Source: https://patents.google.com/patent/US8922754B2/en
Timestamp: 2018-10-18 21:41:58
Document Index: 372980613

Matched Legal Cases: ['Application No. 182850', 'Application No. 05', 'Application No. 182850', 'Application No. 094138185', 'Application No. 2006', 'Application No. 200703230', 'Application No. 1751', 'Application No. 200910149533', 'Application No. 2007', 'Application No. 05805449', 'Application No. 2010', 'Application No. 200580037186', 'Application No. 05805449', 'Application No. 200703230', 'Application No. 2006', 'Application No. 12', 'Application No. 200910149533']

US8922754B2 - Immersion exposure apparatus and device fabricating method with two substrate stages and metrology station - Google Patents
Immersion exposure apparatus and device fabricating method with two substrate stages and metrology station Download PDF
US8922754B2
US8922754B2 US12007348 US734808A US8922754B2 US 8922754 B2 US8922754 B2 US 8922754B2 US 12007348 US12007348 US 12007348 US 734808 A US734808 A US 734808A US 8922754 B2 US8922754 B2 US 8922754B2
US12007348
US20080117393A1 (en )
The present invention provides an exposure apparatus can suppress the occurrence of residual liquid. An exposure apparatus comprises: a first stage that holds the substrate and is movable; a second stage that is movable independently of the first stage; and a liquid immersion mechanism that forms a liquid immersion region of a liquid on an upper surface of at least one stage of the first stage and the second stage; wherein, a recovery port that is capable of recovering the liquid is provided to the upper surface of the second stage.
This is a Divisional of U.S. patent application Ser. No. 11/666,420, filed Apr. 27, 2007 now U.S. Pat. No. 8,330,939 is the U.S. National Stage of International Application No. PCT/JP2005/020020 filed Oct. 31, 2005. The disclosure of each of the above-identified applications is incorporated herein by reference in its entirety.
A purpose of some aspects of the invention is to provide an exposure apparatus that can maintain a desired performance by suppressing the occurrence of residual liquid, and a device fabricating method.
A first aspect of the present invention provides an exposure apparatus that exposes a substrate through a projection optical system, comprising: a first stage that holds the substrate and is movable within a two dimensional plane on the image plane side of the projection optical system that is substantially parallel to the image plane; a second stage that is movable independently of the first stage within a two dimensional plane on the image plane side of the projection optical system that is substantially parallel to the image plane; and a liquid immersion mechanism that forms a liquid immersion region of a liquid on an upper surface of at least one stage of the first stage and the second stage; wherein, a recovery port that is capable of recovering the liquid is provided to or in the vicinity of the upper surface of the second stage.
According to the second aspect of the invention, it is possible to fabricate a device with an exposure apparatus that maintains a desired performance.
The exposure apparatus EX of the present embodiment is a liquid immersion exposure apparatus that adapts the liquid immersion method to substantially shorten the exposure wavelength, improve the resolution, as well as substantially increase the depth of focus, and comprises a liquid immersion mechanism 1 for forming a liquid immersion region LR of a liquid LQ on the image plane side of the projection optical system PL. The liquid immersion mechanism 1 comprises: a nozzle member 70, which is provided in the vicinity of the image plane side of the projection optical system PL, has supply ports 12 that supply the liquid LQ and recovery ports 22 that recover the liquid LQ; a liquid supply mechanism 10 that supplies the liquid LQ to the image plane side of the projection optical system PL through the supply ports 12 provided to the nozzle member 70; and a liquid recovery mechanism 20 that recovers the liquid LQ on the image plane side of the projection optical system PL through the recovery ports 22 provided to the nozzle member 70. The nozzle member 70 is annularly formed so that it surrounds a tip portion of the projection optical system PL on the image plane side. At least during the projection of the image of the pattern of the mask M onto the substrate P; the liquid immersion mechanism 1 uses the liquid LQ that is supplied by the liquid supply mechanism 10 to locally form the liquid immersion region LR of the liquid LQ, which is larger than a projection area AR and smaller than the substrate P, on one part of the substrate P that includes the projection area AR of the projection optical system PL. Specifically, the exposure apparatus EX employs a local liquid immersion system that fills the liquid LQ in the space of the optical path that is between a lower surface LSA of a first optical element LS1, which is closest to the image plane of the projection optical system PL, and one part of the upper surface of the substrate P that is disposed on the image plane side of the projection optical system PL, and then exposes the substrate P by projecting a pattern of the mask M onto the substrate P by irradiating such with the exposure light EL that passes through the mask M via the projection optical system PL and the liquid LQ that forms the liquid immersion region LR.
The illumination optical system IL comprises: an exposure light source; an optical integrator that uniformizes the luminous flux intensity of the light beam emitted from the exposure light source; a condenser lens that condenses the exposure light EL from the optical integrator; a relay lens system; and a field stop that sets an illumination region on the mask M illuminated by the exposure light EL. The illumination optical system IL illuminates the prescribed illumination region on the mask M with the exposure light EL, which has a uniform luminous flux intensity distribution. Examples of light that can be used as the exposure light EL emitted from the illumination optical system IL include: deep ultraviolet (DUV) light such as the bright lines (g-rays, h-rays, and i-rays) emitted from a mercury lamp and the like, and KrF excimer laser light (248 nm wavelength); and vacuum ultraviolet (VUV) light such as ArF excimer laser light (193 nm wavelength) and F2 laser light (157 nm wavelength). ArF excimer laser light is used in the present embodiment.
The projection optical system PL, which projects the pattern of the mask M onto the substrate P at a prescribed projection magnification β, comprises a plurality of optical elements that are held by a lens barrel PK. In the present embodiment, the projection optical system PL is a reduction system that has a projection magnification P of, for example, ¼, ⅕, or ⅛. Furthermore, the projection optical system PL may also be a unity magnification system or an enlargement system. In addition, the projection optical system PL may be: a dioptric system that does not include reflecting optical elements; a catoptric system that does not include refracting optical elements; or a catadioptric system that includes both reflecting optical elements and refracting optical elements. Among the plurality of optical elements that constitute the projection optical system PL, the first optical element LS1, which is the closest to the image plane of the projection optical system PL, protrudes from the lens barrel PK.
The measurement stage ST2 mounts various measuring instruments (including a measuring member) that perform measurements related to the exposure process, and is movable on the image plane side of the projection optical system PL. Examples of such measuring instruments include: a fiducial mark plate whereon a plurality of fiducial (reference) marks are formed as disclosed in, for example, Japanese Unexamined Patent Application, Publication No. H5-21314; a nonuniformity sensor for measuring the luminous flux intensity nonuniformity as disclosed in, for example, Japanese Unexamined Patent Application, Publication No. S57-117238 and for measuring the amount of fluctuations in the transmittance of a projection optical system PL for exposure light EL as disclosed in Japanese Unexamined Patent Application, Publication No. 2001-267239; an aerial image measuring sensor as disclosed in Japanese Unexamined Patent Application, Publication No. 2002-14005; and an irradiance sensor (luminous flux intensity sensor) as disclosed in Japanese Unexamined Patent Application, Publication No. H11-16816. Like the upper surface F1 of the substrate stage ST1, the upper surface F2 of the measurement stage ST2 is a flat surface (flat portion).
An off axis alignment system ALG, which detects alignment marks on the substrate P and fiducial marks on the fiducial mark plate, is provided in the vicinity of the tip of the projection optical system PL. With the alignment system ALG of the present embodiment, a FIA (Field Image Alignment) system of the type disclosed in, for example, Japanese Unexamined Patent Application, Publication No. H4-65603 is employed that: irradiates a target mark on the substrate P with a broadband detection light beam that does not photosensitize the photosensitive material on the substrate P; uses an imaging device (e.g., a CCD) to capture an image of an index (an index pattern on an index plate provided in the alignment system ALG), which is not shown, and an image of the target mark that is imaged on a light receiving surface by the light reflected from that target mark; and measures the position of the mark by image processing these imaging signals.
By moving the substrate stage ST1 and the measurement stage ST2 together, the control apparatus CONT moves the liquid LQ, which is retained between the substrate P and the first optical element LS1 of the projection optical system PL, from the upper surface F1 of the substrate stage ST1 to the upper surface F2 of the measurement stage ST2. With the movement of the substrate stage ST1 and the measurement stage ST2 in the −Y direction, the liquid immersion region LR of the liquid LQ, which is formed between the substrate P and the first optical element LS1 of the projection optical system PL, moves to the upper surface of the substrate P, the upper surface F1 of the substrate stage ST1, and the upper surface F2 of the measurement stage ST2, in that order. Furthermore, along the way of moving from the upper surface F1 of the substrate stage ST1 to the upper surface F2 of the measurement stage ST2, the liquid immersion region LR of the liquid LQ spans the upper surface F1 of the substrate stage ST1 and the upper surface F2 of the measurement stage ST2, as shown in FIG. 7B.
Subsequently, in the reverse sequence of that described earlier, the control apparatus CONT moves both stages ST1, ST2 together in the +Y direction while maintaining the relative positional relationship of the substrate stage ST1 and the measurement stage ST2 in the Y axial directions, and, after moving the substrate stage ST1 (substrate P) to below the projection optical system PL, retracts the measurement stage ST2 to a prescribed position. Thereby, the liquid immersion region LR is disposed on the upper surface F1 of the substrate stage ST1. Also, when moving the liquid immersion region LR of the liquid LQ from the upper surface F2 of the measurement stage ST2 to the upper surface F1 of the substrate stage ST1, the liquid immersion region LR spans the upper surface F1 of the substrate stage ST1 and the upper surface F2 of the measurement stage ST2.
Furthermore, by moving the substrate stage ST1 and the measurement stage ST2 together in a state wherein the recovery ports 51 are closed by the overhanging portion H1, the control apparatus CONT moves the liquid immersion region LR between the upper surface F1 of the substrate stage ST1 and the upper surface F2 of the measurement stage ST2 in a state wherein the liquid LQ is held between the projection optical system PL and at least one of the upper surface F1 of the substrate stage ST1 and the upper surface F2 of the measurement stage ST2.
In addition, each of the embodiments discussed above can also be adapted to a so-called multistage type exposure apparatus, which comprises a plurality of (e.g., two) movable substrate stages that each holds the substrate P, as disclosed in, for example, Japanese Unexamined Patent Application, Publication No. H10-163099, Japanese Unexamined Patent Application, Publication No. H10-214783, and Published Japanese Translation No. 2000-505958 of the PCT International Application.
a projection system by which a patterned radiation beam is projected onto a substrate;
a liquid confinement system which is configured to at least partly confine liquid in a space beneath the projection system, the liquid confinement system having an inlet and an outlet, the inlet being configured to supply the liquid to beneath a lower surface of the liquid confinement system, the outlet being disposed to surround the inlet and being configured to remove the liquid from beneath the lower surface;
at least a first stage and a second stage;
a positioning system configured to move the first stage and the second stage;
a controller configured to control the positioning system; and
a channel system,
the controller controls the positioning system to perform a joint scan movement in which the first stage and the second stage cooperate while moving between a first situation and a second situation, the liquid being confined between the first stage and the projection system in the first situation and the liquid being confined between the second stage and the projection system in the second situation, such that during the joint scan movement the liquid is essentially confined within the space beneath the projection system,
the first stage has a first immersion cross edge at or near a side of the first stage,
the second stage has a second immersion cross edge at or near a side of the second stage,
the first immersion cross edge and the second immersion cross edge being face-to-face with each other with a gap between the immersion cross edges during the joint scan movement of the first and second stages,
the first stage has a first lower portion located below the first immersion cross edge of the first stage, the first lower portion protruding outward beyond the first immersion cross edge and being stationary relative to the first immersion cross edge,
the second stage has a second lower portion located below the second immersion cross edge of the second stage, the second immersion cross edge of the second stage protruding outward beyond the second lower portion to form an overhang portion of the second stage, the overhang portion having the second immersion cross edge of the second stage,
during the joint scan movement, the first lower portion of the first stage is disposed below the gap and at least a part of the first lower portion is disposed under the overhang portion of the second stage, and
the channel system has an opening provided at the first lower portion of the first stage, and the channel system is configured to drain the liquid that passes through the gap formed between the first and second immersion cross edges during the joint scan movement via the opening.
2. The lithographic apparatus according to claim 1, wherein the liquid is confined between the substrate held by the first stage of the two stages and the projection system in the first situation.
3. The lithographic apparatus according to claim 2, wherein the second stage holds another substrate.
4. The lithographic apparatus according to claim 2, wherein the first stage is moved away from under the projection system to a substrate-exchange position in the second situation.
5. The lithographic apparatus according to claim 2, wherein in the first situation, the second stage stays for a period of time at a position away from under the projection system while moving the first stage under the projection system.
6. The lithographic apparatus according to claim 2, wherein the second stage is moved away from the first stage while the first stage is moved under the projection system in the first situation, and the first stage and the second stage are moved close to each other before the second situation and before the first stage is moved away from under the projection system.
exposing a substrate to a patterned beam through the projection system of the lithographic apparatus of claim 1; and
8. The lithographic apparatus according to claim 1, wherein during the joint scan movement, an upper surface of the first stage is adjacent to an upper surface of the second stage via the gap.
9. The lithographic apparatus according to claim 8, wherein a positional relationship between the upper surface of the first stage and the part of the first stage disposed under the overhang portion is substantially fixed.
10. The lithographic apparatus according to claim 1, wherein during the joint scan movement, an upper surface of the first stage is adjacent to an upper surface of the second stage via the gap, and the overhang portion has the upper surface of the second stage.
11. The lithographic apparatus according to claim 1, wherein the opening is connected to a vacuum system, and gas and the liquid are separated from each other between the opening and the vacuum system.
12. The lithographic apparatus according to claim 1, wherein the second stage has a plurality of support portions configured to support the substrate and a wall portion that is disposed to surround the support portions, the second stage being configured to hold the substrate on the support portions by sucking a gas from a space surrounded by the wall portion and a bottom surface of the substrate supported by the support portions.
US12007348 2004-11-01 2008-01-09 Immersion exposure apparatus and device fabricating method with two substrate stages and metrology station Active US8922754B2 (en)
US66642007 true 2007-04-27 2007-04-27
US12007348 US8922754B2 (en) 2004-11-01 2008-01-09 Immersion exposure apparatus and device fabricating method with two substrate stages and metrology station
US13961383 US20130321785A1 (en) 2004-11-01 2013-08-07 Exposure apparatus and device fabricating method
US14553095 US9709900B2 (en) 2004-11-01 2014-11-25 Exposure apparatus and device fabricating method
US15647997 US20170322496A1 (en) 2004-11-01 2017-07-12 Exposure apparatus and device fabricating method
US11666420 Division
PCT/JP2005/020020 Division WO2006049134A1 (en) 2004-11-01 2005-10-31 Exposure apparatus and device producing method
US11666420 Division US8330939B2 (en) 2004-11-01 2005-10-31 Immersion exposure apparatus and device manufacturing method with a liquid recovery port provided on at least one of a first stage and second stage
US66642007 Division 2007-04-27 2007-04-27
US13961383 Division US20130321785A1 (en) 2004-11-01 2013-08-07 Exposure apparatus and device fabricating method
US14553095 Division US9709900B2 (en) 2004-11-01 2014-11-25 Exposure apparatus and device fabricating method
US20080117393A1 true US20080117393A1 (en) 2008-05-22
US8922754B2 true US8922754B2 (en) 2014-12-30
US11666420 Active US8330939B2 (en) 2004-11-01 2005-10-31 Immersion exposure apparatus and device manufacturing method with a liquid recovery port provided on at least one of a first stage and second stage
US12007348 Active US8922754B2 (en) 2004-11-01 2008-01-09 Immersion exposure apparatus and device fabricating method with two substrate stages and metrology station
US13961383 Abandoned US20130321785A1 (en) 2004-11-01 2013-08-07 Exposure apparatus and device fabricating method
US14553095 Active US9709900B2 (en) 2004-11-01 2014-11-25 Exposure apparatus and device fabricating method
US15647997 Pending US20170322496A1 (en) 2004-11-01 2017-07-12 Exposure apparatus and device fabricating method
EP (2) EP1811546A4 (en)
JP2006523026A (en) 2003-04-09 2006-10-05 株式会社ニコン Immersion lithography fluid control system
JP2006121077A (en) 2004-10-18 2006-05-11 Asml Netherlands Bv Lithography equipment and device manufacturing method
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US20170322496A1 (en) * 2004-11-01 2017-11-09 Nikon Corporation Exposure apparatus and device fabricating method
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