Vacuum chamber with a thick aluminum base plate

A target processing machine (100), such as a lithography or inspection machine, comprising a rigid base plate (150), a projection column (101) for projecting one or more optical or particle beams on to a target (130), a support frame (102) supporting the projection column, the support frame being supported by and fixed to the base plate, a stage comprising a movable part (128) for carrying the target and a fixed part (132, 133) being supported by and fixed to the base plate, a beam sensor (160) for detecting one or more of the beams projected by the column, the beam sensor at least in part being supported by and fixed to the base plate, and a vacuum chamber (110) enclosing the support frame and the column, for maintaining a vacuum environment in the interior space of the chamber, the vacuum chamber formed with the base plate forming part thereof, and supporting a plurality of wall panels (171, 172) including a plurality of side wall panels (171) supported by and fixed thereto.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates to a vacuum chamber for a lithographic apparatus having an integrated base plate.

BRIEF SUMMARY OF THE INVENTION

A target processing machine, such as a lithography or inspection machine, comprising a rigid base plate, a projection column for projecting one or more optical or particle beams on to a target, a support frame supporting the projection column, the support frame being supported by and fixed to the base plate, a stage comprising a movable part for carrying the target and a fixed part being supported by and fixed to the base plate, a beam sensor for detecting one or more of the beams projected by the column, the beam sensor at least in part being supported by and fixed to the base plate, and a vacuum chamber enclosing the support frame and the column, for maintaining a vacuum environment in the interior space of the chamber, the vacuum chamber formed with the base plate forming part thereof, and supporting a plurality of wall panels including a plurality of side wall panels supported by and fixed thereto.

The beam sensor is preferably accommodated at least partially below the stage, and the base plate preferably includes a recess or hole into which the beam sensor extends. The stage preferably comprises one or more drives for moving a movable part of the stage, the drives being located at least partially outside the vacuum chamber, and the base plate preferably includes one or more openings through which the one or more drives communicate with the movable part of the stage.

The machine preferably comprises one or more vibration isolation members between the side walls and the base plate, and the base plate preferably includes three support points on its underside for supporting the machine on a pedestal. The support frame preferably forms part of a vibration isolation module, the module comprising an intermediate body connected to the support frame by means of at least one spring element, and a support body for accommodating the projection column, the support body being connected to the intermediate body by means of at least one pendulum rod.

The wall panels are preferably assembled to form the chamber using a plurality of connection members, the connection members being adapted to removably connect the wall panels with one or more sealing members provided at the edges of the wall panels. The connection members may be adapted to locate the wall panels while providing for a small predetermined range of movement of a wall panel. The connection members may comprise pins or bolts, and the one or more of the sealing members may comprise an O-ring or C-ring disposed between adjacent wall panels. At least one face of the wall panels of the chamber may be substantially covered with a mu metal.

The beam sensor is preferably fixed to the base plate so that the beam sensor has a fixed spatial relationship with the fixed part of the stage. The base plate may comprise a center section forming an interface to the support frame and a peripheral section forming an interface with the side walls of the vacuum chamber, the base plate sections being releasably connected.

The base plate may be constructed of a single thick piece of metal. The base plate may also be made in two pieces, comprising a center section forming an interface to the support frame and a peripheral section forming an interface with the side walls of the vacuum chamber. These two sections are preferably releasably connected. Preferably, the base plate is substantially constructed of aluminium.

The base plate may have a thickness substantially greater than the wall panels of the vacuum chamber. Preferably, the base plate has sufficient mass to limit the effect of vibration on the machine without requiring a fixed connection to a supporting slab.

The machine operates in a vacuum environment. A vacuum of at least 10−3mbar is typically required for a charged particle lithography machine. All of the major elements of the machine are preferably housed in a common vacuum chamber, including for a charged particle lithography machine, the charged particle source, beamlet apertures and blanking system, projector system for projecting the beamlets onto the wafer, and the moveable wafer stage. In another embodiment the charged particle source may be housed in a separate vacuum chamber.

The target processing machine is sensitive to vibration, and in the illustrated embodiment the support frame102provides vibration isolation for the projection column101. To this end, the support frame102comprises an intermediate body103and a support body104arranged for accommodating the projection column101. The support frame102is connected to the intermediate body103by means of spring elements105comprising leaf springs in this embodiment. The spring element may also include damping elements to enable vibrational damping, particularly in the z-direction.

The support body104is also connected to the intermediate body103, by means of at least one rod-like structure, further referred to as pendulum rod108. The at least one pendulum rod108should be sufficiently strong to carry the body104, which may have a mass of several hundreds of kilograms, and capable of permitting the body104to swing. The intermediate body103and/or the support body104may be provided with damping elements to dampen vibrations in the horizontal plane and preferably also to dampen vibrations in a rotational direction about the z-direction axis, i.e. Rz. The pendulum rods108comprise two flexure points, which may be created by locally reducing the cross-sectional area of the rod108at the point of flexure. The presence of the two flexure points causes the swinging motion of the support body104to occur in the horizontal plane, i.e. the xy-plane. The term “flexure point” used herein is meant to refer to a point about which a part of the rod108at one side of the flexure point is able to pivot and/or swivel with respect to a part of the rod108at the other side of the flexure point.

The target130, such as a substrate or wafer, is held on a substrate support structure127, which is arranged on a movable stage. The stage comprises a movable part, chuck128, for carrying the target and a fixed part132,133being supported by and fixed to the base plate. The stage further comprises a long-stroke section including an X-stage120arranged for movement in the x-direction (inFIG. 1in the direction into and out of the paper) and a Y-stage122arranged for movement in the y-direction (inFIG. 1in a horizontal direction). The stage short-stroke section comprises positioners124for moving the chuck128in the X, Y, and/or Z-direction and in one or more rotational directions Rz, Rx, Ry. The positioners typically take the form of electro-motors, preferably linear motors, preferably comprising Lorentz-type actuators. A gravity compensation spring125for decoupling vibrations in the support frame102from the substrate support structure127and the target130provided thereon.

FIG. 2shows a horizontal cross-sectional view through the base plate150. The base plate150is preferably made from a thick and rigid block of metal such as aluminium. The support frame102is supported by and fixed to the upper side of the base plate, and the fixed part132,133of the stage is also supported by and fixed to the base plate. The base plate includes supporting legs152for supporting the machine on a pedestal154. The base plate preferably has three supporting legs to provide stable support for the machine on the pedestal. The legs are preferably formed as an integral part of the base plate, the metal base plate being machined in one process to form the legs and interfaces to other components in one process from a block of metal so that a single error and high accuracy is defined. The legs preferably take the form of inverted pyramids with three or more sides and a flattened portion at the peak of the pyramid where each leg rests on the pedestal.

The base plate150includes interfaces for the beam sensor160, the fixed part of the stage132,133, the support frame102, and the vacuum chamber walls171. The interfaces are formed on the top side of the base plate.

The base plate150may include one or more openings through which one or more drives140are arranged. The drives are preferably located at least partially outside the vacuum chamber. Although not depicted inFIG. 2, the drives are preferably physically connected with the stage for moving the movable part of the stage. A more detailed embodiment is described with reference toFIG. 7.

A beam sensor160is located under the stage for detecting one or more of the beams projected by the projection column. The beam sensor may be used to detect beam position, beam spot size, and other characteristics of the beams projected by the column. The beam sensor is supported by and fixed to the base plate. The beam sensor extends into a recess in the base plate, and in the embodiment ofFIG. 2the beam sensor160is fitted into a housing162which extends into a hole formed in the base plate. For measurement of beam position, it is important for the beam sensor to be located in a fixed spatial relation to the fixed part of the stage, so that measurement of beam position with respect to the stage can be made with high accuracy.

The support frame102is also supported by the base plate150. In the embodiment shown inFIG. 2the bottom of the legs of the support frame are fixed to the base plate, e.g. bolted or welded to the base plate to provide a rigid and stable support for the frame.

The vacuum chamber110encloses the support frame and the projection column, for maintaining a vacuum environment in the interior space of the chamber. The base plate150forms a part of the vacuum chamber, together with the side wall panels171and top wall panel172. The side wall panels171which are supported by and fixed to the base plate.

FIG. 3shows an embodiment of the vacuum chamber having side wall panels171, top panel172, and temporary floor panel174. The vacuum chamber is shown on its side as it may be positioned during assembly. The chamber may be assembled with a temporary floor panel as shown or may be assembled directly onto the base plate150. The wall panels are joined at their edges by connection members such as bolts, enabling easy assembly and disassembly. The edges of the wall panels include a recess for locating a sealing member such as an O-ring or C-ring of the like between adjacent panels. A door frame175is provided for one wall, the door176being substantially the same size as a wall panel and in the fitting into the door frame. This provides a large opening substantially the size of an entire wall of the vacuum chamber. The top or ceiling panel172has holes for passage of data communication cables, electrical supply cables, cooling water tubes and the like into the chamber to connect to the machine inside the chamber.

FIG. 4shows the vacuum chamber assembled and positioned upright, sitting on temporary legs179used to facilitate assembly.

The vacuum chamber can be constructed as a kitset that can be shipped in a disassembled flat pack configuration and assembled on site or at a location nearer its final location. The components of the vacuum chamber may be assembled without welding, and the chamber constructed so that when the chamber is pumped down, the force of the vacuum within the chamber assists in forming a vacuum-tight construction by exerting force that acts to close any gaps between wall panels and hold the panels tightly together.

This type of construction has numerous advantages over conventional designs. The parts of the vacuum chamber may be designed as standardized components and manufactured in larger manufacturing runs, may be manufactured in parallel, and/or the manufacturing may be outsourced to specialist manufacturers to reduce lead-times and cost. Final assembly of the components may be performed without customized tooling or heavy machinery, reducing the amount of welding required and simplifying the manufacturing processes and reducing manufacturing time. The modular design provides greater flexibility in shipping the chamber, as the chamber may be shipped disassembled to reduce shipping volume and allow for separate shipment of different components. The modular design also provides greater flexibility in altering the specifications of the vacuum chamber, e.g. the size and shape of the chamber, even after shipment of the chamber from the factory.

Note that as used herein, “vacuum” does not refer to a perfect vacuum, but to an internal pressure in the interior space of the vacuum chamber that is lower than the pressure in the environment surrounding the chamber. For example, a vacuum of at least 10−3mbar is preferred for a charged particle lithography machine, preferably 10−6mbar.

FIG. 5is a cross sectional view showing detail of a connection between the vacuum chamber walls171and the base plate150in one embodiment. The base plate has a recessed section for receiving the bottom edge of the wall panel171. A vacuum seal180is provided at the interface between the wall panel and the base plate. This may take the form of an O-ring, C-ring, or other sealing member sandwiched between the wall panel and base plate. Vibration isolation members182such as Viton strips may also be placed between the wall panels and the base plate to reduce transmission of vibrations between the two components. The recess may accommodate openings for passing bolts, screws or other fastening members vertically into the end faces of the walls from below the base plate, the bolts passing between the position of the vacuum seal and the outer face of the wall panels.

FIG. 6is a cross sectional view showing detail of the mounting of the beam sensor160in one embodiment. The beam sensor is placed inside a housing162with an opening in the top or a transparent upper section for sensing the beams striking the sensor from above. The housing is attached to the base plate150via flange supports164, and the sensor is positioned in the housing by slide supports165which permit vertical adjustment of the beam sensor using sensor height adjustment166.

FIG. 7shows an embodiment of a stage showing the drive motors140for the X-stage, with arms141and142for moving the bridge121on which the Y-stage122moves. The drive motors140extend under the stage and into recesses in the base plate. The fixed parts of the stage132are supported by the fixed to the base plate150.

The base plate may be constructed of a single thick piece of metal, preferably aluminium, in contrast to previous designs using a relatively thin and light-weight metal base fixed to a thick stone or granite slab. In this previous design, the desired rigidity and stability was provided by the very heavy granite slab, and the metal base was attached rigidly to the slab using a relatively large number of legs fixed to the slab using bolts and set in place using a resin. In the present design, the metal base plate150is sufficiently thick, e.g. preferably of 25-30 cm and preferably thicker than the wall panels of the vacuum chamber, to have sufficient mass to provide the required rigidity and stability and limit the effect of vibrations, without the need for an additional thick massive slab and without the need for elaborate fixed and rigid connection between the base plate and the slab.

The present design eliminates the need for the additional slab, resulting in a simpler design with fewer critical parts and reducing the tolerance train in the lower part of the machine. The beam sensor and the target positioning system can be implemented more simply and economically and their performance improved if their relative positioning can be more accurately controlled. Limiting the number of independent elements of the base of the machine can reduce the magnitude of error by limiting the number of tolerances (otherwise the tolerances are added to one another) inherent in the manufacture and use of each part of the system. A metal base plate also has the advantage that it can be more easily and more accurately machined to precise shapes to interface accurately with other elements of the machine.

In an alternative embodiment, the base plate may be made in two pieces, comprising a center section forming an interface to the support frame and stage and a peripheral section forming an interface with the side walls of the vacuum chamber. The base plate sections made be bolted together, permitting subsequent disassembly if necessary.

The invention has been described by reference to certain embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternative forms well known to those of skill in the art without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention, which is defined in the accompanying claims.