Source: https://patents.google.com/patent/US7924403B2/en
Timestamp: 2019-05-21 21:45:37
Document Index: 662560404

Matched Legal Cases: ['Application No. 60', 'Application No. 06250136', 'Application No. 06250136', 'Application No. 06250136', 'Application No. 2006', 'Application No. 2006', 'Application No. 06']

US7924403B2 - Lithographic apparatus and device and device manufacturing method - Google Patents
Lithographic apparatus and device and device manufacturing method Download PDF
US7924403B2
US7924403B2 US11/330,401 US33040106A US7924403B2 US 7924403 B2 US7924403 B2 US 7924403B2 US 33040106 A US33040106 A US 33040106A US 7924403 B2 US7924403 B2 US 7924403B2
US11/330,401
US20060158628A1 (en
2005-01-14 Priority to US64360805P priority Critical
2006-01-12 Application filed by ASML Netherlands BV filed Critical ASML Netherlands BV
2006-01-12 Priority to US11/330,401 priority patent/US7924403B2/en
2006-03-27 Assigned to ASML NETHERLANDS B.V. reassignment ASML NETHERLANDS B.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JACOBS, JOHANNES HENRICUS WILELMUS, LIEBREGTS, PAULUS MARTINUS MARIA, UITTERDIJK, TAMMO
2006-07-20 Publication of US20060158628A1 publication Critical patent/US20060158628A1/en
2011-04-12 Publication of US7924403B2 publication Critical patent/US7924403B2/en
A immersion lithographic apparatus is disclosed in which one or more liquid diverters are positioned in a space surrounded by a liquid confinement structure. A function of the liquid diverter(s) is to hinder the formation of one or more recirculation zones of immersion liquid which may lead to variations in refractive index of the immersion liquid in the space and thereby imaging errors.
This application claims priority to and benefit from U.S. Provisional Application No. 60/643,608, filed Jan. 14, 2005, the entire contents of which is hereby incorporated by reference.
In an immersion lithographic apparatus, a temperature gradient in the immersion liquid may cause imaging defects because of the temperature dependency of the refractive index of the immersion liquid. A temperature gradient can arise because of absorption of the projection beam by the immersion liquid and/or because of heat transfer from other parts of the apparatus, for example the substrate or the liquid confinement system. Also, leaching of the resist into the immersion liquid and thereby transport of the resist onto the final element of the projection system may cause problems.
Accordingly, it would be advantageous, for example, to provide an immersion lithography apparatus in which a temperature gradient in the immersion liquid is reduced or avoided.
According to an aspect of the invention, there is provided a lithographic projection apparatus arranged to project a pattern from a patterning device onto a substrate through a liquid confined to a space adjacent the substrate, the apparatus comprising a liquid diverter in the space to promote liquid flow across the space.
According to an aspect of the invention, there is provided a device manufacturing method, comprising projecting a patterned beam of radiation onto a substrate through a liquid provided in a space adjacent the substrate, wherein flow of the liquid across the space is promoted by a liquid diverter in the space.
FIG. 5 depicts a further liquid supply system for use in a lithographic apparatus;
FIG. 6 a depicts in plan a liquid supply system according to an embodiment of the invention;
FIG. 6 b illustrates in section the liquid supply system of FIG. 6 a;
FIGS. 7 a and 7 b illustrate in plan and in section respectively a liquid supply system according to an embodiment of the invention;
FIGS. 8 a and 8 b illustrate in plan and in section respectively a liquid supply system according to a further embodiment of the invention; and
FIGS. 9 a and 9 b illustrate in plan and in section respectively a liquid supply system according to a further embodiment of the invention.
The patterning device may be transmissive or reflective. Examples of patterning devices include masks, programmable mirror arrays, and programmable LCD panels. Masks are well known in lithography, and include mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. An example of a programmable mirror array employs a matrix arrangement of small mirrors, each of which can be individually tilted so as to reflect an incoming radiation beam in different directions. The tilted mirrors impart a pattern in a radiation beam which is reflected by the mirror matrix. The term “projection system” used herein should be broadly interpreted as encompassing any type of projection system, including refractive, reflective, catadioptric, magnetic, electromagnetic and electrostatic optical systems, or any combination thereof, as appropriate for the exposure radiation being used, or for other factors such as the use of an immersion liquid or the use of a vacuum. Any use of the term “projection lens” herein may be considered as synonymous with the more general term “projection system”.
FIG. 5 depicts an arrangement of a reservoir 11 of liquid confined to fill a space between the substrate's primary surface, which faces the projection system PL, and the final element of the projection system PL. A contactless seal to the substrate around the image field of the projection system facilitates to confine the liquid in the reservoir 11. A liquid confinement structure 12 positioned below and surrounding the final element of the projection system PL forms the reservoir. Thus, the liquid supply system 10 provides liquid on only a localized area of the substrate. The liquid confinement structure 12 forms part of the liquid supply system configured to fill a space between the final element of the projection system and the substrate W (or substrate table WT) with a liquid. Liquid is brought into the space below the projection system via, for example, inlet 13 and within the liquid confinement structure 12. The liquid confinement structure 12 extends a little above the final element of the projection system and the liquid level rises above the final element so that a buffer of liquid is provided. The liquid confinement structure 12 has an inner periphery that at the upper end preferably closely conforms to the shape of the projection system or the final element thereof and may, e.g., be round. At the bottom, the inner periphery closely conforms to the shape of the image field, e.g., rectangular though this need not be the case. The patterned beam passes through this aperture.
The liquid is confined in the reservoir by a gas seal 16 between the bottom of the liquid confinement structure 12 and the surface of the substrate W. The gas seal is formed by gas, e.g. air, synthetic air, N2 or an inert gas, provided under pressure via inlet 15 to the gap between liquid confinement structure 12 and the substrate W and extracted via outlet 14. The overpressure on the gas inlet 15, vacuum level on the outlet 14 and geometry of the gap are arranged so that there is a high-velocity gas flow inwards that confines the liquid. It will be understood by the person skilled in the art that other types of seal could be used to contain the liquid such as simply an outlet to remove liquid and/or gas. As with any seal, some liquid is likely to escape, for example up the outlet 14. European patent application publication no. EP 1477856 discloses an actuated liquid supply system in which the liquid confinement structure is free to move in the direction of the optical axis.
A potential problem with the liquid supply system of FIG. 5 is that one or more recirculation zones within the immersion liquid may form in the reservoir 11. Liquid which recirculates has more time to leach out resist from the substrate and thereby may have different (optical) properties than desired. Scan movements may transport one or more of these recirculation zones to the target portion TP where it may affect the projected image. Also, liquid which recirculates in the target portion may be heated by the patterned beam B more than liquid which is quickly replaced and because of temperature dependence of the refractive index of the immersion liquid, this may lead to imaging aberrations. Evaporation of immersion liquid may also occur and lead to cooling of the immersion liquid. Therefore, temperature control of the immersion liquid is a consideration.
One way to promote the flow of liquid through the space 11 (which in plan is smaller than the substrate) so that little or no recirculation takes place is to provide fluid to the space 11 only from one side of the liquid confinement structure 12 and to extract the liquid from the other side. The direction in which the liquid flows can be changed to follow the scan direction of the substrate and this can be achieved, for example, by rotating the liquid confinement structure 12 around the optical axis. One way of arranging for this would be to arrange for the liquid confinement structure 12 to be a rotor of a direct drive motor. This would result in low mass and could also advantageously be harnessed to support the liquid confinement structure 12 magnetically. This arrangement allows flow of immersion liquid through the space 11 from any direction at the expense of increased complexity. A controller may be used to anticipate changes in direction of scan (e.g. if the substrate meanders under the projection system PL) and the liquid confinement structure 12 may be rotated accordingly to ensure that the flow direction is correctly oriented relative to the direction that the substrate W is taking relative to the liquid confinement structure 12. Another way is to separate the space vertically by using dividers as is disclosed in the U.S. patent application Ser. No. 10/986,187, filed Nov. 12, 2004, hereby incorporated in its entirety by reference.
FIGS. 6 to 9 illustrate passive embodiments in which liquid flow diverters 50, 60, 62, 64, 66, 68, 70 promote the flow 20 of immersion liquid from one side of a liquid confinement structure 12 to the other side of the liquid confinement structure 12. In this way, laminar flow of immersion liquid through the space 11 may be promoted and thus recirculation of immersion liquid in the space 11 may be reduced or substantially hindered or prevented. In an embodiment, the flow 20 of immersion liquid through the space 11 is in a direction substantially perpendicular to the scan direction 100. However, this need not be the case and, in particular, while the substrate is moved from one row of target portions on the substrate W which have been imaged to the next row of target portions it may be that the path which the substrate W meanders under the projection system PL may result in the substrate W not moving in a direction perpendicular to the flow 20 of the immersion liquid. In a possible implementation, the embodiments of FIGS. 6 to 9 are entirely passive i.e. that they have no moving parts. However, it is possible to arrange for one or more of the liquid flow diverters 50, 60, 62, 64, 66, 68, 70 to be rotatable relative to the projection system PL and perhaps also to the liquid confinement structure 12 such that the direction of flow 20 of the immersion liquid through the space 11 relative to the projection system PL can be changed. This could be arranged for as discussed in the foregoing paragraph.
The embodiments of FIGS. 6 to 9 will now be described in detail and then general comments regarding the construction of the liquid flow diverters 50, 60, 62, 64, 66, 68, 70 will be described.
FIG. 6 a illustrates a liquid confinement structure 12 and liquid flow diverters 50 in plan. The liquid confinement structure 12 defines an inner space 11 which is filled with immersion liquid.
The flow diverters 50 are positioned on either side of a target portion TP on the substrate W. The target portion TP is the portion of the substrate W which is to be imaged. Thus the patterned beam B passes through an image field with the same cross-section as the target portion TP through the immersion liquid. The liquid flow diverters 50 are positioned on either side of that image field so that the patterned beam B has an unobstructed path to the substrate W through the immersion liquid. The region in the space 11 where recirculation should be avoided or minimized is this image field and the liquid diverters 50 are designed to promote laminar flow 20 of the immersion liquid through the space 11 in that image field. In the case of the embodiment of FIG. 6 a, this is achieved by providing two shaped flow obstructing bodies 50 which have a substantial volume compared to the volume of the space 11 (for example, 20 percent of the volume of the space 11) and these have the effect of promoting immersion liquid flow across the space, in particular in the image field which is above a target portion TP and preventing or reducing recirculation and temperature disturbances from being generated (e.g. by scan movements or by surfaces with different temperatures). The diverters direct the immersion liquid through the gap between the two flow diverters 50 thereby promoting (laminar) flow from one side of the liquid confinement structure 12 to the other side. Additionally, the diverters may prevent or reduce transportation of disturbances to the target portion area and may also prevent or reduce the presence of recirculation areas on either side of the target portion.
FIG. 6 b illustrates the embodiment of FIG. 6 a in cross-section. As can be seen in FIG. 6 b, a final element 15 of the projection system PL supports the liquid flow diverters 50. The liquid flow diverters 50 may be integrally formed with the final element 15 (for example, be machined out of a block of a material along with the final element 15) or may be attached by some other means to the final element 15. The flow diverters 50 may not be integrally formed with the final element 15 but may advantageously be made of the same material as the final element 15 nonetheless. The liquid confinement structure 12 is supported in this embodiment independently of the liquid flow diverters 50 and perhaps also independently of the projection system PL.
FIGS. 7 a and 7 b illustrate another embodiment of the present invention which is the same as the embodiment of FIG. 6 a except as described below. In this embodiment the liquid flow diverters are in the form of a plurality of vanes or fins 60, 62, 64, 66, 68, 70 that replace liquid flow diverters 50 of the embodiment of FIG. 6 a and also promote the flow of immersion liquid across the space 11. Immersion liquid flows between the vanes 60, 62, 64, 66, 68, 70 which are positioned on either side of the image field and have the same effect as the liquid diverters 50 of the embodiment of FIG. 6 a in promoting laminar flow of immersion liquid in the image field and thereby preventing or reducing recirculation of immersion liquid. As can be seen in FIG. 6 b, the vanes 60, 62, 64, 66, 68, 70 are also attached to the final element 15 of the projection system.
A further embodiment is illustrated in FIGS. 8 a and 8 b which is the same as the embodiment illustrated in FIG. 6 a except as described below. In this embodiment the flow diverters 50 are attached to the liquid confinement structure 12 on an inner periphery of the liquid confinement structure 12 which at least partly defines the space 11. This embodiment is advantageous because the liquid confinement structure 12 may then move unhindered in the Z direction without any concern about the substrate W coming into contact with the flow diverters 50. The embodiment of FIG. 6 a by contrast works best if the liquid confinement structure 12 is fixed in the Z direction and is not movable in the Z direction.
A further embodiment is illustrated in FIGS. 9 a and 9 b and is the same as the embodiment of FIG. 7 a except as described below. In this embodiment, as can be seen from FIG. 9 a, the vanes 60, 62, 64, 66, 68, 70 are curved and are not straight as in the embodiment of FIG. 7 a. The precise shape of the liquid flow diverters 60, 62, 64, 66, 68, 70 is not vital, as with the liquid diverters 50, so long as the function of the flow diverters is to promote immersion liquid flow across the space thereby preventing or reducing recirculation. The shape illustrated in FIG. 9 where the main channel between two opposing sets of vanes decreases in cross-sectional area from the point at which immersion liquid enters the space 11 to that at which it exits the space (a converging channel) may be efficient at preventing or reducing recirculation zones within the image field because it may produce a stable flow.
As can be seen from FIG. 9 b, this embodiment is similar to that of FIG. 8 a in that the flow diverters are connected to the liquid confinement structure 12 and not to the projection system PL.
The configuration (e.g., curved or straight) or construction of the flow diverters 50, 60, 62, 64, 66, 68, 70 is not vital so long as they achieve the function of promoting flow of immersion liquid across the space thereby preventing or reducing flow recirculation. Further, the flow diverters may prevent or reduce temperature disturbances being generated in the space (e.g., generated by scanning movements and/or surfaces with different temperatures). The diverters may also prevent or reduce any such disturbances from being transported from the side of the space into the target portion TP. In an embodiment, the flow diverters have a surface treatment applied to them to promote laminar flow of immersion liquid past them. In an embodiment, the flow diverters are made out of a porous material which is effective to avoid pressure differentials between either side of the flow diverters. In addition, the diverters may be connected to a low pressure source and constructed and arranged to extract immersion liquid from one or more ports on the surface of the diverter thereby to remove the boundary layer of liquid from the surface of the diverter.
The flow diverters could be made solid. In an embodiment, the flow diverters may be hollow which has the advantage of reducing the weight, particularly in the embodiments where the flow diverters are attached to the liquid confinement structure 12. In an embodiment, the flow diverters are made of a material which is compatible with immersion liquid (i.e., not ion generating) and/or resistant to projection beam illumination. Example materials are stainless steel, ceramic or the same material as the final element of the projection system, such as quartz or calcium fluoride. Low thermal expansion materials such as Zerodur® or ULE® may also be suitable.
Thus it can be seen that the liquid diverters generally divert the immersion liquid in a direction substantially parallel to the plane of the substrate. This can be arranged to occur by making the liquid diverters extend in a direction perpendicular to the plane of the substrate. It can also be thought of as the liquid diverters having a vertical component to divide the space 11 in the horizontal plane (which is substantially parallel to the substrate W).
1. A lithographic projection apparatus arranged to project a pattern from a patterning device onto a substrate through a liquid confined to a space adjacent the substrate using an optical element of a projection system, the apparatus comprising a liquid diverter configured to promote liquid flow in a flow direction substantially parallel to a plane of the substrate across the space, at least part of the liquid diverter, in use, located between the substrate and a surface, nearest the substrate and in contact with the liquid, of the optical element, located within an outer lateral boundary of the optical element, and extending in a direction substantially perpendicular to a plane of the substrate arranged to receive the pattern, the liquid flow being from at least one side of an exposure area of the substrate to another side of the exposure area and further away from the substrate than a surface of the liquid diverter adjacent the substrate.
2. The apparatus of claim 1, wherein the liquid diverter is configured to divert the liquid in a direction substantially parallel to the plane of the substrate.
3. The apparatus of claim 1, wherein the projected pattern is configured to be projected through an image field and a liquid diverter is positioned on each side of the image field.
4. The apparatus of claim 1, wherein the liquid diverter is an obstructing body with a substantial volume compared to the volume of the space.
5. The apparatus of claim 1, wherein the liquid diverter is configured to promote the liquid flow across the space from one side to an opposite side.
6. The apparatus of claim 4, wherein the liquid diverter is curved to promote the liquid to flow in a curved path.
7. The apparatus of claim 1, wherein the liquid diverter is attached to a final element of a projection system which is configured to project the patterned beam onto the substrate.
8. The apparatus of claim 1, wherein the liquid diverter is a vane with an elongate vertical cross-section.
9. The apparatus of claim 1, wherein the liquid diverter has an elongate horizontal cross-section.
10. The apparatus of claim 1, further comprising a liquid confinement structure configured to at least partly confine the liquid to the space and wherein the liquid diverter is attached to the liquid confinement structure.
11. The apparatus of claim 1, wherein the liquid diverter is hollow.
12. The apparatus of claim 1, wherein the liquid diverter is solid.
13. The apparatus of claim 1, wherein the liquid diverter is porous.
14. The apparatus of claim 1, wherein the liquid diverter has a surface finish to promote laminar flow of the liquid.
15. The apparatus of claim 1, comprising a plurality of liquid diverters.
16. The apparatus of claim 1, wherein the liquid diverter divides the space in a horizontal plane into separate channels.
17. The apparatus of claim 1, wherein the liquid diverter has an extraction port in a surface of the liquid diverter configured to remove a boundary layer of liquid from the surface of the liquid diverter.
18. A device manufacturing method, comprising projecting, using an optical element of a projection system, a patterned beam of radiation onto a substrate through a liquid provided in a space adjacent the substrate, wherein flow of the liquid across the space in a flow direction substantially parallel to a plane of the substrate is promoted by a liquid diverter, at least part of the liquid diverter located between the substrate and a surface, nearest the substrate and in contact with the liquid, of the optical element, located within an outer lateral boundary of the optical element, and extending in a direction perpendicular to a plane of the substrate arranged to receive the patterned beam, the liquid flow being from at least one side of an exposure area of the substrate to another side of the exposure area and further away from the substrate than a surface of the liquid diverter adjacent the substrate.
19. The method of claim 18, wherein the liquid diverter is attached to a final element of a projection system used to project the patterned beam onto the substrate.
20. The method of claim 18, further comprising at least partly confining the liquid to the space using a liquid confinement structure, the liquid diverter attached to the liquid confinement structure.
21. The method of claim 18, wherein the liquid diverter is a vane with an elongate vertical cross-section.
22. The method of claim 18, wherein the liquid diverter has an elongate horizontal cross-section.
23. The method of claim 18, wherein the liquid diverter divides the space in a horizontal plane into separate channels.
24. A lithographic projection apparatus arranged to project a pattern from a patterning device onto a substrate through a liquid confined to a space adjacent the substrate using an optical element of a projection system, the apparatus comprising a liquid diverter to promote liquid flow across the space, wherein the liquid diverter divides the space in a horizontal plane into separate vertical channels to promote the liquid flow across the space and at least part of the liquid diverter is, in use, located between the substrate and a surface, nearest the substrate and in contact with the liquid, of the optical element and located within an outer lateral boundary of the optical element.
25. A device manufacturing method, comprising projecting a patterned beam of radiation using an optical element of a projection system onto a substrate through a liquid provided in a space adjacent the substrate, wherein flow of the liquid across the space is promoted by a liquid diverter, wherein the liquid diverter divides the space in a horizontal plane into separate vertical channels to promote the liquid flow across the space and at least part of the liquid diverter is, in use, located between the substrate and a surface, nearest the substrate and in contact with the liquid, of the optical element and located within an outer lateral boundary of the optical element.
US11/330,401 2005-01-14 2006-01-12 Lithographic apparatus and device and device manufacturing method Active 2027-03-17 US7924403B2 (en)
US64360805P true 2005-01-14 2005-01-14
US11/330,401 US7924403B2 (en) 2005-01-14 2006-01-12 Lithographic apparatus and device and device manufacturing method
US13/044,325 US8675173B2 (en) 2005-01-14 2011-03-09 Lithographic apparatus and device manufacturing method
US13/044,325 Continuation US8675173B2 (en) 2005-01-14 2011-03-09 Lithographic apparatus and device manufacturing method
US20060158628A1 US20060158628A1 (en) 2006-07-20
US7924403B2 true US7924403B2 (en) 2011-04-12
ID=36010896
US11/330,401 Active 2027-03-17 US7924403B2 (en) 2005-01-14 2006-01-12 Lithographic apparatus and device and device manufacturing method
US13/044,325 Active 2026-03-13 US8675173B2 (en) 2005-01-14 2011-03-09 Lithographic apparatus and device manufacturing method
US (2) US7924403B2 (en)
EP (1) EP1681596A1 (en)
JP (3) JP4741372B2 (en)
KR (1) KR100737506B1 (en)
CN (1) CN1811601B (en)
SG (1) SG124351A1 (en)
TW (1) TWI322337B (en)
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KR100524312B1 (en) 2003-11-12 2005-10-28 엘지전자 주식회사 Method and apparatus for controling initialization in plasma display panel
2006-01-06 SG SG200600095A patent/SG124351A1/en unknown
2006-01-11 EP EP06250136A patent/EP1681596A1/en not_active Withdrawn
2006-01-12 KR KR1020060003524A patent/KR100737506B1/en not_active IP Right Cessation
2006-01-12 CN CN 200610008927 patent/CN1811601B/en not_active IP Right Cessation
2006-01-12 US US11/330,401 patent/US7924403B2/en active Active
2006-01-13 JP JP2006005942A patent/JP4741372B2/en not_active Expired - Fee Related
2006-01-13 TW TW95101425A patent/TWI322337B/en not_active IP Right Cessation
2008-12-01 JP JP2008306642A patent/JP5108737B2/en active Active
2011-03-09 US US13/044,325 patent/US8675173B2/en active Active
2012-02-08 JP JP2012024784A patent/JP5108157B2/en active Active
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US7589821B2 (en) * 2002-12-10 2009-09-15 Nikon Corporation Exposure apparatus and device manufacturing method
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SG124351A1 (en) 2006-08-30
JP5108737B2 (en) 2012-12-26
US8675173B2 (en) 2014-03-18
US20060158628A1 (en) 2006-07-20
US20110159441A1 (en) 2011-06-30
KR20060083148A (en) 2006-07-20
JP2012114459A (en) 2012-06-14
CN1811601B (en) 2010-08-18
JP4741372B2 (en) 2011-08-03
CN1811601A (en) 2006-08-02
TWI322337B (en) 2010-03-21
EP1681596A1 (en) 2006-07-19
JP2009088551A (en) 2009-04-23
KR100737506B1 (en) 2007-07-09
JP2006196906A (en) 2006-07-27
JP5108157B2 (en) 2012-12-26
TW200632587A (en) 2006-09-16
EP1739492A2 (en) 2007-01-03 Lithographic apparatus and device manufacturing method
CN1811601B (en) 2010-08-18 Lithographic apparatus and device manufacturing method
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LIEBREGTS, PAULUS MARTINUS MARIA;JACOBS, JOHANNES HENRICUS WILELMUS;UITTERDIJK, TAMMO;REEL/FRAME:017729/0515