Source: http://www.google.com/patents/US20050168714?dq=6,907,387
Timestamp: 2014-09-19 04:56:40
Document Index: 472369723

Matched Legal Cases: ['art 15', 'art 15', 'art 15', 'art 14', 'art 15', 'art 15', 'art 15', 'art 15']

Patent US20050168714 - Lithographic apparatus, measurement system, and device manufacturing method - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsThe invention pertains to a measurement system for measuring displacement of a moveable object relative to a base in at least a first direction of measurement, the moveable object having at least one reference part that is moveable in a plane of movement relative to the base, the actual movements of...http://www.google.com/patents/US20050168714?utm_source=gb-gplus-sharePatent US20050168714 - Lithographic apparatus, measurement system, and device manufacturing methodAdvanced Patent SearchPublication numberUS20050168714 A1Publication typeApplicationApplication numberUS 10/769,992Publication dateAug 4, 2005Filing dateFeb 3, 2004Priority dateFeb 3, 2004Also published asUS7102729Publication number10769992, 769992, US 2005/0168714 A1, US 2005/168714 A1, US 20050168714 A1, US 20050168714A1, US 2005168714 A1, US 2005168714A1, US-A1-20050168714, US-A1-2005168714, US2005/0168714A1, US2005/168714A1, US20050168714 A1, US20050168714A1, US2005168714 A1, US2005168714A1InventorsMichael Jozef Renkens, Martinus Cornelis Verhagen, Alexander Struycken, Ruben KokOriginal AssigneeAsml Netherlands B. V.Export CitationBiBTeX, EndNote, RefManReferenced by (29), Classifications (10), Legal Events (3) External Links: USPTO, USPTO Assignment, EspacenetLithographic apparatus, measurement system, and device manufacturing methodUS 20050168714 A1Abstract The invention pertains to a measurement system for measuring displacement of a moveable object relative to a base in at least a first direction of measurement, the moveable object having at least one reference part that is moveable in a plane of movement relative to the base, the actual movements of the reference part being within an area of said plane of movement that is bounded by a closed contour having a shape. The measurement system comprises a sensor head that operatively communicates with a planar element. The sensor head is mounted onto the base and the planar element being mounted onto the reference part of the moveable object or the other way around, wherein the planar element has a shape that is essentially identical to the shape of the closed contour. Images(9) Claims(34)
DETAILED DESCRIPTION OF THE INVENTION Lithographic Projection Apparatus FIG. 1 schematically depicts a lithographic projection apparatus according to a particular embodiment of the invention. The apparatus comprises: an illumination system (illuminator) IL: for providing a projection beam PB of radiation (e.g. UV radiation, DUV radiation, or laser radiation); a first support structure (e.g. a mask table) MT: for supporting patterning device (e.g. a mask) MA and connected to first positioning device PM for accurately positioning the patterning device with respect to item PL; a substrate table or holder (e.g. a wafer table) WT: for holding a substrate (e.g. a resist-coated wafer) W and connected to second positioning device PW for accurately positioning the substrate with respect to item PL; and a projection system (e.g. a refractive projection lens) PL: for imaging a pattern imparted to the projection beam PB by patterning device MA onto a target portion C (e.g. comprising one or more dies) of the substrate W. As here depicted, the apparatus is of a transmissive type (i.e. has a transmissive mask). However, in general, it may also be of a reflective type, for example (with a reflective mask). Alternatively, the apparatus may employ another kind of patterning mechanism, such as a programmable mirror array of a type as referred to above. The illuminator IL receives a beam of radiation from a radiation source SO. The source and the lithographic apparatus may be separate entities, for example when the source is an excimer laser. In such cases, the source is not considered to form part of the lithographic apparatus and the radiation beam is passed from the source SO to the illuminator IL with the aid of a beam delivery system BD comprising for example suitable directing mirrors and/or a beam expander. In other cases the source may be integral part of the apparatus, for example when the source is a mercury lamp. The source SO and the illuminator IL, together with the beam delivery system BD if required, may be referred to as a radiation system. The illuminator IL may comprise adjusting device AM for adjusting the angular intensity distribution of the beam. Generally, at least the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in a pupil plane of the illuminator can be adjusted. In addition, the illuminator IL generally comprises various other components, such as an integrator IN and a condenser CO. The illuminator provides a conditioned beam of radiation, referred to as the projection beam PB, having a desired uniformity and intensity distribution in its cross-section. The projection beam PB is incident on the mask MA, which is held on the mask table MT. Having traversed the mask MA, the projection beam PB passes through the lens PL, which focuses the beam onto a target portion C of the substrate W. With the aid of the second positioning device PW and position sensor IF (e.g. an interferometric device), the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the beam PB. Similarly, the first positioning device PM and another position sensor (which is not explicitly depicted in FIG. 1) can be used to accurately position the mask MA with respect to the path of the beam PB, e.g. after mechanical retrieval from a mask library, or during a scan. In general, movement of the object tables MT and WT will be realized with the aid of a long-stroke module and a short-stroke module, which form part of the positioning device PM and PW. However, in the case of a stepper (as opposed to a scanner) the mask table MT may be connected to a short stroke actuator only, or may be fixed. Mask MA and substrate W may be aligned using mask alignment marks M1, M2 and substrate alignment marks P1, P2. The depicted apparatus can be used in the following preferred modes: 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; 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=� or ⅕). In this manner, a relatively large target portion C can be exposed, without having to compromise on resolution; and other mode: the mask table MT is kept essentially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the projection beam is projected onto a target portion C. In this mode, generally a pulsed radiation source is employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes programmable patterning device, such as a programmable mirror array of a type as referred to above. Combinations and/or variations on the above described modes of use or entirely different modes of use may also be employed. First Embodiment FIG. 2 schematically illustrates the first embodiment of the present invention. In FIG. 2, a base 1 is shown, relative to which moveable object 10 moves in the x-y-plane that is indicated by coordinate system 5. The x-y plane is also indicated as the �plane of movement�. The moveable object 10 follows a track in the x-y-plane. FIG. 2 illustrates this by showing the position of the moveable object 10 at four positions along the track. The moveable object 10 comprises a reference part 15, which moves along with the moveable object 10. The track the reference part 15 of the moveable object 10 follows in the plane of movement is indicated by reference numeral 25. All movements of the reference part 15 are within area 21 of the plane of movement. Area 21 is bound by a closed contour 20. FIG. 3 schematically depicts a part of a lithographic apparatus associated with the first embodiment of the invention. In this case, moveable object 10 is a substrate table or holder 10′. The substrate table 10′ holds wafer 11. The lithographic apparatus comprises a projection system 40, which comprises lens 41. The projection system 40 is adapted to project a patterned projection beam 42 onto the wafer 11. In the embodiment shown, the projected beam only irradiates a part 14 of the wafer surface that has to be irradiated. In order to irradiate the entire surface of the wafer 11, the substrate table 10′ moves relative to the projection system 40 in a plane of movement that is substantially parallel to the plane of the wafer 11. In the embodiment shown, the plane of movement is the x-y-plane. The directions of movement of the substrate table 10′ relative to the projection system 40 are indicated by arrows 12, 13. In the embodiment of FIG. 3, the measurement system is adapted to measure displacement of the substrate table 10′ relative to the projection system 40. As such, for the embodiment of FIG. 3, the moveable object 10 is the substrate table 10′ and the base 1 is the projection system 40. The substrate table 10′ comprises a reference part 15. Onto the reference part 15, a sensor head 30 is mounted. This sensor head 30 is adapted to cooperate with a planar element 35 for measuring displacement of the substrate table 10′ relative to the projection system 40. It is, however, envisaged that the sensor head 30 is mounted onto the projection system 40 and the planar element 35 is mounted onto the reference element. The displacement measured can be in a direction indicated by arrow 12 or 13, in the directions indicated by both arrows 12 and 13, or in a direction perpendicular the plane of movement. If displacement is measured in both directions indicated by arrows 12 and 13, generally two sensor heads 30 a, 30 b will be mounted onto reference part 15. If the direction in which displacement of the substrate table 10′ is measured (hereafter referred to as �the first direction of measurement�) lies within a plane that is at least substantially parallel to the plane of movement, the sensor head 30 is preferably an encoder head, cooperating with a grating as a planar element 35. The grating can be arranged on a ruler. Also, the grating can be integrated with the projections system 40, such as, for example, being printed onto it. The grating may comprise a single set of mutually parallel lines for measuring displacements in a single direction. Alternatively, the grating may be adapted for measuring displacement in two different directions, for example, by means of a checkerboard pattern or a grid pattern on the grating. If the first direction of measurement is at least substantially perpendicular to the plane of movement, the sensor head 30 can be, for example, an interferometer or a capacitive sensor. If the sensor head 30 is an interferometer, the planar element 35 is a mirror. If the sensor head 30 is a capacitive sensor, the planar element 35 is an electrically conductive element. As can be seen in FIG. 3, the planar element 35 has a shape that is essentially identical to the shape of the closed contour 20. It is envisaged that the size of the planar element is not the same as the contour size, as the required size will depend, for example, on the ratio between the size of the area irradiated by the projection beam 42 and the size of the area irradiated by measurement beam 32. In the embodiment of FIG. 3, the sensor head 30 is an encoder, that is adapted to send measurement beam 32 to the planar element 35, which is configured as a grating. Due to the movements of the substrate table 10′ relative to the projection system 40, the irradiated area 14 on the wafer 11 follows a track 45 over the wafer 11. While the measurement system is active, the measurement beam 32 sent by the sensor head 30 to the planar element 35 creates a touch point 33 on the planar element 35. Because the planar element 35 is mounted onto the projection system 40, and the sensor head 30 is mounted onto the reference part 15 of the substrate table 10′, the touch point 33 follows a track 25 over the planar element 35 that is identical in shape to the track 45. By using a planar element 35 that has the same shape as the closed contour 20, the face of the planar element 35 cooperating with the sensor head 30 is used efficiently as no parts of the planar element 35 remain unused. FIG. 4 shows a preferred embodiment of the first aspect of the invention. In this embodiment, the substrate table 10′ is equipped with a first, second, and third reference part. The reference parts are located at known relative positions on the substrate table 10′. On the first reference part, a first sensor head is mounted. The first sensor head cooperates with a first planar element 35 a to measure the displacement of the first reference point relative to the base 1 in a first direction 12′. On the second reference part, a second sensor head is mounted. The second sensor head cooperates with a second planar element 35 b to measure the displacement of the first reference point relative to the base 1, also in the first direction 12′. On the third reference part, a third sensor head is mounted. The third sensor head cooperates with a third planar element 35 c to measure the displacement of the first reference point relative to the base 1 in the second direction 13′. The sensor heads are located at known relative positions on the substrate table 10′. Preferably, the first direction 12′ and the second direction 13′ lie within the plane of movement, and the second direction 13′ is different from the first direction 12′. Moreover, the second direction 13′ is perpendicular to the first direction 12′. In this manner, the displacement of the substrate table 10′ relative to the base 1 (which is in this case the projection system) can be measured in the first direction 12′ and in the second direction 13′. In addition, the rotational displacement of the substrate table 10′ around an axis perpendicular to the plane of movement can be determined. In an alternative embodiment, the measurement system comprises a first, a second, and a third sensor head, but only two planar elements 35 a, b. The sensor heads are encoder heads, and the planar elements 35 a,b are gratings. Only two reference parts are present, on one of which two sensor heads 30 s are mounted. The first grating is provided with a checkerboard pattern or a grid pattern that enables measurement of displacement of the substrate table 10′ relative to the base 1 in two different directions 12′,13′. The second grating is provided with a single set of mutually parallel lines. The second grating is configured to measure the displacement of the substrate table 10′ relative to the base 1 in a direction equal to one of the directions 12′, 13′ the first grating is used for. Alternatively, it is envisaged that the second grating is, like the first grating, adapted for two-dimensional measurements. In that case, a fourth sensor head is provided for cooperating with the second planar element 35 b. The fourth sensor head is mounted onto the second reference part together with the third sensor head. By measuring both directions 12′, 13′ twice, additional accuracy is obtained. It is also envisaged that in the embodiment of FIG. 4, the first direction of measurement and the second direction of measurement are equal, and perpendicular to the plane of movement of the substrate table 10′. This way, displacement of the substrate table 10′ relative to the base 1 in the direction perpendicular to the plane of movement can be determined, as well as rotational displacement of the substrate table 10′ around axes in the plane of movement. In FIGS. 2-4, the moveable object 10 shown is a substrate table. However, the first aspect of the invention can be applied to various kinds of moveable objects, including the reticle stage. FIG. 5 shows a first embodiment of a relevant part of a lithographic apparatus in accordance with the second aspect of the invention. Moveable object 110 is part of the lithographic apparatus and is moveable relative to base 101 in six degrees of freedom. The lithographic apparatus comprises a measurement system for measuring displacement of the moveable object 110 relative to the base 101 in six degrees of freedom. The second aspect of the invention can be applied for various combinations of moveable objects and bases. In an advantageous embodiment, the moveable object 110 is a reticle stage, and the base 101 is the projection system. However, it is also possible that the moveable object 110 is a substrate table, the base 101 again being the projection system. It is also envisaged that the measurement system is used for measuring displacement of the short stroke unit of the reticle stage relative to the long stroke unit of a single reticle stage. In the embodiment of FIG. 5, the measurement system comprises six measurement units. Each measurement unit comprises a sensor head 151, 152, 153, 154, 155, 156 and a planar element 161, 162, 163, 164, 165, 166. The sensor head 151, 152, 153, 154, 155, 156 is configured to send a measurement beam to the associated planar element 161, 162, 163, 164, 165, 166, and the associated planar element 161, 162, 163, 164, 165, 166 is configured to reflect the measurement beam 171, 172, 173, 174, 175, 176 to the sensor head 151, 152, 153, 154, 155, 156 to measure translational displacement of the sensor head 151, 152, 153, 154, 155, 156 relative to the planar element 161, 162,163, 164, 165, 166. In the embodiment of FIG. 5, the sensor heads are encoder heads, and the planar elements comprise gratings. In FIG. 5, the sensor heads 151, 152, 153, 154, 155, 156 are mounted on base 101, and the planar elements 161, 162, 163, 164, 165, 166 are mounted on the moveable object 110. This can, however, also be the other way around, that is: the sensor heads 151, 152, 153, 154, 155, 156 being mounted onto the moveable object 110 and the planar elements 161, 162, 163, 164, 165, 166 being mounted onto the base 101. Three of the measurement units 131 abc, 132 ab, 133 are primary measurement units 131 abc, which measure the translational displacement of the moveable object 110 relative to the base 101 in a first direction. They measure displacement of the moveable object 110 relative to the base 101 in x-direction. Two of the measurement units 131 abc, 132 ab, 133 are secondary measurement units 132 ab, which measure the translational displacement of the moveable object 110 relative to the base 101 in a second direction. They measure displacement of the moveable object 110 relative to the base 101 in z-direction. One of the measurement units 131 abc, 132 ab, 133 is the tertiary measurement unit 133, which measures the translational displacement of the moveable object 110 relative to the base 101 in a third direction. It measures displacement of the moveable object 110 relative to the base 101 in y-direction. Preferably, each of the x-, y- and z-directions is perpendicular to the other two directions. All measurement units 131 abc, 132 ab, 133 are located at known relative positions. This way, rotations of the moveable object 110 axes extending in x-, y- and z-direction can be determined based on the measurements of performed by the measurement units 131 abc, 132 ab, 133. In accordance with the second aspect of the invention, the measurement units 131 abc, 132 ab, 133 are combined into three measurement assemblies. Each of these three measurement assemblies comprises a primary measurement unit 131 abc and either a secondary measurement unit 132 ab or a third measurement unit 133. In the embodiment shown in FIG. 5, the first measurement assembly comprises measurement units 131 a and 132 a. The second measurement assembly comprises measurement units 131 b and 133. The third measurement assembly comprises measurement units 131 c and 132 b. Measurement unit 131 a measures the translational displacement of the moveable object 110 relative to the base 101 in the x-direction. Measurement unit 132 a measures the translational displacement of the moveable object 110 relative to the base 101 in the z-direction. Therefore, the measurement plane associated with the first measurement assembly is the x-z-plane. In accordance with the second aspect of the invention, the planar elements 161, 162 of the first measurement assembly are parallel to the measurement plane. Measurement unit 131 b measures the translational displacement of the moveable object 110 relative to the base 101 in the x-direction. Measurement unit 133 measures translational displacement of the moveable object 110 relative to the base 101 in the y-direction. Therefore, the measurement plane associated with the second measurement assembly is the x-y-plane. In accordance with the second aspect of the invention, the planar elements 163, 164 of the second measurement assembly are parallel to the measurement plane. Measurement unit 131 c measures the translational displacement of the moveable object 110 relative to the base 101 in the x-direction. Measurement unit 132 b measures translational displacement of the moveable object 110 relative to the base 101 in the z-direction. Therefore, the measurement plane associated with the third measurement assembly is the x-z-plane. In accordance with the second aspect of the invention, the planar elements 165, 166 of the third measurement assembly are parallel to the measurement plane. The measurement system according to the second aspect of the invention thus eliminates the necessity for using capacitive sensors or interferometers for determining displacement of a moveable object 110 relative to a base 101. FIG. 6 shows a preferred embodiment of the second aspect of the invention. In this embodiment, the measurement units 131 abc, 132 ab, 133 of each measurement assembly are more or less integrated when compared to the embodiment of FIG. 5. In the embodiment of FIG. 5, each measurement assembly comprises two planar elements 161,162,163,164,165,166, each comprising a grating, the lines of one grating extending in a direction different from the direction in which the lines of the other grating extend. In the embodiment of FIG. 6, the planar elements of each measurement assembly are combined into a single planar element 261, 263, 265 having a two dimensional grating. For allowing measurement in two directions, the planar elements 261, 263, 265 comprise a grid of lines or a checkerboard pattern. In the embodiment of FIG. 6, sensor heads are indicated by reference numerals 251,252,253,254,255,256. Sensor heads that are part of the same measurement assembly use the same planar element. It is also possible that the sensor heads of a measurement assembly are both accommodated in a sensor head unit. As in the embodiment of FIG. 5, each sensor head 251,252,253,254,255,256 is configured to send a measurement beam 271,272,273,274,275,276 to the associated planar element, and the associated planar element is adapted to reflect the measurement beam to the sensor head to measure the translational displacement of the respective sensor head relative to the associated planar element. In both embodiments of the second aspect of the invention, the pitch between the lines of the grating may vary over the grating. In case of a checkerboard pattern, the size and shape of the light and dark areas may vary. In order to reduce measurement errors due to such variations, the measurement system preferably comprises means for determining the average pitch between a plurality of lines or transitions between light and dark of the grating concerned. As an alternative or in addition to this provision, the lines or areas of the grating may be mapped by means of calibration before use. The map of the lines or the areas is subsequently stored in the measurement system. In the lithographic apparatus, the displacement of the moveable object 210 in a first translational degree of freedom is significantly larger than the displacement of that moveable object 210 in the other translational degrees of freedom. This is, for example, the case with the movements of the reticle stage relative to the projection system. The displacements of the reticle stage in its y-direction are far larger than displacements in other directions. In such situations, the direction of measurement associated with the primary measurement units is substantially equal to the direction of the first translational degree of freedom. This increases the accuracy of the measurements. It is envisaged to combine the first aspect of the invention and the second aspect of the invention. This is shown in FIG. 7. In FIG. 7, the moveable object 210 has one reference part. Onto this reference part, sensor heads 253 and 254 are mounted. The reference part is moveable in the x-y plane relative to the base 201 along with the moveable object 210. In the embodiment of FIG. 7, the base 201 is the projection system. The actual movements of the reference part are within an area of said plane of movement, and that area is bound by a closed contour. A planar element of at least one measurement assembly has a measurement plane that is substantially parallel to the plane of movement has a shape that is essentially identical to the shape of the contour. In the embodiment of FIG. 7, the planar element is a two-dimension grating. This embodiment combines the advantages of the first and the second aspect of the invention. Such a measurement system would be suitable for measuring displacement of the substrate table relative to the projection system, as the substrate table make large movements in both the x- and the y-direction during the irradiation of the wafer. As in the embodiment of FIG. 7, two touch points 33 are present, the planar element 263 is larger than area 21 of the wafer 11. The third aspect of the invention proposes to make the grating an integral part of the movable object. This is shown in FIG. 8. Preferably, the moveable object 510 comprises lines 520 or areas 530 of a grating. These lines 520 or areas 530 preferably are printed directly onto the moveable object 510. Instead of printing, the lines or the areas of the grating can be applied to the movable object by means of vapor deposition. Alternatively, it is envisaged that the lines or the areas of the grating are etched into the moveable object. While specific embodiments of the invention have been described above, it will be appreciated that the invention may be practiced otherwise than as described. The description is not intended to limit the invention. 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