Interferometer system, lithography apparatus, and article manufacturing method

Provided is an interferometer system that irradiates an object to be measured with measuring light to thereby measure the position of the object to be measured. The interferometer system includes a laser light source; an interferometer configured to separate laser light emitted from an emission opening of the laser light source into the measuring light and reference light; and an optical path protecting member configured to surround an optical axis such that the laser light passes through the inside thereof and of which one opening is in contact with the emission opening.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to an interferometer system, a lithography apparatus, and an article manufacturing method.

Description of the Related Art

There has been known an interferometer system including an interferometer that measures the position of an object to be measured using laser light emitted from a laser light source. In the interferometer system, the laser light emitted from the light source is firstly guided to the interferometer after splitting by a beam splitter or after folding by a mirror. Next, the interferometer separates the laser light into measuring light and reference light, and detects an interference signal generated by superposition of the measuring light returned by reflection from the object to be measured and the reference light. Consequently, the difference in displacement between the measuring light and the reference light is derived, so that the position of the object to be measured can finally be specified. Here, when any one of temperature, pressure, and humidity changes in an optical path through which either the measuring light or the reference light passes, the refractive index of air changes. Thus, a measurement error may occur by the difference between the measuring light and the reference light both of which have been adversely affected due to a change in the refractive index of air. Accordingly, in order to reduce the occurrence of measurement error, there is also an interferometer system that is provided with a cover on an optical path or is provided with a device which performs local air-conditioning control. In contrast, in the common optical path, through which the superposed measuring light and reference light pass, from the light source to the interferometer, it has been conventionally thought that no measurement error caused by a change in refractive index itself which is changed by variations in temperature or the like occurs in principle. This is because, since the optical path is common to both measuring light and reference light, no optical path length difference occurs if both the measuring light and the reference light are subject to the same change. However, when three hours or greater is taken for measurement, the impact of a nonlinear error caused by a change in pressure or the like may not be ignored even by such a laser interferometer. Accordingly, Japanese Patent Laid-Open No. H11-44506 discloses an interferometer measuring apparatus that seals an optical path with a sealing pipe such that a common optical path is not affected by the exterior environment, particularly, pressure.

However, even when an optical path is sealed with a sealing pipe so as not to be affected by a change in refractive index as disclosed in Japanese Patent. Laid-Open No. H11-44506, a measurement error may occur in a short-time measurement which is substantially immune to pressure variations or the like if a portion open to atmosphere is present in at least a part of the common optical path. This is because, since the refractive index distribution occurs in the common optical path and the interface between airs having different refractive indices constantly changes upon the occurrence of airflow, the angle of laser light (optical axis) also changes with a change in interface. When the angle of laser light changes in the optical path, the irradiation position of measuring light on the object to be measured changes by an amount proportional to the distance from the position at which a change in angle occurs to the object to be measured.FIGS. 7A and 7Bare reference diagrams illustrating a measurement error for comparison. Here, if a surface40to be measured and measuring light41are perfectly orthogonal to each other as shown inFIG. 7A, a measurement error E1occurs as the approximate L(1−cos θ) from the relationship between an optical path length L and an angle change θ. In contrast, when the surface40to be measured is offset from the measuring light41by an offset θ2from the orthogonal relationship as shown inFIG. 7B, an additional measurement error E2occurs as the product of L and tan θ1tan θ2. In this case, examples of factors for causing a change in refractive index in the common optical path include a change in temperature caused by a laser light source. The temperature of the laser light source is typically controlled by using a heater in order to stabilize the wavelength of laser light. Thus, the laser light source itself is a large heat-generating source. In particular, a large temperature distribution is formed in the vicinity of an emission opening for emitting laser light. In other words, even when an optical path is sealed with a sealing pipe as disclosed in Japanese Patent Laid-Open No. H11-44506, a measurement error may occur due to a change in refractive index interface caused by temperature change of the laser light source if a gap which is open to atmosphere is present between the sealing pipe and the laser light source.

SUMMARY OF THE INVENTION

The present invention provides, for example, an interferometer system that is advantageous to reduction of a measurement error when the position of an object to be measured is measured by using a laser interferometer.

According to an aspect of the present invention, an interferometer system that irradiates an object to be measured with measuring light to thereby measure a position of the object to be measured is provided that includes a laser light source; an interferometer configured to separate laser light emitted from an emission opening of the laser light source into the measuring light and reference light; and an optical path protecting member configured to surround an optical axis such that the laser light passes through the inside thereof and of which one opening is in contact with the emission opening.

Further features of the present invention will become apparent from she following description of exemplary embodiments with reference to the attached drawings.

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, preferred embodiments of the present invention will now be described with reference to the accompanying drawings.

First Embodiment

Firstly, a description will be given of an interferometer system according to a first embodiment of the present invention. The interferometer system of the present embodiment employs a laser interferometer and specifies the position of an object to be measured which is movable in any direction by measuring the distance to the object to be measured.FIG. 1is a schematic diagram illustrating a configuration of an interferometer system1according to the present embodiment. InFIG. 1, the Z-axis is set in the direction parallel to the perpendicular direction (in the present embodiment, vertical direction) of the plane of motion of an object to be measured2, the X-axis is set in one scanning direction within the plane of motion, and the Y-axis is set in other scanning direction orthogonal to the X-axis. As an example, the interferometer system1measures the object to be measured2from the X and Y two axial directions by setting the XY stage which moves within the XY plane as the object to be measured2as shown inFIG. 1. The interferometer system1includes a laser light source (laser light source unit). The term “laser light source” used herein refers to a light-emitting source directly emitting laser light or a housing of a product including a light-emitting source therein. In particular, in the present embodiment, a description will be given of a case where a laser light source is a housing of a product including a light-emitting source therein. The interferometer system1has a housing3including a laser-emitting source, a laser interferometer (hereinafter referred to as “first interferometer”)4that irradiates the object to be measured2with measuring light in the X-axis direction, and a laser interferometer (hereinafter referred to as “second interferometer”)5that irradiates the object to be measured2with measuring light in the Y-axis direction. Reflectors (reflecting mirrors)2afor reflecting measuring light radiated from the interferometers4and5facing thereto are provided on the side surfaces of the object to be measured2in the X- and Y-axial directions. The housing3including the laser-emitting source emits laser light (linearly polarized light orthogonal to each other) towards two interferometers4and5. A heater (not shown) is provided on the inside or outside of the housing3including the laser-emitting source in order to stabilize the wavelength of laser light so that the temperature of the housing3is controlled. Each of two interferometers4and5includes a polarized beam splitter that separates laser light into measuring light and reference light. The interferometer system1also includes a beam splitter6for splitting laser light emitted from the housing3including the laser-emitting source into two light beams and a folding mirror7for reflecting and routing laser light to a predetermined position in the common optical path, through which laser light travels, from the housing3to two interferometers4and5. Light receivers8and9for receiving the measuring light returned by reflection from the object to be measured and the reference light are provided within two interferometers4and5, respectively. Each of the light receiver8(the first interferometer4) and the light receiver9(the second interferometer5) detects an interference signal generated by superposition of the measuring light returned by reflection from the object to be measured2and the reference light. At this time, an interference signal output from the light receiver8or the light receiver9is transmitted to a controller (signal processor, not shown) which is provided on the inside or outside of the interferometer system1, and the controller specifies (calculates) the position of the object to be measured2based on a difference in displacement of the received interference signals. When it is assumed that the interferometer system1is employed in an exposure apparatus20to be described below with reference toFIG. 3, a controller27may be responsible for or play a role of the controller.

Furthermore, the interferometer system1includes an optical path protecting member10for covering an optical path at an emission opening3afor emitting laser light from the housing3including the laser-emitting source. Here, the housing3including the laser-emitting source has a heater for stabilizing the wavelength of laser light, and thus, also serves as a heat generating source. Thus, when the vicinity of the emission opening3ais open to atmosphere, a flow of air is generated by forming a large temperature distribution, and thus, the interface between airs having different refractive indices constantly changes, resulting in an angle change of laser light (light beam). Since the angle change may cause a measurement error, it is preferable that the occurrence of such an angle change is suppressed. Accordingly, in the present embodiment, the flow of air which may flow into the vicinity of the emission opening3ais blocked by the optical path protecting member10, so that the occurrence of an angle change of laser light is suppressed.

Firstly, the optical path protecting member10is a tubular member of which the cross section is a circle or a rectangular, and the laser light emitted from the housing3including the laser-emitting source passes inside the tubular member. Here, it is also contemplated that the internal space of the optical path protecting member10is isolated (sealed) from the external space thereof by simply providing optical glasses (transmitting windows) at openings on the laser light-incidence side and the laser light-emission side of the optical path protecting member10such that the interior of the optical path protecting member10is unaffected from the exterior thereof. However, transmission of laser light through the optical glass may lead to the occurrence of a measurement error caused by the following events. These events include a light quantity loss caused by reflection from the glass surface, polarized light leakage caused by retardation which may be caused by birefringence in the glass, the occurrence of a nonlinear measurement error caused by a wavefront change, the angle change of the optical axis due to a change in the degree of parallelism caused by glass heat deformation (shrinkage or expansion), and the like. Thus, it is preferable that an optical member such as an optical glass is not arranged as much as possible in the optical path of laser light. Accordingly, one opening of the optical path protecting member10(the opening on the laser light-incidence side) is firstly brought into contact with the emission opening3aof the housing3including the laser-emitting source via a sealing member11. As the sealing member11, an O-ring made of fluorine rubber may be employed. In addition, a fluorine rubber sponge, a gasket, or the like may also be employed. When the optical path protecting member10is not detached from the emission opening3a, the sealing member11may be employed as adhesive. In this manner, she vicinity of the emission opening3awhich is readily affected by she flow of air if the emission opening3ais open to atmosphere can be blocked such that the flow of air to the surrounding environment such as heat convection caused by the housing3including the laser-emitting source or the like is not transferred to the interior of the optical path protecting member10. In contrast, the other opening of the optical path protecting member10(the opening on the laser light-emission side) is positioned in close proximity of the beam splitter6, and a portion of the other opening through which laser light, passes is open to atmosphere for reasons as described above. The material, of the optical path protecting member10may preferably be an aluminum alloy or may also be other metal materials. A resin material such as POM (polyacetal) having low thermal conductivity or ceramics may also be employed for the optical path protecting member10such that the optical path protecting member10is less sensitive to thermal effect from the exterior thereof.

The optical path protecting member10also has a temperature controller12that controls the temperature of the internal space thereof to be constant. As shown inFIG. 1, the temperature controller12has, for example, a passage12athat circulates cooling water in the inner surfaces of the optical path protecting member10. The passage12ais connected to a supply/recovery unit (not shown) disposed on the exterior of the optical path protecting member10via a line12bthrough a hole formed in the wall portion of the optical path protecting member10. The supply/recovery unit supplies and recovers cooling water of which the temperature is adjusted so as to circulate the cooling water within the passage12a. In this manner, the temperature controller12suppresses the occurrence of a temperature distribution by maintaining she temperature of the internal space of the optical path protecting member10to be constant, so that the influence of heat convection which may be formed in the internal space can be reduced. Note that the passage12ais not limited to the one directly formed on the inner surfaces of the optical path protecting member10but may also be, for example, a tubular member disposed on the inner surfaces of the optical path protecting member10by welding or adhesion. Furthermore, a fluid to be circulated within the passage12ais not limited to cooling water but may be, for example, a liquid other than water or gas such as air. Furthermore, the optical path protecting member10has an insulator (vacuum insulator)13for reducing susceptibility to the temperature of external air on the outer wall (the outer circumferential portion) thereof. While, in the example shown inFIG. 1, the insulator13is attached to the outer wall of the optical path protecting member10, the insulator13may also be attached to the inner wall of the optical path protecting member10.

As described above, according to the present embodiment, an interferometer system, for example, that is advantageous to reduction of a measurement error when the position of an object to be measured is measured by using a laser interferometer may be provided.

The following variation may also be made for the configuration of the interferometer system1described in the above embodiment.FIGS. 2A and 2Bare schematic diagrams illustrating variant examples of the configuration of the interferometer system1. Firstly, as shown inFIG. 2A, the interferometer system1has a light source cover14that encloses and surrounds the housing3including the laser-emitting source. The light source cover14has an opening only at its portion through which the optical path protecting member10which is brought into connection with the housing3including the laser-emitting source extends. With the above configuration, in addition to the effect provided by the optical path protecting member10, heat transmission and thermal conductivity from the housing3including the laser-emitting source to she exterior environment can also be reduced, resulting in a measurement with higher accuracy. Furthermore, with this configuration, as shown inFIG. 2B, an exhauster (vent mechanism)15for exhausting internal gas to the outside can be provided in she light source cover14, so that the heat in the internal space of the light source cover14can be efficiently recovered. Thus, other countermeasures against heat, such as additional provision of the aforementioned temperature controller12or the like, can be omitted by employing the above configuration.

Second Embodiment

Next, a description will be given of an interferometer system according to a second embodiment of the present invention. While, in the first embodiment, the laser light source is a housing of a product including a light-emitting source therein, a feature of the interferometer system of the present embodiment lies in the fact that the laser light source is a light-emitting source directly emitting laser light, such as a laser tube or the like. Each orFIGS. 3 to 5is a schematic diagram illustrating a configuration of the vicinity of the housing3including a laser tube16in the interferometer system of she present embodiment. InFIGS. 3 to 5, she elements corresponding to the configuration of the interferometer system1shown inFIG. 1of the first embodiment have the same reference numerals. The laser tube16amplifies the excited laser light by reflecting and reciprocating it between two mirrors (not shown) at opposite ends thereof to thereby emit it as laser light. The laser light emitted from the laser tube16is emitted to outside through the opening provided in the housing3via an optical component17such as a beam expander for expanding the beam diameter of the laser light. A heater (not shown) is provided on the inside or outside of the laser tube16in order to stabilize the wavelength of laser light so that the temperature of the laser tube16is controlled. Thus, the laser tube16also serves as a heat generating source. The optical path protecting member10is arranged so as to enclose the laser light and the optical component17therein. One opening of the optical path protecting member10(the opening on the laser light-incidence side) is brought into contact with the emission opening16aof the laser tube16via the sealing member (sealing member)11. The housing3has an opening only at its portion through which the optical path protecting member10extends. The other opening of the optical path protecting member10(the opening on the laser light-emission side) is positioned in close proximity of the beam splitter6. In this manner, the heat convection caused by the laser tube16is blocked, so that the interface between airs having different refractive indices can be suppressed from being changed in the optical path of laser light.

As shown inFIG. 3, an exhauster (vent mechanism)17for exhausting internal gas to the outside may be provided in the housing3. In this manner, the gas in the internal space of the housing3can be efficiently recovered. A temperature controller18may also be provided in the housing3. It is preferable that the temperature controller18is provided in the vicinity of the opening, through which the optical path protecting member10extends, provided in the housing3. The temperature controller18performs temperature control such that a temperature near the opening of the housing3is a predetermined temperature. The predetermined temperature is the ambient temperature of the space surrounding the housing3. The temperature controller18can control the temperature of the space near the opening extending between the inside and the outside of the housing3, so that the heat convection caused by the laser tube16is efficiently suppressed. In this manner, a temperature gradient that occurs at the periphery of laser light near the opening can be reduced, resulting in the suppression of a measurement error caused thereby.

On the other hand, while the optical path protecting member10is configured to hold the optical component17therein in the example shown inFIG. 3, a plurality of optical path protecting members10may also be arranged in contact with the optical component17so as not to hold the optical component17therein as shown inFIG. 4. In this case, a plurality of optical path protecting members10is provided between the laser tube16and the optical component17, between the optical components17, and between the optical component17and the beam splitter6via tight contact members11. In this manner, the heat convection caused by the optical component17can be suppressed.

Furthermore, a temperature controller19may also be provided on the outer periphery of the laser tube16as shown inFIG. 5. In this case, the temperatures of the temperature controllers12,18, and19are set to be the same. When the temperature of external air (the space outside the housing3including the laser-emitting source) is adjusted to be constant, the temperatures of the temperature controllers12,18, and19are set to be the same as the temperature of external air. In this manner, heat convection does not occur at the periphery of laser light and a temperature distribution is not produced in air, so that the occurrence of an angle change of laser light can be more efficiently suppressed.

Next, a description will be given of a lithography apparatus according to one embodiment of the present invention.FIG. 6is a schematic diagram illustrating a configuration of the exposure apparatus20as an exemplary lithography apparatus of the present embodiment. The exposure apparatus20is a projection type exposure apparatus that is used for steps of manufacturing semiconductor devices and transfers and exposes a pattern (e.g., circuit pattern) formed on a reticle (original)21using a step-and-repeat system onto a wafer22(substrate), i.e., a substrate to be treated. Note that she exposure apparatus20is not limited to the step-and-repeat system but the exposure apparatus20of the step-and-scan system may also be employed. InFIG. 6, the Z-axis is defined in a direction parallel to the optical axis (in the present embodiment, vertical direction) of a projection optical system23and the X-axis and the Y-axis are defined in two directions orthogonal to each other within a plane perpendicular to the Z-axis. The exposure apparatus20includes an illumination system24, an original stage25, a projection optical system23, a substrate stage26, and a controller27. The illumination system24includes optical elements such as a lens, a mirror, a light integrator, an aperture, and the like and irradiates the reticle21with light by adjusting the light emitted from a light source not shown). As a light source, a pulse laser light source may be employed. The reticle21is, for example, an original made of quartz glass. A pattern to be transferred onto the wafer22is formed on the reticle21. The original stage (holder)25is movable in the XY-axis directions while holding the reticle21. The projection optical system23projects and exposes the pattern on the reticle21, which has been illuminated with exposure light from the illumination system24, onto the wafer22with a predetermined magnification (e.g., ½ to ⅕). Note that the original stage25and the projection optical system23are supported by a barrel surface plate30which is installed on a surface plate28and includes a vibration isolating member29. The wafer22is made of single crystal silicon or the like. A resist (photoresist) is applied to the surface thereof. The substrate stage (holder)26is movable in at least the XY-axis directions while holding the wafer22. Note that the substrate stage26is installed on a stage surface plate31mounted on the surface plate28. Furthermore, the controller27may control the operation, adjustment, and the like of the components provided in the exposure apparatus20. In particular, in the exposure apparatus20, the original stage25or the substrate stage26is treated as the object to be measured2and the interferometer system1described above is employed as an apparatus for measuring the position of the original stage25or the substrate stage26. According to the exposure apparatus20of the present embodiment, the interferometer system1which is preferable for reducing a measurement error is employed, so that a pattern image from the projection optical system23can be aligned with a pattern forming-region on the wafer22with high accuracy. While, in the present embodiment, a description has been given of an exposure apparatus as a lithography apparatus, the lithography apparatus is not limited thereto but may also be a lithography apparatus including at least one of a movable original, stage and a movable substrate stage. For example, the lithography apparatus may also be a lithography apparatus that performs writing on a substrate (a photoresist coated on the substrate) with a charged particle beam such as an electron beam or may also be an imprint apparatus that forms (molds) an imprint material on a substrate using a mold to thereby form a pattern on the substrate.

An article manufacturing method according to an embodiment of the present invention is preferred in manufacturing an article such as a micro device such as a semiconductor device or the like, an element or the like having a microstructure, or the like. The article manufacturing method may include a step of forming a pattern (e.g., latent image pattern) on an object (e.g., substrate on which a photosensitive material is coated) using the aforementioned lithography apparatus; and a step of processing (e.g., step of developing) the object on which the latent image pattern has been formed in the previous step. Furthermore, the article manufacturing method may include other known steps (oxidizing, film forming, vapor depositing, doping, flattening, etching, resist peeling, dicing, bonding, packaging, and the like). The device manufacturing method of this embodiment has an advantage, as compared with a conventional device manufacturing method, in at least one of performance, quality, productivity and production cost of a device.

This application claims the benefit of Japanese Patent Application No. 2013-006617 filed on Jan. 17, 2013, which is hereby incorporated by reference herein in its entirety.