Source: https://patents.google.com/patent/EP1643543A1/en
Timestamp: 2019-08-22 10:45:19
Document Index: 169072655

Matched Legal Cases: ['art 60', 'art) 103', 'art) 103', 'art 103', 'art 161', 'arts 164', 'arts 62', 'art 111', 'arts 161', 'art 171', 'art 161']

EP1643543A1 - Linking unit, exposure apparatus and method for manufacturing device - Google Patents
Linking unit, exposure apparatus and method for manufacturing device Download PDF
EP1643543A1
EP1643543A1 EP04747525A EP04747525A EP1643543A1 EP 1643543 A1 EP1643543 A1 EP 1643543A1 EP 04747525 A EP04747525 A EP 04747525A EP 04747525 A EP04747525 A EP 04747525A EP 1643543 A1 EP1643543 A1 EP 1643543A1
EP04747525A
EP1643543B1 (en
EP1643543A4 (en
2004-07-08 Application filed by Nikon Corp filed Critical Nikon Corp
2006-04-05 Publication of EP1643543A1 publication Critical patent/EP1643543A1/en
2008-04-23 Publication of EP1643543A4 publication Critical patent/EP1643543A4/en
2010-11-24 Publication of EP1643543B1 publication Critical patent/EP1643543B1/en
2011-08-24 First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=34067374&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP1643543(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
An exposure apparatus is an exposure apparatus that exposes a substrate by filling a liquid between a projection optical system and the substrate, and projecting a pattern image onto the substrate via the projection optical system and the liquid, wherein the projection optical system has a first group comprising an optical member that contacts the liquid, and a second group that differs from that first group; the first group is supported by a first support member; and the second group is separated from the first group and is supported by the second support member that differs from the first support member.
Priority is claimed on Japanese Patent Application Nos. 2003-272615 (filed on July 9, 2003) and 2003-281182 (filed on July 28, 2003), the contents of which are incorporated herein by reference.
Semiconductor devices and liquid crystal display devices are fabricated by a so-called photolithography technique, wherein a pattern formed on a mask is transferred onto a photosensitive substrate. An exposure apparatus used by this photolithographic process comprises a mask stage that supports the mask, and a substrate stage that supports the substrate, and transfers the pattern of the mask onto the substrate via a projection optical system while successively moving the mask stage and the substrate stage. There has been demand in recent years for higher resolution projection optical systems in order to handle the much higher levels of integration of device patterns. As the exposure wavelength to be used is shorter, the resolution of the projection optical system becomes higher. As the numerical aperture of the projection optical system is larger, the resolution of the projection optical system becomes higher. Consequently, the exposure wavelength used in exposure apparatuses has shortened year by year, and the numerical aperture of projection optical systems has also increased. Furthermore, the currently mainstream exposure wavelength is the 248 nm KrF excimer laser, but an even shorter wavelength 193 nm ArF excimer laser is also being commercialized. In addition, the depth of focus (DOF) is also important as well as the resolution when performing an exposure. The following equations respectively express the resolution R and the depth of focus δ. R = k 1 ⋅ λ / NA ,
δ = ± k 2 ⋅ λ / NA 2 ,
To solve the abovementioned problems, the present invention adopts the following configuration, associated with FIG 1 to FIG. 17, which depict the embodiments. However, the parenthesized symbol appended to each element is merely an example of the element, and the elements are not limited thereby.
The first aspect of the present invention is an exposure apparatus that exposes a substrate (P) by filling a liquid (50) between a projection optical system (PL) and the substrate (P), and projecting a pattern image onto the substrate (P) via the projection optical system (PL) and the liquid (50), wherein: the projection optical system (PL) includes a first group (60) having an optical member (60) that contacts the liquid (50), and a second group (MPL) that differs from the first group (60); the first group (60) is supported by a first support member (47); and the second group (MPL) is separated from the first group and is supported by a second support member (42) that is different from the first support member (47).
The second aspect of the present invention is an exposure apparatus that exposes a substrate (P) by filling a liquid (50) between a projection optical system (PL) and the substrate (P) and projecting a pattern image onto the substrate (P) via the projection optical system (PL) and the liquid (50), wherein: the projection optical system (PL) includes a first group (60) has an optical member that contacts the liquid (50), and a second group (MPL) that is different from the first group (60); and a drive mechanism (48), which moves the first group (60), adjusts the position of the first group (60) with respect to the second group (MPL).
The third aspect of the present invention is a coupling apparatus (160) that couples a first object (LS2) and a second object (108), including: a parallel link mechanism (160, 161) that couples the first object (LS2) and the second object (108); and a vibration isolating mechanism (167, 172, 173, 174) that is built in the parallel link mechanism (160, 161) so that vibrations of one of the first object (LS2) and the second object(108) do not transmit to the other.
The fourth aspect of the present invention is an exposure apparatus (EX2) that exposes a substrate (P2) by filling a liquid (101) in at least one part between a projection optical system (PL2) and the substrate (P2), and projecting a pattern image onto the substrate via the projection optical system (PL2) and the liquid (101), wherein: the projection optical system (PL2) includes a first group (102) having at least an optical member that contacts the liquid (101), and a second group (MPL2) disposed between the first group (102) and the pattern; and the exposure apparatus (EX2) includes: a first holding member (LS2) that holds the first group (102); a second holding member (PK2) that holds the second group (MPL2) isolated from the first holding member (LS2); and a frame member (108) that supports the first holding member (LS2) and the second holding member (PK2).
The fifth aspect of the present invention is an exposure apparatus (EX2) that exposes a substrate by irradiating the substrate (P2) with an exposure light via a projection optical system (PL2) and a liquid (101), wherein: the projection optical system (PL2) includes a first group (102) having an optical member that contacts the liquid (101), and a second group (MPL2) disposed between the first group (102) and a pattern; and the exposure apparatus (EX2) includes: a first holding member (LS2) that holds the first group (102); a second holding member (PK2) that holds the second group (MPL2) isolated from the first holding member (LS2); a frame member (108) for supporting the first holding member (LS2); and a linking mechanism (160) including a vibration isolating mechanism (161) for controlling the vibrations of at least one of the first holding member (LS2) and the frame member (108), and that links the first holding member (LS2) and the frame member (108).
The sixth aspect of the present invention is an exposure apparatus (EX2) that exposes a substrate by irradiating the substrate (P2) with an exposure light via a projection optical system (PL2) and a liquid (101), including: a liquid immersion mechanism (110, 120) that forms an immersion area (AR2) at only one part on the substrate (P) during exposure of the substrate (P); wherein, the projection optical system (PL2) includes a first group (102) having an optical member that contacts the liquid, and a second group (MPL2) disposed between the first group and a pattern; and the first group (102) and the second group (MPL2) are supported vibrationally isolated.
In addition, the seventh aspect of the present invention is a device fabricating method, wherein an exposure apparatus (EX) as recited above is used.
FIG. 14 is a schematic view for explaining the features of the double pass interferometer depicted in FIG 13.
Here, as an example, the present embodiment explains a case of using, as the exposure apparatus EX, a scanning type exposure apparatus (a so-called scanning stepper) that, while synchronously moving the mask M and the substrate P in mutually different directions (opposite directions) in the scanning direction, exposes the substrate P with the pattern formed on the mask M. In the following explanation, the direction that coincides with an optical axis AX of the projection optical system PL is the Z axial direction, the direction in which the mask M and the substrate P synchronously move in the plane perpendicular to the Z axial direction (the scanning direction) is the X axial direction, and the direction perpendicular to the Z axial direction and the X axial direction (the non-scanning direction) is the Y axial direction. In addition, the rotational (inclined) directions around the X, Y, and Z axes are the θX, θY, and θZ directions, respectively. Furthermore, "substrate" herein includes one in which a semiconductor wafer is coated with a photoresist, and "mask" includes a reticle wherein is formed a device pattern that is reduction projected onto the substrate.
The projection optical system PL projection-exposes the pattern of the mask M onto the substrate P with a predetermined projection magnification β, and includes a plurality of optical elements (lenses), and these optical elements are supported by a lens barrel PK. In the present embodiment, the projection optical system PL is a reduction system having a projection magnification β of, for example, 1/4 or 1/5. Furthermore, the projection optical system PL may be either a unity magnification system or an enlargement system.
FIG. 2 is a front view that depicts the lower portion of the projection optical system PL of the exposure apparatus EX, the liquid supply apparatus 1, the liquid recovery apparatus 2, and the like. A tip portion 60A of the optical element 60 at the lowest end of the projection optical system PL in FIG. 2 is formed to have rectangular shape which is long in the Y axial direction (the non-scanning direction), leaving just the portion needed in the scanning direction. During scanning exposure, the pattern image of one part of the mask M is projected onto the rectangular projection area directly below the tip portion 60A, and, synchronized to the movement of the mask M at a speed V in the -X direction (or the +X direction) with respect to the projection optical system PL, the substrate P moves at a speed β·V (where β is the projection magnification) in the +X direction (or the -X direction) via the XY stage 52. Further, after the exposure of one shot region is completed, the next shot region moves to the scanning start position by stepping the substrate P, and the exposure process is subsequently performed sequentially for each shot region by the step-and-scan system. In the present embodiment, the liquid 50 flows parallel to and in the same direction as the movement direction of the substrate P.
FIG. 3 depicts the positional relationship between the tip portion 60A of the lens 60 of the projection optical system PL, the supply nozzles 4 (4A- 4C) that supply the liquid 50 in the X axial direction, and the recovery nozzles 5 (5A, 5B) that recover the liquid 50. In FIG 3, the tip portion 60A of the lens 60 is a rectangular shape that is long in the Y axial direction; further, the three supply nozzles 4A - 4C are disposed on the +X side and the two recovery nozzles 5A, 5B are disposed on the -X side so that the tip portion 60A of the lens 60 of the projection optical system PL is interposed therebetween in the X axial direction. Further, the supply nozzles 4A - 4C are connected to the liquid supply apparatus 1 via the supply pipe 3, and the recovery nozzles 5A, 5B are connected to the liquid recovery apparatus 2 via the recovery pipe 4. In addition, supply nozzles 8A - 8C and recovery nozzles 9A, 9B are disposed substantially 180° rotated from the supply nozzles 4A - 4C and the recovery nozzles 5A, 5B. The supply nozzles 4A - 4C and the recovery nozzles 9A, 9B are alternately arrayed in the Y axial direction, the supply nozzles 8A- 8C and the recovery nozzles 5A, 5B are alternately arrayed in the Y axial direction, the supply nozzles 8A - 8C are connected to the liquid supply apparatus 1 via a supply pipe 10, and the recovery nozzles 9A, 9B are connected to the liquid recovery apparatus 2 via a recovery pipe 11.
FIG 4 is a schematic diagram for explaining the support structure of the projection optical system PL.
Furthermore, to simplify the explanation, the liquid 50, the liquid supply apparatus 1, the liquid recovery apparatus 2, and the like, are omitted from FIG. 4. In FIG 4, the exposure apparatus EX includes a main frame 42 that supports the projection optical system main body MPL, and a base frame 43 that supports the main frame 42 and the substrate stage PST (the Z stage 51 and the XY stage 52). A flange 41 is provided at the outer circumference of the lens barrel PK that holds the projection optical system main body MPL, and the main frame (second support member) 42 supports the projection optical system main body MPL via this flange 41.
Furthermore, in the configuration depicted in FIG 4, a vibration isolating apparatus the same as the vibration isolating apparatuses 44, 46 may be provided between the support frame 47 and the stage base 53, and an elastic member, such as rubber, may be disposed so that vibrations that do transmit between the support frame 47 and the stage base 53 are attenuated.
A voice coil motor (drive mechanism) 48 is disposed between the support frame 47 and the casing 61 that holds the optical element 60, the support frame 47 supports the casing 61 via the voice coil motor 48 in a non-contact manner, and the optical element 60 held by the casing 61 is movable in the Z axial direction by driving the voice coil motor 48. In addition, the main frame 42 is provided with an interferometer (measuring apparatus) 71 that receives reflected light from a measuring mirror 49a affixed to the casing 61 and from a measuring mirror 49b affixed to the lens barrel PK, and measures the spacing between the projection optical system main body MPL and the optical element 60. Three voice coil motors 48 are disposed between the casing 61 and the support frame 47 at, for example, 120° intervals from one another, and are constituted so that they can each move independently, so that they can move in the Z axial direction, and so that they can incline with respect to the projection optical system MPL. Based on the measurement result of the interferometer 71, the voice coil motor 48 is controlled so that the predetermined positional relationship (predetermined spacing) between the projection optical system main body MPL and the optical element 60 is maintained.
After the mask M is loaded on the mask stage MST and the substrate P is loaded on the substrate stage PST, the control apparatus CONT drives the liquid supply apparatus 1, and starts the operation to supply liquid to the space 56. Further, if scanning exposure is performed by moving the substrate P in the scanning direction (the -X direction) depicted by an arrow Xa (refer to FIG. 3), then the liquid supply apparatus 1 and the liquid recovery apparatus 2 use the supply pipe 3, the supply nozzles 4A - 4C, the recovery pipe 4, and the recovery nozzles 5A, 5B to supply and recover the liquid 50. Namely, when the substrate P moves in the -X direction, the liquid 50 is supplied between the projection optical system PL and the substrate P from the liquid supply apparatus 1 via the supply pipe 3 and the supply nozzles 4 (4A - 4C), the liquid 50 is also recovered by the liquid recovery apparatus 2 via the recovery nozzles 5 (5A, 5B) and the recovery pipe 6, and the liquid 50 thereby flows in the -X direction so that it fills between the optical element 60 and the substrate P. On the other hand, if scanning exposure is performed by moving the substrate P in the scanning direction (the +X direction) depicted by an arrow Xb, then the liquid supply apparatus 1 and the liquid recovery apparatus 2 use the supply pipe 10, the supply nozzles 8A - 8C, the recovery pipe 11, and the recovery nozzles 9A, 9B to supply and recover the liquid 50. Namely, when the substrate P moves in the +X direction, the liquid 50 is supplied between the projection optical system PL and the substrate P by the liquid supply apparatus 1 via the supply pipe 10 and the supply nozzles 8 (8A - 8C), the liquid 50 is also recovered by the liquid recovery apparatus 2 via the recovery nozzles 9 (9A, 9B) and the recovery pipe 11, and the liquid 50 thereby flows in the +X direction so that it fills between the optical element 60 and the substrate P. In this case, the liquid 50 can be easily supplied into the space 56, even if the supplied energy of the liquid supply apparatus 1 is small, because the liquid 50 supplied, for example, from the liquid supply apparatus 1 via the supply nozzles 4 flows so that it is drawn into the space 56 as the substrate P moves in the -X direction. Further, even if the substrate P is scanned in either the +X direction or the -X direction by switching the direction in which the liquid 50 flows in accordance with the scanning direction, the liquid 50 can be filled between the tip surface 7 of the optical element 60 and the substrate P, and a high resolution and large depth of focus can thereby be obtained.
Furthermore, in the first embodiment discussed above, the interferometer system (49a, 49b, 71) is used as the measuring apparatus, but a measuring apparatus employing another system may be used provided that it can measure the positional relationship between the projection optical system main body MPL and the optical element 60 with a predetermined accuracy. For example, instead of the interferometer system discussed above, it is acceptable to use a measuring apparatus that optically measures the relative position information of measurement marks disposed respectively on the lens barrel PK and the casing 61.
The present embodiment differs from the embodiment of the support structure of the projection optical system explained referencing FIG 14 on the point that a support frame 47' that supports the casing 61 that holds the optical element 60 is affixed to the base frame 43. In the present embodiment as well, the main frame 42 that supports the projection optical system main body MPL and the support frame 47' that holds the optical element 60 are vibrationally isolated, and vibrations transmitted to the optical element 60 thereby do not transmit to the projection optical system main body MPL, and the positional relationship between the projection optical system main body MPL and the optical element 60 is also maintained in a predetermined state; therefore, the desired pattern image can be formed on the substrate P without causing degradation of the pattern image, even if performing an immersion exposure by filling the liquid 50 between the optical element 60 of the projection optical system PL and the substrate P.
The above embodiments are not particularly limited to the nozzle configurations discussed above, e.g., the liquid 50 may be supplied and recovered by two pairs of nozzles on the long sides of the tip part 60A. Furthermore, in this case, the supply nozzles and the recovery nozzles may be disposed so that they are arrayed vertically in order to enable the supply and recovery of the liquid 50 from either the +X direction or the -X direction.
FIG 7 is a schematic block diagram that depicts the second embodiment of the exposure apparatus according to the present invention.
In FIG 7, an exposure apparatus EX2 includes a mask stage MST2 that supports a mask M2, a substrate stage PST2 that supports a substrate P2, an illumination optical system IL2 that illuminates the mask M2 supported by the mask stage MST2 with exposure light EL2, a projection optical system PL2 that projects and exposes the pattern image of the mask M2 illuminated by the exposure light EL2 onto the substrate P2 supported by the substrate stage PST2, and a control apparatus CONT2 that performs overall control of the operation of the entire exposure apparatus EX2. Furthermore, the exposure apparatus EX2 includes a main column 103 that supports the mask stage MST2 and the projection optical system PL2. The main column 103 is installed on the base plate 4 which is placed horizontally upon the floor surface. An upper side step part (upper side support part) 103A and a lower side step part (lower side support part) 103B that protrude inwardly are formed in the main column 103.
The exposure apparatus EX2 of the present embodiment is a liquid immersion type exposure apparatus that applies the liquid immersion method to substantially shorten the exposure wavelength, improve the resolution, as well as substantially increase the depth of focus, and includes a liquid supply mechanism 110 that supplies a liquid 101 onto the substrate P2, and a liquid recovery mechanism 120 that recovers the liquid 101 on the substrate P2. At least during the transfer of the pattern image of the mask M2 onto the substrate P2, the exposure apparatus EX2 forms an immersion area AR2, by the liquid 101 supplied from the liquid supply mechanism 110, at one part on the substrate P2 that includes a projection area AR1 of the projection optical system PL2.
Specifically, the exposure apparatus EX2 exposes the substrate P2 by locally filling the liquid 101 between an optical member (optical element) 102 of the tip part (terminal end part) of the projection optical system PL2 and the surface of the substrate P2; and then projecting the pattern image of the mask M2 onto the substrate P2 via the liquid 101 between the projection optical system PL2 and the substrate P2, and via the projection optical system PL2.
As an example, the present embodiment explains a case of using, as the exposure apparatus EX2, a scanning type exposure apparatus (a so-called scanning stepper) that, while synchronously moving the mask M2 and the substrate P2 in mutually different directions (opposite directions) in the scanning direction, exposes the substrate P2 with the pattern formed on the mask M2. In the following explanation, the direction that coincides with an optical axis AX2 of the projection optical system PL2 is the Z axial direction, the direction in which the mask M2 and the substrate P2 synchronously move in the plane perpendicular to the Z axial direction (the scanning direction) is the X axial direction, and the direction perpendicular to the Z axial direction and the X axial direction (the non-scanning direction) is the Y axial direction. In addition, the rotational (inclined) directions around the X, Y, and Z axes are the θX, θY, and θZ directions, respectively. Furthermore, "substrate" herein includes one in which a semiconductor wafer is coated with a photoresist, which is a photosensitive material, and "mask" includes a reticle wherein is formed a device pattern that is reduction projected onto the substrate.
The projection optical system PL2 projects and exposes the pattern of the mask M2 onto the substrate P2 with a predetermined projection magnification β. In the present embodiment, the projection optical system PL2 is a reduction system having a projection magnification β of, for example, 1/4 or 1/5. Furthermore, the projection optical system PL2 may be either a unity magnification system or an enlargement system. The projection optical system PL2 includes: the optical element (first group) 102 disposed on the terminal side (the substrate P2 side) thereof and that contacts the liquid 101; and an optical group (second group) MPL2 that includes a plurality of optical elements disposed between the optical member 102 and the mask M2 having a pattern. Furthermore, in the present embodiment, the first group has only the optical member 102, i.e., only one lens element (optical element). A metal lens cell (first holding member) LS2 holds the lens element 102. The lens cell LS2 is made of metal, and a spring mechanism (not shown) is interposed between the lens cell LS2 and the lens element 102. Further, a lens barrel (second holding member) PK2 holds the optical group MPL2. The lens cell LS2 and the lens barrel PK2 are isolated.
An outer circumferential part of the lens barrel PK2 is provided with a flange part FLG2. In addition, a lens barrel base plate 108 is supported via a vibration isolating unit 107 on the lower side step part 103B of the main column 103.
Furthermore, engaging the flange part FLG2 to the lens barrel base plate 108 causes the lens barrel PK2, which holds the optical group MPL2, to be supported by the lens barrel base plate (frame member) 108.
The substrate stage PST2 is movable while holding the substrate P2 by suction via a substrate holder PH2, and a plurality of gas bearings (air bearing) 142, which are non-contact bearings, is provided at the lower surface thereof. A substrate base plate 141 is supported on a base plate 104 via a vibration isolating unit 109. A substrate stage PST1 is supported by the air bearings 142 in a non-contact manner with respect to an upper surface (guide surface) 141 A of the substrate base plate 141, and is finely rotatable in the θZ direction and two dimensionally movable within a plane perpendicular to the optical axis AX2 of the projection optical system PL2, i.e., within the XY plane, by a substrate stage drive mechanism, such as a linear motor. Furthermore, the substrate stage PST2 is also movable in the Z axial direction, the θX direction, and the θY direction. The control apparatus CONT2 controls the substrate stage drive mechanism. The substrate stage PST2 aligns the surface of the substrate P2 with the image plane of the projection optical system PL2 by an auto focus system and an auto leveling system, by controlling the focus position (Z position) and the inclination angle of the substrate P2, and also positions the substrate P2 in the X axial direction and the Y axial direction.
A movable mirror 180 that moves integrally with the substrate stage PST2 is provided at a predetermined position on the +X side on the substrate stage PST2 (substrate holder PH2), and a reference mirror (fixed mirror) 181 is provided at a predetermined position on the +X side of the lens barrel PK2. In addition, a laser interferometer 182 is provided at a position opposing the movable mirror 180. The laser interferometer 182 irradiates the movable mirror 180 with a measuring beam (measuring light), and also irradiates the reference mirror 181 with a reference beam (reference light) via mirrors 183A, 183B. The reflected light of each of the movable mirror 180 and the reference mirror 181 based on the irradiated measuring beam and the reference beam is received by a light receiving part of the laser interferometer 182. The laser interferometer 182 causes these light beams to interfere, and measures the amount of change in the optical path length of the measuring beam, using the optical path length of the reference beam as a reference, and the position (coordinate) and/or displacement of the movable mirror 180, using the reference mirror 181 as a reference. The lens barrel PK2 supports the reference mirror 181, and the substrate holder PH2 (substrate stage PST2) supports the movable mirror 180. Likewise, although not shown, a movable mirror and a reference mirror are also provided on the +Y side of the lens barrel PK2 on the substrate stage PST2 respectively, and a laser interferometer is provided at a position opposing thereto. The laser interferometer 182 measures in real time the position in the two dimensional direction and the rotational angle of the substrate P, and the measurement results are outputted to the control apparatus CONT2. The control apparatus CONT2 moves and positions the substrate P2 supported by the substrate stage PST2 by driving the substrate stage drive mechanism, which includes a linear motor, based on the measurement results of the laser interferometer 182.
Furthermore, as depicted in the partial cross sectional views of FIG 7 and FIG. 8, the liquid supply mechanism 110 and the liquid recovery mechanism 120 are supported and isolated from the lens barrel base plate 108. Thereby, vibrations produced by the liquid supply mechanism 110 and the liquid recovery mechanism 120 do not transmit to the projection optical system PL2 via the lens barrel base plate 108.
FIG. 9 is plan view that depicts the positional relationship between the liquid supply mechanism 110, the liquid recovery mechanism 120, and the projection area AR1 of the projection optical system PL2. The projection area AR1 of the projection optical system PL2 is a rectangular shape (slit shape) that is long in the Y axial direction; further, the three supply nozzles 114A- 114C are disposed on the +X side and the two recovery nozzles 121A, 121B are disposed on the -X side so that the projection area AR1 is interposed therebetween in the X axial direction. Furthermore, the supply nozzles 114A - 114C are connected to the liquid supply section 111 via the supply pipe 115, and the recovery nozzles 121A, 121B are connected to the liquid recovery section 125 via the recovery pipe 124. In addition, supply nozzles 114A' - 114C' and recovery nozzles 121A', 121 B' are disposed in an arrangement substantially 180° rotated from the supply nozzles 114A- 114C and the recovery nozzles 121A, 121B. The supply nozzles 114A - 114C and the recovery nozzles 121A', 121B' are alternately arrayed in the Y axial direction, the supply nozzles 114A' - 114C' and the recovery nozzles 121A, 121B are alternately arrayed in the Y axial direction, the supply nozzles 114A' - 114C' are connected to the liquid supply section 111 via a supply pipe 115', and the recovery nozzles 121A', 121B' are connected to the liquid recovery section 125 via a recovery pipe 124'.
FIG 10 is an oblique view that depicts the coupling apparatus 160 that couples the lens cell LS2 and the lens barrel base plate 108.
In FIG 11, the link part 161 includes the tubular member 167, and the first and second linking members 164, 166, which are shaft shaped members provided movable (retractable) with respect to the tubular member 167. The spherical bearings 163, 165 are provided respectively at tip parts 164A, 166A of the first and second linking members 164, 166. Gas bearings (air bearings) 168, 169, which are non-contact bearings, are disposed respectively between the tubular member 167 and the first and second linking members 164, 166. Furthermore, other systems of bearings that use magnetism and the like can also be used as the non-contact bearings. Two air bearings 168 are provided arranged in a row in the axial direction at a position opposing the first linking member 164 on the inner surface of the tubular member 167. Likewise, two air bearings 169 are provided lined up in the axial direction at a position opposing the second linking member 166 on the inner surface of the tubular member 167. These air bearings 168, 169 are tubularly provided along the inner surface of the tubular member 167. A gas supply source 171 supplies compressed gas (air) to the air bearings 168, 169 via a passageway 170 formed inside the tubular member 167. The first and second linking members 164, 166 are supported by the air bearings 168, 169 in a non-contact manner with respect to the tubular member 167.
By driving the vacuum apparatus 176, a negative pressure is applied to the space 174. Thereby, in a state wherein the lens cell LS is linked to the first linking member 164 and the lens barrel base plate 108 is linked to the second linking member 166, even if the first linking member 164 receives a force, such as the weight of the lens cell LS2 and its own weight of the first linking member 164, in a direction away from the second linking member 166, a counterforce acts to pull together the first linking member 164 and second linking member 166 which are linked in a non-contact manner. Furthermore, if the lens cell LS2 is held with the projection optical system PL2 turned upside down, then a positive pressure may be applied to the space 174 between the first linking member 164 and the second linking member 166.
Further, based on the measurement results of the first and second encoders 177, 178 provided in each of the six link parts 62, the control apparatus CONT2 obtains the attitude information of the lens cell LS2 (lens element 102) with respect to the lens barrel base plate 108 (optical group MPL2).
During a scanning exposure, the pattern image of part of the mask M2 is projected onto the projection area AR1, and the substrate P2 moves in the +X direction (or -X direction) at a speed β·V (where β is the projection magnification) via the substrate stage PST2 synchronized to the movement of the mask M2 at the speed V in the -X direction (or +X direction) with respect to the projection optical system PL2. Further, after the exposure of one shot region is completed, the next shot region moves to the scanning start position by the stepping of the substrate P2, and the exposure process is successively performed subsequently for each shot region by the step-and-scan system. In the present embodiment, the liquid 101 is flowed in a direction parallel to and identical to the movement direction of the substrate P2. In other words, if the scanning exposure is performed by moving the substrate P2 in the scanning direction (the -X direction) depicted by an arrow Xa2 (refer to FIG. 9), then the liquid supply mechanism 110 and the liquid recovery mechanism 120 use the supply pipe 115, the supply nozzles 114A - 114C, the recovery pipe 124, and the recovery nozzles 121 A, 121B to supply and recover the liquid 101. In other words, when the substrate P moves in the -X direction, the supply nozzles 114 (114A - 114C) supply the liquid 101 between the projection optical system PL2 and the substrate P2, the recovery nozzles 121 (121A, 121B) recover the liquid 101 on the substrate P2, and the liquid 101 thereby flows in the -X direction so that it fills between the lens element 102 at the tip portion of the projection optical system PL2 and the substrate P2. On the other hand, if the scanning exposure is performed by moving the substrate P2 in the scanning direction (the +X direction) depicted by an arrow Xb2 (refer to FIG. 9), then the liquid supply mechanism 110 and the liquid recovery mechanism 120 use the supply pipe 115', the supply nozzles 114A' - 114C', the recovery pipe 124', and the recovery nozzles 121 A', 121B' to supply and recover the liquid 101. In other words, when the substrate P moves in the +X direction, the supply nozzles 114' (114A' - 114C') supply the liquid 101 between the projection optical system PL2 and the substrate P2, the recovery nozzles 121' (121A', 121B') recover the liquid 101, and the surrounding gas, on the substrate P2, and the liquid 101 thereby flows in the +X direction so that it fills between the lens element 102 at the tip portion of the projection optical system PL2 and the substrate P2. In this case, the liquid 101 can be easily supplied between the lens element 102 and the substrate P2, even if the supplied energy of the liquid supply mechanism 110 (liquid supply part 111) is small, because the liquid 101 supplied, for example, via the supply nozzles 114, flows so that it is drawn between the lens element 102 and the substrate P2 as the substrate P2 moves in the -X direction. Further, even if the substrate P2 is scanned in either the +X direction or the -X direction by switching the direction in which the liquid 101 flows in accordance with the scanning direction, the liquid 101 can be filled between the lens element 102 and the substrate P2, and a high resolution and large depth of focus can thereby be obtained.
The control apparatus CONT2 can maintain in a desired state the position (attitude) of the lens element 102 with respect to the optical group MPL2 by driving the first voice coil motor 172 of each of the link parts 161 based on the obtained attitude information. In other words, the control apparatus CONT2 performs feedback control wherein the first voice coil motor 172 is driven to maintain in a desired state the attitude of the lens element 102 with respect to the optical group MPL2 based on the measurement results of the first and second encoders 177, 178. Thereby, even if vibrations act upon the lens element 102, the lens element 102 moves, and thereby the relative position with respect to the optical group MPL is made to change, the positional relationship between the optical group MPL2 and the lens element 102 can be constantly maintained, and it is therefore possible to ensure that vibrations of the lens element 102 do not transmit to the optical group MPL.
Furthermore, because vibrations produced when driving the first voice coil motor 172 are absorbed by the action of the tubular member 167 as a counter mass, which is a vibration isolating mechanism built in the link part 171, it is possible to ensure that the vibrations are not transmitted to the optical group MPL2 via the lens barrel base plate 108 and the lens barrel PK2. Accordingly, it is possible to prevent degradation of the pattern image projected onto the substrate P2.
In the present embodiment, when each link part 161 is expanded and contracted, and the attitude of the lens element 102 held by the lens cell LS2 is controlled, only the first voice coil motor 172 is driven, and the second voice coil motor 173 is not driven, as discussed above. In other words, when controlling the attitude of the lens element 102, electric power for its control is supplied only to the first voice coil motor 172, and hardly any (or no) electric power is supplied to the second voice coil motor 173. Furthermore, when moving the first voice coil motor 172 for controlling the attitude of the lens element 102, for example, toward the arrow J1 side in FIG 11, then the tubular member 167 moves toward the arrow J2 side. At this time, the second linking member 166 linked to the lens barrel base plate 108 does not move. Depending on the scanning exposure conditions, there is a possibility that the tubular member 167 will continue to move only in, for example, the arrow J2 direction. In that case, there is a possibility that the first linking member 164 will disconnect from the tubular member 167 if the relative position gap between the tubular member 167 and the first and second linking members 164, 166 increases. Therefore, when the relative position between the tubular member 167 and the first and second linking members 164, 166 exceeds a permissible value, the control apparatus CONT2 corrects the position of the tubular member 167 by driving the second voice coil motor 173. Furthermore, the second voice coil motor 173 may be driven with a timing other than the exposure operation, such as, for example, during replacement of the substrate, and/or the time from after the exposure of the first shot region until before the exposure of the next second shot region. Furthermore, when the attitude of the lens element 102 (the lens cell LS2) is controlled by the first voice coil motor 172 during exposure, the vacuum apparatus 176 maintains the space 174 at a constant pressure.
In addition, in the exposure apparatus of the second embodiment as well, the projection optical system PL is divided into two groups: the optical element 102, and the projection optical system main body MPL2 between the mask M and the optical element 102; however, it may be divided into three or more groups.
In FIG 12, the measuring apparatus (laser interferometer system) 190 includes a movable mirror 191 provided at a predetermined position on the +X side of the lens cell LS2, a reference mirror (fixed mirror) 192 provided at a predetermined position on the +X side of the lens barrel PK2, and a laser interferometer 193 provided at a position opposing the movable mirror 191 and the reference mirror 192. The laser interferometer 193 irradiates the movable mirror 191 with a measuring beam (measuring light), and irradiates the reference mirror 192 with a reference beam (reference light). The reflected lights respectively from the movable mirror 191 and the reference mirror 192 based on the radiated measuring beam and the reference beam are received by the light receiving portion of the laser interferometer 193, the laser interferometer 193 causes these lights to interfere, and measures the amount of change of the optical path length of the measuring beam using the optical path length of the reference beam as a reference, and consequently measures the position (coordinate) of the movable mirror 191 using the reference mirror 192 as a reference. Because the reference mirror 192 is provided on the lens barrel PK2 and the movable mirror 91 is provided on the lens cell LS2, the laser interferometer 193 can measure the position in the X axial direction of the lens cell LS2 with respect to the lens barrel PK2. Likewise, although not shown, a movable mirror and a reference mirror are also provided on the +Y side of the lens cell LS2 and the lens barrel PK2, a laser interferometer is provided at a position opposing thereto, and this laser interferometer can measure the position in the Y axial direction of the lens cell LS2 with respect to the lens barrel PK2. In addition, the position in the θZ direction of the lens cell LS2 with respect to the lens barrel PK2 can be measured by, for example, the laser interferometer 193 irradiating the movable mirror 191 and the reference mirror 192 with at least two beams lined up in a row in the Y axial direction.
Furthermore, laser interferometers 194 (194A - 194C) are respectively affixed to the lens barrel PK2 at a plurality of mutually differing predetermined locations (three locations) in the circumferential direction of the lens barrel PK2. However, FIG. 12 representatively depicts just the one laser interferometer 194A of the three laser interferometers 194A - 194C. In addition, a movable mirror 195 is affixed at a position opposing each of the laser interferometers 194 on the upper surface of the lens cell LS2, and each movable mirror 195 is irradiated by a measuring beam from each of the laser interferometers 194 parallel to the Z axial direction. Furthermore, the reference mirror corresponding to each laser interferometer 194 is affixed to the lens barrel PK2 or built in the laser interferometer 194, but is not depicted in FIG 12. The laser interferometer 194 can measure the position in the Z axial direction of the lens cell LS2 with respect to the lens barrel PK2. In addition, the position in the θX, θY directions of the lens cell LS with respect to the lens barrel PK2 can be measured based on the measurement result of each of the three laser interferometers 194.
FIG 13 is a schematic block diagram of the interferometer 193. Furthermore, the other interferometers 194, 184 and the like also have a constitution equivalent to the interferometer depicted in FIG 13. The interferometer 193 includes a light source 220 that radiates a light beam; a polarizing beam splitter 224 that divides the light beam that is irradiated from the light source 220 and enters via a reflecting mirror 223 into a measuring beam 191A and a reference beam 192A; quarter-wave plates 225 (225A, 225B) disposed between the polarizing beam splitter 224 and the movable mirror 191 and through which passes the measuring beam 191 A from the polarizing beam splitter 224; quarter-wave plates 226 (226A, 226B) disposed between the polarizing beam splitter 224 and the reference mirror 192 and through which passes the reference beam 192A from the polarizing beam splitter 224 via a reflecting mirror 227; a corner cube 228 to which the measuring beam 191A reflected by the movable mirror 191 and the reference beam 192A reflected by the reference mirror 192 enters via the polarizing beam splitter 224; and a light receiving portion 230 that receives the synthesized light (interference light) of the reflected light of the measuring beam 191A and the reflected light of the reference beam 192A synthesized by the polarizing beam splitter 224.
The light beam that enters the polarizing beam splitter 224 from the light source 220 is divided into the measuring beam 191 A and the reference beam 192A. The measuring beam 191A passes through the quarter-wave plate 225A, and then irradiates the movable mirror 191. By passing through the quarter-wave plate 225A, the linearly polarized measuring beam 191A is converted to circularly polarized light, and then irradiates the movable mirror 191. The reflected light of the measuring beam 191A that irradiated the movable mirror 191 once again passes through the quarter-wave plate 225A, then enters the polarizing beam splitter 224 and is sent to the corner cube 228. The measuring beam 191A from the corner cube 228 once again enters the polarizing beam splitter 224, passes through the quarter-wave plate 225B, and then irradiates the movable mirror 191. That reflected light once again passes through the quarter-wave plate 225B, and enters the polarizing beam splitter 224. The reference beam 192A emitted from the polarizing beam splitter 224 passes through the quarter-wave plate 226A via the reflecting mirror 227, and then irradiates the reference mirror 192. The reference beam 192A irradiates the reference mirror 192 with circularly polarized light. The reflected light once again passes through the quarter-wave plate 226A, then enters the polarizing beam splitter 224 and is sent to the corner cube 228. The reference beam 192A from the corner cube 228 once again enters the polarizing beam splitter 224, passes through the quarter-wave plate 226B, and then irradiates the reference mirror 192. The reflected light once again passes through the quarter-wave plate 226B, and then enters the polarizing beam splitter 224. The measuring beam 191A that passed through the quarter-wave plate 225B and the reference beam 192A that passed through the quarter-wave plate 226B are synthesized by the polarizing beam splitter 224, and then received by the light receiving portion 230. Thus, the interferometer 193 of the present embodiment includes a so-called double pass interferometer that twice irradiates a movable mirror (reference mirror) with a measuring beam (reference beam); even if the movable mirror 191 is, for example, inclined, the interferometer 193 has a characteristic in that there is no change in the travel direction of the reflected light of the measuring beam from that movable mirror 191.
FIG 14 is a schematic view of the double pass interferometer.
FIG 14 depicts only the measuring beam 191A that irradiates the movable mirror 191, and omits the quarter-waveplates, and the like.
In FIG. 14, the light beam emitted from the light source 220 enters the polarizing beam splitter 224 via the reflecting mirror 223. The length measuring beam 191A is reflected by the reflecting surface of the polarizing beam splitter 224, and then irradiates the reflecting surface of the movable mirror 191; after the reflected light twice irradiates the reflecting surface of the movable mirror 191 via the polarizing beam splitter 224 and the corner cube 228, it is received by the light receiving portion 230. At that time, if the reflecting surface of the movable mirror 191 is not inclined (if the angle with the Y axis is 0°), then the measuring beam 191A travels as depicted by the broken line in FIG 14, and the exit light beam emitted from the polarizing beam splitter 224 towards the light receiving portion 230 becomes parallel to the incident light beam that enters the polarizing beam splitter 224. On the other hand, if the reflecting surface of the movable mirror 191 is inclined at an angle θ, then the measuring beam travels as depicted by the chain line 191A' in FIG 14. In this case as well, the exit light beam from the polarizing beam splitter 224 becomes parallel to the incident light beam. In other words, the travel directions of each of the exit light beams are the same regardless of whether the reflecting surface of the movable mirror 191 is inclined. Accordingly, if the constitution is such that the measuring beam 191A irradiates the movable mirror 191 one time, as in the schematic view depicted in FIG. 15, then, if the movable mirror 191 is inclined, the travel direction of that reflected light with respect to the uninclined state changes, causing a problem wherein the light is not received by the light receiving portion 230. However, as explained referencing FIG. 14, even if the movable mirror 191 is, for example, inclined, a double pass interferometer can receive that reflected light by the light receiving portion 230.
Furthermore, in the present embodiment explained referencing FIG. 12, the measuring apparatus 190 including the laser interferometers 193, 194 measures the positional relationship between the lens barrel PK2 and the lens cell LS2; however, a reflecting member having a reflecting surface capable of reflecting the radiated measuring beam may be provided at a predetermined position of the lens element 102, and the laser interferometer may irradiate that reflecting surface with the measuring beam. For example, as depicted in FIG 16, a mirror member having a reflecting surface may be affixed at a position on the lens element 102 where the measuring beam from the laser interferometer 193 will be irradiated, a vacuum metallized film may be provided at a position where the measuring beam from the laser interferometer 194 will be irradiated, and that film surface may be a reflecting surface. For example, if it is constituted so that a spring mechanism (flexure) is interposed between the lens cell LS2 and the lens element 102, and if the lens cell LS2 and the lens element 102 are temporarily mispositioned, then if an attempt is made to control the attitude of the lens element 102 in order to adjust the pattern image based on the position measurement result of the lens cell LS2, as in the embodiment explained referencing FIG. 12, then there is a possibility that the pattern image cannot be controlled to achieve the desired state; however, the position information of the lens element 102 can be accurately derived by forming the reflecting surface on the lens element 102 itself and measuring the position of the lens element 102 using that reflecting surface, as depicted in FIG. 16.
The above embodiments are not particularly limited to the nozzle configurations discussed above, e.g., the liquid 101 may be supplied and recovered by two pairs of nozzles on the long sides of the projection area AR1. Furthermore, in this case, the supply nozzles and the recovery nozzles may be disposed so that they are arrayed vertically in order to enable the supply and recovery of the liquid 101 from either the +X direction or the -X direction.
In addition, the present invention is also applicable to twin stage type exposure apparatuses that include two stages where substrates to be processed, e.g., wafers, are mounted separately, and that can move those substrates independently in the XY directions. The structure and the exposure operation of a twin stage type exposure apparatus is disclosed in, for example, Japanese Unexamined Patent Application, First Publication No. H10-163099 and Japanese Unexamined Patent Application, First Publication No. H10-214783 (corresponding U.S. Patent Nos. 6,341,007; 6,400,441; 6,549,269; and 6,590,634); Published Japanese translation No. 2000-505958 of PCT International Application (corresponding U.S. Patent No. 5,969,441); or U.S. Patent No. 6,208,407; and the contents thereof are hereby incorporated by reference in their entireties to the extent permitted by the laws and regulations of the states designated or elected by the present international patent application.
If a linear motor is used in the substrate stage PST and/or the mask stage MST, then either an air levitation type that uses an air bearing or a magnetic levitation type that uses Lorentz's force or reactance force may be used. In addition, each of the stages PST, MST may be a type that moves along a guide, or may be a guideless type not provided with a guide. An example of using a linear motor in a stage is disclosed in U. S. Patent Nos. 5,623,853 and 5,528,118, and the contents thereof are hereby incorporated by reference in their entireties to the extent permitted by the laws and regulations of the states designated or elected by the present international patent application.
The reaction force generated by the movement of the substrate stage PST may be mechanically discharged to the floor (ground) using a frame member so that it is not transmitted to the projection optical system PL. A method of handling this reaction force is disclosed in detail in, for example, U.S. Patent No. 5,528,118 (Japanese Unexamined Patent Application, First Publication No. H08-166475), and the contents thereof are hereby incorporated by reference in their entireties to the extent permitted by the laws and regulations of the states designated or elected by the present international patent application.
The reaction force generated by the movement of the mask stage MST may be mechanically discharged to the floor (ground) using a frame member so that it is not transmitted to the projection optical system PL. A method of handling this reaction force is disclosed in detail in, for example, U.S. Patent No. 5,874,820 (Japanese Unexamined Patent Application, First Publication No. H08-330224), and the contents thereof are hereby incorporated by reference in their entireties to the extent permitted by the laws and regulations of the states designated or elected by the present international patent application.
An exposure apparatus that exposes a substrate by filling a liquid between a projection optical system and said substrate, and projecting a pattern image onto said substrate via said projection optical system and said liquid, wherein
said projection optical system has a first group including an optical member that contacts said liquid, and a second group that differs from said first group;
said first group is supported by a first support member; and
said second group is separated from said first group and is supported by a second support member that is different from said first support member.
said first support member and said second support member are isolated so that vibrations do not mutually transmit.
An exposure apparatus according to Claim 1, comprising:
a substrate stage that moves while holding said substrate; and
a first base member that movably and noncontactually supports said substrate stage; wherein,
a second base member that supports said first base member; wherein,
An exposure apparatus according to Claim 4, wherein
said first base member and said second base member are isolated so that vibrations do not mutually transmit.
a measuring apparatus that measures the positional relationship between said first group and said second group.
An exposure apparatus according to Claim 7, further comprising:
An exposure apparatus according to Claim 7, wherein
said optical member has a lens.
said optical member has a plane parallel plate.
An exposure apparatus that exposes a substrate by filling a liquid between a projection optical system and said substrate, forming an immersion area at one part on said substrate, and projecting a pattern image onto said substrate via said projection optical system and said liquid, wherein
said projection optical system has a first group including an optical member that contacts said liquid, and a second group that is different from said first group; and
a drive mechanism, which moves said first group, adjusts the position of said first group with respect to said second group.
an exposure apparatus according to Claim 16 is used.
A coupling apparatus that couples a first object and a second object, comprising:
a parallel link mechanism that couples said first object and said second object; and
a vibration isolating mechanism that is built in said parallel link mechanism so that vibrations of one of said first object and said first object do not transmit to the other.
A coupling apparatus according to Claim 19, wherein
said vibration isolating mechanism has a counter mass for absorbing the vibrations of said one.
said projection optical system has a first group including an optical member that contacts said liquid, and a second group disposed between said first group and said pattern; and
said exposure apparatus comprises:
An exposure apparatus according to Claim 21, further comprising:
a linking means for linking said first holding member and said frame member.
An exposure apparatus according to Claim 22, wherein
said linking means includes a parallel link mechanism.
said linking means includes a vibration isolating mechanism so that vibrations of one of said first holding member and said second holding member do not transmit to the other.
An exposure apparatus according to Claim 24, wherein
said vibration isolating mechanism has a counter mass that absorbs the vibrations of said one.
An exposure apparatus according to Claim 28, wherein
said linking means has a first linking member linked to said first holding member, and a second linking member linked to said frame member; and
An exposure apparatus according to Claim 29, wherein
said linking means has a first linking member linked to said first holding member, and a second linking member linked to said frame member.
An exposure apparatus according to Claim 31, wherein
the space between said first linking member and said second linking member is positively pressurized or negatively pressurized.
said linking means is capable of expanding and contracting by moving said first linking member and said second linking member relatively, using Lorentz's force.
said linking means is capable of expanding and contracting.
the pattern image formed via said projection optical system is adjusted by controlling the attitude of said first group by expanding and contracting said linking means.
the control of said pattern image is the control of at least one among the image plane, the image position, and the distortion.
An exposure apparatus according to Claim 36, further comprising:
a measuring means that measures the position information of said first group; wherein,
said linking means controls the attitude of said first group based on a measurement result of said measuring means.
a measuring means that measures the position of said first group.
An exposure apparatus according to Claim 39, wherein
said measuring means has an interferometer system that measures the position of said first holding member.
said measuring means measures the positional relationship between said first holding member and said second holding member.
the attitude of said first group is adjusted based on the position information measured by said measuring means.
An exposure apparatus according to Claim 21, wherein
an exposure apparatus according to Claim 21 is used.
An exposure apparatus that exposes a substrate by irradiating said substrate with an exposure light via a projection optical system and a liquid, wherein
a frame member for supporting said first holding member; and
a linking mechanism has a vibration isolating mechanism for suppressing the vibrations of at least one of said first holding member and said frame member, and that links said first holding member and said frame member.
An exposure apparatus according to Claim 47, wherein
an exposure apparatus according to Claim 47 is used.
An exposure apparatus that exposes a substrate by irradiating said substrate with an exposure light via a projection optical system and a liquid, comprising:
a liquid immersion mechanism that forms an immersion area in only one part of said substrate during exposure of said substrate; wherein,
said first group and said second group are supported and vibrationally isolated from each other.
An exposure apparatus according to Claim 54, wherein
an exposure apparatus according to Claim 54 is used.
EP04747525A 2003-07-09 2004-07-08 Exposure apparatus and method for manufacturing device Revoked EP1643543B1 (en)
EP1643543A1 true EP1643543A1 (en) 2006-04-05
EP1643543A4 EP1643543A4 (en) 2008-04-23
EP1643543B1 EP1643543B1 (en) 2010-11-24
EP04747525A Revoked EP1643543B1 (en) 2003-07-09 2004-07-08 Exposure apparatus and method for manufacturing device
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US20100007865A1 (en) 2010-01-14
US9684248B2 (en) 2017-06-20 Lithographic apparatus having substrate table and sensor table to measure a patterned beam
US20070035711A1 (en) 2007-02-15 Exposure apparatus and method for producing device
WO2005010611A2 (en) 2005-02-03 Wafer table for immersion lithography
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