Source: http://www.google.com/patents/US7969550?dq=4740761
Timestamp: 2015-05-24 05:49:34
Document Index: 554864706

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Patent US7969550 - Lithographic apparatus and device manufacturing method - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA lithographic apparatus includes an illumination system configured to condition a radiation beam; a support constructed to support a patterning device, the patterning device being capable of imparting the radiation beam with a pattern in its cross-section to form a patterned radiation beam; a substrate...http://www.google.com/patents/US7969550?utm_source=gb-gplus-sharePatent US7969550 - Lithographic apparatus and device manufacturing methodAdvanced Patent SearchPublication numberUS7969550 B2Publication typeGrantApplication numberUS 11/785,751Publication dateJun 28, 2011Filing dateApr 19, 2007Priority dateApr 19, 2007Also published asUS20080259299Publication number11785751, 785751, US 7969550 B2, US 7969550B2, US-B2-7969550, US7969550 B2, US7969550B2InventorsJohan Hendrik Geerke, Peter Paul Hempenius, Youssef Karel Maria De Vos, Clementius Andreas Johannes BeijersOriginal AssigneeAsml Netherlands B.V.Export CitationBiBTeX, EndNote, RefManPatent Citations (9), Referenced by (1), Classifications (8), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetLithographic apparatus and device manufacturing method
US 7969550 B2Abstract
A lithographic apparatus includes an illumination system configured to condition a radiation beam; a support constructed to support a patterning device, the patterning device being capable of imparting the radiation beam with a pattern in its cross-section to form a patterned radiation beam; a substrate table constructed to hold a substrate; a projection system configured to project the patterned radiation beam onto a target portion of the substrate, and a shield device arranged between a source of air flows and/or pressure waves and an element sensitive for the air flows and/or pressure waves.
a support constructed to support a patterning device, the patterning device capable of imparting the radiation beam with a pattern in its cross-section to form a patterned radiation beam;
a base frame with a metrology frame mounted thereon, wherein the metrology frame is arranged to support the projection system; and
a shield device arranged between a source of a pressure wave and an element of the lithographic apparatus sensitive to the pressure wave, wherein the source of the pressure wave comprises a moving object of the lithographic apparatus, and wherein the shield device is arranged to substantially absorb or reflect the pressure wave and the shield device comprises two or more adjacent plates separated by one or more gaps filled with one of an air, a gas, or an acoustic damping material.
2. The lithographic apparatus of claim 1, wherein a movement of the element caused by the pressure wave causes an imaging error, wherein the imaging error comprises at least one of one or more of an overlay error and a focus error during projection of the patterned radiation beam onto the substrate.
a base frame with a metrology frame mounted thereon, the metrology frame configured to support the projection system; and
a shield device arranged between the projection system and the support or the substrate table, wherein the shield device is arranged to substantially absorb or reflect a pressure wave induced by a moving object of the lithographic apparatus and the shield device comprises two or more adjacent plates separated by one or more gaps only with one of an air, a gas, or an acoustic damping material.
16. A method of shielding a lithographic apparatus element sensitive to a pressure wave in the environment of the element, the method comprising:
supporting a projection system with a metrology frame, wherein the metrology frame is on a base frame; and
providing a shield device between the element and a source of the pressure wave, wherein the source of the pressure wave comprises a moving object of the lithographic apparatus, and wherein the shield device is arranged to substantially absorb or reflect the pressure wave and the shield device comprises two or more adjacent plates separated by one or more gaps filled with one of an air, a gas, or an acoustic damping material.
coating a substrate with a radiation-sensitive material;
projecting a patterned beam of radiation onto the substrate using the lithographic apparatus of, the lithographic apparatus comprising:
a support constructed to support a pattern device, the patterning device capable of imparting the radiation beam with a pattern in the beam's cross-section to form a patterned radiation beam;
a shield device arranged between a source of a pressure wave and an element of the lithographic apparatus sensitive to the pressure wave, wherein the source of the pressure wave comprises a moving object of the lithographic apparatus, and wherein the shield device is arranged to substantially absorb or reflect the pressure wave and the shield device comprises two or more adjacent plates separated by one or more gaps filled with one of an air, a gas, or an acoustic damping material;
developing the substrate; and
baking the substrate.
supporting a projection system of a lithographic apparatus with a metrology frame, wherein the metrology frame is mounted on a base frame;
projecting a patterned beam of radiation onto a target portion of a substrate with the projection system; and
during the projecting, shielding, via a shield device arranged to substantially absorb or reflect a pressure wave induced by a moving part of the lithographic apparatus and comprising two or more adjacent plates separated by one or more gaps filled with one of an air, a gas, or an acoustic damping material, an element of the lithographic apparatus sensitive to the pressure wave.
26. The lithographic apparatus of claim 22, further comprising:
an additional shield device arranged between the projection system and the substrate table, wherein the addition shield device lies along a plane parallel to the substrate table. Description
In the lithographic process of a lithographic apparatus, it is desirable that at least the patterning device, the projection system and the substrate stage be properly aligned with respect to one another so that the pattern, which is provided by the patterning device in the radiation beam, is properly projected on a target portion of the substrate without overlay errors, imaging errors or focus errors. In particular, in scanners, in which the patterning device support (e.g. reticle stage) and the substrate table (e.g. substrate stage) are movable to position a particular part of the pattern with respect to a particular part of the substrate, high accuracy positioning is desirable. For these movements, positioning systems are provided which control the position of the reticle stage and substrate stage with high accuracy.
With continuously increasing demands on the accuracy of imaging, for instance overlay and focus on the one hand and throughput on the other, proper alignment of the reticle stage, projection system and substrate table becomes increasingly critical. In order to increase the throughput of the lithographic apparatus, it is desirable to increase the speed and acceleration with which the reticle stage and substrate stage are moved and aligned with respect to each other and the projection system.
However, moving the reticle stage or the substrate stage results in air flows and pressure waves which propagate through the space in which these stages but also the projection system are present. Also, the actuation forces of the stage may cause vibrations of parts of the stage resulting in air flows and/or pressure waves, such as acoustic signals or air flows through the working space. These air flows and/or pressure waves may excite the projection system, or at least parts of the projection system such as the lenses, or the frame on which the projection system is mounted. The air flows and/or pressure waves may also excite other parts of the lithographic apparatus being relevant for the alignment of the reticle stage projection system and wafer stage such as sensor or sensor target object of a stage position measurement system. The excitation of the projection system, or the other parts, may cause imaging errors such as errors in overlay and/or focus.
Also, other moving or vibrating parts in the lithographic apparatus may provide air flows and/or pressure waves in the process area, in particular in the environment of the projection system resulting in excitation of the projection system or the other parts. Also, the air flows and/or pressure waves resulting from these movements may result in imaging errors such as overlay and/or focus errors.
According to an embodiment of the invention, there is provided a lithographic apparatus including an illumination system configured to condition a radiation beam; a support constructed to support a patterning device, the patterning device being capable of imparting the radiation beam with a pattern in its cross-section to form a patterned radiation beam; a substrate table constructed to hold a substrate; a projection system configured to project the patterned radiation beam onto a target portion of the substrate, and a shield device arranged between a source of air flows and/or pressure waves and an element sensitive to the air flows and/or pressure waves.
According to an embodiment of the invention, there is provided a lithographic apparatus including an illumination system configured to condition a radiation beam; a support constructed to support a patterning device, the patterning device being capable of imparting the radiation beam with a pattern in its cross-section to form a patterned radiation beam; a substrate table constructed to hold a substrate; a projection system configured to project the patterned radiation beam onto a target portion of the substrate, and a shield device arranged between the projection system and the support or the substrate table.
According to an embodiment of the invention, there is provided a method of shielding a lithographic apparatus element sensitive to air flows and/or pressure waves in the environment of the element, by providing a shield device between the element and a source of air flows and/or pressure waves.
In an embodiment of the invention, there is provided a device manufacturing method including projecting a patterned beam of radiation onto a target portion of a substrate with a lithographic apparatus; and during the projecting, shielding an element of the lithographic apparatus sensitive to air flow and/or pressure wave from and a source of air flow and/or pressure wave.
The support structure (e.g. mask table) supports, i.e. bears the weight of, the patterning device. It holds the patterning device in a manner that depends on the orientation of the patterning device, the design of the lithographic apparatus, and other conditions, such as for example whether or not the patterning device is held in a vacuum environment. The support structure can use mechanical, vacuum, electrostatic or other clamping techniques to hold the patterning device. The support structure may be a frame or a table, for example, which may be fixed or movable as required. The support structure may ensure that the patterning device is at a desired position, for example with respect to the projection system. Any use of the terms “reticle” or “mask” herein may be considered synonymous with the more general term “patterning device.”
The radiation beam B is incident on the patterning device (e.g., mask) MA, which is held on the support structure (e.g., mask table MT), and is patterned by the patterning device. Having traversed the patterning device (e.g. mask) MA, the radiation beam B passes through the projection system PS, 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, linear encoder or capacitive sensor), the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the radiation beam B. 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 patterning device (e.g. mask) MA with respect to the path of the radiation beam B, e.g. after mechanical retrieval from a patterning device of mask library, or during a scan. In general, movement of the support structure (e.g. mask table) MT may be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which form part of the first positioning device PM. Similarly, movement of the substrate table WT or “substrate support” may be realized using a long-stroke module and a short-stroke module, which form part of the second positioner PW. In the case of a stepper (as opposed to a scanner) the support structure (e.g. mask table) MT may be connected to a short-stroke actuator only, or may be fixed. Patterning device (e.g. mask) MA and substrate W may be aligned using mask alignment marks M1, M2 and substrate alignment marks P1, P2. Although the substrate alignment marks as illustrated occupy dedicated target portions, they may be located in spaces between target portions (these are known as scribe-lane alignment marks). Similarly, in situations in which more than one die is provided on the patterning device (e.g. mask) MA, the mask alignment marks may be located between the dies.
1. In step mode, the support structure or pattern support (e.g. mask table) MT or “mask support” and the substrate table WT or “substrate support” are kept essentially stationary, while an entire pattern imparted to the radiation beam is projected onto a target portion C at one time (i.e. a single static exposure). The substrate table WT or “substrate support” is then shifted in the X and/or Y direction so that a different target portion C can be exposed. In step mode, the maximum size of the exposure field limits the size of the target portion C imaged in a single static exposure.
2. In scan mode, the support structure or pattern support (e.g. mask table) MT or “mask support” and the substrate table WT or “substrate support” are scanned synchronously while a pattern imparted to the radiation beam is projected onto a target portion C (i.e. a single dynamic exposure). The velocity and direction of the substrate table WT or “substrate support” relative to the support structure (e.g. mask table) MT or “mask support” may be determined by the (de-)magnification and image reversal characteristics of the projection system PS. In scan mode, the maximum size of the exposure field limits the width (in the non-scanning direction) of the target portion in a single dynamic exposure, whereas the length of the scanning motion determines the height (in the scanning direction) of the target portion.
3. In another mode, the support structure or pattern support (e.g. mask table MT or “mask support” is kept essentially stationary holding a programmable patterning device, and the substrate table WT or “substrate support” is moved or scanned while a pattern imparted to the radiation 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 “substrate support” or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes a programmable patterning device, such as a programmable mirror array of a type as referred to above.
FIG. 2 depicts a part of the lithographic apparatus of FIG. 1. The support structure (e.g. reticle stage) 1 supports a patterning device (e.g. a reticle) 2. The reticle stage 1 is located above a projection system 3. Under the projection system 3, a substrate stage 4 configured to carry a substrate 5 is positioned. The reticle stage 1 and the substrate stage 4 are movable with high accuracy so that during projection the reticle stage 1 and substrate stage 4 can be moved with a scanning movement with respect to the projection system 3 to project a projection beam having a pattern imparted by the reticle 2 on a target portion of the substrate 5 supported by the substrate stage 4.
The projection system 3 is supported by a so-called metrology frame or metro-frame 6 which is a substantially stationary frame. The metro-frame 6 is mounted on a base frame 7 by a number of air mounts 8. These air mounts 8 may include active or passive damping devices so that any vibrations in the base frame 7 are not passed onto the metro-frame 6. In this way, the projection system 3 is substantially isolated from vibrations in the base frame 7 in order to decrease imaging errors such as overlay or focus errors in the projection of the patterned beam on the substrate 5 due to vibration/movement of the projection system 3.
However, the movement of the reticle stage 1 may cause air flows and pressure waves, around the reticle stage 1 and, as a result, in the process area, i.e. the area in which the reticle stage 1, the projection system 3 and the substrate stage 4 are arranged.
Furthermore, the reticle stage 1 may include one or more parts 1 a which may be mounted with some flexibility to the reticle stage main body. As a result of the movements of the reticle stage, such part 1 a may also move with respect to the reticle main body. This part 1 a will typically have a vibrating or oscillating movement on the resonance frequency of the part 1 a. Also, these movements of one or more parts 1 a may result in air flows and/or pressure waves in the process area.
Some of the air flows and/or pressure waves resulting from the movement of the reticle stage 1 or any parts 1 a mounted on the reticle stage 1 will propagate in the direction of the projection system 3 or the metro-frame 6 supporting the projection system 3.
In a conventional lithographic apparatus, the projection system 3 or metro-frame 6 may be excited by these air flows and/or pressure waves, which may result in movements of the projection system, in particular the lenses and/or other optical elements in the projection system 3. These movements may influence the radiation beam passing through the projection system 3 resulting in overlay and/or focus errors. It will be clear that this is undesirable.
In this respect it is remarked that in embodiments of the present application such parts, i.e. projection system and metro-frame are regarded to be sensitive to air flows and/or pressure waves. In this application, in particular parts of the lithographic apparatus which when exposed to air flows and/or pressure waves are influenced such that the accuracy of projection, e.g. overlay and/or focus, of the lithographic apparatus is decreased, are regarded to be sensitive to air flows and/or pressure waves. Such parts may, for instance, include sensors or sensor target objects, such as an interferometer or encoder grating or grid, of a stage position measurement system.
In the lithographic apparatus of FIG. 2, a shield device is provided in the form of a shield plate 9, which is arranged between the reticle stage 1 on the one hand and the projection system 3 and metro-frame 6 on the other hand. The shield plate 9 is preferably a relatively stiff and heavy plate configured to substantially absorb or reflect the air flows and/or pressure waves, and is preferably mounted on the base frame 7 so that resulting reaction forces are led to a less critical part of the lithographic apparatus. When desired, the shield plate 9 may be flexibly supported in order to isolate the shield plate 9 structurally from the base frame 7 in order to avoid generation of air flows and/or pressure waves by the shield plate 9 itself. By providing a shield plate 9, all air flows and/or pressure waves running in the direction of the projection system 3 or metro-frame 6 will at least for a large extent be absorbed or reflected by the shield plate 9 and thus not reach the projection system 3 or metro-frame 6. As a result, the projection system 3 and/or metro-frame 6 are not excited by the air flows and/or pressure waves and the accuracy of projection will not be negatively influenced by the presence of the air flows and/or pressure waves caused by the movement of the reticle stage 1.
The shield plate 9 preferably extends between the whole area in which the reticle stage 1 can be moved, at least during the exposure phase, and the location of the projection system 3 and preferably also the metro-frame 6 in the case the metro-frame is sensitive to the air flows and/or pressure waves. At the location where the projection beam crosses the shield plate 9, a hole 10 is provided in the shield plate 9 in order for the patterned beam of radiation to pass through the shield plate 9. As such, hole 10 generally is undesirable since the hole may allow air flows and/or pressure waves to pass there through. Thus, in an embodiment, the hole 10 is preferably as small as possible.
In an alternative embodiment, the shield plate 9 is at least at the location where the beam of radiation passes the shield plate 9 made from a material which allows the passing of the projection beam. In this way, the provision of a hole in the shield plate 9 is avoided which is desirable as the presence of a hole may substantially decrease the extent in which the air flows and/or pressure waves are absorbed or reflected by the shield plate. However, the passing of the beam of radiation through the material of the shield plate 9 may have a negative influence on the quality of the projection beam and may for that reason be undesirable.
In an embodiment, the thickness of the shield plate 9 is preferably between values X and Y, or at least 2 times Y, whereby the values of X and Y depend on the material and frequency range of the air flows and/or pressure waves. For instance for a shield plate of aluminum or stainless steel and a frequency range of 0 to 1000 Hz, the thickness of the shield plate 9 is preferably between 5 mm and 15 mm, more preferably 8 mm and 12 mm, or at least 24 mm, more preferably at least 30 mm. Such thickness of the shield plate 9 provides a suitable absorption and/or reflection of the air flows and/or pressure waves caused by the movements of the reticle stage 1.
The stiffness of the shield plate which is needed to absorb and/or reflect the air flows and/or pressure waves may be achieved by the material itself but also by the design of the shield plate, for instance by the provision of a number of suitable ribs on the shield plate.
Instead of using a single plate as a shield device, a number of plates may be used on top of each other, preferably with a gap between two adjacent plates. This gap may be filled with air or another gas or be filled with an (acoustic) damping material. Such construction may provide an improved damping of the air flows and/or pressure waves.
FIG. 3 shows an alternative embodiment of a shield device. The shield device includes a shield plate 20 mounted on the projection system 3. The shield plate 20 includes a hole 21 for passing the patterned beam of radiation. Furthermore, the shield device includes a shield plate 22 corresponding to the shield plate 9 of FIG. 2, but having an opening in which the shield plate 20 is tightly placed. For instance, the shield plate 20 may be circular, and the hole in the shield plate 22 may also be circular having a diameter substantially corresponding to the diameter of the shield plate 20.
The shield plate 22 is rigidly mounted on the base frame 7. All reaction forces of the shield plate 22 to absorb and/or reflect the air flows and/or pressure waves are guided to the base frame in accordance with the embodiment of FIG. 2. The shield plate 20 however is mounted on the projection system itself. It is undesirable that the forces of the air flows and/or pressure waves exerted on the shield plate 20 are passed onto the projection system 3. Therefore the mounting of the shield plate 22 on the projection system has been given some flexibility, for instance by providing spring elements between shield plate 22 and projection system 3.
In general the embodiment of FIG. 3 wherein the shield device is subdivided in two parts may be undesirable as this arrangement includes a gap between shield plate 20 and shield plate 22 which may function as a leak for air flows and/or pressure waves. However, in some constructions it may not be possible to provide a (single) closed shield plate, and in those constructions the provision of two shield plates in substantially the same plane as the shield plates 20 and 22 in the embodiment of FIG. 3 may provide a suitable solution.
Furthermore, in FIG. 3, a further shield plate 23 is provided between the substrate stage 4 and the projection system 3. Similar to the movements of the reticle stage 1 the movement of the substrate stage 4 during the expose phase may result in air flows and/or pressure waves propagating through the working space. As these air flows and/or pressure waves may also excite the projection system 3 and/or the metro-frame 6, it may be advantageous to provide a shield plate 23, or other shield device between the substrate stage 4 and the projection system 3/metro-frame 6.
Also, shield plate 23 is provided with a hole 24 in order to allow the projected beam of radiation to pass through the shield plate 23. The shield plate 23 is assembled out of two plates 25 between which a damping material 26 is provided. In an alternative embodiment, the damping material may be omitted, and air or another gas may be present between the two plates 25. In another alternative embodiment, three or more parallel plates may be provided as the shield device.
Furthermore, a pressure wave shield device may be placed between any pressure wave source, such as moving and vibrating parts of the lithographic apparatus, and an element sensitive to the air flows and/or pressure waves, such as projection system parts or parts of the positioning system. Such embodiments are deemed to fall within the scope of the present invention.
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