Faceted mirror for EUV projection lithography and illumination optical unit with same
10488567 ยท 2019-11-26
Assignee
Inventors
Cpc classification
G03F7/70116
PHYSICS
G03F7/70075
PHYSICS
G02B5/09
PHYSICS
G03F7/70091
PHYSICS
International classification
G02B5/09
PHYSICS
Abstract
A facet mirror for EUV projection lithography has a plurality of facets for reflecting EUV illumination light. At least some of the facets are in the form of alignment facets and have a reflection surface, the edge contour of which is aligned along two alignment coordinates of an overall facet arrangement. The reflection surface of at least one of the alignment facets has a surface shape that exhibits different curvatures along two axes of curvature. The axes of curvature are tilted about a finite axis tilt angle relative to the alignment coordinates of the overall facet arrangement. The result is a facet mirror with increased EUV throughput, particularly for prolonged operation of a projection exposure apparatus that is equipped therewith.
Claims
1. A facet mirror, comprising: a plurality of facets configured to reflect EUV illumination light, wherein: at least some of the facets comprise alignment facets; the alignment facets comprise a reflection surface with an edge contour aligned along two alignment coordinates of an overall facet arrangement; the reflection surface of at least one of the alignment facets comprises a surface shape that exhibits different curvatures along two axes of curvature; the two axes of curvature are tilted about a finite axis tilt angle with respect to the alignment coordinates of the overall facet arrangement; and each of the alignment facets has a contiguous reflection surface.
2. The facet mirror of claim 1, wherein: the alignment facets comprise first and second alignment facets; the reflection surface of first and second alignment facets comprise surface shapes exhibiting different curvatures along two axes of curvature; and the axis tilt angles of the first and second alignment facets differ.
3. The facet mirror of claim 1, wherein the finite axis tilt angle is at least one degree.
4. The facet mirror of claim 1, wherein a greater radius of curvature of the reflection surface is infinite.
5. The facet mirror of claim 1, wherein both radii of curvature of the reflection surface are finite.
6. The facet mirror of claim 1, wherein: the alignment facets comprise first and second alignment facets; the reflection surface of first and second alignment facets comprise surface shapes exhibiting different curvatures along two axes of curvature; the axis tilt angles of the first and second alignment facets differ; and the finite axis tilt angle is at least one degree.
7. The facet mirror of claim 6, wherein a greater radius of curvature of the reflection surface is infinite.
8. The facet mirror of claim 6, wherein both radii of curvature of the reflection surface are finite.
9. The facet mirror of claim 1, wherein: the alignment facets comprise first and second alignment facets; the reflection surface of first and second alignment facets comprise surface shapes exhibiting different curvatures along two axes of curvature; the axis tilt angles of the first and second alignment facets differ; and a greater radius of curvature of the reflection surface is infinite.
10. The facet mirror of claim 9, wherein both radii of curvature of the reflection surface are finite.
11. The facet mirror of claim 1, wherein: the alignment facets comprise first and second alignment facets; the reflection surface of first and second alignment facets comprise surface shapes exhibiting different curvatures along two axes of curvature; the axis tilt angles of the first and second alignment facets differ; and both radii of curvature of the reflection surface are finite.
12. The facet mirror of claim 1, wherein a difference between the radii of curvature is between 20 mm and 60 mm.
13. The facet mirror of claim 1, wherein the radii of curvature are between 200 mm and 2000 mm.
14. An illumination optical unit, comprising: a facet mirror according to claim 1, wherein the illumination optical unit is configured to illuminate an object field with illumination light.
15. An illumination system, comprising: a light source; and an illumination optical unit comprising a facet mirror according to claim 1, wherein the illumination optical unit is configured to illuminate an object field with illumination light generated by the light source.
16. An optical system, comprising: an illumination optical unit comprising a facet mirror according to claim 1; and a projection optical unit, wherein the illumination optical unit is configured to illuminate an object field with illumination light, and the projection optical unit is configured to image the object field into an image field.
17. An apparatus, comprising: a light source; an illumination optical unit comprising a facet mirror according to claim 1; and a projection optical unit, wherein the illumination optical unit is configured to illuminate an object field with illumination light generated by the light source, the projection optical unit is configured to image the object field into an image field, and apparatus is a projection exposure apparatus.
18. The apparatus of claim 17, further comprising: an object holder comprising an object displacement drive configured to displace an object in the object field along an object displacement direction; and a wafer holder comprising a wafer displacement drive configured to displace a wafer in synchronization with the object displacement drive.
19. A method of using a projection exposure apparatus comprising an illumination optical unit and a projection optical unit, the method comprising: using the illumination optical unit to illuminate a lithography mask; and using the projection optical unit to project at least a portion of the illuminated lithography mask onto a light-sensitive material, wherein the illumination optical unit comprises a facet mirror according to claim 1.
20. A method of aligning a facet of a facet mirror, the facet mirror comprising a plurality of facets configured to reflect EUV illumination light, at least some of the facets being alignment facets which comprise a reflection surface with an edge contour aligned along two alignment coordinates of an overall facet arrangement, the reflection surface of a first alignment facet having a surface shape that exhibits different curvatures along two axes of curvature, the method comprising: aligning the two axes of curvature of the reflection surface of the first alignment facets by tilting the two axes of curvature about a finite axis tilt angle with respect to the alignment coordinates of the overall facet arrangement.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Exemplary embodiments of the disclosure will be described in more detail below with reference to the drawing, in which:
(2)
(3)
(4)
(5)
(6)
(7)
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DETAILED DESCRIPTION
(11)
(12) The radiation source 2 is an EUV radiation source with an emitted used radiation in the range between 5 nm and 30 nm. This radiation source can be a plasma source, for example a GDPP source (gas-discharge-produced plasma) or an LPP source (laser-produced plasma). A radiation source based on a synchrotron or on a free electron laser (FEL) is also usable as the radiation source 2. A person skilled in the art can find information relating to such a radiation source in U.S. Pat. No. 6,859,515 B2, for example. EUV radiation 16, emerging from the radiation source 2, in particular the used illumination light that illuminates the object field 5, is focused by a collector 17. A corresponding collector is known from EP 1 225 481 A. Downstream of the collector 17, the EUV radiation 16 propagates through an intermediate focal plane 18 before being incident on a field facet mirror 19.
(13) The field facet mirror 19 is a first facet mirror of the illumination optical unit 4. The field facet mirror 19 has a plurality of reflective field facets, which are not shown in
(14) The EUV radiation 16 will also be referred to below as illumination light or as imaging light.
(15) Downstream of the field facet mirror 19, the EUV radiation 16 is reflected by a pupil facet mirror 20. The pupil facet mirror 20 is a second facet mirror of the illumination optical unit 4. The pupil facet mirror 20 is arranged in a pupil plane of the illumination optical unit 4 which is optically conjugate to the intermediate focal plane 18 and to a pupil plane of the illumination optical unit 4 and of the projection optical unit 10 or coincides with this pupil plane. The pupil facet mirror 20 has a plurality of reflective pupil facets, which are not shown in
(16) Illumination light 16, which is guided for example in the object plane 6 toward greater absolute x-values than the x-dimension of the object field 5, can be guided, using a corresponding optical unit (not illustrated), to a plurality of energy or dose sensors, one dose sensor 24a of which is schematically illustrated in
(17) The control device 24b is in signal connection with tilt actuators for the field facets 25 of the field facet mirror 19, among others.
(18) To facilitate the description of positional relationships, a Cartesian xyz coordinate system is shown in
(19) The x-dimension over the object field 5 or the image field 11 is also referred to as the field height. The object displacement direction extends parallel with respect to the y-axis.
(20) Local Cartesian xyz coordinate systems are shown in the other figures. The x-axes of the local coordinate systems extend parallel with respect to the x-axis of the global coordinate system in accordance with
(21)
(22) The field facets 25 can be configured to be tiltable between a plurality of tilt positions by way of an actuator.
(23) The field facet mirror 19 in accordance with
(24) Intermediate spaces 28 are located between the field facet blocks 26.
(25) The field facet mirror 19 in accordance with
(26)
(27) Each of the field facets 25 serves for transferring a portion of the illumination light 16, i.e. of an illumination-light partial beam 16.sub.i, from the light source 2 to one of the pupil facets 29.
(28) The description of illumination-light partial beams 16.sub.i below is based on the assumption that the associated field facet 25 is in each case lit in maximum fashion, i.e. over its entire reflection surface. In this case, an edge contour of the illumination-light partial beam 16.sub.i coincides with an edge contour of the illumination channel, which is why the illumination channels will also be designated 16.sub.i below. The respective illumination channel 16.sub.i represents one possible optical path of an illumination-light partial beam 16.sub.i, which lights the associated field facet 25 in maximum fashion, over the further components of the illumination optical unit 4.
(29) The transfer optical unit 21 has in each case one of the pupil facets 29 for each of the illumination channels 16.sub.i for transferring the illumination-light partial beam 16.sub.i from the field facet 25 to the object field 5.
(30) In each case one illumination-light partial beam 16.sub.i, of which
(31)
(32) The illumination-light partial beam 16.sub.i impinges on the pupil facet 29 in accordance with
(33) In the arrangement illustrated in
(34) The arch-shaped edge contour of the illumination-light partial beam 16.sub.i on the pupil facet 29 represents a light spot of the illumination-light partial beam 16.sub.i.
(35) The dashes in the edge contour of the illumination-light partial beam 16.sub.i on the pupil facet 29 show three subbeams 16.sub.i.sup.1, 16.sub.i.sup.2 and 16.sub.i.sup.3. The illumination-light partial beam 16.sub.i is made up of a multiplicity of such subbeams 16.sub.i.sup.j. The illumination-light partial beam 16.sub.i on the respective pupil facet 29 can, if the optical parameters of the illumination are known, be calculated, for example by way of an optical design program, and is in this context also referred to as a point spread function.
(36) The illumination light 16 of these subbeams 16.sub.i.sup.1 to 16.sub.i.sup.3 originates from a left-hand edge point 25.sup.1, from a central point 25.sup.2 and from a right-hand edge point 25.sup.3 of the associated field facet 25. By way of example,
(37) A field-dependent centroid profile 31.sub.i of all subbeams 16.sub.i.sup.j originating from the associated field facet 25 represents a core of an edge contour of the respective illumination-light partial beam 16.sub.i on each pupil facet 29. This centroid profile 31.sub.i is distinct for each illumination channel 16.sub.i and depends, among others, on the geometric profile of the illumination channel 16.sub.i between the light source 2 and the respective pupil facet 29 via the associated field facet 25.
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(39) To influence an extent of an edge contour of the illumination-light partial beam 13.sub.i or an xy-extent of the respective field-dependent centroid profile 31.sub.i, reflection surfaces 32 of the field facets 25 are in the form of toric surfaces. This will be explained below with reference to
(40) A rectangular edge contour 33 of the field facets 25 is aligned along two alignment coordinates x and y of an overall facet arrangement that is illustrated by way of example in
(41) The facets to which this alignment applies will also be referred to below as alignment facets 25. The axes of curvature x, y of the toric reflection surfaces of the alignment facets 25 are in each case tilted with respect to the alignment coordinates x, y of the overall facet arrangement by a finite axis tilt angle.
(42) The axis of curvature x is here tilted relative to the alignment coordinate x about the alignment coordinate z by an axis tilt angle . The axis of curvature y is in turn tilted relative to the alignment coordinate y about the alignment coordinate z by the axis tilt angle . Since the coordinates of the axes of curvature x, y and the alignment coordinates xyz are Cartesian coordinates, the two angles and are in this case the same size.
(43) The axis of curvature x defines a curvature of the toric reflection surface 32 of the field facet 25 in the yz-plane (cf.
(44) Accordingly, the axis of curvature y defines a curvature of the reflection surface 32 in the xz-plane. A radius of curvature of the reflection surface 32 in the xz-plane is designated R.sub.y.
(45)
(46) It is also true that the smaller of the two radii of curvature R.sub.x, R.sub.y of the toric reflection surface 32 is finite. The other of the two radii of curvature R.sub.y, R.sub.x can be infinite, which results in a cylindrical reflection surface 32, or can be finite, which results in a toric reflection surface 32 having a reflection surface that is curved via two axes of curvature.
(47) A cylindrical surface or cylinder surface represents a special case of a toric surface and is likewise a toric surface within the meaning of this application.
(48) An effect of a toric reflection surface design of the alignment field facets 25 will be explained below with reference to
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(51) On the basis of the imaging by way of the conventional alignment field facet 25, a centroid profile 31.sub.i with a maximum distance R.sub.i from a center Z of the reflection surface of the pupil facet mirror 29 is obtained. This distance value R.sub.i is described in
(52)
(53) The effect of the compression even in the case of the illumination channel 16.sub.j in accordance with
(54) The tilt angles , in the centroid profiles illustrated in
(55) In particular the compression of the centroid profiles 31.sub.i, 31.sub.j, as compared to the illumination-light partial beams guided using the conventional field facets, results in a constriction of the illumination-light partial beams 16.sub.i, 16.sub.j on the pupil facets 29, with the result that complete reflection of the partial beams 16.sub.i, 16.sub.j at the associated pupil facets 29 is facilitated without undesired light losses. Drifts of the partial beams 16.sub.i, 16.sub.j on the pupil facets 29 can be more easily tolerated. The compression of the centroid profiles 31.sub.i, 31.sub.j additionally has the result that a possible cutting-off behavior of illumination-light subbeams 16.sub.i.sup.n becomes less field-dependent and such a dependence is reduced also at the field edge and in particular beyond the field edges at the site of the arrangement of possible energy or dose sensors. Subsequent adjustment of the light source 2 as a reaction to measured intensity changes is thus simplified.
(56) When designing the field facet mirror 19 with the alignment facets, the tilt angles , of all alignment facets 25 are identical.
(57) In an alternative configuration, which is illustrated schematically in
(58) In the projection exposure using the projection exposure apparatus 1, at least part of the reticle 7 in the object field 5 is imaged onto a region of the light-sensitive layer on the wafer 13 in the image field 11 for lithographically producing a microstructured or nanostructured component, in particular a semiconductor component, for example a microchip. Here, the reticle 7 and the wafer 13 are continuously moved in the y-direction in time-synchronized fashion during the scanning operation.