Method for improving the imaging properties of a projection objective, and such a projection objective
09581813 ยท 2017-02-28
Assignee
Inventors
- Olaf Conradi (Westhausen/Westerhofen, DE)
- Heiko Feldmann (Germany, DE)
- Gerald Richter (Abtsgmuend, DE)
- Sascha Bleidistel (Aalen, DE)
- Andreas Frommeyer (Schwaebisch Gmuend, DE)
- Toralf Gruner (Aalen-Hofen, DE)
- Wolfgang Hummel (Aalen, DE)
Cpc classification
G03F7/70266
PHYSICS
Y10S359/90
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G02B26/0825
PHYSICS
G02B27/0068
PHYSICS
G02B3/0081
PHYSICS
International classification
G03B27/32
PHYSICS
G02B27/00
PHYSICS
G03B27/68
PHYSICS
Abstract
The invention relates to a method for improving the imaging properties of a micro lithography projection objective, wherein the projection objective has a plurality of lenses between an object plane and an image plane, a first lens of the plurality of lenses being assigned a first manipulator for actively deforming the lens, the first lens being deformed for at least partially correcting an aberration, at least one second lens of the plurality of lenses furthermore being assigned at least one second manipulator, and the second lens being deformed in addition to the first lens. Furthermore, a method is described for selecting at least one lens of a plurality of lenses of a projection objective as actively deformable element, and a projection objective.
Claims
1. A method, comprising: deforming a first optical element of a plurality of optical elements via a first manipulator; and deforming a second optical element of the plurality of optical elements via a second manipulator, wherein a catadioptric microlithography system comprises the plurality of optical elements, and wherein: a) deformation of the first optical element and the second optical element corrects a radially primary Zernike order of an image defect substantially independently of a radially higher Zernike order of the image defect; or b) deformation of the first optical element and the second optical element corrects the radially higher Zernike order of the image defect substantially independently of the radially primary Zernike order of the image defect.
2. The method of claim 1, wherein the first optical element comprises a first lens.
3. The method of claim 2, wherein the second optical element comprises a second lens.
4. The method of claim 1, wherein: the first optical element is not adjacent the second optical element; the first and second optical elements are not arranged at mutually optically conjugate sites; the first optical element is deformed to have a first deformation profile; and the second optical element is deformed to have a second deformation profile which is different from the first deformation profile.
5. The method of claim 1, wherein first optical element has a first shape, and the second optical element has a second shape which is different from the first shape.
6. The method of claim 1, comprising using a first force to deform the first optical element, and using a second force to deform the second optical element, wherein the second force is different from the first force.
7. The method of claim 1, comprising using a first force to deform the first optical element, and using a second force to deform the second optical element, wherein the second force is oppositely directed compared to the first force.
8. The method of claim 1, wherein the first optical element and the second optical element are arranged at not mutually optically conjugate sites, and the first and second optical elements are at least substantially identically deformed.
9. The method of claim 1, wherein the first optical element and the second optical element are deformed at a specific ratio to one another.
10. The method of claim 9, further comprising selecting the ratio as a function of the influence of the first and second optical elements on wavefront aberrations of a radially primary Zernike order and of a radially higher Zernike order thereof.
11. The method of claim 1, wherein a magnitude of the corrective influence of the first optical element on a ratio of the radially primary Zernike order and a radially higher Zernike order is approximately equal to a corrective influence of the second optical element, but has a different sign.
12. The method of claim 1, wherein the first optical element and the second optical element is deformed with onefold, two-fold, three-fold or n-fold symmetry where n>3.
13. The method of claim 1, comprising deforming the first and second optical elements to correct the radially primary Zernike order of an image defect substantially independently of the radially higher Zernike order of the image defect.
14. The method of claim 1, comprising deforming the first and second optical elements to correct the radially higher Zernike order of the image defect substantially independently of the radially primary Zernike order of the image defect.
15. The method of claim 1, wherein the microlithography system comprises a microlithography projection objective, and the method further comprises using the microlithography projection objective to image a structure or a pattern of a reticle onto a photosensitive material.
16. A system, comprising: a catadioptric microlithography projection system, comprising: a plurality of optical elements the plurality of optical elements including a first optical element and a second optical element; a first manipulator configured to actively deform the first optical element; and a second manipulator configured to actively deform the second optical element, wherein when the first and second optical elements are deformed during use of the microlithography system: a) a radially primary Zernike order of an image defect is corrected substantially independently of a radially higher Zernike order of the image defect; or b) the radially higher Zernike order of the image defect is corrected substantially independently of the radially primary Zernike order of the image defect.
17. The system of claim 16, wherein the first optical element comprises a first lens.
18. The system of claim 17, wherein the second optical element comprises a second lens.
19. The system of claim 16, wherein: the first optical element is not adjacent the second optical element; the first and second optical elements are not arranged at mutually optically conjugate sites; and when the first and second optical elements are deformed during use of the microlithography system: the first optical element is deformed to have a first deformation profile; and the second optical element is deformed to have a second deformation profile which is different from the first deformation profile.
20. The system of claim 16, wherein first optical element has a first shape, and the second optical element has a second shape which is different from the first shape.
21. The system of claim 16, wherein the microlithography system is configured so that when the first and second optical elements are deformed during use of the microlithography system: a first force is used to deform the first optical element; a second force is used to deform the second optical element; and the second force is different from the first force.
22. The system of claim 16, wherein the microlithography system is configured so that when the first and second optical elements are deformed during use of the microlithography system: a first force is used to deform the first optical element; a second force is used to deform the second optical element; and the second force is oppositely directed compared to the first force.
23. The system of claim 16, wherein the first optical element and the second optical element are arranged at not mutually optically conjugate sites, and the first and second optical elements are at least substantially identically deformable.
24. The system of claim 16, wherein the first optical element and the second optical element are deformable at a specific ratio to one another.
25. The system of claim 16, wherein a magnitude of the corrective influence of the first optical element on a ratio of the radially primary Zernike order and a radially higher Zernike order is approximately equal to a corrective influence of the second optical element, but has a different sign.
26. The method of claim 1, wherein the microlithography system comprises a projection objective, and the projection objective comprises the first and second optical elements.
27. The method of claim 26, wherein the microlithography system further comprises a reticle.
28. The method of claim 27, wherein the microlithography system comprises a projection objective, and the projection objective comprises a mirror.
29. The method of claim 1, wherein the microlithography system comprises a projection objective, and the projection objective comprises a mirror.
30. The system of claim 16, wherein the microlithography system comprises a projection objective, and the projection objective comprises the first and second optical elements.
31. The system of claim 30, wherein the microlithography system further comprises a reticle.
32. The system of claim 31, wherein the microlithography system comprises a projection objective, and the projection objective comprises a mirror.
33. The system of claim 16, wherein the microlithography system comprises a projection objective, and the projection objective comprises a mirror.
34. The system of claim 16, wherein the microlithography system comprises a projection objective, and the projection objective comprises the first and second optical elements.
35. A system, comprising: a catadioptric microlithography projection objective, comprising: a plurality of optical elements comprising a first optical element and a second optical element; a first manipulator configured to actively deform the first optical element; and a second manipulator configured to actively deform the second optical element, wherein: the first optical element is not adjacent the second optical element; the first and second optical elements are not arranged at mutually optically conjugate sites; the first optical element has a first shape; the second optical element has a second shape which is different from the first shape; and when the first and second optical elements are deformed during use of the microlithography projection objective: a first force is used to deform the first optical element; a second force is used to deform the second optical element; the second force is different from the first force; and one of the following holds: a) a radially primary Zernike order of an image defect is corrected substantially independently of a radially higher Zernike order of the image defect; and b) the radially higher Zernike order of the image defect is corrected substantially independently of the radially primary Zernike order of the image defect.
Description
(1) The present invention is explained below in more detail with the aid of selected exemplary embodiments. In the drawing:
(2)
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(13) In order in the case of a microlithography projection objective that is constructed from a plurality of lenses to correct image defects that can occur on the basis of heating during operation or ageing of the material of the optical elements, it is provided in the method according to the invention to select at least two lenses from the plurality of lenses of the projection objective and to deform them actively via manipulators in order at least partially to correct image defects that occur.
(14) Irrespective of whether at least two lenses are selected as actively deformable lenses, or whether only one lens is selected as actively deformable lens, a further aspect of the present invention consists in specifying suitable criteria for selecting such a lens as actively deformable lens.
(15) The aspect of the present invention mentioned in the first instance and in accordance with which at least two lenses are selected from the plurality of lenses as actively deformable lenses will firstly be explained in more detail.
(16) If only one lens is used as actively deformable lens for correcting an image defect, only a relatively simple wavefront influence can be produced by the deformation of the individual lens onto the wavefront in the image field. If, by contrast, two or more adjacent lenses or lenses arranged at conjugate positions in the system are combined with one another such that these lenses have deformations of different sign, for example on the basis of a different shape of the lenses and/or a different introduction of forces by the manipulator or manipulators and, if appropriate, of different sign, for example because of introducing oppositely directed forces, it is possible for there to arise in the combination of the different profiles of the deformations of the at least two lenses a complicated wavefront influence such as cannot be attained with the aid of a single deformable lens.
(17) The same result can be achieved when two or more actively deformable lenses are deformed at different positions in the projection objective, these selected lenses being able to have similar deformations, but having different wavefront influences owing to the different positions in the projection objective.
(18) This is illustrated in
(19) Illustrated in the lower curve B is a wavefront influence of an actively deformed second lens that shows a dependence of fourth power and, moreover, differs from the wavefront influence in accordance with curve A by the opposite sign.
(20) The curve C illustrated with a broken line now shows the super-position, resulting as a sum, of the wavefront influences in accordance with curves A and B, which shows a more complicated field profile than the individual wavefront influences of the first lens and of the second lens, taken alone. It is possible in this way by combining two or more lenses and by appropriate deformation to produce a complicated field profile of the wavefront in order at least partially to compensate wavefront aberrations in the image field.
(21) It is possible in this case, in particular, to deform the first lens and the at least second lens at a specific ratio to one another. This ratio is selected as a function of the influence of the first lens and of the at least second lens on wavefront aberrations of a radially primary Zernike order and of a radially higher Zernike order thereof.
(22) This is explained by the example of the primary Zernike order Z5 and of the radially next higher Zernike order Z12 thereof.
(23) It may be assumed that the first lens produces a wavefront influence in the case of which the ratio between Z5 and Z12 is 3. It may further be assumed that this ratio is +2 for the second lens. A desired ratio x between Z5 and Z12 can then be set by selecting the deformation of the second lens at the ratio of 3+x/2x by comparison with that of the first lens. The magnitude is governed by the desired amplitude of Z5 (or Z12) in the wavefront.
(24) When using actively deformable lenses that are deformed in one-fold, two-fold or three-fold or higher-fold fashion with respect to symmetry to correct image defects of a projection objective that can arise, for example, during operation by heating of the optical elements, it is to be borne in mind that if only one actively deformable lens is used for correction the primary Zernike orders and the associated higher Zernike orders are linearly dependent on one another.
(25) Thus, for example, the image defects having two-fold symmetry in accordance with the primary Zernike order Z5, and the radially higher Zernike order Z12, are dependent on one another, and likewise the three-fold primary Zernike order Z11 and the three-fold Zernike order Z20 are dependent, and the four-fold Zernike order Z17 is dependent on the radially higher four-fold Zernike order Z28.
(26) It is not possible to correct Z12 independently of Z5 on the basis of this linear dependence between first and higher orders, for example in the case of image defects having two-fold symmetry, with the aid of only one actively deformable lens, it being possible as a result for one of the two Zernike coefficients to rise considerably after correction. A rational optimization is therefore impossible.
(27) A rational correction of such image defects is possible, however, when at least two lenses are selected for correction purposes as actively deformable lenses within the projection objective. Of course, it is also possible to select more than two lenses as actively deformable lenses, use being made, in particular, of an even number of such lenses. By using at least two lenses as actively deformable lenses, there is a possibility of setting primary and radially higher orders independently of one another.
(28) In order to ensure such an independence of the correction from primary and radially higher orders, the corrective influences of the two lenses must have different signs, but should be similar in terms of magnitude.
(29) It is correspondingly necessary to place specific demands on the geometry and position of the selected lenses in the projection objective.
(30) This results in various selection criteria for the selection of suitable lenses from the plurality of lenses of a projection objective as actively deformable lenses for correction of image defects.
(31) It is possible to achieve a correction that is independent with reference to a first Zernike order and to a radially higher Zernike order relevant thereto by making the first lens a negative lens, for example, and the second lens a positive lens, for example. This is described in more detail hereinafter with reference to
(32)
(33) A light ray 14 impinges on a lens front side 16 of the negative lens 10.
(34) Continuous lines illustrate the negative lens 10 in the nondeformed state, and broken lines illustrate it in the deformed state, which has been brought about by means of a manipulator 21.
(35) The propagation of the impinging light ray 14 inside the negative lens 10 takes place in the nondeformed state in accordance with line 18, in the deformed state in accordance with line 20. After exiting from the rear side 22 of the negative lens 10, the light ray propagates further in accordance with a line 24 in the nondeformed state of the negative lens 10, and in accordance with a line 26 in the deformed state.
(36) 28 denotes the front side of the positive lens 12, and 30 the rear side. Continuous lines illustrate the positive lens 12 in the nondeformed state, and broken lines illustrate it in the deformed state. Deformation of lens 12 is accomplished by manipulator 31. An impinging light ray 32 propagates in accordance with lines 34 and 36 in the nondeformed state of the positive lens 12, and in accordance with lines 38 and 40 in the deformed state.
(37) It is assumed below that the deformation of the negative lens 10, as also the deformation of the positive lens 12, is a quadratic function of the distance r perpendicular to the optical axis z.
(38) It then holds approximately for the lens thickness d(r) arising after deformation that
(39)
d.sub.0 being the center thickness of the negative lens 10 or the positive lens 12, and R.sub.V being the radius of curvature of the lens front side 16 or 28, and R.sub.H being the radius of curvature of the lens rear side 22 or 30.
(40) An n-fold wavefront deformation WFD can be described-approximately via the subaperture radius R.sub.S at the respective lens front side 16 or 28, and the respective lens rear side 22 or 30, as
WFD(1+aR.sub.s.sup.2).sup.n.
(41) Since the radii of curvature R.sub.H and R.sub.V are affected by sign, and since these signs differ from one another correspondingly between the negative lens 10 and the positive lens 12, is a>0 for the negative lens 10 and a<0 for the positive lens 12.
(42) Assuming that the deformation with n-fold symmetry that is imposed on the negative lens 10 and the positive lens 12 is two-fold (n=2), it follows approximately for the wavefront deformation WFD that:
WFD1+2aR.sub.s.sup.2+a.sup.2R.sub.s.sup.4.
(43) Turning now to the contributions of the wavefront deformation WFD to the primary Zernike order Z5 and to the radially higher Zernike order Z12, it holds for the negative lens 10 that:
WFDa.sub.5Z5+a.sub.12Z12, and
for the positive lens 12 that:
WFDa.sub.5Z5+a.sub.12Z12.
(44) If the deformations are selected such that the contributions a.sub.5 to the Zernike coefficient Z5 in the wavefront deformation are equal, the contributions of the wavefront deformation to Z5 eliminate one another, and the wavefront deformation in the order Z12 can be attacked independently of the first Zernike order Z5.
(45) Conversely, it is also possible, of course, to proceed in such a way that the contributions of the wavefront deformation in Z12 eliminate one another, and the contributions in Z5 relating to the correction of Z5 add up to a finite value such that Z5 can be corrected independently of Z12 in this case.
(46) In addition to the geometry of the lenses to be selected as actively deformable lenses inside a projection objective, importance attaches to further selection criteria for selecting suitable lenses as actively deformable lenses that are described hereinafter with reference to
(47) The optical effect of a lens or of a deformation of the latter on wavefront deformations in the image field also depends on the position of the lens inside the projection objective.
(48) The optical effect of a deformation of a lens, which depends on the position of the lens inside the projection objective, is influenced at least inter alia by the ratio of the subapertures at the lens front side and the lens rear side, as well as by the ratio of the subaperture at the front or rear side (or the larger of these two) to the maximum height of the lens.
(49)
(50) The abscissa of the diagram shows the ratio of subaperture (at the lens front side or lens rear side, or the larger of these two) to the maximum lens height, this ratio naturally being incapable of exceeding 1.
(51) The ordinate of the diagram shows the ratio of the subaperture at the lens front side to the subaperture at the lens rear side.
(52) 23 lenses LE1 to LE23 are assigned to the value pairs (R.sub.SV/R.sub.SH; R.sub.SH/H.sub.max) in the diagram. The lenses LE1 to LE23 belong to the projection objective, as is illustrated in
(53) Also plotted in the diagram are lines, each line illustrating an identical optical effect of a deformation for the value pairs (R.sub.SV/R.sub.SH; R.sub.SH/H.sub.max).
(54) The direction of the increase in the optical effect is illustrated by arrows A and B.
(55) The optical effect is a measure of the resulting wavefront deformation that results in the case of a deformation assumed to be identical for all lenses. An increasing resulting wavefront deformation signifies an increasing optical effect.
(56) Also plotted in
(57) It may be inferred correspondingly that in order to correct image defects that have overwhelmingly field-dependent components or consist of a combination of field-dependent and constant-field components, there are selected as actively deformable lenses ones for which the ratio of the subaperture to maximum lens height is smaller than approximately 0.7, and in the case of which the ratio of subaperture at the lens front side to subaperture at the lens rear side is in the range from approximately 0.9 to approximately 1.1 for positive lenses, and in the range from approximately 0.8 to approximately 0.9 or from approximately 1.1 to approximately 1.2 for negative lenses. This is shown in
(58) Further selection criteria for lenses to be selected as actively deformable lenses are the lens thickness, in which case the ratio of the center thickness of the lens to lens height should be smaller than approximately 0.4, and whether, during operation of the projection objective, the light passes through the corresponding lens not only once, but twice or several times, since in the latter case the optical effect is virtually doubled or multiplied with each passage.
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(61) In the following sequence of optically effective modules, the projection objective 50 includes in the sense of the passage of light, a first, purely dioptric part of positive refractive power, a biconcave lens that is arranged in the middle region of the projection objective 50, and a third, purely dioptric part of positive refractive power.
(62) The maximum radius Y that an image point can have in the case of this projection objective 50 is 11.0 mm.
(63)
(64) In this region, the lenses present there can be selected as actively deformable lenses for correcting aberrations which are then to be assigned appropriate manipulators M.sub.1, . . . , M.sub.n (n1), in order at least partially to correct overwhelmingly field-dependent image defects or combinations of constant-field and field-dependent image defects (for example astigmatism on the axis and anamorphism) that can be produced by lens heating or lens ageing.
(65) Illustrated with a dark background in
(66) It is also to be seen from
(67) The lenses with a dark background in
(68) The same projection objective 50 is illustrated in
(69)
(70) The projection objective illustrated in
(71) In the sense of the passage of light, the projection objective illustrated in
(72) In the sense of the passage of light, the projection objective illustrated in
(73) The projection objective illustrated in
(74) In the sense of the passage of light, the projection objective illustrated in
(75) The projection objective illustrated in
(76) The projection objective illustrated in
(77) Finally, the projection objective illustrated in
(78) The numerical apertures NA and the maximum radii Y that an image point can have for the respective projection objective are summarized in the following table:
(79) TABLE-US-00001 NA 2Y/mm FIG. 4a) and 4b) 1.10 22.0 FIG. 5a) and 5b) 1.00 36.0 FIG. 6a) and 6b) 1.35 32.5 FIG. 7a) and 7b) 1.20 28.8 FIG. 8a) and 8b) 1.25 30.0 FIG. 9a) and 9b) 1.30 31.5 FIG. 10a) and 10b) 0.92 32.2 FIG. 11a) and 11b) 0.95 28.0