WO2009084199A1 - 露光装置及び露光方法、並びにデバイス製造方法 - Google Patents
露光装置及び露光方法、並びにデバイス製造方法 Download PDFInfo
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- WO2009084199A1 WO2009084199A1 PCT/JP2008/003955 JP2008003955W WO2009084199A1 WO 2009084199 A1 WO2009084199 A1 WO 2009084199A1 JP 2008003955 W JP2008003955 W JP 2008003955W WO 2009084199 A1 WO2009084199 A1 WO 2009084199A1
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- exposure apparatus
- encoder
- exposure
- optical member
- measurement
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Classifications
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
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- G—PHYSICS
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- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/26—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
- G01D5/32—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light
- G01D5/34—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells
- G01D5/347—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
- G01D5/34707—Scales; Discs, e.g. fixation, fabrication, compensation
- G01D5/34715—Scale reading or illumination devices
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/26—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
- G01D5/32—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light
- G01D5/34—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells
- G01D5/347—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
- G01D5/34746—Linear encoders
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- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
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- G03F7/708—Construction of apparatus, e.g. environment aspects, hygiene aspects or materials
- G03F7/70808—Construction details, e.g. housing, load-lock, seals or windows for passing light in or out of apparatus
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- G—PHYSICS
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/708—Construction of apparatus, e.g. environment aspects, hygiene aspects or materials
- G03F7/70858—Environment aspects, e.g. pressure of beam-path gas, temperature
- G03F7/70883—Environment aspects, e.g. pressure of beam-path gas, temperature of optical system
Definitions
- the present invention relates to an exposure apparatus, an exposure method, and a device manufacturing method, and more particularly, an exposure apparatus that forms a pattern on an object with an energy beam, an exposure method, and a device that uses the exposure apparatus or the exposure method. It relates to a manufacturing method.
- a step-and-repeat projection exposure apparatus (so-called stepper) or a step-and-scan projection exposure apparatus (so-called so-called stepper).
- Scanning steppers (also called scanners)) are mainly used.
- the position of a wafer stage that holds a substrate to be exposed (hereinafter referred to as a wafer) such as a wafer or a glass plate, using a laser interferometer, as a reference with respect to the lens barrel side surface of the projection optical system.
- a wafer stage such as a wafer or a glass plate
- a laser interferometer as a reference with respect to the lens barrel side surface of the projection optical system.
- measurement is performed and position control of the stage with respect to the projection optical system is performed using the measurement result (see, for example, Patent Document 1).
- the wafer stage can be accurately followed.
- an exposure apparatus for exposing an object through an optical member with an energy beam and forming a pattern on the object, holding the object, and moving along a predetermined plane
- a movable body that holds the optical member, and a first encoder that measures a distance between a predetermined reference position and the holding member in a first axial direction parallel to the plane. It is an exposure apparatus.
- the distance in the first axial direction from the reference position to the holding member that holds the optical member is measured by the first encoder. Accordingly, even if an atmosphere change such as temperature fluctuation occurs around the first encoder and the holding member, the distance from the reference position to the optical member can be accurately measured. Therefore, the moving body can be accurately moved or positioned with reference to the optical system member.
- the present invention is an exposure apparatus that exposes an object with an energy beam via an optical member, the movable body holding the object and movable within a predetermined plane; A holding member to hold; an encoder device in which a scale is provided on one of the optical member and the holding member and a head is provided on the other, and measures positional information of the optical member in a direction parallel to the predetermined plane; Is a second exposure apparatus.
- the position information of the optical member in the direction parallel to the predetermined plane is measured by the encoder device in which the scale is provided on one of the optical member and the holding member and the head is provided on the other.
- an exposure method for exposing an object through an optical member with an energy beam to form a pattern on the object, the object having the optical member and a predetermined reference position Is a first exposure method including a first measurement step of measuring the positional relationship in the moving surface of the moving body that moves while holding the position using an encoder system.
- the positional relationship between the optical member and the predetermined reference position within the moving surface of the moving body that holds and moves the object is measured using the encoder system. This makes it possible to accurately measure the positional relationship between the optical member and the predetermined reference position within the moving surface of the moving body. Therefore, the moving body can be accurately moved or positioned with reference to the optical system member.
- a second exposure including a step of measuring positional information of the optical member in a direction parallel to the predetermined plane using an encoder device in which a scale is provided on one of the holding members to be held and a head is provided on the other; Is the method.
- the position information of the optical member in the direction parallel to the predetermined plane is measured using the encoder device in which the scale is provided on one of the optical member and the holding member and the head is provided on the other.
- a step of forming a pattern on an object using any one of the first and second exposure methods of the present invention and a step of developing the object on which the pattern is formed And a device manufacturing method.
- FIG. 2A is a view for explaining the arrangement of the head unit and the pickup
- FIG. 2B is a plan view showing the wafer stage.
- It is a perspective view which shows a measurement mount.
- It is a figure for demonstrating arrangement
- It is a block diagram which shows the control system of one Embodiment.
- FIG. 1 shows a schematic configuration of an exposure apparatus 10 according to an embodiment.
- the exposure apparatus 10 is a step-and-scan projection exposure apparatus, that is, a so-called scanning stepper.
- the projection optical system PL is provided.
- the optical axis direction of the projection optical system PL is the Z-axis direction, and the reticle and the wafer are relative to each other in a plane perpendicular to the Z-axis direction.
- the direction to be scanned is the Y-axis direction
- the direction perpendicular to the Z-axis and the Y-axis is the X-axis direction
- the rotation (tilt) directions around the X-axis, Y-axis, and Z-axis are the ⁇ x, ⁇ y, and ⁇ z directions, respectively. Will be described.
- the exposure apparatus 10 includes an illumination unit IOP, a reticle stage RST that holds the reticle R, a projection unit PU that includes the projection optical system PL, a wafer stage WST that holds the wafer W and moves in the XY plane, and a control system thereof.
- a column 34 or the like for holding the projection unit PU is provided.
- the illumination unit IOP includes a light source and an illumination optical system, and irradiates the illumination light IL to a rectangular or arc-shaped illumination area defined by a field stop (also referred to as a mask king blade or a reticle blind) disposed therein,
- a field stop also referred to as a mask king blade or a reticle blind
- the reticle R on which the circuit pattern is formed is illuminated with uniform illuminance.
- ArF excimer laser light (wavelength 193 nm) is used as an example of the illumination light IL.
- the reticle stage RST is disposed on a reticle stage base 32a that forms a top plate of a column 34, which will be described later, and the reticle stage base is generated by a magnetic levitation force generated by, for example, a magnetic levitation type two-dimensional linear actuator that constitutes a reticle stage drive system 19R. It is levitated and supported on 32a.
- reticle stage RST On reticle stage RST, reticle R is fixed by, for example, vacuum chucking or electrostatic chucking.
- Reticle stage RST is driven by reticle stage drive system 19R with a predetermined stroke in the Y-axis direction (left and right in the plane of the paper in FIG. 1), and also minute in the X-axis direction (the direction orthogonal to the plane of the paper in FIG. 1) and ⁇ z direction. Further, it is finely driven in the Z-axis direction and the tilt directions ( ⁇ x direction and ⁇ y direction) with respect to the XY plane.
- the position of reticle stage RST (reticle R) in the XY plane is a reticle laser interferometer (hereinafter referred to as a reticle laser interferometer) that irradiates a laser beam onto a reflecting surface fixed (or formed) to reticle stage RST. 18R) (referred to as “reticle interferometer”) is always detected with a resolution of about 0.25 to 1 nm, for example.
- the position of the reticle R in the Z-axis direction is, for example, a reticle focus sensor RF (not shown in FIG. 1, see FIG. 5) comprising a multipoint focus position detection system disclosed in US Pat. No. 5,448,332. ).
- Measured values of reticle interferometer 18R and reticle focus sensor RF are supplied to main controller 11 (see FIG. 5).
- Main controller 11 drives reticle stage RST via reticle stage drive system 19R based on the supplied measurement value.
- the projection unit PU has a cylindrical lens barrel 40 and a projection optical system PL composed of a plurality of optical elements held by the lens barrel 40.
- the lens barrel 40 is single.
- a plurality of lens barrels each holding one or a plurality of optical elements may be stacked.
- it is preferable that the plurality of lens barrels are housed in a sealing member to keep the cleanness of the projection optical system PL high.
- the projection optical system PL for example, a refractive optical system including a plurality of optical elements (lens elements) arranged along an optical axis parallel to the Z-axis direction is used.
- the projection optical system PL is, for example, both-side telecentric and has a predetermined projection magnification (for example, 1/4 or 1/5). For this reason, when the above-mentioned illumination area is illuminated by the illumination light IL from the illumination unit IOP, it passes through the reticle R in which the first surface (object surface) of the projection optical system PL and the pattern surface are substantially aligned.
- a reduced image (a projection image of a part of the circuit pattern) of the reticle R in the illumination area via the projection optical system PL becomes a second surface (image plane) side of the projection optical system PL. And is formed in a region (exposure region) conjugate to the illumination region on the wafer W having a resist (photosensitive agent) coated on the surface thereof.
- reticle R is moved relative to the illumination area (illumination light IL) in the scanning direction (Y-axis direction) and at the same time with respect to the exposure area (illumination light IL).
- illumination area illumination light IL
- Y-axis direction scanning direction
- the pattern of the reticle R is transferred to the shot area. That is, in this embodiment, a pattern is generated on the wafer W by the illumination unit IOP, the reticle R, and the projection optical system PL, and the sensitive layer (resist layer) on the wafer W is exposed on the wafer W by the illumination light IL. That pattern is formed.
- the column 34 has a plurality of (in this case, for example, three) leg portions 32b (the leg portions on the back side of the paper are not shown) whose lower end portions are fixed to the floor surface F, and the floor portion F above the floor surface F by the leg portions 32b. And a reticle stage base 32a supported by the above. In the center of the reticle stage base 32a, an opening 34a that is rectangular in a plan view (viewed from above) that penetrates in the vertical direction (Z-axis direction) is formed.
- the lens barrel 40 is a cylindrical hollow member whose longitudinal direction that accommodates the projection optical system PL is the Z-axis direction, for example, and a protrusion is formed at the center of the bottom wall. An optical member located at the lower end of the projection optical system PL is held inside the protrusion, and an opening serving as a path for illumination light is formed at the center of the protrusion.
- the bottom wall of the lens barrel 40 is configured by a plate member having a circular opening formed in the center, and a holding member that holds the optical member positioned at the lower end of the projection optical system PL is projected from the circular opening. May be.
- a ring-shaped flange FLG is integrally provided on the outer peripheral portion at a position somewhat below the center in the height direction of the lens barrel 40.
- the lens barrel 40 has a flange FLG supported by a plurality of, for example, three suspension support mechanisms 137 (one of which is not shown) on the lower surface side of the reticle stage base 32a. As a result, it is suspended and supported below the reticle stage base 32a.
- Each suspension support mechanism 137 includes a coil spring 136 and a wire 135 which are, for example, flexible connection members.
- the coil spring 136 vibrates like a pendulum in a direction perpendicular to the optical axis (Z-axis) of the projection optical system PL, and dampens vibration in a direction perpendicular to the optical axis of the projection optical system PL (that is, floor vibration). To prevent vibrations from being transmitted to the projection optical system PL).
- the coil spring 136 also has high vibration isolation performance in the direction parallel to the optical axis.
- the lens barrel surface plate may be supported by being suspended by, for example, three suspension support mechanisms 137.
- the convex part 134a is formed in the center part vicinity regarding the Z-axis direction of each of the three leg parts 32b of the column 34.
- a drive mechanism 440 is provided between each convex portion 134a and the flange FLG of the projection optical system PL.
- Each drive mechanism 440 includes a voice coil motor that drives the projection optical system PL in the radial direction of the lens barrel 40 and a voice coil motor that drives the projection optical system PL in the optical axis direction (Z-axis direction).
- the projection optical system PL can be driven in the direction of six degrees of freedom by three driving mechanisms 440 (the driving mechanism on the back side in FIG.
- the main control device 11 has the projection optical system PL connected to the column 34 based on acceleration information detected by an acceleration sensor (not shown) provided on the flange FLG of the projection optical system PL, for example. And the drive of the voice coil motor of each drive mechanism 440 is controlled so that it may be in a stationary state with respect to the floor surface F.
- Wafer stage WST is arranged below projection optical system PL, and is placed on stage surface plate BS placed horizontally on floor surface F via a plurality of non-contact bearings provided on the bottom surface thereof, such as air bearings. Is supported by levitation.
- wafer W is held by vacuum suction (or electrostatic suction) via a wafer holder (not shown).
- this encoder system has four linear encoders 70A to 70D (see FIG. 5), and as shown in FIG. 2A, the four encoder head units 62A to 62D are provided with measurement mounts (holding members). ) On the lower surface of 51 (details will be described later). On the other hand, on the upper surface of wafer stage WST, as shown in FIG.
- a pair of Y scales 44A, 44C having a longitudinal direction as the Y-axis direction and a pair of X are surrounded so as to surround wafer W.
- Scales 44B and 44D are fixed, respectively.
- a reflection type diffraction grating having the longitudinal direction as a periodic direction is formed.
- the surface (upper surface) on the + Z side of the stage surface plate BS is processed so as to have a very high flatness, and serves as a reference surface (guide surface) when the wafer stage WST is moved.
- Wafer stage WST is driven by wafer stage drive system 19W with a predetermined stroke in the Y-axis direction, and is also finely driven in the X-axis direction and ⁇ z direction. Further, it is inclined with respect to the Z-axis direction and XY plane ( ⁇ x direction and It is also finely driven in the ⁇ y direction).
- the measurement mount 51 is suspended and supported by a flange FLG of the projection optical system PL via a plurality of (for example, four) support members 53 (note that a support member on the back side of the drawing is not shown).
- Each support member 53 is actually configured to include link members having flexure portions at both ends.
- Each flexure portion has high rigidity in the longitudinal direction (Z-axis direction) of the support member and low rigidity in the other five-degree-of-freedom directions. Therefore, the measurement mount 51 is supported by the four support members with almost no stress between the measurement mount 51 and the flange FLG.
- the measurement mount 51 has a circular plate-like main body 52 and a plan view projecting from the main body 52 in the + X direction, the + Y direction, the ⁇ X direction, and the ⁇ Y direction. It has four extending portions 53A, 53B, 53C, 53D having a substantially square shape.
- a portion (an inner circular portion) excluding the ring-shaped rim portion on the outer peripheral edge of the upper surface is a recess 52a whose inner bottom surface is one step lower than the rim portion.
- an annular surface region parallel to the upper surface is formed which is somewhat lower than the inner bottom surface of the recess 52a.
- the inner peripheral edge and the outer peripheral edge of the annular surface region are concentric with the rim portion described above.
- the inner peripheral edge of the surface region is the inner peripheral surface of the circular opening 52c.
- the surface region and the inner bottom surface of the recess 52a are connected by a tapered slope.
- An accommodating portion 52b is formed by the surface area around the circular opening 52c and the tapered slope.
- the pickup 54x is arranged on a straight line Px as shown in FIG. 2A, and includes an x head 56x that irradiates light upward (+ Z direction).
- the pickup 54y is disposed on the straight line Py and includes a y head 56y that emits light upward.
- the x scale 58 is opposed to the pickups 54x and 54y, respectively, as representatively shown in FIG.
- the 58x and y scale 58y are fixed.
- the x scale 58x has a direction parallel to the straight line Px on the straight line Px that is orthogonal to the optical axis of the projection optical system PL and forms an angle of 45 degrees with the X axis.
- the y scale 58y is disposed on the straight line Py orthogonal to the optical axis of the projection optical system PL and at an angle of 45 degrees with the direction parallel to the straight line Py as the longitudinal direction.
- a reflection type diffraction grating having a longitudinal direction as a periodic direction is formed on the lower surfaces (surfaces on the ⁇ Z side) of the scales 58x and 58y.
- the pickup 54x uses reflected light (diffracted light from the diffraction grating) obtained by irradiating light to the x scale 58x fixed to the lower surface of the lens barrel 40, and is parallel to the straight line Px caused by vibration, for example.
- An optical x linear encoder 50x (see FIG. 5) that detects the displacement of the direction barrel 40 (projection optical system PL) is configured.
- the pickup 54y uses the reflected light (diffracted light from the diffraction grating) obtained by irradiating light to the y scale 58y fixed to the lower surface of the lens barrel 40, and the lens barrel in the direction parallel to the straight line Py.
- An optical y linear encoder 50y (see FIG. 5) for detecting a displacement of 40 (projection optical system PL) is configured.
- the x linear encoder 50x and the y linear encoder 50y have the same configuration as the encoder head disclosed in, for example, US Pat. No. 7,238,931 and US Patent Application Publication No. 2007/0288121.
- the pickups 54x and 54y include an optical system including a polarizing beam splitter in which a light source and a light receiving system (including a photodetector) are arranged outside the measurement mount 51 and separates light from the light source. Only (a part of) is disposed on the inner bottom surface of the recess 52a of the measurement mount 51, that is, facing the x scale 58x and the y scale 58y.
- the pickups 54x and 54y may be provided on the measurement mount 51.
- light and / or signals are transmitted and received between the light source, the light receiving system, and the optical system via an optical fiber (not shown) or by air transmission.
- the optical system disposed on the inner bottom surface of the recess 52a of the measurement mount 51 is referred to as a pickup.
- members disposed outside the measurement mount 51 are not limited to the light source and the light receiving system, and may be, for example, only the light source or only the light source and the light receiving element (sensor).
- the head units 62A and 62C are arranged symmetrically with respect to the optical axis of the projection optical system PL, with the X-axis direction as the longitudinal direction on the + X side and the ⁇ X side of the projection unit PU, respectively.
- the head units 62B and 62D are arranged symmetrically with respect to the optical axis of the projection optical system PL, with the Y-axis direction as the longitudinal direction on the + Y side and ⁇ Y side of the projection unit PU, respectively.
- the head units 62A and 62C include a plurality of, in this case, five Y heads 64 arranged at predetermined intervals along the X-axis direction.
- the head unit 62A is a multi-lens, in this case, five eyes, equipped with a plurality of Y heads 64 that measure the position (Y position) of the wafer stage WST in the Y-axis direction using the Y scale 44A on the wafer stage WST.
- Y linear encoder 70A see FIG. 5
- the head unit 62C constitutes a five-lens Y linear encoder 70C (see FIG. 5) including five Y heads 64 for measuring the Y position of the wafer stage WST using the above-described Y scale 44C. .
- the head units 62B and 62D include a plurality of (here, five) X heads 66 arranged at a predetermined interval along the Y-axis direction.
- the head unit 62B is a multi-lens, in this case, five-lens X linear encoder 70B, which includes a plurality of X heads 66 that measure the position (X position) of the wafer stage WST in the X-axis direction using the aforementioned X scale 44B. (See FIG. 5).
- the head unit 62D constitutes a five-lens X linear encoder 70D (see FIG. 5) including five X heads 66 for measuring the X position of the wafer stage WST using the above-described X scale 44D. .
- the measurement mount 51 configured as described above has the upper end fixed (connected) to the flange FLG and the lower end fixed (connected) to the extending portions 53A to 53D. It is suspended and supported by a book support member 53 (however, a support member on the back side of the drawing is not shown), and is disposed at a position ( ⁇ Z direction) below a predetermined distance from the lower surface of the lens barrel 40. In this suspended support state, as shown in FIG. 4, the protruding portion at the lower end of the lens barrel 40 is housed in the housing portion 52 b formed in the measurement mount 51. Further, as shown in FIG.
- the lower surface of the lens barrel 40 and the inner bottom surface of the recess 52a face each other with a predetermined gap, and the x head 56x of the pickup 54x and the x head disposed on the lower surface of the lens barrel 40 are arranged.
- the scale 58x faces, and the y head 56y of the pickup 54y and the y scale 58y disposed on the lower surface of the lens barrel 40 face each other.
- the measurement mount 51 is equipped with an alignment system ALG, a wafer focus sensor WF, etc. (see FIG. 5).
- an alignment system ALG an image processing type sensor can be used. This image processing type sensor is disclosed in, for example, Japanese Patent Application Laid-Open No. 04-065603 (corresponding to US Pat. No. 5,493,403). Has been.
- the wafer focus sensor WF for example, a wafer focus sensor disclosed in Japanese Patent Laid-Open No. 06-283403 (corresponding to US Pat. No. 5,448,332) can be used.
- the measurement mount 51 can also be called a metrology frame or the like.
- the measurement mount 51 not only the scales 58x and 58y but also the head units 62A to 62D, the alignment system ALG, and the wafer focus sensor WF are provided in the measurement mount 51.
- the present invention is not limited to this. At least one of ⁇ 62D, alignment system ALG, and wafer focus sensor WF may be provided on a member different from measurement mount 51.
- FIG. 5 is a block diagram showing a control system of the exposure apparatus 10 of the present embodiment.
- the control system shown in FIG. 5 includes a so-called microcomputer (or workstation) comprising a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), etc.
- the main controller 11 is configured mainly for overall control.
- the head units 62A and 62C (Y linear encoders 70A and 70C) facing the Y scales 44A and 44C measure the position of the wafer stage WST in the Y axis direction, and the head units 62B and 44D facing the X scales 44B and 44D, respectively.
- the position of wafer stage WST in the X-axis direction is measured by 62D (X linear encoders 70B and 70D).
- a pickup 54x (x linear encoder 50x) facing the x scale 58x and a pickup 54y (y linear encoder 50y) facing the y scale 58y disposed on the lower surface of the lens barrel 40 are straight lines.
- the displacement in the direction parallel to Px and the straight line Py, that is, the position of the lens barrel 40 in the XY plane is measured.
- the main control measure 11 monitors the measurement results of the Y linear encoders 70A and 70C and the X linear encoders 70B and 70D and the measurement results of the x linear encoder 50x and the y linear encoder 50y, and moves the wafer stage WST to the XY plane.
- the lens barrel 40 is moved with reference to the inside.
- the displacement in the XY plane of the lens barrel 40 during the exposure operation is arranged on the measurement mount 51 facing the scale 58x arranged on the lower surface of the lens barrel 40. Measurement is performed by the pickup 54x (x linear encoder 50x) and the pickup 54y (y linear encoder 50y) disposed on the measurement mount 51 facing the scale 58y disposed on the lower surface of the lens barrel 40. Therefore, even if the position of the lens barrel 40 in the XY plane slightly fluctuates due to vibration caused by the movement of the wafer stage WST, the displacement can be accurately measured. It is possible to accurately control the position of wafer stage WST with reference to the optical axis of projection optical system PL being held.
- length measuring light light emitted from the pickups 54x and 54y (hereinafter referred to as length measuring light) is reflected by the x scale 58x or y scale 58y, and is fixed to the pickups 54x and 54y and the lens barrel 40.
- the path of the measuring light is so small that it can be ignored as compared with the path of the measuring light in the interferometer, for example. Therefore, even if air fluctuations or the like occur around the lens barrel 40 during exposure, the short-term stability of the measured values of the x linear encoder 50x and the y linear encoder 50y is significantly higher than that when an interferometer is used. It becomes possible to improve.
- the pickups 54x and 54y for emitting the measurement light used for measuring the displacement of the lens barrel 40 and the head units 62A to 62D for measuring the position of the wafer stage WST are both disposed on the measurement mount 51. ing. Therefore, the positional relationship between the pickups 54x and 54y and the head units 62A to 62D is maintained constant, and the X linear encoders 70B and 70D and Y linear encoders 70A and 70C for measuring the wafer stage WST and the measurement for the lens barrel 40 are measured. It is possible to reduce measurement errors that occur between the x linear encoder 50x and the y linear encoder 50y.
- the x linear encoder 50x and the y linear encoder 50y measure the displacement of the lens barrel 40 in the direction parallel to the straight line Px and the straight line Py that form an angle of 45 degrees with respect to the X axis and the Y axis.
- the present invention is not limited to this, and the displacement of the lens barrel 40 in the X-axis direction and the Y-axis direction may be measured using an encoder, and any different two-axis displacements may be measured. Forty displacements on the XY plane may be measured. That is, the scales 58x and 58y are not limited to the direction in which the longitudinal direction (measurement direction, periodic direction / arrangement direction of the diffraction grating) is parallel to the straight lines Px and Py, and may be arbitrary.
- the optical system (a part) is arranged on the measurement mount 51 in order to avoid the heat source.
- the influence of heat can be eliminated or the influence of heat can be excluded.
- a light source and / or a light receiving system may be arranged on the measurement mount 51.
- the pickups 54x and 54y of the x linear encoder 50x and the y linear encoder 50y are attached to the measurement mount 51.
- the present invention is not limited to this, and the pickups 54x and 54y are attached to the lens barrel 40.
- the displacement of the lens barrel 40 relative to the measurement mount 51 may be measured using the scales 58x and 58y attached to the measurement mount 51.
- the pickups 54x and 54y or the scales 58x and 58y are attached to the lower end surface of the projection unit PU (lens barrel 40).
- the pickups 54x and 54y or the scales 58x and 58y may be fixed.
- the optical x linear encoder 50x and the y linear encoder 50y are used to measure the displacement of the lens barrel 40.
- the present invention is not limited to this, and an electromagnetic induction encoder or the like may be used, for example.
- the displacement of the lens barrel 40 is measured using the x linear encoder 50x and the y linear encoder 50y including the pickups 54x and 54y that receive the reflected light obtained by irradiating the scale with light.
- the present invention is not limited to this, and as an encoder that measures the displacement of the lens barrel 40, for example, an encoder that measures displacement using transmitted light that has passed through the scales 58x and 58y may be employed.
- the encoder is not limited to any different two-axis directions such as the X-axis and the Y-axis, and for example, the displacement of the lens barrel 40 may be measured in other directions (such as the ⁇ z direction).
- the projection unit PU (projection optical system PL) is suspended and supported by the three suspension support mechanisms 137 below the reticle stage base 32a via the flange FLG.
- the projection unit PU projection optical system PL
- the measurement mount 51 may be suspended and supported by the lens barrel surface plate.
- it is only necessary that the positional relationship between the projection unit PU (projection optical system PL) and the reference position in the XY plane can be measured by the linear encoder.
- at least one of the head units 62A to 62D, the alignment system ALG, and the wafer focus sensor WF may be provided on the lens barrel surface plate independently of the measurement mount 51.
- the position measurement of wafer stage WST is performed using an encoder system including X linear encoders 70B and 70D and Y linear encoders 70A and 70C. It is not limited to.
- position measurement of wafer stage WST may be performed by an interferometer system, or an interferometer system and an encoder system.
- this interferometer system since it is not necessary to measure the position of the wafer stage with reference to the projection optical system PL, the reflection surface of the measurement beam of the interferometer system need not be provided in the projection optical system PL.
- An exposure apparatus including both an interferometer system and an encoder system is disclosed in, for example, US Patent Application Publication No. 2007/0288121, US Patent Application Publication No. 2008/0088843.
- the encoder system is configured such that the grating portion (Y scale, X scale) is provided on the wafer table (wafer stage), and the X head and the Y head are arranged outside the wafer stage so as to face the lattice portion.
- the present invention is not limited to this, and as disclosed in, for example, US Patent Application Publication No. 2006/0227309, an encoder head is provided on the wafer stage, and the wafer stage is opposed to the encoder head.
- a Z head that measures the position of the wafer table in the Z-axis direction may also be provided on the wafer stage, and the surface of the grating portion may be a reflective surface to which the Z head measurement beam is irradiated.
- a single head having the functions of the encoder head and the Z head may be used.
- the lattice portion (scale) may be supported by the above-described measurement mount or lens barrel surface plate.
- the present invention is not limited to this, and the present invention may be applied to a stationary exposure apparatus such as a stepper.
- the present invention can also be applied to a step-and-stitch projection exposure apparatus that synthesizes a shot area and a shot area.
- the magnification of the projection optical system may be not only a reduction system but also an equal magnification and an enlargement system.
- the projected image may be either an inverted image or an erect image.
- the illumination light IL is not limited to ArF excimer laser light (wavelength 193 nm), but may be ultraviolet light such as KrF excimer laser light (wavelength 248 nm) or vacuum ultraviolet light such as F 2 laser light (wavelength 157 nm). good.
- ultraviolet light such as KrF excimer laser light (wavelength 248 nm) or vacuum ultraviolet light such as F 2 laser light (wavelength 157 nm). good.
- bright lines in the ultraviolet region such as g-line (wavelength 436 nm) and i-line (wavelength 365 nm) emitted from an ultra-high pressure mercury lamp can be used as the illumination light IL.
- a single wavelength laser beam in an infrared region or a visible region oscillated from a DFB semiconductor laser or a fiber laser as vacuum ultraviolet light For example, a harmonic which is amplified by a fiber amplifier doped with erbium (or both erbium and ytterbium) and wavelength-converted into ultraviolet light using a nonlinear optical crystal may be used.
- the illumination light IL of the exposure apparatus is not limited to light having a wavelength of 100 nm or more, and light having a wavelength of less than 100 nm may be used.
- EUV Extreme Ultraviolet
- a soft X-ray region for example, a wavelength region of 5 to 15 nm
- the exposure wavelength Development of an EUV exposure apparatus using an all-reflection reduction optical system designed under (for example, 13.5 nm) and a reflective mask is underway.
- the present invention can be applied to such an apparatus.
- the present invention can be applied to an exposure apparatus using a charged particle beam such as an electron beam or an ion beam.
- the present invention can be applied to an immersion exposure apparatus that is disclosed in, for example, International Publication WO 99/49504 pamphlet and the like in which a liquid (for example, pure water) is filled between the projection optical system PL and the wafer. it can.
- a liquid for example, pure water
- a light transmissive mask in which a predetermined light shielding pattern (or phase pattern / dimming pattern) is formed on a light transmissive substrate is used.
- a predetermined light shielding pattern or phase pattern / dimming pattern
- an electronic mask variant molding mask that forms a transmission pattern, a reflection pattern, or a light emission pattern based on electronic data of a pattern to be exposed is used. May be.
- an exposure apparatus (lithography system) that forms line and space patterns on the wafer W by forming interference fringes on the wafer W.
- the present invention can also be applied to.
- two reticle patterns are synthesized on a wafer via a projection optical system, and one scan exposure is performed on one wafer.
- the present invention can also be applied to an exposure apparatus that performs double exposure of shot areas almost simultaneously.
- the object on which the pattern is to be formed in the above embodiment is not limited to the wafer, but other objects such as a glass plate, a ceramic substrate, a film member, or a mask blank. But it ’s okay.
- the use of the exposure apparatus is not limited to the exposure apparatus for semiconductor manufacturing, but for example, an exposure apparatus for liquid crystal that transfers a liquid crystal display element pattern to a square glass plate, an organic EL, a thin film magnetic head, an image sensor (CCD, etc.), micromachines, DNA chips and the like can also be widely applied to exposure apparatuses. Further, in order to manufacture reticles or masks used in not only microdevices such as semiconductor elements but also light exposure apparatuses, EUV exposure apparatuses, X-ray exposure apparatuses, and electron beam exposure apparatuses, glass substrates, silicon wafers, etc. The present invention can also be applied to an exposure apparatus that transfers a circuit pattern.
- the semiconductor device includes a step of designing the function / performance of the device, a step of manufacturing a reticle based on the design step, a step of manufacturing a wafer from a silicon material, and the exposure apparatus (pattern forming apparatus) of the above-described embodiment.
- a lithography step for transferring a mask (reticle) pattern onto a wafer, a development step for developing the exposed wafer, an etching step for removing exposed members other than the portion where the resist remains by etching, and etching is unnecessary. It is manufactured through a resist removal step for removing the resist, a device assembly step (including a dicing process, a bonding process, and a packaging process), an inspection step, and the like. In this case, since the exposure apparatus of the above embodiment is used in the lithography step, a highly integrated device can be manufactured with a high yield.
- the exposure apparatus, the exposure method, and the device manufacturing method of the present invention are suitable for manufacturing electronic devices such as semiconductor elements and liquid crystal display elements.
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Abstract
Description
Claims (18)
- エネルギビームにより光学部材を介して物体を露光し、前記物体上にパターンを形成する露光装置であって、
前記物体を保持し、所定の平面に沿って移動する移動体と;
前記光学部材を保持する保持部材と;
所定の基準位置と前記保持部材との、前記平面に平行な第1軸方向の距離を計測する第1エンコーダと;を備える露光装置。 - 請求項1に記載の露光装置において、
前記基準位置と前記保持部材との、前記平面に平行で前記第1軸方向とは異なる第2軸方向の距離を計測する第2エンコーダを更に備える露光装置。 - 請求項2に記載の露光装置において、
前記第2エンコーダは、照明光を射出する第2検出装置を有し、
前記照明光に対して相対移動する第2スケールからの反射光又は透過光を受光して、前記基準位置に対する前記保持部材の、前記第2軸方向の位置を計測する露光装置。 - 請求項3に記載の露光装置において、
前記第1エンコーダは、照明光を射出する第1検出装置を有し、
前記照明光に対して相対移動する第1スケールからの反射光又は透過光を受光して、前記基準位置に対する前記保持部材の、前記第1軸方向の位置を計測する露光装置。 - 請求項4に記載の露光装置において、
前記第1スケール及び前記第2スケールは、前記保持部材に設けられている露光装置。 - 請求項2~5のいずれか一項に記載の露光装置において、
前記基準位置に対する前記移動体の変位を計測する計測装置と;
前記計測装置の計測結果と、前記第1エンコーダ及び前記第2エンコーダの計測結果のうちの少なくとも一方の計測結果とに基づいて、前記移動体の移動を制御する制御装置と;を更に備える露光装置。 - 請求項2~6のいずれか一項に記載の露光装置において、
前記第1軸方向と前記第2軸方向とは、直交している露光装置。 - 光学部材を介してエネルギビームで物体を露光する露光装置であって、
前記物体を保持して所定平面内で移動可能な移動体と;
前記光学部材を保持する保持部材と;
前記光学部材と前記保持部材との一方にスケールが設けられかつ他方にヘッドが設けられ、前記所定平面と平行な方向に関する前記光学部材の位置情報を計測するエンコーダ装置と;を備える露光装置。 - 請求項8に記載の露光装置において、
前記エンコーダ装置は、計測方向が異なる2つのスケールが前記光学部材と前記保持部材との一方に設けられ、前記所定平面内で互いに直交する第1及び第2方向に関する前記光学部材の位置情報を計測する露光装置。 - 請求項8又は9に記載の露光装置において、
前記移動体と前記保持部材との一方にスケールが設けられかつ他方にヘッドが設けられ、前記所定平面内で互いに直交する第1及び第2方向に関する前記移動体の位置情報を計測するエンコーダシステムを備え、
前記エンコーダ装置及び前記エンコーダシステムの計測情報を用いて前記移動体の移動が制御される露光装置。 - 請求項1~10のいずれか一項に記載の露光装置を用いて物体上にパターンを形成する工程と;
前記パターンが形成された物体を現像する工程と;を含むデバイス製造方法。 - エネルギビームにより光学部材を介して物体を露光し、前記物体上にパターンを形成する露光方法であって、
前記光学部材と所定の基準位置との、前記物体を保持して移動する移動体の移動面内の位置関係を、エンコーダシステムを用いて計測する第1の計測工程を含む露光方法。 - 請求項12に記載の露光方法において、
前記第1の計測工程では、前記基準位置と前記光学部材との、前記移動面内の直交2軸方向の少なくとも一方向の距離を前記エンコーダシステムを用いて計測する露光方法。 - 請求項12又は13に記載の露光方法において、
前記基準位置に対する前記移動体の変位をエンコーダシステムを用いて計測する第2の計測工程と;
前記第1、第2の計測工程の計測結果に基づいて、前記移動体の移動を制御する制御工程と;を更に含む露光方法。 - 光学部材を介してエネルギビームで、所定平面内で移動可能な移動体に保持された物体を露光する露光方法であって、
前記光学部材と該光学部材を保持する保持部材との一方にスケールが設けられかつ他方にヘッドが設けられたエンコーダ装置を用いて、前記所定平面と平行な方向に関する前記光学部材の位置情報を計測する工程を含む露光方法。 - 請求項15に記載の露光方法において、
前記エンコーダ装置は、計測方向が異なる2つのスケールが前記光学部材と前記保持部材との一方に設けられ、前記所定平面内で互いに直交する第1及び第2方向に関する前記光学部材の位置情報を計測する露光方法。 - 請求項15又は16に記載の露光方法において、
前記移動体と前記保持部材との一方にスケールが設けられかつ他方にヘッドが設けられたエンコーダシステムを用いて、前記所定平面内で互いに直交する第1及び第2方向に関する前記移動体の位置情報を計測する工程をさらに含み、
前記エンコーダ装置及び前記エンコーダシステムの計測情報を用いて前記移動体の移動が制御される露光方法。 - 請求項12~17のいずれか一項に記載の露光方法を用いて物体上にパターンを形成する工程と;
前記パターンが形成された物体を現像する工程と;を含むデバイス製造方法。
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SG186651A1 (en) | 2013-01-30 |
JP2013128126A (ja) | 2013-06-27 |
JPWO2009084199A1 (ja) | 2011-05-12 |
JP5605768B2 (ja) | 2014-10-15 |
TWI436168B (zh) | 2014-05-01 |
KR101476865B1 (ko) | 2014-12-26 |
US20090201513A1 (en) | 2009-08-13 |
KR20100101048A (ko) | 2010-09-16 |
TW200944951A (en) | 2009-11-01 |
US8792079B2 (en) | 2014-07-29 |
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