reflective optical element 22, the reflective optical element 22 is heated with the aid of a temperature-regulating device 45, for example in the form of a Peltier element, during the recovery operating mode R.
[0078] Particularly during an exposure pause P, but optionally also during the recovery operating mode R, at least one purge device 46 can be activated in order to reduce a partial pressure p(O.sub.2) of oxidizing species, e.g. in the form of oxygen O.sub.2, in the region of the surface 22a of the reflective optical element 22. The purge device 46 can generate for example a gas flow of an inert gas, e.g. of a noble gas, which is guided along the surface 22a of the reflective optical element 22 and protects the surface 22a, or the not yet oxidized contaminants that have deposited there, against oxidizing species in the residual gas 40.
[0079] Particularly during an exposure pause P, but optionally also during the recovery operating mode R, at least one pump device 47 can be activated in order to reduce the concentration of oxidizing species, in particular of molecular oxygen, in the vacuum housing 27a. The pump device 47 can be a cryopump or a getter pump, for example.
[0080] The EUV lithography apparatus 1 comprises a control device 48 (cf.
[0081] The control device 48 is also configured to define a time duration Δt.sub.R of the recovery operating mode R depending on a transmission loss T.sub.B−T.sub.R of the EUV lithography apparatus 1 during the exposure pause P. The transmission loss T.sub.B−T.sub.R occurs between the beginning and the end of the exposure pause P. In order to define the time duration Δt.sub.R of the recovery operating mode R, the control device 48 can have recourse to measurement values known in advance or determined experimentally, which optionally take account of a time duration of the exposure pause P. The measurement values for the transmission loss can be stored for example in the form of a table in a control device 48 of the EUV lithography apparatus 1. Suitable (power) sensors can be used for the measurement of the transmission T.sub.B during the exposure operating mode B and respectively the measurement of the transmission T.sub.R during the recovery operating mode R. The time duration Δt.sub.R of the recovery operating mode R is generally chosen to be all the longer, the greater the transmission loss, i.e. the greater the difference T.sub.B−T.sub.R during the exposure pause P.
[0082] The time duration Δt.sub.R of the recovery operating mode R can optionally be reduced further if, in addition to the measured transmission loss T.sub.B−T.sub.R, that proportion of the transmission loss T.sub.B−T.sub.R is known which is attributable to the oxidation of contaminants at the surface 12a, 22a of a respective reflective optical element 12, 22. The time duration Δt.sub.R of the recovery operating mode R can also be reduced if the composition of the residual gas 40 and the excitation of the plasma 43 are defined or optimized depending on the components 50 which outgas contaminants in the vicinity of a respective reflective optical element 12, 22 and/or depending on the type of a contaminant that has respectively deposited on the surface 12a, 22a of the reflective optical element 12, 22.