Lithographic apparatus with patterning device position determination

A lithographic apparatus is disclosed. The apparatus includes a radiation system for supplying a beam of radiation, and a support structure for supporting a patterning device. The patterning device serves to pattern the beam of radiation according to a desired pattern. The apparatus also includes a projection system for projecting the patterned beam of radiation onto a target portion of a substrate, and an assembly for determining a spatial position of the patterning device relative to the projection system. The assembly includes a measuring unit that has a plurality of sensors that are mounted on the projection system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority from European Patent Application No. 03077013.5, entitled “LITHOGRAPHIC APPARATUS AND INTEGRATED CIRCUIT MANUFACTURING METHOD”, filed Jun. 27, 2003, the content of which is incorporated herein by reference in its entirety.

FIELD

The invention generally relates to a lithographic apparatus and an integrated circuit manufacturing method. More specifically, the invention relates to a measurement unit that measures the position of a patterning device.

BACKGROUND

The term “patterning device” as employed above should be broadly interpreted as referring to a device that can be used to endow an incoming radiation beam with a patterned cross-section, corresponding to a pattern that is to be created in a target portion of the substrate; the term “light valve” can also be used in this context. Generally, the said pattern will correspond to a particular functional layer in a device being created in the target portion, such as an integrated circuit or other device (see below). Examples of such patterning devices include:

A mask. The concept of a mask is well known in lithography, and it includes mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. Placement of such a mask in the radiation beam causes selective transmission (in the case of a transmissive mask) or reflection (in the case of a reflective mask) of the radiation impinging on the mask, according to the pattern on the mask. In the case of a mask, the support structure will generally be a mask table, which ensures that the mask can be held at a desired position in the incoming radiation beam, and that it can be moved relative to the beam if so desired;

A programmable mirror array. One example of such a device is a matrix-addressable surface having a viscoelastic control layer and a reflective surface. The basic principle behind such an apparatus is that (for example) addressed areas of the reflective surface reflect incident light as diffracted light, whereas unaddressed areas reflect incident light as undiffracted light. Using an appropriate filter, the said undiffracted light can be filtered out of the reflected beam, leaving only the diffracted light behind; in this manner, the beam becomes patterned according to the addressing pattern of the matrix-addressable surface. An alternative embodiment of a programmable mirror array employs a matrix arrangement of tiny mirrors, each of which can be individually tilted about an axis by applying a suitable localized electric field, or by employing a piezoelectric actuation device. Once again, the mirrors are matrix-addressable, such that addressed mirrors will reflect an incoming radiation beam in a different direction to unaddressed mirrors; in this manner, the reflected beam is patterned according to the addressing pattern of the matrix-addressable mirrors. The required matrix addressing can be performed using suitable electronic devices. In both of the situations described hereabove, the patterning device can include one or more programmable mirror arrays. More information on mirror arrays as here referred to can be gleaned, for example, from United States Patents U.S. Pat. No. 5,296,891 and U.S. Pat. No. 5,523,193, and PCT patent applications WO 98/38597 and WO 98/33096, which are incorporated herein by reference. In the case of a programmable mirror array, the said support structure may be embodied as a frame or table, for example, which may be fixed or movable as required; and

A programmable LCD array. An example of such a construction is given in United States Patent U.S. Pat. No. 5,229,872, which is incorporated herein by reference. As above, the support structure in this case may be embodied as a frame or table, for example, which may be fixed or movable as required.

For purposes of simplicity, the rest of this text may, at certain locations, specifically direct itself to examples involving a mask and mask table; however, the general principles discussed in such instances should be seen in the broader context of the patterning device as hereabove set forth.

In a manufacturing process using a lithographic projection apparatus, a pattern (e.g. in a mask) is imaged onto a substrate that is at least partially covered by a layer of radiation sensitive material (resist). Prior to,this imaging step, the substrate may undergo various procedures, such as priming, resist coating and a soft bake. After exposure, the substrate may be subjected to other procedures, such as a post exposure bake (PEB), development, a hard bake and measurement/inspection of the imaged features. This array of procedures is used as a basis to pattern an individual layer of a device, e.g. an IC. Such a patterned layer may then undergo various processes such as etching, ion implantation (doping), metallization, oxidation, chemo mechanical polishing, etc., all intended to finish off an individual layer. If several layers are required, then the whole procedure, or a variant thereof, will have to be repeated for each new layer. Eventually, an array of devices will be present on the substrate (wafer). These devices are then separated from one another by a technique such as dicing or sawing, whence the individual devices can be mounted on a carrier, connected to pins, etc. Further information regarding such processes can be obtained, for example, from the book “Microchip Fabrication: A Practical Guide to Semiconductor Processing”, Third Edition, by Peter van Zant, McGraw Hill Publishing Co., 1997, ISBN 0 07 067250 4, incorporated herein by reference.

Although specific reference may be made in this text to the use of the apparatus according to the invention in the manufacture of ICs, it should be explicitly understood that such an apparatus has many other possible applications. For example, it may be employed in the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, liquid crystal display panels, thin film magnetic heads, etc. The skilled artisan will appreciate that, in the context of such alternative applications, any use of the terms “reticle”, “wafer” or “die” in this text should be considered as being replaced by the more general terms “mask”, “substrate” and “target portion”, respectively.

A lithographic projection apparatus having an assembly for determining a spatial position of the patterning device relative to the projection system is for example known from U.S. Pat. No. 6,359,678. A problem with the assembly disclosed in U.S. Pat. No. 6,359,670 is however, that it is insufficiently accurate in measuring the position of the patterning device relative to the projection system. One of the reasons for this inaccuracy is that variations in the dimensions of the assembly caused by temperature changes, causing in turn thermomechanical stresses, and/or vibrations will influence the measurement of the position of the patterning device relative to the projection system. In particular, measurement errors may be generated by relative rotations between the projection system and the sensors around the x-axis and/or y-axis. Other inaccuracies are introduced by measuring directly on the patterning device with a sensor because of local variations in height and reflections under small angles.

In the November 2001 issue ofResearch Disclosure, an assembly for determining the spatial position of the patterning device relative to a projection system is disclosed in which one sensor is located directly on the projection system. Although the solution presented in this disclosure solves some problems related to the relative rotations between the projection system and the respective sensors, dynamical movements of the patterning device relative to the projection system can only be partly compensated for with this proposed solution.

SUMMARY

It is therefore an aspect of the present invention to provide a lithographic projection apparatus, that includes an assembly for determining more accurately the position of patterning device relative to a projection system. In particular, the invention aims at providing a lithographic projection apparatus including such an assembly that is relatively insensitive to thermomechanical stresses and rotational changes due to dynamical motion.

These aspects may be achieved by a lithographic projection apparatus that includes a support structure that is constructed to hold a patterning device to be irradiated by a projection beam to pattern a projection beam, of radiation. The apparatus also includes a projection system that is constructed and arranged to image an irradiated portion of the patterning device onto a target portion of a substrate and an assembly for determining a spatial position of the patterning device relative to the projection system. The assembly includes a measuring unit with a number of sensors sufficient to determine the spatial position.

In an embodiment, the apparatus includes a radiation system for supplying a beam of radiation; a support structure for supporting the patterning device, the patterning device serving to pattern the beam of radiation according to a desired pattern, a projection system for projecting the patterned beam onto a target portion of a substrate and an assembly for determining a spatial position of the patterning device relative to the projection system, the assembly including a measuring unit having a number of sensors sufficient to determine the spatial position, wherein the number of sensors is mounted on the projection system. In comparison to the present state of the art, this assembly does not need extra construction bars (MF bars), which may result in a number of advantages. The assembly may perform better under vacuum and may entail less contamination risks. Also, the assembly may be less expensive to manufacture. Moreover, swinging of the frame in which the projection system is mounted, does not result in aberrations in position detection. The assembly may have a better short time stability. The assembly is less complex. Furthermore, no frame reference measurement is required. Besides, a strong decrease of parts in the vacuum chamber and consequently lower outgassing rates result. The heat load on the projection system is reduced which means the absence of cooling water which reduces the presence of dynamic disturbance forces. A strong increase of lay out space results around and above the projection system. With all these advantages, the difference in setup of the lithographic apparatus is only marginal.

Mounting of the sensor may, for example, be effected by means of bolts and/or by clamping. The sensor has at least its optical components mounted on the projection system.

In an embodiment, the invention is characterized in that the measuring unit includes a 6 degrees of freedom interferometer measurement system. Interferometric measurement techniques have proven to be reliable, robust and accurate.

In an embodiment, the invention is characterized in that at least one of the sensors uses a laser beam on a reflective part of the patterning device outside a pattern area of the said patterning device. This has the advantage that the radiation used in the position measurement can not be influenced by the pattern of the patterning device. Due to local topography in the pattern and after reflection on that local topography, changes of wave front are generated and thereof measurement errors can occur.

In an embodiment, the invention relates to a lithographic projection apparatus as described above, the patterning device in the lithographic projection apparatus being irradiated along a scanning direction wherein the spatial position of the patterning device relative to the projection system is determined by the use of at least three measurement points in a first plane, the first plane being at an angle to the scanning direction, at least two measurement points on a first line being not in the first plane and at least one point both being not in the first plane and being not on the first line. This results in an accurate determination of the six degrees of freedom of the patterning device.

An embodiment also relates to a method of manufacturing an integrated circuit (IC) by a lithographic process. The method includes: providing a radiation system to form a projection beam of radiation, from radiation emitted by a radiation source, providing a support structure constructed to hold the patterning device, to be irradiated by the projection beam to pattern the projection beam, providing a substrate table constructed to hold a substrate, and providing a projection system constructed and arranged to image an irradiated portion of the patterning device onto a target portion of the substrate, characterized by determining the position of the patterning device relative to the support structure at least once, determining, during operation of the lithographic projection apparatus, the position of the patterning device relative to the projection system, from a measurement of the position of the support structure.

In an embodiment, a method of manufacturing an integrated circuit with a lithographic includes patterning a beam of radiation with a patterning device that is supported by a support structure, projecting the patterned beam of radiation onto a substrate, by use of a projection system, determining the position of the patterning device relative to the support structure at least once, and determining, during operation of the lithographic apparatus, the position of the patterning device relative to the projection system, from a measurement of the position of the support structure.

In an embodiment, a method of manufacturing an integrated circuit with a lithographic apparatus includes patterning a beam of radiation with a patterning device that is supported by a support, imaging the patterned beam of radiation onto a target portion of a substrate with a projection system, measuring a position of the patterning device relative to the support, measuring a position of the support, and determining, during operation of the lithographic apparatus, a position of the patterning device relative to the projection system.

DETAILED DESCRIPTION

FIG. 1schematically depicts a lithographic projection apparatus1according to a particular embodiment of the invention.

The apparatus includes: a radiation system Ex, IL, for supplying a projection beam PB of radiation (e.g. EUV radiation with a wavelength of 11-14 nm). In this particular case, the radiation system also includes a radiation source LA; a first object table (mask table) MT provided with a mask holder for holding a mask MA (e.g. a reticle), and connected to a first positioning device PM for accurately positioning the mask with respect to item PL; a second object table (substrate table) WT provided with a substrate holder for holding a substrate W (e.g. a resist coated silicon wafer), and connected to a second positioning device PW for accurately positioning the substrate with respect to item PL; and a projection system (“lens”) PL for imaging an irradiated portion of the mask MA onto a target portion C (e.g. comprising one or more dies) of the substrate W. The term object table as used herein can also be considered or termed as an object support. It should be understood that the term object support or object table broadly refers to a structure that supports, hold, or carries an object.

As here depicted, the apparatus is of a reflective type (i.e. has a reflective mask). However, in general, it may also be of a transmissive type, for example, with a transmissive mask. Alternatively, the apparatus may employ another kind of patterning device, such as a programmable mirror array of a type as referred to above.

The source LA (e.g. a laser-produced plasma or a discharge plasma EUV radiation source) produces a beam of radiation. This beam is fed into an illumination system (illuminator) IL, either directly or after having a traversed conditioning device, such as a beam expander Ex, for example. The illuminator IL may include an adjusting device AM for setting the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in the beam. In addition, it will generally include various other components, such as an integrator IN and a condenser CO. In this way, the beam PB impinging on the mask MA has a desired uniformity and intensity distribution in its cross section.

It should be noted with regard toFIG. 1that the source LA may be within the housing of the lithographic projection apparatus (as is often the case when the source LA is a mercury lamp, for example), but that it may also be remote from the lithographic projection apparatus, the radiation beam which it produces being led into the apparatus (e.g. with the aid of suitable directing mirrors); this latter scenario is often the case when the source LA is an excimer laser. The current invention and claims encompass both of these scenarios.

The depicted apparatus can be used in two different modes:

1. In step mode, the mask table MT is kept essentially stationary, and an entire mask image is projected in one go (i.e. a single “flash”) onto a target portion C. The substrate table WT is then shifted in the x and/or y directions so that a different target portion C can be irradiated by the beam PB; and

2. In scan mode, essentially the same scenario applies, except that a given target portion C is not exposed in a single “flash”. Instead, the mask table MT is movable in a given direction (the so called “scan direction”, e.g. the y direction) with a speed v, so that the projection beam PB is caused to scan over a mask image; concurrently, the substrate table WT is simultaneously moved in the same or opposite direction at a speed V=Mv, in which M is the magnification of the lens PL (typically, M=¼ or ⅕). In this manner, a relatively large target portion C can be exposed, without having to compromise on resolution. InFIG. 1, an assembly12for determining a spatial position of the patterning device relative to the projection system forming a portion of the lithographic projection apparatus1is shown. The assembly12is further explained with reference toFIG. 3.

In the following explanation, a Cartesian coordinate frame is used having a y-direction parallel to the scanning direction in the lithographic projection apparatus1.

InFIG. 2, an assembly112for determining the position of a patterning device (reticle)123relative to a part111that contains projection optics is shown. The part111is also referred to as projection system111or assembly of “lenses”111. The reticle123is mounted underneath a reticle stage113. A reticle123is not visible inFIG. 2and therefore is drawn with a dashed line. In the z direction, laser beams115from a sensor121are directed from the part111to the reticle123. In the x direction, laser beams117are directed to the part111and the reticle stage113. In the y direction, laser beams119are directed to the part111and the reticle113. InFIG. 2, it is indicated that the laser beams117and119are directed in pair towards the assembly112. Theoretically, a single beam117,119could be used but for practical reasons a pair of beams is used.

The position of the reticle123relative to the part111is determined from the z measurement directly on the reticle123. The position of the reticle123relative to the part111in the x direction and y direction is derived from the measurements by the laser beams117and119. This is possible because the position of the reticle123on the reticle stage113in the xy plane, is known. The sensors from which the laser beams117and119originate, are not located on the part111.

InFIG. 3, an assembly12ofFIG. 1for determining the position of a reticle23relative to a part11that contains projection optics in accordance with an embodiment of the invention is shown. Sensors27and25are mounted on the part11, and directly measure the position of the reticle stage13. Laser beams26and28are used for these measurements. Two paired laser beams make up one measurement point. For reasons of clarity, such a paired laser beam is indicated with only one line, as is the case, for example, with the laser beams28(i.e. a total of 4) of sensor25.

In the arrangement ofFIG. 3, the assembly12includes a sensor21that differs from sensor121shown inFIG. 2. The sensor21produces three pair of laser beams instead of two pair. Two of those three pair are directed to two reflecting strips on reticle23, and one pair is directed to a reflecting strip33on the bottom side of reticle stage13, as will be further explained below with reference toFIG. 4. Moreover, there are two pair of laser beams28produced by sensor25and three pair of laser beams26by sensor27, as will be explained in detail with reference toFIG. 5.

During operation of the lithographic projection apparatus1, the reticle23is illuminated by a radiation source. The sensor21is arranged in such a way that it uses its laser beams15determining the z position of the reticle23and reticle stage13. In this way the x, y and z-positions of the reticle stage13are measured using sensors directly connected to the part11. Since the position of the reticle23relative to the reticle stage13is known, from this measurement the x and y position of the reticle23relative to the assembly of lenses11follow as well. In an embodiment, determining the z position of the reticle23relative to the part11is done by measuring the distance from a part of the reticle23outside the radiation beam and outside the patterned area at least once. Then, it is further assumed that the z position of the reticle23relative to the reticle stage13does not change during scanning. Consequently, there is no need to monitor the z position of the reticle23continuously during operation of the lithographic projection apparatus1.

As will be appreciated by a person of ordinary skill in the art, information about the position of the reticle23may be derived from the sensors21,25and27positioned in a different manner than shown inFIG. 3. For example, the sensors25and27may be integrated into one sensor that is able to determine the same positional information as the sensors25and27individually.

FIG. 4shows a reticle stage chuck (RS chuck)31in bottom view. The RS chuck31includes the reflecting parts33,35and37. The reticle23is attached to the RS chuck31in a way known in the art. Two additional reflecting strips41,43, located outside the mask area, are present on the on the reticle23. A pattern is present on the reticle23, indicated by reference numeral45and reference numeral47indicates a radiation beam scanning along the pattern45, as is known to persons skilled in the art.

Contrary to the assembly112shown inFIG. 2, all of the reflecting strips33,41,43are outside the pattern, so are outside the area illuminated by projection beam PB during operation. This prevents any detrimental effect by the pattern to the three pair of laser beams15, that can influence measurement accuracy of the derived information out of the beams.

The sensors21,25,27direct their respective laser beams15,28,26towards the reflecting parts33,35and37. The reflected laser beams give information about the position of the RS chuck31relative to the projection system11ofFIG. 3. The reflective parts33,37and35reflect light in the z, x and y direction of a reference coordinate frame respectively.

InFIG. 5, the reticle stage chuck31is shown in perspective. This figure serves to further illustrate the way the invention functions. In the x-direction, reflecting strips37are attached to the reticle stage chuck31. In the y-direction, the scanning direction as indicated by an arrow39, reflecting surfaces35shaped in the form of spots are attached to the reticle stage chuck31. Reflecting strip33for light propagating in the z-direction is attached at the bottom of the reticle stage chuck31and, as it cannot be seen directly in the perspective view ofFIG. 5, indicated with a dashed line. The same applies to the reticle23itself and the reflecting strips41and43on the reticle23.

The reason that the reflecting surfaces35in the y-direction are tiny spots is that the movement of the reticle stage chuck31in the x-direction during operation of the lithographic projection apparatus1will be marginal. On the contrary, reflecting strips37are needed in the x direction since the movement of the reticle stage chuck in the y direction is substantial. A much more extensive movement has to be covered by the reflecting strips37in order to ensure a proper reflection of the laser beams28that are directed towards these reflecting strips37during the period in which exposure light is present on the mask. The length during which exposure light is present on the mask is the sum of the pattern length and the slit length in the y-direction.

Since a total of six pairs of laser beams are used, a 6 degrees of freedom (6 DOF) interferometer measurement system is provided. Since there are three pairs of laser beams in the y-direction and two pair in the x-direction, the laser beams28and26together no only provide information about the position of the reticle stage13in the x- and y-direction, but also provide information about the tilt in the x-direction (Ry, i.e., a rotation about the y-axis), the tilt in the y-direction (Rx, i.e., a rotation about the x-axis), and the rotation about the z-axis (Rz). To that end, the three reflecting parts35may not be located on a straight line. Preferably, they are located on the three corners of a right-angled triangle.

FIGS. 6a,6b,and6cschematically show cross sections through the reticle stage chuck31. They show views in the y-direction, the x-direction and again the y-direction, respectively, to define various parameters and variables that can be used to calculate the exact position of reticle13. The parameters and variables shown have the following meaning:

x1=x position as measured by one of the two pair of beams28;

x2=x position as measured by the other one of the two pair of beams28;

y1, y2, y3=y positions as measured by one of the three pair of beams26, respectively;

z1=z position as measured by beam15that is directed to reflecting strip33;

zr1, zr2=z positions as measured by beams15directed to reflecting strips41,43; these positions are measured non real-time; and

The position x, y, z of the reticle stage chuck31may be determined from the distances measured by the laser beams15,28,26relative to a reference point according to the following general formulae, which represent an ideal case. With reflecting strips/surface, small cosine dependent corrections should be added:
x=x1+Ry*a1
y={(y1+y2)/2}+{Rx*(a1+a2)/2}
z=z1+Rx*zy+Ry*zx
Rx=(y1−y3)/b1
Ry=(x1−x2)/b1
Rz=(y1−y2)/(e1+e2)

The laser beams may have one common origin or may be generated by independent individual laser sources. The additional reflecting strips41and43may be used to determine non real-time, the position in the z direction and the Ry orientation of the reticle39itself relative to the reference point. Because of the limited stroke in x-direction and z-direction, reflection parts35may also consist of 3 cube corners as reflectors.